Yamaha 2016-2018 Viking Service Manual

BASE / HUNTER
EPS / EPS HUNTER / EPS SPECIAL

EDITION / EPS RANCH EDITION
2016-2018
EBS20002
YXM70VDXG/YXM70VDHGNXM70VPXG/
YXM70VPHGNXM70VPSG
SERVICE MANUAL
©2015 by Yamaha Motor Corporation, U.S.A.
First edition, September 2015
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-11616-29-20
EBS20003
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
• Designs and specifications are subject to change without notice.
ESS30001
IMPORTANT MANUAL INFORMATION

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

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

NOTICE 1 the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.

EBS20004
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
"1" is shown at the top of each page.
• Sub-section titles "2" appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams "3" at the start of each
removal and disassembly section .
• Numbers "4" are given in the order of the jobs in the exploded diagram . A number indicates a disas-
sembly step.
• Symbols "5" indicate parts to be lubricated or replaced.
Refer to "SYMBOLS".
• A job instruction chart "6" accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs "7" requiring more information (such as special tools and technical data) are described sequen-
tially.
CLUTCH CLUTCH
CLUTCH
·-
"'"""- -tin-,..,
______
A!MCMHG TH€CUffCH
,.. _ (>,e----·
...
• Otle-wa<y CUCft DeaflnO
• ~h~'lllliilY"°*" bNrrng.-:teiAl:f'I
--
hOulinglteNI
WOl\ll,o l'I CW*Ci'OM ~ NClh tlOII
3 -+-+- 1/4 d aun. Aemow'*'1...., 11 d '*".,. • The cn.-W1Y ~ Mll'bg "W tie ......
'MW\ .... flatlge tldt ~ mY.flrd
4 --1---+---..
.._______
UM a '**" tw:tif'IO 1:)()1 7 .:, hCII, N ~
car"- . . d IUy,
........................................... .................
........... "°'°"
~~Ch'*°"
CHECKJNGTiiE Q.UTQi $HOE . -- - - + - 2
-·
---
1-'--J U"'"'"-1 du1,ch a.ck·
1.
Yu.t1042
·(U;to-
_______
,.""
~
~
.... •Sond ...
- Aoplke.
oo.M . . . . .
A.tie, sanciflO lhe !jlD2ed a,e,as, deal'I N CUC9'
-·"""
,._.,• Q.cd'I tl"OO ~
-
C H(COtO ~ CLUTCH
1 a-
.o..,,-.,
<MOl~l()R - ~
DIW~----~
S-65 5-67
EBS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
.. Serviceable with engine mounted -1 Gear oil

~
1-
~ Filling fluid
~
Molybdenum disulfide oil
I Lubricant
1- Brake fluid
~
~ Special tool -Q>I Wheel bearing grease
~~ Tightening torque
~ Lithium-soap-based grease
Wear limit, clearance

~ Molybdenum disulfide grease
w Engine speed
~ Silicone grease
-'
~ Electrical data
A Apply locking agent (LOCTITE®).
1-
m Engine oil Replace the part with a new one.
ESS10003
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND

ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL SYSTEM
DRIVE TRAIN
ELECTRICAL SYSTEM
TROUBLESHOOTING
GENERAL INFORMATION
IDENTIFICATION .......... ......... .......... ......... ......... .......... ........ .......... ......... ........ 1-1
VEHICLE IDENTIFICATION NUMBER ..... ......... ......... .......... ......... ......... .. 1-1
MODEL LABEL ........ ......... .......... ......... ......... .......... ........ .......... ......... ........ 1-1
FEATURES .......... .......... ......... .......... ......... ......... .......... ........ .......... ......... ........ 1-3
OUTLINE OF TH E EPS (ELECTR IC POWER STEERING) SYSTEM
(for EPS models) ... .......... ......... ......... ........ .......... ......... ......... ......... ......... . 1-3
INSTRUMENT FUNCTIONS ..... .......... ......... ........ .......... ......... .......... ........ 1-5
IMPORTANT INFORMATION ......... .......... ......... .......... ........ ......... .......... ........ 1-7
PREPARATION FOR REMOVAL AND DISASSEMBLY ......... ......... ......... 1-7
REPLACEMENT PARTS .......... ......... ........ .......... ......... .......... ......... ......... . 1-7
GASKETS, OIL SEALS AND 0-R INGS ........ ......... ......... ......... ......... ........ 1-7
LOCK WASHERS/PLATES AND COTTER PINS ......... .......... ......... ......... 1-7
BEARINGS AND OIL SEALS ... .......... ........ .......... ......... ......... .......... ......... 1-8
CIRCLIPS ...... ......... .......... ......... ......... ........ .......... ......... ......... ......... .......... 1-8
RUBB ER PARTS .... ......... ......... ......... ......... ........ ......... ......... ........... ........ .. 1-8
BASIC SERVICE INFORMATION .. .......... ........ ......... .......... ......... .......... ......... 1-9
QUICK FASTEN ERS ........ ......... .......... ......... ........ .......... ......... .......... ........ 1-9
ELECTRICAL SYSTEM .... .......... ......... ......... .......... ......... ......... .......... ..... 1-1 O
SPECIAL TOOLS .......... ......... ......... .......... ......... .......... ........ .......... ......... ...... 1-14
IDENTIFICATION
EBS20009
IDENTIFICATION
EBS30003
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number "1" is stamped
into the frame.
EBS30004
MODEL LABEL
The model label "1" is affixed to the frame under
the driver seat. This information will be needed
to order spare parts.
1-1
IDENTIFICATION
1-2
FEATURES
ESS20010
FEATURES
ESS30007
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
.
1 •
I d I. 3
•••
e
Ii .. •••
C
••• ••
f ••• ••• 5 a
11 11 ••• ••• 11 11
f
6
b
5
0
1-3
FEATURES
1. Speed information from speed sensor b. Twists torsion bar

2. Engine RPM information from ECU C. Sends the torque sensor signal
3. Battery d. EPS control unit calculates assist power
4. EPS control unit e. Electricity output switched by EPS control unit
5. EPS unit f. Activates EPS motor
6. EPS motor
7. Torque sensor
a. Operates steering
EC801790
NOTICE
-----------------------------------
To prevent accidental damage to the EPS unit, it must not be disassembled.
1-4
FEATURES
EBS30008
Pushing the "SELECT' button switches the dis-
INSTRUMENT FUNCTIONS
play between the odometer mode "ODO" and
the tripmeter modes "TRIP A" and "TRIP B" in
Multi-function meter unit
the following order:
4 5 ODO~ TRIP A~ TR IP B ~ ODO
To reset a tripmeter, select it by pushing the "SE-
LECT" button, and then push the "RESET" but-
L i''-' LI :I.ii ton for at least three seconds. The tripmeters
H :11 ,, Jr.&t:I· can be used to estimate the distance that can be
~ :aasas:aaeaa:•i traveled with a full tank of fuel. This information
W 'l '~L1~9~§~LD
~-~~//P3~ enables you to plan future fuel stops.
TIP ~~~~~~~~~~~~~~
7 6 To switch the display between "mph" and "km/h",
1. "CLOCK" button turn the key to "O " (off) , then push and hold the
2. "RESET" button "SELECT" button while turning the key to " 0 "
3. "SELECT" button (on).
4. Speedometer
5. Fuel meter Clock, hour meter and voltage display
6. Clock/Hour meterNoltage display modes
7. Odometer/Tripmeter A!Tripmeter B
The multi-function meter unit is equipped with

the following:
• a speedometer
• an odometer
• two tripmeters (which show the distance trav-
eled since they were last set to zero)
• a clock
• an hour meter (which shows the total time the 4
engine has been running)
• a voltage display (which shows the battery volt- 1. "SELECT" button
age) 2. "RESET" button
• a fuel meter 3. "CLOCK" button
• a self-diagnosis device 4. Clock/Hour meter/Voltage display
Pushing the "CLOCK" button switches the dis-

Odometer and tripmeter modes play between the clock mode "CLOCK", the hour
meter mode "HOUR", and the voltage display
mode "be ,-'::I" in the following order:
CLOCK~ HOUR~ be,-':;/~ CLOCK
L~ In ,oo 1,:, To set the clock:
H PtfLJDr.&~I 1. Set the display to the clock mode.
~@ ODO
BO BBBBB
CLOCKHOIJR
2. Push the "SELECT" button and "RESET" but-
~=I~ ~~~ ton together for at least three seconds.
3. When the hour digits start flashing, push the
3 "RESET' button to set the hours.
4. Push the "SELECT' button, and the minute
1. "SELECT" button digits will start flashing.
2. "RESET" button 5. Push the "RESET' button to set the minutes.
3. Odometer/Tripmeter A!Tripmeter B 6. Push the "SELECT" button, and then release
it to start the clock.
Voltage display mode
1-5
FEATURES
Self-diagnosis device
oett:c 1r.=--~-~-~- ""m'I

L W ,1 11 1 iu ~ ~-======~ '-:::._==--:::::::...~~ 2
H
Ftf 1 11 1rJ1ill LCT.:!i ~ I ' . ,. , iii C
N
R BBBBB b : 122111!! ~ .~!JI I I I fn\>~11
(®) ODOTRIPAB ~ R l _____ j 88:8881!
CI.OCKHOUR 1
EPS
(®) ~
bl:, =I .. b : 12.2
This display shows the battery voltage.
"bt ,-':/" appears for 1 second when the voltage 1. Fault code display
display mode is first selected, and then "b ~· ap- 2. Engine trouble warning light " 0 "
pears and the battery voltage is displayed.
This model is equipped with a self-diagnosis de-
If the battery voltage is less than 1O volts, "LO" is
vice for various electrical circuits.
displayed, and if the voltage is above 16 volts,
If a problem is detected in any of those circuits,
"HI" is displayed.
ECB02020 the engine trouble warning light comes on or
NOTICE flashes, and the multi-function display indicates
------------- a fault code.
1f the voltage display indicates "LO" or "HI",
there may be trouble with the battery If the multi-function display indicates a fault
charging circuit or the battery may be faulty. code, note the code number, and then check the
If this occurs, check or repair the vehicle. fuel injection system.
Refer to "FUEL INJECTION SYSTEM" on page
9-31 .
Fuel meter ECB02030
NOTICE
~~ -------------
1f the display indicates a fault code, the vehi-
DIFF.
OLOCK cle should be checked as soon as possible
L t&t II 11 1 :-~ in order to avoid engine damage.
H tYt f I f I:iiilll•~Jkm/h:
mph:1.lii
1 I
N
R BBBBB BB:BBB!l•i~ .. __ _
(®) ODOTRIP AB CLOCKHOUR :IGl,...._i- -
1. Fuel level warning indicator

2. Fuel meter
3. "E" segment
The fuel meter indicates the amount of fuel in the

fuel tank. The display segments of the fuel meter
disappear from "F" (full) towards "E" (empty) as
the fuel level decreases. When the "E" segment
disappears and the fuel level warning indicator
flashes, refuel as soon as possible.
TIP - - - - - - - - - - - - - - -
This fuel meter is equipped with a self-diagnosis
system. If a problem is detected in an electrical
circuit, all the display segments and fuel level
warning indicator start flashing. If this occurs,
check the electrical circuit.
Refer to "SIGNALING SYSTEM" on page 9-19.
1-6
IMPORTANT INFORMATION
ESS20011
EBS30009
PREPARATION FOR REMOVAL AND

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

1. When overhauling the engine, replace all
gaskets, seals and 0-rings. All gasket surfac-
es, oil seal lips and 0-rings must be cleaned .
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip- lips with grease.
ment.
Refer to "SPECIAL TOOLS" on page 1-14.
3. When disassembling, always keep mated '----2
parts together. This includes gears, cylinders, ~ --3
pistons and other parts that have been "mat- I
1 •
ed" through normal wear. Mated parts must
always be reused or replaced as an assem- 4
bly.
1. Oil
2. Lip
3. Spring
4. Grease
EBS30012
LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates
4. During disassembly, clean all of the parts and "1" and cotter pins. After the bolt or nut has been
place them in trays in the order of disassem- tightened to specification, bend the lock tabs
bly. This will speed up assembly and allow for along a flat of the bolt or nut.
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EBS30010
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but 1
inferior in quality.
1-7
ESS30013 EBS30015
BEARINGS AND OIL SEALS RUBBER PARTS

Install bearings "1" and oil seals "2" so that the Check rubber parts for deterioration during in-
manufacturer's marks or numbers are visible. spection. Some of the rubber parts are sensitive
When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc. Do not al-
lips with a light coat of lithium-soap-based low any items other than the specified one to
grease. Oil bearings liberally when installing, if contact the parts.
appropriate.
ECB01260
NOTICE
-------------
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
ESS30014
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip "1", make sure the
sharp-edged corner "2" is positioned opposite
the thrust "3" that the circlip receives.
3
2
1-8
BASIC SERVICE INFORMATION
EBS20012

ESS30016
QUICK FASTENERS
. ...~:. I
.. -·--:
... . . ..., .......
~
Rivet type
1. Remove:
• Quick fastener .
TIP ~~~~~~~~~~~~~~
To remove the quick fastener, push its pin with a

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

with a screwdriver, then pull the fastener out.
..
@
2. Install:
• Quick fastener
TIP ~~~~~~~~~~~~~~~
To install the quick fastener, push its pin so that

it protrudes from the fastener head, then insert
the fastener into the part to be secured and push 2. Install:
the pin in with a screwdriver. Make sure that the • Quick fastener
pin is flush with the fastener's head.
TIP ~~~~~~~~~~~~~~
To install the quick fastener, insert the fastener

into the part to be secured and tighten the screw.
1IT• ·~ ...
·:
ill
1-9
EC.801520
ESS30017
NOTICE
ELECTRICAL SYSTEM --------------
Be sure to connect the battery leads to the
Electrical parts handling correct battery terminals. Reversing the bat-
EC801460 tery lead connections could damage the
NOTICE electrical components.
- - - - - - - - - - - - - -
Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical
components could be damaged. "+"
EC.801530
NOTICE
--------------
When connecting the battery leads to the
ECB01510 battery, be sure to connect the positive bat-
NOTICE tery lead first, then the negative battery lead.
--------------
When disconnecting the battery leads from If the negative battery lead is connected first
the battery, be sure to disconnect the nega- and a tool or similar item contacts the vehi-
tive battery lead first, then the positive bat- cle while the positive battery lead is being
tery lead. If the positive battery lead is connected, a spark could be generated,
disconnected first and a tool or similar item which is extremely dangerous.
contacts the vehicle, a spark could be gener-
ated, which is extremely dangerous.
e
e
ECB01470
NOTICE
--------------
TIP ~~~~~~~~~~~~~~
Turn the main switch to " OFF" before dis-
connecting or connecting an electrical com-
If a battery lead is difficult to disconnect due to
ponent.
rust on the battery terminal, remove the rust us-
ing hot water.
1-10
~ ---
N
~
..
0
ECB01480
NOTICE Checking the electrical system

-------------- TIP ~~~~~~~~~~~~~~
Hand Ie electrical components with special
care, and do not subject them to strong Before checking the electrical system, make
shocks. sure that the battery voltage is at least 12 V.
ECB01490 ECB01440
NOTICE NOTICE
--------------
EIectricaI components are very sensitive to
--------------
Never insert the tester probes into the cou-
and can be damaged by static electricity. pler terminal slots. Always insert the probes
Therefore, never touch the terminals and be from the opposite end "a" of the coupler, tak-
sure to keep the contacts clean. ing care not to loosen or damage the leads.
ECB01500
TIP ~~~~~~~~~~~~~~
NOTICE
When resetting the ECU by turning the main --------------
For waterproof couplers, never insert the
switch to "O FF", be sure to wait approximately 5
seconds before turning the main switch back to tester probes directly into the coupler. When
"ON". performing any checks using a waterproof
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
1-11
2. Check:
Checking the connections
• Lead
Check the leads, couplers, and connectors for
• Coupler
stains, rust, moisture, etc.
• Connector
1. Disconnect:
Moisture~ Dry with an air blower.
• Lead
Rust/stains ~ Connect and disconnect sev-
• Coupler
eral times.
• Connector
EC801540
NOTICE
- - - - - - - - - - - - - - -
• When disconnecting a coupler, release the
coupler lock, hold both sections of the cou-
pler securely, and then disconnect the cou-
pler.
• There are many types of coupler locks;
therefore, be sure to check the type of cou-
pler lock before disconnecting the coupler.
3. Connect:
• Lead
• Coupler
• Connector
TIP - - - - - - - - - - - - - - - ~
• When connecting a coupler or connector, push
both sections of the coupler or connector to-
gether until they are connected securely.
• Make sure all connections are tight.
EC8015SO
NOTICE
--------------
When disconnecting a connector, do not pull
the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.
1-12
TIP ~~~~~~~~~~~~~~
• :
The resistance values shown were obtained at
the standard measuring temperature of 20 °c
(68 °F). If the measuring temperature is not 20
0
c (68 °F), the specified measuring conditions
will be shown.
: Intake air temperature sensor re-
sistance
5.40-6.60 kQ at O °C (32 °F)
4. Check: 290-390 Q at 80 °C (176 °F)
• Continuity
(with the pocket tester)
V / '
Pocket tester
90890-03112
~@~
Analog pocket tester , t~ 7
YU-03112-C I
" "
I
~
TIP~~~~~~~~~~~~~~
• If there is no continuity, clean the terminals.

·1 )
M-J
• When checking the wire harness, perform
steps (1) to (3) .
• Asa quick remedy, use a contact revitalizer
available at most part stores.
5. Check:
• Resistance
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1-13
SPECIAL TOOLS
ESS20013
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• For U.S.A. and Canada, use part number starting with "YM-", "YU-", "YS-", "YK-", or "ACC-".
• For others, use part number starting with "90890-".
Reference
Tool name/Tool No. Illustration
pages
Pocket tester 1-13, 1-13, 9-91 '
90890-03112 9-92, 9-93, 9-94 '
Analog pocket tester 9-97, 9-100 '
YU-03112-C 9-100, 9-101 ,
9-102, 9-102,
9-103, 9-104,
9-104, 9-106,
9-106, 9-107,
9-108, 9-108,
9-108, 9-109,
9-109, 9-11 0
Thickness gauge 3-4
90890-03079
Narrow gauge set
YM-34483
Tappet adjusting tool 90890-01311 3-4

90890-01311
Six piece tappet set 3mm
YM-A5970
YM-A5970
Oil filter wrench 3-14

90890-01426
Oil filter wrench
YU-38411
Boots band installation tool 4-63, 8-10, 8-12 '

90890-01526 8-24, 8-26
Boots band installation tool
YM-01526
1-14
SPECIAL TOOLS
Reference
pages
Ball joint remover 4-67 4-71
90890-01474 '
Ball joint remover
YM-01474
Ball joint remover adapter set 4-67 4-71

90890-01477 '
Ball joint remover adapter set
YM-01477
Base plate 35mm 4-67 4-71

90890-01553 '
Base plate 35mm
YM-01553
Ball joint installer attachment 39mm 4-67 4-71

90890-01555 '
Ball joint installer attachment 39mm
YS-01881 -A
Compression gauge 90890-03081

5-1
90890-03081
Engine compression tester
YU-33223
YU -33223
Slide hammer bolt 5-21 5-23

90890-01083 '
Slide hammer bolt 6 mm
YU-01083-1
Weight 5-21
90890-01084 90890-01084
Weight
YU-01083-3
YU-01083-3
1-15
SPECIAL TOOLS
Reference
pages
Valve spring compressor 5-25 5-30
90890-04019 '
Valve spring compressor
YM-04019
Valve spring compressor attachment 5-25 5-30

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

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

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

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

90890-01304
Piston pin puller
YU-01304
YU-01304
Sheave holder 5-38 5-38 5-39

90890-01701 5-40' 5-58' 5-63 '
Primary clu tch holder ' '
YS-01880-A
Flywheel puller 5-38

90890-01362
Heavy duty puller
YU-33270-B
1-16
SPECIAL TOOLS
Reference
pages
Yamaha bond No. 1215 5-40 5-74 8-29
90890-85505 ' '
(Three bond No.1215®)
Digital circuit tester 5-43 7-14

90890-03174 ' 9-105
9-103, '
Model 88 Multimeter with tachometer
YU-A1927
Sheave fixed block 5-58 5-62

90890-04135 90890-04135 '
Sheave fixed bracket 00
YM-04135
YM-04135
Locknut wrench 5-58 5-62

90890-01348 90890-01348 '
Locknut wrench
YM-01348
YM-01348
={=·===e
Sheave spring compressor 5-58 5-62
90890-04134 90890-04134 '
Sheave spring compressor
YM-04134
YM-04134
1-17
SPECIAL TOOLS
Reference
pages
Universal clutch holder 5-67 5-68
90890-04086 90890-04086 M8 XP1.25 '
119
Universal clutch holder
YM-91042
YM-91042
Crankcase separating tool 5-78

90890-01 135
90890-01135
Crankcase separator
YU-01135-B M8x P1 .25
M8xP1 .25
YU-01135-8
M5x P0.80
M8xP1 .25
M6x P1.00
Crankshaft installer pot 5-80

90890-01274
90890-01274
Installing pot
YU-90058
YU -90058/YU-90059
)
©
Crankshaft installer bolt 5-80
90890-01275
Bolt
YU-90060
M14x P 1.5
Adapter (M16) 5-80

90890-04130
Adapter #13
YM-04059
M16 XP1 .5
1-18
SPECIAL TOOLS
Reference
pages
Spacer (crankshaft installer) 5-80
90890-04081
90890-04081
Pot spacer
YM-91044
YM-91044
Spacer 5-80
1--070 - - i
90890-04167
Spacer
YM-04167
Coupling gear/middle shaft tool 2 x22x1. 5-92 5-92 5-95

90890-01229 5-95' ' '
Gear holder
YM-01229
Bearing retainer wrench 5-93 5-94

90890-04128 '
Middle gear bearing retainer
YM-04128
50X23X2.0
Ring nut wrench 5-93 5-94

90890-01430 '
Ring nut wrench
YM-38404
' I
047
Final gear backlash band 5-96
90890-01511
Middle drive gear lash tool
YM-01230
Radiator cap tester 90890-01325 6-6

90890-01325
Mityvac cooling system tester kit
YU-24460-A
YU-24460-A
1-19
SPECIAL TOOLS
Reference
pages
Radiator cap tester adapter 6-6
90890-01352
90890-01352
Pressure tester adapter
YU-33984
YU-33984
Mechanical seal installer 6-14

90890-04132 033
Water pump seal installer
YM-33221 -A
Middle driven shaft bearing driver 6-14

90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
Pressure gauge 7-5

90890-03153
Pressure gauge
YU-03153
Fuel pressure adapter 7-5

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

90890-03204
Test harness- TPS (3P)
YU-03204
Universal joint holder 8-13 8-15

90890-04062 90890-04062 '
Universal joint holder
YM-04062
0 M24xP2
60
2~
YM-04062
1-20
SPECIAL TOOLS
Reference
pages
Ring gear fix bolt (M 10) 8-16
90890-01527
Ring gear fix bolt (M10)
YM-01527
M10xP1.25
Gear lash measurement tool 8-16

90890-01475
Middle drive gear lash tool 65
YM-01475
Coupling gear holding tool (35) 8-26 8-29

90890-01571 '
Coupling gear holding tool (35)
YM-01571
Ring gear fix bolt (M10 x 1.5) 8-27

90890-01572
Ring gear fix bolt (M10 x 1.5)
YM-01572
M10xP1 .50
Gear lash measurement tool 8-28

90890-01467
Gear lash measurement tool 35
YM-01467
Yamaha diagnostic tool (US)

90890-03234
--.; <O
9-35
0 -=
'lf/
___!YAIIAlll
on •w
Ignition checker
~ ~ 9-101
90890-06754
Oppama pet-4000 spark checker
YM-34487
Test harness- lean angle sensor (3P) 9-102

90890-03213
Test harness- lean angle sensor (3P)
YU-03213
Test harness- speed sensor (3P) 9-104

90890-03208
Test harness- speed sensor (3P)
YU-03208
1-21
SPECIAL TOOLS
Reference
pages
Test harness S- pressure sensor 587 (3P) 9-107
90890-03211
Test harness S- pressure sensor 587 (3P)
YU-03211
1-22
SPECIAL TOOLS
1-23
SPECIFICATIONS
GENERAL SPECIFICATIONS ........ .......... ......... .......... ........ ......... .......... ........ 2-1
ENGINE SPECIFICATIONS .. ......... .......... ........ .......... ......... ......... .......... ......... 2-2
CHASSIS SPECIFICATIONS ......... .......... ........ .......... ......... ......... .......... ......... 2-6
ELECTRICAL SPECIFICATIONS .. .......... ........ ......... .......... ......... .......... ......... 2-8
TIGHTENING TORQUES ....... ......... .......... ......... .......... ........ ......... .......... ...... 2-10
GENERAL TIGHTENING TORQUE SPECIFICATIONS .......... ......... ...... 2-1 O
ENGINE TIGHTENING TORQUES ..... ......... .......... ........ .......... ......... ...... 2-11
CHASSIS TIGHTENING TORQUES ... ......... ......... ......... .......... ......... ...... 2-15
LUBRICATION AND SEALING POINTS ......... .......... ......... .......... .......... ...... 2-23
ENGINE ......... .......... ......... .......... ......... ......... .......... ........ .......... ......... ...... 2-23
LUBRICATION SYSTEM CHART AND DIAGRAMS ........... .......... ......... ...... 2-25
ENGINE OIL LUBRICATION CHART ........ .......... .......... .......... ......... ...... 2-25
LUBRICATION DIAGRAMS ....... ......... .......... ......... ........ .......... ......... ...... 2-27
COOLING SYSTEM DIAGRAMS ..... .......... .......... .......... .......... .......... ........... 2-31
CABLE ROUTING ......... ......... .......... ......... ......... .......... ........ .......... ......... ...... 2-37
GENERAL SPECIFICATIONS
ESS20014
GENERAL SPECIFICATIONS
Model
Model
B421 (YXM70VPXG) (for EPS models)
B425 (YXM70VPHG) (for EPS models)
B429 (YXM70VPSG) (for EPS/special edition
models)
BD91 (YXM70VDXG)
BD93 (YXM70VDHG)
Dimensions
Overall length 3100 mm (122.0 in)
Overall width 1570 mm (61 .8 in) (except for special edition
models)
1625 mm (64.0 in) (for special edition models)
Overall height 1925 mm (75.8 in)
Wheelbase 2135 mm (84.1 in)
Ground clearance 300 mm (11 .8 in)
Minimum turning radius 4500 mm (177 in)
Maximum water depth 37 cm (15 in)
Weight
Curb weight 644.0 kg (1420 lb)
(YXM70VDHG/YXM70VDXG)
649.0 kg (1431 lb)
(YXM70VPHG/YXM70VPXG)
657.0 kg (1448 lb) (YXM70VPSG)
Maximum loading limit 411 .0 kg (906 lb) (Total weight of rider,
passengers, cargo, accessories, and tongue)
Loading
Rear carrier load limit 272.0 kg (600 lb)
Storage compartment load limit 4.5 kg (1 O lb) (for special edition models)
Trailer hitch pulling load limit 6664 N (680 kgf, 1498 lbf)
Trailer hitch vertical load limit 490 N (50 kgf, 11 O lbf)
2-1
ENGINE SPECIFICATIONS
EBS20015
Engine
Engine type Liquid cooled 4-stroke, SOHC
Cylinder arrangement Single cylinder
Displacement 686 cm 3
Bore x stroke 102.0 x 84.0 mm (4.02 x 3.31 in)
Compression ratio 10.0 : 1
Standard compression pressure (at sea level) 440-560 kPa (4.4-5.6 kgf/cm 2 , 62.6-79.6 psi)
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline only
Fuel tank capacity 36.7 L (9.69 US gal, 8.07 Imp.gal)
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 5W-30, 1OW-30, 1OW-40, 15W-40, 20W-
40 or 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Without oil filter cartridge replacement 2.20 L (2.33 US qt, 1.94 Imp.qt)
With oil filter cartridge replacement 2.30 L (2.43 US qt, 2.02 Imp.qt)
Quantity (disassembled) 2.60 L (2.75 US qt, 2.29 Imp.qt)
Differential gear oil

Type SAE 80 API GL-4 Hypoid gear oil
Quantity 0.18 L (0.19 US qt, 0.16 Imp.qt)
Final gear oil

Type SAE 80 API GL-4 Hypoid gear oil
Quantity 0.40 L (0.42 US qt, 0.35 Imp.qt)
Oil filter
Oil filter type Cartridge
Oil pump
Inner-rotor-to-outer-rotor-tip clearance limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance limit 0.240 mm (0.0094 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance limit 0.17 mm (0.0067 in)
Oil pressure (hot) 50.0 kPa/1600 r/min (0.50 kgf/cm 2/1600 r/min,
7.3 psi/1600 r/min)
Cooling system
Coolant quantity
Radiator (including all routes) 2.74 L (2.90 US qt, 2.41 Imp.qt)
2-2
Coolant reservoir (up to the maximum level

mark) 0.28 L (0.30 US qt, 0.25 Imp.qt)
Radiator core
W idth 400.0 mm (15.75 in)
Height 253.4 mm (9.98 in)
Depth 28.0 mm (1 .1 O in)
Radiator cap opening pressure 107.9-137.3 kPa (1 .1 -1 .4 kgf/cm 2 , 15.6- 19.9
psi)
Thermostat
Valve opening temperature 69-73 °C (156-163 °F)
Valve full open temperature 85 °C (185 °F)
Valve lift (full open) 7.0 mm (0.28 in)
Water pump
Water pump type Single suction centrifugal pump
Impeller shaft tilt limit 0.15 mm (0.006 in)
Spark plug
Manufacturer/model NGK/CPR7EA-9
Spark plug gap 0.8-0.9 mm (0.031-0.035 in)
Cylinder head
Warpage limit 0.03 mm (0.0012 in)
Camshaft
Drive system Chain drive (right)
Camshaft lobe dimensions
Lobe height (Intake) limit 42.885 mm (1 .6884 in)
Base circle diameter (Intake) limit 36.850 mm (1 .4508 in)
Lobe height (Exhaust) limit 43.390 mm (1 .7083 in)
Base circle diameter (Exhaust) limit 36.850 mm (1 .4508 in)
Camshaft runout limit 0.015 mm (0.0006 in)
Rocker arm/rocker arm shaft

Rocker arm inside diameter lim it 12.033 mm (0.4737 in)
Rocker arm shaft outside diameter limit 11.950 mm (0.4705 in)
Rocker-arm-to-rocker-arm-shaft clearance limit 0.080 mm (0.0032 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.09-0.1 3 mm (0.0035-0.0051 in)
Exhaust 0.1 6-0.20 mm (0.0063-0.0079 in)
Valve dimensions
Valve head diameter (intake) 37.90-38.1 0 mm (1 .4921-1 .5000 in)
Valve head diameter (exhaust) 31 .90-32.1 0 mm (1 .2559-1 .2638 in)
Valve seat contact width (intake) 1.00-1 .20 mm (0.0394-0.0472 in)
Valve seat contact width (intake) lim it 1.60 mm (0.0630 in)
Valve seat contact width (exhaust) 1.00-1.20 mm (0.0394-0.0472 in)
Valve seat contact width (exhaust) limit 1.60 mm (0.0630 in)
Valve stem diameter (intake) limit 5.945 mm (0.2341 in)
Valve stem diameter (exhaust) limit 5.930 mm (0.2335 in)
Valve guide inside diameter (intake) limit 6.050 mm (0.2382 in)
Valve guide inside diameter (exhaust) limit 6.050 mm (0.2382 in)
2-3
Valve-stem-to-valve-guide clearance (intake)

limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance
(exhaust) limit 0.1 00 mm (0.0039 in)
Valve stem runout 0.040 mm (0.0016 in)
Valve spring
Installed length (intake) 35.00 mm (1 .38 in)
Installed length (exhaust) 35.00 mm (1 .38 in)
Installed compression spring force (intake) 171.00- 197.00 N (17.44-20.09 kgf, 38.44-
44.29 lbf)
Installed compression spring force (exhaust) 171.00- 197.00 N (17.44- 20.09 kgf, 38.44-
44.29 lbf)
Spring tilt (intake) 1.8 mm (0.07 in)
Spring tilt (exhaust) 1.8 mm (0.07 in)
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise
Cylinder
Bore 102.000- 102.010 mm (4.0157-4.0161 in)
Wear limit 102.080 mm (4.0189 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.030- 0.055 mm (0.0012- 0.0022 in)
Diameter 101.955- 101.970 mm (4.0140-4.0146 in)
Measuring point (from piston skirt bottom) 10.0 mm (0.39 in)
Piston pin bore inside diameter limit 23.045 mm (0.9073 in)
Piston pin outside diameter limit 22.971 mm (0.9044 in)
Piston ring
Top ring
Ring type Barrel
End gap (installed) limit 0 .60 mm (0.024 in)
Ring side clearance limit 0.1 2 mm (0.0047 in)
2nd ring
Ring type Taper
End gap (installed) limit 1.25 mm (0.049 in)
Ring side clearance limit 0.1 3 mm (0.0051 in)
Oil ring
End gap (installed) limit 0.20 mm (0.01 in)
Crankshaft
Crank assembly width 74.92- 75.00 mm (2.950- 2.953 in)
Runout limit 0.030 mm (0.0012 in)
Big end side clearance 0.350- 0.650 mm (0.0138- 0.0256 in)
Clutch
Clutch type Wet, centrifugal automatic
Clutch shoe thickness limit 1.0 mm (0.04 in)
Clutch housing inside diameter 150.0 mm (5.91 in)
Clutch-in revolution 1950- 2050 r/min
2-4
Clutch-stall revolution 3550-3650 r/min
V-belt
V-belt width limit 32.5 mm (1 .28 in)
Transmission type V-belt automatic
Low range 31/16 (1 .938)
High range 30/21 (1 .429)
Reverse gear 23/14 X 28/23 (2.000)
Gear ratio 2.474-0.656: 1
Main axle runout limit 0.06 mm (0.0024 in)
Drive axle runout limit 0.06 mm (0.0024 in)
Secondary reduction ratio 41/21 x 17/12x33/9(10.1 42)
Secondary reduction system Shaft drive
Shaft drive
Middle gear backlash 0.1 0-0.30 mm (0.004-0.012 in)
Final gear backlash 0.1 3-0.23 mm (0.005-0.009 in)
Differential gear backlash 0.05-0.25 mm (0.002-0.01 O in)
Shifting mechanism
Shift fork thickness 5.76-5.89 mm (0.2268-0.2319 in)
Air filter
Air filter element Wet element
Air filter oil grade Foam air-filter oil
Fuel pump
Pump type Electrical
Throttle body
Type/quantity 44EHS/1
ID mark 1XD1 00
Fuel injector
Model/quantity EAT291 / 1
Resistance 11.5- 12.5 Q
Throttle position sensor

Resistance 2.64-6.1 6 kQ
Idling condition
Engine idling speed 1550- 1650 r/min
C0°/o (air induction system ON) 1.0 °/o
C0°/o (air induction system OFF) 5.5-6.5 °/o
Intake vacuum 32.7 kPa (245 mmHg , 9.7 inHg)
Water temperature 75-85 °C (167-185 °F)
Oil temperature 55-65 °C (131-149 °F)
Accelerator pedal free play More than 8.0 mm (0.31 in)
Air induction system

Solenoid resistance 20-24 Q
2-5
CHASSIS SPECIFICATIONS
EBS20016
Chassis
Frame type Steel tube frame
Caster angle 3.70°
Camber angle 0.4°
Kingpin angle 12.7°
Kingpin offset 7.7 mm (0.30 in)
Trail 19.0 mm (0.75 in)
Toe-in (with tires touching the ground) 5.0-15.0 mm (0.20-0.59 in)
Tread rear (STD) 1304.0 mm (51 .34 in)
Tread front (STD) 1320.0 mm (51 .97 in)
Front wheel
Wheel type Cast wheel (for special edition models)
Panel wheel (except for special edition models)
Rim size 12 x 6.0AT
Wheel material Aluminum (for special edition models)
Steel (except for special edition models)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Rear wheel
Wheel type Cast wheel (for special edition models)
Panel wheel (except for special edition models)
Rim size 12 x ?.SAT
Wheel material Aluminum (for special edition models)
Steel (except for special edition models)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Front tire
Type Tubeless
Size 25 x 8- 12NHS
Manufacturer/model MAXXIS/MU09
Wear limit (front) 3.0 mm (0.1 2 in)
Rear tire
Type Tubeless
Size 25 x 10-12NHS
Manufacturer/model MAXXIS/MU1 O
Wear limit (rear) 3.0 mm (0.1 2 in)
Tire air pressure (measured on cold tires)

Recommended
Vehicle load 0-300 kg (Q-661 lb)
Front 75.0 kPa (0.750 kgf/cm 2 , 10.9 psi)
Rear 100.0 kPa (1 .000 kgf/cm 2 , 14.5 psi)
Vehicle load 300 kg-maximum (661 lb-maximum)
2-6
Minimum
Vehicle load 0-300 kg (Q-661 lb)
Rear 95.0 kPa (0.950 kgf/cm 2 , 13.8 psi)
Vehicle load 300 kg-maximum (661 lb-maximum)
Front brake
Type Hydraulic disc brake
Operation Unified brake
Disc outside diameter x thickness 207.0 x 4.0 mm (8.15 x 0.1 6 in)
Brake disc thickness limit 3.5 mm (0.1 4 in)
Brake disc deflection limit 0.1O mm (0.0039 in)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 17.46 mm (0.69 in)
Caliper cylinder inside diameter 32.03 mm x 2 (1 .26 in x 2)
Specified brake fluid DOT4
Rear brake
Type Hydraulic disc brake
Operation Unified brake
Brake disc deflection limit 0.1O mm (0.0039 in)
Master cylinder inside diameter 17.46 mm (0.69 in)
Caliper cylinder inside diameter 27.00 mm x 2
Specified brake fluid DOT4
Brake pedal free play O mm (0 in)
Parking brake
Type Disc
Front suspension
Type Double wishbone
Spring/shock absorber type Coil spring/ gas-oil damper
Shock absorber travel 123.0 mm (4.84 in)
Installed length 277.0 mm (10.91 in)
Wheel travel 205 mm (8.1 in)
Rear suspension
Type Double wishbone
Spring/shock absorber type Coil spring/ gas-oil damper
Wheel travel 205 mm (8.1 in)
Rear shock absorber assembly travel 112.0 mm (4.41 in)
Installed length 316.2 mm (12.45 in)
2-7
ELECTRICAL SPECIFICATIONS
ESS20017
Voltage
System voltage 12 V
Engine control unit

Model/manufacturer F8T85878/MITSUB1SHI
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T .D.C.) 5.0°/1600 r/min
Pickup coil resistance 408.0-612.0 Q
Ignition coil
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.1 6-2.64 Q
Secondary coil resistance 8.64-12.96 kQ
Spark plug cap

Resistance 7.5-12.5 kQ
Charging system
Charging system AC magneto
Standard output 14.0 V, 36.4 A at 5000 r/min
Stator coil resistance 0.09-0.1 3 Q
Rectifier/regulator
Regulator type Semi conductor-short circuit
Regulated voltage (DC) 14.3-14.7 V
Rectifier capacity (DC) 50.0 A
Battery
Model U1-H11L
Voltage, capacity 12 V, 28.0 Ah
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage x quantity

Headlight 12 V, 35.0/35.0 W x 2
Tail/brake light 12 V, 5.0/21 .0 W x 2
Indicator light
Neutral indicator light LED
Reverse indicator light LED
Coolant temperature warning light LED
Park indicator light LED
On-Command four-wheel-drive/differential gear
lock indicator LCD
Engine trouble warning light LED
High-range indicator light LED
2-8
Low-range indicator light LED

Differential gear lock indicator light LED
Helmet/Seat belt indicator light 14 V, 0.85 W x 2
EPS warning light LED (for EPS models)
Starter motor
Power output 0.80 kW
Armature coil resistance 0.025-0.035 Q
Brush overall length limit 5.00 mm (0.20 in)
Commutator diameter limit 27.0 mm (1.06 in)
Mica undercut (depth) 0.70 mm (0.03 in)
Starter relay
Amperage 180.0 A
Coil resistance 4.1 8-4.62 Q
Fuel sender unit

Sender unit resistance (full) 19.00-21.00 Q
Sender unit resistance (empty) 139.00-141.00 Q
Fan motor relay

Coil resistance 87.2-106.6 Q
EPS torque sensor

Coil resistance 0.875-1.625 kQ (for EPS models)
Auxiliary DC output
Jack capacity 12 V, 10.0 A (120 W)
Fuel injection sensor

Crankshaft position sensor resistance 408-6 12 Q
Intake air pressure sensor output voltage 3.59-3.68 V
Intake air temperature sensor resistance 5400-6600 Q at O 0 c (540Q-6600 Q at 32 °F)
Coolant temperature sensor resistance 2320-2590 Q at 20 °c (2320-2590 Q at 68 °F)
Fuses
Main fuse 40.0 A
Headlight fuse 15.0 A
Signaling system fuse 10.0 A
Ignition fuse 10.0 A
Radiator fan motor fuse 25.0 A
Auxiliary DC jack fuse 10.0 A
Fuel injection system fuse 10.0 A
Backup fuse 10.0 A
Four-wheel-drive motor fuse 10.0 A
EPS fuse 40.0 A (for EPS models)
Spare fuse 25.0 A
Spare fuse 15.0 A
Spare fuse 10.0 Ax2
2-9
TIGHTENING TORQUES
ESS20018
TIGHTENING TORQUES
ESS30018
GENERAL TIGHTENING TORQUE

