Service manual

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LIT-11616-17-23 5UG-F8197-10

YXR660FAS

SERVICE MANUAL

Summary of content (421 pages)

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YXR660FAS SERVICE MANUAL LIT-11616-17-23 5UG-F8197-10
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EBS00001 YXR660FAS SERVICE MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. First Edition, July 2003 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.
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EBS00002 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe and unfit for use.
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EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.
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1 EBS00006 2 GEN INFO SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 0 indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Fuel system 7 Drive train 8 Chassis 9 Electrical 0 Troubleshooting ENG 5 6 FUEL COOL 7 8 CHAS DRIV 9 0 – ELEC TRBL SHTG + A B C D E F Symbols A to H indicate the following.
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EBS00008 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM FUEL SYSTEM DRIVE TRAIN CHASSIS GEN INFO 1 SPEC 2 CHK ADJ 3 ENG 4 COOL 5 FUEL 6 DRIV 7 CHAS 8 – ELECTRICAL TROUBLESHOOTING + ELEC 9 TRBL SHTG 10
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CONTENTS CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION............................................................................1-1 VEHICLE IDENTIFICATION NUMBER .....................................................1-1 MODEL LABEL.......................................................................................... 1-1 FEATURES...................................................................................................... 1-2 SELF-ADJUSTING PARKING BRAKE MECHANISM.........................
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LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-23 ENGINE................................................................................................... 2-23 COOLANT FLOW DIAGRAMS ..................................................................... 2-24 OIL FLOW DIAGRAMS ................................................................................. 2-27 CABLE ROUTING .........................................................................................
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CHANGING THE DIFFERENTIAL GEAR OIL ........................................ 3-35 CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS ..........3-36 CHECKING THE STEERING SYSTEM .................................................. 3-37 ADJUSTING THE TOE-IN....................................................................... 3-37 ADJUSTING THE FRONT SHOCK ABSORBERS .................................3-39 ADJUSTING THE REAR SHOCK ABSORBERS.................................... 3-39 CHECKING THE TIRES..................
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VALVES AND VALVE SPRINGS.................................................................. 4-25 REMOVING THE VALVES AND VALVE SPRINGS ...............................4-26 CHECKING THE VALVES AND VALVE SPRINGS ................................4-27 INSTALLING THE VALVES AND VALVE SPRINGS ..............................4-31 CYLINDER AND PISTON.............................................................................. 4-33 REMOVING THE PISTON .....................................................................
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CRANKCASE ................................................................................................4-66 STARTER MOTOR, TIMING CHAIN AND OIL FILTER.......................... 4-66 CRANKCASE .......................................................................................... 4-68 CRANKCASE BEARINGS....................................................................... 4-69 SEPARATING THE CRANKCASE.......................................................... 4-70 CHECKING THE TIMING CHAIN AND GUIDES .
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CHAPTER 5 COOLING SYSTEM RADIATOR AND COOLANT RESERVOIR .................................................... 5-1 CHECKING THE RADIATOR.................................................................... 5-3 INSTALLING THE RADIATOR..................................................................5-4 WATER PUMP.................................................................................................5-5 DISASSEMBLING THE WATER PUMP....................................................
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT ......................................................................................7-18 ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS................. 7-24 DISASSEMBLING THE FINAL GEAR CASE..........................................7-24 REMOVING THE FINAL DRIVE ROLLER BEARINGS........................... 7-25 INSTALLING THE FINAL DRIVE ROLLER BEARINGS ......................... 7-26 POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR ...
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REAR BRAKE CALIPER .........................................................................8-31 DISASSEMBLING THE FRONT BRAKE CALIPERS..............................8-35 DISASSEMBLING THE REAR BRAKE CALIPER ..................................8-35 CHECKING THE FRONT AND REAR BRAKE CALIPERS ....................8-36 ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 8-37 ASSEMBLING THE REAR BRAKE CALIPER ........................................ 8-38 INSTALLING THE FRONT BRAKE CALIPERS .....
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CHECKING THE BULBS AND BULB SOCKETS .......................................... 9-6 TYPES OF BULBS .................................................................................... 9-6 CHECKING THE CONDITION OF THE BULBS ....................................... 9-6 CHECKING THE CONDITION OF THE BULB SOCKETS .......................9-8 IGNITION SYSTEM ......................................................................................... 9-9 CIRCUIT DIAGRAM .................................................
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CHAPTER 10 TROUBLESHOOTING STARTING FAILURE/HARD STARTING .....................................................10-1 FUEL SYSTEM........................................................................................ 10-1 ELECTRICAL SYSTEM...........................................................................10-1 COMPRESSION SYSTEM...................................................................... 10-2 POOR IDLE SPEED PERFORMANCE .........................................................
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VEHICLE IDENTIFICATION GEN INFO GENERAL INFORMATION VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 stamped into the left side of the frame. is MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
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FEATURES GEN INFO FEATURES SELF-ADJUSTING PARKING BRAKE MECHANISM Usually, for vehicles equipped with a parking brake that must be adjusted manually, it is necessary to adjust the adjusting bolt to achieve the proper clearance between the brake caliper piston and the adjusting bolt. This adjustment procedure is unnecessary for vehicles equipped with a self-adjusting parking brake mechanism.
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FEATURES GEN INFO Parking Brake Operation 1 2 6 4 5 1 Parking brake arm 2 Parking brake arm shaft 3 Set bolt 3 4 Adjusting bolt sleeve 5 Brake caliper piston 6 Brake pad When the parking brake is operated, the parking brake cable turns the parking brake arm 1. The rotation of the parking brake arm is changed to axial thrust in the parking brake arm shaft 2 and the set bolt 3 is pushed against the adjusting bolt sleeve 4.
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FEATURES GEN INFO Parking Brake Adjustment È É 1 2 3 4 Ê 1 Brake caliper piston 2 Nut 3 Adjusting bolt 4 Adjusting bolt sleeve When the brake pedal is operated, the brake fluid pressure in the master cylinder increases and the brake caliper piston 1 and the nut 2 are pushed.
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IMPORTANT INFORMATION GEN INFO EB101000 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”. 3. When disassembling the vehicle, always keep mated parts together. This includes gears, cylinder, piston and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
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IMPORTANT INFORMATION GEN INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1. Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, apply a light coating of lithium-soap-based grease to the seal lips.
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CHECKING OF CONNECTIONS GEN INFO EB801000 CHECKING OF CONNECTIONS Check the connectors for stains, rust, moisture, etc. 1. Disconnect: • Connector 2. Check: • Connector Moisture → Dry each terminal with an air blower. Stains/rust → Connect and disconnect the terminals several times. 3. Check: • Connector leads Looseness → Bend up the pin 1 and connect the terminals. 4. Connect: • Connector terminals NOTE: The two terminals “click” together. 5.
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SPECIAL TOOLS GEN INFO EB102001 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided. When placing an order, refer to the list provided below to avoid any mistakes. For US and CDN P/N.
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SPECIAL TOOLS Tool No. Tool name/Function Tappet adjusting tool 90890-01311 YM-08035-A This tool is necessary for adjusting the valve clearance. Fuel level gauge 90890-01312 YM-01312-A This gauge is used to measure the fuel level in the float chamber. Radiator cap tester 90890-01325 YU-24460-01 This tool is used to check the cooling system. Locknut wrench 90890-01348 YM-01348 This tool is needed when removing or installing the secondary sheave spring.
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SPECIAL TOOLS Tool No. Tool name/Function Ring nut wrench 90890-01430 YM-38404 This tool is needed to removing and installing the middle driven shaft bearing retainer. Gear lash measurement tool 90890-01467 YM-01467 This tool is used to measure the gear lash. Ball joint remover/installer set Ball joint adapter set 90890-01474 YM-01474 These tools are used to removing or installing the ball joints.
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SPECIAL TOOLS Tool No. Compressor 90890-04019 YM-04019 Attachment 90890-01243 YM-01253-1 Middle driven shaft bearing driver 90890-04058 YM-04058-1 Mechanical seal installer 90890-04078 YM-33221 Tool name/Function Valve spring compressor Valve spring compressor attachment This tool is needed to remove and install the valve assemblies. Middle driven shaft bearing driver Mechanical seal installer Water pump seal installer These tools are used to install the water pump seal.
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SPECIAL TOOLS Tool No. Tool name/Function Sheave spring compressor 90890-04134 YM-04134 This tool is needed when removing or installing the secondary sheave spring. Sheave fixed block 90890-04135 YM-04135 This tool is needed when removing or installing the secondary sheave spring. Ignition checker Pulse ignition spark checker 90890-06754 YM-34487 This instrument is necessary for checking the ignition system components. Bond 90890-85505 Sealant ACC-11001-05-01 Yamaha bond No.
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GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Basic weight With oil and full fuel tank Engine Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Standard compression pressure (at sea level) Starting system Lubrication system Oil type or grade Engine oil 0° 10° 30° 50° 70° 90° 110° 130°F 5UG1 2,885 mm (
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GENERAL SPECIFICATIONS Item Differential gear case oil Periodic oil change Total amount Air filter Fuel Type Fuel tank capacity Carburetor Type/quantity Manufacturer Spark plug Type/manufacturer Spark plug gap Clutch type Transmission Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Single speed automatic Sub transmission ratio Reverse gear Chassis Frame type Caster angle Camber angle Kingpin angle Kingpin offset Trail Tread (STD) Toe-in Tire Type Siz
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GENERAL SPECIFICATIONS Item Tire pressure (cold tire) Maximum load* Off-road riding SPEC Standard front rear * Load in total weight of cargo, operator, passenger, accessories and tongue weight Brake Front brake type operation Rear brake type operation Suspension Front suspension Rear suspension Shock absorber Front shock absorber Rear shock absorber Wheel travel Front wheel travel Rear wheel travel Electrical Ignition system Generator system Battery type Battery capacity Headlight type Bulb wattage × qua
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ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Item Standard Cylinder head Warp limit Cylinder Bore size Measuring point Camshaft Drive method Cam dimensions Limit ---- 0.03 mm (0.0012 in) 100.005 ~ 100.055 mm (3.9372 ~ 3.9392 in) 50 mm (1.97 in) 100.10 mm (3.9410 in) ---- Chain drive (Left) ---- A B Intake “A” “B” Exhaust “A” “B” Camshaft runout limit 35.69 ~ 35.79 mm (1.4051 ~ 1.4091 in) 30.06 ~ 30.16 mm (1.1835 ~ 1.1874 in) 36.50 ~ 36.60 mm (1.4370 ~ 1.4409 in) 30.11 ~ 30.21 mm (1.
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ENGINE SPECIFICATIONS Item Standard Cam chain Cam chain type/No. of links Cam chain adjustment method Rocker arm/rocker arm shaft Rocker arm inside diameter Shaft outside diameter Arm-to-shaft clearance Valve, valve seat, valve guide Valve clearance (cold) IN EX SPEC Limit 92RH2010J/126M Automatic ------- 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) 11.976 ~ 11.991 mm (0.4715 ~ 0.4721 in) 0.009 ~ 0.042 mm (0.0004 ~ 0.0017 in) ---- 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) 0.15 ~ 0.20 mm (0.0059 ~ 0.
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ENGINE SPECIFICATIONS Item Stem-to-guide clearance Standard IN EX Stem runout limit Valve seat width IN EX Valve spring Inner spring Free length 32.63 mm (1.28 in) EX 36.46 mm (1.44 in) 27.5 mm (1.08 in) 31.0 mm (1.22 in) IN 100.0 ~ 115.7 N (10.20 ~ 11.80 kg, 22.49 ~ 26.01 lb) 120.6 ~ 138.3 N (12.30 ~ 14.10 kg, 27.12 ~ 31.09 lb) ---- EX ---- IN EX Clockwise Clockwise EX Direction of winding (top view) 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 0.9 ~ 1.1 mm (0.0354 ~ 0.
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ENGINE SPECIFICATIONS Item Standard Piston Piston to cylinder clearance Piston size “D” SPEC Limit 0.050 ~ 0.070 mm (0.0020 ~ 0.0028 in) 99.945 ~ 99.995 mm (3.9348 ~ 3.9368 in) 0.15 mm (0.0059 in) ---- 2.5 mm (0.10 in) 1.0 mm (0.0394 in) Intake side 22.004 ~ 22.015 mm (0.8663 ~ 0.8667 in) 21.991 ~ 22.000 mm (0.8658 ~ 0.8661 in) ---------22.045 mm (0.8679 in) 21.971 mm (0.
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ENGINE SPECIFICATIONS Item Standard SPEC Limit Oil ring B T Dimensions (B × T) End gap (installed) Side clearance 2.5 × 3.4 mm (0.0984 × 0.1339 in) 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) 0.06 ~ 0.15 mm (0.0024 ~ 0.0059 in) ---- 74.95 ~ 75.00 mm (2.9508 ~ 2.
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ENGINE SPECIFICATIONS Item Standard Transmission Main axle deflection limit ---- Drive axle deflection limit ---- Shifter Shifter type Air filter oil grade Carburetor I. D. mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Valve seat size Starter jet Starter jet Throttle valve size Float height Fuel level Engine idle speed Intake vacuum (M.J) (M.A.J) (J.N) (N.J) (P.A.J.1) (P.A.J.2) (P.O) (P.J) (B.P.1) (B.P.2) (B.P.3) (V.
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ENGINE SPECIFICATIONS Item Cooling system Radiator core Width Height Thickness Radiator cap opening pressure Radiator capacity (including all routes) Coolant reservoir Capacity From low to full level Water pump Type Reduction ratio Shaft drive Middle gear backlash Final gear backlash Differential gear backlash SPEC Standard Limit 380 mm (14.96 in) 238 mm (9.37 in) 24 mm (0.94 in) 107.9 ~ 137.3 kPa (1.079 ~ 1.373 kg/cm2, 15.35 ~ 19.53 psi) 2.5 L (2.20 Imp qt, 2.64 US qt) ---------------- 0.35 L (0.
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ENGINE SPECIFICATIONS Cylinder head tightening sequence 2 - 11 SPEC
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CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Item Steering system Type Front suspension Shock absorber travel Spring free length Spring fitting length Spring rate Stroke Optional spring Rear suspension Shock absorber travel Spring free length Spring fitting length Spring rate Stroke Optional spring Front wheel Type Rim size Rim material Rim runout limit Rear wheel Type Rim size Rim material Rim runout limit Standard (K1) (K1) (K1) (K2) (K1) (K2) Limit Rack and pinion ---- 108 mm (4.
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CHASSIS SPECIFICATIONS Item Standard Front disc brake Type Disc outside diameter × thickness Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Rear disc brake Type Disc outside diameter × thickness Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Brake lever and brake pedal Accelerator pedal free play Brake pedal free play Parking brake cable free play Dual
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ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Item Voltage Ignition system Ignition timing (BTDC) Advancer type C.D.I. Magneto model/manufacturer Pickup coil resistance/color Rotor rotation direction sensing coil resistance/color C.D.I.
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ELECTRICAL SPECIFICATIONS Item Electric starter system Type Starter motor Model/manufacturer Output Armature coil resistance Brush overall length Spring force Commutator diameter Mica undercut Starter relay Model/manufacturer Amperage rating Coil winding resistance Radiator fan Running rpm Thermo switch Thermo switch 1 Model/manufacturer Thermo switch 2 Model/manufacturer Thermo switch 3 Model/manufacturer Circuit breaker Type Amperage for individual circuit Main fuse Lighting system fuse Ignition fuse Auxi
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TIGHTENING TORQUES SPEC EBS01005 TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Part to be tightened Cylinder head Spark plug Cylinder head (exhaust pipe) Cylinder head cover Tappet cover (exhaust) Tappet cover (intake) Oil gallery bolt Camshaft end cap Cylinder Part name Bolt Bolt — Stud bolt Bolt — Bolt — Bolt Bolt Bolt Nut Bolt Bolt Bolt Bolt Bolt — — — — Bolt Union bolt Union bolt Union bolt Balancer driven gear Timing chain tensioner Timing chain tensioner cap Timing chain guide (intake side) Camsha
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TIGHTENING TORQUES Part to be tightened Crankcase Bearing housing (clutch housing assembly) Air duct assembly 1 bracket Oil seal (engine cooling fan pulley) retainer Drive belt case Drive belt cover Engine cooling fan Air shroud 1 and air shroud 2 Air shroud 2 and A.C. magneto cover Engine cooling fan pulley Engine cooling fan air duct assembly Stator assembly Pickup coil Stator lead holder A.C.
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TIGHTENING TORQUES Part to be tightened Primary sheave assembly Primary pulley sheave cap Secondary sheave assembly Secondary sheave spring retainer Shift lever cover Shift lever 2 assembly Shift drum stopper Shift arm Shift rod locknut (select lever unit side) Shift rod locknut (shift arm side) Select lever unit Plug (right crankcase) Water pump assembly Water pump housing cover Coolant drain bolt Coolant inlet joint Coolant outlet joint Air bleed bolt (coolant outlet joint) Coolant reservoir Radiator brac
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TIGHTENING TORQUES SPEC EBS01006 CHASSIS TIGHTENING TORQUES Part to be tightened Thread size Rubber damper and frame Engine and rubber damper (front) Tightening torque Nm m · kg ft · lb Remarks M10 M10 M6 M8 M6 M10 M10 M10 M10 M10 M10 M8 M10 M10 M10 M14 M10 M14 M8 52 52 10 33 10 45 45 45 45 45 45 32 56 56 55 23 10 62 13 5.2 5.2 1.0 3.3 1.0 4.5 4.5 4.5 4.5 4.5 4.5 3.2 5.6 5.6 5.5 2.3 1.0 6.2 1.3 37 37 7.2 24 7.2 32 32 32 32 32 32 23 40 40 40 17 7.2 45 9.4 M8 25 2.
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TIGHTENING TORQUES Part to be tightened Thread size Steering knuckle and front lower arm Tie-rod locknut Steering knuckle and tie-rod Front arm protector and front lower arm Seat belt and frame Seat belt and side frame (enclosure) Front wheel and front wheel hub Front wheel hub and constant velocity joint Steering knuckle and brake disc guard Front brake caliper and front wheel hub Front brake hose union bolt Front brake hose holder and steering knuckle Front brake hose holder and front upper arm Front br
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TIGHTENING TORQUES Part to be tightened Thread size Front bumper and frame Hood stopper and frame Upper instrument panel and frame Side frame (enclosure) and frame Support frame (enclosure) and frame Left support frame (enclosure) and right support frame (enclosure) Support frame (enclosure) and side frame (enclosure) Top frame (enclosure) and side frame (enclosure) Seat support and frame Select lever bracket and seat support Skid plate and frame 2 - 21 SPEC Tightening torque Nm m · kg ft · lb M10 M12
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HOW TO USE THE CONVERSION TABLE/ GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EBS00022 EBS00023 HOW TO USE THE CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch.
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LUBRICATION POINTS AND LUBRICANT TYPES SPEC EBS00024 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication points Oil seal lips Lubricant LS Bearings E O-rings LS Piston, piston ring E Piston pin E Buffer boss and balancer drive gear E Crankshaft seal and spacer E Valve stem M Valve stem end M Rocker arm shaft E Rocker arm M Camshaft lobe and journal M Oil pump assembly E Oil filter cartridge O-ring LS Starter idle gear shaft M Starter wheel gear E Clutch housing assem
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COOLANT FLOW DIAGRAMS SPEC COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermo switch 3 3 Radiator outlet hose 4 Radiator inlet hose 5 Radiator outlet pipe 6 Radiator inlet pipe 6 5 A-A 1 2 4 3 A A 2 - 24
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COOLANT FLOW DIAGRAMS SPEC 1 Coolant breather hose 2 Coolant breather pipe 3 Radiator outlet pipe 4 Water pump inlet hose 5 Water pump outlet pipe 6 Water pump outlet hose 7 Coolant outlet hose 8 Radiator inlet pipe 8 3 A-A 7 1 A 6 5 4 3 2 2 - 25 A
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COOLANT FLOW DIAGRAMS SPEC 1 Coolant outlet hose 2 Radiator inlet pipe 1 2 2 - 26
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OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Camshaft 2 Oil delivery pipe 2 3 Oil delivery pipe 3 4 Crankshaft 1 2 3 4 2 - 27 SPEC
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OIL FLOW DIAGRAMS SPEC 1 Oil delivery pipe 1 2 Oil delivery pipe 2 3 Oil delivery pipe 3 4 Oil pump 5 Oil strainer 2 1 3 5 4 2 - 28
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OIL FLOW DIAGRAMS SPEC 1 Oil filter cartridge 2 Oil pipe adapter 3 Oil delivery pipe 2 4 Oil delivery pipe 1 5 Drive axle 6 Relief valve 7 Oil pump 8 Oil strainer 1 2 3 4 5 6 7 8 2 - 29
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SPEC OIL FLOW DIAGRAMS 1 Oil outlet pipe 2 Oil inlet pipe 3 Oil outlet hose 4 Oil inlet hose 5 Oil cooler inlet pipe 2 6 Oil cooler outlet pipe 2 5 6 A-A 1 2 4 3 A A 2 - 30
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SPEC OIL FLOW DIAGRAMS 1 Oil cooler 2 Oil cooler inlet pipe 2 3 Oil cooler outlet pipe 2 4 Oil cooler inlet hose 5 Oil cooler outlet hose 6 Oil cooler inlet pipe 1 7 Oil cooler outlet pipe 1 2 3 6 A-A C 2 7 4 1 3 B 5 B A C A 2 - 31
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SPEC CABLE ROUTING CABLE ROUTING 1 Left headlight lead 2 Wire harness 3 Throttle cable 4 Brake light switch lead 5 Radiator fan motor breather hose 6 Starter cable 7 Starter (choke) knob 8 Light switch 9 Coolant reservoir breather hose 0 Parking brake switch lead A Parking brake cable B Crankcase breather hose C Gear position switch D Reverse switch lead E Front brake hoses F Differential gear case breather hose G Reverse switch terminal H Gear position switch lead G 3 9 5 F A H Ñ Ñ B Ë 6 D C 7
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SPEC CABLE ROUTING Í Fasten the throttle cable to the air duct assembly 1 with the plastic band. Î Fasten the radiator inlet hose and throttle cable with the plastic bands. Ï 20 mm (0.79 in) or less Ð 5 mm (0.20 in) or less Ñ 15° È 30 ~ 60 mm (1.18 ~ 2.36 in) É 160 ~ 190 mm (6.30 ~ 7.48 in) Ê Fasten the wire harness to the frame with the plastic bands. Ë Pull the excess of the hoses through the guide in the upper instrument panel so that there is no slack in the hoses.