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

B. Outside thread diameter
General tightening torques

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

Thread
Item Q'ty Tightening torque Remarks
size
Exhaust pipe nut M8 2 20 Nm (2.0 m-kgf, 14 ft-lbf)
Muffler bolt M8 1 23 Nm (2.3 m-kgf, 17 ft-lbf)
Muffler mount shaft M8 1 17 Nm (1.7 m-kgf, 12 ft-lbf) -G
Spark arrester bolt M6 4 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Intake air pressure sensor screw MS 1 3.6 Nm (0.36 m-kgf, 2.6 ft-lbf)
Throttle position sensor screw MS 2 3.5 Nm (0.35 m-kgf, 2.5 ft-lbf)
Injector fuel rail screw M6 2 5 Nm (0.5 m-kgf, 3.6 ft-lbf)
Throttle cable locknut (air intake si-
lencer side)
M7 1 4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
Throttle cable locknut (throttle body

side)
M6 1 0.8 Nm (0.08 m-kgf, 0.58 ft-lbf)
Throttle cable housing cover screw M4 3 2.0 Nm (0.20 m-kgf, 1.4 ft-lbf)
Cylinder head stud bolt (exhaust
pipe)
M8 2 15 Nm (1.5 m-kgf, 11 ft-lbf)
Reed valve cover bolt M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf) -G

I= 135mm
(5.31 in),
I=
Cylinder head bolt M9 4 35 Nm (3.5 m-kgf, 25 ft-lbf) 145mm
(5. 71 in)
-«M>I
I= 39 mm
Cylinder head bolt M9 2 38 Nm (3.8 m-kgf, 27 ft-lbf) (1.54 in)
-1@
Cylinder head bolt M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Tappet cover bolt M6 8 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Camshaft sprocket cover bolt M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Thermostat cover bolt M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Thermostat cover air bleed bolt M6 1 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Oil check bolt M8 1 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Camshaft sprocket bolt M7 2 20 Nm (2.0 m-kgf, 14 ft-lbf)
Decompression assembly bolt M7 2 20 Nm (2.0 m-kgf, 14 ft-lbf)
Valve adjusting screw locknut M6 4 14 Nm (1.4 m-kgf, 10 ft-lbf)
Bearing retainer bolt (camshaft) M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf) -G
Cylinder bolt M10 4 See TIP. - 1@
Cylinder bolt M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Timing chain guide (intake side) bolt M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf) -G
Timing chain tensioner cap bolt M16 1 20 Nm (2.0 m-kgf, 14 ft-lbf)
Timing chain tensioner bolt M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Oil pipe (crankcase to cylinder head)
M10 1 20 Nm (2.0 m-kgf, 14 ft-lbf)
union bolt
M14 2 35 Nm (3.5 m-kgf, 25 ft-lbf)
union bolt
2-11
TIGHTENING TORQUES
Thread
size
M6 1 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
bolt
Oil pipe union bolt (AC magneto cov-
er)
M8 2 18 Nm (1.8 m-kgf, 13 tt-lbf)
Thermostat outlet hose guide bolt M10 1 48 Nm (4.8 m-kgf, 35 ft-lbf)

Crankcase bolt M8 3 26 Nm (2.6 m-kgf, 19 tt-lbf)
Crankcase bolt M6 13 10 Nm (1.0 m-kgf, 7.2 tt-lbf)
Dipstick guide bolt M6 1 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Engine oil drain bolt M14 1 30 Nm (3.0 m-kgf, 22 tt-lbf)
Crankcase plug M16 1 8 Nm (0.8 m-kgf, 5.8 tt-lbf)
Crankcase plug M14 1 18 Nm (1.8 m-kgf, 13 tt-lbf)
Oil filter cartridge
Oil filter cartridge union bolt
M20
M20
1
1
17 Nm (1.7 m-kgf, 12 tt-lbf)
30 Nm (3.0 m-kgf, 22 tt-lbf)
.......
---41@
Timing chain stopper guide (lower)
bolt
M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf) -CJ
Bearing retainer bolt (crankcase) M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf) -CJ
Oil pump bolt M6 3 10 Nm (1.0 m-kgf, 7.2 tt-lbf)
Oil pump housing cover screw MS 1 5 Nm (0.5 m-kgf, 3.6 tt-lbf)
Water jacket joint bolt M6 2 10 Nm (1.0 m-kgf, 7.2 tt-lbf)
Water pump outlet hose clamp
screw MS 2 1.5 Nm (0.15 m-kgf, 1.1 tt-lbf)
Water pump housing bolt M6 3 10 Nm (1.0 m-kgf, 7.2 tt-lbf)

Coolant drain bolt M6 1 10 Nm (1.0 m-kgf, 7.2 tt-lbf)
Water pump air bleed bolt M6 1 10 Nm (1.0 m-kgf, 7.2 tt-lbf)
Water pump outlet pipe bolt M6 1 10 Nm (1.0 m-kgf, 7.2 tt-lbf)
Crankshaft end accessing screw M36 1 2.0 Nm (0.20 m-kgf, 1.4 tt-lbf)
Timing mark accessing screw M14 1 1.5 Nm (0.15 m-kgf, 1.1 ft-lbf)
Drive select lever shift cable bracket
bolt (engine side)
M6 1 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
AC magneto cover bolt M6 11 10 Nm (1.0 m-kgf, 7.2 tt-lbf)

AC magneto rotor nut M16 1 60 Nm (6.0 m-kgf, 43 tt-lbf) ---41@
AC magneto/crankshaft position
sensor lead holder bolt
MS 2 7 Nm (0.7 m-kgf, 5.1 tt-lbf) -CJ
Starter clutch bolt M8 3 30 Nm (3.0 m-kgf, 22 tt-lbf) -CJ
Use a lock
Oil pump driven sprocket nut M10 1 22 Nm (2.2 m-kgf, 16 tt-lbf)
washer.
Use a lock
Balancer driven gear nut M18 1 85 Nm (8.5 m-kgf, 61 ft-lbf) washer.
---41@
Drive belt cover bolt M6 11 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Bearing housing bolt (primary
M6 4 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
sheave assembly)
Bearing retainer bolt (bearing hous-
M6 1 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
ing)
2-12
TIGHTENING TORQUES
Thread
size
Primary sheave assembly nut M16 1 190 Nm (19 m-kgf, 137 ft-lbf)
Primary sheave cap screw M4 8 3.0 Nm (0.30 m-kgf, 2.2 ft-lbf)
Secondary sheave assembly nut M16 1 100 Nm (10 m-kgf, 72 ft-lbf)
Secondary sheave spring retaining
M36 1 90 Nm (9.0 m-kgf, 65 ft-lbf)
nut
Drive belt case bolt M6 8 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Clutch housing assembly bolt M6 9 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Left-hand
threads
Clutch carrier assembly nut M22 1 190 Nm (19 m-kgf, 137 ft-lbf) Stake.
~
Drive select lever unit bolt M6 5 13 Nm (1.3 m-kgf, 9.4 ft-lbf)
Drive select lever shift cable bracket
M8 2 16 Nm (1.6 m-kgf, 12 ft-lbf)
bolt (drive select lever side)
Drive select lever shift cable locknut M14 1 39 Nm (3.9 m-kgf, 28 ft-lbf)
Shift arm bolt M6 1 14 Nm (1.4 m-kgf, 10 ft-lbf)
Shift lever cover bolt M6 4 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Shift lever 2 bolt M6 1 14 Nm (1.4 m-kgf, 10 ft-lbf)
Shift drum stopper bolt M14 1 18 Nm (1.8 m-kgf, 13 ft-lbf)
Middle drive pinion gear nut M22 1 190 Nm (19 m-kgf, 137 ft-lbf) Stake.
Middle drive shaft bearing housing
bolt
M8 4 32 Nm (3.2 m-kgf, 23 ft-lbf) -G
Middle drive shaft bearing retainer Stake.
M8 4 29 Nm (2.9 m-kgf, 21 ft-lbf)
bolt -G
Front drive shaft yoke nut (middle
gear side)
M16 1 190 Nm (19 m-kgf, 137 ft-lbf) -G
Left-hand
Middle driven shaft bearing retainer M55 1 80 Nm (8.0 m-kgf, 58 ft-lbf) threads
-G
Middle driven pinion gear bearing
M8 4 25 Nm (2.5 m-kgf, 18 ft-lbf)
housing bolt
Left-hand
Middle driven pinion gear bearing re-
M60 1 130 Nm (13 m-kgf, 94 ft-lbf) threads
tainer
-G
Rear drive shaft yoke nut (middle
gear side)
M16 1 190 Nm (19 m-kgf, 137 ft-lbf) -G
Starter motor bolt M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Starter motor cover bolt M5 2 4.9 Nm (0.49 m-kgf, 3.5 ft-lbf)
Brush set bolt M6 1 11 Nm (1.1 m-kgf, 8.0 ft-lbf)
Starter motor lead nut M6 1 4.9 Nm (0.49 m-kgf, 3.5 ft-lbf)
Negative battery lead bolt M6 1 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Spark plug M10 1 13 Nm (1.3 m-kgf, 9.4 ft-lbf)
Stator coil assembly bolt M6 3 7 Nm (0.7 m-kgf, 5.1 ft-lbf) -G
Crankshaft position sensor bolt M5 2 7 Nm (0.7 m-kgf, 5.1 ft-lbf) -G
Coolant temperature sensor M12 1 18 Nm (1.8 m-kgf, 13 ft-lbf)
2-13
TIGHTENING TORQUES
Thread
size
Gear position switch bolt M6 2 7 Nm (0.7 m-kgf, 5.1 tt-lbf)
Reverse switch M10 1 17 Nm (1.7 m-kgf, 12 tt-lbf)
Speed sensor bolt M6 1 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Cylinder bolt
Temporarily tighten the cylinder bolts to 15 Nm (1.5 m-kgf, 11 ft-lbf), and then tighten them to 50 Nm
(5.0 m-kgf, 36 ft-lbf).
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Cylinder head bolt

Tighten the cylinder head bolts to specification in the proper tightening sequence.
Cylinder head tightening sequence:
~8
2-14
TIGHTENING TORQUES
EBS30020
CHASSIS TIGHTENING TORQUES

Thread
size
Engine mounting bolt (front) (M10) M10 2 42 Nm (4.2 m-kgf, 30 tt-lbf)
Engine mounting bolt (rear) (M10) M10 2 42 Nm (4.2 m-kgf, 30 tt-lbf)
Engine mounting bolt (front) (M6) M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf) -G
Engine mounting bolt (rear) (M6) M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf) -G
Engine bracket nut (front) M10 2 42 Nm (4.2 m-kgf, 30 tt-lbf)
Engine bracket nut (rear) M10 2 42 Nm (4.2 m-kgf, 30 ft-lbf)
Engine mount damper stay holder
M10 1 51 Nm (5.1 m-kgf, 37 tt-lbf)
nut
Engine mount damper stay nut (en-
M10 1 51 Nm (5.1 m-kgf, 37 tt-lbf)
gine side)
Engine mount damper stay bolt
M10 1 51 Nm (5.1 m-kgf, 37 tt-lbf)
(frame side)
Engine mount damper stay bracket
M10 1 51 Nm (5.1 m-kgf, 37 tt-lbf)
bolt
M6 1 4.0 Nm (0.40 m-kgf, 2.9 tt-lbf)
fixed screw
M6 1 4.0 Nm (0.40 m-kgf, 2.9 tt-lbf)
fixed locknut
Front fender and front grill bolt M6 6 4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
Radiator bracket bolt M6 2 7 Nm (0.7 m-kgf, 5.1 tt-lbf)
Radiator fan bolt M6 4 8 Nm (0.8 m-kgf, 5.8 ft-lbf)
Radiator pipe holder bolt M6 4 7 Nm (0.7 m-kgf, 5.1 tt-lbf)
Front fender and electrical compo-
M6 4 4.0 Nm (0.40 m-kgf, 2.9 tt-lbf)
nents tray bolt
Front grill and front guard bolt M6 2 4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
Front guard bolt M10 4 48 Nm (4.8 m-kgf, 35 tt-lbf)
Front guard cover screw M6 4 2.5 Nm (0.25 m-kgf, 1.8 tt-lbf)
Front grill and frame bolt M6 2 4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
Headlight screw M5 6 1.5 Nm (0.15 m-kgf, 1.1 tt-lbf)
Front fender and frame bolt M6 2 4.0 Nm (0.40 m-kgf, 2.9 tt-lbf)
Electrical components tray and
M6 4 4.0 Nm (0.40 m-kgf, 2.9 tt-lbf)
frame bolt
Muffler heat protector plate bolt M8 2 17 Nm (1.7 m-kgf, 12 tt-lbf)
Side panel bolt M6 6 4.0 Nm (0.40 m-kgf, 2.9 tt-lbf)
ECU nut M6 1 7 Nm (0.7 m-kgf, 5.1 tt-lbf)
Lean angle sensor bolt M5 2 3.8 Nm (0.38 m-kgf, 2.8 tt-lbf)
Starter relay lead bolt M6 2 3.6 Nm (0.36 m-kgf, 2.6 tt-lbf)
Positive battery lead nut M8 1 1.5 Nm (0.15 m-kgf, 1.1 tt-lbf)
Negative battery lead nut M8 1 1.5 Nm (0.15 m-kgf, 1.1 tt-lbf)
EPS control unit bolt (for EPS mod-
M6 1 2.5 Nm (0.25 m-kgf, 1.8 tt-lbf)
els)
2-15
TIGHTENING TORQUES
Thread
size
V-belt cooling intake duct joint 1
clamp screw (V-belt cooling intake M4 1 1.5 Nm (0.15 m-kgf, 1.1 tt-lbf)
duct side)
M6 1 2.0 Nm (0.20 m-kgf, 1.4 tt-lbf)
clamp screw (drive belt cover side)
M4 2 1.5 Nm (0.15 m-kgf, 1.1 tt-lbf)
clamp screw
V-belt cooling exhaust duct joint
clamp screw (V-belt cooling exhaust M4 1 1.5 Nm (0.15 m-kgf, 1.1 tt-lbf)
duct side)
V-belt cooling exhaust duct joint
M6 1 2.0 Nm (0.20 m-kgf, 1.4 tt-lbf)
clamp screw (drive belt cover side)
Fuel tank retainer bolt M8 2 16 Nm (1.6 m-kgf, 12 tt-lbf)
Fuel tank bolt M6 3 7 Nm (0.7 m-kgf, 5.1 tt-lbf)
Fuel tank bracket bolt M6 2 7 Nm (0.7 m-kgf, 5.1 tt-lbf)
Fuel tank breather hose joint bolt M6 1 7 Nm (0.7 m-kgf, 5.1 tt-lbf)
Fuel pump nut M6 6 See TIP.
Throttle body joint clamp screw MS 2 2.8 Nm (0.28 m-kgf, 2.0 tt-lbf)
Air intake silencer joint clamp screw
MS 1 3.5 Nm (0.35 m-kgf, 2.5 tt-lbf)
(throttle body side)
Air intake silencer joint clamp screw
M6 1 2.0 Nm (0.20 m-kgf, 1.4 tt-lbf)
(air intake silencer side)
Air filter case joint clamp screw M6 2 2.0 Nm (0.20 m-kgf, 1.4 tt-lbf)
Air intake duct joint clamp screw M6 2 2.0 Nm (0.20 m-kgf, 1.4 tt-lbf)
Air filter case bolt M6 3 7 Nm (0.7 m-kgf, 5.1 tt-lbf)
Coolant reservoir bolt M6 2 7 Nm (0.7 m-kgf, 5.1 tt-lbf)
Door hinge nut M6 8 7 Nm (0.7 m-kgf, 5.1 tt-lbf)
Door hinge bolt M6 4 7 Nm (0.7 m-kgf, 5.1 tt-lbf)
Door handle latch nut M6 6 7 Nm (0.7 m-kgf, 5.1 tt-lbf)
Skid plate bolt M6 4 7 Nm (0.7 m-kgf, 5.1 tt-lbf)
Lower panel and floor board bolt M6 2 4.0 Nm (0.40 m-kgf, 2.9 tt-lbf)
Lower panel and frame bolt M6 4 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Frame cross member bolt M8 4 17 Nm (1.7 m-kgf, 12 tt-lbf)
Exhaust pipe heat protector plate
M8 4 17 Nm (1.7 m-kgf, 12 tt-lbf)
bolt
Front wheel axle nut M24 2 350 Nm (35 m-kgf, 253 ft-lbf) Stake.
Front wheel nut M12 8 75 Nm (7.5 m-kgf, 54 tt-lbf)
Rear wheel axle nut M24 2 350 Nm (35 m-kgf, 253 ft-lbf) Stake.
Rear wheel nut M12 8 75 Nm (7.5 m-kgf, 54 tt-lbf)
Front brake disc guard bolt M6 6 9 Nm (0.9 m-kgf, 6.5 tt-lbf)
Front brake caliper bolt M10 4 48 Nm (4.8 m-kgf, 35 ft-lbf)
Front brake disc bolt M8 8 30 Nm (3.0 m-kgf, 22 tt-lbf) -CJ
Front brake caliper retaining pin nut M8 2 22 Nm (2.2 m-kgf, 16 ft-lbf) -CJ
Front brake pad bolt M10 4 17 Nm (1.7 m-kgf, 12 tt-lbf)
2-16
TIGHTENING TORQUES
Thread
size
Front brake caliper guide pin M8 2 17 Nm (1. 7 m-kgf, 12 ft-lbf)
Front brake caliper bleed screw M8 2 5 Nm (0.5 m-kgf, 3.6 ft-lbf)
Rear brake disc guard bolt M6 4 9 Nm (0.9 m-kgf, 6.5 ft-lbf)
Rear brake disc cleaning plate bolt M6 4 9 Nm (0.9 m-kgf, 6.5 ft-lbf)
Rear brake disc bolt M8 8 30 Nm (3.0 m-kgf, 22 ft-lbf) -G
Rear brake caliper bolt M10 4 48 Nm (4.8 m-kgf, 35 ft-lbf)
Rear brake caliper retaining pin nut M8 2 22 Nm (2.2 m-kgf, 16 ft-lbf) -G
Rear brake pad bolt M10 4 17 Nm (1.7 m-kgf, 12 ft-lbf)
Rear brake caliper guide pin M8 2 17 Nm (1.7 m-kgf, 12 ft-lbf)
Rear brake caliper bleed screw M8 2 5 Nm (0.5 m-kgf, 3.6 ft-lbf)
Brake pipe flare nut M10 4 19 Nm (1.9 m-kgf, 14 ft-lbf)
Front brake hose joint bolt M6 1 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Rear brake hose joint bolt M6 1 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Front brake hose holder bolt M6 4 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Rear brake hose holder bolt M6 2 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Front brake hose union bolt M10 2 27 Nm (2.7 m-kgf, 20 ft-lbf)
Rear brake hose union bolt M10 2 27 Nm (2.7 m-kgf, 20 ft-lbf)
Brake master cylinder reservoir cap - 1 3.5 Nm (0.35 m-kgf, 2.5 ft-lbf)
Brake master cylinder reservoir
M6 1 6 Nm (0.6 m-kgf, 4.3 ft-lbf)
clamp screw
Parking brake cable holder bolt M6 2 12 Nm (1.2 m-kgf, 8.7 ft-lbf)
Parking brake caliper guide pin M8 1 17 Nm (1.7 m-kgf, 12 ft-lbf)
Parking brake caliper retaining pin
nut
M8 1 22 Nm (2.2 m-kgf, 16 ft-lbf) -G
Parking brake pad bolt M8 2 17 Nm (1.7 m-kgf, 12 ft-lbf)
Parking brake caliper arm nut M8 1 17 Nm (1.7 m-kgf, 12 ft-lbf)
Brake master cylinder bolt M8 2 16 Nm (1.6 m-kgf, 12 ft-lbf)
Pedal assembly bolt M8 3 16 Nm (1.6 m-kgf, 12 ft-lbf)
Brake pedal rod locknut M8 1 17 Nm (1.7 m-kgf, 12 ft-lbf)
Throttle cable locknut (accelerator
M6 1 2.5 Nm (0.25 m-kgf, 1.8 ft-lbf)
pedal end)
Parking brake lever bolt M6 2 13 Nm (1.3 m-kgf, 9.4 ft-lbf)
Parking brake caliper bolt M10 2 40 Nm (4.0 m-kgf, 29 ft-lbf)
Parking brake disc nut M6 3 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Parking brake cable locknut M6 2 16 Nm (1.6 m-kgf, 12 ft-lbf)
Front arm nut
Front shock absorber assembly nut
M10
M10
8
4
55 Nm (5.5 m-kgf, 40 ft-lbf)
55 Nm (5.5 m-kgf, 40 ft-lbf)
......
Steering knuckle nut M12 4 30 Nm (3.0 m-kgf, 22 ft-lbf)
Front arm protector bolt M6 4 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Steering wheel nut M12 1 35 Nm (3.5 m-kgf, 25 ft-lbf)
Steering column bolt (except for EPS
models)
M8 4 21 Nm (2.1 m-kgf, 15 ft-lbf)
2-17
TIGHTENING TORQUES
Thread
size
EPS unit bolt (for EPS models) M8 4 21 Nm (2.1 m-kgf, 15 ft-lbf)
EPS unit and bracket bolt (for EPS
M8 4 16 Nm (1.6 m-kgf, 12 ft-lbf)
models)
Steering joint bolt M8 2 33 Nm (3.3 m-kgf, 24 ft-lbf)
Steering assembly bolt M10 4 See TIP.
Tie-rod M28 2 55 Nm (5.5 m-kgf, 40 ft-lbf)
Tie-rod end locknut M12 2 40 Nm (4.0 m-kgf, 29 ft-lbf)
Steering knuckle and tie-rod end nut M12 2 39 Nm (3.9 m-kgf, 28 ft-lbf)
Rear arm nut M10 4 55 Nm (5.5 m-kgf, 40 ft-lbf)

~
Rear shock absorber assembly nut M12 4 82 Nm (8.2 m-kgf, 59 ft-lbf)
Stabilizer joint nut M10 4 60 Nm (6.0 m-kgf, 43 ft-lbf)
Stabilizer holder bolt M10 4 85 Nm (8.5 m-kgf, 61 ft-lbf)
Rear knuckle nut M12 2 90 Nm (9.0 m-kgf, 65 ft-lbf)
Rear arm protector bolt M6 4 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Rear arm protector screw M6 2 8 Nm (0.8 m-kgf, 5.8 ft-lbf)
Rear knuckle grease nipple M6 4 3.8 Nm (0.38 m-kgf, 2.8 ft-lbf)
Differential gear oil filler bolt M14 1 23 Nm (2.3 m-kgf, 17 ft-lbf)
Differential gear oil drain bolt M10 1 10 Nm (1.0 m-kgf, 7.2 ft-lbf)
Differential motor bolt M6 3 11 Nm (1.1 m-kgf, 8.0 ft-lbf)
Front drive shaft yoke nut M14 1 62 Nm (6.2 m-kgf, 45 ft-lbf)
Differential case bolt M8 5 24 Nm (2.4 m-kgf, 17 ft-lbf)
Front drive shaft universal joint yoke
nut
M16 1 150 Nm (15 m-kgf, 108 ft-lbf) -G
Differential assembly nut M12 1 105 Nm (10.5 m-kgf, 76 ft-lbf)
Differential assembly bolt M10 2 60 Nm (6.0 m-kgf, 43 ft-lbf)
Differential assembly nut M10 1 60 Nm (6.0 m-kgf, 43 ft-lbf)
Support bearing bracket bolt M8 2 18 Nm (1.8 m-kgf, 13 ft-lbf)
Final gear oil filler bolt M10 1 23 Nm (2.3 m-kgf, 17 ft-lbf)
Final gear oil drain bolt M10 1 23 Nm (2.3 m-kgf, 17 ft-lbf)
Final drive assembly bracket bolt
M8 4 33 Nm (3.3 m-kgf, 24 ft-lbf)
(upper side)
M8 2 33 Nm (3.3 m-kgf, 24 ft-lbf)
(lower side)
Final drive assembly nut (upper side) M12 2 105 Nm (10.5 m-kgf, 76 ft-lbf)
Final drive assembly nut (lower side) M12 1 105 Nm (10.5 m-kgf, 76 ft-lbf)
Rear drive shaft yoke nut (final drive
assembly side)
M14 1 97 Nm (9.7 m-kgf, 70 ft-lbf) -G
Final drive pinion gear bearing hous-
M8 4 26 Nm (2.6 m-kgf, 19 ft-lbf)
ing bolt
Ring gear stopper nut M8 1 16 Nm (1.6 m-kgf, 12 ft-lbf) -G
Final drive case cover bolt M10 8 52 Nm (5.2 m-kgf, 38 ft-lbf)
Driver seat frame bolt M8 4 23 Nm (2.3 m-kgf, 17 ft-lbf)
Center passenger seat frame bolt M8 4 23 Nm (2.3 m-kgf, 17 ft-lbf)
2-18
TIGHTENING TORQUES
Thread
size
Outer passenger seat frame bolt M8 4 23 Nm (2.3 m-kgf, 17 ft-lbf)
Seat back bolt M6 9 6 Nm (0.6 m-kgf, 4.3 ft-lbf)
Headrest bolt M6 9 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Seat belt bolt M12 6 59 Nm (5.9 m-kgf, 43 ft-lbf)
Seat belt buckle bolt M12 3 59 Nm (5.9 m-kgf, 43 ft-lbf)
Seat belt guide bolt M11 3 59 Nm (5.9 m-kgf, 43 ft-lbf)
Passenger handhold stopper nut M6 1 3.0 Nm (0.30 m-kgf, 2.2 ft-lbf)
Sound-deflection panel bolt M6 3 4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
Sound-deflection panel screw M6 3 1.3 Nm (0.13 m-kgf, 0.94 ft-lbf)
Sound-deflection panel holder bolt M6 2 4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
V-belt cooling intake duct cover bolt M6 5 4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
Floor board and frame bolt (left) M6 6 4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
Center floor board and frame bolt M6 2 4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
Floor board and frame bolt (right) M6 6 4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
Center floor board and left floor
M6 4 4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
board bolt
Center floor board and right floor
M6 5 4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
board bolt
Instrument panel bolt M6 8 4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
Under-seat storage compartment
cover bolt (except for special edition M8 1 17 Nm (1.7 m-kgf, 12 ft-lbf)
models)
holder bolt (for special edition mod- M8 2 16 Nm (1.6 m-kgf, 12 ft-lbf)
els)
under bracket bolt (for special edition M6 2 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
models)
Meter assembly nut M5 3 3.8 Nm (0.38 m-kgf, 2.8 ft-lbf)
Meter assembly bracket bolt M6 2 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Glove compartment latch plate
M4 1 1.3 Nm (0.13 m-kgf, 0.94 ft-lbf)
screw
Front over fender nut (for special edi-
M6 10 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
tion models)
Gas spring assembly ball stud nut M8 4 16 Nm (1.6 m-kgf, 12 ft-lbf)
Tail/brake light nut M6 4 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Cargo bed release lever bolt M6 4 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Cargo bed release lever holder bolt M6 4 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Cargo hook nut M6 8 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Rear over fender nut (for special edi-
M6 12 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
tion models)
Mud flap upper bracket bolt (for spe-
M6 4 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
cial edition models)
Mud flap lower bracket bolt (for spe-
M6 8 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
cial edition models)
2-19
TIGHTENING TORQUES
Item Thread Q'ty Tightening torque Remarks

s ize
Mud flap nut (for special edition
M6 4 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
models)
Tailgate shaft bolt M6 3 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Tailgate cable bolt M6 4 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Tailgate cable bracket bolt M6 4 9 Nm (0.9 m-kgf, 6.5 ft-lbf)
Cargo bed heat protector plate bolt M6 5 8 Nm (0.8 m-kgf, 5.8 ft-lbf)
Side frame nut (front left) M10 2 65 Nm (6.5 m-kgf, 47 ft-lbf)
Side frame nut (rear left) M10 1 48 Nm (4.8 m-kgf, 35 ft-lbf)
Side frame nut (front right) M10 2 65 Nm (6.5 m-kgf, 47 ft-lbf)
Side frame nut (rear right) M10 1 48 Nm (4.8 m-kgf, 35 ft-lbf)
Front top frame bolt M10 4 48 Nm (4.8 m-kgf, 35 ft-lbf)
Rear top frame bolt M10 4 48 Nm (4.8 m-kgf, 35 ft-lbf)
Rear center frame bolt M10 4 48 Nm (4.8 m-kgf, 35 ft-lbf)
Rear frame bolt (left) M10 4 48 Nm (4.8 m-kgf, 35 ft-lbf)
Rear frame bolt (right) M10 4 48 Nm (4.8 m-kgf, 35 ft-lbf)
Sun top front bracket screw M6 8 3.0 Nm (0.30 m-kgf, 2.2 ft-lbf)
Sun top rear bracket screw M6 8 3.0 Nm (0.30 m-kgf, 2.2 ft-lbf)
Sun top lower bracket bolt M6 4 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Sun top lower bracket nut M6 4 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Intake air temperature sensor screw M5 1 1.5 Nm (0.15 m-kgf, 1.1 ft-lbf)
Rectifier/ regulator bolt M6 2 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Parking brake buzzer bolt M5 1 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Ground lead bolt M6 1 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Ignition coil bolt M6 2 7 Nm (0.7 m-kgf, 5.1 ft-lbf)
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Enclosure bolt and nut

Tighten the enclosure bolts and nuts to specification in the proper tightening sequence.
Enclosure tightening sequence:
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Steering assembly bolt

Tighten the steering assembly bolts to 48 Nm (4.8 m-kgf, 35 ft-lbf) in the proper tightening sequence.
2-20
TIGHTENING TORQUES
Steering assembly tightening sequence:

FWD
4
y
lf
'I.
3
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Fuel pump nut

Tighten the fuel pump nuts to 7 Nm (0.7 m-kgf, 5.1 ft-lbf) in the proper tightening sequence.
Fuel pump tightening sequence:
5 >: CQ;< 6 ¢ FWD
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Fuel tank bolt

Tighten the fuel tank bolts and fuel tank retainer bolts to specification in the proper tightening sequence.
Fuel tank tightening sequence:

1-----... 0
i--:;-;~~~o
1
' 00 o 0
)..s
0
0
0
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Final drive assembly bolt and nut

Tighten the final drive assembly bolts and nuts to specification in the proper tightening sequence.
2-21
TIGHTENING TORQUES
Final drive assembly tightening sequence:

6 'I
.li,,. ©i
4!©
c::) FWD
2~
0n
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Engine mount damper stay bolts and nuts

Tighten the engine mount damper stay bolts and nuts to specification in the proper tightening se-
quence.
Engine mount damper stay bolts and nuts sequence:
"
"
"
' ---'
I I ::
II
~ - - - -- -ft~:<4
~ ~~[7- - - -~ ·~©~j 4 ..:...5
"'
"'
"'
"'
ic___ ,i(s
~ :::
; ,.
"
"
"
"
2-22
LUBRICATION AND SEALING POINTS
EBS20019

ESS30021
ENGINE
Lubrication point Lubricant/Sealant
Oil seal lips -..-a
Bearings - -o@
0 -rings ---..1
Cylinder head bolts ~
Crankshaft pin -1@
Connecting rod big end thrust surface - 1@
Crankshaft sprocket ~
Inner race (crankshaft) -1@
Buffer boss (crankshaft) - 1@
Crankshaft seal -1@
Piston pin -1@
Piston rings and ring grooves -1@
Valve stems and stem ends (intake and exhaust) -1@
Valve stem seals (intake and exhaust) - 1@
Rocker arm shafts -1@
Camshaft lobes - 1@
Decompressor lever pin -1@
Decompressor lever -1@
Rocker arms (intake and exhaust) ~
Oil pump shaft -1@
0 -ring (oil filter cartridge) ---..1
Water pump impeller shaft ~
Dipstick mating surface -1@
Starter idler gear inner surface -1@
Starter idler gear shaft -1@
Starter wheel gear -1@
Torque limiter - 1@
Clutch housing shaft end ---..1
Clutch carrier assembly -1@
One-way clutch bearing -1@
Clutch dog -1@
Reverse idle gear shaft -1@
Reverse idle gear - 1@
Middle driven shaft splines -1@
Shift drum -1@
Shift forks and shift fork guide bar -1@
2-23
Lubrication point Lubricant/Sealant

Shift drum stopper ball ---41@
Shift lever 1 and shift lever 2 ---41@
Yamaha bond No.1215
AC magneto lead grommet
Yamaha bond No.1215
Crankcase mating surface
2-24
LUBRICATION SYSTEM CHART AND DIAGRAMS
EBS20020

EBS30022
ENGINE OIL LUBRICATION CHART
- 9 9
6
11 10 8 7 5
--w-;
'
'
'
3 '
'
'
•
'
1 2
2-25
1. Oil pan
2. Oil strainer
3. Oil pump assembly
4. Relief valve assembly
5. Oil cooler
6. Oil filter cartridge
7. Drive axle
8. Reverse idle gear shaft
9. Oil pipe (crankcase to cylinder head)
10. Crankshaft
11 . Cylinder head
2-26
EBS30023
LUBRICATION DIAGRAMS
6 1
5 4 3 2
7 8
+ ..
.
+ .. I I -- ~ ~
3 2
2-27
1. Oil pipe (crankcase to cylinder head)

2. Oil filter cartridge
3. Oil cooler
4. Oil strainer
5. Oil pump
6. Oil pipe (AC magneto cover)
7. Reverse idle gear shaft
8. Drive axle
9. Relief valve assembly
2-28
--
'-,-----..D ~ ...
nl-!-<'; ;M'~-~\[- = '
I ,. 1 :c
V T
:b .. v:::: \
LI
( ,,;t_f)-1 ~ .
1/1
V
,,
~
...,
I I I
,..
- ~
>--
') ~
=
II
r
I
- ' 2
- /
-
] ~
- '-
..
H
I
\
:0.
F
[I]
• •
"' -
Jl
I I
i: ~
.i .i l
i.
--
I
.. ,-
"'
I _..._ -
5 4 3
,/
2-29
1. Camshaft
2. Crankshaft
3. Oil strainer
4. Oil pump
5. Oil pump driven sprocket
2-30
COOLING SYSTEM DIAGRAMS
ESS20021
1 2 3
F::,-,- 0
,,
V
0 ·"'---: : :==- ..
•• ... .-
<> 0 0
••
'
•
·' "
"
0
bC-'_,__ o
6 5 4
1
, .'
I 1
2 5
~ .I
. I
I:
:I
I:
C•..--·
<- ,,?_,I
• •
•
4
2-31
1. Radiator
2. Radiator outlet hose
3. Radiator outlet pipe
4. Radiator inlet pipe
5. Radiator inlet hose
6. Radiator cap
2-32
1 2
--
:
: ~~ J,
o w,
I .. I ,
'" ':
c~
I
... _
0
•'o/;
' '
I:
~oJ' ' :: \
---,
0
r·· . . ..\
• •
, ( - "") I '.\
___ _) ____ :.
r,: 0
: l' \0 '•J
,()
\ __)
- -'
-----~~, --=-.....~--- ' '--"
'
.. i: \
I
'
-~ ... '' ''

... ' V
' : (~) : :o'' /

...... ...-::-:::: -...... :--j:_~. . =.:·. .:-_--:-,,,._ - ...lL .LI...:-
0
.L I -""-~-..:..:.=I•-
..j .L. = ... ~ - ,,
-- < --·· (' . 1~ ---- < _ _·: ____ _
5 4 3
3 6
5
•
- - - - - ' I' 1~
· - -1 ,'
' ' -
"
... '
'
-- .. ""'- ..... ..__ .. -- .. -- .. --
2 4
2-33
1. Radiator outlet pipe

2. Water pump inlet hose
3. Thermostat outlet hose
4. Oil cooler outlet hose
5. Radiator inlet pipe
6. Thermostat
2-34
4 3 2
5 4
~'7 ,.,
©)
0
e
.. ,
\ 4 7
6
2-35

2. Water pump inlet hose
3. Water pump
4. Water pump outlet pipe
5. Oil cooler inlet hose
6. Oil cooler
7. Oil cooler outlet hose
8. Water pump outlet hose
9. Water jacket joint
2-36
CABLE ROUTING
EBS20022
CABLE ROUTING
Radiator view
· (right side)
1 3
-@
\ \ _ _-lg
,--t-\l--1---
II \ ®
7 \ b.____.
0
0~ E
0
0
- --
--- --?-
--
.:::,. ..·
--=-- ------ -
-=-
~ -:~----
~ -----::::-- 0
2-37
CABLE ROUTING
1. Wire harness
2. Radiator fan motor breather hose
3. Differential assembly breather hose
4. Coolant reservoir breather hose
5. Radiator outlet hose
6. Differential motor lead
7. Coolant reservoir hose
8. Radiator fan motor lead
9. Drive select lever shift cable
1o. Parking brake cable
11 . Ground lead
12. Auxiliary DC jack lead
A. Route the wire harness, starter motor lead, and
negative battery lead into the electrical
components tray.
B. Make sure that there is no slack in the coolant
reservoir breather hose in the area shown in the
illustration.
C. Fasten the coolant reservoir breather hose to the
radiator outlet hose with the plastic band. Align the
plastic band with the portion of the radiator outlet
hose where the hose begins to bend.
D. Fasten the differential assembly breather hose with
the holder on the radiator.
E. Fasten the coolant reservoir hose to the radiator
outlet hose with the plastic band. Align the plastic
band with the portion of the radiator outlet hose
where the hose begins to bend.
F. Fasten the radiator fan motor lead to the radiator
outlet hose with the plastic band.
G. Insert the projection on the wire harness holder
into the hole in the frame from the inside of the
frame.
H. Fasten the wire harness, starter motor lead,
negative battery lead, drive select lever shift cable,
and parking brake cable with the plastic band.
I. Fasten the wire harness, starter motor lead, and
negative battery lead with the plastic band.
Position the plastic band at the section of the wire
harness where the leads branch off from the
harness.
2-38
CABLE ROUTING
Radiator view (left side)
11 1 2 D
6 c::::::::::::) •
• 0 0 0 0 0
3
4
2
1
O_J
...•. '.-
- --®
2-39
CABLE ROUTING
1. Coolant reservoir hose

2. Wire harness
3. Throttle cable
4. Brake light switch lead
5. EPS motor lead (for EPS models)
6. EPS torque sensor lead (for EPS models)
7. Parking brake buzzer lead
9. Parking brake cable
10. Radiator inlet hose
11 . Differential assembly breather hose
12. Coolant reservoir breather hose
13. Radiator fan motor breather hose
A. Fasten the coolant reservoir hose with the holder
on the radiator.
B. Route the right headlight lead into the electrical
components tray, and then faste n the lead with the
holder on the electrical components tray.
C. Route the differential assembly breather hose,
coolant reservoir breather hose, and radiator fan
motor breather hose through the hole in the
electrical components tray. Make sure that the end
of each breather hose protrudes out of the
electrical components tray.
D. Fasten the right headlight lead with the holder on
the electrical components tray.
E. Fasten the throttle cable to the radiator inlet hose
with the plastic band. Be sure to route the throttle
cable to the outside of the radiator inlet hose and
install the plastic band around the hose protector
of the radiator inlet hose, not the hose itself.
F. Fasten the throttle cable to the radiator inlet hose
with the plastic band. Be sure to route the throttle
cable to the inside of the radiator inlet hose and
install the plastic band around the hose protector
of the radiator inlet hose, not the hose itself.
2-40
CABLE ROUTING
Radiator view (top)
4 3 2
3 2
2 D E
C
• n
0 0 0
00 0
0 0 0
0
080 0 0
0g 0
~
0
:
0 0
2-41
CABLE ROUTING
1. Headlight lead (right)

2. Wire harness
3. Negative battery lead
4. Starter motor lead
7. Throttle cable
8. Meter assembly lead
9. Indicator light assembly lead
10. Parking brake switch lead
11 . Main switch lead
14. Light switch lead
15. On-Command four-wheel-drive switch lead
16. Headlight lead (left)
A. Fasten the right headlight lead to the frame with
the plastic band.
B. To the electrical components tray
C. Fasten the wire harness with the plastic band.
harness before the leads branch off from the
harness.
D. Fasten the wire harness at the white mark with the
plastic band.
E. Fasten the wire harness, starter motor lead,
negative battery lead, drive select lever shift cable,
and parking brake cable with the plastic band.
F. Fasten the throttle cable with the plastic band.
G. Fasten the parking brake switch lead with the
plastic band.
H. Route the EPS torque sensor lead through the
frame, and then connect the coupler to the EPS
torque sensor. (For EPS models)
I. Fasten the wire harness with the plastic band.
harness before the leads branch off from the
harness.
J. Fasten the wire harness and EPS motor lead (for
EPS models) with the plastic band. Position the
plastic band at the section of the wire harness
before the leads branch off from the harness.
K. Route the EPS torque sensor lead and EPS motor
lead through the hole in the electrical components
tray, and then connect the couplers to the EPS
control unit. (For EPS models)
L. Fasten the left headlight lead to the frame with the
plastic band.
M. Insert the projection on the holder into the second
hole from the right in the frame, and then fasten the
wire harness with the holder.
2-42
CABLE ROUTING
Engine view (right side)
-[HJ
QJ
[j]
6
9 8 7 6 5
2-43
CABLE ROUTING
1. Wire harness
2. Final drive assembly breather hose
4. Intake air temperature sensor lead
5. Speed sensor lead
7. AC magneto lead
A. Route the final drive assembly breather hose
through the hole in the frame.
B. Fasten the final drive assembly breather hose with
the holder.
C. Fasten the wire harness with the plastic band.
Position the plastic band to the front of the split in
the wire harness.
D. Fasten the negative battery lead and starter motor
lead with the holder.
E. Fasten the wire harness to the frame with the
plastic band. Be sure to position the plastic band
above the bracket.
F. Route the wire harness in front of the frame, and
then fasten the wire harness to the frame with the
plastic band. Be sure to position the plastic band
under the bracket.
G. Route the wire harness to the inside of the frame.
H. Fasten the negative battery lead and starter motor
lead with the plastic band.
I. 10-30°
J. 50-60 mm (1.97-2.36 in)
K. Align the holder with the white mark on the final
drive assembly breather hose.
2-44
CABLE ROUTING
Engine view (left side)
L._,
I
10 11
5 6 7 8
4
---------------- __________ ,..~- /
.- ------°'1~~¥--------
_,... _,.. I I
-------
- - - -~-::::.-.-==..:
- -- ------~=~ --- - -'IJ .J,.. _ - - _ _ ,,,, /
2-45
CABLE ROUTING
1 . Seat belt switch lead

2. Gear position switch lead
3. Reverse switch lead
4. Throttle cable
5. Cylinder head breather hose
6. Throttle body breather hose
7. ISC unit lead
8. Coolant temperature sensor lead
9. Air induction system solenoid lead
10. Spark plug lead
11 . Wire harness
A. Fasten the seat belt switch lead with the holder.
B. Route the seat belt switch lead to the left side of
the frame.
C. To the seat belt switch
D. Fasten the wire harness with the plastic band.
Position the plastic band near the ignition coil
bracket and at the section of the wire harness
before the leads branch off from the harness.
E. Make sure that the throttle body breather hose is
not pinched.
2-46
CABLE ROUTING
Engine view (top)
*A *B *C *D *E *F
1 C 7 8 11
*A ""
""
*A
""
dit-,
l I I I
'"'If'
""
"" "
""
"
""'
""
*B
-- -- • _,.._
- ... -- --~-
*C "
~
II *C
C, 0
f& ·,
8 g *D *D
0 0 i
0 0
~
0 0 0
*D *D
. :l• .~ I
'
'
~, 0 a ~
" J
8
8 8
0
_./-' "
//
*D
_____p,
""" -
_.,_
~ £::::.
*E """
II *E
11
*D ""
"" *D
1 16 K J I H G 1 11
~. ""
I I I I
'ii"
""
""
""
•"
*F *F
~ ~
1
1 !Ml
2-47
CABLE ROUTING
1. Wire harness
4. Fuel pump lead
5. Fuel hose
6. TPS lead
7. Intake air pressure sensor lead
8. Air induction system hose (air cut-off valve to reed
valve cover)
9. Tail/brake light lead (right)
10. Tail/brake light lead (left)
11 . Spark plug lead
12. Air induction system solenoid lead
13. Air induction system hose (air intake silencer to air
cut-off valve)
15. ISC unit lead
16. Throttle cable
17. Seat belt switch lead
A. To the fuel pump
B. Fasten the wire harness with the holder.
C. Fasten the hose protector of the fuel hose with the
holder.
D. Insert the projection on the holder into the hole in
the frame cross member from under the member,
and then fasten the wire harness with the holder.
E. Connect the right tail/brake light connectors. Make
sure that there is no slack in the lead between the
holders in the area shown in the illustration. Place
the slack in the lead to the outside of the outermost
holder.
F. Connect the left tail/brake light connectors. Make
sure that there is no slack in the lead between the
holders in the area shown in the illustration. Place
the slack in the lead to the outside of the outermost
holder.
G. Route the wire harness between the air induction
system hose (air intake silencer to air cut-off valve)
and the thermostat outlet hose.
H. Fasten the air induction system solenoid lead with
the holder under the frame cross member. Position
the holder at the section of the lead after the lead
branches off from the wire harness.
I. Fasten the spark plug lead to the air induction
with the holder. Align the holder with the portion of
the air induction system hose (air intake silencer to
air cut-off valve) where the hose begins to bend.
J. Route the spark plug lead above the air induction
and wire harness.
K. Fasten the wire harness with the holder. Position
the holder at the section of the wire harness before
the leads branch off from the harness.
L. Fasten the throttle cable at the white paint mark to
the hose protector of the thermostat outlet hose
with the plastic band. Align the plastic band with
the portion of the thermostat outlet hose where the
hose begins to bend.
M. Route the wire harness under the frame. Make
sure that the wire harness is not pinched between
the frame and the air intake silencer.
2-48
CABLE ROUTING
Final drive assembly view
0 G
0 0 0 (])
0 0
0
0 Q;)
--- --
------
®- - -----:i--/+:
I
------.-. . ,- - -
- _. -
- --:c--"'
_,
-,
2-49
CABLE ROUTING
1. Wire harness
2. Final drive assembly breather hose
4. Rear brake hose
A. Fasten the wire harness with the holder.
B. Fasten the final drive assembly breather hose with
the holder.
C. Insert the projection on the holder into the hole in
the cargo bed, and then fasten the wire harness
with the holder.
D. Fasten the rear brake hose with the holder.
E. Fasten the rear brake hose and final drive
assembly breather hose with the holder. Position
the holder to the right of the centerline between the
holders securing the brake hose.
F. Centerline
2-50
CABLE ROUTING
Fuel tank view
B
I I 0
0
I I 0
I I
d. \ 0
0 0 0 0 0 0 0
~L...='~
=------=~\-==,j e ~----.._c::::===;;:,-----, e
jgd_--tl
o.Y-----~~---::in-:'. o 0 0
0
1 - ---,-...,,_----"-..ll,,'~
'""F"':2 0 0 : ® : 0
-;H,-,C_1i_J_ -~~ 0
0
3
C
4
@-
2-51
CABLE ROUTING
1. Fuel hose
2. Fuel pump lead
3. Fuel tank breather hose (fuel tank to fuel tank
breather hose joint)
4. Fuel tank breather hose (fuel tank breather hose
joint to air)
A. Fasten the grommet on the fuel hose with the
holder.
B. Fasten the fuel pump lead with the holder.
C. Insert the fuel tank breather hose (fuel tank
breather hose joint to air) into the hole in the frame.
D. 0-3.0 mm (0- 0.12 in)
2-52
CABLE ROUTING
Front brake caliper view (left side)
0
0
0
2 3
2-53
CABLE ROUTING
1. Front brake pipe

2. Front brake hose
3. Rear brake pipe
A. Connect the front brake hose end that has a
projection to the left front brake caliper.
B. Fasten the front brake hose with the holder.
2-54
CABLE ROUTING
Front brake caliper view (top)
0 0
0
0
0
2-55
CABLE ROUTING
1. Front brake hose

2. Front brake pipe
3. Rear brake pipe
A. Face the paint mark upward.
B. Route the front brake hose under the front upper
arm.
C. Fasten the front brake hose with the holder.
2-56
CABLE ROUTING
Rear brake caliper view (left side)
ti
.. - --
. - -:.·-.....
- ..- ...~·:,- ::.~::•
C) C)
0 0
-----..,2
2-57
CABLE ROUTING
1. Rear brake pipe

2. Rear brake hose
A. Fasten the rear brake pipe with the holder.
B. Fasten the rear brake hose with the holder.
C. Face the paint mark forward.
2-58
CABLE ROUTING
Rear brake caliper view (top)
A 1 A
• •
•
0 • ~
•
• •
(> • •L
0 4-'-
0
0 e -fill
(>
'
'' '
'
''
0 ' 0
. .. -- .. . .. .. .. .. ''
. ,.
., .. '
8
; :.::
B
:,·
:.::
::,
:::
CJ CJ
0
@ @
0
0
'' '
' '
'',•,•...
.•,
\~
.. :.~
....._.
·:~·
:·}·
2-59
CABLE ROUTING
1. Rear brake pipe

2. Rear brake hose
A. Fasten the rear brake pipe with the holder.
B. Fasten the rear brake hose with the holder.
C. Right side
D. Connect the rear brake hose end that has a
projection to the right rear brake caliper.
2-60
CABLE ROUTING
Parking brake view
0
'
0
@
\ 0
0 0
-~
00
0
'
-------
2-61
CABLE ROUTING
1 . Parking brake cable

A. Fit the parking brake cable into the slit in the
parking brake lever.
B. Fit the parking brake cable into the holder on the
parking brake caliper.
2-62
CABLE ROUTING
Electrical components tray view
4
8 7
--@
1
19
0
16 11
2-63
CABLE ROUTING
1. Wire harness
2. Headlight lead (right)
3. Load control relay
4. Differential motor relay 2
5. Fuel injection system relay
7. Radiator fan motor relay
8. Headlight relay
9. Main fuse lead
10. Fuel injection system fuse
11 . Battery
12. EPS control unit (for EPS models)
14. Headlight lead (left)
16. Lean angle sensor lead
18. Starter relay lead
19. Positive battery lead
20. EPS fuse (for EPS models)
21 . ECU (Engine Control Unit) lead
22. Main fuse
24. Fuse box
A. Fasten the right headlight lead with the holder on
the electrical components tray.
B. Fasten the wire harness and main fuse lead with a
plastic band, making sure to align the band with
the white tape on the harness.
C. Fasten the left headlight lead, EPS motor lead (for
EPS models), and EPS torque sensor lead (for
EPS models) with the holder on the electrical
components tray.
D. Place the slack in the leads in the electrical
components tray.
E. Connect the EPS motor coupler and EPS torque
sensor coupler, and then insert the projection on
each coupler into the hole in the electrical
components tray. (For EPS models)
2-64
CABLE ROUTING
2-65
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE .. ......... .......... ........ .......... ......... ......... .......... ......... 3-1
INTRODUCTION .... ......... .......... ......... ........ ......... ......... .......... ......... ......... . 3-1
PER IOD IC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM .. .... ......... ......... ......... ......... ......... ......... ......... ......... ......... .......... .. 3-1
GENERAL MAINTENANCE AND LUBR ICATION CHART ..... .......... ........ 3-1
CHECKING THE FUEL LINE .... ......... .......... ........ ......... ......... .......... ......... 3-3
ADJUSTING THE VALVE CLEARANCE ... .......... .......... ......... .......... ........ 3-3
CHECKING THE SPARK PLUG .. ........ ......... ........ ......... .......... ......... ........ 3-5
CHECKING THE BREATHER HOSES ...... ......... ......... .......... ......... .......... 3-6
CHECKING THE EXHAUST SYSTEM ....... ......... ........ ........... ........ ......... .. 3-6
CLEAN ING THE SPARK ARRESTER ....... ......... .......... ......... .......... ......... 3-6
CHECKING THE AIR INDUCTION SYSTEM ....... ......... .......... ......... ......... 3-7
CHECKING THE COOLING SYSTEM ....... ......... ......... .......... ......... .......... 3-7
CHECKING THE COOLANT LEVEL .. ......... ......... ......... ......... ......... ......... . 3-8
CHANG ING THE COOLANT ..... .......... ......... ........ .......... ......... .......... ........ 3-9
CLEAN ING THE AIR FI LTER ELEMENT ...... ......... ........ ......... .......... ...... 3-10
CHECKING THE ENGINE OIL LEVEL ......... ......... ......... .......... ......... ...... 3-13
CHANG ING THE ENGINE O IL .......... .......... ........ ......... .......... ......... ....... 3-14
CHECKING TH E FI NAL GEAR OIL LEV EL ........ .......... ......... .......... ....... 3-15
CHANG ING THE FINAL GEAR OIL ... .......... ........ .......... ......... .......... ...... 3-16
CHECKING TH E DIFFERENTIAL GEAR OIL LEVEL ..... .......... ......... ..... 3-16
CHANG ING THE DIFFERENTIAL GEAR OIL ....... ......... .......... ......... ..... 3-17
CHECKING TH E FRONT BRAKE PADS ...... ......... ......... ........... ......... .... 3-17
CHECKING TH E BRAKE FLU ID LEVEL ....... .......... ........ ......... .......... ..... 3-17
BLEEDING THE HYDRAULIC BRAKE SYSTEM ........... ......... ......... ...... 3-18
CHECKING TH E BRAKE HOSES AND BRAKE PIPES ........... ......... ..... 3-19
ADJUSTING THE BRAKE PEDAL ..... .......... ........ .......... ......... .......... ...... 3-20
LUBRICATING THE BRAKE PEDAL AND ACC ELERATOR PEDAL ..... 3-21
CHECKING TH E REAR BRAKE PADS ......... ......... .......... ......... ......... .... 3-21
CHECKING TH E PARKING BRAKE PADS ........ .......... ......... .......... ....... 3-21
ADJUSTING THE PARKING BRAKE LEVER ...... .......... ......... ......... ....... 3-21
CHECKING AND LUBR ICATING THE CABLES ... ......... ......... .......... ..... 3-22
ADJUSTING THE ACC ELERATOR PEDAL FR EE PLAY ..... .......... ....... 3-22
CHECKING TH E V-BELT ......... .......... .......... ........ .......... ......... .......... ...... 3-23
REPLACING TH E V-BELT ......... ......... .......... ......... ......... ......... ......... ...... 3-24
CHECKING TH E WHEELS ....... .......... .......... ......... ......... ......... .......... ..... 3-25
CHECKING TH E TIRES .. ......... ......... ......... ......... .......... ......... ......... ........ 3-25
CHECKING TH E FRONT SHOCK ABSORBER ASSEMBLIES ........ ..... 3-27
CHECKING TH E REAR SHOCK ABSORBER ASSEMBLIES ... ......... .... 3-27
CHECKING TH E STEER ING SYSTEM ....... .......... ......... ......... ......... ...... 3-27
ADJUSTING THE TOE-IN .......... ......... .......... .......... ........ .......... ......... ..... 3-28
CHECKING TH E STABILIZER BUSHINGS ......... ......... .......... .......... ...... 3-29
LUBRICATING TH E REAR KNUCKLE PIVOTS .. .......... .......... ......... ...... 3-29
LUBRICATING TH E DRIVE SHAFT UNIVERSAL JOINTS ... .......... ....... 3-29
CHECKING TH E ENGINE MOUNT ... .......... ......... ......... .......... ......... ...... 3-29
CHECKING TH E CONSTANT VELOCITY SHAFT ASSEMBLY DUST
BOOTS ......... .......... ......... ......... .......... ......... .......... ........ ......... .......... ...... 3-30
CHECKING TH E FASTENERS .......... ........ ......... .......... ......... .......... ....... 3-30
PERIODIC MAINTENANCE
EBS20023
ESS30024
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed , these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EBS30025
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals.
• For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance
intervals. However, keep in mind that if the vehicle isn't used for a long period of time, the month main-
tenance intervals should be followed.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
INITIAL EVERY
month 1 3 6 6 12
CHECK OR MAINTENANCE Whichever
NO. ITEM
JOB comes first km (ml) 320 1200 2400 2400 4800
(200) (750) (1500) (1500) (3000)
s>
hours 20 75 150 150 300
• Check fuel hose for cracks or damage.

1 *
*
Fuel line
• Replace if necessary.
• Check valve clearance.
..J
" " ..J
2 Valves ..J ..J ..J
• Adjust if necessary.
• Check condition.
3 Spark plug • Adjust gap and clean.
• Replace if necessary.
..J
" ..J
" ..J
* Crankcase breather • Check breather hose for cracks or damage. ..J

4 ..J ..J
system • Replace if necessary.
• Check for leakage.
5 * Exhaust system • Tighten if necessary. ..J ..J ..J
• Replace gasket(s) if necessary.
6 Spark arrester • Clean. ..J ..J ..J
• Check the air cut-off valve, reed valve, and hose for
7 * Air induction system damage.
• Replace any damaged parts if necessary.
..J
" ..J
" ..J
EBS30026
GENERAL MAINTENANCE AND LUBRICATION CHART

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals.
• For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance
intervals. However, keep in mind that if the vehicle isn't used for a long period of time, the month main-
tenance intervals should be followed.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
3-1
INITIAL EVERY
month 1 3 6 6 12
CHECK OR MAINTENANCE Whichever
NO. ITEM JOB
comes first km (ml) 320 1200 2400 2400 4800
(200) (750) (1500) (1500) (3000)
¢
hours 20 75 150 150 300
• Check coolant leakage.
1 • Cooling system • Repair if necessary.
• Replace coolant.
" " " " " Every 2 years
• Clean. Every 2Q-40 hours
2 Air filter element • Replace if necessary. (more often in wet or dusty areas.)
3 Engine oil
Engine oil filter car-
• Replace (warm engine before draining).
" " " "
4 tridge
Final gear oil/Differ-
• Replace.
• Check oil level/oil leakage.

" " "
5 entlal gear oil • Replace.
• Check operation/brake pad wear/fluid leakage.
" "
•
6 Front brake • Correct if necessary. Replace pads if worn to the lim-
it.
• Check operation/brake pad wear/fluid leakage.
" " " " "
•
7 Rear brake • Correct if necessary. Replace pads if worn to the lim-
it.
• Check operation and free play/brake pad wear.
" " " " "
•
8
9 •
Parking brake
Brake fluid
• Correct if necessary. Replace pads if worn to the lim-
it.
• Change.
" " " " "
Every 2 years
•
10
•
Accelerator pedal • Check operation and free play.
• Check operation. " " " " "
11
•
V-belt
• Check for wear, cracks, or damage.
• Check balance/damage/runout.
" " "
12
•
Wheels
• Repair if necessary.
• Check bearing assemblies for looseness/damage.
" " " "
13
•
Wheel bearings
Front and rear sus-

• Replace if damaged.
• Check operation and for leakage.
" " " "
14
pension • Correct if necessary.
• Check operation and for looseness/ Replace if dam-
" "
•
15 Steering system aged.
• Check toe-in/Adjust if necessary.
• Check for cracks or other damage, and replace if
" " " " "
•
16
•
Stabilizer bushes
Rear upper and lower

necessary.
" " "
17
•
knuckle pivots
Drive shaft universal
• Lubricate with lithium-soap-based grease.
" " "
18
•
Joint
• Lubricate with lithium-soap-based grease.
• Check for cracks or damage.

" " "
19
•
Engine mount
Front and rear axle

• Check bolt tightness.
• Check for cracks or other damage, and replace if
" " "
20
•
boots
Fittings and fasten-
necessary.
• Check all chassis fittings and fasteners.
" "
21 ers • Correct if necessary.
" " " " "
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy
or muddy areas, or at full throttle.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-2
ESS30027
• When the valve clearance is to be measured or
CHECKING THE FUEL LINE
adjusted , the piston must be at top dead center
1. Lift the cargo bed.
(TDC) on the compression stroke.
2. Remove:
• Outer passenger seat frame 1. Lift the cargo bed.
• Center passenger seat frame 2. Remove:
Refer to "G ENERAL CHASSIS (2)" on page • Frame cross member
4-4. Refer to "GENERAL CHASSIS (1O)" on page
• Sound-deflection panel (right) 4-28.
Refer to "G ENERAL CHASSIS (4)" on page • Rear panel (right)
4-1 0. Refer to "GENERAL CHASSIS (7)" on page
• Outer passenger compartment panel 4-20.
• Center passenger lower panel • Exhaust pipe heat protector plate
• Center passenger compartment panel Refer to "ENGIN E REMOVAL (1 )" on page
Refer to "G ENERAL CHASSIS (7)" on page 5-2.
4-20. 3. Disconnect:
3. Check: • Cylinder head breather hose "1"
• Fuel hose "1" 4. Remove:
Cracks/damage~ Replace. • Intake tappet cover "2"
Loose connection ~ Connect properly. • Exhaust tappet cover "3"
• Camshaft sprocket cover "4"
4.
•
Install:
Center passenger compartment panel 5. Disconnect:
----
• Center passenger lower panel • Spark plug cap
• Outer passenger compartment panel 6. Remove:
Refer to "G ENERAL CHASSIS (7)" on page • Spark plug
EC.801270
4-20.
NOTICE
• Sound-deflection panel (right) -------------
Refer to "G ENERAL CHASSIS (4)" on page Before removing the spark plug, blow away
4-1 0. any dirt accumulated in the spark plug well
• Outer passenger seat frame with compressed air to prevent it from falling
• Center passenger seat frame into the cylinder.
Refer to "G ENERAL CHASSIS (2)" on page 7. Remove:
4-4. • Crankshaft end accessing screw "1"
5. Lower the cargo bed. • Timing mark accessing screw "2"
EBS30028
ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the
valves.
TIP -~~~~~~~~~~~~~
• Valve clearance adjustment should be made

on a cold engine, at room temperature.
3-3
8. Measure:
• Valve clearance
Out of specification ~ Adjust.
Valve clearance (cold)

Intake
0.09-0.13 mm (0.0035-0.0051 in)
Exhaust
0.16-0.20 mm (0.0063-0.0079 in)
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Turn the crankshaft counterclockwise.
b. When the piston is at TDC on the compres-
•9.•••••••••••••••••••••••••••••••
Adjust:
sion stroke, align the "I" mark "a" on the AC • Valve clearance
magneto rotor with the stationary pointer "b" TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
on the AC magneto cover. a. Loosen the locknut "1".
b. Insert the thickness gauge "2" between the
end of the adjusting screw and the valve tip.
c. Turn the adjusting screw "3" in direction "a" or
"b" with the tappet adjusting tool "4" until the
specified valve clearance is obtained.
Tappet adjusting tool

90890-01311
Six piece tappet set
YM-A5970
TIP ~~~~~~~~~~~~~~~~
To position the piston at TDC on the compres- Direction "a"

sion stroke, align the "I" mark "c" on the camshaft Valve clearance is increased.
sprocket with the stationary pointer "d" on the Direction "b"
cylinder head , as shown in the illustration . Valve clearance is decreased.
.J\
c. Measure the valve clearance with the thick- • Hold the adjusting screw to prevent it from
ness gauge "1". moving and tighten the locknut to specifica-
O ut of specification ~ Adjust. tion.
Thickness gauge Valve adjusting screw locknut

90890-03079 14 Nm (1.4 m-kgf, 1O ft-lbf)
Narrow gauge set
YM-34483 d. Measure the valve clearance again.
3-4
e. If the valve clearance is still out of specifica- 15.lnstall :

tion , repeat all of the valve clearance adjust- • Exhaust pipe heat protector plate
ment steps until the specified clearance is Refer to "ENG IN E REMOVAL (1 )" on page
obtained. 5-2.
••••••••••••••••••••••••••••••••
1a.Install:
• Rear panel (right)
Refer to "GENERAL CHASSIS (7)" on page
4-20.
• 0 -ring 1~f4ij
• Frame cross member
• Timing mark accessing screw
Refer to "GENERAL CHASSIS (1O)" on page
• 0 -ring 1~f4ij 4-28.
• Crankshaft end accessing screw 16.Lower the cargo bed.
Timing mark accessing screw EBS30029
1.5 Nm (0.15 m -kgf, 1.1 ft-lbf) CHECKING THE SPARK PLUG

Crankshaft end accessing screw 1. Lift the cargo bed.
2.0 Nm (0.20 m -kgf, 1.4 ft-lbf) 2. Disconnect:
• Spark plug cap
11.lnstall: 3. Remove:
• Spark plug • Spark plug
TIP ~~~~~~~~~~~~~~ ECB01270 ~
NOTICE
Before installing the spark plug , clean the spark -------------
plug and gasket surface. Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling
Spark plug
13 Nm (1.3 m-kgf, 9.4 ft-lbf) into the cylinder.
4. Check:
12.Connect: • Spark plug type
• Spark plug cap Incorrect ~ Change.
13.lnstall:
• 0 -ring 1~f4ij Manufacturer/model
• Camshaft sprocket cover
NGK/CPR7EA-9
• 0 -ring "1" 1~f4ij 5. Check:
• Intake tappet cover • Electrodes "1"
• 0 -ring 1~f4ij Damage/wear ~ Replace the spark plug.
• Exhaust tappet cover • Insulator "2"
Abnormal color ~ Replace the spark plug.
Camshaft sprocket cover bolt Normal color is medium-to-light tan .
1 O Nm (1.0 m-kgf, 7.2 ft-lbf) 6. Clean :
Tappet cover bolt
• Spark plug
1 O Nm (1.0 m-kgf, 7.2 ft-lbf)
(with a spark plug cleaner or wire brush)
7. Measure:
• Spark plug gap "a"
(with a wire thickness gauge)
Out of specification ~ Regap.
Spark plug gap

0.8-0.9 mm (0.031-0.035 in)
14.Connect:
• Cylinder head breather hose
3-5
5. Lower the cargo bed .

. EBS30031
>
CHECKING THE EXHAUST SYSTEM
1. Lift the cargo bed .
• 2. Check:
•
a + I
•
~
'
'
,
- 2
• Exhaust pipe "1"
• Muffle r "2"
f "\
1
• Muffler mount "3"
• Springs "4"
Cracks/damage ~ Replace.
8. Install : • Gaskets "5"
• Spark plug Exhaust gas leaks ~ Replace.
3. Check:
Spark plug
• Tightening torque
13 Nm (1.3 m-kgf, 9.4 ft-lbf)
Exhaust pipe nut
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
20 Nm (2.0 m-kgf, 14 ft-lbf)
Before installing the spark plug , clean the spark Muffler bolt
plug and gasket surface. 23 Nm (2.3 m-kgf, 17 ft-lbf)
Muffler mount shaft
9. Connect: 17 Nm (1.7 m-kgf, 12 ft-lbf)
• Spark plug cap LOCTITE®
1a.Lower the cargo bed .
EBS30030
CHECKING THE BREATHER HOSES

2. Remove:
Refer to "GENERAL CHASSIS (1 O)" on page
4-28.
3. Check:
• Cylinder head breather hose "1" 2
• Throttle body breather hose "2"
Cracks/damage~ Replace. 4. Lower the cargo bed.
Loose connection ~ Connect properly. EBS30032
ECB01680
CLEANING THE SPARK ARRESTER
NOTICE
------------- 1. Clean :
Make sure the cylinder head breather hose is • Spark arrester
routed correctly. TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
EWB03080
A WARNING
• Select a well-ventilated area free of com-
bustible materials.
• Always let the exhaust system cool before
performing this operation.
• Do not start the engine when removing the
tailpipe from the muffler.
r
a. Remove the bolts "1".
I I b. Remove the tailpipe "2" by pulling it out of the
4. Install : muffler and gasket "3".
4-28.
3-6
• Instrument panel
•
4-15 .
e • Floor boards and panels
4-20.
• Heat shield
Refer to "ENGIN E REMOVAL (3)" on page
5-7.
• Air filter case
Refer to "AIR FILTER CASE" on page 7-6.
2~ - 3. Check:
0 • Radiator "1"
• Coolant reservoir hose "2"
• Coolant reservoir "3"
• Radiator outlet hose "4"
0 • Radiator inlet hose "5"
• Radiator outlet pipe "6"
• Radiator inlet pipe "7"
c. Tap the tailpipe lightly with a soft-face ham- • Thermostat outlet hose "8"
mer or suitable tool, then use a wire brush to • Thermostat cover "9"
remove any carbon deposits from the spark • Water pump inlet hose "1O"
arrester portion of the tailpipe and the inner • Water pump housing "11 "
contact surfaces of the muffler. • Water pump outlet pipe "12"
d. Install a new gasket, and then insert the tail- • Water pump outlet hose "13"
pipe into the muffler and align the bolt holes. • Water jacket joint "14"
e. Install the bolts "1" and tighten them . • Oil cooler inlet hose "15"
• Oil cooler "16"
Spark arrester bolt • Oil cooler outlet hose "17 '
1O Nm (1.0 m-kgf, 7.2 ft-lbf) Cracks/damage ~ Replace.
Coolant leakage ~ Replace any damaged
hose and pipe
EBS30033 Refer to "OIL COOLER" on page 6-1 , "RADI-
CHECKING THE AIR INDUCTION SYSTEM ATOR" on page 6-4, ''THERMOSTAT" on
Refer to "CH ECKING THE AIR INDUCTION page 6-7 and "WATER PUMP" on page 6-1 0.
SYSTEM" on page 7-18.
7 5
EBS30034
CHECKING THE COOLING SYSTEM

1. Remove:
• Seat frames
Refer to "GENERAL CHASSIS (2)" on page iP
4-4. 6 y
• Sound-deflection panels 4 1
Refer to "GENERAL CHASSIS (4)" on page 2
3
4-1 0.
• Front side frames
4-1 2.
• Hood
• Front fender
3-7
2. Check:
• Coolant level
8 The coolant level should be between the
maximum level mark "a" and minimum level
9
mark "b".
Below the minimum level mark ~ Add the
recommended coolant to the proper level.
ECB01300
NOTICE
-
-
- - - - - - - - - - - -
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
~ 17 essary, correct the antifreeze concentra-
~
tion of the coolant.
14 • Use only distilled water. However, if dis-
12 10
13 ~ tilled water is not available, soft water may
/:J_
r-a=---~ _JAL
\..IEf
be used.
'-- - -:-)
16 ~ -~ 11
4. Lower the cargo bed. a
5. Install:
• Heat shield # ! FULL
Refer to "ENGINE REMOVAL (3)" on page LOW
5-7.
• Air filter case
I
• Floor boards and panels 3. If the coolant is at or below the minimum level
Refer to "GENERAL CHASSIS (7)" on page mark, remove the reservoir cap "1", add cool-
4-20. ant or distilled water to the maximum level
• Instrument panel mark "a", install the reservoir cap.
• Front fender
Coolant reservoir (up to the maxi-
• Hood
mum level mark)
0.28 L (0.30 US qt, 0.25 Imp.qt)
4-1 5.
4-1 2.
• Sound-deflection panels
4-1 0. a
• Seat frames
~
LO
4-4.
I
EBS30035
CHECKING THE COOLANT LEVEL

1. Place the vehicle on a level surface.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
The coolant level must be checked on a cold en-
gine since the level varies with engine tempera-
ture.
3-8
EBS30036
9. Remove:
CHANGING THE COOLANT
• Coolant drain bolt "1"
1. Remove the hood.
(along with the copper washer)
TIP ~~~~~~~~~~~~~~
3. Remove:
• Rear panel (right) Place a container under the engine, and then re-
Refer to "G ENERAL CHASSIS (7)" on page move the coolant drain bolt.
4-20.
4.
•
Remove:
Coolant reservoir cap "1"
\J J
5. Disconnect:
• Coolant reservoir hose "2"
FULL 1a.Drain:
2~ ~
0 ~~~u • Coolant
(from the engine and radiator)
I I
11.lnstall :
• Coolant drain bolt
6. Drain:
• Coolant
(along with the copper washer i@f41D
(from the coolant reservoir) Coolant drain bolt
7. Connect: 1 O Nm (1.0 m -kgf, 7.2 ft-lbf)
• Coolant reservoir hose
8. Remove: 12.Fill:
• Radiator cap "1" • Cooling system
ews02no
(with the specified amount of the recom-
& WARNING mended coolant)
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en- Recommended antifreeze
gine is hot. Scalding hot fluid and steam may High-quality ethylene glycol an-
be blown out, which could cause serious in- tifreeze containing corrosion in-
jury. When the engine has cooled, open the hibitors for aluminum engines
Mixing ratio
radiator cap as follows:
1: 1 (antifreeze:water)
Place a thick rag or a towel over the radiator
Radiator (including all routes)
cap and slowly turn the radiator cap counter- 2.74 L (2.90 US qt, 2.41 Imp.qt)
clockwise toward the detent to allow any re- Coolant reservoir (up to the maxi-
sidual pressure to escape. When the hissing mum level mark)
sound has stopped, press down on the radi- 0.28 L (0.30 US qt, 0.25 Imp.qt)
ator cap and turn it counterclockwise to re-
move. Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
EWB02780
& WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.
• If coolant splashes on your clothes, quickly
/ wash it away with water and then with soap

and water.
3-9
• If coolant is swallowed, induce vomiting

and get immediate medical attention. Water pump air bleed bolt
1O Nm (1.0 m -kgf, 7.2 ft-lbf)
ECB01310
NOTICE
-------------
• Adding water instead of coolant dilutes the
c. Loosen the thermostat cover air bleed bolt
"2", without removing it , to allow all of the air
antifreeze concentration of the coolant. If to escape from the air bleed bolt hole.
water is used instead of coolant; check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.
• Do not mix different types of antifreeze.
13.lnstall: d. When coolant begins to flow out of the bolt
• Radiator cap hole, tighten the thermostat cover air bleed
14.Fill: bolt to specification .
• Coolant reservoir
(with the recommended coolant to the maxi- Thermostat cover air bleed bolt
1 O Nm (1.0 m -kgf, 7.2 ft-lbf)
mum level mark "a")
15.lnstall:
• Coolant reservoir cap "1" ••••••••••••••••••••••••••••••••
17.Start the engine, warm it up for ten minutes,
and then rev the engine five times.
18.Pour the recommended coolant into the radi-
ator until it is full.
19.Stop the engine and allow it to cool. If the
a coolant level has dropped after the engine
~ has cooled, add sufficient coolant until it
reaches the top of the radiator, and then in-
I stall the radiator cap.
r 20.Check:
• Coolant level
16.Bleed:
Refer to "CHECKING THE COOLA NT LEV-
• Cooling system
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT EL" on page 3-8.
a. Loosen the water pump air bleed bolt "1", 2 1.Start the engine, and then check for coolant
w ithout removing it , to allow all of the air to es- leakage.
cape from the air bleed bolt hole. 22.lnstall :
4-20.
23.Lower the cargo bed.
24.lnstall the hood.
EBS30037
-- CLEANING THE AIR FILTER ELEMENT

1. Check:
• Check hoses "1"
b. When coolant begins to flow out of the bolt

hole, tighten the water pump air bleed bolt to
specification.
3-10
TIP ~~~~~~~~~~~~~~
There are check hoses "1" at the bottom of the

air filter case and on the air intake duct. If dust
and/or water collects in these hoses, clean the
air filter element, filter frame, and air filter case.
n
3. Remove: '
• Air filter case cover "1"
A. Air filter case check hose

B. Air intake duct check hose
2. Remove:
• Center passenger seat cushion "1"
• Center passenger seat rubber damper "2"
~1
• Quick fastener screws "3"
• Center passenger compartment panel (left) 4. Remove:
"4" • Air filter element "1"
• Center passenger compartment panel (right)
"5"
5. Disassemble:
• Air filter element holder "1"
• Air filter element "2"
• Air filter element frame "3"
3-11
ECB01800
NOTICE
--------------
The engine should never be run without the
air filter; excessive piston and/or cylinder
wear may result.
c. Properly dispose of the used solvent.

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

Foam air-filter oil
g. Place the air filter element into the storage

bag and repeatedly squeeze the element un-
til the air filter element is saturated with oil.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~
The air filter element should be wet but not drip-
b. After cleaning , squeeze the air filter element ping.
to remove the excess solvent.
EC801290
NOTICE
--------------
Do not twist the air filter element when
squeezing it.
3-12
8. Assemble: EBS30038
CHECKING THE ENGINE OIL LEVEL

• Air filter element frame
2. Check the engine oil level on a cold engine.
• Air filter element holder
9. Install: TIP - - - - - - - - - - - - - - - ~
• Air filter element assembly If the engine was started before the oil level was
1a.Install: checked , be sure to warm up the engine suffi-
• Air filter case cover ciently, and then wait at least 1O minutes until
11.lnstall: the oil settles for an accurate reading .
• Center passenger compartment panel (right) 3. Lift the cargo bed.
"1" 4. Check:
• Center passenger compartment panel (left) • Engine oil level
"2" The engine oil level should be between the
• Quick fastener screws minimum level mark "a" and maximum level
• Center passenger seat rubber damper mark "b".
• Center passenger seat cushion Below the minimum level mark ~ Add the
TIP - - - - - - - - - - - - - - - ~ recommended engine oil to the proper level.
• Install the center passenger compartment pan- ECB01810
NOTICE
el (right) "1", and then install the center passen-
ger compartment panel (left) "2".
-------------
Do not allow foreign materials to enter the
• Fit the projections "a" on the center passenger crankcase.
compartment panel (right) "1" under the panels TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~
as shown in the illustration.
• Fit the projections "b" on the center passenger Insert the dipstick completely into the oil filler
hole, and then remove it again to check the oil
compartment panel (left) "2" under the driver
level.
sheet compartment panel "3" as shown in the
illustration.
b
a --
Recommended brand
YAMALUBE
Type
SAE SW-30, 1 OW-30, 1OW-40,
1 SW-40, 20W-40 or 20W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
3-13
O 1O 30 50 70 90 11 0 130 °F
. .
I I I I
SAE . .•
. 5W-30
.•sAE. 10W-30
. .
1SA~ 1Ov;J-40/
SAE 15W-40
. .
. .SAE 20v;J-40 /
. . 2
I SAE
. 20W-50
. .
j I I i I I I i
- 20 - 10 o 10 20 30 40 50 ·c
ECB01820
6. Drain:
NOTICE~~~~~~~~~~~~ • Engine oil
• Engine oil also lubricates the clutch and the (completely from the crankcase)
wrong oil types or additives could cause 7. If the oil filter cartridge is also to be replaced,
clutch slippage. Therefore, do not add any perform the following procedure.
chemical additives or use engine oils with a TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
grade of "CD" or higher and do not use oils a. Remove the oil filter cartridge "1" with the oil
labeled "ENERGY CONSERVING II" . filter wrench "2".
• Do not allow foreign materials to enter the
crankcase. Oil filter wrench
90890-01426
5. Check the engine oil level again . Oil filter wrench
ECB01830
YU-38411
NOTICE~~~~~~~~~~~~
Be sure the engine oil is at the correct level,
(
otherwise engine damage may result.
0
6. Lower the cargo bed .
EBS30039
CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several m in-
utes, and then turn it off.
3. Remove:
b. Lubricate the 0-ring "3" of a new oil filter car-
Refer to "G ENERAL CHASSIS (7)" on page
tridge with a thin coat of engine oil.
4-20. ECB01280
4. Place a container under the engine oil drain NOTICE ~~~~~~~~~~~~

bolt.
Make sure the 0-ring "3" is positioned cor-
5. Remove:
rectly in the groove of the oil filter cartridge.
• Dipstick "1"
• Engine oiI drain bolt "2"
(along with the gasket)
\
c. Tighten the new oil filter cartridge to specifi-

cation with the oil filter wrench.
3-14
b. Start the engine and keep it idling until engine

Oil filter cartridge oil starts to seep from the oil check bolt. If no
17 Nm (1. 7 m-kgf, 12 ft-lbf) engine oil comes out after one minute, turn
the engine off so that it will not seize.
••••••••••••••••••••••••••••••••
8. Install :
c. Check the engine oil passages, the oil filter
cartridge and the oil pump for damage or
• Engine oil drain bolt leakage. Refer to "CRANKSHA FT AN D OIL
(along with the gasket l~(:ijj) PUMP" on page 5-76.
d. Start the engine after solving the problems
Engine oil drain bolt and check the engine oil pressure again.
30 Nm (3.0 m-kgf, 22 ft-lbf) e. Tighten the oil check bolt to specification .
9. Fill : Oil check bolt
• Crankcase 1 O Nm (1.0 m-kgf, 7.2 ft-lbf)
mended engine oil)
••••••••••••••••••••••••••••••••
15.lnstall :
Engine oil quantity
Quantity (disassembled)
2.60 L (2.75 US qt, 2.29 Imp.qt)
Without oil filter cartridge re- 4-20.
placement 16.Lower the cargo bed.
2.20 L (2.33 US qt, 1.94 Imp.qt) EBS30040
With oil filter cartridge replace- CHECKING THE FINAL GEAR OIL LEVEL
ment 1. Place the vehicle on a level surface.
2.30 L (2.43 US qt, 2.02 Imp.qt) 2. Remove:
• Final gear oil filter bolt "1"
1a.Install:
• Dipstick
3. Check:
11.Start the engine, warm it up for several min-
• Final gear oil level
utes, and then turn it off.
The final gear oil level should be up to the
12.Check:
brim "2" of the hole.
• Engine
Below the brim ~ Add the recommended fi-
(for engine oil leaks)
nal gear oil to the proper level.
13.Check:
• Engine oil level Type
Refer to "CHECKING T HE ENGIN E O IL SAE 80 API GL-4 Hypoid gear
LEVEL" on page 3-1 3. oil
14.Check:
ECB01690
• Engine oil pressure
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT NOTICE~--------------------------------------------------~
a. Slightly loosen the oil check bolt "1". Take care not to allow foreign material to en-
ter the final drive case.
3-15
4. Check: 6. Check:
• Final gear oil filler bolt gasket • Oil level
Damage ~ Replace. Refer to "CHECKING THE FINAL GEAR OIL
5. Install: LEVEL" on page 3-15.
• Final gear oil filler bolt 7. Install:
(along with the gasket) • Final gear oil filler bolt
Final gear oil filler bolt
23 Nm (2.3 m-kgf, 17 ft-lbf) Final gear oil filler bolt
23 Nm (2.3 m-kgf, 17 ft-lbf)
ESS30041
CHANGING THE FINAL GEAR OIL EBS30042
1. Place the vehicle on a level surface. CHECKING THE DIFFERENTIAL GEAR OIL
2. Place a container under the final drive case. LEVEL
3. Remove: 1. Place the vehicle on a level surface.
• Final gear oil filler bolt "1" 2. Remove:
(along with the gasket) • Differential gear oil filler bolt "1"
• Final gear oil drain bolt "2" (along with the gasket)
(along with the gasket) 3. Check:
Completely drain the final drive case of its oil. • Differential gear oil level
I The differential gear oil level should be up to
the brim "2" of the hole.
Below the brim ~ Add the recommended dif-
ferential gear oil to the proper level.
Type
SAE 80 API GL-4 Hypoid gear
oil
EC.801600
NOTICE
4. Install: - - - - - - - - - - - - -
Take care not to allow foreign material to en-
• Final gear oil drain bolt ter the differential case.
(along with the gasket r.11~1111(:j•*••)
Final gear oil drain bolt

23 Nm (2.3 m-kgf, 17 ft-lbf)
5. Fill :
• Final drive case
mended final gear oil)
Type
SAE 80 API GL-4 Hypoid gear 4. Check:
oil • Differential gear oil filler bolt gasket
Quantity (disassembled)
Damage~ Replace.
0.45 L (0.48 US qt, 0.40 Imp.qt)
Quantity 5. Install:
0.40 L (0.42 US qt, 0.35 Imp.qt) • Differential gear oil filler bolt
EC801690
NOTICE Differential gear oil filler bolt

------------- 23 Nm (2.3 m-kgf, 17 ft-lbf)
ter the final drive case.
3-16
EBS30043
CHANGING THE DIFFERENTIAL GEAR OIL

ECB01600
NOTICE
-
-
- - - - - - - - - - - -
2. Place a container under the differential case. ter the differential case.
3. Remove:
• Differential gear oil filler bolt "1" 6. Check:
(along with the gasket) • Oil level
• Differential gear oil drain bolt "2" Refer to "CHECKING THE DIFFERENT IAL
(along with the gasket) GEAR O IL LEVEL" on page 3-16.
Completely drain the differential case of its 7. Install:
oil. • Differential gear oil filler bolt
Differential gear oil filler bolt

23 Nm (2.3 m-kgf, 17 ft-lbf)
\...
EBS30044
CHECKING THE FRONT BRAKE PADS

The following procedure applies to all of the front
brake pads.
1. Remove:
• Front wheels
Refer to "FRONT AND REAR WHEELS" on
page 4-33.
2. Operate the brake.
3. Check:
• Front brake pads
Wear indicator grooves "a" have almost dis-
(® appeared ~ Replace the brake pads and
brake pad spring as a set.
~ ~ ~ ~ ~ ~ ' . . . : :1 ~2 Refer to "FRONT AND REAR BRAKES" on
page 4-37.
4. Install:
• Differential gear oil drain bolt a
(along with the gasket i~f41D
Differential gear oil drain bolt
5. Fill :
• Differential case
-
mended differential gear oil) 4. Install:
• Front wheels
Type Refer to "FRONT AND REAR WHEELS" on
SAE 80 API GL-4 Hypoid gear
page 4-33.
oil
Quantity (disassembled) EBS30045
0.20 L (0.21 US qt, 0.18 Imp.qt) CHECKING THE BRAKE FLUID LEVEL
Quantity 1. Place the vehicle on a level surface.
0.18 L (0.19 US qt, 0.16 Imp.qt) TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
When checking the brake fluid level , make sure
that the top of the brake master cylinder reser-
voir is horizontal.
3-17
2. Check: • brake operation is faulty.