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SPEC CABLE ROUTING 1 Float chamber breather hose 2 Throttle cable 3 Parking brake cable 4 Thermo switch 1 5 Vacuum hose 6 Spark plug cap 7 Wire harness 8 Tail/brake light lead 9 Starter motor lead 0 Carburetor heater leads A Carburetor heater È Fasten the parking brake switch lead and parking brake cable to the air duct assembly 1 with the plastic band. É 55 ~ 65 mm (2.17 ~ 2.56 in) Ê Fasten the wire harness to the frame with the plastic bands. Ë Pass the tail/brake light lead through the grommet.
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SPEC CABLE ROUTING Ò Fasten the tail/brake light lead with the plastic holders. Ó Push the excess tail/brake light lead into the rear fender so that there is no slack in the lead. Í Fasten the parking brake cable to the air duct assembly 2 with the plastic band. Î Fasten the parking brake cable and float chamber breather hose with the plastic clip.
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SPEC CABLE ROUTING 1 Main switch 2 Starter (choke) knob 3 Starter (choke) cable 4 Rectifier/regulator 5 Wire harness 6 Coolant reservoir breather hose 7 Right headlight lead 8 Radiator fan motor breather hose 9 Radiator fan motor coupler 0 Differential gear case breather hose A Thermo switch 3 B Gear motor couplers C Coolant reservoir hose D Speed sensor coupler E A.C.
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SPEC CABLE ROUTING Í Fasten the radiator outlet hose and coolant reservoir hose with the plastic clip. Î 12 ~ 22 mm (0.47 ~ 0.87 in) Ï Fasten the wire harness, starter motor lead, ground lead, and starter (choke) cable to the frame with the plastic band. È 70 ~ 80 mm (2.76 ~ 3.15 in) É Fasten the wire harness with the plastic bands. Ê Fasten the wire harness to the frame with the plastic locking ties. Ë 30 ~ 60 mm (1.18 ~ 2.36 in) Ì 160 ~ 190 mm (6.30 ~ 7.
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SPEC CABLE ROUTING × Fasten the wire harness, starter (choke) cable, starter motor lead, and ground lead with the plastic bands. Ø Fasten the gear motor lead with the plastic band. Ù Fasten the wire harness, brake light switch lead, and starter (choke) cable with the plastic band. Ò 70 ~ 90 mm (2.76 ~ 3.54 in) Ó Fasten the throttle cable with the plastic band. Ô Fasten the radiator inlet pipe with the plastic band. Õ Fasten the rear brake pipe with the plastic band.
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CABLE ROUTING 1 Ignition coil lead 2 Spark plug lead 3 Final gear case breather hose 4 Vacuum hose 5 Fuel hoses 6 Air vent hoses 7 Starter (choke) cable 8 Crankcase breather hose 9 Ground lead 0 Rear brake hose A Parking brake cable SPEC B Ignition coil C Rear brake pipe D Wire harness E Fuel tank breather hose F Rollover valve G Fuel return hose H Fuel suction hose Ô B 5 C Ñ Ù 0 D-D Ö A Ø 3 Õ 3 Ð A × 3 5 × E-E Ø A Ò B E 0 C Ú D 3 0 Ù 5 G-G Ó Û H F-F A F G I ËË 3 É I Ê Í
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CABLE ROUTING SPEC Í Fasten the A.C. magneto leads, reverse switch lead, gear position switch lead, thermo switch 1 lead, carburetor heater lead, and parking brake switch lead with the plastic bands. Î 195 ~ 205 mm (7.68 ~ 8.07 in) Ï 15 ~ 25 mm (0.59 ~ 0.98 in) Ð Fasten the wire harness with the plastic band. Ñ Fasten the parking brake cable and wire harness with the plastic clip. È Fasten the spark plug lead with the plastic holder. É 20 ~ 30 mm (0.79 ~ 1.
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CABLE ROUTING SPEC Ø Fasten the parking brake cable and final gear case breather hose with the plastic holders. Ù Fasten the rear brake hose with the plastic bands. Ú Fasten the rear brake pipe with the plastic bands. Û Fasten the wire harness with the plastic bands. Ò Fasten the parking brake cable with the metal holder. Ó Fasten the wire harness, ignition coil lead, and rear brake hose with the plastic band. Ô Fasten the final gear case breather hose and fuel hose with the plastic clip.
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CABLE ROUTING 1 Throttle cable 2 Rear brake pipe 3 A.C. magneto couplers 4 Starter (choke) cable 5 Rear brake hose 6 Fuel hose 7 Vacuum hose 8 Spark plug lead 9 Parking brake cable SPEC È Pass the throttle cable through the cable guide. É Fasten the speed sensor lead, starter (choke) cable, starter motor lead, and ground lead with the plastic band. Ê Fasten the wire harness and A.C. magneto lead with the plastic band. Ë Fasten the wire harness with the plastic band.
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CABLE ROUTING Í Fasten the fuel hose and vacuum hose with the plastic clip. Î Make sure that the spark plug lead does not contact the frame. Ï Fasten the final gear case breather hose with the plastic holder. Ð 105 ~ 115 mm (4.13 ~ 4.53 in) Ñ Fasten the wire harness with the plastic bands. Ò The end of the spark plug cap boot must face towards the passenger side of the vehicle. Ó Pass the spark plug lead through the cutout in the protective cover as shown.
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SPEC CABLE ROUTING 1 Battery 2 Negative battery lead 3 Rectifier/regulator 4 Starter (choke) cable 5 Indicator light assembly couplers 6 On-Command four-wheel drive switch and differential gear lock switch leads 7 On-Command four-wheel drive switch and differential gear lock switch 8 Main switch 9 Starter (choke) knob Q R P 0 Light switch A Differential gear case breather hose B Radiator fan motor breather hose C Left headlight lead D Throttle cable E Right headlight lead F Starter motor lead G Starter
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SPEC CABLE ROUTING K Four-wheel drive relay 3 L Differential gear lock indicator light relay M Four-wheel drive indicator light relay N Fuse box O Positive battery lead P Neutral indicator light Q Reverse indicator light R Parking brake indicator light S Four-wheel drive indicator light T Differential gear lock indicator light U Coolant temperature indicator light Q R P V C.D.I. unit È Fasten the wire harness with the plastic bands.
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SPEC CABLE ROUTING Ñ 4 mm (0.16 in) of clearance or more is required around the boot. Ò Make sure that the washer is installed on the side of the pedal assembly bracket towards the boot. Ë Fasten the throttle cable with the plastic holder. Ì Fasten the left headlight lead, differential gear case breather hose, and radiator fan motor breather hose with the plastic holder. Í Fasten the left headlight lead and differential gear case breather hose with the plastic holder.
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CABLE ROUTING 1 Auxiliary DC jack 2 Auxiliary DC jack lead 3 Coolant reservoir breather hose 4 Throttle cable 5 Radiator fan motor breather hose 6 Differential gear case breather hose 7 Starter (choke) cable 8 Wire harness 9 Front brake hoses 0 Coolant reservoir hose A Ground lead SPEC B Starter relay lead È Fasten the coolant reservoir breather hose with the plastic band. É Fasten the front brake hose with the plastic band. Ê Fasten the front brake hose with the plastic band.
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CABLE ROUTING SPEC Ì Fasten the wire harness and ground lead with the plastic band. Í Fasten the differential gear case breather hose, coolant reservoir hose, radiator fan motor lead, and thermo switch 3 lead with the plastic holder.
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INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION CHK ADJ EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
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PERIODIC MAINTENANCE/LUBRICATION CHK ADJ INITIAL ITEM ROUTINE Whichever comes first EVERY month 1 3 6 6 12 km (mi) 320 (200) 1,200 (750) 2,400 (1,500) 2,400 (1,500) 4,800 (3,000) hours 20 75 150 150 300 Accelerator pedal* • Check operation and free play. V-belt* • Check operation. • Check for wear, cracks, or damage. Wheels* • Check balance/damage/runout. • Repair if necessary. Wheel bearings* • Check bearing assemblies for looseness/damage. • Replace if damaged.
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ADJUSTING THE VALVE CLEARANCE CHK ADJ ENGINE ADJUSTING THE VALVE CLEARANCE NOTE: • The valve clearance must be adjusted when the engine is cool to the touch. • Adjust the valve clearance when the piston is at the Top Dead Center (TDC) on the compression stroke. 1. • • • Remove: driver seat passenger seat console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. 2. Lift the cargo bed up. 3. • • 4. • 5.
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ADJUSTING THE VALVE CLEARANCE CHK ADJ 7. Remove: • engine cooling fan 1 1 8. Remove: • timing plug 1 1 9. Check: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) Exhaust 0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise with a wrench. b. Align the “I” mark 1 on the rotor with the stationary pointer 2 on the A.C. magneto cover.
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ADJUSTING THE VALVE CLEARANCE CHK ADJ 10.Adjust: • valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut 1. b. Insert a thickness gauge 2 between the adjuster end and the valve end. c. Turn the adjuster 3 clockwise or counterclockwise with the tappet adjusting tool 4 until the proper clearance is obtained. Tappet adjusting tool P/N. YM-08035-A, 90890-01311 d. Hold the adjuster to prevent it from moving and then tighten the locknut. T. Locknut 14 Nm (1.4 m · kg, 10 ft · lb) R. e.
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ADJUSTING THE TIMING CHAIN/ ADJUSTING THE IDLING SPEED CHK ADJ ADJUSTING THE TIMING CHAIN Adjustment free. ADJUSTING THE IDLING SPEED 1. Start the engine and let it warm up for several minutes. 2. Remove: • driver seat • passenger seat • console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. 3. Lift the cargo bed up. 4. Attach: • tachometer (to the spark plug lead) Digital engine test tachometer P/N. YU-8036-C Engine tachometer P/N. 90890-03113 5.
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ADJUSTING THE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE 7. • 8. 9. • • • CHK ADJ Detach: tachometer Lower the cargo bed. Install: console passenger seat driver seat Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. ADJUSTING THE THROTTLE CABLE NOTE: Throttle cable free play should be adjusted properly before adjusting the engine idling speed. _ 1. • • • 2. • 3. • Remove: driver seat passenger seat console Remove: throttle valve cover 1 Check: throttle cable a Slack → Remove the slack.
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ADJUSTING THE THROTTLE CABLE/ ADJUSTING THE STARTER CABLE 5. • 6. • • • CHK ADJ Remove: throttle valve cover Install: console passenger seat driver seat ADJUSTING THE STARTER CABLE 1. Remove: • driver seat • passenger seat • console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. 2. Adjust: • starter cable ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the starter cable 1 from the carburetor body. NOTE: Do not remove the starter plunger 2 from the starter cable. b.
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ADJUSTING THE STARTER CABLE/ CHECKING THE SPARK PLUG 3. • • • CHK ADJ Install: console passenger seat driver seat Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. CHECKING THE SPARK PLUG 1. Lift the cargo bed up. 2. Remove: • spark plug 3. Check: • spark plug type Incorrect → Replace. Standard spark plug DPR8EA-9/NGK 4. Check: • electrode 1 Wear/damage → Replace. • insulator 2 Abnormal color → Replace. Normal color is a medium-to-light tan color. 5.
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CHECKING THE IGNITION TIMING CHK ADJ CHECKING THE IGNITION TIMING NOTE: Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1. • • • 2. 3. • • Remove: driver seat passenger seat console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. Lift the cargo bed up. Attach: tachometer timing light (to the spark plug lead) Digital engine test tachometer P/N. YU-8036-C Engine tachometer P/N. 90890-03113 Timing light P/N.
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CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE CHK ADJ 6. Check: • ignition timing 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Warm up the engine and keep it at the specified speed. Engine speed 1,450 ~ 1,550 r/min b. Remove the timing plug 1. c. Visually check the stationary pointer 2 to verify it is within the required firing range 3 indicated on the flywheel. Incorrect firing range → Check the pulser coil assembly. d. Install the timing plug. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7.
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MEASURING THE COMPRESSION PRESSURE 5. • 6. • • CHK ADJ Remove: spark plug Attach: adapter compression gauge 1 Compression gauge P/N. YU-33223, 90890-03081 Adapter P/N. YU-33223-4, 90890-04082 7. Measure: • compression pressure Above the maximum pressure: Check the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure: Squirt a few drops of oil into the affected cylinder and measure again. Refer to the table below.
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MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL CHK ADJ WARNING When cranking the engine, ground the spark plug lead to prevent sparking. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ T. 8. Install: • spark plug 18 Nm (1.8 m · kg, 13 ft · lb) 9. Lower the cargo bed. R. CHECKING THE ENGINE OIL LEVEL 1. Place the vehicle on a level surface. 2. Remove: • driver seat • passenger seat • console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. 3.
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CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CHK ADJ 5. Stop the engine and check the oil level again. NOTE: Wait a few minutes until the oil settles before checking the oil level. WARNING Never remove the dipstick just after high speed operation because the heated oil could spurt out. Wait until the oil cools down before removing the dipstick. 6. • • • Install: console passenger seat driver seat Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. CHANGING THE ENGINE OIL 1.
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CHANGING THE ENGINE OIL CHK ADJ b. Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of lithium-soapbased grease. CAUTION: Make sure that the O-ring 3 is positioned correctly in the groove of the oil filter cartridge. c. Tighten the new oil filter cartridge to specification with an oil filter wrench. T. Oil filter cartridge 17 Nm (1.7 m · kg, 12 ft · lb) R. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • engine oil drain bolt 1 T. 30 Nm (3.0 m · kg, 22 ft · lb) 7.
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CHANGING THE ENGINE OIL/ CLEANING THE AIR FILTER CHK ADJ 11.Check: • engine oil pressure ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slightly loosen the oil gallery bolt 1. b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. c. Check the engine oil passages, the oil filter cartridge and the oil pump for damage or leakage. Refer to “CRANKSHAFT AND OIL PUMP” in chapter 4. d.
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CLEANING THE AIR FILTER CHK ADJ 2. Remove: • air filter case cover 1 3. • • • Remove: air filter element assembly 1 air filter element cap air filter element 2 Air filter element cap 3 Air filter element CAUTION: Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing rapid wear and possible engine damage.
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CLEANING THE AIR FILTER/ CHECKING THE COOLANT LEVEL CHK ADJ c. Apply Yamaha foam air filter oil or other quality foam air filter oil. d. Squeeze out the excess oil. NOTE: The element should be wet but not dripping. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • air filter element • air filter case cover NOTE: To prevent air leaks make sure that the sealing surface of the element matches the sealing surface of the case. 7.
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CHECKING THE COOLANT LEVEL/ CHANGING THE COOLANT CHK ADJ 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check: • coolant level NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. 6. Close the hood. CHANGING THE COOLANT 1. Remove: • driver seat • passenger seat • console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. 2. Lift the hood up. 3. • 4. • Remove: coolant reservoir cap 1 Disconnect: coolant reservoir hose 2 5.
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CHANGING THE COOLANT CHK ADJ 8. Remove: • radiator cap 1 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape.
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CHANGING THE COOLANT CHK ADJ 14.Connect: • water pump inlet hose • coolant outlet hose 15.Remove: • air bleed bolt 1 16.Fill: • cooling system (with the specified amount of the recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1 : 1 (antifreeze : water) Quantity Total amount 2.5 L (2.20 Imp qt, 2.64 US qt) Coolant reservoir capacity 0.35 L (0.31 Imp qt, 0.
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CHANGING THE COOLANT CHK ADJ CAUTION: • Adding water instead of coolant lowers the antifreeze content 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, soft water may be used if distilled water is not available. • If coolant comes into contact with painted surfaces, immediately wash them with water. • Do not mix different types of antifreeze. T. R. 17.Install: • air bleed bolt 18.
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CHECKING THE COOLANT TEMPERATURE WARNING LIGHT/CHECKING THE V-BELT CHK ADJ CHECKING THE COOLANT TEMPERATURE WARNING LIGHT 1 Coolant temperature indicator light Coolant temperature warning light checking method Turn the main switch “ON”. Coolant temperature warning light comes on. Coolant temperature warning light does not come on. Turn the main switch to “START” with the transmission in neutral position. Coolant temperature warning light comes on momentarily.
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CHECKING THE V-BELT CHK ADJ 2. Check: • V-belt 1 Cracks/wear/scaling/chipping → Replace. Oil/grease → Check primary sheave and secondary sheave. 3. Measure: • V-belt width 2 Out of specification → Replace. V-belt width 33.2 mm (1.31 in) 29.9 mm (1.18 in) 4. Replace: • V-belt ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the bolts 1 (90101-06016) into the secondary fixed sheave hold.
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CHECKING THE V-BELT/ CLEANING THE SPARK ARRESTER CHK ADJ 5. Remove: • drive belt cover Refer to “PRIMARY AND SECONDARY SHEAVES” in chapter 4. • console • passenger seat • driver seat Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. CLEANING THE SPARK ARRESTER 1. Clean: • spark arrester ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING • Select a well-ventilated area free of combustible materials. • Always let the exhaust system cool before performing this operation.
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ADJUSTING THE BRAKE PEDAL CHK ADJ CHASSIS ADJUSTING THE BRAKE PEDAL 1. Check: • brake pedal free play a Out of specification → Adjust. NOTE: The end of the brake rod 1 should lightly contact the brake master cylinder 2. _ Brake pedal free play 0 mm (0.0 in) 2. Adjust: • brake pedal free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut 1. b. Turn brake rod 2 in or out until the correct free play is obtained. Turning in Free play is increased. Turning out Free play is decreased. c.
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ADJUSTING THE PARKING BRAKE CHK ADJ ADJUSTING THE PARKING BRAKE 1. Shift the drive select lever into low gear “L”. 2. Remove: • driver seat • passenger seat • console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. 3. Check: • parking brake cable free play a Out of specification → Adjust. Parking brake cable free play 2 ~ 3 mm (0.079 ~ 0.118 in) 4. Adjust: • parking brake cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Pull back the adjuster cover 1. b. Loosen the locknut 2. c.
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CHECKING THE BRAKE FLUID LEVEL CHK ADJ CHECKING THE BRAKE FLUID LEVEL 1. Place the vehicle on a level surface. NOTE: When checking the brake fluid level, make sure that the top of the brake fluid reservoir top is horizontal. 2. Lift the hood up. 3. Check: • brake fluid level Fluid level is under “MIN” level line 1 → Fill up. Recommended brake fluid DOT 4 CAUTION: Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.
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CHECKING THE FRONT BRAKE PADS/CHECKING THE REAR BRAKE PADS/CHECKING THE BRAKE HOSES AND BRAKE PIPES CHK ADJ CHECKING THE FRONT BRAKE PADS 1. Remove: • front wheels 2. Check: • brake pads Wear indicator groove 1 almost disappeared → Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES” in chapter 8. Brake pad wear limit a 1.5 mm (0.06 in) 3. Operate the brake pedal. 4. Install: • front wheels CHECKING THE REAR BRAKE PADS 1.
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CHECKING THE BRAKE HOSES AND BRAKE PIPES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM 2. 3. 4. • • • CHK ADJ Lift the hood up. Lift the cargo bed. Check: front brake hoses 1 rear brake pipes 2 rear brake hoses 3 Cracks/wear/damage → Replace. Fluid leakage → Replace all damaged parts. Refer to “FRONT AND REAR BRAKES” in chapter 8. NOTE: Hold the vehicle in an upright position and apply the brake pedal. 5. Check: • brake hose clamps Loosen → Tighten. 6. Lower the cargo bed. 7. Close the hood. 8.
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BLEEDING THE HYDRAULIC BRAKE SYSTEM È CHK ADJ 1. Bleed: • brake system ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Add the proper brake fluid to the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c. Connect the clear plastic hose 1 tightly to the caliper bleed screw 2. È Front É Rear É d. Place the other end of the hose into a container. e. Slowly apply the brake pedal several times. f. Push down on the pedal and hold it. g.
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ADJUSTING THE SELECT LEVER SHIFT ROD/ ADJUSTING THE BRAKE LIGHT SWITCH CHK ADJ ADJUSTING THE SELECT LEVER SHIFT ROD 1 Neutral 2 High 3 Low 4 Reverse 5 Select lever shift rod CAUTION: Before shifting, you must stop the vehicle and take your foot off the accelerator pedal. Otherwise, the transmission may be damaged. 1. Adjust: • Select lever shift rod ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Make sure the select lever is in NEUTRAL. b. Loosen both locknuts 1.
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ADJUSTING THE BRAKE LIGHT SWITCH/ CHECKING THE FINAL GEAR OIL LEVEL CHK ADJ 1. Check: • brake light operation timing Incorrect → Adjust. 2. Adjust: • brake light operation timing ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the main body 1 of the brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the brake light comes on at the proper time. Direction a Brake light comes on sooner. Direction b Brake light comes on later.
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CHANGING THE FINAL GEAR OIL/ CHECKING THE DIFFERENTIAL GEAR OIL CHK ADJ T. CHANGING THE FINAL GEAR OIL 1. Place the vehicle on a level surface. 2. Place a container under the final gear case to collect the used oil. 3. Remove: • oil filler plug 1 • drain plug 2 4. Drain: • final gear oil 5. Install: • drain plug 20 Nm (2.0 m · kg, 14 ft · lb) R. NOTE: Check the drain plug gasket. If it is damaged, replace it with a new one. 6. Fill: • final gear case Periodic oil change 0.25 L (0.22 Imp qt, 0.
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CHECKING THE DIFFERENTIAL GEAR OIL/ CHANGING THE DIFFERENTIAL GEAR OIL CHK ADJ 3. Check: • oil level Oil level should be up to the brim of hole. Oil level low → Add oil to proper level. Recommended oil SAE 80 API “GL-4” Hypoid gear oil CAUTION: Take care not allow foreign material to enter the differential gear case. T. R. 4. Install: • oil filler plug 23 Nm (2.3 m · kg, 17 ft · lb) T. CHANGING THE DIFFERENTIAL GEAR OIL 1. Place the vehicle on a level surface. 2.
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CHANGING THE DIFFERENTIAL GEAR OIL/CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS CHK ADJ 6. Fill: • differential gear case Periodic oil change 0.32 L (0.28 Imp qt, 0.34 US qt) Total amount 0.33 L (0.29 Imp qt, 0.35 US qt) Recommended oil SAE 80 API “GL-4” Hypoid gear oil NOTE: If gear oil is filled to the brim of the oil filler hole, oil may start leaking from the differential gear case breather hose. Therefore, check the quantity of the oil, not its level.