• Brake fluid level
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~
Below the minimum level mark "a" ~ Add the
specified brake fluid to the proper level. • Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir to overflow.
Specified brake fluid • When bleeding the hydraulic brake system ,
DOT4 make sure there is always enough brake fluid
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.
a • If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared .
1. Remove:
• Front wheels
EWB02880 • Rear wheels
A WARNING Refer to "FRONT AND REAR WHEELS" on
• Use only the designated brake fluid. Other page 4-33.
brake fluids may cause the rubber seals to 2. Bleed :
deteriorate, causing leakage and poor • Hydraulic brake system
brake performance. TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Fill the brake master cylinder reservoir to the
• Refill with the same type of brake fluid that
proper level with the specified brake fluid.
is already in the system. Mixing brake fluids
b. Install the diaphragm (brake master cylinder
may result in a harmful chemical reaction,
reservoir).
leading to poor brake performance.
c. Connect a clear plastic hose "1" tightly to the
• When refilling, be careful that water does
bleed screw "2".
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
ECB01320
NOTICE
-------------
Bra ke fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
TIP ~~~~~~~~~~~~~~
In order to ensure a correct reading of the brake

fluid level, make sure the top of the brake master
cylinder reservoir is horizontal.
EBS30046
BLEEDING THE HYDRAULIC BRAKE

SYSTEM
EWB02800
AwARNING
Bleed the hydraulic brake system whenever:
• the system is disassembled. A. Front brake
• a brake hose is loosened, disconnected or B. Rear brake
replaced.
• the brake fluid level is very low.
3-18
d. Place the other end of the hose into a con- • Sound-deflection panel
tainer. Refer to "GENERAL CHASSIS (4)" on page
e. Slowly apply the brake several times. 4-10.
f. Fully depress the brake pedal and hold it in • Floor boards and panels
position. Refer to "GENERAL CHASSIS (7)" on page
g. Loosen the bleed screw. 4-20.
TIP ~~~~~~~~~~~~~~ • Heat shield
Loosening the bleed screw will release the pres- Refer to "ENGINE REMOVAL (3)" on page
sure and cause the brake pedal to fully extend . 5-7.
• Air filter case
h. Tighten the bleed screw, and then release Refer to "AIR FILTEA CASE" on page 7-6.
the brake pedal. 2. Check:
1. Repeat steps (e) to (h) until all of the air bub- • Front brake hoses "1"
bles have disappeared from the brake fluid in Cracks/damage/wear~ Replace.
the plastic hose. 3. Check:
J. Tighten the bleed screw to specification. • Front brake pipe "2"
Front brake caliper bleed screw
4. Check:
5 Nm (0.5 m-kgf, 3.6 ft-lbf)
• Rear brake pipe "3"
Rear brake caliper bleed screw
5 Nm (0.5 m-kgf, 3.6 ft-lbf) Cracks/damage ~ Replace.
5. Check:
k. Fill the brake master cylinder reservoir to the • Rear brake hoses "4"
proper level with the specified brake fluid. Cracks/damage/wear~ Replace.
Refer to "CHECKING THE BRAKE FLUID
LEVEL" on page 3-17.
EWB02810
A WARNING
After bleeding the hydraulic brake system,
check the brake operation.
••••••••••••••••••••••••••••••••
3. Install:
~ ,?
• Rear wheels
• Front wheels
page 4-33.
3
ESS30047
CHECKING THE BRAKE HOSES AND

BRAKE PIPES
1. Remove: 2
4-12.
• Hood
• Front fender 0
0
4-15. 3
• Seat frames
i_
4-4.
'
3-19

4-12.
EBS30048
ADJUSTING THE BRAKE PEDAL

1. Check:
• Brake pedal free play "a"
-. Out of specification ~ Adjust.
TIP ~~~~~~~~~~~~~~
The end of the brake pedal rod "1" should lightly

contact the brake master cylinder "2".
Brake pedal free play

O mm (0 in)
6. Check:
• Brake hose holders
Loose ~ Tighten the holder bolts.
Damage ~ Replace.
7. Place the vehicle in an upright position and
apply the brake several times. 2. Adjust:
8. Check: • Brake pedal free play
• Brake hoses TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
• Brake pipe a. Loosen the locknut "1".
Brake fluid leakage ~ Replace any damaged b. Turn the brake pedal rod "2" in direction "a" or
hose and pipe. "b" until the correct free play is obtained.
Refer to "FRONT AND REAR BRAKES" on
page 4-37. Direction "a"
9. Install: Brake pedal free play is increased.
• Air filter case Direction "b"
Refer to "AIR FILTER CASE" on page 7-6. Brake pedal free play is decreased.
• Heat shield
Refer to "ENGINE REMOVAL (3)" on page
5-7.
• Floor boards and panels
4-20.
• Sound-deflection panel
4-10. a
• Seat frames 0 2
4-4. c. Tighten the locknut to specification .
Brake pedal rod locknut
• Front fender 17 Nm (1.7 m-kgf, 12 ft-lbf)
• Hood
4-15.
3-20
EWB03090
4. Install:
A WARNING • Rear wheels
After this adjustment is performed, lift the Refer to "FRONT AND REAR WHEELS" on
front and rear wheels off the ground by plac- page 4-33.
ing a block under the frame, and spin the
EBS30051
front and rear wheels to ensure there is no
CHECKING THE PARKING BRAKE PADS
brake drag. If any brake drag is noticed per-
form the above steps again.
2. Check:
• Parking brake pads
EBS30049
A wear indicator groove "a" has almost ap-
LUBRICATING THE BRAKE PEDAL AND peared ~ Replace the brake pads and brake
ACCELERATOR PEDAL pad spring as a set.
Lubricate the pivoting point and metal-to-metal Refer to "PARKING BRAKE" on page 4-50 .
moving parts of the pedal.
Recommended lubricant
-\
I Lithium-soap-based grease a
----
EBS30052
ADJUSTING THE PARKING BRAKE LEVER

1. Shift the drive select lever into low gear "L".
2. Check:
• Parking brake lever free play "a"
EBS30050
The maximum free play is equal to one click
CHECKINGTHEREARBRAKEPADS
of the parking brake lever.
The following procedure applies to all of the rear
Incorrect ~ Adjust.
brake pads.
1. Remove:
• Rear wheels
I
page 4-33.
3. Check: ~ /r-.-·
• Rear brake pads 'i
Wear indicator grooves "a" have almost dis- ~--!../IV
'
appeared ~ Replace the brake pads and

~
brake pad spring as a set.
3. Adjust:
• Parking brake lever free play
page 4-37.
a. Release the parking brake lever.
a
b. Slide back the rubber cover "1".
c. Loosen the locknut "2".
d. Turn the adjusting nut "3" indirection "a" or "b"
until the correct free play is obtained.
3-21
3. Apply:
Direction "a" • Lithium-soap-based grease
Parking brake cable free play is in- (onto end of the throttle cable and drive select
creased. lever shift cable)
Direction "b"
Parking brake cable free play is de- EBS30054
creased. ADJUSTING THE ACCELERATOR PEDAL

FREE PLAY
1. Check:
• Accelerator pedal free play "a"
Accelerator pedal free play

More than 8.0 mm (0.31 in)
(\ ""
e. Tighten the locknut to specification .
Parking brake cable locknut

16 Nm (1.6 m-kgf, 12 ft-lbf)
f. Slide the rubber cover to its original position .

••••••••••••••••••••••••••••••••
EBS30053
CHECKING AND LUBRICATING THE 3. Remove:
CABLES • Frame cross member
The following procedure applies to all of the in- Refer to "GENERAL CHASSIS (1O)" on page
ner and outer cables. 4-28.
EWB02820 4. Adjust:
~ WARNING • Accelerator pedal free play
Damaged outer cable may cause the cable to TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
corrode and interfere with its movement. Re- a. Remove the throttle cable housing cover "1".
place damaged outer cable and inner cables
as soon as possible.
1. Check:
• Outer cable
Damage ~ Replace.
2. Check:
• Cable operation
Rough movement ~ Lubricate.
I b. Slide back the rubber cover "2".
Engine oil or a suitable cable lu-
bricant
d. Turn the adjusting nut "4" in direction "a" or "b"
TIP ~~~~~~~~~~~~~~~~
until the specified accelerator pedal free play
is obtained.
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.
3-22
TIP ~~~~~~~~~~~~~~~
Direction "a"
When the accelerator pedal is fully depressed
Accelerator pedal free play is in-
creased. (throttle valve fully open) , the gap ''f' between
Direction "b" the throttle valve pulley "7" and the pulley stop-
Accelerator pedal free play is de- per "8" should be 1 mm (0.04 in) or less.
creased.
h. Install the throttle cable housing cover.
TIP ~~~~~~~~~~~~~~~ Throttle cable housing cover

If length "c" is 8.5 mm (0.33 in) or more, loosen screw
locknut "5" and turn the adjusting nut "6" in direc- 2.0 Nm (0.20 m-kgf, 1.4 ft-lbf)
tion "d" or "e" until the specified accelerator ped-
al free play is obtained . •5.•••••••••••••••••••••••••••••••
Install:
Direction "d" Refer to "GENERAL CHASSIS (1 O)" on page
Accelerator pedal free play is in-
4-28.
creased.
Direction "e" 6. Lower the cargo bed .
Accelerator pedal free play is de- EBS30055
creased. CHECKING THE V-BELT

2. Remove:
4-28.
• Rear panel (left)
4-20.
• Seat frames
4-4.
e. Tighten the locknuts to specification. • Sound-deflection panel
Throttle cable locknut (air intake 4-10.
silencer side) • V-belt cooling ducts
4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
Throttle cable locknut (throttle
4-26.
body side)
0.8 Nm (0.08 m-kgf, 0.58 ft-lbf) 3. Remove:
• Drive belt cover
f. Slide the rubber cover to its original position. Refer to "PRIMARY AND SECONDARY
g. Check the throttle valve pulley stopper gap. SH EAVES" on page 5-54.
3-23
4. Check: 8. Lower the cargo bed.

• V-belt "1"
EBS30056
Cracks/damage/wear~ Replace. REPLACING THE V-BELT
Grease/oil~ Clean the primary and second- 1. Lift the cargo bed.
ary sheaves. 2. Remove:
Refer to "REPLACING THE V-BELT' on • Frame cross member
page 3-24. Refer to "GENERAL CHASSIS (1 O)" on page
5. Measure: 4-28.
• V-belt w idth "a" • Rear panel (left)
Out of specification ~ Replace. Refer to "GENERAL CHASSIS (7)" on page
Refer to "REPLACING THE V-BELT' on 4-20.
page 3-24. • Seat frames
V-belt width limit
32.5 mm (1.28 in)
4-4.
• Sound-deflection panel
4-10.
• V-belt cooling ducts
4-26.
3. Remove:
r- a--J • Bearing housing
Refer to "PRIMARY AND SECONDARY
\ I SHEAVES" on page 5-54.

4. Replace:
6. Install : • V-belt
• Drive belt cover TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Install the bolts "1" (90101-06016) into the
secondary fixed sheave holes.
SHEAVES" on page 5-54.
TIP ~~~~~~~~~~~~~~
7. Install :
• V-belt cooling ducts Tightening the bolts "1" will push the secondary
Refer to "GENERAL CHASSIS (9)" on page sliding sheave away, causing the gap between
4-26. the secondary fixed and sliding sheaves to wid-
• Sound-deflection panel en.
4-10.
• Seat frames
4-4.
• Rear panel (left)
4-20.
4-28. b. Remove the V-belt "2" from the primary
sheave and secondary sheave.
3-24
• Lateral wheel runout

Refer to "CHECKING THE W HEELS" on
page 4-34.
3. Check:
• Wheel bearings
Refer to "CHECKING THE STEERING
KNUCKLES AND FRONT WHEEL BEAR-
INGS" on page 4-66 and "CHECKING THE
REAR KNUCKLES AND REAR W HEEL
BEARIN GS" on page 4-75.
c. Install a new V-belt.
EBS30058
TIP ~~~~~~~~~~~~~~ CHECKING THE TIRES
Install the new V-belt so that its arrow faces the The following procedure applies to all of the
direction shown in the illustration. tires.
EWB02960
& WARNING
This model is equipped with low-pressure
tires. It is important that they be inflated cor-
rectly and maintained at the proper pres-
sures.
Tire characteristics
EWB02970
& WARNING
d. Remove the bolts. Tire characteristics influence the handling of
vehicles. The tires listed below have been
approved by Yamaha Motor Co., Ltd. for this
EBS30057
model. If other tire combinations are used,
CHECKING THE WHEELS
they can adversely affect your vehicle's han-
dling characteristics and are therefore not
wheels.
recommended.
1. Check:
• Wheel "1"
Damage/bends ~ Replace. Front tire
EWB03010 Type
& WARNING Tubeless
Size
• Never attempt even small repairs to the
25 x 8-12NHS
wheel.
Manufacturer/model
• Ride conservatively after installing a tire to MAXXIS/MU09
allow it to seat itself properly on the rim. Rear tire
Type
Tubeless
Size
25 x 10-12NHS
Manufacturer/model
MAXXIS/MU10
Tire pressure
EWB02960
& WARNING
2. Measure: • Tire pressure below the minimum specifi-
• Radial wheel runout cation could cause the tire to dislodge from
the rim under severe riding conditions.
3-25
• Use no more than the following pressures

when seating the tire beads. Maximum loading limit
Front 411.0 kg (906 lb) (Total weight of
250 kPa (2.5 kgf/cm 2 ) (36 psi) rider, passengers, cargo, acces-
sories, and tongue)
Rear
Rear carrier load limit
250 kPa (2.5 kgf/cm 2 ) (36 psi) 272.0 kg (600 lb)
Higher pressures and fast inflation may Storage compartment load limit
cause a tire to burst. Inflate the tires very 4.5 kg (1 O lb) (for special edition
slowly and carefully. models)
Trailer hitch pulling load limit
~ Tire air pressure (measured on 6664 N (680 kgf, 1498 lbf)
cold tires) Trailer hitch vertical load limit
Recommended 490 N (50 kgf, 110 lbf)
Vehicle load
0-300 kg (0-661 lb) 1. Measure:
Front • Tire pressure
75.0 kPa (0.750 kgf/cm 2 , 10.9 Out of specification ~ Adjust.
psi) EWB03000
Rear AwARNING
100.0 kPa (1.000 kgf/cm 2 , 14.5 Uneven or improper tire pressure may ad-
psi) versely affect the handling of this vehicle
Vehicle load and may cause loss of control.
300 kg-maximum (661 lb-maxi- • Maintain proper tire pressures.
mum) • Set tire pressures when the tires are cold.
Front
• Tire pressures must be equal in both front
75.0 kPa (0.750 kgf/cm 2 , 10.9
psi) tires and equal in both rear tires.
Rear TIP ~~~~~~~~~~~~~~~
125.0 kPa (1.250 kgf/cm 2 , 18.1
• The tire pressure gauge "1" is included as stan-
psi)
Minimum dard equipment.
Vehicle load • In order to insure an accurate reading, make
0-300 kg (0-661 lb) sure that the gauge is clean before use.
Front
70.0 kPa (0.700 kgf/cm 2 , 10.2
psi)
Rear
95.0 kPa (0.950 kgf/cm 2 , 13.8
psi)
Vehicle load
300 kg-maximum (661 lb-maxi-
mum)
Front
70.0 kPa (0.700 kgf/cm 2 , 10.2
psi) 2. Check:
Rear • Tire surfaces
120.0 kPa (1.200 kgf/cm 2 , 17.4 Wear/damage ~ Replace.
psi)
Wear limit (front)
Maximum loading limit 3.0 mm (0.12 in)
EWB02990 Wear limit (rear)
AwARNING 3.0 mm (0.12 in)
Be extra careful of the vehicle balance and
stability when towing a trailer.
3-26
EWB03100
Refer to "REAR ARMS AND REAR SHOCK
A WARNING ABSORBER ASSEMBLIES" on page 4-76.
It is dangerous to ride with a worn-out tire.
EBS30061
When the tire tread reaches the wear limit, re-
CHECKING THE STEERING SYSTEM
place the tire immediately. 1. Place the vehicle on a level surface.
2. Check:
• Steering column (except for EPS models)
r- - - , • EPS unit (for EPS models)
I ' - -- - - . - • Steering wheel nut
a Move the steering wheel up and down, and
back and forth .
Excessive play ~ Check that the steering
column bolts, EPS unit bolts, or steering
wheel nut are tightened to specification .
Refer to "STEERING SYSTEM" on page
a. Wear limit 4-60.
EBS30059
CHECKINGTHEFRONTSHOCKABSORBER
ASSEMBLIES
The following procedure applies to both of the
front shock absorber assemblies.
1. Place the vehicle on a level place.
2. Check:
• Front shock absorber assembly
Refer to "CHECKING TH E FRONT SHOCK
ABSORBER ASSEMBLIES" on page 4-70. --------
3. Check:
3. Check:
• Tie-rod ends
• Operation
Free play ~ Replace the tie-rod end.
Pump the front shock absorber assembly up
and down several times. a. Turn the steering wheel left until it stops.
Unsmooth operation ~ Replace front shock b. Move the steering wheel slightly to the right
absorber assembly. and left.
Re~rto "FRONTARMSAND FRONT c. Check for play in the tie-rod ends.
SHOCK ABSORBER ASSEMBLIES" on d. Turn the steering wheel right until it stops.
page 4-68. e. Move the steering wheel slightly to the left
EBS30060 and right.
CHECKINGTHEREARSHOCKABSORBER f. Check for play in the tie-rod ends.
ASSEMBLIES
rear shock absorber assemblies. \ (
1. Place the vehicle on a level place.
2. Check:
• Rear shock absorber assembly
\ l
Refer to "CH ECKING TH E REAR SHOCK
ABSORBER ASSEMBLIES" on page 4-78.
3. Check:
• Operation
Pump the rear shock absorber assembly up
and down several times.
Unsmooth operation ~ Replace rear shock
absorber assembly.
3-27
4. Raise the front end of the vehicle so that

there is no weight on the front wheels. I
5. Check:
• Ball joints and wheel bearings
Move the wheels laterally back and forth .
Excessive free play ~ Replace the front
arms (upper and lower) and/or wheel bear-
ings.
'
C
• 1f •
I \
EBS30062 B
ADJUSTING THE TOE-IN
C. Forward
2. Measure:
• Toe-in
••••••••••••••••••••••••••••••••
3. Adjust:
• Toe-in
Toe-in (with tires touching the EWB03110
ground) AwARNING
5.0-15.0 mm (0.20-0.59 in)
• Be sure that both tie-rods are turned the
same amount. If not, the vehicle will drift
TIP~~~~~~~~~~~~~~
right or left even though the steering wheel
Before measuring the toe-in, make sure that the is straight. This may lead to mishandling
tire pressure is correct. and an accident.
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT • After setting the toe-in to specification, run
a. Mark both front tire tread centers. the vehicle slowly for some distance with
b. Face the steering wheel straight ahead . both hands lightly holding the steering
c. Measure the width "A" between the marks. wheel and check that the steering wheel re-
d. Rotate the front tires 180° until the marks are sponds correctly. If not, turn either the right
exactly opposite one another. or left tie-rod within the toe-in specification.
e. Measure the width "B" between the marks. TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
f. Calculate the toe-in using the formula given a. Mark both tie-rods ends.
below. This reference point will be needed during
adjustment.
I Toe-in = "B" - "A"
g. If the toe-in is incorrect, adjust it.

I b. Loosen the tie-rod end locknuts "1" of both
tie-rods.
c. The same number of turns should be given to
both the right and left tie-rods "2" until the
specified toe-in is obtained . This is to keep
the length of the tie-rods the same.
3-28
EBS30066
LUBRICATING THE DRIVE SHAFT

UNIVERSAL JOINTS
1. Remove:
• Seat frames
4-4.
• Sound-deflection panels
4-10.
• Floor boards and panels
d. Tighten the tie-rod end locknuts to specifica-
tion .
4-20.
Tie-rod end locknut • Heat shield
40 Nm (4.0 m-kgf, 29 ft-lbf) Refer to "ENG IN E REMOVAL (3)" on page
5-7.
••••••••••••••••••••••••••••••••
4. Check:
• Air filter case
• Steering wheel 2. Lubricate:
TIP ~~~~~~~~~~~~~~
• Drive shaft universal joint
After adjusting the toe-in , the steering wheel Recommended lubricant
should be centered. l Lithium-soap-based grease
Refer to "INSTALLING THE STEERING
WHEEL" on page 4-18.
EBS30064
CHECKING THE STABILIZER BUSHINGS

1. Check:
• Stabilizer bushings
Damage/wear~ Replace.
Refer to "REAR KNUCKLES AND STABILIZ-
ER" on page 4-73.
EBS30065
LUBRICATING THE REAR KNUCKLE

PIVOTS
1. Remove:
• Rear arm protectors
2. Lubricate:
• Rear knuckle pivots
l Lithium-soap-based grease
(~.------,
EBS30067
CHECKING THE ENGINE MOUNT

1. Check:
• Engine brackets
• Engine mounting bolts
• Engine bracket nuts
Loosen~ Tighten.
Refer to "ENGINE REMOVAL (1 )" on page
5-2.
3-29
EBS30068
CHECKING THE CONSTANT VELOCITY

SHAFT ASSEMBLY DUST BOOTS
1. Check:
• Dust boots "1"
Damage~ Replace.
Refer to "FRONT CONSTANT VELOCITY
SHAFT ASSEMBLIES, DIFFERENTIAL AS-
SEMBLY AND FRONT DR IVE SHAFT" on
page 8-4 and "REAR CONSTANT VELOC I-
TY SHAFT ASSEMBLIES, FINAL DRIVE
ASSEMBLY AND REAR DRIVE SHAFT" on
page 8-18.
IA] ~ I
·'
-
1 1
A. Front
B. Rear
EBS30069
CHECKING THE FASTENERS

1. Check:
• Fasteners
Damage/pitting ~ Replace.
Refer to "GENERAL CHASSIS (1 )" on page
4-1 , "GENERAL CHASSIS (4)" on page 4-10,
"GENERAL CHASSIS (6)" on page 4-15,
"GENERAL CHASSIS (7)" on page 4-20,
"GENERAL CHASSIS (9)" on page 4-26 and
"GENERAL CHASSIS (1 O)" on page 4-28.
3-30
3-31
CHASSIS
GENERAL CHASSIS (1) ........ ......... .......... ......... .......... ........ ......... .......... ........ 4-1
INSTALLING THE DOOR ......... ......... ......... ......... ......... ......... .......... ......... . 4-3
GENERAL CHASSIS (2) ........ ......... .......... ......... .......... ........ ......... .......... ........ 4-4
REMOVING TH E SEATS .......... ......... ........ ......... .......... ......... ......... ......... . 4-5
ADJUSTING THE DRIVER SEAT POSITION ..... ......... .......... ......... ......... . 4-5
INSTALLING THE SEATS .......... ......... ......... ......... ......... ......... .......... ........ 4-5
GENERAL CHASSIS (3) ........ .......... ......... ......... .......... ........ ......... .......... ........ 4-7
INSTALLING THE SEAT BELTS ......... ......... ......... ......... .......... ......... ........ 4-9
GENERAL CHASSIS (4) ........ ......... .......... ......... .......... ........ .......... ......... ...... 4-10
INSTALLING THE SOUND-DEFLECTION PANEL ....... .......... ......... ....... 4-1 1
INSTALLING THE SOUND-DEFLECTION PANEL RUBBER STRIPS ... 4- 11
GENERAL CHASSIS (5) ........ ......... .......... ......... .......... ........ .......... ......... ...... 4-12
INSTALLING THE ENCLOSURE ........ ......... .......... ........ .......... ......... ...... 4-14
GENERAL CHASSIS (6) ........ .......... ......... ......... .......... ........ .......... ......... ...... 4-15
REMOVING TH E STEERING WHEEL ......... ........ ......... ......... .......... ....... 4-18
INSTALLING THE CU P HOLDER INSERT .. ........ .......... .......... ......... ...... 4-18
INSTALLING THE STEERING WHEEL ....... ........ .......... ......... .......... ...... 4-18
INSTALLING THE FRONT OVER FEND ER
(for special ed ition models) ...... .......... .......... ........ .......... ......... .......... ...... 4-18
GENERAL CHASSIS (7) ........ .......... ......... ......... .......... ........ .......... ......... ...... 4-20
INSTALLING THE CENTER PASSENGER COMPARTMENT
PANELS .. .... ......... .......... ......... .......... ........ ......... .......... ......... .......... ....... 4-23
GENERAL CHASSIS (8) ........ .......... ......... ......... .......... ........ .......... ......... ...... 4-24
GENERAL CHASSIS (9) ........ .......... ......... ......... .......... ........ .......... ......... ...... 4-26
INSTALLING THE V-B ELT COOLING DUCTS .... .......... ......... .......... ...... 4-27
GENERAL CHASSIS (10) ....... .......... .......... .......... .......... .......... ........... ......... 4-28
DISASSEMBLING THE CARGO BED ......... ......... .......... ......... ......... ...... 4-31
ASSEMBLING TH E CARGO BED ...... .......... ......... ......... .......... ......... ..... 4-31
INSTALLING THE MUD FLAPS (for special edition models) .. .......... ...... 4-31
INSTALLING THE REAR OV ER FENDER
(for special ed ition models) ...... .......... .......... ........ .......... ......... .......... ...... 4-32
FRONT AND REAR WHEELS ........ .......... ......... .......... ........ ......... .......... ...... 4-33
REMOVING THE WHEELS ......... ......... .......... .......... ......... ......... ......... .... 4-34
REMOVING THE WHEEL HUBS .......... ......... .......... ......... ......... ......... .... 4-34
CHECKING THE WHEELS ....... .......... .......... ......... ......... ......... .......... ..... 4-34
CHECKING THE WHEEL HUBS ........ .......... ........ .......... .......... ......... ...... 4-35
INSTALLING THE BRAKE DISCS ...... .......... ......... ......... ......... ......... ...... 4-35
INSTALLING THE WHEEL HUBS ..... ........ ......... .......... ......... ......... ......... 4-35
INSTALLING THE WHEELS .... .......... ........ ......... ......... .......... ......... ........ 4-36
FRONT AND REAR BRAKES ......... .......... ......... .......... ........ ......... .......... ...... 4-37
INTRODUCTION ..... ......... .......... ......... .......... .......... ........ .......... ......... ..... 4-44
CHECKING THE BRAKE DISCS ........ ......... .......... ........ .......... ......... ...... 4-44
REPLACING THE BRAKE PADS .......... ......... ......... ......... ......... ......... ..... 4-45
DI SASS EM BLI NG THE BRAKE CALI PERS ......... ......... .......... ......... ...... 4-46
CHECKING THE BRAKE CALIPERS ........ .......... ......... ......... .......... ....... 4-46
ASSEMBLING THE BRAKE CALIPERS ...... ........ .......... ......... .......... ...... 4-46
INSTALLING THE BRAKE CALIPERS ...... .......... ......... .......... ......... ....... 4-47
CHECKING THE BRAKE MASTER CYLINDER ..... ........ .......... ......... ..... 4-48
CHECKING THE BRAKE PIPES ......... ......... ........ ......... .......... ......... ....... 4-48
INSTALLING THE BRAKE MASTER CYLINDER ... ........ ......... .......... ..... 4-48
PARKING BRAKE ......... ......... ......... .......... ......... .......... ........ .......... ......... ...... 4-50
REMOVING THE PARKING BRAKE CALIPER ...... ......... ......... ......... ..... 4-55
CHECKING THE PARKING BRAKE CALIPER ...... ......... .......... .......... .... 4-55
CHECKING THE PARKING BRAKE DISC .. ........ .......... ......... .......... ...... 4-55
REPLACING THE PARKING BRAKE PADS ......... ......... ......... ......... ...... 4-55
INSTALLING THE PARKING BRAKE CALIPER .... ......... .......... .......... .... 4-56
INSTALLING THE PARKING BRAKE LEVER ..... .......... ......... .......... ...... 4-56
PEDAL ASSEMBLY ..... ......... ......... .......... ........ .......... ......... .......... ......... .... ... 4-57
INSTALLING THE PEDAL ASSEMBLY ...... ......... .......... ......... .......... ...... 4-59
STEERING SYSTEM .... ......... ......... .......... ........ .......... ......... ......... .......... .... ... 4-60
REMOVING THE TIE-ROD ........ .......... ......... .......... ........ .......... ......... ..... 4-62
CHECKING THE STEERING JOINT .......... .......... ......... .......... ......... ....... 4-62
CHECKING THE TIE-ROD ENDS ...... .......... .......... ........ .......... ......... ...... 4-62
INSTALLING THE STEERING SYSTEM ..... ......... ......... ........... ......... ..... 4-62
LUBRICATING THE STEERING SHAFT ...... .......... ........ ......... ......... ...... 4-64
STEERING KNUCKLES ......... ......... .......... ......... .......... ........ ......... .......... ...... 4-65
REMOVING THE STEERING KNUCKLES .. .......... ......... .......... .......... .... 4-66
CHECKING THE STEERING KNUCKLES AND FRONT WHEEL
BEARINGS .... ......... ........... ......... ......... ......... .......... ......... .......... ......... .... 4-66
CHECKING THE STEERING KNUCKLE BALL JOINTS ......... .......... ..... 4-66
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ....... ...... 4-68
CHECKING THE FRONT ARMS ......... .......... .......... ........ .......... .......... .... 4-70
HANDLING THE FRONT SHOCK ABSORBER ASSEMBLIES ......... ..... 4-70
DISPOSING OF A FRONT SHOCK ABSORBER ASSEMBL Y .......... ..... 4-70
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ........ ..... 4-70
CHECKING THE FRONT ARM BALL JOINTS ...... ......... .......... .......... .... 4-71
INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER
ASS EM BLI ES ......... ......... .......... ......... ......... .......... ......... ......... .......... ..... 4-72
REAR KNUCKLES AND STABILIZER ..... ......... .......... ......... ......... .......... ..... 4-73
CHECKING THE REAR KNUCKLES AND REAR WHEEL
BEARINGS .... ......... ........... ......... ......... ......... .......... .......... ......... ......... .... 4-75
CHECKING THE STABILIZER ........... .......... ........ .......... ......... .......... ...... 4-75
INSTALLING THE STABILIZER ......... ........ .......... .......... ......... .......... ...... 4-75
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES ........... ...... 4-76
CHECKING THE REAR ARMS .......... .......... .......... ........ .......... ......... ...... 4-78
HAND LI NG THE REAR SHOCK ABSORBER ASSEMBLIES .. ......... ..... 4-78
DISPOSING OF A REAR SHOCK ABSORBER ASSEMBLY ... ......... ..... 4-78
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES .. ......... ..... 4-78
INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER
ASSEMBLIES ......... ......... .......... ......... ......... .......... ......... ......... .......... ..... 4-79
GENERAL CHASSIS (1)
ESS20024
GENERAL CHASSIS (1)

Removing the skid plates
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Order Job/Parts to remove Q'ty Remarks

1 Skid plate 1
4-1
GENERAL CHASSIS (1)
Removing the doors and side panels
~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
4.0 Nm 0.40 m·k f, 2.9 ft·lbf
L
6
@@ I. 1
7 Nm (0.7 m·kgf, 5.1 ft·lbf)

The following procedure applies to both of
the doors.
1 Door hinge 1
2 Door 1
3 Door handle latch 1
4 Rubber damper 1
5 Fuel tank cap 1 Right side only.
6 Side panel 1 Lift the cargo bed.
4-2
GENERAL CHASSIS (1)
ESS30419
INSTALLING THE DOOR

The following procedure applies to both of the 2
doors. ~/1.'1!0,
1. Install:
• Door hinge "1"
Door hinge nut

7 Nm (0.7 m-kgf, 5.1 ft-lbf)
1
2. Install:
• Door "1"
TIP~~~~~~~~~~~~~~
• Fit the tab "a" on the door hinge with the slot "b"
in the frame.
Door hinge bolt

7 Nm (0.7 m-kgf, 5.1 ft-lbf)
3. Install:
/
• Door handle latch "1"
TIP ~~~~~~~~~~~~~~
Adjust the position of the door latch so that it fully

engages the bar "2" on the frame when the door
is closed.
Make sure that the spring force of the front door
hinge can close the front door without latching it
when the front door is opened 45°-60°.
Door handle latch nut

7 Nm (0.7 m-kgf, 5.1 ft-lbf)
4-3
GENERAL CHASSIS (2)
ESS20087
GENERAL CHASSIS (2)

Removing the seats
~ 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
- ,,
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
,,
n~ 1
1
.
r--J 2
7
(3)
(3)
Gm> - -
(3)
i@m, - -
(3)
4
3
\ -~
'
5 23 Nm (2.3 m·kgf, 17 ft·lbf)
1 Seat cushion 3
2 Center passenger seat rubber damper 1
3 Center passenger seat frame 1
4 Driver seat frame 1
5 Outer passenger seat frame 1
6 Seat back 3
7 Shoulder holster 2
8 Headrest 3
4-4
GENERAL CHASSIS (2)
EBS30340
REMOVING THE SEATS

seats.
1. Remove:
• Seat cushion "1"
a. Lift the front of the seat cushion .
b. Pull the cushion off.
I
r b. Move the driver seat frame "2" to the desired
position and align the bolt holes in the seat
frame with the bolt holes "a" in the vehicle
frame.
' '
''
••••••••••••••••••••••••••••••••
2. Remove (center passenger seat only) : ''
• Center passenger seat rubber damper "1"
• Center passenger seat frame bolt
• Center passenger seat frame "2"
TIP ~~~~~~~~~~~~~~
b. Forward position
Remove the center passenger seat rubber c. Center position
damper, and then remove the center passenger d. Rear position
seat frame bolts.
c. Install the driver seat frame bolts, and then
tighten the bolts to specification .
Driver seat frame bolt

23 Nm (2.3 m -kgf, 17 ft-lbf)
••••••••••••••••••••••••••••••••
3. Install:
• Driver seat cushion
Refer to "INSTALLING THE SEATS" on page
/ 4-5.
ESS30341
EBS30342
ADJUSTING THE DRIVER SEAT POSITION
INSTALLING THE SEATS
The driver seat can be adjusted to one of three
positions to suit the driver's preference.
seats.
1. Remove:
1. Install:
• Driver seat cushion
• Seat cushion "1"
Refer to "REMOVING TH E SEATS" on page EWB03120
4-5. & WARNING

2. Adjust: A loose seat could cause the operator to lose
• Driver seat position control, or cause the operator or passengers
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT to fall.
a. Remove the driver seat frame bolts "1".
a. Insert the projections "a" on the rear of the
seat cushion under the seat frame.
4-5
GENERAL CHASSIS (2)
b. Insert the projection "b" on the front of the

cushion into the grommet while pushing the
cushion downward.
TIP ~~~~~~~~~~~~~~
Make sure the seats are properly secured before

riding.
4-6
GENERAL CHASSIS (3)
EBS20088
GENERAL CHASSIS (3)

Removing the seat belts
~ 59 Nm (5.9 m·kgf, 43 ft·lbf)
3
- - - - - - - - - ~
~ 59 Nm (5.9 m·kgf, 43 ft·lbf)
Side panels Refer to "GENERAL CHASSIS (1 )" on page

4-1 .
Seat frames
4-4.
Lift the cargo bed.
Sound-deflection panels Refer to "GENERAL CHASSIS (4)" on page
4-10.
Center passenger compartment panel 4-20.
1 Driver seat belt 1
2 Seat belt rubber cover (driver seat left) 1
3 Seat belt switch coupler 1 Disconnect.
4 Driver seat belt buckle 1
5 Center passenger seat belt 1
6 Seat belt rubber cover (driver's seat right) 1
4-7
GENERAL CHASSIS (3)
Removing the seat belts
~ 59 Nm (5.9 m·kgf, 43 ft·lbf)
59 Nm (5.9 m·kgf, 43 ft·lbf)
59 Nm 5.9 m·k f, 43 ft·lbf
7 Center passenger seat belt buckle 1

8 Outer passenger seat belt 1
Seat belt rubber cover (outer passenger seat
9 1
right)
10 Outer passenger seat belt buckle 1
Seat belt rubber cover (outer passenger seat
11 left) 1
4-8
GENERAL CHASSIS (3)
EBS30343
INSTALLING THE SEAT BELTS

1. Install :
• Seat belt buckles 1
Seat belt buckle bolt a~ ,,@¥~
59 Nm (5.9 m-kgf, 43 ft-lbf)
TIP ~~~~~~~~~~~~~~
• Fit the outer passenger seat belt buckle "1" into

the slot "a" in the frame.
• Fit the center passenger seat belt buckle "2"
into the slot "b" in the frame.
• Fit the driver seat belt buckle "3" into the slot "c"
in the frame.
------
2. Install :
C
• Seatbelts
Seat belt bolt

59 Nm (5.9 m-kgf, 43 ft-lbf)
Seat belt guide bolt
59 Nm (5.9 m-kgf, 43 ft-lbf)
TIP ~~~~~~~~~~~~~~
• Install the seat belt anchor plates "1" so that

they contact the stoppers "a".
• Fit the projection "b" on each seat belt "2" into
the holes "c" in the frame.
4-9
GENERAL CHASSIS (4)
EBS20089
GENERAL CHASSIS (4)

Removing the sound-deflection panels
1.3 Nm 0.13 m·k f, 0.94 ft·lbf
1 1
e
""
u~
• -'-'_ 1.. 1 ~· ~ro~:;:::::=::=f~:;:::::=::';;3
1
6
- . P\
18
, ~ .. - -
€
/~
:.o
--===· I
-ro
.. --
7
(3)
/
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
E-:;.;.c:::::::::::3\
,
~ '
', • . . --ro
\ "-.;.. -ro 4
A--~~=:-
_.::;p -- l
-0 8
o/
(3) · ~ ~ ~ k ~ c = --~
~ ~ (2)
~ \ \ \ (5) .£..--~ =-..\
-------'---'-(-~____,, +-J.~0.
~ 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
L7.
.--~ I
\
I rr
Order Job/Parts to remove Q 'ty Remarks

Seat frames
4-4.
1 Sound-deflection panel rubber strip 2 Lift the cargo bed.
2 Sound-deflection panel rubber damper 1
3 V-belt cooling intake duct cover 1
4 Sound-deflection panel holder 1
5 Plastic band 3
6 Sound-deflection panel (left) 1
7 Sound-deflection panel (right) 1
8 Damper 7
4-10
GENERAL CHASSIS (4)
EBS30586
TIP ~~~~~~~~~~~~~~
INSTALLING THE SOUND-DEFLECTION
PANEL Install the sound-deflection panel rubber strips
1. Install "1" to the sound-deflection panels as shown in
• Sound-deflection panel (left) "1" the illustration.
• Sound-deflection panel (right) "2"
a. Make sure that the frame "a" fits into the por-
tion "b" of the sound-deflection panel (left) "1".
b. Make sure that the frame "c" fits into the por-
tion "d" of the sound-deflection panel (right)
"2".
••••••••••••••••••••••••••••••••
2. Install
• Plastic bands "1"
TIP~~~~~~~~~~~~~~
After installing the plastic bands, cut off the ex-

cess end of the tie "a" to 5 mm (0.20 in) or less.
~r -
-2:::1
,_J
I /
4 ~
-
-
-1
r l' 1
~
~ ' .._
~
a V/
',\ c!l ~ -
.
.. ~
~
,A
...
'
'
-~
-r1- ~
Ji
r---
1
EBS30590
INSTALLING THE SOUND-DEFLECTION

PANEL RUBBER STRIPS
1. Install
• Sound-deflection panel rubber strips "1"
4-11
GENERAL CHASSIS (5)
EBS20090
GENERAL CHASSIS (5)

Removing the s un top
. 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

5
'
,, ,, ,, ' ,,
,,
' ,,
' ,
,
1
r~J7 Nm (0.7 m•kgf, 5.1 ft•lbf) I
'
'>~>\'N'1 \ (4) '
~ (4)
1\
1 (4)
~ - 11~Mf+ti
·~- 2 3 ' (4) ---
' - (4) (4) I
(4)
,
A4
(4)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf) ~ 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
1 Sun top lower bracket 2

2 Damper 4
3 Sun top rear bracket 4
4 Sun top front bracket 4
5 Sun top 1
6 Damper 4
7 Damper 4
4-12
GENERAL CHASSIS (5)
Removing the enclos ure

~ 48 Nm (4.8 m·kgf, 35 ft·lbf)
48 Nm (4.8 m·kgf, 35 ft·lbf)
3
'
5
7
~Ai)
_.) r o~~
\ ,rl/
~ 48 Nm (4.8 m·kgf, 35 ft·lbf)

0------
)
0
~ 48 Nm (4.8 m·kgf, 35 ft·lbf) 65 Nm (6.5 m·kgf, 47 ft·lbf)

Headrests/Seat frames
4-4.

4-10.
Seat belts Refer to "GENERAL CHASSIS (3)" on page

4-7.
Sun top 4-15.
1 Rear top frame 1
2 Front top frame 1
3 Rear frame (right) 1
4 Rear frame (left) 1
5 Side frame (right) 1
6 Side frame (left) 1
7 Rear center frame 1
4-13
GENERAL CHASSIS (5)
EBS30344
INSTALLING THE ENCLOSURE

1. Install:
• Rear center frame "1"
• Side frame (right) "2"
• Side frame (left) "3"
• Rear frame (right) "4"
• Rear frame (left) "5"
• Front top frame "6"
• Rear top frame "7"
TIP ~~~~~~~~~~~~~~~
Do not fully tighten the bolts and nuts. ••••••••••••••••••••••••••••••••

2. Tighten:
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT • Rear frame bolts (right)
a. Install the rear center frame "1". • Rear frame bolts (left)
• Front top frame bolts
1 • Rear top frame bolts
• Side frame nuts (front right)
• Side frame nuts (front left)
• Rear center frame bolts
• Side frame nut (rear right)
• Side frame nut (rear left)
TIP~~~~~~~~~~~~~~
Tighten the bolts and nuts in the proper se-

quence as shown (~1 . ~2. and so on) .
b. Install the side frame (right) "2" and side
frame (left) "3".
Rear frame bolt (right)
48 Nm (4.8 m-kgf, 35 ft-lbf)
Rear frame bolt (left)
48 Nm (4.8 m-kgf, 35 ft-lbf)
Front top frame bolt
48 Nm (4.8 m-kgf, 35 ft-lbf)
'
Rear top frame bolt
l- 48 Nm (4.8 m-kgf, 35 ft-lbf)
Side frame nut (front right)
65 Nm (6.5 m-kgf, 47 ft-lbf)
Side frame nut (front left)
c. Install the rear frame (right) "4" and rear 65 Nm (6.5 m-kgf, 47 ft-lbf)
frame (left) "5". Rear center frame bolt
48 Nm (4.8 m-kgf, 35 ft-lbf)
5 Side frame nut (rear right)
4
~
Jfj)\
r
'
48 Nm (4.8 m-kgf, 35 ft-lbf)
Side frame nut (rear left)
48 Nm (4.8 m-kgf, 35 ft-lbf)
'
~\
.] <
d. Install the front top frame "6" and rear top
frame "7".
4-14
GENERAL CHASSIS (6)
ESS20091
GENERAL CHASSIS (6)

Removing the hood and battery
...----.-----------,
~ 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
! I 1
I
10
DD
7
' ' ' ~
'
' ' ' '
,
48 Nm 4.8 m·k f, 35 ft·lbf ' '' ' 8

Skid plate 4-1 .
1 Hood 1
2 Air intake duct cover 1
3 Negative battery lead 1 Disconnect.
4 Positive battery lead 1 Disconnect.
5 Battery band 2
6 Battery 1
7 Front guard 1
8 Front guard cover 2
9 Headlight coupler 2 Disconnect.
10 Front grill 1
4-15
GENERAL CHASSIS (6)
Removing the front fender and instrument panel

~,-----------,
35 Nm 3.5 m·k f, 25 ft·lbf 4.0 Nm 0.40 m·k f, 2.9 ft·lbf
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) 7 --........J
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
'
3.0 Nm 0.30 m·k f, 2.2 ft·lbf
• For special edition models

Sun top 4-12.
Side frames 4-10.
Hood 4-15.
1 Front over fender (left) 1 For special edition models
2 Front over fender (right) 1 For special edition models
3 Front fender 1
4 Cup holder insert 2
5 Passenger handhold 1
6 Steering wheel cover 1
7 Steering wheel 1
8 Meter assembly 1
9 Meter assembly bracket 1
4-16
GENERAL CHASSIS (6)
4.0 Nm 0.40 m·k f, 2.9 ft·lbf
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) 10
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
16
11
(1
6 --
_d er< >
~ I~ 7 Nm 0.7 m·k f, 5.1 ft·lbf
'
.,;;:::;.::.-1
3.0 Nm 0.30 m·k f, 2.2 ft·lbf
• For special edition models

10 Parkin g brake lever rubber cover 1
11 On-Command four-wheel-drive switch 1
12 Light switch 1
13 Main switch 1
14 Indicator light assembly 1
15 Auxiliary DC jack 1
16 Instrument panel 1
4-17
GENERAL CHASSIS (6)
EBS30345
REMOVING THE STEERING WHEEL 1

1. Turn the steering wheel so that it is straight
and the front wheels are pointing straight
ahead.
2. Remove:
• Steering wheel cover "1"
TIP ~~~~~~~~~~~~~~~~
While pushing the ends of the projections "a" to-

gether, remove the steering wheel cover from
the steering wheel. EBS30347
INSTALLING THE STEERING WHEEL

1. Install:
• Steering wheel "1"
Steering wheel nut

35 Nm (3.5 m-kgf, 25 ft-lbf)
1 TIP ~~~~~~~~~~~~~~
Install the steering wheel onto the steering col-

umn so that it is centered as shown in the illus-
tration .
3. Remove:
• Steering wheel "1"
TIP ~~~~~~~~~~~~~~~~
Use a general puller "2" to separate the steering

wheel and steering column .
2
2. Operate the vehicle at low speeds and make
sure that the steering wheel is straight when
the vehicle is advancing straight ahead.
EBS30646
INSTALLING THE FRONT OVER FENDER

EBS30346
(for special edition models)
INSTALLING THE CUP HOLDER INSERT
1. Install:
1. Install:
• Front over fender
• Cup holder insert "1"
TIP ~~~~~~~~~~~~~~ a. Fit the front over fender on the front fender.
Insert the projection "a" on the cup holder insert Temporarily tighten the front over fender bolt
"1" completely into the hole "b" on the front fend- "1".
er "2".
4-18
GENERAL CHASSIS (6)
b. Rotate the front over fender. Temporarily TIP ~~~~~~~~~~~~~~

tighten the front fender and frame bolt "1". Make sure that the gap between the front over
fender and the front fender is less than 2 mm.
f. Tighten the front fender and frame bolt "1" to
specification .
Front fender and frame bolt

4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
c. Rotate the front fender to fit the fender on the

front fender.
d. Temporarily tighten the front over fender
bolts and nuts "1"- "5".
e. Tighten the front over fender bolts to specifi-

cation .
TIP ~~~~~~~~~~~~~~
Tighten the front over fender nuts to specifica-

tion in the proper tightening sequence.
Front over fender nut (for special

edition models)
7 Nm (0.7 m-kgf, 5.1 ft-lbf)
4-19
GENERAL CHASSIS (7)
EBS20092
GENERAL CHASSIS (7)
THI-.. '
(s) (
~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
______________ , , ' -------- (4)
16 Nm 1.6 m·k f, 12 ft·lbf ~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

4-1 .
Seat frames
4-4.
Lift the cargo bed.
4-10.
Seat belts Refer to "GENERAL CHASSIS (3)" on page

4-7.
Side frames 4-12.
Instrument panel Refer to "GENERAL CHASSIS (6)" on page

4-15.
4-20
GENERAL CHASSIS (7)
7
THI-.. '
(s) (
~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
______________ , , ' -------- (4)
16 Nm 1.6 m·k f, 12 ft·lbf ~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
1 Center passenger compartment panel (left) 1

2 Center passenger compartment panel (right) 1
3 Rubber cover 1
4 Center floor board 1
5 Floor board (left) 1
6 Floor board (right) 1
7 Lower panel (left) 1
8 Lower panel (right) 1
4-21
GENERAL CHASSIS (7)
12
11
THI-.. '
(s) ( 14
______________ , , ' -------- 13

(4)
'X 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
9 Center passenger lower panel 1

10 Under-seat storage compartment cover 1 Except for special edition models
11 Driver seat compartment panel 1
12 Outer passenger compartment panel 1
13 Rear panel (left) 1
14 Rear panel (right) 1
15 Under-seat storage compartment 1 For special edition models
4-22
GENERAL CHASSIS (7)
ESS30591
INSTALLING THE CENTER PASSENGER

COMPARTMENT PANELS
1. Install:
• Center passenger compartment panel (right)
"1"
• Center passenger compartment panel (left)
"2"
• Quick fastener screws
TIP ~~~~~~~~~~~~~~
• Install the center passenger compartment pan-

el (right) "1", and then install the center passen-
ger compartment panel (left) "2".
• Fit the projections "a" on the center passenger
compartment panel (right) "1" under the panels
as shown in the illustration.
• Fit the projections "b" on the center passenger
compartment panel (left) "2" under the driver
seat compartment panel "3" as shown in the il-
lustration.
4-23
GENERAL CHASSIS (8)
ESS20102
GENERAL CHASSIS (8)

Removing the electrical components tray
3.6 Nm (0.36 m·kgf, 2.6 ft·lbf)
9
4.0 Nm 0.40 m·k f, 2.9 ft·lbf
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
6 '
'
\
~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)

Side frames 4-12.
Hood 4-15.

4-15.
1 Headlight coupler 2 Disconnect.
2 Lean angle sensor 1
3 Starter relay 1
4 Main fuse 1
5 EPS fuse 1 For EPS models
6 ECU (Engine Control Unit) 1
7 EPS (electronic power steering) control unit 1 For EPS models
8 Fuse box 1
9 Differential motor relay 2 1
4-24
GENERAL CHASSIS (8)
Removing the electrical components tray

11 10 3.6 Nm (0.36 m·kgf, 2.6 ft·lbf)
4.0 Nm 0.40 m·k f, 2.9 ft·lbf
'
\
~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)

15
10 Differential motor relay 1 1

11 Headlight relay 1
12 Load control relay 1
13 Fuel injection system relay 1
14 Radiator fan motor relay 1
15 Electrical components tray 1
4-25
GENERAL CHASSIS (9)
ESS20103
GENERAL CHASSIS (9)

Removing the V-belt cooling ducts
59 Nm 5.9 m·k f, 43 ft·lbf

1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
r---- 4
~~} ,,
s- ~'J
f!j'/;&r:f ~-~-
('~( I f /'
2
~ 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) ~ 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
2.0 Nm 0.20 m·k f, 1.4 ft·lbf

Seat frames
4-4.

4-10.
Refer to "GENERAL CHASSIS (1 O)" on
Frame cross member page 4-28.
1 V-belt cooling exhaust duct 1
2 V-belt cooling exhaust duct joint 1
3 Outer passenger seat belt bolt 1
4 V-belt cooling intake duct 1
5 V-belt cooling intake duct joint 1 1
6 V-belt cooling intake duct joint 2 1
4-26
GENERAL CHASSIS (9)
EBS30348
INSTALLING THE V-BELT COOLING DUCTS

1. Install:
• V-belt cooling intake duct joint 2 "1"
• V-belt cooling intake duct joint 1 "2"
• V-belt cooling exhaust duct joint "3"
TIP ~~~~~~~~~~~~~~
• Align the projection "a" on V-belt cooling intake

duct joint 2 with the lib on the crankcase.
• Fit the projection "b" on the V-belt cooling in-
take duct joints and V-belt cooling exhaust duct
joint between the projections on the V-belt
cooling intake duct and V-belt cooling exhaust
duct.
• Align the slit "c" in V-belt cooling intake duct
joint 1 and V-belt cooling exhaust duct joint
with the projection on the drive belt cover.
- ·3
4-27
GENERAL CHASSIS (10)
ESS20104

Removing the cargo bed
.. ,. - - - - -'
''
. 16 Nm (1.6 m·kgf, 12 ft·lbf)

'
''
''
17 Nm (1.7 m·kgf, 12 ft·lbf) '
''
''
'
''
''
'
''
''
'
'
'
'
'
• •'
-· •
'
''
''
''
'
''
16 Nm 1.6 m·k f, 12 ft·lbf 16Nm 1.6m·k f,12ft·lbf

1 Frame cross member 1 Lift the cargo bed.
2 Tail/brake light connector 6 Disconnect.
TIP
3 Gas spring assembly 2 Install the gas spring assembly so that the
cylinder end is pointing upward.
4 Pin 2
5 Cargo bed assembly 1
4-28
Disassembling the cargo bed

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
(7) * 8
#lJ(7)
/
J
9 Nm (0.9 m·kgf, 6.5 ft·lbf)

4.0 Nm 0.40 m·kgf, 2.9 ft·lbf (5) 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
~ 8 Nm (0.8 m·kgf, 5.8 ft·lbf) ~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 4
1 Mud flap upper bracket (left) 1 For special edition models

2 Mud flap upper bracket (right) 1 For special edition models
3 Mud flap lower bracket 2 For special edition models
4 Mud flap 2 For special edition models
5 Cargo hook 4
6 Cargo bed panel (left) 1
7 Rear over fender (left) 1 For special edition models
8 Cargo bed panel (right) 1
9 Rear over fender (right) 1 For special edition models
4-29
Disassembling the cargo bed

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
(7) *
#lJ (7)
/
J 10
9 Nm (0.9 m·kgf, 6.5 ft·lbf)

4.0 Nm 0.40 m·kgf, 2.9 ft·lbf (5) 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
~ 8 Nm (0.8 m·kgf, 5.8 ft·lbf) ~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
10 Tail/brake light 2
11 Tailgate cable 2
12 Tailgate 1
13 Tailgate shaft 1
14 Cargo bed release lever 1
15 Cargo bed heat protector plate 1
4-30
EBS30349
DISASSEMBLING THE CARGO BED 25·

1. Remove:
• Tailgate "1"
TIP ~~~~~~~~~~~~~~~
Align the slot "a" in the left end of the tailgate

b
shaft with the flat portions of the projection "b" on
the cargo bed, and then lift the left end of the tail-
gate.
•3.•••••••••••••••••••••••••••••••
Install:
• Tailgate cables "1"
Tailgate cable bolt

7 Nm (0.7 m-kgf, 5.1 ft-lbf)
TIP ~~~~~~~~~~~~~~
Connect the straight end "a" of each tailgate ca-
EBS30350
ble to the tailgate "2", and the offset end "b" to
ASSEMBLING THE CARGO BED the cargo bed "3".
1. Install :
• Tailgate shaft "1"
Tailgate shaft bolt

7 Nm (0.7 m-kgf, 5.1 ft-lbf)
TIP ~~~~~~~~~~~~~~
Install the tailgate shaft so that the end with the

slot "a" is pointing to the left.
EBS30631
INSTALLING THE MUD FLAPS (for special

edition models)
1. Install:
• Mud flap
• Mud flap upper bracket
• Mud flap lower bracket
• Mud flap upper bracket bolt
• Mud flap lower bracket bolt
2. Install : • Mud flap lower bracket nut
• Tailgate "1" 2. Tighten:
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT • Mud flap upper bracket bolt
a. Fit the right end of the tailgate shaft onto the • Mud flap lower bracket bolt
projection "a" on the cargo bed . • Mud flap lower bracket nut
b. Align the slot "b" in the left end of the tailgate TIP~~~~~~~~~~~~~~
shaft w ith the flat portions of the projection "c"
Tighten the bolts and nuts to specification in the
on the cargo bed , and then fit the tailgate
proper tighten sequence as shown.
shaft onto the projection.
4-31
4 0 2 0 3
\ I
Mud flap upper bracket bolt (for

special edition models)
7 Nm (0. 7 m-kgf, 5.1 ft-lbf)
Mud flap lower bracket bolt (for
7 Nm (0. 7 m-kgf, 5.1 ft-lbf)
Mud flap nut (for special edition
models)
7 Nm (0. 7 m-kgf, 5.1 ft-lbf)
EBS30645
INSTALLING THE REAR OVER FENDER (for

1. Install:
• Rear over fender
Rear over fender nut (for special

edition models)
7 Nm (0. 7 m-kgf, 5.1 ft-lbf)
TIP ~~~~~~~~~~~~~~
Make sure that the gap between the rear over

fender and the cargo bed panel is less than 2
mm.
4-32
FRONT AND REAR WHEELS
EBS20025

Removing the wheels and brake discs
~ !48 Nm (4.8 m·kgf, 35 ft·lbf) I
30 Nm (3.0 m·kgf, 22 ft·lbf) 6
- 5
B ·~- 3
350 Nm (35.0 m·kgf, 253 ft·lbf)
. 75 Nm (7.5 m·kgf, 54 ft·lbf)

wheels.
1 Wheel 1
2 Wheel cap 1
3 Wheel axle nut 1
TIP
4 Brake caliper 1 Do not apply the brake pedal when the
brake caliper is off of the brake disc as the
brake pads will be forced shut.
5 Wheel hub 1
6 Brake disc 1
4-33
EBS30083
• Wheel
REMOVING THE WHEELS
Refer to "CHECKING THE T IRES" on page
3-25 and "CHECKING T HE W HEELS" on
2. Elevate:
page 3-25.
• Wheels EWB03020
TIP ~~~~~~~~~~~~~~ & WARNING

Place the vehicle on a suitable stand so that the After replacing the tire, ride conservatively to
wheels are elevated. allow the tire to be properly seated in the rim.
Failure to do so may cause an accident re-
EBS30084 sulting in vehicle damage and possible inju-
REMOVING THE WHEEL HUBS ry.
wheel hubs.
1. Straighten the wheel axle nut rib "a".
2. Measure:
• Radial wheel runout "1"
2. Remove: • Lateral wheel runout "2"
• Wheel axle nut Over the specified limit~ Replace the wheel
3. Remove: or check the wheel bearing play.
Refer to "CHECKING THE STEERING
• Brake caliper
KNUCKLES AND FRONT W HEEL BEAR-
TIP ~~~~~~~~~~~~~~~
INGS" on page 4-66 and "C HECKING T HE
Do not apply the brake pedal when removing the REAR KNUCKLES AND REAR W HEEL
brake caliper. BEARIN GS" on page 4-75.
4. Remove:
Radial wheel runout limit
• Wheel hub "1"
2.0 mm (0.08 in)
TIP ~~~~~~~~~~~~~~~
Lateral wheel runout limit
Use a general puller "2" to separate the wheel 2.0 mm (0.08 in)
hub and constant velocity shaft.
EBS30085
CHECKING THE WHEELS

wheels.
1. Check:
• Tire
4-34
TIP ~~~~~~~~~~~~~~
Install the brake disc so that the recessed por-

tion of the bolt hole faces away from the hub.
-- -- ----
EBS30088
INSTALLING THE WHEEL HUBS

wheel hubs.
1. Install:
• Wheel hub "1"
TIP _~~~~~~~~~~~~~
EBS30086 Tap lightly on the wheel hub with a plastic ham-

CHECKING THE WHEEL HUBS mer until five threads on the end of the constant
The following procedure applies to all of the velocity shaft will be exposed when the washer
wheel hubs. is installed.
1. Check:
• Wheel hub "1"
Cracks/damage~ Replace.
• Splines (wheel hub) "2"
Wear/damage ~ Replace the wheel hub.
2. Install:
• Wheel axle nut i~M
Front wheel axle nut
350 Nm (35 m•kgf, 253 ft·lbf)
ESS30087
Rear wheel axle nut
INSTALLING THE BRAKE DISCS
350 Nm (35 m•kgf, 253 ft·lbf)
brake discs. TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
1. Install:
• Brake disc • Do not apply oil to the threads of the nut.
• After tightening the nut, stake the collar of the
Front brake disc bolt nut into the notch of the shaft.
30 Nm (3.0 m•kgf, 22 ft·lbf)
LOCTITE®
Rear brake disc bolt
30 Nm (3.0 m•kgf, 22 ft·lbf)
LOCTITE®
4-35
3. Check:
• Brake disc
Refer to "CHECKING THE BRAKE DISCS"
on page 4-44.
EBS30089
INSTALLING THE WHEELS

wheels.
1. Tighten:
• Wheel nuts "1"
Front wheel nut

75 Nm (7.5 m-kgf, 54 ft-lbf)
Rear wheel nut
75 Nm (7.5 m-kgf, 54 ft-lbf)
EWB03130
A WARNING
Tapered wheel nuts are used for both the
front and rear wheels. Install each nut with
its tapered side towards the wheel.
4-36
FRONT AND REAR BRAKES
EBS20026

Removing the front brake pads
48 Nm 4.8 m·k f, 35 ft·lbf
17 Nm (1.7 m·kgf, 12 ft·lbf)

the front brake calipers.
Front wheel
page 4-33.
1 Brake caliper bolt 2
2 Brake pad bolt 2
3 Brake pad 2
4 Brake pad spring 1
4-37
Removing the rear brake pads
3
1
17 Nm (1.7 m·kgf, 12 ft·lbf)

4

the rear brake calipers.
Rear wheel
page 4-33.
2 Brake pad bolt 2
3 Brake pad 2
4-38
Removing the front brake calipers
6
_______ l__ _ ,
3
I
I
i ·~- 2
I
21@f4Wj
. ,, I
'~ 1
~ I
27 Nm (2.7 m·kgf, 20 ft·lbf)
I
-----------------------~

Front wheel
page 4-33.
Drain.
Brake fluid Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-18.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1 Disconnect.
4 Brake pad bolt 2 Loosen.
6 Brake caliper 1
4-39
Removing the rear brake calipers
,----------- 5
27 Nm (2.7 m·kgf, 20 ft·lbf)
6 2 I~- 1

Rear wheel
page 4-33.
Drain.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1 Disconnect.
4 Brake pad bolt 2 Loosen.
6 Brake caliper 1
4-40
Disassembling the front brake calipers

22 Nm (2.2 m·kgf, 16 ft·lbf)
17Nm 1.7m·k f,12ft·lbf
a 81~@4 2
0 91~-
'
'
10
1
5 Nm 0.5 m·k f, 3.6 ft·lbf
17 Nm (1.7 m·kgf, 12 ft·lbf)

1 Brake pad bolt 2
2 Brake pad 2
4 Brake caliper bracket 1
5 Brake caliper guide pin 1
6 Brake caliper retaining pin 1
7 Brake caliper piston 2
8 Brake caliper piston dust seal 2
9 Brake caliper piston seal 2
10 Bleed screw 1
4-41
Disassembling the rear brake calipers

_........,.- - - , - - - - - - - - - - ,
. 22 Nm (2.2 m·kgf, 16 ft·lbf)
17 Nm (1.7 m·kgf, 12 ft·lbf)
B 81~(:iti
2
91~tN
'
' 3
10
1
~ 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
17 Nm 1.7 m·k f, 12 ft·lbf

1 Brake pad bolt 2
2 Brake pad 2
5 Brake caliper guide pin 1
6 Brake caliper retaining pin 1
8 Brake caliper piston dust seal 2
10 Bleed screw 1
4-42
Removing the brake master cylinder
19 Nm (1.9 m·kgf, 14 ft·lbf)
3.5 Nm 0.35 m·k f, 2.5 ft·lbf
-- --
16 Nm (1.6 m·kgf, 12 ft·lbf)
Drain.
1 Brake master cylinder reservoir cap 1
2 Brake master cylinder reservoir diaphragm 1
Brake master cylinder reservoir diaphragm hold-
3 1
er
4 Rear brake pipe 1 Disconnect.
5 Front brake pipe 1 Disconnect.
6 Brake master cylinder 1
4-43
EBS30090
INTRODUCTION
EWB02930
AwARNING
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained, ••••••••••••••••••••••••••••••••
4. Measure:
cleaned, properly filled, and bled after reas-
sembly. • Brake disc thickness "a"
• Never use solvents on internal brake com- Measure the brake disc thickness at a few dif-
ponents. ferent locations.
• Use only clean or new brake fluid for clean- Out of specification ~ Replace.
ing brake components.
Brake disc thickness limit
• Brake fluid may damage painted surfaces
3.5 mm (0.14 in)
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.
-·H-a
EBS30091
CHECKING THE BRAKE DISCS

brake discs. 5. Adjust:
1. Remove: • Brake disc deflection
• Wheels a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
page 4-33. c. Install the brake disc.
2. Check:
• Brake disc Front brake disc bolt
Damage/galling~ Replace. 30 Nm (3.0 m-kgf, 22 ft-lbf)
3. Measure: LOCTITE®
• Brake disc deflection Rear brake disc bolt
Out of specification ~ Correct the brake disc 30 Nm (3.0 m-kgf, 22 ft-lbf)
deflection or replace the brake disc. LOCTITE®
Brake disc deflection limit TIP ~~~~~~~~~~~~~~

0.1 O mm (0.0039 in) Install the brake disc so that the recessed por-
tion of the bolt hole faces away from the hub.
a. Hold the dial gauge at a right angle against
the brake disc surface.
b. Measure the deflection 3.0 mm (0.12 in) be-
low the edge of the brake disc.
4-44
• Brake pads
TIP ~~~~~~~~~~~~~~~~
Always install new brake pads and brake pad

~==-©"""":::::~~~,---- spring as a set.
~ a. Connect a clear plastic hose "1" tightly to the

bleed screw "2". Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with your
d. Measure the brake disc deflection .
finger.
e. If out of specification , repeat the adjustment
steps until the brake disc deflection is w ithin
specification.
f. If the brake disc deflection cannot be brought
w ithin specification, replace the brake disc .
••••••••••••••••••••••••••••••••
6. Install :
• Wheels
page 4-33.
EBS30092 c. Tighten the bleed screw.
REPLACING THE BRAKE PADS
The following procedure applies to all of the Front brake caliper bleed screw
brake calipers. 5 Nm (0.5 m-kgf, 3.6 ft-lbf)
Rear brake caliper bleed screw
TIP~~~~~~~~~~~~~~
5 Nm (0.5 m-kgf, 3.6 ft-lbf)
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem- d. Install the brake pad spring and brake pads.
ble the brake caliper.
•3.•••••••••••••••••••••••••••••••
Install:
1. Measure:
• Brake pad wear limit "a" • Brake pad bolts
Out of specification ~ Replace the brake • Brake caliper
pads as a set.
Front brake pad bolt
Front brake 17 Nm (1.7 m-kgf, 12 ft-lbf)
Brake pad lining thickness limit Rear brake pad bolt
1.0 mm (0.04 in) 17 Nm (1.7 m-kgf, 12 ft-lbf)
Rear brake Front brake caliper bolt
Brake pad lining thickness limit 48 Nm (4.8 m-kgf, 35 ft-lbf)
1.0 mm (0.04 in) Rear brake caliper bolt
48 Nm (4.8 m-kgf, 35 ft-lbf)
4. Check:
specified brake fluid to the proper level.
a i !.
II '
u u u =)
11 Refer to "CHECKING THE BRAKE FLUID
t LEVEL" on page 3-17.
5. Check:
• Brake pedal operation
Soft or spongy feeling~ Bleed the brake sys-
2. Install : tem.
• Brake pad spring
4-45
Refer to "BLEEDING TH E HYDRAULIC Recommended brake component replacement

BRAKE SYSTEM" on page 3-18. schedule
EBS30093 Brake pads If necessary
DISASSEMBLING THE BRAKE CALIPERS
Piston seals, piston
The following procedure applies to all of the Every two years
dust seals
brake calipers.
Brake hoses Every four years
TIP ~~~~~~~~~~~~~~~~
Every two years and
Before disassembling the brake caliper, drain Brake fluid whenever the brake is
the brake fluid from the entire brake system. disassembled
1. Remove:
1. Check:
• Brake caliper pistons "1" • Brake caliper pistons "1"
• Brake caliper piston dust seals "2" Rust/scratches/wear ~ Replace the brake
• Brake caliper piston seals "3" caliper pistons.
• Brake caliper cylinders "2"
Scratches/wear~ Replace the brake caliper.
• Brake caliper body "3"
2 Cracks/damage ~ Replace the brake cali-
per.
• Brake fluid delivery passages
3 (brake caliper body)
Obstruction~ Blow out with compressed air.
1""'---......! 2 EWB03140
& WARNING
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT Whenever a brake caliper is disassembled,
a. Blow compressed air into the brake hose joint
replace the brake caliper piston dust seals
opening "a" to force out the pistons from the
and brake caliper piston seals.
brake caliper.
EWB02890
& WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
3
1
2
EBS30095
ASSEMBLING THE BRAKE CALIPERS

brake calipers.
EWB03150
a & WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
b. Remove the brake caliper piston dust seals with clean or new brake fluid.
and piston seals.
• Never use solvents on internal brake com-
•••••••••••••••••••••••••••••••• ponents as they will cause the brake caliper
EBS30094
piston dust seals and brake caliper piston
CHECKING THE BRAKE CALIPERS seals to swell and distort.
brake calipers.
4-46
• Whenever a brake caliper is disassembled, ~

replace the brake caliper piston dust seals
and brake caliper piston seals.
Specified brake fluid

D0T4
EBS30096
INSTALLING THE BRAKE CALIPERS

1___.
3 '
brake calipers.
1. Install:
• Brake caliper "1"
(temporarily)
• Copper washers i@M 2
• Brake hose "2"
• Brake hose union bolt "3"
/ 3
Front brake hose union bolt
27 Nm (2. 7 m-kgf, 20 ft-lbf)
Rear brake hose union bolt
----1
27 Nm (2. 7 m-kgf, 20 ft-lbf)
EWB02870
A WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
EC801610
NOTICE
-------------
• When installing the front brake hose (left)
onto the front brake caliper (left), fit the pro-
jection "a" on the brake hose into the slot in
the brake caliper.
• When installing the front brake hose (right)
onto the front brake caliper (right), make
sure that the pipe section "b" on the end of
the brake hose contacts the rib on the
brake caliper.
• When installing the rear brake hose (left)
onto the rear brake caliper (left), fit the pipe
section "c" on the end of the brake hose
into the slot in the brake caliper. A. Front brake (left)
• When installing the rear brake hose (right) B. Front brake (right)
onto the rear brake caliper (right), make C. Rear brake (left)
sure that the projection "d" on the brake D. Rear brake (right)
hose contacts the rib on the brake caliper.
2. Remove:
• Brake caliper
3. Install:
• Brake pads
• Brake pad spring
• Brake pad bolts
4-47
• Brake caliper 7. Check:

Refer to "REPLACING TH E BRAKE PADS" • Brake pedal operation
on page 4-45. Soft or spongy feeling~ Bleed the brake sys-
tem.
Front brake pad bolt Refer to "BLEEDING TH E HYDRAULIC
17 Nm (1.7 m-kgf, 12 ft-lbf) BRAKE SYSTEM" on page 3-18.
Rear brake pad bolt
17 Nm (1.7 m-kgf, 12 ft-lbf) EBS30097
Front brake caliper bolt CHECKING THE BRAKE MASTER

48 Nm (4.8 m-kgf, 35 ft-lbf) CYLINDER
Rear brake caliper bolt 1. Check:
48 Nm (4.8 m-kgf, 35 ft-lbf) • Brake master cylinder
Damage/scratches/wear ~ Replace.
4. Fill: • Brake fluid delivery passages
• Brake master cylinder reservoir (brake master cylinder body)
(with the specified amount of the specified Obstruction~ Blow out with compressed air.
brake fluid) 2. Check:
• Brake master cylinder reservoir
Cracks/damage~ Replace the brake master
DOT4
cylinder.
EWB02880 • Brake master cylinder reservoir diaphragm
A WARNING • Brake master cylinder reservoir diaphragm
• Use only the designated brake fluid. Other holder
brake fluids may cause the rubber seals to Cracks/damage ~ Replace.
deteriorate, causing leakage and poor 3. Check:
brake performance. • Brake pipes
• Refill with the same type of brake fluid that Cracks/damage ~ Replace.
is already in the system. Mixing brake fluids EBS30098
may result in a harmful chemical reaction, CHECKING THE BRAKE PIPES
leading to poor brake performance. The following procedure applies to both of the
• When refilling, be careful that water does brake pipes.
not enter the brake master cylinder reser- 1. Check:
voir. Water will significantly lower the boil- • Brake pipe end (flare nut)
ing point of the brake fluid and could cause Damage ~ Replace the brake master cylin-
vapor lock. der, brake pipes, and related parts as a set.
ECB01320
NOTICE
-------------
5. Bleed:
• Brake system
Refer to "BLEEDING TH E HYDRAULIC
6. Check:
EBS30099
• Brake fluid level INSTALLING THE BRAKE MASTER
Below the minimum level mark ~ Add the CYLINDER
specified brake fluid to the proper level. 1. Install:
Refer to "CHECKING TH E BRAKE FLUID • Brake master cylinder
LEVEL" on page 3-1 7. • Brake pipes
4-48
Refer to "BLEEDING THE HYDRAULIC

Brake master cylinder bolt BRAKE SYSTEM" on page 3-18.
16 Nm (1.6 m-kgf, 12 ft-lbf)
Brake pipe flare nut
19 Nm (1.9 m-kgf, 14 ft-lbf)
EWB03160
A WARNING
Proper brake pipe routing is essential to in-
sure safe vehicle operation.
2. Fill:
• Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)

D0T4
EWB02880
A WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
EC8 01320
NOTICE
-------------
3. Bleed:
• Brake system
Refer to "BLEEDING TH E HYDRAULIC
4. Check:
specified brake fluid to the proper level.
Refer to "CHECKING TH E BRAKE FLUID
LEVEL" on page 3-1 7.
5. Check:
• Brake pedal operation
Soft or spongy feeling~ Bleed the brake sys-
tem.
4-49
PARKING BRAKE
ESS20027
PARKING BRAKE
Removing the parking brake pads
7
1
5
'
40 Nm (4.0 m·kgf, 29 ft·lbf)
17 Nm 1.7 m·kgf, 12 ft·lbf)

4---1
t-- 3
~ 17 Nm (1.7 m·kgf, 12 ft·lbf)
1 Parking brake caliper bolt 2

2 Parking brake caliper 1
3 Parking brake cable (parking brake caliper end) 1 Disconnect.
4 Spring 1
5 Parking brake pad bolt 2
6 Parking brake pad 2
8 Parking brake caliper arm nut 1
9 Parking brake caliper arm 1
4-50
PARKING BRAKE
Removing the parking brake caliper
/; \
0(:; (
../ 2
'\~ ~ -------------~ --------
---------------· ------~
40 Nm (4.0 m·kgf, 29 ft·lbf)
1 Parking brake caliper bolt 2

2 Parking brake caliper 1
3 Parking brake cable (parking brake caliper end) 1 Disconnect.
4-51
PARKING BRAKE
Disassembling the parking brake caliper
~ 17 Nm (1.7 m·kgf, 12 ft·lbf)

. 17 Nm (1.7 m·kgf, 12 ft·lbf)
2
10
>
a
22 Nm 2.2 m·k f, 16 ft·lbf
12
13
~ 4
3
.
9
~ 12 Nm 1.2 m·kgf, 8.7 ft·lbf 6
5
17 Nm (1.7 m·kgf, 12 ft·lbf)
1 Spring 1
2 Parking brake pad bolt 2
3 Parking brake pad 2
5 Parking brake caliper arm nut 1
6 Parking brake caliper arm 1
8 Push rod 1
9 Parking brake caliper arm shaft 1 Left-hand threads
11 Parking brake caliper guide pin 1
12 Parking brake caliper retaining pin 1
13 Parking brake cable holder 1
4-52
PARKING BRAKE
Removing the parking brake lever
1.--- 3
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
16Nm 1.6m·k f,12ft·lbf
I~!7 Nm (0.7 m·kgf, 5.1 ft·lbf) I


Side frames 4-12.

4-15.
1 Parking brake switch 1
2 Parking brake buzzer 1
3 Parking brake lever 1
4 Parking brake cable (parking brake lever end) 1 Disconnect.
4-53
PARKING BRAKE
Removing the parking brake disc
~ 1O Nm (1.0 m·kgf, 7.2 ft·lbf)

Refer to "REAR CONSTANT VELOCITY
SHAFT ASSEMBLIES, FINAL DRIVE AS-
Final drive assembly
SEMBLY AND REAR DRIVE SHAFT" on
page 8-18.
1 Parking brake disc 1
4-54
PARKING BRAKE
ESS30100
REMOVING THE PARKING BRAKE CALIPER

1. Move the parking brake lever to the released
position, and then loosen the parking brake
cable adjuster so that the parking brake cable a
is slack. I u ! t
ESS3010 1
~[- - - - - - --~)
CHECKING THE PARKING BRAKE CALIPER
1. Check:
• Brake caliper piston
Scratches/rusVwear ~ Replace. 2. Install:
• Brake caliper body • Brake pad spring
Cracks/damage~ Replace the parking • Parking brake pads
brake caliper. • Parking brake pad bolts
EBS30102
CHECKING THE PARKING BRAKE DISC Parking brake pad bolt

17 Nm (1.7 m-kgf, 12 ft-lbf)
1. Check:
• Brake disc
TIP~~~~~~~~~~~~~~
Galling/damage ~ Replace.
2. Measure: Always install new brake pads and brake pad
• Brake disc deflection spring as a set.
• Brake disc thickness "a" 3. Adjust:
Out of specification ~ Replace. • Brake pad clearance
Brake disc deflection limit a. Fully turn in the parking brake caliper arm
0.1 O mm (0.0039 in) shaft "1".
Brake disc thickness limit
3.0 mm (0.12 in)
TIP ~~~~~~~~~~~~~~ 1
Measure the deflection 3.0 mm (0.1 2 in) below
the edge of the brake disc.
--a
TIP ~~~~~~~~~~~~~~
The parking brake arm shaft has left hand

threads. To turn in the shaft, turn it counterclock-
wise.
b. Install the parking brake caliper arm "2" onto
the parking brake caliper arm shaft, and then
ESS30103
rotate the arm until it contacts the stopper "a".
REPLACING THE PARKING BRAKE PADS
1. Measure: a •
• Brake pad wear limit "a"
Out of specification ~ Replace the brake
pads and brake pad spring as a set.
Brake pad lining thickness limit

1.0 mm (0.04 in)
4-55
PARKING BRAKE
c. Install the parking brake caliper arm nut "3", 2. Adjust:

and then temporarily tighten it. • Parking brake lever free play
Refer to "ADJUSTING THE PARKING
BRAKE LEVER" on page 3-21 .
d. Insert a suitable tool "4" with a thickness of

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

17 Nm (1. 7 m-kgf, 12 ft-lbf)
f. Install the spring .

••••••••••••••••••••••••••••••••
ESS30104
INSTALLING THE PARKING BRAKE

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

40 Nm (4.0 m-kgf, 29 ft-lbf)
2. Adjust:
• Parking brake cable free play
Refer to "ADJUSTING THE PARKING
BRAKE LEVER" on page 3-2 1.
ESS30105
INSTALLING THE PARKING BRAKE LEVER

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

13 Nm (1.3 m-kgf, 9.4 ft-lbf)
4-56
PEDAL ASSEMBLV
EBS20028
PEDAL ASSEMBLY
Removing the pedal assembly
~ 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
16 Nm (1.6 m·kgf, 12 ft·lbf) -------------------~

Side frames 4-12.
Hood/ Front fender/Instrument panel Refer to "GENERAL CHASSIS (6)" on page

4-15.
Drain.
Brake master cylinder page 4-37.
Refer to "STEERING SYSTEM" on page
Steering joint 4-60.
1 Brake light switch 1
2 Throttle cable 1 Disconnect.
3 Pedal assembly 1
4-57
PEDAL ASSEMBLV
Disassembling the pedal assembly
11
·~· 8
3 10
9
'
)) 5
·~·4 5
6
17 Nm (1.7 m·kgf, 12 ft·lbf)
1 Pin 1
2 Brake pedal rod 1
3 Spring 1
4 Circlip 1
5 Washer 2
6 Brake pedal 1
7 Spring 1
8 Circlip 1
9 Washer 2
10 Accelerator pedal 1
11 Pedal assembly bracket 1
4-58
PEDAL ASSEMBLV
ESS30106
INSTALLING THE PEDAL ASSEMBLY

1. Install :
• Throttle cable
a. Turn the adjusting nut "1" until the specified
length is obtained.
b. Tighten the locknut "2" to specification .
Throttle cable locknut (accelera-

tor pedal end)
2.5 Nm (0.25 m-kgf, 1.8 ft-lbf)
••••••••••••••••••••••••••••••••
2. Adjust:
• Accelerator pedal free play
Refer to "ADJUSTING THE ACCELERATOR
PEDAL FREE PLAY" on page 3-22.
3. Adjust:
• Brake pedal free play
Refer to "ADJUSTING THE BRAKE PEDAL"
on page 3-20.
4. Adjust:
• Brake light operation timing
TIP ~~~~~~~~~~~~~~
Adjustment is correct when the brake light

comes on by depressing the brake pedal less
than 5.0-10.0 mm (0.20-0.39 in).
a. Hold the main body "1" of the brake light
switch so that it does not rotate and turn the
adjusting nut "2" in direction "a" or "b" until the
brake light comes on at the proper time.
Direction "a"
Brake light comes on sooner.
Direction "b"
Brake light comes on later.
4-59
STEERING SYSTEM
EBS20029
STEERING SYSTEM
Removing the steering assembly
21 Nm (2.1 m·kgf, 15 ft·lbf) 33 Nm (3.3 m·kgf, 24 ft·lbf)
3
40 Nm (4.0 m·kgf, 29 ft·lbf)
39 Nm (3.9 m·kgf, 28 ft·lbf)
5
. '
''"
' .,
'
., 1
40 Nm (4.0 m·kgf, 29 ft·lbf)

55 Nm (5.5 m·kgf, 40 ft·lbf)
~ 48 Nm (4.8 m·kgf, 35 ft·lbf)

55 Nm (5.5 m·kgf, 40 ft·lbf)
.,..-,----------/
~ 39 Nm (3.9 m·kgf, 28 ft·lbf)
* Apply MOLVKOTE® EM-30L GREASE.

Side frames 4-12.
Hood/ Front fender/Instrument panel Refer to "GENERAL CHASSIS (6)" on page

4-15.
1 Steering joint bolt 2
2 Steering column 1 Except for EPS models
EPS motor coupler Disconnect.