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CHECKING THE STEERING SYSTEM/ ADJUSTING THE TOE-IN CHK ADJ CHECKING THE STEERING SYSTEM 1. Place the vehicle on a level surface. 2. Check: • steering assembly bearings Try to the steering wheel up and down, and back and forth. Excessive play → Replace the steering shaft assembly. 3. Check: • tie-rod ends Turn the steering wheel to the left and right until it stops completely, and then move the steering wheel slightly in the opposite direction.
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ADJUSTING THE TOE-IN CHK ADJ c. Measure distance È between the marks. d. Rotate the front tires 180° until the marks are exactly opposite one another. e. Measure distance É between the marks. f. Calculate the toe-in using the formula given below. Toe-in = É – È g. If the toe-in is incorrect, adjust it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Adjust: • toe-in WARNING • Be sure that both tie-rods are turned the same amount.
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ADJUSTING THE FRONT SHOCK ABSORBERS/ ADJUSTING THE REAR SHOCK ABSORBERS CHK ADJ ADJUSTING THE FRONT SHOCK ABSORBERS WARNING Always adjust both shock absorber spring preload to the same setting. Uneven adjustment can cause poor handling and loss of stability. NOTE: The spring preload of the shock absorbers can be adjusted to suit the operator’s preference, weight, and the operating conditions. 1. Adjust: • spring preload Turn the adjuster 1 to increase or decrease the spring preload.
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CHK ADJ CHECKING THE TIRES CHECKING THE TIRES WARNING • TIRE CHARACTERISTICS 1) Tire characteristics influence the handling of vehicle’s. The tires listed below have been approved by Yamaha Motor Manufacturing corporation of America. for this model. If other tire combinations are used, they can adversely affect your vehicle’s handling characteristics and are therefore not recommended.
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CHECKING THE TIRES CHK ADJ 1. Measure: • tire pressure (cold tire pressure) Out of specification → Adjust. NOTE: • The tire pressure gauge 1 is included as standard equipment. • If dust or the like is stuck to this gauge, it will not provide the correct readings. Therefore, take two measurements of the tire’s pressure and use the second reading. Cold tire pressure Front Rear Standard 70 kPa (0.70 kg/cm2, 10 psi) 98 kPa (0.98 kg/cm2, 14 psi) Minimum 63 kPa (0.63 kg/cm2, 9 psi) 91 kPa (0.
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CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES CHK ADJ CHECKING THE WHEELS 1. Check: • wheels 1 Damage/bends → Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. WARNING • Never attempt even small repairs to the wheel. • Ride conservatively after installing a tire to allow it to seat itself properly on the rim. CHECKING AND LUBRICATING THE CABLES WARNING A damaged cable sheath may cause corrosion and interfere with the cable movement.
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LUBRICATING THE PEDAL, ETC. CHK ADJ LUBRICATING THE PEDAL, ETC. 1. Lubricate the pivoting parts.
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CHECKING AND CHARGING THE BATTERY CHK ADJ EB305000 ELECTRICAL CHECKING AND CHARGING THE BATTERY WARNING _ Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries. • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
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CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. _ 1. 2. • 3. • Lift the hood up. Remove: battery case cover Disconnect: battery leads CAUTION: _ First, disconnect the negative battery lead 1, and then the positive battery lead 2. 4. • 5.
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CHECKING AND CHARGING THE BATTERY Ambient temperature 20 °C (68 °F) Open-circuit voltage (V) Charging CHK ADJ 6. Charge: • battery (refer to the appropriate charging method illustration) WARNING _ Do not quick charge a battery. Time (minutes) Check the open-circuit voltage. CAUTION: _ Open-circuit voltage (V) Ambient temperature 20 °C (68 °F) Charging condition of the battery (%) • Never remove the MF battery sealing caps.
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CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger NOTE: Charger Measure the open-circuit voltage prior to charging. Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Ammeter NOTE: Connect a charger and ammeter to the battery and start charging. YES Is the amperage higher than the standard charging amperage written on the battery? Set the charging voltage to 16 ~ 17 V.
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CHECKING AND CHARGING THE BATTERY CHK ADJ Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging. NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging. YES Is the amperage higher than the standard charging amperage written on the battery? Charge the battery until the charging voltage reaches 15 V.
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CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 7. • 8. • CHK ADJ Install: battery Connect: battery leads CAUTION: _ First, connect the positive battery lead 1, and then the negative battery lead 2. 9. Check: • battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 10.Lubricate: • battery terminals Recommended lubricant Dielectric grease 11.Install: • battery case cover 12.Close the hood.
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CHECKING THE FUSES CHK ADJ 4. Replace: • blown fuse ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn off the ignition. b. Install a new fuse of the proper amperage. c. Turn on switches to verify operation of the related electrical devices. d. If the fuse immediately blows again, check the electrical circuit.
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ADJUSTING THE HEADLIGHT BEAM/ CHANGING THE HEADLIGHT BULB CHK ADJ ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • headlight beam (vertically) Turn the adjuster 1 in or out. Turning in Headlight beam raised. Turning out Headlight beam lowered. CHANGING THE HEADLIGHT BULB 1. Lift the hood up. 2. Remove: • headlight bulb holder cover 1 3. Remove: • headlight bulb holder (with bulb) 1 • bulb NOTE: Remove the defective bulb by unhooking the headlight bulb holder tabs 2.
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CHANGING THE HEADLIGHT BULB/ CHANGING THE TAIL/BRAKE LIGHT BULB 5. • • 6. CHK ADJ Install: headlight bulb holder (with bulb) headlight bulb holder cover Close the hood. CHANGING THE TAIL/BRAKE LIGHT BULB 1. Remove: • cargo bed panel 1 2. Remove: • tail/brake light bulb holder (with bulb) 1 • bulb NOTE: Turn the bulb holder counterclockwise and remove the defective bulb. WARNING Keep flammable products and your hands away from the bulb while it is on, since it will be hot.
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CHANGING THE TAIL/BRAKE LIGHT BULB 4. • 5. • Install: tail/brake light bulb holder (with bulb) Install: cargo bed panel 7 Nm (0.7 m · kg, 5.1 ft · lb) T. R.
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ENGINE REMOVAL ENG ENGINE ENGINE REMOVAL AIR DUCTS, MUFFLER AND EXHAUST PIPE T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. (6) T. R. 1 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 8 3 4 T. 5 R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 6 New 2 T. R. New 5 T. 20 Nm (2.0 m • kg, 14 ft • Ib) R. 14 Nm (1.4 m • kg, 10 ft • Ib) T. R. 11 Nm (1.1 m • kg, 8.
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ENGINE REMOVAL T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) R. (6) T. R. 1 ENG 10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 8 3 4 T. 5 R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 6 New 2 T. R. New 5 T. 20 Nm (2.0 m • kg, 14 ft • Ib) R. 14 Nm (1.4 m • kg, 10 ft • Ib) T. R. 11 Nm (1.1 m • kg, 8.
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ENGINE REMOVAL ENG SELECT LEVER UNIT AND COOLANT RESERVOIR 3 T. R. 14 Nm (1.4 m • kg, 10 ft • Ib) T. R. 1 2 Job/Part Removing the select lever unit and coolant reservoir Shift arm Select lever shift rod Q’ty 1 1 R. R. 1 2 15 Nm (1.5 m • kg, 11 ft • Ib) T. T. Order 15 Nm (1.5 m • kg, 11 ft • Ib) 15 Nm (1.5 m • kg, 11 ft • Ib) Remarks Remove the parts in the order listed. CAUTION: The select lever shift rod locknut (select lever side) has left-handed threads.
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ENGINE REMOVAL ENG HOSES AND LEADS 5 2 6 7 8 9 13 1 4 14 12 3 10 . R. Order 1 2 3 4 5 6 7 8 9 10 11 12 Job/Part Removing the hoses and leads Water pump inlet hose Coolant outlet hose Oil inlet hose Oil outlet hose Vacuum hose Spark plug lead Crankcase breather hose Thermo switch 1 lead Starter motor lead A.C. magneto lead coupler Speed sensor lead coupler Gear position switch lead coupler Q’ty 1 1 1 1 1 1 1 1 1 2 1 1 4-4 10 Nm (1.0 m • kg, 7.
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ENGINE REMOVAL ENG 5 2 6 7 8 9 13 1 4 14 12 3 10 . R. Order 13 14 Job/Part Reverse switch lead Engine ground lead 10 Nm (1.0 m • kg, 7.2 ft • Ib) 11 Q’ty Remarks 1 Green/White 1 Disconnect. For installation, reverse the removal procedure.
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ENGINE REMOVAL ENG ENGINE MOUNTING BOLTS Order Job/Part Removing the engine mounting bolts Front skid plate/center skid plate/rear skid plate Rear wheels Q’ty Final drive gear assembly 4-6 Remarks Remove the parts in the order listed. Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. Refer to “REAR WHEELS AND BRAKE DISC” in chapter 8. Refer to “REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT” in chapter 7.
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ENGINE REMOVAL Order 1 2 3 4 5 6 7 8 9 10 Job/Part Rubber damper nut (rear) Engine mounting bolt (front-upper) Engine mounting bolt (front-lower)/nut Engine assembly Rubber damper nut (front) Rubber damper (front) Rubber damper (rear) Engine mounting bolt (rear) Engine bracket (left) Engine bracket (right) Q’ty 2 2 1/1 1 2 2 2 4 1 1 4-7 ENG Remarks NOTE: Remove the engine assembly from the top of the vehicle. CAUTION: Install all of the bolts/nuts and then tighten them to full torque specifications.
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ENGINE REMOVAL ENG INSTALLING THE ENGINE 1. Install: • engine mounting bolt (rear) 1 • rubber damper (rear) 2 • rubber damper nut (front) 3 • engine assembly 4 • engine mounting bolt (front lower)/nut 5 • engine mounting bolt (front upper) 6 • rubber damper nut (rear) 7 NOTE: Do not fully tighten the bolts and nuts. 2. Tighten: • engine mounting bolt (rear) 1 T. R. 33 Nm (3.3 m · kg, 24 ft · lb) • rubber damper nut (front) 3 T. R. 52 Nm (5.2 m · kg, 37 ft · lb) T.
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CYLINDER HEAD COVER ENG CYLINDER HEAD COVER Order 1 2 3 4 5 6 7 Job/Part Removing the cylinder head cover Driver seat/passenger seat/console Q’ty air shroud 1/engine cooling fan/timing plug Union bolt Copper washer Oil delivery pipe 3 Oil delivery pipe 2 Spark plug Tappet cover (intake) Tappet cover (exhaust) 3 7 1 1 1 1 2 4-9 Remarks Remove the parts in the order listed. Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3.
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CYLINDER HEAD COVER Order 8 9 Job/Part Cylinder head cover Dowel pin ENG Q’ty Remarks 1 Refer to “REMOVING THE CYLINDER HEAD COVER” and “INSTALLING THE CYLINDER HEAD COVER”. 2 For installation, reverse the removal procedure.
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CYLINDER HEAD COVER 1 2 ENG REMOVING THE CYLINDER HEAD COVER 1. Align: • “I” mark (with stationary pointer) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise with a wrench. b. Align the “I” mark 1 on the rotor with the stationary pointer 2 on the A.C. magneto cover. When the “I” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (TDC).
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CYLINDER HEAD COVER ENG INSTALLING THE CYLINDER HEAD COVER 1. Apply: • sealant (Quick Gasket®) 1 (to the mating surfaces of the cylinder head and cylinder head cover) Sealant (Quick Gasket®) P/N. ACC-11001-05-01 Yamaha bond No. 1215 P/N. 90890-85505 Install: cylinder head cover washers 1 10 Nm (1.0 m · kg, 7.2 ft · lb) bolts R. 2 Bolt: 3 Bolt: 4 Bolt: 5 Bolt: 6 Bolt: 7 Bolt: T. 2.
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ROCKER ARMS ENG ROCKER ARMS Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the rocker arms Cylinder head cover Plug/O-ring Rocker arm shaft stopper Rocker arm shaft 2 Rocker arm 3 Rocker arm shaft 3/O-ring Rocker arm 4 Rocker arm shaft 1/O-ring Rocker arm 1 Rocker arm 2 Q’ty 1/1 2 1 1 1/1 1 1/1 1 1 4 - 13 Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD COVER”. Refer to “REMOVING THE ROCKER ARMS” and “INSTALLING THE ROCKER ARMS”.
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ROCKER ARMS Order 10 11 12 Job/Part Wave washer Locknut Valve adjuster Q’ty 4 5 5 ENG Remarks For installation, reverse the removal procedure.
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ROCKER ARMS ENG REMOVING THE ROCKER ARMS 1. Remove: • rocker arm shafts 1 • rocker arms 2 NOTE: Use a slide hammer bolt 3 and weight 4 to remove the rocker arm shafts. Slide hammer set P/N. YU-01083-A Slide hammer bolt (M6) P/N. 90890-01083 Weight P/N. 90890-01084 CHECKING THE ROCKER ARMS 1. Check: • rocker arm lobes 1 • valve adjusters 2 Blue discoloration/pitting/scratches → Replace. 2. Check: • rocker arms • rocker arm shafts Damage/wear → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
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ROCKER ARMS ENG d. Measure the outside diameter b of the rocker arm shafts. Out of specification → Replace. Rocker arm shaft outside diameter 11.976 ~ 11.991 mm (0.4715 ~ 0.4721 in) e. Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Out of specification → Replace the defective part(s). Rocker arm to shaft standard clearance 0.009 ~ 0.042 mm (0.0004 ~ 0.0017 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ INSTALLING THE ROCKER ARMS 1.
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CAMSHAFT AND CYLINDER HEAD ENG CAMSHAFT AND CYLINDER HEAD Order 1 2 3 4 5 6 Job/Part Removing the camshaft and cylinder head Carburetor Coolant outlet joint breather hose Muffler/exhaust pipe/thermo switch 1 lead Cylinder head cover Timing chain tensioner cap bolt Timing chain tensioner/gasket Timing chain guide (exhaust side) Decompressor cam guide plate Camshaft sprocket Camshaft Q’ty Remarks Remove the parts in the order listed. Refer to “CARBURETOR” in chapter 6.
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CAMSHAFT AND CYLINDER HEAD Order 7 8 9 10 11 12 13 Job/Part Thermo switch 1 Cylinder head Coolant outlet joint Gasket Cylinder head gasket Dowel pin Intake manifold Q’ty 1 1 1 1 1 2 1 ENG Remarks For installation, reverse the removal procedure.
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CAMSHAFT AND CYLINDER HEAD ENG REMOVING THE CAMSHAFT AND CYLINDER HEAD 1. Loosen: • camshaft sprocket bolts 1 2. Loosen: • timing chain tensioner cap bolt 3. Remove: • timing chain tensioner • timing chain guide (exhaust side) • decompressor cam guide plates • camshaft sprocket • camshaft NOTE: • Fasten a safety wire to the timing chain to prevent it from falling into the crankcase. • When removing the camshaft sprocket, it is not necessary to separate the timing chain. 4.
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CAMSHAFT AND CYLINDER HEAD ENG CHECKING THE CAMSHAFT SPROCKET 1. Check: • camshaft sprocket Wear/damage → Replace the camshaft sprocket and timing chain as a set. a 1/4 of a tooth b Correct 1 Timing chain 2 Sprocket CHECKING THE DECOMPRESSION SYSTEM 1. Check: • decompression system ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Check while the camshaft sprocket is installed on the camshaft. a. Check that the decompressor lever pin 1 projects from the camshaft. b. Check that the decompressor cam 2 moves smoothly.
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CAMSHAFT AND CYLINDER HEAD ENG b. Removing the screwdriver and slowly release the timing chain tensioner rod. c. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough movement, replace the timing chain tensioner. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE CYLINDER HEAD 1. Eliminate: • carbon deposits (from the combustion chamber) Use a rounded scraper.
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CAMSHAFT AND CYLINDER HEAD ENG d. Place a 400 ~ 600 grit wet sandpaper on the surface plate, and resurface the head using a figure-eight sanding pattern. NOTE: To ensure an even surface rotate the cylinder head several times. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ INSTALLING THE CAMSHAFT AND CYLINDER HEAD 1. Install: • cylinder head gasket New • cylinder head • bolts (M9: 1 ~ 6) T. R. T. R. • bolt (M6: 7) 38 Nm (3.8 m · kg, 27 ft · lb) 10 Nm (1.0 m · kg, 7.
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CAMSHAFT AND CYLINDER HEAD ENG c. Temporarily install the camshaft sprocket on the camshaft. (Do not install the bolts.) Then, install the timing chain on the camshaft sprocket. NOTE: Make sure the small holes 3 on the camshaft face upward. d. Align the notches 4 on the decompressor cams with the projections 5 on the decompressor spring lever, then install the camshaft sprocket on the camshaft. NOTE: Check that each part is positioned as shown in the illustration.
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CAMSHAFT AND CYLINDER HEAD ENG c. With the screwdriver still inserted into the timing chain tensioner, install the timing chain tensioner and gasket onto the cylinder block. Then, tighten the timing chain tensioner bolts to the specified torque. WARNING Always use a new gasket. NOTE: The “UP” mark on the timing chain tensioner should face up. T. Timing chain tensioner bolt 10 Nm (1.0 m · kg, 7.2 ft · lb) R. d.
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VALVES AND VALVE SPRINGS ENG VALVES AND VALVE SPRINGS Order 1 2 3 4 5 6 7 8 Job/Part Removing the valves and valve springs Cylinder head Valve cotter Valve spring retainer Intake valve spring Exhaust valve spring Intake valve Exhaust valve Valve stem seal Valve spring seat Q’ty Remarks Remove the parts in the order listed. Refer to “CAMSHAFT AND CYLINDER HEAD”. 10 5 3 2 3 2 5 5 Refer to “REMOVING THE VALVES AND VALVE SPRINGS” and “INSTALLING THE VALVES AND VALVE SPRINGS”.
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VALVES AND VALVE SPRINGS ENG REMOVING THE VALVES AND VALVE SPRINGS 1. Check: • valve sealing Leakage at the valve seat → Check the valve face, valve seat and valve seat width. Refer to “CHECKING THE VALVES AND VALVE SPRINGS”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Pour a clean solvent 1 into the intake and exhaust ports. b. Check that the valve seals properly. There should be no leakage at the valve seat 2. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2.
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VALVES AND VALVE SPRINGS ENG CHECKING THE VALVES AND VALVE SPRINGS 1. Measure: • stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Stem-to-guide clearance Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) : 0.08 mm (0.0031 in) Exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) : 0.10 mm (0.0039 in) 2.
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VALVES AND VALVE SPRINGS ENG 3. Check: • valve face Pitting/wear → Grind the face. • valve stem end Mushroom shape or diameter larger than the body of the stem → Replace. 4. Measure: • margin thickness a Out of specification → Replace. Margin thickness Intake 0.85 ~ 1.15 mm (0.0335 ~ 0.0453 in) Exhaust 0.85 ~ 1.15 mm (0.0335 ~ 0.0453 in) 5. Measure: • valve stem runout Out of specification → Replace. Runout limit 0.01 mm (0.0004 in) NOTE: • When installing a new valve always replace the guide.
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VALVES AND VALVE SPRINGS ENG 8. Measure: • valve seat width a Out of specification → Reface the valve seat. Valve seat width Intake 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) : 1.6 mm (0.0630 in) Exhaust 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) : 1.6 mm (0.0630 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply Mechanic’s blueing dye (Dykem) b to the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear pattern. d.
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VALVES AND VALVE SPRINGS ENG 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 compound. NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. e. Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: After every lapping operation be sure to clean off all of the compound from the valve face and valve seat. f.
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VALVES AND VALVE SPRINGS ENG 11.Measure: • compressed spring force a Out of specification → Replace. b Installed length Compressed spring force Intake 100.0 ~ 115.7 N at 27.5 mm (10.20 ~ 11.80 kg, 22.49 ~ 26.01 lb at 1.08 in) Exhaust 120.6 ~ 138.3 N at 31.0 mm (12.30 ~ 14.10 kg, 27.12 ~ 31.09 lb at 1.22 in) 12.Measure: • spring tilt a Out of specification → Replace. Spring tilt limit Intake 2.5°/1.4 mm (0.055 in) Exhaust 2.5°/1.6 mm (0.063 in) INSTALLING THE VALVES AND VALVE SPRINGS 1.
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VALVES AND VALVE SPRINGS ENG 3. Install: • valve cotters NOTE: Install the valve cotters while compressing the valve spring with the valve spring compressor 1 and valve spring compressor attachment 2. Valve spring compressor set P/N. YM-04019 Valve spring compressor P/N. 90890-04019 Valve spring compressor attachment P/N. YM-01253-1, 90890-01243 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood.
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CYLINDER AND PISTON ENG CYLINDER AND PISTON Order 1 2 3 4 5 6 7 8 Job/Part Removing the cylinder and piston Water pump outlet hose Cylinder head Q’ty Coolant inlet joint Cylinder/O-ring Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Piston ring set 1 1/1 1 2 2 1 1 1 Remarks Remove the parts in the order listed. Refer to “WATER PUMP” in chapter 5. Refer to “CAMSHAFT AND CYLINDER HEAD”. Refer to “INSTALLING THE CYLINDER”. Refer to “REMOVING THE PISTON” and “INSTALLING THE PISTON”.
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CYLINDER AND PISTON ENG REMOVING THE PISTON 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 NOTE: Before removing piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4. Piston pin puller P/N. YU-01304, 90890-01304 CAUTION: Do not use a hammer to drive the piston pin out. 2.
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CYLINDER AND PISTON Cylinder bore “C” ENG Standard Wear limit 100.005 ~ 100.055 mm (3.9372 ~ 3.9392 in) 100.10 mm (3.9410 in) C= X+Y 2 b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. 2nd step: a. Measure piston skirt diameter “P” with a micrometer. b 2.5 mm (0.10 in) from the piston bottom edge Piston skirt diameter “P” Standard 99.945 ~ 99.995 mm (3.9348 ~ 3.9368 in) b.
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CYLINDER AND PISTON ENG CHECKING THE PISTON RINGS 1. Measure: • ring side clearance Use a thickness gauge. Out of specification → Replace the piston and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance Standard Limit Top ring 0.04 ~ 0.08 mm 0.13 mm (0.0016 ~ 0.0031 in) (0.0051 in) 2nd ring 0.03 ~ 0.07 mm 0.13 mm (0.0012 ~ 0.0028 in) (0.0051 in) 2.