3 1
For EPS models
EPS torque sensor coupler Disconnect.

4 1
For EPS models
5 EPS unit 1 For EPS models
6 Steering joint 1
4-60
STEERING SYSTEM
Removing the steering assembly

21 Nm (2.1 m·kgf, 15 ft·lbf) 33 Nm (3.3 m·kgf, 24 ft·lbf)
40 Nm (4.0 m·kgf, 29 ft·lbf)
39 Nm (3.9 m·kgf, 28 ft·lbf)

7
,.....,,.....
~- . '
' ''"
' .,
'
1J .,
\' '
~
'
7
10 ~ 9
'*·'~
~I:
.. ~
••
• ' '
~ 33 Nm (3.3 m·kgf, 24 ft·lbf)

40 Nm (4.0 m·kgf, 29 ft·lbf)
55 Nm (5.5 m·kgf, 40 ft·lbf)
~ 48 Nm (4.8 m·kgf, 35 ft·lbf)

55 Nm (5.5 m·kgf, 40 ft·lbf)
10
~ 39 Nm (3.9 m·kgf, 28 ft·lbf)
* Apply MOLVKOTE® EM-30L GREASE.
7 Tie-rod end locknut 2

8 Steering assembly 1
9 Tie-rod end 2
10 Dust boot 2
TIP
11 Tie-rod set 2 Replace the tie-rod and lock washer as a
set.
4-61
STEERING SYSTEM
ESS30488
REMOVING THE TIE-ROD

1. Straighten the lock washer "a". '
,. I J
~
I
2. Check:
• Tie-rod end
Bends/damage ~ Replace.
2. Loosen:
Rubber boot damage ~ Replace the tie-rod
• Tie-rod "1"
end.
EBS30109
INSTALLING THE STEERING SYSTEM

1. Install:
• Lock washer "1" l~tii
TIP~~~~~~~~~~~~~~
Align the tabs "a" on the lock washer with the
groove "b" in the steering assembly.
ESS30107
CHECKING THE STEERING JOINT

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

tie-rod ends.
1. Check:
• Tie-rod end free play and movement
Rough movement~ Replace the tie-rod end.
4-62
STEERING SYSTEM
3. Bends the lock washer "a". TIP ~~~~~~~~~~~~~~
Tighten the steering assembly bolts in the prop-

er tightening sequence as shown .
FWD
' 1J 1 ~
I>'-----. ,..____.L___,~
~1tm11ITmm
4. Install :
• Dust boots
a. Fit the tabs "a" into the holes "b" in the boot 6. Install:
band "1". • Steering joint "1"
• Steering column "2" (except for EPS models)
• EPS unit "2" (for EPS models)
Steering column bolt (except for

EPS models)
21 Nm (2.1 m-kgf, 15 ft-lbf)
EPS unit bolt (for EPS models)
21 Nm (2.1 m-kgf, 15 ft-lbf)
Steering joint bolt
33 Nm (3.3 m-kgf, 24 ft-lbf)
b. Crimp the portion "c" of the boot band with the TIP ~~~~~~~~~~~~~~~
boots band installation tool "2".
• Align the alignment mark "a" on the steering
Boots band installation tool assembly shaft and the alignment mark "b" on
90890-01526 the steering joint with the alignment mark "c" on
Boots band installation tool the steering assembly housing .
YM-01526 • Fit the steering joint onto the steering column
shaft or EPS unit shaft so that the bolt hole "d"
in the joint is aligned with the area "e" on the
shaft that does not have splines.
a )
b
••••••••••••••••••••••••••••••••
5. Install :
• Steering assembly "1"
Steering assembly bolt

48 Nm (4.8 m-kgf, 35 ft-lbf)
4-63
STEERING SYSTEM
1
L
d
e
7. Adjust:
• Toe-in
Refer to "ADJUSTING TH E TOE-I N" on page
3-28.
ESS30426
LUBRICATING THE STEERING SHAFT

Lubricate the pivoting point and metal-to-metal
moving parts of the shaft.
I
Lithium-soap-based grease
4-64
STEERING KNUCKLES
EBS20030
STEERING KNUCKLES
Removing the steering knuckles
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
. 39 Nm (3.9 m·kgf, 28 ft·lbf)
7 8
9
30 Nm (3.0 m·kgf, 22 ft·lbf)
i~tws---0 I 4 8
30 Nm (3.0 m·kgf, 22 ft·lbf)

si~WI
~ 9 Nm (0.9 m·kgf, 6.5 ft·lbf)

the steering knuckles.
Front wheel hub
page 4-33.
1 Brake disc guard 1
2 Tie-rod end 1 Disconnect.
3 Front brake hose holder 1
4 Steering knuckle 1
5 Circlip 1
6 Ball joint 1
7 Oil seal 2
8 Bearing 2
9 Spacer 1
4-65
STEERING KNUCKLES
ESS30110
e. Apply lithium-soap-based grease to the spac-
REMOVING THE STEERING KNUCKLES
er, new bearings and oil seals.
f. Install the spacer to the steering knuckle.
steering knuckles.
g. Install the new bearings.
1. Remove:
• Steering knuckle "1" TIP - - - - - - - - - - - - - - - ~
TIP ~~~~~~~~~~~~~~
Install the wheel side bearing first.
EC.801620
Use a general puller to separate the ball joints
NOTICE
"2" from the steering knuckle "1" or the front low-
er arm "3".
-------------
Do not strike the inner race or balls of the
bearing. Contact should be made only with
the outer race.
h. Install the new oil seals.
2 1
t EBS30112
CHECKING THE STEERING KNUCKLE BALL

JOINTS
3 The following procedure applies to both of the
, 2
steering knuckle ball joints.
1. Check:
• Ball joint (steering knuckle)
ESS30111
CHECKING THE STEERING KNUCKLES Damage/pitting ~ Replace the ball joint.

AND FRONT WHEEL BEARINGS Rubber boot damage ~ Replace the ball
The following procedure applies to both of the joint.
steering knuckles and front wheel bearings. Rough movement ~ Replace the ball joint.
1. Check:
• Steering knuckle
Damage/pitting ~ Replace.
2. Check:
• Front wheel bearings "1"
Rough movement/excessive free play ~ Re-
place.
• O il seals "2"
Damage ~ Replace.
a. Clean the surface of the steering knuckle. TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
b. Remove the oil seals. a. Clean the surface of the steering knuckle.
c. Drive out the bearings. b. Remove the circlip "1".
EWB03030
A WARNING
Eye protection is recommended when using
striking tools.
y 2
c. Remove the ball joint "2".
TIP - - - - - - - - - - - - - - - ~
Use a suitable socket "3" to separate the ball
joint "2" from the steering knuckle "4".
4-66
STEERING KNUCKLES
No. Tool name Tool No.

6 Long bolt
90890-014 74
7 Body
YM-01474
8 Guide bolt
90890-014 77
9 Installer washer
YM-01477
t '--r---,-,' t 10 Base plate 35 mm

90890-01553
YM-01553
+--- 2
0
Ball joint installer at- 90890-01555
d. Measure the ball joint bore inside diameter 11
tachment 39 mm YS-01881-A
"a".
Out of specification ~ Replace the steering
knuckle. 8 11
7
9
Ball joint bore inside diameter
32.90-32.95 mm (1.295-1.297 in) 6
10
8
e. Attach the special tools and a new ball joint

"5" to the steering knuckle "4".
TIP ~ - - - - - - - - - - - - - - ~
• Always use a new ball joint. 8 4
• Do not tap or damage the top of the ball joint or f. Hold the base plate "1O" in place while turning
rubber boot. in the long bolt "6" to install the new ball joint
"5" into the steering knuckle "4".
Ball joint remover g. Remove the special tools.
90890-01474 h. Install a new circlip.
Ball joint remover
YM-01474 ••••••••••••••••••••••••••••••••
90890-01477
YM-01477
Base plate 35mm
90890-01553
Base plate 35mm
YM-01553
Ball joint installer attachment
39mm
90890-01555
39mm
YS-01881-A
4-67
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
ESS20031

Removing the front arm s and front shock absorber assemblies
~ 55 Nm (5.5 m·kgf, 40 ft·lbf)
5
~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
4
~ 30 Nm (3.0 m·kgf, 22 ft·lbf)
'
1
30 Nm (3.0 m·kgf, 22 ft·lbf)
7 Nm 0.7 m·k f, 5.1 ft·lbf

the front upper arms, front lower arms, and
front shock absorber assemblies.
Front wheel
page 4-33.
1 Front arm protector 1
4 Nut 2
5 Nut/Bolt (front shock absorber assembly) 2/2
6 Front shock absorber assembly 1
7 Nut/Bolt (front upper arm) 212
8 Front upper arm 1
9 Dust cover 2
4-68
Removing the front arms and front shock absorber assemblies

~ 55 Nm (5.5 m·kgf, 40 ft·lbf)
~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
~ 30 Nm (3.0 m·kgf, 22 ft·lbf)
11
'
7 Nm 0.7 m·k f, 5.1 ft·lbf
10 Nut/Bolt (front lower arm) 2/2

11 Front lower arm 1
12 Dust cover 2
13 Bushing 2
14 Circlip 1
15 Ball joint 1
16 Bushing 2
4-69
ESS30113
damage or personal injury that may result
CHECKINGTHEFRONTARMS
from improper handling of the front shock
absorber and gas cylinder.
front upper arms and front lower arms.
• Do not tamper or attempt to open the front
1. Check:
shock absorber or gas cylinder.
• Front arm free play
• Do not subject the front shock absorber or
a. Check the front arm side play "A" by moving gas cylinder to an open flame or any other
it from side to side. source of high heat. High heat can cause an
If side play is noticeable, check the bushings. explosion due to excessive gas pressure.
• Do not deform or damage the front shock
absorber or gas cylinder in any way. If the
front shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.
EBS301 15
DISPOSING OF A FRONT SHOCK

ABSORBER ASSEMBLY
Gas pressure must be released before dispos-
ing of a front shock absorber assembly. To re-
b. Check the front arm vertical movement "B" by
lease the gas pressure, drill a 2-3 mm (0.08-
moving it up and down.
0.1 2 in) hole through the front shock absorber at
If the vertical movement is tight or rough, or if a point 60-70 mm (2.4-2.8 in) from its end as
there is binding , check the bushings.
shown.
EWB03180
& WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
••••••••••••••••••••••••••••••••
2. Check:
-......, __________ _
• Front upper arm
• Front lower arm
EBS301 16
3. Check: CHECKINGTHEFRONTSHOCKABSORBER
• Bushings ASSEMBLIES
Wear/damage ~ Replace. The following procedure applies to both of the
EBS30114 front shock absorber assemblies.
HANDLINGTHEFRONTSHOCKABSORBER 1. Check:
ASSEMBLIES • Front shock absorber assembly
EWB03170
Oil leaks/gas leaks ~ Replace the front
& WARNING shock absorber assembly.
Shock absorbers and gas cylinders contain • Front shock absorber rod
highly compressed nitrogen gas. Before Bends/damage ~ Replace the front shock
handling the front shock absorber or gas cyl- absorber assembly.
inder, read and make sure you understand • Spring
the following information. The manufacturer Move the spring up and down.
cannot be held responsible for property
4-70
Fatigue ~ Replace the front shock absorber TIP ~~~~~~~~~~~~~~

assembly. • Always use a new ball joint.
ESS30117 • Do not tap or damage the top of the ball joint or
CHECKING THE FRONT ARM BALL JOINTS rubber boot.
front arm ball joints. Ball joint remover
1. Check: 90890-01474
• Ball joint (front upper arm) Ball joint remover
Damage/pitting ~ Replace the ball joint. YM-01474
Rubber boot damage ~ Replace the ball Ball joint remover adapter set
joint. 90890-01477
Rough movement ~ Replace the ball joint. Ball joint remover adapter set
YM-01477
Base plate 35mm
90890-01553
Base plate 35mm
YM-01553
39mm
90890-01555
39mm
YS-01881-A
a. Clean the surface of the front upper arm. No. Tool name Tool No.
b. Remove the circlip "1".
6 Long bolt
90890-014 74
7 Body
YM-01474
8 Guide bolt
90890-014 77
9 Installer washer
YM-01477
1 90890-01553
10 Base plate 35 mm
YM-01553
Ball joint installer at- 90890-01555
11
tachment 39 mm YS-01881-A
c. Remove the ball joint "2".

TIP ~~~~~~~~~~~~~~ 8 11
7 9
Use a suitable socket "3" to separate the ball
joint "2" from the front upper arm "4".
6
3
10
8
+--- 4
t~ ~t
'-r-----.._.,
,-__ 2
0
d. Attach the special tools and a new ball joint

"5" to the front upper arm "4".
4-71
Steering knuckle nut

30 Nm (3.0 m-kgf, 22 ft-lbf)
d. Install new cotter pins.

e. Tighten the front upper and lower arm nuts
"4" to specification .
Front arm nut

55 Nm (5.5 m-kgf, 40 ft-lbf)
e. Hold the base plate "1O" in place while turning

in the long bolt "6" to install the new ball joint
"5" into the front upper arm "4".
f. Remove the special tools.
g. Install a new circlip.
••••••••••••••••••••••••••••••••
ESS30118
INSTALLING THE FRONT ARMS AND

FRONT SHOCK ABSORBER ASSEMBLIES
front upper arms, front lower arms, and front 6,7
shock absorber assemblies.
1. Install:
• Front upper arm
• Front lower arm
• Front shock absorber assembly
a. Install the front upper arm "1" and front lower
arm "2".
TIP ~~~~~~~~~~~~~~ 8
• Lubricate the front upper and lower arm bolts
"3" with lithium-soap-based grease.
• Be sure to position the front upper and lower
arm bolts "3" so that the bolt heads face for-
ward.
• Temporarily tighten the front upper and lower
arm nuts "4".
b. Install the front shock absorber assembly "5",
bolts "6", and nuts "7".
Front shock absorber assembly

nut
55 Nm (5.5 m-kgf, 40 ft-lbf)
TIP ~~~~~~~~~~~~~~
• Install the front shock absorber assembly so

that the warning label is facing out.
• Be sure to position the front shock absorber
bolts "6" so that the bolt heads face forward.
c. Install the steering knuckle and nuts "8".
4-72
REAR KNUCKLES AND STABILIZER
EBS20032

Removing the rear knuckles and stabilizer
~ 85 Nm (8.5 m·kgf, 61 ft·lbf)
60 Nm 6.0 m·k f, 43 ft·lbf
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
·~·6
90 Nm (9.0 m·kgf, 65 ft·lbf)

the rear knuckles.
Rear wheel hub
page 4-33.
1 Rear brake disc cleaning plate 1
2 Brake disc guard 1
3 Rear knuckle 1
4 Spacer cover 4
5 Spacer 2
6 Oil seal 2
7 Bearing 2
8 Spacer 1
9 Stabilizer joint 2
4-73
Removing the rear knuckles and stabilizer
60 Nm 6.0 m·k f, 43 ft·lbf
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
90 Nm (9.0 m·kgf, 65 ft·lbf)

1O Stabilizer holder 2
11 Bushing 2
12 Stabilizer 1
4-74
EBS30119 EBS30121
CHECKINGTHEREARKNUCKLESAND INSTALLING THE STABILIZER

REAR WHEEL BEARINGS 1. Install:
The following procedure applies to both of the • Stabilizer "1"
rear knuckles and rear wheel bearings. • Bushing "2"
1. Check: • Stabilizer holder "3"
• Rear knuckle
Damage/pitting ~ Replace. Stabilizer holder bolt
2. Check: 85 Nm (8.5 m-kgf, 61 ft-lbf)
• Rear wheel bearings "1"
TIP ~~~~~~~~~~~~~~
Rough movement/excessive free play ~ Re-
place. Install the bushing with its slit "a" facing down-
• Oil seals "2" ward.
Damage ~ Replace.
a. C lean the surface of the rear knuckle.
b. Remove the oil seals.
c. Drive out the bearings.
EWB03030
A WARNING
Eye protection is recommended when using
striking tools. 0
d. Remove the spacer "3".
e. Apply lithium-soap-based grease to the spac-

er, new bearings and oil seals.
f. Install the spacer to the rear knuckle.
g. Install the new bearings.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~
Install the wheel side bearing first.
EC801620
NOTICE
-------------
Do not strike the inner race or balls of the
bearing. Contact should be made only with
the outer race.
h. Install the new oil seals.
EBS30120
CHECKING THE STABILIZER

1. Check:
• Stabilizer
Bends/cracks/damage ~ Replace.
4-75
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES
EBS20033

Removing the rear arms and rear shock absorber assemblies
7 Nm 0.7 m·k f, 5.1 ft·lbf

90 Nm (9.0 m·kgf, 65 ft·lbf)
~ Ia Nm (0.8 m·kgf, 5.8 ft·lbf) I

~ t\J 1 Nm (0.7 m·kgf, 5.1 ft·lbf) I
the rear upper arms, rear lower arms, and
rear shock absorber assemblies.
Rear wheel
page 4-33.
Refer to "REAR KNUCKLES AND STABI-
Stabilizer joint
LIZER" on page 4-73.
1 Rear arm protector 1
2 Rear brake hose holder 1
3 Nut/Bolt (rear shock absorber) 2/2
4 Rear shock absorber 1
5 Nut/Bolt (rear upper arm - rear knuckle) 1/1
6 Nut/Bolt (rear upper arm - frame) 2/2
7 Rear upper arm 1
8 Dust cover 2
4-76
Removing the rear arms and rear shock absorber assemblies
7 Nm 0.7 m·kgf, 5.1 ft·lbf)
-- l>\I8 Nm (0.8 m·kgf, 5.8 ft·lbf) I

VD\] 7 Nm (0.7 m·kgf, 5.1 ft·lbf) ]
9 Nut/Bolt (rear lower arm - rear knuckle) 1/1

10 Nut/Bolt (rear lower arm - frame) 2/2
11 Rear lower arm 1
12 Dust cover 2
13 Bushing 4
4-77
EBS30122
property damage or personal injury that may
CHECKING THE REAR ARMS result from improper handling of the rear
shock absorber and gas cylinder.
rear upper arms and rear lower arms.
• Do not tamper or attempt to open the rear
1. Check:
shock absorber or gas cylinder.
• Rear arm free play
• Do not subject the rear shock absorber or
a. Check the rear arm side play "A" by moving it gas cylinder to an open flame or any other
from side to side. source of high heat. High heat can cause an
If side play is noticeable, check the bushings. explosion due to excessive gas pressure.
• Do not deform or damage the rear shock
·i~
absorber or gas cylinder in any way. If the
0
' o, rear shock absorber, gas cylinder or both
'
~
are damaged, damping performance will
suffer.
E8S30t24
DISPOSING OF A REAR SHOCK ABSORBER

ASSEMBLY
Gas pressure must be released before dispos-
ing of a rear shock absorber assembly. To re-
b. Check the rear arm vertical movement "B" by
lease the gas pressure, drill a 2-3 mm (0.08-
moving it up and down.
0.1 2 in) hole through the rear shock absorber at
If the vertical movement is tight or rough, or if a point 40-50 mm (1 .6- 2.0 in) from its end as
there is binding , check the bushings.
shown .
EWB03180
A WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
-::r-
-
-- -- -- -- -_,...__
-----------'"' •-
••••••••••••••••••••••••••••••••
2. Check:
• Rear upper arm
• Rear lower arm
EBS30125
3. Check: CHECKINGTHEREARSHOCKABSORBER
• Bushings ASSEMBLIES
Wear/damage ~ Replace. The following procedure applies to both of the
EBS30123 rear shock absorber assemblies.
HANDLINGTHEREARSHOCKABSORBER 1. Check:
ASSEMBLIES • Rear shock absorber assembly
EWB03190
Oil leaks/gas leaks~ Replace the rear shock
A WARNING
absorber assembly.
This rear shock absorber and gas cylinder • Rear shock absorber rod
contain highly compressed nitrogen gas. Be- Bends/damage ~ Replace the rear shock
fore handling the rear shock absorber or gas absorber assembly.
cylinder, read and make sure you under- • Spring
stand the following information. The manu- Move the spring up and down.
facturer cannot be held responsible for
4-78
Fatigue ~ Replace the rear shock absorber

assembly.
EBS30126
INSTALLING THE REAR ARMS AND REAR

SHOCK ABSORBER ASSEMBLIES
rear upper arms, rear lower arms, and rear
shock absorber assemblies.
1. Install:
• Rear upper arm '
• Rear lower arm
• Rear shock absorber assembly
a. Install the rear upper arm "1" and rear lower
arm "2".
TIP ~~~~~~~~~~~~~~ ::!,-,L_/?
• Lubricate the rear upper and lower arm bolts 3,4
"3" with lithium-soap-based grease.
• Be sure to position the rear upper and lower
arm bolts "3" so that the bolt heads face for- '-'--_;~8 9
ward. '
• Temporarily tighten the rear upper and lower
arm nuts "4".
b. Install the rear shock absorber assembly "5",
bolts "6", and nuts "7".
Rear shock absorber assembly

nut
82 Nm (8.2 m-kgf, 59 ft-lbf)
TIP ~~~~~~~~~~~~~~~
• Install the rear shock absorber assembly so

that the warning label is facing rearward .
• Be sure to position the rear shock absorber
bolts "6" so that the bolt heads face forward.
c. Install the rear knuckle bolts "8", and nuts "9".
Rear knuckle nut

90 Nm (9.0 m-kgf, 65 ft-lbf)
d. Tighten the rear upper and lower arm nuts "4"

to specification.
Rear arm nut

55 Nm (5.5 m-kgf, 40 ft-lbf)
4-79
ENGINE
ENGINE INSPECTION .. ......... ......... .......... ......... .......... ........ ......... .......... ........ 5-1
MEASURING THE COMPRESSION PRESSURE ......... ........ ......... ......... . 5-1
ENGINE REMOVAL (1) .......... ......... .......... ......... .......... ........ ......... .......... ........ 5-2
INSTALLING THE EXHAUST PIPE AND MUFFLER ... ......... .......... ......... . 5-3
ENGINE REMOVAL (2) .......... ......... .......... ......... .......... ........ ......... .......... ........ 5-4
ASSEMBLING THE ENGINE MOUNT DAMPER STAY ........ ......... ......... . 5-5
INSTALLING THE ENGINE MOUNT DAMPER STAY .. ......... .......... ......... 5-5
ENGINE REMOVAL (3) .......... ......... .......... ......... .......... ........ ......... .......... ........ 5-7
INSTALLING THE ENGINE ...... .......... ........ ......... ......... .......... ......... ........ 5-12
CYLINDER HEAD .......... ......... .......... ......... ......... .......... ........ .......... ......... ...... 5-13
REMOVING THE CYLINDER HEAD ... ......... ........ ......... .......... ......... ....... 5-15
CHECKING THE CYLINDER HEAD .......... .......... ......... .......... ......... ....... 5-15
CHECKING THE CAMSHAFT SPROCKET ........ .......... ......... .......... ....... 5-16
CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET
COVER ......... .......... ......... ......... .......... ......... .......... ........ .......... ......... ...... 5-16
CHECKING THE TIMING CHAIN TENSIONER ..... ......... .......... .......... .... 5-16
INSTALLING THE CYLINDER HEAD ........ ......... .......... .......... ......... ....... 5-17
ROCKER ARMS AND CAMSHAFT ......... ........ .......... ......... ......... .......... ....... 5-20
REMOVING THE ROCKER ARMS AND CAMSHAFT ... .......... ......... ...... 5-21
CHECKING THE CAMSHAFT .. .......... ........ .......... .......... ......... .......... ...... 5-21
CHECKING THE DECOMPRESSION SYSTEM .... ......... .......... ......... ..... 5-21
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-22
INSTALLING THE CAMSHAFT AND ROCKER ARMS ........... .......... ..... 5-22
VALVES AND VALVE SPRINGS ..... .......... .......... .......... .......... .......... ........... 5-24
REMOVING THE VALVES ......... .......... .......... ......... .......... ........ .......... .... 5-25
CHECKING THE VALVES AND VALVE GUIDES .......... ......... ......... ...... 5-25
CHECKING THE VALVE SEATS ........ .......... ......... ......... .......... .......... .... 5-27
CHECKING THE VALVE SPRINGS .... ......... ........ .......... ......... .......... ...... 5-28
INSTALLING THE VALVES ...... .......... ......... .......... ........ .......... ......... ...... 5-29
CYLINDER AND PISTON ....... ......... .......... ......... .......... ........ ......... .......... ...... 5-31
REMOVING THE PISTON .......... ......... ......... ......... ........ ......... ......... ....... 5-32
CHECKING THE CYLINDER AND PISTON ....... ......... .......... ......... ........ 5-32
CHECKING THE PISTON RINGS ....... ......... ........ .......... ......... .......... ...... 5-33
CHECKING THE PISTON PIN .. ......... .......... ........ .......... ......... .......... ...... 5-34
INSTALLING THE PISTON AND CYLINDER ........ ........ .......... ......... ...... 5-34
AC MAGNETO AND STARTER CLUTCH ... .... .......... ......... .......... .......... ...... 5-36
REMOVING THE AC MAGNETO ROTOR ... ........ .......... ......... ......... ....... 5-38
REMOVING THE STARTER CLUTCH ........ .......... ........ .......... .......... ..... 5-38
CHECKING THE STARTER CLUTCH ......... ........ .......... ......... .......... ...... 5-39
CHECKING THE TORQUE LIMITER ......... ......... .......... ......... .......... ....... 5-39
INSTALLING THE STARTER CLUTCH ....... ........ .......... ......... ......... ....... 5-39
INSTALLING THE AC MAGNETO ROTOR ........ ......... .......... ......... ........ 5-39
ELECTRIC STARTER .. ......... ......... .......... ........ .......... ......... .......... ......... ....... 5-41
CHECKING THE STARTER MOTOR ........ .......... .......... ......... .......... ...... 5-43
ASSEMBLING THE STARTER MOTOR ...... ........ .......... ......... .......... ...... 5-44
BALANCER GEARS AND OIL PUMP GEARS ......... ......... .......... ......... ....... 5-45
REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP
DRIVEN SPROCKET ...... ......... .......... ......... .......... ......... ......... .......... ..... 5-47
CHECKING THE OIL PUMP GEARS ......... .......... ......... .......... .......... ...... 5-47
CHECKING THE BALANCER GEARS ...... .......... ......... .......... .......... ...... 5-47
INSTALLING THE BALANCER DRIVE GEAR, BALANCER DRIVEN
GEAR, AND OIL PUMP DRIVEN SPROCKET ..... ......... ......... .......... ..... 5-47
SHIFT LEVER ..... .......... ......... .......... ......... ........ .......... ......... .......... ......... ....... 5-49
CHECKING THE STOPPER LEVER .......... .......... ......... ........... ......... ..... 5-52
CHECKING THE SHIFT LEVERS ....... ......... ......... .......... .......... ......... ..... 5-52
INSTALLING THE SHIFT LEVERS ..... ......... .......... ......... ......... .......... ..... 5-52
ADJUSTING THE DRIVE SELECT LEVER SHIFT CABLE ..... ......... ...... 5-52
PRIMARY AND SECONDARY SHEAVES ... .... .......... ......... .......... .......... ...... 5-54
REMOVING THE PRIMARY AND SECONDARY SHEAVES .. ......... ...... 5-58
DISASSEMBLING THE SECONDARY SHEAVE ... ......... .......... ......... ..... 5-58
CHECKING THE V-BELT ......... .......... .......... ........ .......... ......... .......... ...... 5-59
CHECKING THE PRIMARY SHEAVE ....... .......... ......... .......... .......... ...... 5-59
CHECKING THE PRIMARY SHEAVE WEIGHTS .......... .......... ......... ...... 5-59
CHECKING THE PRIMARY SHEAVE SLIDERS ........... .......... .......... ..... 5-59
CHECKING THE SECONDARY SHEAVE ... ......... ......... ........... ......... ..... 5-59
ASSEMBLING THE PRIMARY SHEAVE ..... ......... ......... .......... ......... ...... 5-60
ASSEMBLING THE SECONDARY SHEAVE ........ ......... ......... ......... ....... 5-61
INSTALLING THE PRIMARY AND SECONDARY SHEAVES .. ......... ..... 5-62
CLUTCH .... ......... .......... ......... .......... ......... ........ .......... ......... .......... ......... ....... 5-65
REMOVING THE CLUTCH ......... ......... .......... ......... .......... ........ .......... .... 5-67
CHECKING THE CLUTCH ........ .......... ......... .......... ......... ......... .......... ..... 5-67
CHECKING THE CLUTCH SHOE ....... ......... .......... ........ .......... ......... ...... 5-67
ASSEMBLING THE CLUTCH HOUSING ..... .......... ........ .......... .......... ..... 5-68
INSTALLING THE CLUTCH ...... .......... ......... .......... ........ .......... .......... ..... 5-68
CRANKCASE ..... .......... ......... .......... ......... ........ .......... ......... .......... ......... ....... 5-70
SEPARATIN G THE CRANKCASE ..... .......... .......... ........ .......... ......... ...... 5-73
CHECKING TH E TIMING CHAIN AND TIMING CHAIN GUIDE ....... ...... 5-73
CH ECKING TH E RELIEF VALVE ...... .......... .......... ........ .......... ......... ...... 5-73
CH ECKING TH E BEARINGS .... .......... ......... ......... .......... .......... .......... .... 5-73
CHECKING TH E CRANKCASE ......... ........ .......... ......... .......... ......... ....... 5-74
ASSEMBLING TH E CRANKCASE ..... .......... ........ .......... .......... ......... ...... 5-74
CRANKSHAFT AND OIL PUMP ..... .......... ......... .......... ........ ......... .......... ...... 5-76
REMOVING TH E CRANKSHAFT ........ ......... .......... ........ .......... .......... .... 5-78
CHECKING TH E OIL PUMP ..... ......... .......... ........ .......... ......... ......... ....... 5-78
CHECKING TH E OIL STRAINER ...... .......... ........ .......... ......... .......... ...... 5-78
CH ECKING TH E CRANKSHAFT ........ ......... .......... ........ .......... ......... ...... 5-79
ASS EMBLING TH E OIL PUMP ......... ......... ......... ......... .......... ......... ........ 5-79
INSTALLING THE CRANKSHAFT ..... .......... .......... ........ .......... ......... ...... 5-79
TRANSMISSION .. .......... ......... .......... ......... ......... .......... ........ .......... ......... ...... 5-8 1
REMOVING TH E TRANSM ISSION ..... .......... .......... ......... ......... ......... .... 5-85
DISASSEMBLING THE DRIVE AXLE .......... ......... ......... .......... ......... ...... 5-85
CHECKING TH E SHIFT FORKS ........ .......... ........ .......... .......... ......... ...... 5-85
CH ECKING TH E SHIFT DRUM ......... ......... ......... .......... .......... ......... ...... 5-85
CHECKING TH E TRANSMISSION .... .......... ........ .......... ......... .......... ...... 5-86
CHECKING TH E SECONDARY SHAFT ...... .......... ........ .......... ......... ...... 5-86
ASSEMBLING TH E DRIVE AXLE ASSEMBLY ....... ......... ......... ......... .... 5-86
ASSEMBLING TH E SHIFT FORK ASSEMBLY ...... ......... ......... .......... .... 5-86
INSTALLING THE SHIFT FORKS AND SHIFT DRUM .. .......... .......... ..... 5-87
MIDDLE GEAR ... .......... ......... .......... ......... ........ .......... ......... .......... ......... ....... 5-88
REMOVING TH E MIDDLE DRIVE SHAFT ... .......... .......... ........ .......... .... 5-92
REMOVING TH E MIDDLE DRIVEN SHAFT .......... ........ .......... ......... ...... 5-92
CHECKING TH E PI NION GEARS ...... .......... ......... ......... ......... .......... ..... 5-93
INSTALLING TH E BEAR ING AND OIL SEALS ...... ......... ......... ......... ..... 5-94
INSTALLING THE MIDDLE DRIVEN SHAFT ..... .......... .......... ......... ....... 5-94
INSTALLING THE MIDDLE DRIVE SHAFT ......... ......... .......... .......... ...... 5-95
MEASUR ING TH E MIDDLE GEAR BACKLASH ..... ......... ......... ......... ..... 5-96
ALIGNING TH E MIDDLE GEAR ......... ......... .......... ........ .......... ......... ...... 5-97
ENGINE INSPECTION
ESS20105
ENGINE INSPECTION
ESS30135
MEASURING THE COMPRESSION a. W ith the throttle wide open, crank the engine
PRESSURE until the reading on the compression gauge
TIP - - - - - - - - - - - - - - - ~ stabilizes.
EW B03200
Insufficient compression pressure will result in a
AwARNING
loss of performance.
To prevent sparking, ground the spark plug
1. Measure: lead before cranking the engine.
• Valve clearance
Out of specification ~ Adjust. b. If the compression pressure is above the
Refer to "ADJUSTING TH E VALVE CLEAR- maximum specification, check the cylinder
ANCE" on page 3-3. head , valve surfaces and piston crown for
2. Start the engine, warm it up for several m in- carbon deposits.
utes, and then turn it off. Carbon deposits ~ Eliminate.
3. Lift the cargo bed. c. If the compression pressure is below the min-
4. Disconnect: imum specification , pour a teaspoonful of en-
• Spark plug cap gine oil into the spark plug bore and measure
5. Remove: again.
• Spark plug Refer to the following table.
ECB01870
Compression pressure (with oil applied into the
NOTICE cylinder)
--------------
Before removing the spark plug, use com- Reading Diagnosis
pressed air to blow away any dirt accumulat- Piston ring(s) wear or
ed in the spark plug well to prevent it from Higher than without oil
damage ~ Repair.
falling into the cylinder. Piston, valves, cylinder
6. Attach: head gasket or piston
Same as without oil
• Compression gauge "1" ring(s) possibly defec-
tive ~ Repair.
Compression gauge
90890-03081 ••••••••••••••••••••••••••••••••
8. Install:
Engine compression tester
YU-33223 • Spark plug
Spark plug
13 Nm (1.3 m-kgf, 9.4 ft-lbf)
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~
Before install ing the spark plug, clean the spark
plug and gasket surface.
9. Connect:
• Spark plug cap
1a.Lower the cargo bed.
7. Measure:
• Compression pressure
Out of specification~ Refer to steps (b) and
(c).
Standard compression pressure

(at sea level)
440-560 kPa (4.4-5.6 kgf/cm2,
62.6-79.6 psi)
5-1
ENGINE REMOVAL (1)
EBS20034
ENGINE REMOVAL (1)

Removing the muffler and exhaust pipe
~ 17 Nm (1.7 m·kgf, 12 ft·lbf)
20 Nm (2.0 m·kgf, 14 ft·lbf)

1
'
'
17 Nm (1.7 m·kgf, 12 ft·lbf)
23 Nm (2.3 m·kgf, 17 ft·lbf)
1 Muffler heat protector plate 1 Lift the cargo bed.

2 Spring 2
3 Muffler 1
4 Gasket 1
5 Muffler mount 1
6 Exhaust pipe 1
7 Gasket 1
5-2
ENGINE REMOVAL (1)
ESS30127
INSTALLING THE EXHAUST PIPE AND

MUFFLER 1
1. Install:
• Gasket "1" iltii
(muffler side)
EC8 01640
NOTICE
-------------
Be careful not to damage the muffler contact
1
surface of the gasket.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Install the gasket completely onto the exhaust
pipe "2" by pushing the side "a" of the gasket. If
the gasket is difficult to install, tap lightly on the
gasket with a soft-face hammer.
1@&1 2
.. rr7
,!,f~==t'"i
a
2. Install:
• Muffler mount "1"
Installed length "a"

34 mm (1.34 in)
3. Install:
• Springs "1"
TIP - - - - - - - - - - - - - - -
lnstall the springs so that the spring ends are
pointing inward as shown in the illustration .
5-3
ENGINE REMOVAL (2)
EBS20093
ENGINE REMOVAL (2)

Removing the Engine mount damper stay
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
51 Nm (5.1 m·kgf, 37 ft·lbf)
17 Nm (1.7 m·kgf, 12 ft·lbf)

2
1 Engine mount damper stay nut (engine side) 1 Lift the cargo bed.
2 Engine mount damper stay bolt (frame side) 1
3 Engine mount damper stay 1
4 Collar 1
5 Damper 1
6 Engine mount damper 2
7 Engine mount damper stay bracket 1
8 Exhaust pipe heat protector plate 1
9 Engine mount damper stay holder 1
5-4
ENGINE REMOVAL (2)
EBS30588
3. Install:
ASSEMBLING THE ENGINE MOUNT
• Engine mount damper stay "1"
DAMPER STAY
• Collar "2"
1. Install:
• Engine mount damper stay nut (engine side)
• Engine mount damper "1"
"3"
TIP ~~~~~~~~~~~~~~
• Engine mount damper stay bolt (frame side)
Fit the projection "a" on the engine mount damp- "4"
er "1" from the groove "b" in the engine mount • Engine mount damper stay bracket
damper stay "2". • Engine mount damper stay bracket bolt "5"
a. Temporary tighten the engine mount damper
stay bolVnut (engine side) "3".
b. Temporary tighten the engine mount damper
stay bolt (frame side) "4".
c. Temporary tighten the engine mount damper
stay bracket bolt "5" .
----; b
.~:::-....._ - 2
2 ~ ::,::3:~
''°'~ ~ ;:/ 1 ~~~
EBS30589
INSTALLING THE ENGINE MOUNT DAMPER

STAY
1. Install:
• Engine mount damper stay holder "1"
• Engine mount damper stay holder bolVnut "2"
• Engine mount damper stay holder fixed
screw "3" ••••••••••••••••••••••••••••••••
4. Tighten:
• Engine mount damper stay holder fixed lock-
nut "4" • Engine mount damper stay holder fixed
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT screw "1"
a. Temporary tighten the engine mount damper • Engine mount damper stay holder fixed lock-
stay holder bolVnut "2". nut "2"
b. Temporary tighten the engine mount damper • Engine mount damper stay holder bolt "3"
stay holder fixed screw "3" and locknut "4". • Engine mount damper stay bolt (frame side)
"4"
• Engine mount damper stay bracket bolt "5"
(0 • Engine mount damper stay nut (engine side)
"6"
TIP ~~~~~~~~~~~~~~
Tighten the nuts to specification in the proper

tightening sequence as shown .
••••••••••••••••••••••••••••••••
2. Install:
• Exhaust pipe heat protector plate
• Exhaust pipe heat protector plate bolt
Exhaust pipe heat protector plate

bolt
17 Nm (1. 7 m-kgf, 12 ft-lbf)
5-5
ENGINE REMOVAL (2)
Engine mount damper stay hold-

er fixed screw
4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
er fixed locknut
4.0 Nm (0.40 m-kgf, 2.9 ft-lbf)
er nut
51 Nm (5.1 m-kgf, 37 ft-lbf)
Engine mount damper stay bolt
(frame side)
51 Nm (5.1 m-kgf, 37 ft-lbf)
Engine mount damper stay
bracket bolt
51 Nm (5.1 m-kgf, 37 ft-lbf)
Engine mount damper stay nut
(engine side)
51 Nm (5.1 m-kgf, 37 ft-lbf)
""
""
"" "
"
" "
'"
ii I
ii I
I
I
ii I I
ii I I
IcL 5
ii I t
11\ _ _ _ ,.
I
I
3,6 "" '

'
"' ''
5-6
ENGINE REMOVAL (3)
EBS20120
ENGINE REMOVAL (3)

Removing the heat shield and disconnecting the couplers and leads
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
0t ,
/JV /
' ''
_J ,'
'-~
/'
C)
Cargo bed Refer to "GENERAL CHASSIS (1 O)" on

page 4-28.
Seat frames Refer to "GENERAL CHASSIS (2)" on page

4-4.

4-10.
Rear panels Refer to "GENERAL CHASSIS (7)" on page

4-20.
Center passenger compartment panel Refer to "GENERAL CHASSIS (7)" on page

4-20.
V-belt cooling ducts Refer to "GENERAL CHASSIS (9)" on page

4-26.
Drive select lever shift cable Disconnect.

Refer to "SHIFT LEVER" on page 5-49.
5-7
ENGINE REMOVAL (3)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
' ''
_J ,'
'-~
/'
'
C)
Drain.
Coolant Refer to "CHANGING THE COOLANT' on
page 3-9.
Thermostat outlet hose Disconnect.

Refer to "THERMOSTAT' on page 6-7.
Water pump inlet hose Disconnect.

Refer to "WATER PUMP" on page 6-10.
Disconnect.
Oil cooler outlet hose Refer to "OIL COOLER" on page 6-1 .
Air induction system hose (air cut-off valve to Disconnect.