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CYLINDER AND PISTON ENG CHECKING THE PISTON PIN 1. Check: • piston pin Blue discoloration/grooves → Replace, then check the lubrication system. 2. Measure: • piston pin-to-piston clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure the piston pin outside diameter a. If out of specification, replace the piston pin. Piston pin outside diameter 21.991 ~ 22.000 mm (0.8658 ~ 0.8661 in) : 21.971 mm (0.8650 in) b. Measure the piston pin bore inside diameter b. Piston pin bore inside diameter 22.
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CYLINDER AND PISTON 2. • • • ENG Position: top ring 2nd ring oil ring Offset the piston ring end gaps as shown. a Top ring end b Upper oil ring rail end C Oil ring expander end d Lower oil ring rail end e 2nd ring end f 20 mm (0.79 in) 3. • • • Install: piston 1 piston pin 2 piston pin clips 3 New NOTE: • Apply engine oil onto the piston pin, piston rings and piston. • Be sure that the arrow mark a on the piston points to the exhaust side of the engine.
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CYLINDER AND PISTON ENG T. INSTALLING THE CYLINDER 1. Install: • cylinder • O-ring New 42 Nm (4.2 m · kg, 30 ft · lb) • bolts (M10) 10 Nm (1.0 m · kg, 7.2 ft · lb) • bolts (M6) R. T. R. NOTE: Install the cylinder with one hand while compressing the piston rings with the other hand. CAUTION: • Be careful not to damage the timing chain guide during installation. • Pass the timing chain through the timing chain cavity.
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ENGINE COOLING FAN AND A.C. MAGNETO ENG ENGINE COOLING FAN AND A.C. MAGNETO Order Job/Part Removing the engine cooling fan and A.C. magneto Driver seat/passenger seat/console Q’ty Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. Refer to “PRIMARY AND SECONDARY SHEAVES”. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Refer to “WATER PUMP” in chapter 5.
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ENGINE COOLING FAN AND A.C. MAGNETO Order 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Job/Part Engine cooling fan Air shroud 2 A.C. magneto coupler Engine cooling fan pulley base A.C. magneto cover/gasket Dowel pin Stator lead holder Pickup coil Stator assembly A.C. magneto rotor Woodruff key Starter wheel gear Washer Starter idle gear shaft Bearing ENG Q’ty Remarks 1 1 2 Disconnect. 1 Refer to “REMOVING THE A.C. MAG1/1 NETO” and “INSTALLING THE A.C. MAGNETO”. 2 1 1 1 1 Refer to “REMOVING THE A.C.
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ENGINE COOLING FAN AND A.C. MAGNETO Order 18 Job/Part Starter idle gear Q’ty 1 ENG Remarks For installation, reverse the removal procedure.
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ENGINE COOLING FAN AND A.C. MAGNETO ENG REMOVING THE A.C. MAGNETO 1. Remove: • engine cooling fan pulley 1 NOTE: Use the sheave holder 2 to hold the primary sheave. Primary sheave holder P/N. YS-01880-A Sheave holder P/N. 90890-01701 2. • • • Remove: A.C. magneto cover gasket dowel pins NOTE: Working in a crisscross pattern, loosen each bolt 1/4 of a turn. Remove them after all of them are loosened. 3. Remove: • A.C. magneto rotor 1 NOTE: Use the flywheel puller 2. Flywheel puller P/N.
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ENGINE COOLING FAN AND A.C. MAGNETO ENG CHECKING THE STARTER CLUTCH 1. Check: • starter clutch 1 Cracks/damage → Replace. • starter clutch bolts 2 Loose → Replace with new ones, and clinch the end of the bolts. NOTE: The arrow mark on the starter clutch must face inward, away from the A.C. magneto rotor. T. R. Starter clutch bolts 30 Nm (3.0 m · kg, 22 ft · lb) LOCTITE® ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the starter wheel gear onto the starter clutch, and hold the starter clutch.
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ENGINE COOLING FAN AND A.C. MAGNETO ENG CHECKING THE ENGINE COOLING FAN 1. Check: • engine cooling fan • air shroud 1 • air shroud 2 Cracks/damage → Replace. INSTALLING THE A.C. MAGNETO 1. Apply: • sealant (Quick Gasket®) 1 (into the slit) Sealant (Quick Gasket®) P/N. ACC-11001-05-01 Yamaha bond No. 1215 P/N. 90890-85505 2. Install: • woodruff key • A.C. magneto rotor NOTE: • Before installing the rotor, clean the outside of the crankshaft and the inside of the rotor.
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ENGINE COOLING FAN AND A.C. MAGNETO 1 2 3. • • • ENG Install: dowel pins gasket New A.C. magneto cover T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: • When installing the A.C. magneto cover, use a long rod to hold the A.C. magneto rotor in position from the outside. This will make assembly easier. Be careful not to damage the oil seal. • Apply sealant (Quick Gasket®) 1 to the thread of the bolt 2 shown in the illustration. • Tighten the bolts in stages, using a crisscross pattern.
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ENGINE COOLING FAN AND A.C. MAGNETO 5. • 6. • ENG Connect: A.C. magneto couplers Install: engine cooling fan 1 T. R. 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Install the bolts in the holes in the collar of the engine cooling fan. T. 7. Install: 10 Nm (1.0 m · kg, 7.2 ft · lb) • air shroud 1 • engine cooling fan air duct assembly 1 R. NOTE: Install the engine cooling fan air duct assembly with the arrow mark a towards the air shroud 1.
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BALANCER GEARS AND OIL PUMP GEARS ENG BALANCER GEARS AND OIL PUMP GEARS Order Job/Part Removing the balancer gears and oil pump gears Starter wheel gear Q’ty 1 2 3 4 Nut/lock washer Balancer driven/oil pump drive gear Chain Straight key 1/1 1 1 1 5 6 7 8 Oil pump driven gear Plate Balancer drive gear Spring Remarks Remove the parts in the order listed. Refer to “ENGINE COOLING FAN AND A.C. MAGNETO”.
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BALANCER GEARS AND OIL PUMP GEARS Order 9 Job/Part Pin Q’ty 4 ENG Remarks For installation, reverse the removal procedure.
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BALANCER GEARS AND OIL PUMP GEARS ENG REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1. Straighten the lock washer tabs. 2. Loosen: • balancer driven gear nut 1 NOTE: Place an aluminum plate 2 between the teeth of the balancer drive gear 3 and balancer driven gear 4. 3. • • • • • Remove: circlip plate 1 balancer drive gear 2 springs 3 pins 4 CHECKING THE OIL PUMP DRIVE GEAR AND OIL PUMP DRIVEN GEAR 1. Check: • oil pump drive gear 1 • oil pump driven gear 2 Cracks/wear/damage → Replace.
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BALANCER GEARS AND OIL PUMP GEARS ENG INSTALLING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1. Install: • pins • springs • balancer drive gear (onto the buffer boss) • plate • circlip NOTE: Align the punch mark a on the balancer drive gear with the hole b to the buffer boss. 2. Install: • balancer driven gear NOTE: Align the punch mark a on the balancer drive gear with the punch mark b on the balancer driven gear. 3. Install: • lock washer New • balancer driven gear nut 1 T. R. 110 Nm (11.
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PRIMARY AND SECONDARY SHEAVES ENG PRIMARY AND SECONDARY SHEAVES T. R. 14 Nm (1.4 m • kg, 10 ft • Ib) 10 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) (7) 6 7 8 T. R. 100 Nm (10.0 m • kg, 72 ft • lb) 10 9 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 5 4 LS 2 (12) 1 3 R. R. T. T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 120 Nm (12.0 m • kg, 85 ft • lb) T. R.
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PRIMARY AND SECONDARY SHEAVES ENG T. R. 14 Nm (1.4 m • kg, 10 ft • Ib) 10 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) (7) 6 7 8 T. R. 100 Nm (10.0 m • kg, 72 ft • lb) 10 9 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 5 4 LS 2 (12) 1 3 R. R. T. T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 120 Nm (12.0 m • kg, 85 ft • lb) T. R. Order 7 8 9 10 Job/Part Primary fixed sheave Secondary sheave assembly Drive belt case Rubber gasket Q’ty 1 1 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.
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PRIMARY AND SECONDARY SHEAVES ENG PRIMARY SHEAVE Order 1 2 3 4 5 6 7 8 9 Job/Part Disassembling the primary sheave Primary pulley sheave cap Primary pulley slider Spacer Primary pulley cam Primary pulley weight Collar Oil seal Primary sliding sheave O-ring Q’ty 1 4 4 1 8 1 2 1 1 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE PRIMARY SHEAVE”. For assembly, reverse the disassembly procedure.
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PRIMARY AND SECONDARY SHEAVES ENG SECONDARY SHEAVE Order 1 2 3 4 5 6 7 8 9 0 Job/Part Disassembling the secondary sheave Nut Spring seat Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Secondary fixed sheave Oil seal Oil seal Q’ty 1 1 1 1 4 1 2 1 1 1 Remarks Remove the parts in the order listed. Refer to “DISASSEMBLING THE SECONDARY SHEAVE” and “ASSEMBLING THE SECONDARY SHEAVE”. For assembly, reverse the disassembly procedure.
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PRIMARY AND SECONDARY SHEAVES ENG REMOVING THE PRIMARY AND SECONDARY SHEAVES 1. Loosen: • secondary sheave nut 1 • primary sheave nut 2 NOTE: • Use the sheave holder 3 to hold the primary sheave. • First, loosen the secondary sheave nut 1, then loosen the primary sheave nut 2. Primary sheave holder P/N. YS-01880-A Sheave holder P/N. 90890-01701 DISASSEMBLING THE SECONDARY SHEAVE 1. Remove: • nut 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
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PRIMARY AND SECONDARY SHEAVES ENG CHECKING THE PRIMARY SHEAVE 1. Check: • weight outside diameter a Out of specification → Replace the weight. Weight outside diameter 30 mm (1.18 in) : 29.5 mm (1.16 in) 2. Check: • primary pulley slider • primary sliding sheave splines Wear/cracks/damage → Replace. • spacer • primary pulley cam Cracks/damage → Replace. 3. Check: • primary sliding sheave • primary fixed sheave Cracks/damage → Replace. CHECKING THE SECONDARY SHEAVE 1.
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PRIMARY AND SECONDARY SHEAVES ENG ASSEMBLING THE PRIMARY SHEAVE 1. Clean: • primary sliding sheave face 1 • primary fixed sheave face 2 • collar 3 • weights 4 • primary sliding sheave cam face NOTE: Remove any excess grease. 2. Install: • weights 1 NOTE: • Apply Yamaha Grizzly grease (90 g) to the whole outer surface of the weights and install. • Apply Yamaha Grizzly grease to the inner surface of the collar. • Apply Yamaha Grizzly grease to the inner surface of the primary sliding sheave. 3.
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PRIMARY AND SECONDARY SHEAVES ENG 3. Apply: • BEL-RAY assembly lube® (to the guide pin sliding grooves 1, and Orings 2 New ) 4. • • • • Install: spring seat compression spring spring seat nut ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Attach the sheave fixed block, locknut wrench and sheave spring compressor to the secondary sheave assembly. Sheave fixed block P/N. YM-04135, 90890-04135 Locknut wrench P/N. YM-01348, 90890-01348 Sheave spring compressor P/N. YM-04134, 90890-04134 b.
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PRIMARY AND SECONDARY SHEAVES ENG INSTALLING THE PRIMARY AND SECONDARY SHEAVES 1. Install: • secondary sheave assembly • V-belt • primary sheave assembly NOTE: • Tightening the bolts 1 will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen. • Install the V-belt so that its arrow faces the direction show in the illustration. 2. Tighten: • primary sheave nut 1 T. R. 120 Nm (12.0 m · kg, 85 ft · lb) • secondary sheave nut 2 T. R.
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CLUTCH ENG CLUTCH Order 1 2 3 4 5 Job/Part Removing the clutch Primary and secondary sheaves Q’ty Clutch housing assembly Gasket/dowel pin One-way clutch bearing Nut Clutch carrier assembly 1 1/2 1 1 1 Remarks Remove the parts in the order listed. Refer to “PRIMARY AND SECONDARY SHEAVES”. Refer to “REMOVING THE CLUTCH” and “INSTALLING THE CLUTCH”. For installation, reverse the removal procedure.
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CLUTCH Order 1 2 3 4 5 6 7 8 Job/Part Disassembling the clutch housing Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing Q’ty ENG Remarks Remove the parts in the order listed. 1 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
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CLUTCH ENG REMOVING THE CLUTCH 1. Remove: • clutch housing assembly • gasket • dowel pins NOTE: Working in crisscross pattern, loosen each bolt 1/4 of a turn. Remove them after all of them are loosened. 2. • 3. • Straighten: punched portion of the nut 1 Remove: nut 1 NOTE: Use a universal clutch holder 2 to hold the clutch carrier assembly. Universal clutch holder P/N. YM-91042, 90890-04086 CHECKING THE CLUTCH 1. Check: • clutch housing 1 Heat damage/wear/damage → Replace.
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CLUTCH ENG b. When turning the clutch housing clockwise È, the clutch housing should turn freely. If not, the one-way clutch assembly is faulty. Replace it. c. When turning the clutch housing counterclockwise É, the clutch housing and crankshaft should be engaged. If not, the one-way clutch assembly is faulty. Replace it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • clutch shoe Heat damage → Replace. 3. Measure: • clutch shoe thickness Out of specification → Replace. Clutch shoe thickness 1.5 mm (0.
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CLUTCH ENG 3. Install: • one-way clutch bearing NOTE: The one-way clutch bearing should be installed in the clutch carrier assembly with the arrow mark a facing toward the clutch housing. 4. • • • Install: dowel pins gasket New clutch housing assembly T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: • Tighten the bolts in stages, using a crisscross pattern. • After tightening the bolts, check that the clutch housing assembly to counterclockwise rotates smoothly.
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CRANKCASE ENG CRANKCASE STARTER MOTOR, TIMING CHAIN AND OIL FILTER Order Job/Part Remove the starter motor, timing chain and oil filter Engine assembly Cylinder head Q’ty Refer to “ENGINE REMOVAL”. Refer to “CAMSHAFT AND CYLINDER HEAD”. Refer to “CYLINDER AND PISTON”. Refer to “ENGINE COOLING FAN AND A.C. MAGNETO”. Refer to “PRIMARY AND SECONDARY SHEAVES”. Refer to “CLUTCH”. Cylinder and piston A.C.
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CRANKCASE Order 5 6 7 8 9 10 11 12 13 14 Job/Part Oil pipe assembly/O-ring Oil pipe adapter/O-ring Relief valve assembly Speed sensor Shift drum stopper Gear position switch Reverse switch Oil filler cap Oil delivery pipe 1 Drain plug Q’ty 1/2 1/1 1 1 1 1 1 1 1 1 ENG Remarks For installation, reverse the removal procedure.
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CRANKCASE ENG CRANKCASE Order 1 2 3 4 5 6 7 8 9 Job/Part Separating the crankcase Shift lever cover/gasket Dowel pin Shift lever 1 Shift lever 2 assembly Right crankcase Dowel pin Left crankcase Spacer Crankshaft seal Q’ty 1/1 1 1 1 1 2 1 1 2 Remarks Remove the parts in the order listed. Refer to “INSTALLING THE SHIFT LEVERS”. Refer to “SEPARATING THE CRANKCASE” and “ASSEMBLING THE CRANKCASE”. For installation, reverse the removal procedure.
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ENG CRANKCASE CRANKCASE BEARINGS LS 1 E 4 New 2 4 E 3 T. R. 4 10 Nm (1.0 m kg, 7.2 ft Ib) E 4 4 4 E 4 4 4 E Order 1 2 3 4 Job/Part Removing the crankcase bearings Crankshaft and oil pump Transmission Middle drive/driven shaft O-ring/collar Oil seal Bearing retainer Bearing Q’ty E Remarks Remove the parts in the order listed. Refer to “CRANKSHAFT AND OIL PUMP”. Refer to “TRANSMISSION”. Refer to “MIDDLE GEAR”. 1/1 1 1 9 For installation, reverse the removal procedure.
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CRANKCASE È ENG SEPARATING THE CRANKCASE 1. Separate: • right crankcase • left crankcase ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the crankcase bolts. É NOTE: • Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. • Loosen the bolts in stages, using a crisscross pattern. È Right crankcase É Left crankcase b. Remove the left crankcase. CAUTION: Use a soft hammer to tap on one side of the crankcase. Tap only on reinforced portions of the crankcase.
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CRANKCASE ENG CHECKING THE RELIEF VALVE 1. Check: • relief valve 1 • spring 2 Damage/wear → Replace the defective part(s). CHECKING THE CRANKCASE 1. Thoroughly wash the case halves in a mild solvent. 2. Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly. 3. Check: • crankcase Cracks/damage → Replace. • oil delivery passages Clogged → Blow out with compressed air. CHECKING THE BEARINGS 1. Check: • bearings Clean and lubricate, then rotate the inner race with a finger.
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CRANKCASE ENG 3. Fit the left crankcase onto the right case. Tap lightly on the case with a soft hammer. CAUTION: Before installing and torquing the crankcase holding bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both directions. È 4. Tighten: • crankcase bolts 1, 2 (follow the proper tightening sequence) 1 1 T. R. 1 T. R. 1 1 É 2 1 4 1 26 Nm (2.
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CRANKSHAFT AND OIL PUMP ENG CRANKSHAFT AND OIL PUMP Order 1 2 3 4 5 6 Job/Part Removing the crankshaft and oil pump Crankcase separation Oil strainer/O-ring Oil pump assembly/gasket Balancer Plate Relief valve assembly Crankshaft Q’ty Remarks Remove the parts in the order listed. Refer to “CRANKCASE”. 1/1 1/1 1 1 1 1 Refer to “REMOVING THE CRANKSHAFT” and “INSTALLING THE CRANKSHAFT AND BALANCER”. For installation, reverse the removal procedure.
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CRANKSHAFT AND OIL PUMP ENG OIL PUMP Order 1 2 3 4 5 6 7 Job/Part Disassembling the oil pump Rotor cover Pin Shaft Pin Inner rotor Outer rotor Oil pump housing Q’ty Remarks Remove the parts in the order listed. 1 2 1 1 1 1 1 For assembly, reverse the disassembly procedure.
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CRANKSHAFT AND OIL PUMP ENG REMOVING THE CRANKSHAFT 1. Remove: • crankshaft Use a crankcase separating tool 1. Crankcase separating tool P/N. YU-01135-A, 90890-01135 CHECKING THE OIL PUMP 1. Check: • rotor housing • rotor cover Cracks/wear/damage → Replace. 2. Measure: • tip clearance a (between the inner rotor rotor 2) • side clearance b (between the outer rotor housing 3) • body clearance c (between the outer rotor housing 3) Out of specification → pump.
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CRANKSHAFT AND OIL PUMP ENG CHECKING THE RELIEF VALVE 1. Check: • relief valve body 1 • relief valve 2 • spring 3 • O-ring 4 Damage/wear → Replace the defective part(s). CHECKING THE OIL STRAINER 1. Check: • oil strainer 1 • O-ring 2 Damage → Replace. Contaminants → Clean with engine oil. ASSEMBLING THE OIL PUMP 1.
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CRANKSHAFT AND OIL PUMP ENG CHECKING THE CRANKSHAFT 1. Measure: • crank width A Out of specification → Replace the crankshaft. Crank width 74.95 ~ 75.00 mm (2.9508 ~ 2.9528 in) • side clearance D Out of specification → Replace the crankshaft. Big end side clearance 0.35 ~ 0.65 mm (0.0138 ~ 0.0256 in) : 1.0 mm (0.0394 in) • runout C Out of specification → Replace the crankshaft. Runout limit C1: 0.03 mm (0.0012 in) C2: 0.03 mm (0.
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CRANKSHAFT AND OIL PUMP ENG INSTALLING THE CRANKSHAFT AND BALANCER 1. Install: • crankshaft Crankshaft installer pot 1 P/N. 90890-01274 Crankshaft installer bolt 2 P/N. 90890-01275 Crankshaft installer set 3 P/N. YU-90050 Adapter 4 P/N. YM-01383, 90890-01383 Spacer (crankshaft installer) 5 P/N. YM-91044, 90890-04081 Spacer 6 P/N. 90890-01309 NOTE: Hold the connecting rod at the Top Dead Center (TDC) with one hand while turning the nut of the installing tool with the other.
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TRANSMISSION ENG TRANSMISSION Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Removing the transmission Crankcase separation Middle driven gear Low wheel gear Shift drum Shift fork assembly Short spring Shift fork 1 Long spring Shift fork 2 Guide bar Secondary shaft Drive axle assembly Chain Q’ty 1 1 1 1 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “CRANKCASE”. Refer to “MIDDLE GEAR”. White painting Refer to “REMOVING THE TRANSMISSION” and “INSTALLING THE TRANSMISSION”.
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TRANSMISSION ENG DRIVE AXLE ASSEMBLY Order 1 2 3 4 5 Job/Part Disassembling the drive axle assembly Clutch dog High wheel gear Middle drive gear Driven sprocket Drive axle Q’ty Remarks Remove the parts in the order listed. 1 1 1 1 1 For assembly, reverse the disassembly procedure.
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TRANSMISSION ENG REMOVING THE TRANSMISSION 1. Remove: • shift drum 1 • shift fork assembly 2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Pull out the guide bar from the right crankcase. b. Slide the shift fork assembly and remove the shift fork followers from the shift drum grooves. c. Remove the shift drum. d. Remove the shift fork assembly. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2.
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TRANSMISSION ENG 3. Check: • shift fork movement (on the guide bar) Unsmooth operation → Replace the shift fork and the guide bar. 4. Check: • springs Cracks/damage → Replace. CHECKING THE SHIFT DRUM 1. Check: • shift drum grooves Scratches/wear/damage → Replace. CHECKING THE DRIVE AXLE 1. Measure: • axle runout Use a centering device and a dial gauge. Out of specification → Replace the bent axle. Drive axle runout limit 0.06 mm (0.0024 in) CHECKING THE HIGH WHEEL GEAR AND MIDDLE DRIVE GEAR 1.
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TRANSMISSION ENG 2. Check: • gear movement Unsmooth → Repeat steps #1 or replace the defective parts. 3. Check: • circlip Bends/looseness/damage → Replace. CHECKING THE SECONDARY SHAFT AND DRIVEN SPROCKET 1. Check: • gear teeth Blue discoloration/pitting/wear → Replace. 2. Check: • gear movement Unsmooth → Repeat steps #1 or replace the defective parts. 3. Check: • circlip Bends/looseness/damage → Replace. CHECKING THE CHAIN 1.
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TRANSMISSION ENG ASSEMBLING THE SHIFT FORK ASSEMBLY 1. Install: • guide bar 1 • shift fork 2 2 • long spring 3 • shift fork 1 4 • short spring 5 INSTALLING THE TRANSMISSION 1. Install: • chain 1 • drive axle assembly 2 • secondary shaft 3 • shift fork assembly 4 • shift drum 5 • low wheel gear 2. Check: • shift operation Unsmooth operation → Repair. NOTE: • Oil each gear and bearing thoroughly. • Before assembling the crankcase, be sure that the transmission is in neutral and that the gears turn freely.
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MIDDLE GEAR ENG MIDDLE GEAR MIDDLE DRIVE SHAFT Order 1 2 3 4 Job/Part Removing the middle drive shaft Crankcase separation Bearing housing Middle driven gear Nut Middle drive pinion gear 5 Shim 6 7 Middle drive shaft Bearing retainer Q’ty 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “CRANKCASE”. Refer to “REMOVING THE MIDDLE DRIVE SHAFT” and “INSTALLING THE MIDDLE DRIVE SHAFT”. Refer to “SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS”.
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MIDDLE GEAR ENG MIDDLE DRIVEN SHAFT Order 1 2 3 4 5 6 7 Job/Part Removing the middle driven shaft Crankcase separation Drive shaft coupling Circlip Bearing Universal joint Universal joint yoke Bearing housing/O-ring Shim 8 9 Middle driven pinion gear Bearing retainer Q’ty 1 2 2 1 1 1/1 1 1 4 - 86 Remarks Remove the parts in the order listed. Refer to “CRANKCASE”. Refer to “REMOVING THE MIDDLE DRIVEN SHAFT” and “INSTALLING THE MIDDLE DRIVEN SHAFT”.
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MIDDLE GEAR Order 10 11 Job/Part Bearing retainer Middle driven shaft Q’ty 1 1 ENG Remarks For installation, reverse the removal procedure.
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MIDDLE GEAR ENG REMOVING THE MIDDLE DRIVE SHAFT 1. Straighten: • punched portion of the nut (middle drive pinion gear) 2. Loosen: • middle drive pinion gear nut 1 NOTE: Secure the middle drive shaft in the vise with a clean rag. 3. • • • Remove: middle drive pinion gear nut middle drive pinion gear shim(s) REMOVING THE MIDDLE DRIVEN SHAFT 1. Remove: • nut 1 • washer • drive shaft coupling 1 2 NOTE: Use the coupling gear/middle shaft tool 2 to hold the drive shaft coupling.
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MIDDLE GEAR ENG 2. Remove: • universal joint ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the circlips 1. b. Place the universal joint in a press. c. With a suitable diameter pipe 2 beneath the yoke 3, press the bearing 4 into the pipe as shown. NOTE: It may be necessary to lightly tap the yoke with a punch. d. Repeat the steps for the opposite bearing. e. Remove the yoke. NOTE: It may be necessary to lightly tap the yoke with a punch. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3.
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MIDDLE GEAR ENG 4. Remove: • bearing housing assembly 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside of the bearing housing assembly. b. Place the bearing housing assembly onto a hydraulic press. CAUTION: • Never directly press the middle driven pinion gear end with a hydraulic press, this will result in damage to the middle driven pinion gear thread. • Install the suitable socket 2 on the middle driven pinion gear end to protect the thread from damage. c.
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MIDDLE GEAR 6. • • • • ENG Remove: drive shaft coupling oil seal 1 bearing retainer 2 bearing NOTE: Attach the ring nut wrench 3. Ring nut wrench P/N. YM-38404, 90890-01430 CAUTION: The middle driven shaft bearing retainer has left-handed threads. To loosen the retainer, turn it clockwise. 7. Remove: • middle driven shaft 1 (with bearing) CHECKING THE PINION GEARS 1. Check: • gear teeth (drive pinion gear) 1 • gear teeth (driven pinion gear) 2 Pitting/galling/wear → Replace. 2.
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MIDDLE GEAR ENG SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS When the drive and driven gear, bearing housing assembly and/or crankcase replaced, be sure to adjust the gear shims 1 and 2. 1. Select: • middle drive gear shim 1 • middle driven gear shim 2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Position middle drive and driven gear by using shims 1 and 2 with their respective thickness calculated from information marked on crankcase, bearing housing and drive gear end.
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MIDDLE GEAR ENG Example: 1) If the bearing housing is marked “+02”, ...... a is 7.52, 2) b is 17 3) c is 55 4) If the crankcase (left) is marked “64.98”, ...... d is 64.98. 5) Therefore, the shim thickness is 0.50 mm. A = 7.52 + 64.98 – 17 – 55 = 0.50 6) Round off hundredths digit and select appropriate shim(s). In the example above, the calculated shim thickness is 0.50 mm. The chart instructs you, however, to round off 0 to 0.
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MIDDLE GEAR ENG g = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from “80.5”. h = a numeral (usually a decimal number) on the right crankcase specifies a thickness of “97.26”. i = a numeral (usually a decimal number) on the left crankcase specifies a thickness of “1.66”. Example: 1) If the bearing housing is marked “–06”, ...... e is 75.94. 2) If the driven pinion gear is marked “+0”, ...... f is 60.00.
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MIDDLE GEAR ENG INSTALLING THE MIDDLE DRIVEN SHAFT 1. Install: • bearing retainer 1 T. R. Bearing retainer 80 Nm (8.0 m · kg, 58 ft · lb) LOCTITE® NOTE: Attach the ring nut wrench 2. Ring nut wrench P/N. YM-38404, 90890-01430 CAUTION: The middle driven shaft bearing retainer has left-handed threads. To tighten the retainer, turn it counterclockwise. 2. Install: • bearing retainer 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place a rag 2 in the vise. b. Secure the bearing housing edge in the vise. c.
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MIDDLE GEAR ENG 3. Install: • shims 1 • bearing housing NOTE: Install the shims so that the tabs are positioned as shown in the illustration. 4. • • • Install: universal joint yoke washer nut 1 NOTE: Use the universal joint holder 2 to hold the yoke. T. R. Universal joint yoke nut 150 Nm (15.0 m · kg, 110 ft · lb) LOCTITE® Universal joint holder P/N. YM-04062, 90890-04062 5. Install: • universal joint ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the opposite yoke into the universal joint. b.
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MIDDLE GEAR ENG d. Press each bearing into the universal joint using a suitable socket. NOTE: The bearing must be inserted far enough into the universal joint so that the circlip can be installed. e. Install the circlips 2 into the groove of each bearing. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ R. 1 Install: drive shaft coupling washer nut 1 97 Nm (9.7 m · kg, 70 ft · lb) T. 6. • • • NOTE: Use the coupling gear/middle shaft tool 2 to hold the drive shaft coupling. 2 Coupling gear/middle shaft tool P/N.
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MIDDLE GEAR ENG MEASURING THE MIDDLE GEAR BACKLASH 1. Measure: • gear lash Middle gear lash 0.1 ~ 0.3 mm (0.004 ~ 0.012 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Temporary install the left crankcase. b. Wrap a rag 1 around a screwdriver 2, and then insert it into the installation hole 3 of the right crankcase speed sensor to hold the middle driven gear. c. Attach the gear lash measurement tool 4 and dial gauge 5. Gear lash measurement tool P/N. YM-01467, 90890-01467 a 6.7 mm (0.26 in) d.
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COOL RADIATOR AND COOLANT RESERVOIR COOLING SYSTEM RADIATOR AND COOLANT RESERVOIR 12 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 11 2 3 6 5 8 7 4 10 1 9 T. R. Order 1 2 3 4 5 6 7 8 9 10 5 28 Nm (2.
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COOL RADIATOR AND COOLANT RESERVOIR 12 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 11 2 3 6 5 8 7 4 10 1 9 T. R. Order 11 12 28 Nm (2.8 m • kg, 20 ft • Ib) Job/Part Coolant reservoir Coolant reservoir breather hose Q’ty Remarks 1 1 Disconnect. For installation, reverse the removal procedure.
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RADIATOR AND COOLANT RESERVOIR COOL CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. 2. Check: • radiator hoses Cracks/damage → Replace. 3. Measure: • radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Radiator cap opening pressure 107.9 ~ 137.3 kPa (1.079 ~ 1.373 kg/cm2, 15.35 ~ 19.
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RADIATOR AND COOLANT RESERVOIR COOL INSTALLING THE RADIATOR 1. Fill: • cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part.
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WATER PUMP COOL WATER PUMP 3 2 1 4 8 5 New LS 7 New LS New 6 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) Order 1 2 3 4 5 6 7 8 Job/Part Removing the water pump Driver seat/passenger seat/console Coolant outlet joint breather hose Water pump inlet hose Water pump outlet hose Water pump outlet pipe O-ring Water pump assembly O-ring Water pump breather hose Q’ty Remarks Remove the parts in the order listed. Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8.
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WATER PUMP Order 1 2 3 4 5 6 7 8 9 0 Job/Part Disassembling the water pump Water pump housing cover Gasket Circlip Impeller Rubber damper holder Rubber damper Water pump seal Oil seal Bearing Water pump housing Q’ty COOL Remarks Remove the parts in the order listed. 1 1 1 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
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WATER PUMP COOL DISASSEMBLING THE WATER PUMP 1. Remove: • rubber damper holder 1 • rubber damper 2 (from the impeller, with a thin, flathead screwdriver) NOTE: Do not scratch the impeller shaft. 2. Remove: • water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing. 2 Water pump housing 3. Remove: • bearing 1 • oil seal 2 NOTE: Tap out the bearing and oil seal from the outside of the water pump housing. 3 Water pump housing CHECKING THE WATER PUMP 1.
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WATER PUMP COOL 3. Measure: • impeller shaft tilt Out of specification → Replace. Max. impeller shaft tilt 0.15 mm (0.006 in) 1 Straightedge 2 Impeller ASSEMBLING THE WATER PUMP 1. Install: • oil seal 1 New (into the water pump housing 2) NOTE: • Before installing the oil seal, apply tap water or coolant onto its outer surface. • Install the oil seal with a socket 3 that matches its outside diameter. 2.
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WATER PUMP COOL 3. Install: • rubber damper 1 New • rubber damper holder 2 New NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. CAUTION: Make sure that the rubber damper and rubber damper holder are flush with the impeller.
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OIL COOLER COOL OIL COOLER . R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) . R. 7 Nm (0.7 m • kg, 5.
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OIL COOLER COOL . R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) . R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 2 New LS 5 2 LS 7 New 4 6 3 8 (4) Order 8 Job/Part Oil cooler inlet pipe 2/oil cooler outlet pipe 2 Q’ty 1/1 Remarks For installation, reverse the removal procedure.
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OIL COOLER COOL CHECKING THE OIL COOLER 1. Check: • oil cooler Obstruction → Clean. Apply compressed air to the rear of the oil cooler. Damage → Repair or replace the oil cooler. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. 2. Check: • oil hoses Cracks/damage → Replace.
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FUEL PUMP AND FUEL TANK FUEL FUEL SYSTEM FUEL PUMP AND FUEL TANK R. R. 9 6 T. T. 30 Nm (3.0 m • kg, 22 ft • Ib) 7 Nm (0.7 m • kg, 5.
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FUEL PUMP AND FUEL TANK R. R. 6 T. T. 30 Nm (3.0 m • kg, 22 ft • Ib) FUEL 7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 9 2 1 10 5 3 4 2 7 8 11 Order 10 11 Job/Part Fuel tank cap Fuel tank Q’ty 1 1 Remarks For installation, reverse the removal procedure.
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FUEL PUMP AND FUEL TANK FUEL EAS00506 CHECKING THE FUEL PUMP OPERATION 1. Remove: • driver seat • passenger seat • console • right protector Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. 2. Place a container under the end of the fuel hose 1. 1 3. Check: • fuel pump operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1 a. Suck on the end of the vacuum hose 1. Fuel flows. Fuel pump is OK. Fuel does not flow. Replace the fuel pump. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4.
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CARBURETOR FUEL CARBURETOR 6 9 14 5 3 2 12 11 7 10 1 4 8 13 Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Removing the carburetor Driver seat/passenger seat/console Q’ty Crankcase breather hose Air filter case Carburetor joint (air filter case) Vacuum chamber breather hose Air vent hose Starter cable/starter plunger Fuel hose Carburetor heater lead Carburetor assembly Drain hose Throttle valve cover 1 1 1 1 1 1/1 1 2 1 1 1 1 6-4 Remarks Remove the parts in the order listed.
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CARBURETOR 6 9 FUEL 14 5 3 2 12 11 7 10 1 4 8 13 Order 12 13 14 Job/Part Throttle cable end Throttle cable Carburetor joint (intake manifold) Q’ty 1 1 1 Remarks For installation, reverse the removal procedure.
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CARBURETOR Order Job/Part Disassembling the carburetor Q’ty FUEL Remarks Remove the parts in the order listed. NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position.
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CARBURETOR Order 9 0 A B Job/Part Pilot air jet Drain screw Float chamber Float C D E Needle valve set Main jet Needle jet F G H Pilot jet Starter jet Carburetor heater FUEL Q’ty Remarks 1 1 1 1 Refer to “ASSEMBLING THE CARBURETOR”. 1 1 1 Refer to “ASSEMBLING THE CARBURETOR”. 1 1 1 For assembly, reverse the disassembly procedure.
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CARBURETOR FUEL DISASSEMBLING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. CHECKING THE CARBURETOR 1. Check: • carburetor body • float chamber Cracks/damage → Replace. • fuel passage Contamination → Clean as indicated. • fuel chamber body Contamination → Clean. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wash the carburetor in a petroleum based solvent.
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CARBURETOR FUEL 4. Check: • piston valve 1 Scratches/wear/damage → Replace. • rubber diaphragm 2 Tears → Replace. 5. Check: • vacuum chamber cover 1 • spring 2 Cracks/damage → Replace. 6-9 6. • • • Check: diaphragm (coasting enricher) 1 spring 2 cover 3 Tears (diaphragm) /damage → Replace. 7. • • • • • • • Check: jet needle 1 main jet 2 needle jet 3 pilot air jet 4 pilot jet 5 starter jet 6 starter plunger 7 Bends/wear/damage → Replace. Blockage → Blow out the jets with compressed air.
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CARBURETOR FUEL 8. Check: • free movement (piston valve) Sticks → Replace the piston valve guide and the piston valve. Insert the piston valve into the carburetor body, and check for free movement. 9. Check: • free movement (throttle valve) Sticks → Replace. ASSEMBLING THE CARBURETOR NOTE: Before assembling the carburetor, make sure to turn out the pilot screw the same number of times, as noted before disassembly, from the seated position to the set position.
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CARBURETOR FUEL ADJUSTING THE FUEL LEVEL 1. Measure: • fuel level a Out of specification → Adjust. Fuel level 4.0 ~ 5.0 mm (0.16 ~ 0.20 in) Above the float chamber mating surface ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place the vehicle on a level surface. b. Connect the fuel level gauge 1 to the drain pipe 2. Fuel level gauge P/N. YM-01312-A, 90890-01312 c. Loosen the drain screw 3. d. Hold the gauge vertically next to the float chamber line. e. Measure the fuel level a with the gauge. f.
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TROUBLESHOOTING DRIV DRIVE TRAIN TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1. A pronounced hesitation or “jerky” movement during acceleration, deceleration, or sustained speed. (This must not be confused with engine surging or transmission characteristics.) 2. A “rolling rumble” noticeable at low speed; a high-pitched whine; a “clunk” from a shaft drive component or area. 3.
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TROUBLESHOOTING DRIV CAUTION: Too little gear lash is extremely destructive to the gear teeth. If a test ride following reassembly indicates this condition, stop riding immediately to minimize gear damage. c. A slight “thunk” evident at low speed operation. This noise must be distinguished from normal vehicle operation. Diagnosis: Possible broken gear teeth. WARNING Stop riding immediately if broken gear teeth are suspected.
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TROUBLESHOOTING DRIV Troubleshooting chart When basic condition “a” and “b” exist, check the following points: Elevate and spin both wheels. Feel for wheel YES Replace the wheel bearing. bearing damage. (Refer to “STEERING SYSTEM” and “REAR KNUCKLE AND STABILIZER” in chapter 8.) NO Check the wheel nuts and hub nuts for tight- NO Torque to specification. ness. (Refer to “FRONT WHEELS AND BRAKE DISCS” and “REAR WHEELS AND BRAKE DISC” in chapter 8.) YES Check the front constant velocity joints.
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FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT DRIV FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT T. R. 55 Nm (5.5 m • kg, 40 ft • Ib) 1 LS 3 2 5 6 LS 4 LS LS T. R. 55 Nm (5.5 m • kg, 40 ft • Ib) 1 Order Job/Part Removing the front constant velocity joints, differential gear and drive shaft Front skid plate Q’ty Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. Drain. Refer to “STEERING SYSTEM” in chapter 8.
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FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT DRIV T. R. 55 Nm (5.5 m • kg, 40 ft • Ib) 1 LS 3 2 5 6 LS 4 LS LS T. R. 55 Nm (5.5 m • kg, 40 ft • Ib) 1 Order 4 5 6 Job/Part Differential gear assembly Drive shaft Compression spring Q’ty 1 1 1 Remarks For installation, reverse the removal procedure.
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FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT Order 1 2 3 4 5 6 7 8 9 Job/Part Disassembling the constant velocity joint Circlip Boot band Boot band Dust boot Circlip Double off-set joint Circlip Ball bearing Joint shaft assembly Q’ty 1 2 2 2 1 1 1 1 1 DRIV Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS”. For assembly, reverse the disassembly procedure.
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FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT Order DRIV Q’ty Remarks Remove the parts in the order listed. 1 Job/Part Disassembling the differential gear Gear motor/O-ring 1/1 NOTE: Do not disassemble the gear motor or remove the pinion gear.
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FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT Order B C D E F G H I J Job/Part Shim (right) Differential gear assembly Shim (left) Bearing Bearing Circlip/bearing Drive pinion gear Differential gear case Bearing Q’ty DRIV Remarks 1 1 1 1/1 1 1 1 For assembly, reverse the disassembly procedure.
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FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT DRIV DISASSEMBLING THE UNIVERSAL JOINT 1. Remove: • universal joint ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the circlips 1. b. Place the universal joint in a press. c. With a suitable diameter pipe 2 beneath the yoke 3, press the bearing 4 into the pipe as shown. NOTE: It may be necessary to lightly tap the yoke with a punch. d. Repeat the steps for the opposite bearing. e. Remove the yoke. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2.
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FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT DRIV CHECKING THE CONSTANT VELOCITY JOINTS 1. Check: • double off-set joint spline • ball joint spline • shaft spline Wear/damage → Replace. 2. Check: • dust boots Cracks/damage → Replace. CAUTION: Always use a new boot band. 3. Check: • balls and ball races • inner surface of double off-set joint Pitting/wear/damage → Replace. CHECKING THE DIFFERENTIAL GEAR 1.
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FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT 1 DRIV 3. Check: • front drive shaft Bends → Replace. • torque limiter Loose → Replace the front drive shaft. WARNING Do not attempt to straighten a bent shaft; this may dangerously weaken the shaft. È CHECKING THE GEAR MOTOR 1. Check: • gear motor ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect two C size batteries to the gear motor terminals 1 (as shown in the illustrations).
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FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT DRIV 2. Install: • dust boots 1 • boot bands 2, 3 New ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply molybdenum disulfide grease into the dust boots. Molybdenum disulfide grease 40 g (1.4 oz) per dust boot (front wheel side) 45 g (1.6 oz) per dust boot (differential gear case side) b. Install the dust boots. c. Install the dust boot bands. NOTE: • The new boot bands may differ from the original ones.
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FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT DRIV b. Connect two C size batteries to the gear motor terminal 2 to operate the pinion gear 3. Operate the pinion gear until the paint mark 4 on the gear is aligned with the paint mark 5 on the gear motor case. CAUTION: Do not use a 12 V battery to operate the pinion gear. c.
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FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT DRIV 4. Check: • differential gear operation Unsmooth operation → Replace the differential gear assembly. Insert the double off-set joint into the differential gear, and turn the gear back and forth. ASSEMBLING THE UNIVERSAL JOINT 1. Install: • universal joint ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the opposite yoke into the universal joint. b. Apply wheel bearing grease to the bearings. c. Install the bearing 1 onto the yoke.
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FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT DRIV 3. Install: • a bolt of the specified size 1 (into the drain plug hole) CAUTION: Finger tighten the bolt until it holds the ring gear. Otherwise, the ring gear will be damaged. 4. Attach: • gear lash measurement tool 1 • dial gauge 2 Gear lash measurement tool P/N. YM-01467, 90890-01467 a Measuring point is 21 mm (0.83 in) 5. Measure: • gear lash Gently rotate the gear coupling from engagement to engagement. Differential gear lash 0.
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FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT DRIV 2. Adjust: • gear lash ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Select the suitable shims using the following chart. Too little gear lash Reduce right shim thickness. Too large gear lash Increase right shim thickness. Ring gear shim (left and right) Thickness (mm) 0.1 0.2 0.3 0.4 0.5 1.0 1.5* * right shim only NOTE: • Use a combination of shims (left and right) so that the differential gear lash is within specification.