Refer to "AIR INDUCTION SYSTEM" on
reed valve cover)
page 7-15.
Air intake silencer Refer to "THROTTLE BODY" on page 7-9.
Refer to "REAR CONSTANT VELOCITY
SHAFT ASSEMBLIES, FINAL DRIVE AS-
Rear drive shaft SEMBLY AND REAR DRIVE SHAFT" on
page 8-18.
5-8
ENGINE REMOVAL (3)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
' ''
_J ,'
'-~
/'
C) 1
1 Heat shield 1
2 Spark plug cap 1 Disconnect.
3 Coolant temperature sensor coupler 1 Disconnect.
4 Reverse switch coupler 1 Disconnect.
5 Gear position switch coupler 1 Disconnect.
6 Engine ground lead 1 Disconnect.
7 Starter motor lead 1 Disconnect.
8 Speed sensor coupler 1 Disconnect.
9 Crankshaft position sensor coupler 1 Disconnect.
10 AC magneto coupler 2 Disconnect.
5-9
ENGINE REMOVAL (3)
Removing the engine
7
6
5 a
3 7 -
B
42 Nm (4.2 m·kgf, 30 ft·lbf) 1O Nm 1.0 m·k f, 7.2 ft·lbf
1O Nm (1.0 m·kgf, 7.2 ft·lbf) . 42 Nm (4.2 m·kgf, 30 ft·lbf)
1 Engine mounting bolt (front) 2

2 Engine mounting bolt (front) 2
3 Engine bracket nut (rear) 2
TIP
4 Engine 1 Remove the engine from the top of the vehi-
cle.
5 Engine bracket nut (front) 2

6 Engine bracket (front) 2
7 Engine mounting bolt (rear) 2
5-10
ENGINE REMOVAL (3)
Removing the engine
a
8
42 Nm (4.2 m·kgf, 30 ft·lbf) 1O Nm 1.0 m·k f, 7.2 ft·lbf
1O Nm (1.0 m·kgf, 7.2 ft·lbf) . 42 Nm (4.2 m·kgf, 30 ft·lbf)
8 Engine mounting bolt (rear) 2

9 Engine bracket (rear) 2
5-11
ENGINE REMOVAL (3)
EBS30128
INSTALLING THE ENGINE

1. Install:
• Engine brackets (rear) "1"
(onto the engine)
6
• Engine mounting bolts (rear) (M10) "2"
• Engine mounting bolts (rear) (M6) "3"
TIP - - - - - - - - - - - - - -
Before installing the engine, tighten the engine
mounting bolts (rear) to specification . 2
Engine mounting bolt (rear) (M10)

42 Nm (4.2 m-kgf, 30 ft-lbf)
Engine mounting bolt (rear) (M6)
LOCTITE® 5
1
2. Install:
• Engine brackets (front) "4"
(onto the frame)
• Engine bracket nuts (front) "5"
• Engine "6"
• Engine bracket nuts (rear) "7"
• Engine mounting bolts (front) (M10) "8"
ECB01630
NOTICE
------------
Make sure that the engine does not strike the
brake pipe when installing it.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Do not fully tighten the bolts and nuts.
3. Tighten:
• Engine bracket nuts (front) "5"
• Engine bracket nuts (rear) "7"
Engine bracket nut (front)

42 Nm (4.2 m-kgf, 30 ft-lbf)
Engine bracket nut (rear)
42 Nm (4.2 m-kgf, 30 ft-lbf)
Engine mounting bolt (front)
(M10)
42 Nm (4.2 m-kgf, 30 ft-lbf)
Engine mounting bolt (front) (M6)
LOCTITE®
5-12
CYLINDER HEAD
EBS20035
CYLINDER HEAD
Removing the cylinder head
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
20 Nm (2.0 m·kgf, 14 ft·lbf)
~ 35 Nm (3.5 m·kgf, 25 ft·lbf)
1O Nm 1.0 m·k f, 7.2 ft·lbf
20 Nm (2.0 m·kgf, 14 ft·lbf)
. 1O Nm (1.0 m·kgf, 7.2 ft·lbf) 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
38 Nm (3.8 m·kgf, 27 ft·lbf) 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Rear panel (right) Refer to "GENERAL CHASSIS (7)" on page

4-20.
Frame cross member Refer to "GENERAL CHASSIS (1 O)" on

page 4-28.
Refer to "ENGINE REMOVAL (1 )" on page
Exhaust pipe 5-2.
Disconnect.
Engine oil Refer to "CHANGING THE ENGINE OIL'.' on
page 3-14.
Oil pipe (crankcase to cylinder head) Refer to "OIL COOLER" on page 6-1 .
Drain.
page 3-9.
Thermostat/Coolant temperature sensor Refer to "THERMOSTAT' on page 6-7.
Throttle body assembly Refer to "THROTTLE BODY" on page 7-9.
Reed valve assembly Refer to "AIR INDUCTION SYSTEM" on

page 7-15.
5-13
CYLINDER HEAD
Removing the cylinder head

13 Nm (1.3 m·kgf, 9.4 ft·lbf)
~ 20 Nm (2.0 m·kgf, 14 ft·lbf)
~ 35 Nm (3.5 m·kgf, 25 ft·lbf)
20 Nm (2.0 m·kgf, 14 ft·lbf)
6 ----- 7
. 1O Nm (1.0 m·kgf, 7.2 ft·lbf) 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
38 Nm (3.8 m·kgf, 27 ft·lbf) 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
1 Spark plug cap 1 Disconnect.

2 Spark plug 1
3 Cylinder head breather hose 1 Disconnect.
4 Camshaft sprocket cover 1
5 Tappet cover 2
6 Oil check bolt 1
7 Timing chain tensioner cap bolt 1
8 Timing chain tensioner 1
9 Timing chain tensioner gasket 1
10 Camshaft sprocket 1
11 Decompresser assembly 1
12 Cylinder head 1
13 Cylinder head gasket 1
14 Dowel pin 2
5-14
CYLINDER HEAD
EBS30129
4. Remove:
REMOVING THE CYLINDER HEAD
• Timing chain tensioner
1. Align:
• "I" mark "a" on the AC magneto rotor
• Camshaft sprocket
(with the stationary pointer "b" on the AC
• Timing chain
magneto cover)
TIP ~~~~~~~~~~~~~~
a. Turn the crankshaft counterclockwise. To prevent the timing chain from falling into the
crankcase, fasten it with a wire.
5. Remove:
• Cylinder head
TIP ~~~~~~~~~~~~~~~~
• Loosen the bolts in the proper sequence as

shown .
• Loosen each bolt 1/2 of a turn at a time. After
all of the bolts are fully loosened, remove them.
b. When the piston is at TDC on the compres-

sion stroke, align the "I" mark "c" on the cam-
shaft sprocket with the stationary pointer "d"
on the cylinder head . 1 2 3 4
x2 x2 x2
'
x2
••••••••••••••••••••••••••••••••
2. Loosen:
~8
• Camshaft sprocket bolts "1"
• Decompressor assembly bolts "2"
TIP ~~~~~~~~~~~~~~
While holding the AC magneto rotor nut with a

wrench , loosen the camshaft sprocket bolts and Cylinder head bolts "1"
decompressor assembly bolts. Length : 135 mm (5.31 in)
Cylinder head bolts "2"
Length : 145 mm (5.71 in)
Length : 39 mm (1 .54 in)
Length : 30 mm (1 .18 in)
EBS30130
CHECKING THE CYLINDER HEAD

1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
3. Loosen:
• Timing chain tensioner cap bolt
5-15
CYLINDER HEAD
ECB01851
c. If the limit is exceeded, resurface the cylinder
NOTICE
-------------- head as fallows.
Do not use a sharp instrument; otherwise, d. Place a 400- 600 grit wet sandpaper on the
the following may be damaged or scratched: surface plate and resurface the cylinder head
• Spark plug bore threads using a figure-eight sanding pattern.
• Valve seats
TIP - - - - - - - - - - - - - - - ~
To ensure an even surface, rotate the cylinder
head several times.
EBS30131
CHECKING THE CAMSHAFT SPROCKET

1. Check:
More than 1/4 tooth wear "a" ~ Replace the
camshaft sprocket and the timing chain as a
2. Check: set.
• Cylinder head
Damage/scratches ~ Replace.
• Cylinder head water jacket
Mineral deposits/rust ~ Eliminate.
b ............-
3. Measure: •••
• Cylinder head warpage
Out of specification ~ Resurface the cylinder 2
head.
Warpage limit
0.03 mm (0.0012 in) a. 1/4 tooth
b. Correct
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 1. Timing chain roller
a. Place a straightedge "1" and a thickness 2. Camshaft sprocket
gauge "2" across the cylinder head.
EBS30132
CHECKING THE TAPPET COVERS AND

CAMSHAFT SPROCKET COVER
tappet covers.
1. Check:
• Tappet cover
• Camshaft sprocket cover
EBS30133
CHECKING THE TIMING CHAIN TENSIONER

1. Check:
• Timing chain tensioner
2. Check:
• One-way cam operation
Rough movement ~ Replace the timing
chain tensioner.
3. Check:
J} ~ ~ • Timing chain tensioner cap bolt
b. Measure the warpage. Damage/wear~ Replace.
5-16
CYLINDER HEAD
• Spring
• One-way cam
• Timing chain tensioner rod
1 2 3 4
Damage/wear ~ Replace the timing chain
tensioner.
x2
4
x2 x2
1
'
x2
7 ..,,,.
EBS30134
INSTALLING THE CYLINDER HEAD

1. Install:
• Dowel pins
4 2 1
• Cylinder head gasket i~Mi
2. Install:
• Cylinder head 3. Install:
• Cylinder head bolts • Decompressor assembly
Cylinder head bolt "1" (onto the camshaft)
35 Nm (3.5 m-kgf, 25 ft-lbf) TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
Cylinder head bolt "2" a. Install the decompressor assembly onto the
35 Nm (3.5 m-kgf, 25 ft-lbf) camshaft, and then finger tighten the decom-
Cylinder head bolt "3" pressor assembly bolts "1".
38 Nm (3.8 m-kgf, 27 ft-lbf) b. Turn the crankshaft counterclockwise.
Cylinder head bolt "4" c. Align the "I" mark "a" on the AC magneto rotor
1 O Nm (1.0 m-kgf, 7.2 ft-lbf) with the stationary pointer "b" on the AC mag-
neto cover.
Cylinder head bolts "1" d. Align the "I" mark "c" on the camshaft sprock-
Length: 135 mm (5.31 in) et with the stationary pointer "d" on the cylin-
Cylinder head bolts "2" der head .
Length: 145 mm (5.71 in) e. Install the timing chain "2" onto the camshaft
Cylinder head bolts "3" sprocket "3", and install the camshaft sprock-
Length: 39 mm (1.54 in) et onto the camshaft, and then finger tighten
Cylinder head bolts "4" the camshaft sprocket bolts "4".
Length: 30 mm (1.1 8 in)
TIP~~~~~~~~~~~~~~
• Lubricate the threads and mating surface of

the cylinder head bolts "1" and "2" with molyb-
'E,j a
denum disulfide grease.
b~
• Lubricate the threads and mating surface of
the cylinder head bolts "3" with engine oil.
• Tighten the cylinder head bolts in the proper
tightening sequence as shown ( ~ 1 , ~2. and
so on) and torque them in two stages.
5-17
CYLINDER HEAD
d. Install the spring "5", a new copper washer

"6", and the timing chain tensioner cap bolt
"7".
Timing chain tensioner cap bolt

20 Nm (2.0 m-kgf, 14 ft-lbf)
TIP ~~~~~~~~~~~~~~
When installing the camshaft sprocket, be sure

to keep the timing chain as tight as possible on
the exhaust side.
ECB01860
NOTICE
--------------
Do not turn the crankshaft when installing ••••••••••••••••••••••••••••••••
5. Turn :
the camshaft to avoid damage or improper
valve timing. • Crankshaft
(several turns counterclockwise)
f. Remove the wire from the timing chain.
6. Check:
••••••••••••••••••••••••••••••••
4. Install:
• "I" mark "a"
A lign the "I" mark on the AC magneto rotor
• Timing chain tensioner with the stationary pointer "b" on the AC mag-
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT neto cover.
a. Remove the timing chain tensioner cap bolt,
• "I" mark "c"
copper washer, and spring .
A lign the "I" mark on the camshaft sprocket
b. Release the timing chain tensioner one-way
with the stationary pointer "d" on the cylinder
cam "1" and push the timing chain tensioner
head.
rod "2" all the way into the timing chain ten-
Out of alignment ~ Correct.
sioner housing.
Refer to the installation steps above.
c. Install the timing chain tensioner housing "3"

and a new gasket "4" onto the cylinder.
Timing chain tensioner bolt

TIP - - - - - - - - - - - - - - - ~
Install the gasket with its beaded side facing the
timing chain tensioner.
5-18
CYLINDER HEAD
7. Tighten:
• Camshaft sprocket bolts "1"
• Decompressor assembly bolts "2"
Camshaft sprocket bolt

20 Nm (2.0 m-kgf, 14 ft-lbf)
Decompression assembly bolt
20 Nm (2.0 m-kgf, 14 ft-lbf)
ECB01780
NOTICE
-------------
Be sure to tighten the camshaft sprocket
bolts to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• While holding the AC magneto rotor nut with a
wrench , tighten the camshaft sprocket bolts
and decompressor assembly bolts.
• After tightening the decompressor assembly
bolts, check that decompressor assembly
moves smoothly.
8. Measure:
• Valve clearance
Refer to "ADJUSTING THE VALVE CLEAR-
ANCE" on page 3-3.
5-19
ROCKER ARMS AND CAMSHAFT
EBS20036

Removing the rocker arms and camshaft
5 14 Nm 1.4 m·kgf, 1O ft·lbf)
~ 14 Nm (1.4 m·kgf, 1O ft·lbf) 6~ 5

3
1---_ 6
1O Nm (1.0 m·kgf, 7.2 ft·lbf)

•
-
B
Cylinder head Refer to "CYLINDER HEAD" on page 5-13.

1 Bearing retainer 1
2 Rocker arm shaft 2
3 Intake rocker arm 1
4 Exhaust rocker arm 1
5 Locknut 4
6 Valve adjusting screw 4
7 Camshaft 1
8 Decompressor lever 1
9 Decompressor lever pin 1
10 Bearing 1
5-20
EBS30136
REMOVING THE ROCKER ARMS AND Camshaft lobe dimensions

CAMSHAFT Lobe height (Intake) limit
1. Loosen: 42.885 mm (1.6884 in)
• Locknuts Base circle diameter (Intake)
• Valve adjusting screws limit
2. Remove: 36.850 mm (1.4508 in)
• Intake rocker arm shaft Lobe height (Exhaust) limit
• Exhaust rocker arm shaft 43.390 mm (1.7083 in)
• Intake rocker arm Base circle diameter (Exhaust)
limit
• Exhaust rocker arm
36.850 mm (1.4508 in)
TIP ~~~~~~~~~~~~~~
Remove the rocker arm shafts with the slide

hammer bolt "1" and weight "2".
Slide hammer bolt

90890-01083
Slide hammer bolt 6 mm
YU-01083-1
Weight
90890-01084
Weight
YU-01083-3
3. Measure:
ESS30137
• Camshaft runout
CHECKING THE CAMSHAFT Out of specification ~ Replace the camshaft.
1. Check:
Camshaft runout limit
• Camshaft lobes
0.015 mm (0.0006 in)
Blue discoloration/pitting/ scratches ~ Re-
place the camshaft.
2. Measure:
• Camshaft lobe dimensions "a" and "b" I
Out of specification ~ Replace the camshaft.
EBS30138
CHECKING THE DECOMPRESSION SYSTEM

1. Check:
• Decompression system
5-21
a. Check the decompression system with the Rocker arm shaft outside diame-
camshaft sprocket installed on the decom- ter limit
presser lever and the decompresser lever pin 11.950 mm (0.4705 in)
"1" installed in the camshaft.
b. Check that the decompresser lever pin "1"
projects from the camshaft.
c. Check that the decompresser cam "2" moves
smoothly.
5. Calculate:
• Rocker-arm-to-rocker-arm-shaft clearance
Out of specification ~ Replace the defective
part(s) .
Rocker-arm-to-rocker-arm-shaft
EBS30139 clearance limit
CHECKINGTHEROCKERARMSAND 0.080 mm (0.0032 in)
ROCKER ARM SHAFTS
The following procedure applies to all of the TIP ~~~~~~~~~~~~~~
rocker arms and rocker arm shafts. Calculate the clearance by subtracting the rock-
1. Check: er arm shaft outside diameter from the rocker
• Rocker arm arm inside diameter.
Damage/wear ~ Replace.
2. Check: EBS30140
• Rocker arm shaft INSTALLING THE CAMSHAFT AND ROCKER
Blue discoloration/excessive wear/pit- ARMS
ting/ scratches ~ Replace or check the lubri- 1. Install:
cation system . • Bearing "1"
3. Measure: (into the cylinder head "2")
• Rocker arm inside diameter TIP ~~~~~~~~~~~~~~~~
Out of specification ~ Replace.
• Apply engine oil to the bearing.
Rocker arm inside diameter limit • Install the bearing so that the seal "a" is facing
12.033 mm (0.4737 in) the camshaft.
Installed depth
O mm (0 in)
4. Measure: a-.
• Rocker arm shaft outside diameter
Out of specification ~ Replace. / b
b. Installed depth
5-22
2. Lubricate:
• Camshaft Recommended lubricant
l
• Decompresser lever pin Rocker arm inner surface
• Decompresser lever
Molybdenum disulfide grease
Rocker arm shaft
Recommended lubricant Engine oil
l
Camshaft
Molybdenum disulfide oil 6. Install:
Camshaft bearing, decompressor • Exhaust rocker arm "1"
lever pin, decompressor lever • Exhaust rocker arm shaft "2"
Engine oil • Intake rocker arm
• Intake rocker arm shaft
3. Install : TIP ~~~~~~~~~~~~~~
• Decompresser lever pin "1"
• Use a slide hammer bolt "3" to install the rocker
• Decompresser lever "2"
arm shaft.
TIP ~~~~~~~~~~~~~~ • Make sure the rocker arm shafts are complete-
Install the decompresser lever pin and decom- ly pushed into the cylinder head.
presser lever into the camshaft "3" as shown in
the illustration. Slide hammer bolt
90890-01 083
3 Slide hammer bolt 6 mm
J, YU-0108.3-1
4. Install :
• Camshaft "1"
TIP ~~~~~~~~~~~~~~~~
Install the camshaft so that the pins "a" become

horizontal.
a
5. Lubricate:
• Rocker arms
• Rocker arm shafts
5-23
VALVES AND VALVE SPRINGS
ESS20037

Removing the valves and valve springs
1
2
3
s ---
a
8
8
a

Refer to "ROCKER ARMS AND CAM-
Camshaft SHAFT' on page 5-20.
1 Valve cotter 8
2 Valve spring retainer 4
3 Valve spring 4
4 Exhaust valve 2
5 Intake valve 2
6 Valve stem seal 4
7 Valve spring seat 4
8 Valve guide 4
5-24
ESS30141
REMOVING THE VALVES

The following proced ure applies to all of the
valves and related components.
TIP ~~~~~~~~~~~~~~~~
Before removing the internal parts of the cylinder

head (e.g., valves, valve springs, valve seats) ,
make sure the valves properly seal.
1. Check:
• Valve sealing
Leakage at the valve seat ~ Check the valve 3. Remove:
face, valve seat, and valve seat width . • Valve spring retainer "1"
Refer to "CHECKING THE VALVE SEATS" • Valve spring "2"
on page 5-27. • Valve "3"
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT • Valve stem seal "4"
a. Pour a clean solvent "a" into the intake and • Valve spring seat "5"
exhaust ports. TIP ~~~~~~~~~~~~~~
b. Check that the valves properly seal. Identify the position of each part very carefully so
TIP ~~~~~~~~~~~~~~~~ that it can be reinstalled in its original place.
There should be no leakage at the valve seat "1".
i.............. ......._
. ......._
'
EBS30142
CHECKING THE VALVES AND VALVE

••••••••••••••••••••••••••••••••
2. Remove: GUIDES
The following procedure applies to a ll of the
• Valve cotters
valves and valve guides.
TIP ~~~~~~~~~~~~~~~~
1. Measure:
Remove the valve cotters by compressing the • Valve-stem-to-valve-guide c learance
valve spring with the valve spring compressor Out of specification ~ Replace the valve
"1" and the valve spring compressor attachment guide.
"2".
• Valve-stem-to-valve-guide clearance =
Valve guide inside diameter "a" -
Valve spring compressor Valve stem diameter "b"
90890-04019
Valve-stem-to-valve-guide clear-
YM-04019
ance (intake) limit
Valve spring compressor attach-
0.080 mm (0.0032 in)
ment
Valve-stem-to-valve-guide clear-
90890-01243
ance (exhaust) limit
Valve spring compressor adapt-
0.100 mm (0.0039 in)
er (26 mm)
YM-01253-1
5-25
(
a. Valve guide position
c. After installing the valve guide, bore the valve
guide with the valve guide reamer "3" to ob-
tain the proper valve-stem-to-valve-guide
clearance.
2. Replace:
• Valve guide
TIP~~~~~~~~~~~~~~
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 °c (212 °F) in an oven . TIP~~~~~~~~~~~~~~
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT After replacing the valve guide, reface the valve

a. Remove the valve guide with the valve guide seat.
remover "1".
Valve guide remover (06)
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
Valve guide installer (06)
90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
Valve guide reamer (06)
90890-04066
b. Install a new valve guide with the valve guide Valve guide reamer (6.0 mm)
YM-04066
installer "2" and valve guide remover "1".
Valve guide position

12.7-13.1 mm (0.50-0.52 in)
•3.•••••••••••••••••••••••••••••••
Eliminate:
• Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear~ Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem~ Replace the valve.
5-26
5. Measure:
• Valve stem runout
Out of specification ~ Replace the valve.
TIP ~~~~~~~~~~~~~~
• When installing a new valve, always replace

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

0.040 mm (0.0016 in) a. Apply blue layout fluid "b" onto the valve face.
//
b. Install the valve into the cylinder head.

ESS30143
c. Press the valve through the valve guide and
CHECKING THE VALVE SEATS
onto the valve seat to make a clear impres-
sion.
valves and valve seats.
d. Measure the valve seat width.
1. Eliminate:
TIP ~~~~~~~~~~~~~~
• Carbon deposits
(from the valve face and valve seat) Where the valve seat and valve face contacted
2. Check: one another, the blue layout fluid will have been
• Valve seat removed.
Pitting/wear~ Replace the cylinder head .
3. Measure: •4.•••••••••••••••••••••••••••••••
Lap:
• Valve seat width C "a"
• Valve face
Out of specification ~ Replace the cylinder
• Valve seat
head.
TIP ~~~~~~~~~~~~~~
Valve seat contact width (intake) After replacing the cylinder head or replacing the
1.00-1.20 mm (0.0394-0.0472 in) valve and valve guide, the valve seat and valve
Valve seat contact width (intake) face should be lapped.
limit
1.60 mm (0.0630 in) TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
Valve seat contact width (ex- a. Apply a coarse lapping compound "a" to the
haust) valve face.
EC B01360
1.00-1.20 mm (0.0394-0.0472 in)
NOTICE
Valve seat contact width (ex- -------------
haust) limit Do not let the lapping compound enter the
1.60 mm (0.0630 in) gap between the valve stem and the valve
guide.
5-27
a
b
b. Apply molybdenum disulfide oil onto the h. Install the valve into the cylinder head.
valve stem. 1. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
J. Measure the valve seat width "c" again. If the
valve seat width is out of specification , reface
and lap the valve seat.
c. Install the valve into the cylinder head .

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

seat while rotating the valve back and forth be- EBS30144
tween your hands. CHECKING THE VALVE SPRINGS

valve springs.
1. Measure:
• Compressed valve spring force "a"
Out of specification ~ Replace the valve
spring.
0
\) Installed compression spring
force (intake)
\\ 0 ~ 171.00-197.00 N (17 .44-20.09
~\....: kgf, 38.44 44.29 lbf)
e. Apply a fine lapping compound to the valve Installed compression spring
face and repeat the above steps. force ( exhaust)
171.00-197.00 N (17 .44-20.09
f. After every lapping procedure, be sure to
kgf, 38.44 44.29 lbf)
clean off all of the lapping compound from the
Installed length (intake)
valve face and valve seat. 35.00 mm (1.38 in)
g. Apply blue layout fluid "b" onto the valve face. Installed length (exhaust)
35.00 mm (1.38 in)
5-28
l
Molybdenum disulfide oil
b
-
b. Installed length m
2. Measure:
• Valve spring tilt "a"
Out of specification ~ Replace the valve 3. Install:
spnng . • Valve spring seat "1"
• Valve stem seal "2" m1~1'1!!(:j!llll(,"I
Spring tilt (intake) • Valve "3"
1.8 mm (0.07 in)
• Valve spring "4"
Spring tilt (exhaust)
1.8 mm (0.07 in) • Valve spring retainer "5"
(into the cylinder head)
TIP~~~~~~~~~~~~~~
- -- a • Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch "a"
facing up.
·-.......
I --....._
--.......
' ®-5
ESS30145
®-- 2 1~@1
INSTALLING THE VALVES
The following procedure applies to all of the 4
valves and related components. 3
1. Deburr:
• Valve stem end
(with an oil stone)
b. Smaller pitch
2. Lubricate:
4. Install:
• Valve stem "1"
• Valve cotters
• Valve stem seal "2" l~f:ii
(with the recommended lubricant)
5-29
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Install the valve cotters by compressing the
valve spring with the valve spring compressor
"1" and the valve spring compressor attachment
"2".

90890-04019
YM-04019
Valve spring compressor attach-
ment
90890-01243
Valve spring compressor adapt-
er (26 mm)
YM-01253-1
5. To secure the valve cotters onto the valve

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

Removing the cylinder and piston
7
8 31~-
9
10
'
·~t4ti 5 i
6
·~mus

Water jacket joint Refer to "WATER PUMP" on page 6-10.
1 Timing chain guide (exhaust side) 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 2
6 Piston pin 1
7 Piston 1
8 Top ring 1
9 2nd ring 1
10 Oil ring 1
5-31
CYLINDER AND PISTON
ESS30146
TIP ~~~~~~~~~~~~~~
REMOVING THE PISTON
1. Remove: When removing a piston ring , open the end gap
• Piston pin clips "1" with your fingers and lift the other side of the ring
• Piston pin "2" over the piston crown .
• Piston "3"
ECB01380
NOTICE
--------------
Do not use a hammer to drive the piston pin
out.
I
TIP ~~~~~~~~~~~~~~
• Before removing the piston pin clips, cover the

crankcase opening with a clean rag to prevent
the piston pin clips from falling into the crank-
case.
EBS30147
• Before removing the piston pin, deburr the pis-
CHECKING THE CYLINDER AND PISTON
ton pin clip grooves and the piston pin bore ar-
ea. If both areas are deburred and the piston
1. Check:
• Piston wall
pin is still difficult to remove, remove it with the
piston pin puller set "4". • Cylinder wall
Vertical scratches ~ Replace the cylinder,
and replace the piston and piston rings as a
Piston pin puller set set.
90890-01304
2. Measure:
Piston pin puller
YU-01304 • Piston-to-cylinder clearance
a. Measure the cylinder bore "C" with the cylin-
der bore gauge.
TIP - - - - - - - - - - - - - - - ~
Measure the cylinder bore "C" by taking side-to-
side and front-to-back measurements of the cyl-
inder.
Bore
102.000-102.010 mm (4.0157-
4.0161 in)
Wear limit
2 102.080 mm (4.0189 in)
Taper limit
0.050 mm (0.0020 in)
.. Out of round limit
0.050 mm (0.0020 in)
"C" = maximum of 0 1, 0 2, 0 3, 0 4, 0 5, 0 6
Taper (front-to-back) = maximum difference be-
tween 01 , 03, 05
4
Taper (side-to-side) = maximum difference be-
2. Remove: tween 0 2 , 0 4, 0 6
• Top ring
• 2nd ring Out of round (top)= difference between 0 1, 0 2
Out of round (middle)= difference between 0 3,
• O il ring
04
Out of round (bottom) = difference between 0 5,
05
5-32
CYLINDER AND PISTON
EBS30148
D, CHECKING THE PISTON RINGS

1. Measure:
• Piston ring side c learance
, ,. -----03---.. . ' Out of specification ~ Replace the piston
o. and piston rings as a set.
'
------ --
"">"
TIP ~~~~~~~~~~~~~~
Ds Before measuring the piston ring s ide clearance,

De e liminate any carbon deposits from the piston
ring grooves and piston rings.
b. If out of specification , replace the cylinder,
and replace the piston and piston rings as a Top ring
set. Ring side clearance limit
c. Measure piston skirt d iameter "P" with a mi- 0.12 mm (0.0047 in)
crometer. 2nd ring
Ring side clearance limit
Diameter 0.13 mm (0.0051 in)
101.955-101.970 mm (4.0140-
4.0146 in)
I· p
2. Install:
• Piston ring
a. 10.0 mm (0.39 in) from the bottom edge of the (into the cylinder)
piston
TIP ------------------------------~
d. If out of specification , replace the piston and Use the piston crown to level the piston ring near
piston rings as a set. bottom of cylinder "a", where cylinder wear is
e. Calculate the piston-to-cylinder clearance lowest.
with the following formula.
• Piston-to-cylinder clearance =
Cylinder bore "C" - a
Piston skirt diameter "P"
Piston-to-cylinder clearance
0.030-0.055 mm (0.0012-0.0022
in)
f. If out of specification , replace the cylinder, b

and replace the piston and piston rings as a
b. Upper of cylinder
set.
3. Measure:
• Piston ring end gap
Out of specification ~ Replace the piston
nng.
5-33
CYLINDER AND PISTON
TIP ~~~~~~~~~~~~~~
The oil ri ng expander end gap cannot be mea-

sured . If the oil ring rail gap is excessive, replace
all three piston rings.
)
Top ring
End gap (installed) limit
0.60 mm (0.024 in)
2nd ring
End gap (installed) limit
1.25 mm (0.049 in) EBS30150
Oil ring INSTALLING THE PISTON AND CYLINDER

End gap (installed) limit 1. Install:
0.20 mm (0.01 in) • Lower oil ring rail "1"
• Oil ring expander "2"
EBS30149 • Upper oil ring rail "3"
CHECKING THE PISTON PIN • 2nd ring "4"
1. Check: • Top ring "5"
• Piston pin
TIP ~~~~~~~~~~~~~~
Blue discoloration/grooves ~ Replace the
Be sure to install the piston rings so that the
piston pin, and then check the lubrication sys-
manufacturer marks or numbers face up.
tem.
2. Measure:
• Piston pin outside diameter "a"
Out of specification~ Replace the piston pin.
....... . . ,,, 1-5
Piston pin outside diameter limit =---~A,-4
22.971 mm (0.9044 in)
1-3
,---2
~ ~ , -1
/ 2. Install:
• Piston "1"
• Piston pin "2"
• Piston pin clips "3" ilt¥i
TIP ~~~~~~~~~~~~~~~~
a • Apply engine oil to the piston pin .
3. Measure: • Make sure the punch mark "a" on the piston
• Piston pin bore diameter "b" points towards the exhaust side of the cylinder.
Out of specification ~ Replace the piston. • Before installing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
Piston pin bore inside diameter the clips from falling into the crankcase.
limit
23.045 mm (0.9073 in)
1
a --~"'°
2
0--3IIM
5-34
CYLINDER AND PISTON
3. Install: TIP ~~~~~~~~~~~~~~
• Cylinder gasket ilf:Sl1i • Lubricate the threads and mating surface of

• Dowel pins the cylinder bolts "1" with engine oil.
4. Lubricate: • Finger tighten the bolts.
• Piston
8. Tighten:
• Piston rings
• Cylinder bolts "1"
• Cylinder
• Cylinder bolts (timing chain side) "2"
Cylinder bolt
I 1st
Engine oil
15 Nm (1.5 m-kgf, 11 ft-lbf)
2nd
5. Offset:
50 Nm (5.0 m-kgf, 36 ft-lbf)
• Piston ring end gaps
Cylinder bolt (timing chain side)
a 1 O Nm (1.0 m-kgf, 7.2 ft-lbf)
135"
;.--.
45•
2
45•
45• 45•
d C
a. Upper oil ring rail 2

b. Top ring
c. Oil ring expander
d. Lower oil ring rail
e. 2nd ring
A. Exhaust side
6. Install:
• Cylinder "1"
• Timing chain guide (exhaust side)
TIP ~~~~~~~~~~~~~~
• While compressing the piston rings with one

hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cavity.
7. Install:
• Cylinder bolts "1"
• Cylinder bolts (timing chain side) "2"
5-35
AC MAGNETO AND STARTER CLUTCH
EBS20039

Removing the AC magneto and starter clutch
~ 18 Nm (1.8 m·kgf, 13 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
a- 1.5 Nm 0.15 m·k f, 1.1 ft·lbf
~ ~ ~ ~3 ) ~ ~ - - - - - - - - - ,
- 30 Nm 3.0 m·k f, 22 ft·lbf
G) 60 Nm (6.0 m·kgf, 43 ft·lbf)
Rear panel (right) Refer to "GENERAL CHASSIS (7)" on page

4-20.
Drain.
page 3-14.
Drain.
page 3-9.
Water pump housing Refer to "WATER PUMP'' on page 6-10.
1 Stator coil coupler 2 Disconnect.
3 AC magneto cover 1
4 Oil pipe (AC magneto cover) 1
5 AC magneto cover gasket 1
6 Dowel pin 2
7 Lead holder 1
5-36
Removing the AC magneto and starter clutch

~ 1O Nm (1.0 m·kgf, 7.2 ft·lbf)
~ 18 Nm (1.8 m·kgf, 13 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
1.5 Nm 0.15 m·k f, 1.1 ft·lbf
- 30 Nm 3.0 m·k f, 22 ft·lbf
Gl 60 Nm (6.0 m·kgf, 43 ft·lbf)
8 Crankshaft position sensor 1

9 Stator coil 1
10 Torque limiter 1
11 Starter idle gear 1
12 Starter idle gear shaft 1
13 AC magneto rotor 1
14 Starter clutch 1
15 Woodruff key 1
16 Starter wheel gear 1
17 Washer 1
18 Bushing 2
5-37
ESS30151
REMOVING THE AC MAGNETO ROTOR

1. Remove:
ECB01390
NOTICE - -------------
To protect the end of the crankshaft, place an
• AC magneto cover appropriate sized socket between the fly-
TIP - - - - - - - - - - - - - - - wheel puller set center bolt and the crank-
Loosen each bolt 1/4 of a turn at a time, in stag- shaft.
es and in a crisscross pattern. After all of the TIP _ _ _ _ _ _ _ _ _ _ _ _ __
bolts are fully loosened, remove them.
• Use the flywheel puller "2".
• Make sure the flywheel puller is centered over
the AC magneto rotor.
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
2. Remove:
• AC magneto rotor nut "1"
• Washer
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Hold the AC magneto rotor "2" with the sheave
holder "3" while loosening the AC magneto ro-
tor nut.
• Do not allow the sheave holder to touch the
projection on the rotor. EBS30152
REMOVING THE STARTER CLUTCH

1. Remove:
Sheave holder
90890-01701 • Starter clutch bolts "1"
Primary clutch holder TIP _ _ _ _ _ _ _ _ _ _ _ _ __
YS-01880-A • Hold the AC magneto rotor "2" with the sheave
holder "3" while removing the starter clutch
bolts.
• Do not allow the sheave holder to touch the
projection on the AC magneto rotor.
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
3. Remove: 1
• AC magneto rotor "1"
(with the starter clutch) r
r
• Woodruff key
5-38
EBS30153
TIP ~~~~~~~~~~~~~~
CHECKING THE STARTER CLUTCH
1. Check: • Be sure to install the starter clutch (outer ring)
• Starter clutch rollers so that its side with the arrow mark "a" is facing
Damage/wear~ Replace. outward.
2. Check: • While holding the AC magneto rotor "2" with
• Starter idle gear the sheave holder "3", tighten the starter clutch
• Starter wheel gear bolts.
Burrs/chips/roughness/wear ~ Replace the • Do not allow the sheave holder to touch the
defective part(s) . projection on the AC magneto rotor.
3. Check:
• Starter clutch gear contact surfaces Sheave holder
Damage/pitting/wear~ Replace the defec- 90890-01701
tive part(s) . Primary clutch holder
4. Check: YS-01880-A
• Starter clutch operation
a. Install the starter wheel gear onto the starter 1
clutch, and then hold the starter clutch.
b. When turning the starter wheel gear counter-
clockwise "A", the starter clutch and the start-
er wheel gear should engage; otherwise, the
starter clutch is faulty and must be replaced. r
c. When turning the starter wheel gear clock- 3 _-,- r
w ise "B", it should turn freely; otherwise, the
starter clutch is faulty and must be replaced.
EBS30156
EBS30154
INSTALLING THE AC MAGNETO ROTOR
CHECKING THE TORQUE LIMITER 1. Install:
1. Check: • Woodruff key
• Torque limiter • AC magneto rotor
Damage/wear ~ Replace. • Washer
TIP ~~~~~~~~~~~~~~ • AC magneto rotor nut
Do not disassemble the torque limiter. TIP ~~~~~~~~~~~~~~
• Clean the tapered portion of the crankshaft and

EBS30155 the AC magneto rotor hub.
INSTALLING THE STARTER CLUTCH • When installing the AC magneto rotor, make
1. Install : sure the woodruff key is properly seated in the
• Starter clutch keyway of the crankshaft.
• Starter clutch bolts "1" • Lubricate the threads of the crankshaft with en-
gine oil.
Starter clutch bolt
30 Nm (3.0 m-kgf, 22 ft-lbf)
LOCTITE®
5-39
• After installing the AC magneto rotor, check

that the AC magneto rotor rotates smoothly. If AC magneto cover bolt
not, reinstall the woodruff key and AC magneto 1 O Nm (1.0 m -kgf, 7.2 ft-lbf)
rotor.
TIP ~~~~~~~~~~~~~~
2. Tighten: • Align the slot "a" in the impeller shaft "1" with
• AC magneto rotor nut "1" the projection "b" on the oil pump shaft "2".
• Tighten the AC magneto cover bolts in stages,
AC magneto rotor nut
60 Nm (6.0 m-kgf, 43 ft-lbf) using a crisscross pattern .
TIP ~~~~~~~~~~~~~~
• Hold the AC magneto rotor "2" with the sheave __,

holder "3" while tightening the AC magneto ro-
tor nut.
fl
• Do not allow the sheave holder to touch the n
projection on the AC magneto rotor.
Sheave holder
90890-01701
YS-01880-A
3. Apply:
• Sealant
(onto the crankshaft position sensor/stator
assembly lead grommet)
Yamaha bond No. 1215

90890-85505
4. Install:
• AC magneto cover
5-40
ELECTRIC STARTER
EBS20040
ELECTRIC STARTER
Removing the starter motor
1 O Nm (1.0 m·kgf, 7.2 ft·lbf)
~ 4.9 Nm (0.49 m·kgf, 3.5 ft·lbf)

1
.----,~, ',,"' , '

', '
.. ,, ,
........
,, ' '
,,
,
,, , ,
,,
'
'
''
' ,,
''
'
','
''
'
Refer to "GENERAL CHASSIS (1 O)" on

Frame cross member
page 4-28.
Air intake silencer Refer to "THROTTLE BODY" on page 7-9.
1 Negative battery lead 1 Disconnect.
2 Starter motor lead 1 Disconnect.
3 Starter motor 1
5-41
ELECTRIC STARTER
Disassembling the starter motor
4 .9 Nm 0.49 m·k f, 3.5 ft·lbf
~ 11 Nm (1.1 m·kgf, 8.0 ft·lbf)

4
1 Starter motor front cover 1

2 Starter motor rear cover 1
3 Washer kit 1
4 Armature assembly 1
5 Brush set 1
6 Starter motor yoke 1
5-42
ELECTRIC STARTER
ESS30157
CHECKING THE STARTER MOTOR Digital circuit tester

1. Check: 90890-03174
• Commutator Model 88 Multimeter with ta-
Dirt~ Clean with 600-grit sandpaper. chometer
2. Measure: YU-A1927
• Commutator diameter "a"
Out of specification ~ Replace the starter
Armature coil
motor.
Commutator resistance "1"
0.0250--0.0350 n
Commutator diameter limit
27.0 mm (1.06 in) Insulation resistance "2"
Above 1 Mn
b. If any resistance is out of specification , re-

place the starter motor.
~
.
<== Q)
1
I I
3. Measure: I I
•r
• Mica undercut "a"
Out of specification ~ Cut the mica to the
proper measurement with a hacksaw blade ••••••••••••••••••••••••••••••••
5. Measure:
that has been grounded to fit the commutator.
• Brush length "a"
Mica undercut (depth) Out of specification ~ Replace the brush set.
0.70 mm (0.03 in)
Brush overall length limit
TIP~~~~~~~~~~~~~~ 5.00 mm (0.20 in)
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
182 10~02
6. Check:
• Gear teeth
4. Measure: Damage/wear ~ Replace the armature as-
• Armature assembly resistances (commutator sembly.
and insulation) 7. Check:
Out of specification ~ Replace the starter • Bushing
motor. • Bearing
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT • Oil seal
a. Measure the armature assembly resistances Damage/wear ~ Replace the starter motor.
w ith the digital circuit tester.
5-43
ELECTRIC STARTER
EBS30158
ASSEMBLING THE STARTER MOTOR

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

4.9 Nm (0.49 m-kgf, 3.5 ft-lbf)
TIP ~~~~~~~~~~~~~~~
Align the match marks "a" on the starter motor

yoke with the match marks "b" on the starter mo-
tor front and rear covers.
b a b
3
2 1 0
5-44
BALANCER GEARS AND OIL PUMP GEARS
ESS20041

Removing the balancer gears and oil pump gears
85 Nm (8.5 m·kgf, 61 ft·lbf)
11@&
3 l@M
22 Nm (2.2 m·kgf, 16 ft·lbf)

Rear panel (right) 4-20.
Drain.
page 3-14.
Drain.
page 3-9.
Water pump housing Refer to "WATER PUMP'' on page 6-10.
Refer to "AC MAGNETO AND STARTER
Starter wheel gear CLUTCH" on page 5-36.
1 Lock washer 1
2 Balancer driven gear 1
3 Lock washer 1
4 Oil pump drive gear 1
5 Oil pump driven sprocket 1
5-45
Removing the balancer gears and oil pump gears
85 Nm (8.5 m·kgf, 61 ft·lbf)
-
m 10
22 Nm (2.2 m·kgf, 16 ft·lbf)
6 Chain 1
7 Straight key 1
8 Spacer 1
9 Plate 1
10 Balancer drive gear 1
11 Spring 8
12 Pin 4
5-46
EBS30159
REMOVING THE BALANCER DRIVEN GEAR

AND OIL PUMP DRIVEN SPROCKET
1. Straighten the lock washer tabs.
2. Loosen:
• Balancer driven gear nut "1"
• O il pump driven sprocket nut "2"
TIP ~~~~~~~~~~~~~~~
Place a aluminum plate "3" between the teeth of

the balancer drive gear "4" and balancer driven
gear "5", and then loosen the nuts. 2. Install:
• Spacer
• Oil pump drive gear
• Oil pump driven sprocket "1"
• Chain "2"
TIP ~~~~~~~~~~~~~~
Install the oil pump driven sprocket with the

"3B4" mark "a" facing out.
EBS30160
0
0
CHECKING THE OIL PUMP GEARS
1. Check:
0
• O il pump drive gear
• O il pump driven sprocket
Cracks/wear/damage ~ Replace.
EBS30161
CHECKING THE BALANCER GEARS 3. Install:

1. Check: • Balancer driven gear "1"
• Balancer drive gear TIP ~~~~~~~~~~~~~~~
• Balancer driven gear
Align the punch mark "a" on the balancer drive
Damage/wear ~ Replace the balancer drive
gear "2" with the punch mark "b" on the balancer
gear and balancer driven gear as a set.
driven gear.
Excessive noise during operation ~ Replace
the balancer drive gear and balancer driven
gear as a set.
EBS30162
INSTALLING THE BALANCER DRIVE GEAR,

BALANCER DRIVEN GEAR, AND OIL PUMP
DRIVEN SPROCKET
1. Install:
• Balancer drive gear
(onto the buffer boss)
• Pins
• Springs 4. Install:
• Oil pump driven sprocket nut "1"
TIP ~~~~~~~~~~~~~~~
• Balancer driven gear nut "2"
• Align the punch mark "a" on the balancer drive
gear with the hole "b" in the buffer boss. • Lock washers i~M
• Be sure to install a pin to every other spring.
5-47
Oil pump driven sprocket nut

22 Nm (2.2 m-kgf, 16 ft-lbf)
Balancer driven gear nut
85 Nm (8.5 m-kgf, 61 ft-lbf)
TIP ~~~~~~~~~~~~~~
• Apply the engine oil to the threads of shafts

and nuts.
• Place a aluminum plate "3" between the teeth
of the balancer drive gear "4" and balancer
driven gear "5", and then tighten the nuts.
5. Bend the lock washer tabs along the balancer

driven gear nut and oil pump driven sprocket
nut.
5-48
SHIFT LEVER
EBS20042
SHIFT LEVER
Removing the drive select lever unit and drive select lever shift cable
2 ~ 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
13 Nm 1.3 m·k f, 9.4 ft·lbf
39 Nm 3.9 m·k f, 28 ft·lbf
'
~
\
3
16 Nm (1.6 m·kgf, 12 ft·lbf)

Side frames 4-12.