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FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT DRIV 3. Measure the starting torque of the front wheel (i.e., differential gear preload) with a torque wrench. NOTE: • Repeat this step several times to obtain an average figure. • During this test, the other front wheel will turn in the opposite direction. T. R. Front wheel starting torque (differential gear preload) New unit 17 ~ 25 Nm (1.7 ~ 2.5 m · kg, 12 ~ 18 ft · lb) Minimum 10 Nm (1.0 m · kg, 7.2 ft · lb) 4.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT DRIV REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT T. R. 70 Nm (7.0m • kg, 51 ft • Ib) 1 LS LS 2 4 6 5 3 LS 1 Order Job/Part Removing the rear constant velocity joints, final drive gear and drive shaft Rear skid plate Q’ty Muffler/exhaust pipe Final gear oil Rear knuckle Rear lower arm Brake caliper assembly 7 - 18 Remarks Remove the parts in the order listed.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT DRIV T. R. 70 Nm (7.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT Order 1 2 3 4 5 6 7 8 9 Job/Part Disassembling the rear constant velocity joint Circlip Boot band Boot band Dust boot Circlip Double off-set joint Circlip Ball bearing Joint shaft assembly Q’ty 1 2 2 2 1 1 1 1 1 DRIV Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS”. For assembly, reverse the disassembly procedure.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT Order 1 2 3 4 5 6 7 8 9 0 A Job/Part Disassembling the final gear case Rear brake disc Q’ty Bolt Final drive pinion gear shim Drive shaft coupling Final drive pinion gear Inner race Oil seal Bearing retainer Bearing O-ring Final drive pinion gear bearing housing Ring gear stopper 4 * 1 1 1 1 1 1 1 1 1 7 - 21 DRIV Remarks Remove the parts in the order listed. Refer to “REAR WHEELS AND BRAKE DISC” in chapter 8.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT Order B C D E F G H I J K L Job/Part Bolt Bolt Oil seal Bearing O-ring Ring gear bearing housing Ring gear shim Ring gear Thrust washer Oil seal Final gear case Q’ty 2 6 1 1 1 1 * 1 1 1 1 7 - 22 DRIV Remarks NOTE: Working in a crisscross pattern, loosen each bolt 1/4 of a turn. After all the bolts are loosened, remove them.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT Order M N Job/Part Bearing Bearing Q’ty 1 1 7 - 23 DRIV Remarks Refer to “REMOVING THE FINAL DRIVE ROLLER BEARINGS” and “INSTALLING THE FINAL DRIVE ROLLER BEARINGS”. For assembly, reverse the disassembly procedure.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT DRIV ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS 1. Apply: • molybdenum disulfide grease (into the ball joint assembly) 2. Install: • dust boots 1 • boot bands 2, 3 New ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply molybdenum disulfide grease into the dust boots. Molybdenum disulfide grease 40 g (1.8 oz) per dust boot (rear wheel side) 60 g (2.3 oz) per dust boot (final gear case side) b. Install the dust boots. c. Install the dust boot bands.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 2. Remove: • final drive pinion gear bearing housing assembly 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean the outside surface of the final drive pinion gear. b. Place the final drive pinion gear in a hydraulic press. CAUTION: _ • Never directly press the gear end with a hydraulic press, this will result in damage to the gear thread. • Install the suitable socket 2 on the gear end to protect the thread from damage. c.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 2. Remove: • roller bearing (final drive pinion gear) 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Heat the main housing only to 150 °C (302 °F). b. Remove the roller bearing outer race with an appropriately shaped punch 2. c. Remove the inner race from the final drive pinion gear. NOTE: The removal of the final drive pinion gear roller bearing is difficult and seldom necessary.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT DRIV Selecting the final drive pinion gear shim 1. Select: • final drive pinion gear shim(s) 1 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ “A” a. To find the final drive pinion gear shim thickness “A”, use the following formula. Final drive pinion gear shim thickness: “A” = a + (c – b) – d b c a d a = 92.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT DRIV Shims are supplied in the following thicknesses. Final drive pinion gear shim Thickness (mm) 0.25 0.40 0.30 0.45 0.35 0.50 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Selecting the ring gear shim 1. Select: • ring gear shim(s) 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. To find the ring gear shim thickness “B”, use the following formula.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 6) Round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated number is 0.48. The chart instructs you to round off 8 to 10 at the hundredth place. Thus, the shim thickness is 0.50 mm. Hundredths Rounded value 0, 1, 2 0 3, 4, 5, 6, 7 5 8, 9 10 Shims are supplied in the following thicknesses. Ring gear shim Thickness (mm) 0.25 0.40 0.30 0.45 0.35 0.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT DRIV c. Remove the final gear case assembly. d. Measure the thrust clearance. Calculate the width of the flattened Plastigauge® 1. Ring gear thrust clearance 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) e. If out of specification, select the correct washer. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Select: • ring gear thrust clearance “C” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Select a suitable thrust washer using the following chart.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT 1 2 DRIV CHECKING THE DRIVE SHAFT 1. Check: • drive shaft (splines) 1 • coupling gear (splines) 2 Wear/damage → Replace. CHECKING THE FINAL GEAR CASE 1. Check: • final gear case 1 • ring gear bearing housing 2 Cracks/damage → Replace. NOTE: When the final gear case and/or the ring gear bearing housing are replaced, be sure to adjust the shim of the final drive pinion gear and/or ring gear. 2.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT DRIV MEASURING AND ADJUSTING THE FINAL GEAR LASH Measuring the final gear lash 1. Secure the gear case in a vise or another supporting device. 2. Remove: • drain plug • gasket 3. Install: • a bolt of the specified size 1 (into the drain plug hole) CAUTION: Finger tighten the bolt until it holds the ring gear. Otherwise, the ring gear will be damaged. 4. Attach: • gear lash measurement tool 1 • dial gauge 2 Gear lash measurement tool P/N.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT DRIV Adjusting the final gear lash 1. Remove: • ring gear bearing housing 1 • ring gear shim(s) 2 • ring gear 3 • thrust washer 4 2. Adjust: • gear lash ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Select a suitable shim(s) and washer(s) using the following chart. thrust Too little gear lash Reduce shim thickness. Too large gear lash Increase shim thickness. b. If increased by more than 0.2 mm (0.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 2. Install: • ring gear bearing housing • M8 bolts (ring gear bearing housing) 1 T. R. 23 Nm (2.3 m · kg, 17 ft · lb) • M10 bolts (ring gear bearing housing) 2 T. R. 40 Nm (4.0 m · kg, 29 ft · lb) NOTE: Apply Quick Gasket® to the bolts 1 and 2 threads. 3. Install: • bearing retainer ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place a folded rag 1. b. Secure the final drive pinion gear bearing housing edge in the vise.
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REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT DRIV 4. Install: • drive shaft coupling nut ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place a folded rag 1. b. Secure the drive shaft coupling edge in the vise. c. Tighten the drive shaft coupling nut. T. Drive shaft coupling nut 80 Nm (8.0 m · kg, 58 ft · lb) R. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Check: • final drive gear operation Unsmooth operation → Replace the final drive gear assembly.
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SEATS, ENCLOSURE, HOOD AND CARGO BED CHAS CHASSIS SEATS, ENCLOSURE, HOOD AND CARGO BED FRONT BUMPER AND HOOD 4 T. R. 16 Nm (1.6 m • kg, 11 ft • Ib) 3 T. R. 32 Nm (3.2 m • kg, 23 ft • Ib) T. R. 59 Nm (5.9 m • kg, 43 ft • Ib) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 2 1 Order 1 2 3 4 Job/Part Removing the front bumper and front fender Front bumper protector Front bumper Headlight coupler Hood Q’ty 1 1 2 1 Remarks Remove the parts in the order listed. Disconnect.
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CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED SEATS, CONSOLE AND INSTRUMENT PANELS 2 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 3 (7) 13 12 (16) 14 T. R. 35 Nm (3.
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CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED 2 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 3 (7) 13 12 (16) 14 T. R. 35 Nm (3.5 m • kg, 25 ft • Ib) 6 12 (5) 4 (9) 11 Order 11 12 13 14 Job/Part Auxiliary DC jack connector Nut/starter cable Upper instrument panel Lower instrument panel 10 9 5 8 7 Q’ty Remarks 2 Disconnect. 1/1 1 1 For installation, reverse the removal procedure.
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SEATS, ENCLOSURE, HOOD AND CARGO BED CHAS PANELS AND FOOTREST COVER 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. 6 R. 10 T. R. 8 16 Nm (1.6 m • kg, 11 ft • Ib) 6 5 2 7 (4) 4 (6) (4) 9 (6) 3 (12) (4) 13 (4) (8) 11 1 (8) 12 T. R.
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SEATS, ENCLOSURE, HOOD AND CARGO BED 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. 6 R. 10 CHAS T. R. 8 16 Nm (1.6 m • kg, 11 ft • Ib) 6 5 2 7 (4) 4 (6) (4) 9 (6) 3 (12) (4) 13 (4) (8) 11 1 (8) 12 T. R. Order 13 Job/Part Passenger seat support Q’ty 1 32 Nm (3.2 m • kg, 23 ft • Ib) Remarks For installation, reverse the removal procedure.
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SEATS, ENCLOSURE, HOOD AND CARGO BED CHAS CARGO BED T. R. 16 Nm (1.6 m • kg, 11 ft • Ib) 1 New 2 New 3 1 2 4 3 T. R. Order 1 2 3 4 16 Nm (1.6 m • kg, 11 ft • Ib) Job/Part Removing the cargo bed Tail/brake light connector Damper Pin Cargo bed assembly Q’ty 6 2 2 1 Remarks Remove the parts in the order listed. Disconnect. For installation, reverse the removal procedure.
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SEATS, ENCLOSURE, HOOD AND CARGO BED CHAS T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) (12) T. R. 5 7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 (12) 2 (9) 3 4 1 7 4 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) (9) 6 3 T. R. 26 Nm (2.6 m • kg, 19 ft • Ib) T. R. Order 1 2 3 4 5 6 7 Job/Part Disassembling the cargo bed Hinge cover Tailgate Cargo bed panel Tail/brake light bulb holder Mud guard Cargo bed release lever Cargo bed Q’ty 11 Nm (1.1 m • kg, 8.0 ft • Ib) Remarks Remove the parts in the order listed.
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SEATS, ENCLOSURE, HOOD AND CARGO BED CHAS SKID PLATES T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) (4) 3 (4) (7) (7) 2 (11) 1 (11) (11) (11) T. R. Order 1 2 3 Job/Part Removing the engine skid plates Front skid plate Center skid plate Rear skid plate Q’ty 7 Nm (0.7 m • kg, 5.1 ft • Ib) Remarks Remove the parts in the order listed. 1 1 1 For installation, reverse the removal procedure.
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CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED ENCLOSURE AND SEAT BELTS (8) 2 T. R. 64 Nm (6.4 m • kg, 46 ft • Ib) 1 T. R. 64 Nm (6.4 m • kg, 46 ft • Ib) (4) 6 3 4 T. R. 64 Nm (6.4 m • kg, 46 ft • Ib) T. R. 59 Nm (5.9 m • kg, 43 ft • Ib) 7 (4) 5 (8) 8 T. R. Order 1 2 3 4 5 6 7 8 Job/Part Removing the enclosure and seat belts Front top frame Rear top frame Left support frame Right support frame Left side frame Right side frame Seat belt Buckle 59 Nm (5.
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FRONT WHEELS AND BRAKE DISCS CHAS FRONT WHEELS AND BRAKE DISCS T. R. 260 Nm (26.0 m • kg, 190 ft • lb) 4 3 New 1 LT LT 6 5 2 T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) T. R. 48 Nm (4.8 m • kg, 35 ft • Ib) T. R. Order Job/Part Removing the front wheel Q’ty 55 Nm (5.5 m • kg, 40 ft • Ib) Remarks Remove the parts in the order listed. Place the vehicle on a level surface. WARNING Securely support the vehicle so there is no danger of it falling over.
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FRONT WHEELS AND BRAKE DISCS CHAS T. R. 260 Nm (26.0 m • kg, 190 ft • lb) 4 3 New 1 LT LT 6 5 2 T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) T. R. 48 Nm (4.8 m • kg, 35 ft • Ib) T. R. Order 4 5 6 Job/Part Brake caliper assembly Front wheel hub Brake disc 55 Nm (5.5 m • kg, 40 ft • Ib) Q’ty Remarks 1 NOTE: Do not depress the brake pedal when the brake caliper is off of the brake disc as the brake pads will be forced shut. 1 1 For installation, reverse the removal procedure.
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FRONT WHEELS AND BRAKE DISCS CHAS CHECKING THE FRONT WHEEL 1. Check: • wheel 2. Measure: • wheel runout Over the specified limit → Replace the wheel or check the wheel bearing play 1. Wheel runout limit Radial 2: 2.0 mm (0.08 in) Lateral 3: 2.0 mm (0.08 in) 3. Check: • wheel balance Out of balance → Adjust. WARNING After replacing the tire, ride conservatively to allow the tire to be properly seated in the rim. Failure to do so may cause an accident resulting in vehicle damage and possible injury.
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FRONT WHEELS AND BRAKE DISCS CHAS CHECKING THE FRONT BRAKE DISC 1. Check: • brake disc Galling/damage → Replace. 2. Measure: • brake disc deflection Out of specification → Check the wheel runout. If wheel runout is within the limits, replace the brake disc. Brake disc maximum deflection 0.10 mm (0.004 in) • brake disc thickness a Out of specification → Replace. Brake disc minimum thickness 3.0 mm (0.12 in) INSTALLING THE FRONT WHEEL HUB 1. Install: • axle nut New T. R. 260 Nm (26.
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REAR WHEELS AND BRAKE DISC CHAS REAR WHEELS AND BRAKE DISC REAR WHEELS T. R. 260 Nm (26.0 m • kg, 190 ft • lb) T. R. 55 Nm (5.5 m • kg, 40 ft • Ib) 4 3 2 New 1 Order Job/Part Removing the rear wheel Q’ty Remarks Remove the parts in the order listed. Place the vehicle on a level surface. WARNING Securely support the vehicle so there is no danger of it falling over. 1 Rear wheel 1 2 3 Center cap Axle nut 1 1 4 Rear wheel hub 1 Refer to “INSTALLING THE REAR WHEEL”.
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REAR WHEELS AND BRAKE DISC CHAS REAR BRAKE DISC T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 (6) Order 1 Job/Part Removing the rear brake disc Brake caliper assembly Final drive gear Rear brake disc Q’ty Remarks Remove the parts in the order listed. Refer to “FRONT AND REAR BRAKES”. Refer to “REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT” in chapter 7. 1 For installation, reverse the removal procedure.
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REAR WHEELS AND BRAKE DISC CHAS CHECKING THE REAR WHEEL 1. Check: • wheel Refer to “CHECKING THE FRONT WHEEL”. 2. Measure: • wheel runout Refer to “CHECKING THE FRONT WHEEL”. Over the specified limit → Replace. Wheel runout limit Radial: 2.0 mm (0.08 in) Lateral: 2.0 mm (0.08 in) 3. Check: • wheel balance Refer to “CHECKING WHEEL”. Out of balance → Adjust. THE FRONT CHECKING THE REAR WHEEL HUB 1. Check: • wheel hub 1 Cracks/damage → Replace. • splines (wheel hub) 2 Wear/damage → Replace.
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REAR WHEELS AND BRAKE DISC CHAS INSTALLING THE REAR WHEEL HUB 1. Install: • axle nut New Refer to “INSTALLING THE FRONT WHEEL HUB”. INSTALLING THE REAR WHEEL 1. Install: • wheel Refer to “INSTALLING THE WHEEL”. 2. Tighten: • wheel nuts Refer to “INSTALLING THE WHEEL”.
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FRONT AND REAR BRAKES CHAS FRONT AND REAR BRAKES FRONT BRAKE PADS 3 4 1 2 T. R. T. R. Order 1 2 3 4 18 Nm (1.8 m • kg, 13 ft • Ib) 48 Nm (4.8 m • kg, 35 ft • Ib) Job/Part Removing the front brake pads Front wheel Brake caliper mounting bolt Brake pad holding bolt Brake pad Pad spring Q’ty 2 2 2 1 Remarks Remove the parts in the order listed. Refer to “FRONT WHEELS AND BRAKE DISCS”. Refer to “REPLACING THE FRONT BRAKE PADS”. For installation, reverse the removal procedure.
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CHAS FRONT AND REAR BRAKES REAR BRAKE PADS T. R. 40Nm (4.0 m • kg, 29 ft • Ib) 3 6 T. R. 7 5 8 1 2 3 4 5 6 7 8 7 4 2 1 Order 17 Nm (1.7 m • kg, 12 ft • Ib) Job/Part Removing the rear brake pads Rear skid plate Q’ty Spring Parking brake cable Brake caliper mounting bolt Brake pad holding bolt Brake pad (piston side) Brake pad Insulator/pad shim Pad spring 1 1 2 2 1 1 2/2 1 Remarks Remove the parts in the order listed. Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED”.
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FRONT AND REAR BRAKES CHAS CAUTION: Disc brake components rarely require disassembly.
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FRONT AND REAR BRAKES CHAS 2. Install: • brake pads • brake pad spring 2 NOTE: Always install new brake pads and brake pad spring as a set. 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a suitable hose 1 tightly to the brake caliper bleed screw 2. Put the other end of this hose into an open container. b. Loosen the brake caliper bleed screw and, using a finger, push the caliper piston into the brake caliper. c. Tighten the brake caliper bleed screw. T. Brake caliper bleed screw 6 Nm (0.6 m · kg, 4.
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FRONT AND REAR BRAKES CHAS 1. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 1.5 mm (0.06 in) 2. Install: • brake pads • brake pad spring NOTE: Always install new brake pads, new brake pad shims, new insulators, and a new brake pad spring as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a suitable hose 1 tightly to the brake caliper bleed screw 2. Put the other end of this hose into an open container. b.
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FRONT AND REAR BRAKES CHAS e. Install the brake pad holding bolts, the brake caliper, and the brake caliper mounting bolts. T. R. Brake pad holding bolt 17 Nm (1.7 m · kg, 12 ft · lb) Brake caliper mounting bolt 40 Nm (4.0 m · kg, 29 ft · lb) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: • brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 4. Check: • brake pedal operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
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FRONT AND REAR BRAKES CHAS BRAKE MASTER CYLINDER T. R. 19 Nm (1.9 m • kg, 13 ft • Ib) 8 1 2 3 7 5 New 6 5 New T. R. 16 Nm (1.6 m • kg, 11 ft • Ib) 1 2 3 4 5 6 7 8 Job/Part Removing the brake master cylinder Brake fluid Brake fluid reservoir cap Brake fluid reservoir diaphragm Brake fluid reservoir float Union bolt Copper washer Brake hose Brake pipe Brake master cylinder Q’ty 1 1 1 1 2 1 1 1 R. Order T. 4 27 Nm (2.7 m • kg, 19 ft • Ib) Remarks Remove the parts in the order listed. Drain.
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FRONT AND REAR BRAKES CHAS 3 New 1 2 6 New New 5 T. R. Order 1 2 3 4 5 6 4 9 Nm (0.9 m • kg, 6.5 ft • Ib) Job/Part Q’ty Remarks Disassembling the brake master cylRemove the parts in the order listed. inder Dust boot 1 Circlip 1 Primary brake master cylinder kit 1 Refer to “ASSEMBLING THE BRAKE Secondary brake master cylinder kit 1 MASTER CYLINDER”. stopper Gasket 1 Secondary brake master cylinder kit 1 For assembly, reverse the disassembly procedure.
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FRONT AND REAR BRAKES CHECKING THE MASTER CYLINDER 1. Check: • brake master cylinder 1 Wear/scratches → Replace the brake master cylinder assembly. • brake master cylinder body Cracks/damage → Replace. • brake fluid delivery passage (brake master cylinder body) Blockage → Blow out with compressed air. 2. Check: • brake master cylinder kit Scratches/wear/damage → Replace as a set. 1 È CHAS É È Primary brake master cylinder kit É Secondary brake master cylinder kit 1 2 3.
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FRONT AND REAR BRAKES CHAS INSTALLING THE BRAKE MASTER CYLINDER 1. Install: • brake master cylinder T. R. 5˚ R. ~6 Install: 19 Nm (1.9 m · kg, 13 ft · lb) brake pipe copper washers New brake hose union bolt 27 Nm (2.7 m · kg, 19 ft · lb) T. 55 T. R. 2. • • • • 16 Nm (1.6 m · kg, 11 ft · lb) NOTE: Tighten the union bolt while holding the brake hose as shown. WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING” in chapter 2. 3.
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FRONT AND REAR BRAKES CHAS 4. Air bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: • brake fluid level Brake fluid level is under the “MIN” level line → Fill up. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 6. Adjust: • brake pedal free play Refer to “ADJUSTING THE BRAKE PEDAL” in chapter 3.
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FRONT AND REAR BRAKES CHAS FRONT BRAKE CALIPER Order 1 2 3 4 5 6 Job/Part Removing the front brake caliper Brake fluid Front wheel Union bolt Copper washer Brake hose Brake pad holding bolt Brake caliper mounting bolt Brake caliper assembly Q’ty 1 2 1 2 2 1 Remarks Remove the parts in the order listed. Drain. Refer to “FRONT WHEELS AND BRAKE DISCS”. Disconnect. Loosen. Refer to “INSTALLING THE FRONT BRAKE CALIPERS”. For installation, reverse the removal procedure.
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FRONT AND REAR BRAKES CHAS 2 T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) 3 8 New 6 7 5 T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) 6 7 New 1 Order 4 1 2 3 4 5 6 7 Job/Part Disassembling the front brake caliper Brake pad holding bolt Brake pad Pad spring Caliper bracket Brake caliper piston Dust seal Caliper piston seal 8 Bleed screw Q’ty 2 2 1 1 2 2 2 Remarks Remove the parts in the order listed. Refer to “DISASSEMBLING THE FRONT BRAKE CALIPERS” and “ASSEMBLING THE FRONT BRAKE CALIPERS”.
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FRONT AND REAR BRAKES CHAS REAR BRAKE CALIPER T. R. 40 Nm (4.0m • kg, 29 ft • Ib) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 1 4 9 3 10 8 2 New 7 6 T. R. Order 1 2 3 4 5 Job/Part Removing the rear brake caliper Rear skid plate Q’ty Brake fluid Parking brake switch coupler Spring Parking brake cable Parking brake lever assembly mounting bolt Parking brake lever assembly 1 1 1 1 1 8 - 31 27 Nm (2.7 m • kg, 19 ft • Ib) Remarks Remove the parts in the order listed.
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FRONT AND REAR BRAKES CHAS T. R. 40 Nm (4.0m • kg, 29 ft • Ib) T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 1 4 9 3 10 8 2 New 7 6 T. R. Order 6 7 8 9 10 Job/Part Union bolt Copper washer Brake hose Brake caliper mounting bolt Brake caliper assembly 27 Nm (2.7 m • kg, 19 ft • Ib) Q’ty Remarks 1 2 Refer to “INSTALLING 1 Disconnect. THE REAR BRAKE CALIPER”. 2 1 For installation, reverse the removal procedure.
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CHAS FRONT AND REAR BRAKES 4 3 2 6 4 5 C D B E New F New A 7 8 9 1 0 G A R. R. T. R. 1 2 3 4 5 6 7 8 9 0 A 5 Nm (0.5 m • kg, 3.6 ft • Ib) T. T. LS Order LS 17 Nm (1.7 m • kg, 12 ft • Ib) 22 Nm (2.
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CHAS FRONT AND REAR BRAKES 4 3 2 6 4 5 C D B E New F New A 7 8 9 1 0 G A 17 Nm (1.7 m • kg, 12 ft • Ib) R. 22 Nm (2.2 m • kg, 16 ft • Ib) Job/Part Parking brake case Gasket Brake caliper piston Dust seal Caliper piston seal Bleed screw R. R. T. G 5 Nm (0.5 m • kg, 3.6 ft • Ib) T. T. LS Order B C D E F LS Q’ty 1 1 1 1 1 Remarks Refer to “ASSEMBLING THE REAR BRAKE CALIPER”. Refer to “DISASSEMBLING THE FRONT BRAKE CALIPERS” and “ASSEMBLING THE REAR BRAKE CALIPER”.
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FRONT AND REAR BRAKES CHAS EBS00427 1 DISASSEMBLING THE FRONT BRAKE CALIPERS 1. Remove: • brake caliper pistons • dust seals 1 • caliper piston seals 2 2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body. WARNING _ • Never try to pry out a caliper piston. • Cover the caliper piston with a rag. Be careful not to get injured when the piston is expelled from the caliper cylinder. b.
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FRONT AND REAR BRAKES CHAS EB702040 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule: Brake pads As required Piston seals, dust seals Every two years Brake hoses Every two years Brake fluid Replace when brakes are disassembled. WARNING All internal brake components should be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort. È 2 1 2 3 1 É 2 1 3 1.
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FRONT AND REAR BRAKES CHAS EBS00431 ASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the front brake calipers. WARNING _ • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid DOT 4 • Replace the caliper piston seals and dust seal whenever a brake caliper is disassembled. 2 New 1. Install: • caliper piston seals 1 New • dust seals 2 New 1 New 2.
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FRONT AND REAR BRAKES CHAS EBS00432 ASSEMBLING THE REAR BRAKE CALIPER WARNING _ • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid DOT 4 • Replace the caliper piston seal and dust seal whenever a brake caliper is disassembled. 1 New 2 New 1. Install: • caliper piston seal 1 New • dust seal 2 New 1 1 a 1 b c 4 2.
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FRONT AND REAR BRAKES a 1 4. • • • • 1 b CHAS Install: parking brake arm shaft 1 parking brake arm 2 set bolt 3 parking brake arm nut 4 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: Apply lithium-soap-based grease to the parking brake arm shaft and set bolt. d a 3 c 4 2 a. Screw in the parking brake arm shaft counterclockwise completely so that the punch mark a on the parking brake arm shaft is between the alignment marks b. NOTE: The hole for the parking brake arm shaft has multiple threads.
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FRONT AND REAR BRAKES CHAS 6. Install: • brake pad holding bolts T. R. 17 Nm (1.7 m · kg, 12 ft · lb) EBS00434 1 a 3 T. R. 2 New INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the front brake calipers. 1. Install: • brake caliper assembly • brake caliper mounting bolts 48 Nm (4.8 m · kg, 35 ft · lb) T. • brake hose 1 • copper washers 2 New 27 Nm (2.7 m · kg, 19 ft · lb) • union bolt 3 R.
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FRONT AND REAR BRAKES CHAS WARNING _ • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of brake fluid: mixing brake fluids may result in a harmful chemical reaction and lead to poor brake performance. • Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the brake fluid and may result in vapor lock. 3.
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FRONT AND REAR BRAKES CHAS 2. Fill: • brake reservoir Recommended brake fluid DOT 4 CAUTION: _ Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. WARNING _ • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of brake fluid: mixing brake fluids may result in a harmful chemical reaction and lead to poor brake performance.
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PEDAL ASSEMBLY CHAS PEDAL ASSEMBLY 2 3 T. R. 16 Nm (1.6 m • kg, 11 ft • Ib) 4 6 New 5 7 1 Order 1 2 3 4 5 6 7 Job/Part Removing the pedal assembly Steering wheel cover/steering wheel/ pedal cover/upper instrument panel/ lower instrument panel Steering joint Brake master cylinder Splash plate Brake light switch coupler Brake switch Throttle cable Pin Brake pedal rod Pedal assembly Q’ty Remarks Remove the parts in the order listed. Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED”.
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CHAS PEDAL ASSEMBLY LS 1 7 7 6 8 3 9 5 Job/Part Disassembling the pedal assembly Spring Circlip Washer Brake pedal Spring Circlip Washer Accelerator pedal Pedal assembly bracket Q’ty 23 4 Order 1 2 3 4 5 6 7 8 9 Remarks Remove the parts in the order listed. 1 1 2 1 1 1 2 1 1 For assembly, reverse the disassembly procedure.
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STEERING SYSTEM CHAS STEERING SYSTEM STEERING COLUMN AND STEERING ASSEMBLY 1 T. R. 21 Nm (2.1 m • kg, 15 ft • Ib) T. R. 2 22 Nm (2.2 m • kg, 16 ft • Ib) T. R. 39 Nm (3.9 m • kg, 28 ft • Ib) 3 T. R. Order 1 2 3 48 Nm (4.8 m • kg, 35 ft • Ib) Job/Part Removing the steering column and steering assembly Steering wheel cover/steering wheel/ upper instrument panel/lower instrument panel Steering shaft Steering joint Steering assembly Q’ty Remarks Remove the parts in the order listed.
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STEERING SYSTEM 2 CHAS 4 T. R. New 3 40 Nm (4.0 m • kg, 29 ft • Ib) 1 8 New 9 A B 0 C 7 6 5 1 3 New 4 2 Order 1 2 3 4 5 6 7 8 9 0 A B Job/Part Disassembling the steering assembly Tie-rod end locknut Tie-rod end Plastic locking tie Dust boot Adjuster Spring Pressure pad Oil seal Circlip Pinion gear Circlip Bearing Q’ty 2 2 2 2 1 1 1 1 1 1 1 1 8 - 46 Remarks Remove the parts in the order listed. Refer to “ASSEMBLING THE STEERING ASSEMBLY”.
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STEERING SYSTEM 2 CHAS 4 T. R. New 3 40 Nm (4.0 m • kg, 29 ft • Ib) 1 8 New 9 A B 0 C 7 6 5 1 3 New 4 2 Order C Job/Part Steering assembly Q’ty Remarks 1 Refer to “ASSEMBLING THE STEERING ASSEMBLY”. For assembly, reverse the disassembly procedure.
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STEERING SYSTEM CHAS DISASSEMBLING THE STEERING ASSEMBLY 1. Remove: • oil seal • circlip • pinion gear with bearing 1 NOTE: Lightly tap on the steering housing with a soft hammer to remove the pinion gear easily. CHECKING THE STEERING JOINT 1. Check: • steering joint Rough movement → Replace. CHECKING THE STEERING ASSEMBLY 1. Check: • pinion gear bearing Check the bearing movement on the pinion gear by rotating with the fingers. Roughness → Replace. 1 2.
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STEERING SYSTEM CHAS 3. Check: • rack gear teeth 1 • pinion gear teeth 2 Wear/damage → Replace the steering assembly. 1 2 NOTE: The wear pattern on the rack and pinion gear teeth should be uniform. An uneven wear pattern may indicate improper adjustment or lack of lubrication. 4. Check: • pressure pad 1 Wear/damage → Replace. • dust boots 2 Damage → Replace. 1 2 5. Check: • tie-rod free play and movement Free play → Replace the tie-rod end. Turns roughly → Replace the tie-rod end. 6.
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STEERING SYSTEM 2. • • • • • a CHAS Install: steering assembly bearing circlips pinion gear oil seal New NOTE: After centering the rack gear, make two alignment marks a on the pinion gear and the steering housing to mark the position of the pinion gear. This is necessary to install the steering joint to the pinion gear properly. 3. Apply lithium-soap-based grease to the gear surface of the rack gear. Lithium-soap-based grease 5 ~ 10 g (0.2 ~ 0.4 oz) 4.
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STEERING SYSTEM CHAS TIE-ROD AND STEERING KNUCKLE 5 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 T. R. 39 Nm (3.9 m • kg, 28 ft • Ib) New 2 New 9 New 3 R. R. 30 Nm (3.0 m • kg, 22 ft • Ib) T. T. Order 6 4 8 7 3 Job/Part Removing the tie-rod and steering knuckle Front wheel/brake disc Q’ty LS 7 Nm (0.7 m • kg, 5.1 ft • Ib) Remarks Remove the parts in the order listed. Refer to “FRONT WHEELS AND BRAKE DISCS”.
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STEERING SYSTEM CHAS REMOVING THE STEERING KNUCKLES 1. Remove: • steering knuckle 1 NOTE: Use a general puller to separate the ball joints 2 from the steering knuckle 1 or the front lower arm 3. CHECKING THE TIE-RODS 1. Check: • tie-rod free play and movement Free play → Replace the tie-rod end. Turns roughly → Replace the tie-rod end. 2. Check: • tie-rods Bends/damage → Replace. CHECKING THE STEERING KNUCKLES 1. Check: • steering knuckles Damage/pitting → Replace. 2.
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STEERING SYSTEM CHAS Ball joint remover/installer set P/N. 90890-01474 Ball joint adapter set P/N. YM-01474 Ball joint remover/installer attachment set P/N. YM-01477 3 Body YM-01474 90890-01474 4 Long bolt YM-01474 90890-01474 5 Short bolt YM-01477 6 Remover washer YM-01477 7 Remover spacer YM-01477 8 Installer attachment YM-01477 9 Installer spacer YM-01477 0 Installer guide YM-01477 d. Install the body 3, short bolt 5, remover washer 6 and remover spacer 7 onto the ball joint.
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STEERING SYSTEM CHAS h. Attach the assembled ball joint remover/ installer, new ball joint B and installer attachment 8 to the steering knuckle C. NOTE: Do not tap or damage the top of the ball joint. i. Hold the body 3 in place while turning in the long bolt 4 to install the new ball joint B into the steering knuckle C. j. Remove the ball joint remover/installer. k. Apply lithium-soap base grease to the new ball joint B. l. Install a new rubber boot and new circlip. NOTE: Always use a new ball joint set.
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STEERING SYSTEM CHAS h. Install the new oil seals. NOTE: When installing the oil seals, the “seal side” of the oil seal faces out.
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FRONT ARMS AND FRONT SHOCK ABSORBER CHAS FRONT ARMS AND FRONT SHOCK ABSORBER T. R. T. R. 45 Nm (4.5 m • kg, 32 ft • Ib) 45 Nm (4.5 m • kg, 32 ft • Ib) 6 7 6 LS LS 9 8 8 9 6 8 4 8 LS 6 4 10 11 4 3 LS 4 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) New 5 5 1 T. R. 2 7 Nm (0.7 m • kg, 5.1 ft • Ib) 3 T. R. 30 Nm (3.
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FRONT ARMS AND FRONT SHOCK ABSORBER T. R. T. R. 45 Nm (4.5 m • kg, 32 ft • Ib) CHAS 45 Nm (4.5 m • kg, 32 ft • Ib) 6 7 6 LS LS 9 8 8 9 6 8 4 8 LS 6 4 10 11 4 3 LS 4 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) New 5 5 1 T. R. 2 7 Nm (0.7 m • kg, 5.1 ft • Ib) 3 T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) New Order 10 11 Job/Part Circlip Ball joint Q’ty 1 1 Remarks For installation, reverse the removal procedure.
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FRONT ARMS AND FRONT SHOCK ABSORBER CHAS REMOVING THE FRONT ARMS 1. Check: • front arm free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the front arm side play È by moving it from side to side. If side play is noticeable, check the bushings. b. Check the front arm vertical movement É by moving it up and down. If the vertical movement is tight or rough, or if there is binding, check the bushings. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Remove: • front arms CHECKING THE FRONT ARMS 1.
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FRONT ARMS AND FRONT SHOCK ABSORBER CHAS Ball joint remover/installer set P/N. 90890-01474 Ball joint adapter set P/N. YM-01474 Ball joint remover/installer attachment set P/N. YM-01477 3 Body YM-01474 90890-01474 4 Long bolt YM-01474 90890-01474 5 Remover washer YM-01477 6 Remover spacer YM-01477 7 Installer attachment YM-01477 8 Installer spacer YM-01477 9 Installer guide YM-01477 c. Install the body 3, long bolt 4, remover washer 5 and remover spacer 6 onto ball joint.
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FRONT ARMS AND FRONT SHOCK ABSORBER CHAS j. Apply lithium-soap base grease to the new ball joint A. k. Install a new rubber boot and new circlip. NOTE: Always use a new ball joint set. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE FRONT SHOCK ABSORBER 1. Check: • shock absorber rod Bends/damage → Replace the shock absorber assembly. • shock absorber assembly Oil leaks → Replace the shock absorber assembly. • spring Fatigue → Replace the shock absorber assembly. Move the spring up and down.
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FRONT ARMS AND FRONT SHOCK ABSORBER CHAS INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 1. Install: • front arms • front shock absorber 6 5 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the front upper arm 1 and front lower arm 2. NOTE: • Lubricate the bolts 3 with lithium-soapbased grease. • Be sure to position the bolts 3 so that the bolt head faces outward. • Temporarily tighten the nuts 4. 6 1 34 7 34 b. Install the front shock absorber 5. T. Nut 6 45 Nm (4.5 m · kg, 32 ft · lb) R.
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CHAS REAR KNUCKLE AND STABILIZER REAR KNUCKLE AND STABILIZER 6 T. R. 32 Nm (3.2m • kg, 23 ft • Ib) 7 6 5 7 8 5 T. R. 56 Nm (5.6 m • kg, 40 ft • Ib) T. R. T. 3 R. LS 1 LS 1 2 3 4 5 6 7 8 45 Nm (4.5 m • kg, 32 ft • Ib) 43 3 Order 56 Nm (5.6 m • kg, 40 ft • Ib) 2 4 3 Job/Part Removing the rear knuckle and stabilizer Rear wheel hubs O-ring Rear knuckle Spacer cover Spacer Stabilizer joint Stabilizer holder Bushing Stabilizer Q’ty Remarks Remove the parts in the order listed.
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REAR KNUCKLE AND STABILIZER CHAS CHECKING THE REAR KNUCKLE 1. Check: • rear knuckle Damage/pitting → Replace. 2. Check: • rear wheel bearings Bearings allow play in the wheel hubs or the wheel turns roughly → Replace. • oil seals Damage → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1 1 a. Clean the outside of the rear knuckle. b. Remove the oil seals 1. c. Drive out the bearings 2. WARNING 3 Eye protection is recommended when using striking tools. 2 d. Remove the spacer 3. e.
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REAR ARMS AND REAR SHOCK ABSORBER CHAS REAR ARMS AND REAR SHOCK ABSORBER 3 T. R. 45 Nm (4.5 m • kg, 32 ft • Ib) LS LS T. 45 Nm (4.5 m • kg, 32 ft • Ib) R. 1 1 1 5 5 2 5 2 T. R. 45 Nm (4.5 m • kg, 32 ft • Ib) 5 LS 6 4 3 6 3 T. R. Order 1 2 3 4 5 6 45 Nm (4.
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REAR ARMS AND REAR SHOCK ABSORBER 2 2 CHAS CHECKING THE REAR ARMS 1. Check: • rear arms 1 Bends/damage → Replace. 2. Check: • bushings 2 Wear/damage → Replace. 1 CHECKING THE REAR SHOCK ABSORBER 1. Check: • shock absorber rod Bends/damage → Replace the shock absorber assembly. • shock absorber assembly Oil leaks → Replace the shock absorber assembly. • spring Move the spring up and down. Fatigue → Replace the shock absorber assembly.
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REAR ARMS AND REAR SHOCK ABSORBER INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER 1. Install: • rear arms • rear shock absorber 6 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 5 a. Install the rear upper arm 1 and rear lower arm 2. 34 1 7 CHAS NOTE: • Lubricate the bolts 3 with lithium-soapbased grease. • Be sure to position the bolts 3 so that the bolt head faces inward. • Temporarily tighten the nuts 4. b. Install the rear shock absorber 5. 7 2 6 T. Nut 6 45 Nm (4.5 m · kg, 32 ft · lb) R. c.
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ELECTRICAL COMPONENTS ELEC – + EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Diode 1 2 Thermo switch 2 3 Diode 2 4 Circuit breaker (radiator fan motor) 5 Carburetor heater 6 Thermo switch 1 7 Ignition coil 8 Gear position switch 9 Reverse switch 0 Brake light switch A Parking brake switch B Pickup coil/stator assembly C Speed sensor D Gear motor E Radiator fan F Thermo switch 3 5 6 4 7 3 8 2 9 1 0 F E A D 9 B C 9-1
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ELECTRICAL COMPONENTS 1 Rectifier/regulator 2 Auxiliary DC jack 3 Indicator light assembly 1 4 Indicator light assembly 2 5 On-Command four-wheel drive switch and differential gear lock switch 6 Main switch 7 Light switch 8 Four-wheel drive relay 1 9 Four-wheel drive relay 2 0 Starter relay – ELEC + A Main fuse B Four-wheel drive relay 3 C Differential gear lock indicator light relay D Four-wheel drive indicator light relay E Fuse box F C.D.I.
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CHECKING THE SWITCH ELEC – + CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester P/N. YU-03112-C, 90890-03112 NOTE: • Set the pocket tester to “0” before starting the test. • The pocket tester should be set to the “Ω × 1” range when testing the switch for continuity. • Turn the switch on and off a few times when checking it.
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CHECKING THE SWITCH – ELEC + CHECKING THE SWITCH CONTINUITY Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals. Poor connection, no continuity → Correct or replace. The coupler locations are circled.
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CHECKING THE SWITCH 1 Fuse 2 Brake light switch 3 On-Command four-wheel drive switch and differential gear lock switch 4 Main switch 5 Light switch 6 Parking brake switch 7 Gear position switch 8 Reverse switch 9 Four-wheel drive switch 9-5 ELEC – +
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CHECKING THE BULBS AND BULB SOCKETS ELEC – + EB801020 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected → Properly connect. Incorrect continuity reading → Repair or replace the bulb, bulb socket or both. TYPES OF BULBS The bulbs used on this vehicle are shown in the illustration on the left.
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CHECKING THE BULBS AND BULB SOCKETS ELEC – + WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: • Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.
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CHECKING THE BULBS AND BULB SOCKETS ELEC – + CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • Bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester P/N. YU-03112-C, 90890-03112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a good bulb into the bulb socket. b.
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9-9 B p L L R/B L B L B n P P Br/L Br/L R/Y B B B G Y B G B B R/W L r Y R/Y Y G G Y Br/L i Y G Y G B L/B q Y G OFF m R/Y Br/L R (BLACK) R W B W 2 W L Y G ON OFF START W W W j 3 W W W q (BLACK) B LB Br/L R k 1 (BROWN) L B o R/B R/B l Br/L W W W W W/R W/G W W R W/G W/L W/R W/G R R W/G W/R W/G B Y L B R r B Br Br Br L/R G/L Sb Br B B B R Br Sb G/L 7 8 R Br L/R R Y/L L/B Br W/L [ L/B (BLUE) W/B B Br W/Y W/Y b
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IGNITION SYSTEM ELEC – + EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1. Fuses (main, ignition) 2. Battery 3. Spark plug 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Main switch 8. Pickup coil resistance 9. Rotor rotation direction detection coil resistance 10.
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IGNITION SYSTEM ELEC * 3. Spark plug Standard spark plug DPR8EA-9/NGK • Check the spark plug condition. • Check the spark plug type. • Check the spark plug gap. Refer to “CHECKING THE SPARK PLUG” in chapter 3. INCORRECT Spark plug gap 0.8 ~ 0.9 mm (0.031 ~ 0.035 in) CORRECT Repair or replace the spark plug. 4. Ignition spark gap • Disconnect the spark plug cap from the spark plug. • Connect the pulse ignition spark checker or ignition checker 1 as shown.
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IGNITION SYSTEM ELEC * 5. Spark plug cap resistance • Remove the spark plug cap. • Connect the pocket tester (Ω × 1k) to the spark plug cap. • Check that the spark plug cap has the specified resistance. OUT OF SPECIFICATION Spark plug cap resistance 10 kΩ at 20 °C (68 °F) MEETS SPECIFICATION Replace the spark plug cap. 6. Ignition coil resistance • Disconnect the ignition coil connector from the wire harness. • Connect the pocket tester (Ω × 1) to the ignition coil.
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IGNITION SYSTEM ELEC – * INCORRECT 7. Main switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the main switch. 8. Pickup coil resistance • Disconnect the A.C. magneto coupler from the wire harness. • Connect the pocket tester (Ω × 100) to the pickup coil terminal. Tester (+) lead → White/Red terminal 1 Tester (–) lead → White/Green terminal 2 • Check the pickup coil for the specified resistance.
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IGNITION SYSTEM ELEC * POOR CONNECTION 10.Wiring connection • Check the connections of the entire ignition system. Refer to “CIRCUIT DIAGRAM”. Properly connect the ignition system. CORRECT Replace the C.D.I. unit.
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9 - 15 (BROWN) R/B L L n P P Br/L (BLACK) B LB Br/L R k 1 Br/L R/Y Y G OFF m R/Y Br/L R B B L L L B B B G B B B G Y B B B Y G G Y R/W L r Y R/Y Y G Y G Br/L i L/B (BLACK) R W B W 2 W L Y G ON OFF START W W W j 3 W W W 3 Main switch 6 Battery p 7 Main fuse 8 Starter relay 9 Starter motor q q 0 Brake light switch A Diode 1 C C.D.I.
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ELECTRIC STARTING SYSTEM ELEC – + STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, brake light switch, C.D.I. unit and gear position switch. If the main switch is “START” position, the starter motor can be operated only if: • The transmission is in neutral (the gear position switch is in the neutral gear position). or • The brake pedal is pressed (the brake light switch is closed).
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ELECTRIC STARTING SYSTEM ELEC – + EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1. Fuses (main, ignition, signaling system) 2. Battery 3. Starter motor 4. Starter relay 5. Main switch 6. 7. 8. 9. NOTE: • Remove the following part(s) before troubleshooting: 1) Console • Use the following special tool(s) for troubleshooting. Gear position switch Brake light switch Diode 1 Wiring connection (the entire starting system) Pocket tester P/N.
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ELECTRIC STARTING SYSTEM ELEC – + * * 3. Starter motor • Connect the battery (+) terminal 1 and starter motor cable 2 using a jumper lead 3 . • Check the operation of the starter motor. * WARNING • A wire that is used as a jumper lead must have the equivalent capacity or more as that of the battery lead, otherwise the jumper lead may burn. • This check is likely to produce sparks, so be sure that no flammable gas or fluid is in the vicinity. DOES NOT TURN Repair or replace the starter motor.
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ELECTRIC STARTING SYSTEM ELEC – + * INCORRECT 6. Gear position switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the gear position switch. INCORRECT 7. Brake light switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the brake light switch. 8. Diode 1 3 • Remove the diode from the coupler. • Connect the pocket tester (Ω × 1) to the diode terminals as shown. • Check the diode for continuity as follows.
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ELECTRIC STARTING SYSTEM ELEC – + STARTER MOTOR Order 1 2 1 2 3 4 5 6 7 Job/Part Removing the starter motor Starter motor lead Starter motor/O-ring Disassembling the starter motor Bracket 1 Washer kit Bracket 2 Shims Brush seat 1/brush seat 2 Armature coil Yoke Q’ty Remarks Remove the parts in the order listed. 1 1/1 For installation, reverse the removal procedure. Remove the parts in the order listed. 1 1 1 1/1 1 1 Refer to “ASSEMBLING THE STARTER MOTOR”.
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ELECTRIC STARTING SYSTEM ELEC – + CHECKING THE STARTER MOTOR 1. Check: • commutator Dirty → Clean it with #600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Outside diameter 28 mm (1.10 in) : 27 mm (1.06 in) 3. Measure: • mica undercut b Out of specification → Scrape the mica using a hacksaw blade. Mica undercut 0.7 mm (0.
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ELECTRIC STARTING SYSTEM ELEC – + 5. Measure: • brush length a (each) Out of specification → Replace the brush. Brush length 12.5 mm (0.49 in) : 5 mm (0.20 in) 6. Measure: • brush spring force Fatigue/out of specification → Replace as a set. Brush spring force 7.65 ~ 10.01 Nm (780 ~ 1,021 g, 27.5 ~ 36.0 oz) 7. • • • Check: oil seal bushing O-rings Wear/damage → Replace. ASSEMBLING THE STARTER MOTOR 1.
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9 - 23 L B B (BROWN) R/B L L B n P P Br/L Br/L R/Y B G Y B B G B G Y B R/W L r Y R/Y Y G B Br/L i Y G Y G B L/B q Y G OFF m R/Y Br/L R (BLACK) R W B W 2 W L Y G ON OFF START j 3 W W W q (BLACK) B LB Br/L R k 1 W W W 1 A.C.
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CHARGING SYSTEM ELEC – EB804010 TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: Procedure Check: 1. Fuse (main) 2. Battery 3. Charging voltage 4. Charging coil resistance 5. Wiring connections (the entire charging system) NOTE: • Remove the following part(s) before troubleshooting: 1) Console 2) Footrest cover • Use the following special tool(s) for troubleshooting. Digital engine test tachometer P/N. YU-8036-C Engine tachometer P/N. 90890-03113 Pocket tester P/N. YU-03112-C, 90890-03112 EB802011 1.
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CHARGING SYSTEM ELEC – • Start the engine and accelerate to about 1,000 r/min. Charging voltage 14 V at 1,000 r/min MEETS SPECIFICATION NOTE: Use a fully charged battery. The charging circuit is not faulty. OUT OF SPECIFICATION EB804012 4. Charging coil resistance • Disconnect the A.C. magneto coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the charging coils.
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9 - 26 B p L L R/B L B L B n P P Br/L Br/L R/Y G Y B G Y B B G B B R/W L r Y R/Y Y G B Br/L i Y G Y G B L/B q Y G OFF m R/Y Br/L R (BLACK) R W B W 2 W L Y G ON OFF START W W W j 3 W W W q (BLACK) B LB Br/L R k 1 (BROWN) L B o R/B R/B l Br/L W W W W W/R W/G W W R W/G W/L W/R W/G R R W/G W/R W/G B Y L B R r B Br Br Br L/R G/L Sb Br B B B R Br Sb G/L 7 8 R Br L/R R Y/L L/B Br W/L [ L/B (BLUE) W/B B Br W/Y W/Y
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LIGHTING SYSTEM ELEC – EB805010 TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check: 1. Fuses (main, lighting system) 2. Battery 3. Main switch 4. Light switch 5. Wiring connections (the entire lighting system) NOTE: • Remove the following part(s) before troubleshooting: 1) Console • Use the following special tool(s) for troubleshooting. Pocket tester P/N. YU-03112-C, 90890-03112 EB802011 NO CONTINUITY 1. Fuses (main, lighting system) Refer to “CHECKING THE SWITCH”.
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LIGHTING SYSTEM ELEC * INCORRECT 4. Light switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the light switch. EB805013 5. Wiring connection • Check the connections of the entire lighting system. Refer to “CIRCUIT DIAGRAM”. CORRECT POOR CONNECTION Properly connect the lighting system. Check the condition of each of the lighting system’s circuits. Refer to “CHECKING THE LIGHTING SYSTEM”.
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LIGHTING SYSTEM ELEC – + EB805020 CHECKING THE LIGHTING SYSTEM 1. If the headlights fail to come on: 1. Bulb and bulb socket • Check the bulb and bulb socket for continuity. CONTINUITY NO CONTINUITY Replace the bulb and/or bulb socket. 2. Voltage • Connect the pocket tester (DC 20 V) to the headlight couplers. É È Tester (+) lead → Green terminal 1 or Yellow terminal 2 Tester (–) lead → Black terminal 3 È When the light switch is on “ É When the light switch is on “ L H ”. ”.
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LIGHTING SYSTEM ELEC – + EB805021 2. If the taillights fail to come on: 1. Bulb and bulb socket • Check the bulb and bulb socket for continuity. CONTINUITY NO CONTINUITY Replace the bulb and/or bulb socket. 2. Voltage • Connect the pocket tester (DC 20 V) to the tail/brake light connectors. Tester (+) lead → Blue lead terminal 1 Tester (–) lead → Black lead terminal 2 • Turn the main switch to “ON”. • Turn the light switch to “ L ” or “ H ”.
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LIGHTING SYSTEM 9 - 31 ELEC – +
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9 - 32 B p L L R/B L B L B n P P Br/L Br/L R/Y G Y B G Y B B G B B R/W L r Y R/Y Y G B Br/L i Y G Y G B L/B q Y G OFF m R/Y Br/L R (BLACK) R W B W 2 W L Y G ON OFF START W W W j 3 W W W q (BLACK) B LB Br/L R k 1 (BROWN) L B o R/B R/B l Br/L W W W W W/R W/G W W R W/G W/L W/R W/G R R W/G W/R W/G B Y L B R r B Br Br Br L/R G/L Sb Br B B B R Br Sb G/L 7 8 R Br L/R R Y/L L/B Br W/L [ L/B Br (BLUE) B W/B Br W/Y
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SIGNALING SYSTEM 3 Main switch 6 Battery 7 Main fuse 0 Brake light switch B Reverse switch C C.D.I.
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SIGNALING SYSTEM ELEC – + EB806010 TROUBLESHOOTING IF A BRAKE LIGHT, AN INDICATOR LIGHT, OR THE WARNING LIGHT FAILS TO COME ON: Procedure Check: 1. Fuses (main, signaling system) 2. Battery 3. Main switch 4. Wiring connections (the entire signal system) NOTE: • Remove the following part(s) before troubleshooting: 1) Console • Use the following special tool(s) for troubleshooting. Pocket tester P/N. YU-03112-C, 90890-03112 EB802011 NO CONTINUITY 1.
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SIGNALING SYSTEM ELEC * EB806011 4. Wiring connections • Check the connections of the entire signal system. Refer to “CIRCUIT DIAGRAM”. CORRECT POOR CONNECTION Properly connect the signal system. Check the condition of each of the signal system’s circuits. Refer to “CHECKING THE SIGNAL SYSTEM”.
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SIGNALING SYSTEM ELEC – + CHECKING THE SIGNAL SYSTEM 1. If the brake lights fail to come on: 1. Bulb and bulb socket • Check the bulb and bulb socket for continuity. CONTINUITY NO CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2. Brake light switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the brake light switch. 3. Voltage • Connect the pocket tester (DC 20 V) to the bulb socket connector.
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SIGNALING SYSTEM ELEC – + EB806024 2. If the neutral indicator light fails to come on: 1. Bulb and bulb socket • Check the bulb and bulb socket for continuity. NO CONTINUITY CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2. Gear position switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the gear position switch. 3. Voltage 1 • Connect the pocket tester (DC 20 V) to the indicator light assembly 2 coupler.
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SIGNALING SYSTEM ELEC – + 3. If the parking brake indicator light fails to come on: 1. Bulb and bulb socket • Check the bulb and bulb socket for continuity. CONTINUITY NO CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2. Parking brake switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the parking brake switch. 3. Voltage • Connect the pocket tester (DC 20 V) to the indicator light assembly 2 coupler.
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SIGNALING SYSTEM ELEC – + 4. If the reverse indicator light fails to come on: 1. Bulb and bulb socket • Check the bulb and bulb socket for continuity. CONTINUITY NO CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2. Reverse switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the reverse switch. 3. Voltage 1 • Connect the pocket tester (DC 20 V) to the indicator light assembly 2 coupler.
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SIGNALING SYSTEM ELEC – + 5. If the coolant temperature warning light does not come on when the main switch to “ON”, or if the coolant temperature warning light does not come on when the temperature is high (more than 117 ~ 123 °C (242.6 ~ 253.4 °F)): 1. Bulb and bulb socket • Check the bulb and bulb socket for continuity. CONTINUITY NO CONTINUITY Replace the bulb and /or bulb socket. 2. Thermo switch 1 • Remove the thermo switch 1 from the cylinder head.
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ELEC SIGNALING SYSTEM – + * 3. Voltage • Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. Tester (+) lead → Brown terminal 1 Tester (–) lead → White/Blue terminal 2 W/Y Br Br W/Y B/G Br Br B/G W/L Br Br W/L 1 2 OUT OF SPECIFICATION • Turn the main switch to “ON”. • Check the voltage (12 V). MEETS SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty, repair it. 4. Diode 2 1 • Remove the diode from the coupler.
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SIGNALING SYSTEM ELEC – + 6. If the differential gear lock indicator light fails to come on: 1. Bulb and bulb socket • Check the bulb and bulb socket for continuity. CONTINUITY NO CONTINUITY Replace the bulb and/or bulb socket. 2. Differential gear lock indicator light relay • Remove the differential gear lock indicator light relay from the wire harness. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the differential gear lock indicator light relay terminals.
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SIGNALING SYSTEM ELEC – + * 4. Voltage • Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. 1 Tester (+) lead → Brown terminal 1 Tester (–) lead → Black/Green terminal 2 • Turn the main switch to “ON”. • Check the voltage (12 V). MEETS SPECIFICATION This circuit is not faulty. 2 W/Y Br Br W/Y B/G Br Br B/G W/L Br Br W/L OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty, repair it.
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SIGNALING SYSTEM ELEC – + 7. If the four-wheel drive indicator light fails to come on: 1. Bulb and bulb socket • Check the bulb and bulb socket for continuity. CONTINUITY NO CONTINUITY Replace the bulb and bulb socket. 2. Four-wheel drive indicator light relay • Remove the four-wheel drive indicator light relay from the wire harness. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the four-wheel drive indicator light relay terminals.
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SIGNALING SYSTEM ELEC – + * 4. Voltage 1 • Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. Tester (+) lead → Brown terminal 1 Tester (–) lead → White/Yellow terminal 2 • Turn the main switch to “ON”. • Check the voltage (12 V). MEETS SPECIFICATION This circuit is not faulty. 2 W/Y Br Br W/Y B/G Br Br B/G W/L Br Br W/L OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty, repair it.
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9 - 46 B p L L R/B L B L B n P P Br/L Br/L R/Y G Y B G Y B B G Y G B R/W L r Y R/Y B B Br/L i Y G Y G B L/B q Y G OFF m R/Y Br/L R (BLACK) R W B W 2 W L Y G ON OFF START W W W j 3 W W W q (BLACK) B LB Br/L R k 1 (BROWN) L B o R/B R/B l Br/L W W W W W/R W/G W W R W/G W/L W/R W/G R R W/G W/R W/G B Y L B R r B Br Br Br L/R G/L Sb Br B B B R Br Sb G/L 7 8 R Br L/R R Y/L L/B Br W/L [ L/B (BLUE) W/B B Br W/Y W/Y
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COOLING SYSTEM ELEC – TROUBLESHOOTING IF THE FAN MOTOR DOES NOT MOVE: Procedure Check: 1. Fuse (main) 2. Battery 3. Main switch 4. Radiator fan motor 5. Circuit breaker (radiator fan motor) 6. Thermo switch 3 7. Wiring connection (the entire cooling system) NOTE: • Remove the following part(s) before troubleshooting. 1) Console • Use the following special tool(s) for troubleshooting. Pocket tester P/N. YU-03112-C, 90890-03112 EB802011 NO CONTINUITY 1. Fuse (main) Refer to “CHECKING THE SWITCH”.
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COOLING SYSTEM ELEC * 4. Radiator fan motor • Disconnect the radiator fan motor coupler. • Connect the battery (12 V) as shown. Battery (+) lead → Blue terminal 1 Battery (–) lead → Black terminal 2 • Check the operation of the radiator fan motor. TURNS DOES NOT TURN Replace the radiator fan motor. 5. Circuit breaker (radiator fan motor) • Remove the circuit breaker from the wire harness. • Connect the pocket tester (Ω × 1) to the circuit breaker.
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COOLING SYSTEM ELEC * 6. Thermo switch 3 • Remove the thermo switch 3 from the radiator. • Connect the pocket tester (Ω × 1) to the thermo switch 3 1. • Immerse the thermo switch 3 in coolant 2. • Check the thermo switch 3 for continuity. While heating the coolant use a thermometer 3 to record the temperatures. È The thermo switch 3 circuit is closed. É The thermo switch 3 circuit is open. Test step Coolant temperature Continuity 1 Less than 75 ± 3 °C (167 ± 5.4 °F) No 2 More than 75 ± 3 °C (167 ± 5.
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COOLING SYSTEM ELEC * EB803028 7. Wiring connection • Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM”. CORRECT POOR CONNECTION Properly connect the cooling system. This circuit is not faulty.
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9 - 51 (BROWN) R/B L L n P P Br/L (BLACK) B LB Br/L R k 1 Br/L R/Y Y G OFF m R/Y Br/L R B Br/L G L Y R/Y R/W i L/B (BLACK) R W B W 2 W L Y G ON OFF START W W W j 3 W W W Y L B R Br R/G R/W R/W R/W Sb G/L L/R Br Br/L h 5 4 Y L Br/L R B 6 B L L L B B B B B B B G Y B B G Y Y G Y G Y G B B Br Br Br L/R G/L Sb Sb Br G/L 7 8 R Br L/R R Y/L L/B Br W/L [ L/B (BLUE) W/B B Br W/Y W/Y b B/G B/Y Br (BLUE) B B c (GRAY) B
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2WD/4WD SELECTING SYSTEM ELEC – + EB803020 TROUBLESHOOTING IF THE FOUR-WHEEL DRIVE INDICATOR FAILS TO COME ON: Procedure Check: 1. Fuses (main, four-wheel drive) 2. Battery 3. Main switch 4. Four-wheel drive relay 1 5. Four-wheel drive relay 2 6. Four-wheel drive relay 3 7. On-Command four-wheel drive switch and differential gear lock switch 8. Gear motor 9.
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2WD/4WD SELECTING SYSTEM ELEC * 4. Four-wheel drive relay 1 • Remove the four-wheel drive relay 1 from the wire harness. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the four-wheel drive relay 1 terminals.
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2WD/4WD SELECTING SYSTEM ELEC – + * 6. Four-wheel drive relay 3 • Remove the four-wheel drive relay 3 from the wire harness. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the four-wheel drive relay 3 terminals. Battery (+) terminal → Brown/Red terminal 1 Battery (–) terminal → Yellow/Black terminal 2 NO CONTINUITY Tester (+) lead → Blue/Red terminal 3 Tester (–) lead → Gray terminal 4 • Check the four-wheel drive relay 3 for continuity. Replace the four-wheel drive relay 3.
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2WD/4WD SELECTING SYSTEM ELEC – + * È 8. Gear motor • Disconnect the gear motor coupler. • Remove the gear motor from the differential gear case. Refer to “FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT” in chapter 7. • Connect two C size batteries to the gear motor terminals 1 (as shown illustrations). È Check that the pinion gear 2 turns counterclockwise. É Check that the pinion gear 2 turns clockwise.
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9 - 56 B p L L R/B L B L B n P P Br/L Br/L R/Y G Y B G Y B B G B B R/W L r Y R/Y Y G B Br/L i Y G Y G B L/B q Y G OFF m R/Y Br/L R (BLACK) R W B W 2 W L Y G ON OFF START W W W j 3 W W W q (BLACk) B LB Br/L R k 1 (BROWN) L B o R/B R/B l Br/L W W W W W/R W/G W W R W/G W/L W/R W/G R R W/G W/R W/G B Y L B R r B Br Br Br L/R G/L Sb Br B B B R Br Sb G/L 7 8 R Br L/R R Y/L L/B Br W/L [ L/B (BLUE) W/B B Br W/Y W/Y
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CARBURETOR HEATING SYSTEM ELEC – TROUBLESHOOTING IF THE CARBURETOR HEATING SYSTEM FAILS TO OPERATE: Procedure Check: 1. Fuses (main, carburetor heater) 2. Battery 3. Main switch 4. Thermo switch 2 5. Carburetor heater 6. Wiring connection (the entire carburetor warning system) NOTE: • Remove the following part(s) before troubleshooting. 1) Console • Use the following special tool(s) for troubleshooting. Pocket tester P/N. YU-03112-C, 90890-03112 NO CONTINUITY 1.
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CARBURETOR HEATING SYSTEM ELEC * 4. Thermo switch 2 3 • Remove the thermo switch 2 from the wire harness. • Connect the pocket tester (Ω × 1) to the thermo switch 2 1. • Immerse the thermo switch 2 in a container filled with water 2. • Place a thermometer 3 in the water. • Slowly heat the water, than let it cool to the specified temperature as indicated in the table. • Check the thermo switch 2 for continuity at the temperatures indicated in the table. Ω×1 1 2 È The thermo switch 2 circuit is closed.
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CARBURETOR HEATING SYSTEM ELEC – + * 5. Carburetor heater • Remove the carburetor heater from the carburetor. • Connect the pocket tester (Ω × 1) to the carburetor heater. Tester (+) lead → Carburetor heater terminal 1 Tester (–) lead → Carburetor heater body 2 • Measure the carburetor heater resistance. INCORRECT Carburetor heater resistance 6 ~ 12 Ω at 20 °C (68 °F) CORRECT Replace the carburetor heater. 6. Wiring connection • Check the connections on the entire carburetor heating system.
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STARTING FAILURE/HARD STARTING TRBL SHTG EBS00537 TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for check, adjustment and replacement of parts.
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STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head • Loose spark plug • Loose cylinder head or cylinder • Broken cylinder head gasket • Broken cylinder gasket • Worn, damaged or seized cylinder Valve, camshaft and crankshaft • Improperly sealed valve • Improperly contacted valve and valve seat • Improper valve timing • Broken valve spring • Seized camshaft • Seized crankshaft TRBL SHTG Piston and piston rings • Im
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FAULTY DRIVE TRAIN TRBL SHTG EBS00540 FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1. A pronounced hesitation or “jerky” movement during acceleration, deceleration, or sustained speed. (This must not be confused with engine surging or transmission characteristics.) 2. A “rolling rumble” noticeable at low speed; a high-pitched whine; a “clunk” from a shaft drive component or area. 3.
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FAULTY GEAR SHIFTING/ FAULTY CLUTCH PERFORMANCE TRBL SHTG EBS00542 FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH SLIPPING”.
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FAULTY CLUTCH PERFORMANCE/OVERHEATING/ FAULTY BRAKE/SHOCK ABSORBER MALFUNCTION POOR SPEED PERFORMANCE V-belt • Oil or grease on the V-belt Primary pulley weight • Faulty operation • Worn primary pulley weight Primary fixed sheave • Worn primary fixed sheave TRBL SHTG Primary sliding sheave • Worn primary sliding sheave Secondary fixed sheave • Worn secondary fixed sheave Secondary sliding sheave • Worn secondary sliding sheave EBS00547 OVERHEATING OVERHEATING Ignition system • Improper spark plug gap •
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UNSTABLE HANDLING/ LIGHTING SYSTEM TRBL SHTG EBS00552 UNSTABLE HANDLING UNSTABLE HANDLING Steering wheel • Improperly installed or bent Steering • Incorrect toe-in • Bent steering shaft • Improperly installed steering shaft • Damaged bearing • Bent tie-rods • Deformed steering knuckles Tires • Uneven tire pressures on both sides • Incorrect tire pressure • Uneven tire wear Wheels • Deformed wheel • Loose bearing • Bent or loose wheel axle • Excessive wheel runout Frame • Bent • Damaged frame EBS00553
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YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
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YXR660FAS WIRING DIAGRAM W/G R R W/G W/R W/G W/L W/R W W W W W W W L/Y Y/B B/R G/L G/W W/B Sb G/R (BLACK) (BLACK) (BLACK) O O A O R R W/G W/R W/G 1 R/W L/W O B R W/R W/G W W W W W W R 2 B B W R R R R R R B W G/W 7 6 R W W/R W/G L/W R/W G/W Y/B G/R Sb G/L W/B B/R B B O E B B C A (BLACK) Y/L WIRE HARNESS IGNITION COIL LEAD L/Y L/Y W F W L/Y B/L G/W L/W B/Y Y/L L/Y W B B B B/Y L/W L/B B G/W Y/L B Br 9 B B B 0 Br Y W Sb G/L R/W W/B L/W B/R W/L