4-15.
1 Drive select lever shift cable 1 Disconnect.
2 Drive select lever unit 1
3 Drive select lever shift cable bracket 1
5-49
SHIFT LEVER
Disassembling the drive select lever unit
~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

1
6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
C)
I
7
1 Drive select lever knob 1

2 Drive select lever guide 1
3 Dust cover 1
4 Drive select lever 1
5 Spring 1
6 Shift arm 1
7 Drive select lever unit housing 1
5-50
SHIFT LEVER
Removing the shift levers and stopper lever
14 Nm (1.4 m·kgf, 10 ft·lbf)

_____,,,,,
s i~tM
. 14 Nm (1.4 m·kgf, 10 ft·lbf) ~ 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Rear panel (right) 4-20.
1 Drive select lever shift cable 1 Disconnect.
2 Shift arm 1
4 Shift lever cover 1
5 Shift lever cover gasket 1
6 Dowel pin 1
7 Shift lever 1 1
8 Stopper lever spring 1
9 Shift lever 2 1
10 Stopper lever 1
5-51
SHIFT LEVER
EBS30163
3. Install:
CHECKING THE STOPPER LEVER
1. Check: • Oil seal "1" ilf:d
• Stopper lever (into the shift lever cover "2")
Installed depth "a"
• Stopper lever spring 1.0-1.5 mm (0.04-0.06 in)
EBS30164
CHECKING THE SHIFT LEVERS

1. Check:
• Shift lever 1
ilt4W1
• Shift lever 2
ESS30165
INSTALLING THE SHIFT LEVERS

1. Install :
• Shift lever 2 assembly "1"
4. Install:
Shift lever 2 bolt • Shift arm "1"
14 Nm (1.4 m-kgf, 1 O ft-lbf) TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Align the slit "a" in the shift arm with the projec-
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ tion "b" on shift lever 1.
Align the projection "a" on the shift drum w ith the
slit "b" in the stopper lever.
EBS30166
ADJUSTING THE DRIVE SELECT LEVER

2. Install : SHIFT CABLE
EWB03060
• Shift lever 1 "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ NOTICE
- - - - - - - - - - - --
Before moving the drive select lever, bring
When installing shift lever 1, align the alignment
the vehicle to a complete stop and take your
mark "a" on shift lever 1 with the punch marks "b"
foot off the accelerator pedal. Otherwise, the
on shift lever 2 "2".
transmission may be damaged.
1. Check:
• Drive select lever free play "a"
Out of specification ~ Adjust the drive select
lever shift cable.
Drive select lever free play

Less than 4 mm (0.16 in)
5-52
SHIFT LEVER
~ ::-...\
M ' I
/ I \ \
H I I
I \
'\ ',... !R.
~\~ ',
I
\
\
\
'' . . . ,.. ....,_.. ...,' , '·'~'

...h' '
,-,, ./l a
Rts ""
N I '·' ; r '\\ I I
.... ,. ' '
' , , ',\" '
a L---:::::::::::-::::=
. . __-;~- /
2. Check:
• Drive select lever shift cable length "a" 3 L
L
Drive select lever shift cable

length
165 mm (6.50 in)
TIP ~~~~~~~~~~~~~~
When checking the drive select lever shift cable

length , shift the drive select lever into "N" (neu-
e. Tighten the locknut to specification .
tral).
Drive select lever shift cable lock-
nut
39 Nm (3.9 m-kgf, 28 ft-lbf)
f. Tighten the drive select lever shift cable

bracket bolts to specification .
Drive select lever shift cable

bracket bolt (drive select lever
side)
16 Nm (1.6 m-kgf, 12 ft-lbf)
3. Adjust:
• Drive select lever shift cable length g. Turn the main switch to " a " (on) , and then
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT check that the drive select lever can be shift-
a. Loosen the drive select lever shift cable ed to each shift position and that the appropri-
bracket bolts "1". ate indicator light comes on when the lever is
b. Set the drive select lever "2" and shift lever "3" in each position .
in "N" (neutral) position.
••••••••••••••••••••••••••••••••
d. Turn the adjusting nut "5" in direction "a" or "b"
until the specified cable length is obtained.
Direction "a"
Shift cable length is increased.
Direction "b"
Shift cable length is decreased.
5-53
PRIMARY AND SECONDARY SHEAVES
EBS20043

Removing the primary and secondary sheaves
~ 1O Nm (1.0 m·kgf, 7.2 ft·lbf)
6
'
190 Nm (19 m·kgf, 137 ft·lbf)

1
Order
Job/Parts to remove Q 'ty

·~-2 1O Nm 1.0 m·k f, 7.2 ft·lbf
Remarks

page 4-28.
Rear panel (left) Refer to "GENERAL CHASSIS (7)" on page

4-20.
Seat frames Refer to "GENERAL CHASSIS (2)" on page

4-4.

4-10.
V-belt cooling ducts Refer to "GENERAL CHASSIS (9)" on page

4-26.
1 Drive belt cover 1
2 Rubber gasket 1
3 Bearing housing 1
4 Dowel pin 2
5 Primary sheave assembly 1
6 V-belt 1
5-54
Removing the primary and secondary sheaves
1~t41110
~ 1O Nm (1.0 m·kgf, 7.2 ft·lbf)

'
190 Nm (19 m·kgf, 137 ft·lbf)
1O Nm (1.0 m·kgf, 7.2 ft·lbf) 1O Nm 1.0 m·k f, 7.2 ft·lbf
7 Primary fixed sheave 1

8 Secondary sheave assembly 1
9 Drive belt case 1
10 Rubber gasket 1
11 Rubber gasket 1
5-55
Disassembling the primary sheave
6 i~fMI 7
81~[-
6 l~t=i\ll
2"1!i}J
(8)
1 3.0 Nm (0.30 m•kgf, 2.2 ft•lbf)
• Apply Yamaha Grizzly grease or Yamaha grease F.

1 Primary sheave cap 1
2 Primary sheave slider 4
3 Primary sheave cam 1
4 Primary sheave weight 8
5 Spacer 1
6 Oil seal 2
7 Primary sliding sheave 1
8 0-ring 1
5-56
Disassembling the secondary sheave
8 ---.J
91ltM
5
l~t=iJ
7
4
91~- ,
90 Nm (9.0 m•kgf, 65 ft·lbf)

2
1
* Apply Yamaha grease Hor POLYREX EM®
1 Secondary sheave spring retaining nut 1

2 Upper spring seat 1
3 Compression spring 1
4 Lower spring seat 1
5 Guide pin 4
6 Secondary sliding sheave 1
7 0-ring 2
8 Secondary fixed sheave 1
9 Oil seal 2
5-57
ESS30167
REMOVING THE PRIMARY AND Sheave fixed block

SECONDARY SHEAVES 90890-04135
1. Loosen: Sheave fixed bracket
• Primary sheave assembly nut "1" YM-04135
TIP ~~~~~~~~~~~~~~ Locknut wrench
90890-01348
Use the sheave holder "2" to hold the primary
Locknut wrench
sheave. YM-01348
Sheave holder 90890-04134
90890-01701 Sheave spring compressor
Primary clutch holder YM-04134
YS-01880-A
b. Place the sheave fixed block in a vise and se-
cure it.
c. Tighten the sheave spring compressor nut "5"
and compress the spring.
d. Loosen the secondary sheave spring retain-
ing nut "1" with the locknut wrench "3".
e. Remove the secondary sheave spring retain-
ing nut "1".
f. Remove the sheave spring compressor and
locknut wrench.
2. Loosen:
• Secondary sheave assembly nut "1"
TIP ~~~~~~~~~~~~~~~~ 1
Shift the transm ission into "R" (reverse), set the
parking brake, and then loosen the secondary
sheave assembly nut.
II II
II II
II iI
EBS30168
DISASSEMBLING THE SECONDARY

SHEAVE
1. Remove:
• Secondary sheave spring retaining nut "1"
a. Attach the sheave fixed block "2", locknut
wrench "3" and sheave spring compressor "4"
to the secondary sheave assembly.
5-58
2. Check:
• Primary sliding sheave
• Primary fixed sheave
3
EBS30171
CHECKING THE PRIMARY SHEAVE

2
WEIGHTS
The following procedure applies to all of the pri-
mary sheave weights.
1. Check:
• Primary sheave weight
ESS30169 Cracks/damage/wear~ Replace.
CHECKING THE V-BELT 2. Measure:
1. Check: • Primary sheave weight outside diameter "a"
• V-belt "1" Out of specification ~ Replace.
Cracks/damage/wear~ Replace.
Grease/oil~ Clean the primary and second- Primary sheave weight outside
ary sheaves. diameter
2. Measure: 30 mm (1.18 in)
Limit
• V-belt width "a"
29.5 mm (1.16 in)
V-belt width limit

32.5 mm (1.28 in) a
r- a--1
\ I
EBS30172
CHECKING THE PRIMARY SHEAVE

SLIDERS
ESS30170
The following procedure applies to all of the pri-
CHECKING THE PRIMARY SHEAVE mary sheave sliders.
1. Check: 1. Check:
• Primary sliding sheave splines • Primary sheave slider
Wear/cracks/damage ~ Replace. Cracks/damage/wear~ Replace.
• Primary sheave cam EBS30173
Cracks/damage~ Replace. CHECKING THE SECONDARY SHEAVE

1. Check:
0 • Secondary fixed sheave
• Secondary sliding sheave
Cracks/damage/wear ~ Replace the sec-
ondary fixed and sliding sheaves as a set.
2. Check:
• Torque cam grooves "1"
Damage/wear ~ Replace the secondary
fixed and sliding sheaves as a set.
5-59
3. Check:
• Guide pins "2" 1
Damage/wear ~ Replace the secondary 3
fixed and sliding sheaves as a set. 2
2. Install:
• Oil seals "1" 1~f4ij
(into the primary sliding sheaver "2")
4. Check: Installed depth "a"

• Secondary sheave spring O mm (0 in)
Damage ~ Replace.
5. Measure:
• Secondary sheave spring free length "a"
1~f4'41
Out of specification ~ Replace the second-
ary sheave spring.
Free length
130.6 mm (5.14 in)
Limit
128.0 mm (5.04 in)
3. Lubricate:
• Spacer inner surface
• Primary sliding sheave inner surface
Yamaha Grizzly grease or
Yamaha grease F
TIP ~~~~~~~~~~~~~~
• Apply Yamaha Grizzly grease or Yamaha

ESS30174 grease F (2.5 g) to the inner surface of the
ASSEMBLING THE PRIMARY SHEAVE spacer.
1. Clean : • Apply Yamaha Grizzly grease or Yamaha
• Primary sliding sheave "1" grease F (2.5 g) to the inner surface of the pri-
• Spacer "2" mary sliding sheave.
• Primary sheave weights "3"
• Primary sheave cam
TIP~~~~~~~~~~~~~~
Remove any excess grease.
5-60
4. Install:
• Primary sheave weights "1" 1
2
TIP ~~~~~~~~~~~~~~
Apply Yamaha Grizzly grease or Yamaha

0
grease F (90 g) to the whole outer surface of the
-;_.
weights and install.

'
0
3. Install:
• Secondary sliding sheave
4. Install:
• Guide pins "1"
ESS30175
ASSEMBLING THE SECONDARY SHEAVE

1. Install:
• O il seals "1" iltii
(into the secondary sliding sheave "2")
Installed depth "a"

O mm (0 in) 5. Lubricate:
• Guide pin grooves "1"
2 (with the recommended lubricant)
l
Yamaha grease Hor POLYREX
a EM®
a
~
TIP ~~~~~~~~~~~~~~
Apply Yamaha grease Hor POL YREX EM®(5.0

g) to the guide pin grooves.
2. Lubricate:
• Secondary sliding sheave "1"
• Secondary fixed sheave "2"
l
Yamaha grease Hor POLYREX
EM®
TIP ~~~~~~~~~~~~~~
Apply Yamaha grease Hor POLYREX EM® (15 6. Install:

g) to the inner surfaces of the secondary • Lower spring seat "1"
sheaves. • Compression spring "2"
• Upper spring seat "3"
• Secondary sheave spring retaining nut "4"
5-61
a. Attach the sheave fixed block "5", locknut
(
wrench "6" and sheave spring compressor "7"
to the secondary sheave.
Sheave fixed block

90890-04135
Sheave fixed bracket ,::: ~ I I
YM-04135
Locknut wrench - = II I
90890-01348 '--J
Locknut wrench e. Remove the sheave spring compressor, lock-

YM-01348 nut wrench , and sheave fixed block.
90890-04134 ••••••••••••••••••••••••••••••••
Sheave spring compressor E8S30t76
YM-04134 INSTALLING THE PRIMARY AND

SECONDARY SHEAVES
b. Place the sheave fixed block in a vise and se- 1. Install:
cure it. • Secondary sheave
c. Tighten the sheave spring compressor nut "8" • V-belt
and compress the spring . • Primary fixed sheave
d. Install the secondary sheave spring retaining • Primary sheave
nut "4" and tighten it to specification using the TIP ~~~~~~~~~~~~~~~~
locknut wrench . • Be sure to push in the primary sheave cam "1"
when installing the primary sheave so that the
Secondary sheave spring retain-
primary sheave weights "2" will be properly po-
ing nut
sitioned "a".
90 Nm (9.0 m-kgf, 65 ft-lbf)
• Tightening the bolts "3" (90101-06016) will
push the secondary sliding sheave away,
TIP ~~~~~~~~~~~~~~
causing the gap between the secondary fixed
Install the secondary sheave spring retaining nut
and sliding sheaves to widen.
"4" with its tapered side "a" facing the secondary
• Install the V-belt so that its arrow points in the
sheaves.
direction of rotation as shown in the illustration.
1-nrgJr-- 6
I ll:;]
3 2
'1-- 2
5-62
Sheave holder
90890-01701
YS-01880-A
2. Check:
• Primary sheave weights position
Out of specification ~ Repeat step (1).
TIP ~~~~~~~~~~~~~~
To check that the primary sheave weights "1"

are installed correctly, make sure that the sec- 4. Tighten:
ondary sheave "2", primary sheave "3", and V- • Secondary sheave assembly nut "1"
belt "4" are positioned as shown in the illustra-
tion. Secondary sheave assembly nut
100 Nm (1 O m•kgf, 72 ft·lbf)
TIP ~~~~~~~~~~~~~~
Shift the transmission into "L" (low) or "H" (high),
2 set the parking brake, and then tighten the sec-
ondary sheave assembly nut.
3
1
5. Lubricate:
• Bearing housing oil seal inner surface
3 (with the recommended lubricant)
A. Correct position
l Lithium-soap-based grease
B. Incorrect position
TIP ~~~~~~~~~~~~~~
3. Tighten:
• Primary sheave assembly nut "1" Apply 2.3 g or more of lithium-soap-based
grease to the groove in the oil seal as shown in
Primary sheave assembly nut the illustration.
190 Nm (19 m•kgf, 137 ft·lbf)
TIP~~~~~~~~~~~~~~
Use the sheave holder "2" to hold the primary

sheave.
5-63
5-64
CLUTCH
EBS20044
CLUTCH
Removing the clutch
190 Nm 19 m·k f, 137 ft·lbf
(7)
I
I
I
I
0 I
l - - - - - - - - - - - --------~
~

Drive belt case
1 Clutch housing assembly 1
2 Clutch housing assembly gasket 1
3 Dowel pin 2
4 Clutch carrier assembly nut 1 Left-hand threads
5 Clutch carrier assembly 1
5-65
CLUTCH
Disassembling the clutch housing assembly
s i~M
9 8
i~t=iVI 4
5
-
3
m
21~·
1 ll1~"f:t!lll,lllijl \
-
m
1 Oil seal 1
2 Circlip 1
3 Bearing housing 1
4 Circlip 1
5 Bearing 1
6 Seal ring 1
7 One-way clutch bearing 1
8 Bearing 1
9 Clutch housing 1
5-66
CLUTCH
ESS301n
• One-way clutch bearing
REMOVING THE CLUTCH
Chafing/ wear/damage~ Replace.
1. Remove:
TIP ~~~~~~~~~~~~~~
• Clutch housing assembly
• Replace the one-way clutch bearing and clutch
TIP - - - - - - - - - - - - - - - ~
housing as a set.
Working in crisscross pattern , loosen each bolt
• The one-way clutch bearing must be installed
1/4 of a turn . Remove them after all of them are
with the flange side facing inward .
loosened.
2. Check:
• One-way clutch operation
a. Install the one-way clutch bearing and clutch
carrier assembly to the clutch housing and
hold the clutch carrier assembly.
b. When turning the clutch housing clockwise
"A", it should turn freely; otherwise, the one-
way clutch assembly is faulty and must be re-
placed.
c. When turning the clutch housing counter-
2. Straighten: clockwise "B", the clutch housing and crank-
• Punched portion "a" of the clutch carrier as- shaft should engage; otherwise, the one-way
sembly nut "1" clutch assembly is faulty and must be re-
3. Remove: placed.
• Clutch carrier assembly nut "1"
EC801710
NOTICE
-------------
The clutch carrier assembly nut has left-
hand threads. To loosen the clutch carrier
assembly nut, turn it clockwise.
B
TIP ~~~~~~~~~~~~~~
\
Use a clutch holding tool "2" to hold the clutch
carrier assembly.

90890-04086 EBS30179
Universal clutch holder CHECKING THE CLUTCH SHOE

YM-91042 1. Check:
• Clutch shoe
Glazed areas ~ Sand with coarse sandpa-
per.
TIP - - - - - - - - - - - - - - - ~
After sanding the glazed areas, clean the clutch
with a cloth .
2. Measure:
• Clutch shoe thickness
ESS30178
Clutch shoe thickness limit
CHECKING THE CLUTCH
1.0 mm (0.04 in)
1. Check:
• Clutch housing
5-67
CLUTCH
---- 1 · ~ ·
a. Clutch shoe wear limit EBS30181
INSTALLING THE CLUTCH

EBS30180
ASSEMBLING THE CLUTCH HOUSING 1. Install:

1. Install: • Clutch carrier assembly
• Bearing "1" • Clutch carrier assembly nut "1" ilM
(into the clutch housing "2")
Clutch carrier assembly nut
Installed depth "a" 190 Nm (19 m•kgf, 137 ft·lbf)
2.5-2.7 mm (0.10-0.11 in) ECB01720
NOTICE
a - - - - - - - - - - - - -
The clutch carrier assembly nut has left-
hand threads. To tighten the clutch carrier
assembly nut, turn it counterclockwise.
TIP - - - - - - - - - - - - - - - ~
• Lubricate the threads of the clutch carrier as-
sembly nut with molybdenum disulfide grease.
• Use a clutch holding tool "2" to hold the clutch
carrier assembly.
2. Install:
• One-way clutch bearing 90890-04086
TIP ~~~~~~~~~~~~~~ Universal clutch holder
The one-way clutch bearing should be installed YM-91042
in the clutch housing with the "OUT SIDE" mark
"a" facing the clutch housing. 2. Lock the threads with a drift punch .
3. Install:
3. Install: • Dowel pins
• Oil seal "1" i~M • Gasket ilM
(into the bearing housing "2") • Clutch housing assembly
Installed depth "a" Clutch housing assembly bolt
O mm (0 in) 1 O Nm (1.0 m•kgf, 7.2 ft·lbf)
5-68
CLUTCH
TIP ~~~~~~~~~~~~~~
• Tighten the bolts in stages, using a crisscross

pattern.
• After tightening the bolts, check that the clutch
housing assembly rotates smoothly.
5-69
CRANKCASE
EBS20045
CRANKCASE
Separating the crankcase
7 Nm (0.7 m·kgf, 5.1 ft·lbf) 18 Nm (1.8 m·kgf, 13 ft·lbf)

13,!11 Nm (1.7 m·kgf, 12 ft·lbf) I

26 Nm (2.6 m·kgf, 19 ft·lbf)
(3)
30 Nm 3.0 m·k f, 22 ft·lbf

~ 42 Nm (4.2 m·kgf, 30 ft·lbf)
1
~ 1O Nm (1.0 m·kgf, 7.2 ft·lbf)
'
'-
1 O Nm (1.0 m·kgf, 7.2 ft·lbf)
~ 1O Nm 1.0 m·k f, 7.2 ft·lbf

42 Nm 4.2 m·k f, 30 ft·lbf ~ 1O Nm (1.0 m·kgf, 7.2 ft·lbf)

Engine 5-7.
Oil cooler Refer to "OIL COOLER" on page 6-1 .
Refer to "CYLINDER AND PISTON" on page
Piston
5-31 .
Refer to "AC MAGNETO AND STARTER
Starter wheel gear CLUTCH" on page 5-36.
Refer to "ELECTRIC STARTER" on page
Starter motor
5-41 .
Refer to "BALANCER GEARS AND OIL
Balancer gears/Oil pump gears PUMP GEARS" on page 5-45.
Shift levers Refer to "SHIFT LEVER" on page 5-49.
Drive belt case
Clutch carrier assembly Refer to "CLUTCH" on page 5-65.
1 Timing chain guide (intake side) 1
2 Timing chain stopper guide (lower) 1
5-70
CRANKCASE
Separating the crankcase
7 Nm (0.7 m·kgf, 5.1 ft·lbf) 18 Nm (1.8 m·kgf, 13 ft·lbf)

8 r~,l 11 Nm (1.7 m•kgf, 12 ft•lbf) I

26 Nm (2.6 m·kgf, 19 ft·lbf)
(3)
30 Nm 3.0 m·k f, 22 ft·lbf
~ 42 Nm (4.2 m·kgf, 30 ft·lbf)

13
~ 1O Nm (1.0 m·kgf, 7.2 ft·lbf)
'
'-
10
~ 10Nm 1.0 m·k f, 7.2 ft·lbf

42 Nm 4.2 m·k f, 30 ft·lbf ~ 1O Nm (1.0 m·kgf, 7.2 ft·lbf)
3 Timing chain 1
4 Speed sensor 1
5 Dipstick 1
6 Relief valve assembly 1
7 Reverse switch 1
8 Gear position switch 1
9 Thermostat outlet hose guide 1
10 Engine bracket 2
11 Crankcase (left) 1
12 Dowel pin 2
13 Crankcase (right) 1
5-71
CRANKCASE
Removing the crankcase bearings
1~
2
·~-3 1O Nm (1.0 m·kgf, 7.2 ft·lbf)
'
7
7

Refer to "CRANKSHAFT AND OIL PUMP"
Crankshaft/Oil pump
on page 5-76.
Transmission Refer to "TRANSMISSION" on page 5-81 .
Middle drive shaft/Middle driven shaft Refer to "MIDDLE GEAR" on page 5-88.
1 Collar 1
2 0-ring 1
3 Oil seal 1
5 Spacer 1
6 Crankshaft seal 2
7 Bearing 9
5-72
CRANKCASE
EBS30182
SEPARATING THE CRANKCASE

1. Remove:
• Crankcase bolts
TIP ~~~~~~~~~~~~~~~~ •
•
•
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
2. Check:
• Timing chain guide (intake side)
EBS30184
CHECKING THE RELIEF VALVE

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

ECB01400
1. Check:
NOTICE~~~~~~~~~~~~ • Bearings
Tap on one side of the crankcase with a soft- Clean and lubricate, then rotate the inner
face hammer. Tap only on reinforced por- race with a finger.
tions of the crankcase, not on the crankcase Roughness~ Replace.
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa- !
rate evenly. /
ESS30183
CHECKING THE TIMING CHAIN AND TIMING

CHAIN GUIDE
1. Check:
• Timing chain
Damage/stiffness ~ Replace the timing
chain and camshaft sprocket as a set.
5-73
CRANKCASE
EBS30186
CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a
1
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
• Crankcase
• O il delivery passages
Obstruction~ B low out with compressed a ir.
5. Fit the crankcase (left) onto the crankcase
ESS30187 (right). Tap lightly on the crankcase with a
ASSEMBLING THE CRANKCASE soft hammer.
1. Install : ECB01730
NOTICE
• O il seal "1" i@M -------------
(into the crankcase (left) "2") Before tightening the crankcase bolts, make
sure the transmission gears shift correctly
Installed depth "a" when the shift drum assembly is turned by
1.0-1.5 mm (0.04-0.06 in) hand.
6. Install:
11@& • Crankcase bolts
7. Tighten:
• Crankcase bolts
Crankcase bolt "1"

2~
26 Nm (2.6 m -kgf, 19 ft-lbf)
Crankcase bolt "2" "3"
1 O Nm (1.0 m -kgf, '7.2 ft-lbf)
M S x 40 mm "1"
2. Thoroughly clean the crankcase mating sur- M6 x 60 mm "2"
faces. M6 x 30 mm "3"
3. Apply: TIP - - - - - - - - - - - - - - - ~
• Sealant "1" Tighten the bolts in stages, using a crisscross
(onto the crankcase mating surfaces) pattern.
Yamaha bond No. 1215
90890-85505
TIP ~~~~~~~~~~~~~~
• Apply two coats of sealant to the area "a"

shown in the illustration.
• Do not allow any sealant to come into contact
with the o il gallery.
4. Install :
• Dowel pins "2"
5-74
CRANKCASE
2_ 3
I
-- ,
x2
y
x3
1 2 3
x3 x2
y
x6
A. Crankcase (left)
B. Crankcase (right)
8. Apply:
• 4-stroke engine oil
(onto the crankshaft pin , bearings and oil de-
livery hole)
9. Check:
• Crankshaft and transmission operation
Rough operation~ Repair.
5-75
CRANKSHAFT AND OIL PUMP
EBS20046

Removing the crankshaft and oil pump
2 l~f4W
.............. •'
Separate.
Crankcase Refer to "CRANKCASE" on page 5-70.
1 Oil pump 1
2 Oil pump gasket 1
3 Balancer 1
4 Crankshaft 1
5-76
Disassembling the oil pump
5
,
4
5 Nm 0.5 m•k f, 3.6 ft·lbf

1 Oil pump housing cover 1
2 Pin 1
3 Oil pump shaft 1
4 Oil pump inner rotor 1
5 Oil pump outer rotor 1
6 Oil pump housing 1
5-77
EBS30188
REMOVING THE CRANKSHAFT Inner-rotor-to-outer-rotor-tip

1. Remove: clearance limit
• Crankshaft "1" 0.20 mm (0.0079 in)
TIP ~~~~~~~~~~~~~~~~ Outer-rotor-to-oil-pump-housing
• Remove the crankshaft with the crankcase clearance limit
0.240 mm (0.0094 in)
separating tool "2". Oil-pump-housing-to-inner-and-
• Make sure the crankcase separating tool is outer-rotor clearance limit
centered over the crankshaft. 0.17 mm (0.0067 in)
ECB01880
NOTICE~~~~~~~~~~~~
• To protect the end of the crankshaft, place
an appropriate sized socket between the
crankcase separating tool bolt and the
crankshaft.
• Do not tap on the crankshaft.
Crankcase separating tool

90890-01135
Crankcase separator
YU-01135-B
1. Inner rotor
EBS30189 2. Outer rotor
CHECKING THE OIL PUMP 3. Oil pump housing
1. Check:
• Oil pump 3. Check:
Cracks/damage/wear~ Replace the oil • Oil pump operation
pump. Rough movement ~ Replace the oil pump.
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance "a"
• Outer-rotor-to-oil-pump-housing clearance
"b"
• Oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance "c"
Out of specification ~ Replace the oil pump.
EBS30190
CHECKING THE OIL STRAINER

1. Check:
• Oil strainer
Damage ~ Replace the oil pump.
Contaminants ~ Clean with solvent.
5-78
ESS30191
5. Check:
CHECKING THE CRANKSHAFT
• Crankshaft journal
1. Measure:
Scratches/wear ~ Replace the crankshaft.
• Crankshaft width "a"
• Crankshaft journal oil passage
Out of specification ~ Replace the crank-
Obstruction~ Blow out with compressed air.
shaft.
EBS30192
Crank assembly width ASSEMBLING THE OIL PUMP

74.92-75.00 mm (2.950-2.953 in) 1. Lubricate:
• Inner rotor
2. Measure: • Outer rotor
• Crankshaft runout "b" • Oil pump shaft
Out of specification ~ Replace the crank- (with the recommended lubricant)
shaft.
Runout limit l
Engine oil
0.030 mm (0.0012 in)
2. Install:
3. Measure: • Oil pump housing "1"
• Big end side clearance "c" • Oil pump outer rotor "2"
Out of specification ~ Replace the crank- • Oil pump inner rotor "3"
shaft. • Oil pump shaft "4"
• Pin "5"
Big end side clearance
TIP ~~~~~~~~~~~~~~~
0.350-0.650 mm (0.0138-0.0256
in) To install the oil pump shaft "4", align the pin "5"
with the groove "a" in the inner rotor "3".
C a
b b 4
i 3. Check:
5
• Oil pump operation

Refer to "CHECKING TH E O IL PUMP" on
page 5-78.
EBS30193
INSTALLING THE CRANKSHAFT

I.. a
.. I 1. Install:
• Crankshaft "1"
TIP ~~~~~~~~~~~~~~~
Install the crankshaft with the crankshaft installer
4. Check: pot "2", crankshaft installer bolt "3", adapter
• Crankshaft sprocket (M 16) "4", spacer (crankshaft installer) "5", and
Damage/wear ~ Replace the crankshaft. spacer "6".
• Bearing
Cracks/damage/wear~ Replace the crank-
shaft.
5-79
Crankshaft installer pot

90890-0127 4
Installing pot
YU-90058
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
Adapter (M16)
90890-04130
Adapter #13
YM-04059
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
Spacer
90890-04167
Spacer
YM-04167
ECB0l890
NOTICE
-------------
App Iy engine oil to each bearing to protect
the crankshaft against scratches and to
make installation easier.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of the
crankshaft installer bolt with the other. Turn the
crankshaft installer bolt until the crankshaft as-
sembly bottoms against the bearing.
5-80
TRANSMISSION
ESS20047
TRANSMISSION
Removing the transmission, shift drum and shift forks
10
/'
/'
/'
-
m
/'
/'
/'
/'
/' \
/' \
/'
/' \
/'
/
\
\ >
/' \
\ /'
\
\ /'
/'
/'
/'
/'
/'
'
/'
\ ., /'
/'
/'
\ /'
\ /' /
\
\ /
., /'
/'
,,, ,,, ""'

/'
/'
/'
6
/
/'
/'
16)
/'
/'
\ /'
\ /'
/'
/'
Separate.
Middle driven gear Refer to "MIDDLE GEAR" on page 5-88.
1 Bolt 1
2 Spring 1
3 Ball 1
4 Shift drum 1
5 Shift fork assembly 1
6 Shift fork "R" 1
7 Spring 1
8 Shift fork "L" 1
9 Shift fork guide bar 1
10 Secondary shaft 1
5-81
TRANSMISSION
Removing the transmission, shift drum and shift forks
/'
/'
/'
\
\
/'
\ /'
\ /'
/'
/'
/' \
12 /'
/'
/'
/'
/'
/'
'
/'
/' /'
/' /'
/' /'
/'
/'
/'
/'
/'
/'
/'
,0
/'
/'
\ /'
\ /'
/'
\ /'
/'
\
\
\
\
'- - - - _,,,.
11 Drive axle assembly 1

12 Collar 1
13 Reverse idle gear 1
14 Bearing 1
15 Reverse idle gear shaft 1
5-82
TRANSMISSION
Disassembling the drive axle assembly
7
·~- 6
5
4
3
2
1
-
Q
16
15
14
12
131~M
10
11 iltwi
1 Washer 1
2 Collar 1
3 High wheel gear 1
4 Washer 1
5 Clutch dog 1
6 Circlip 1
7 Washer 1
8 Collar 1
9 Low wheel gear 1
10 Washer 1
11 Circlip 1
12 Middle drive gear 1
13 Circlip 1
14 Washer 1
15 Bearing 1
16 Reverse wheel gear 1
5-83
TRANSMISSION
Disassembling the drive axle assembly
17
-
Q 18

17 Collar 1
18 Drive axle 1
5-84
TRANSMISSION
ESS30194
REMOVING THE TRANSMISSION

1. Remove:
• Shift drum "1"
• Shift fork assembly "2" 1
a. Pull out the guide bar from the crankcase
(right), and then remove the shift fork cam fol-
lowers. 2
b. Remove the shift drum.
c. Remove the shift fork assembly.
2. Check:
• Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends~ Replace.
EWB02750
AwARNING
Do not attempt to straighten a bent shift fork
guide bar.
ESS30195
DISASSEMBLING THE DRIVE AXLE

1. Remove:
• Collar "1"
• Drive axle "2"
TIP ~~~~~~~~~~~~~~ 319-0 10
Press the drive axle end and remove the collar. 3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement ~ Replace the shift forks
and shift fork guide bar as a set.
- -2
=
ESS30196
CHECKING THE SHIFT FORKS 319-011
The following procedure applies to both of the 4. Check:

shift forks. • Spring
1. Check: Cracks/damage ~ Replace.
• Shift fork cam follower "1"
EBS30197
• Shift fork pawl "2" CHECKING THE SHIFT DRUM
Bends/damage/scoring/wear ~ Replace the 1. Check:
shift fork. • Shift drum grooves
Damage/scratches/wear~ Replace the shift
drum.
5-85
TRANSMISSION
4. Check:
• Transmission gear movement
Rough movement ~ Replace the defective
part(s) .
5. Check:
• Circlips
Bends/damage/looseness ~ Replace.
EBS30199
CHECKING THE SECONDARY SHAFT

1. Check:
EBS30198
• Gear teeth
CHECKING THE TRANSMISSION Blue discoloration/pitting/wear ~ Replace.
1. Measure:
• Drive axle runout EBS30200
(with a centering device and dial gauge "1") ASSEMBLING THE DRIVE AXLE ASSEMBLY
Out of specification~ Replace the drive axle. 1. Install:
• Washer "1"
Drive axle runout limit • Circlip "2" i@f:d
0.06 mm (0.0024 in) TIP ~~~~~~~~~~~~~~
• Be sure the circlip sharp-edged corner "a" is

- positioned opposite side to the washer and
I '-.. } gear.
1
• Be sure the circlip ends "b" are positioned at
axle spline groove "c".
•
• •
• •
• •
b. /j. i@M2
\
2. Check:
• Transmission gears
Blue discoloration/pitting/ wear ~ Replace
the defective gear(s). C
• Transmission gear dogs

Cracks/damage/rounded edges~ Replace EBS30201
the defective gear(s). ASSEMBLING THE SHIFT FORK ASSEMBLY

1. Install:
ox ox 0 X • Shift fork guide bar "1"
u \J • Shift fork "L" "2"
~ ? nn _[\_ Jl
• Spring "3"
• Shift fork "R" "4"
• Circlips "5" i@M
TIP ~~~~~~~~~~~~~~~~
Install the shift forks with the "28P" mark "a" and
"584" mark "b" facing each other.
3. Check:
• Transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect~ Reassemble the transmission
axle assemblies.
5-86
TRANSMISSION
EBS30202
INSTALLING THE SHIFT FORKS AND SHIFT

DRUM
1. Install:
• Reverse idle gear "1"
• Drive axle assembly "2"
• Secondary shaft "3"
• Shift fork assembly "4"
• Shift drum "5"
TIP ~~~~~~~~~~~~~~
Install the shift fork assembly "4" with the "L"
mark "a" facing the crankcase (right).
2. Check:
• Shift operation
Rough operation~ Repair.
TIP ~~~~~~~~~~~~~~
• Oil each gear and bearing thoroughly.

• Before assembling the crankcase, make sure
that the transmission is in neutral and that the
gears turn freely.
5-87
MIDDLE GEAR
EBS20048
MIDDLE GEAR
Removing the middle drive shaft
190 Nm (19 m·kgf, 137 ft·lbf)
•-------------------------
•
• 3 4
• ~ 32 Nm (3.2 m·kgf, 23 ft·lbf)
:2
'
'' ''
''
''
'
~,' s ''-''
29 Nm (2.9 m·kgf, 21 ft·lbf)
Separate.
1 Middle drive shatvbearing housing assembly 1
2 Middle drive pinion gear nut 1
3 Middle drive pinion gear 1
Refer to "ALIGNING THE MIDDLE GEAR"
4 Middle drive pinion gear shim
on page 5-97.
5 Middle drive shaft assembly 1
6 Middle driven gear 1
7 Circlip 1
8 Middle drive shaft 1
9 Middle drive shaft bearing housing assembly 1
11 Bearing 1
12 Washer 1
5-88
MIDDLE GEAR
Removing the middle drive shaft
190 Nm (19 m·kgf, 137 ft·lbf)

.........................
•
•
•
•
• ~ 32 Nm (3.2 m·kgf, 23 ft·lbf)
'
'
'
'
29 Nm (2.9 m·kgf, 21 ft·lbf)

13 Bearing housing 1
5-89
MIDDLE GEAR
Removing the middle driven shaft

190 Nm 19 m·k f, 137 ft·lbf
,a
,
a
80 Nm (8.0 m·kgf, 58 ft·lbf)
130 Nm (13 m·kgf, 94 ft·lbf)
/
/
4
~
/
/
/ \
'' / ,,., 8
/
/
'
l.1' \ 7
-------
' ' ,, /
/
/
/
/
/
4
/
/
/
/
/
/
Separate.
1 Rear drive shaft yoke nut (middle gear side) 1
2 Rear drive shaft yoke (middle gear side) 1
3 Middle driven pinion gear assembly 1
Refer to "ALIGNING THE MIDDLE GEAR"
4 Middle driven pinion gear shim on page 5-97.
5 Front drive shaft yoke nut (middle gear side) 1
6 Front drive shaft yoke (middle gear side) 1
7 Middle driven pinion gear 1
8 Bearing 1
9 Oil seal 1
10 Middle driven pinion gear bearing retainer 1 Left-hand threads
11 Bearing 1
12 0-ring 1
5-90
MIDDLE GEAR
Removing the middle driven shaft

190 Nm 19 m·k f, 137 ft·lbf
,a
,
a 17
80 Nm (8.0 m·kgf, 58 ft·lbf)

130 Nm (13 m·kgf, 94 ft·lbf)
- I
B: I
190 Nm (19 m·kgf, 137 ft·lbf)
13 Bearing housing 1
14 Oil seal 1
15 Middle driven shaft bearing retainer 1 Left-hand threads
16 Bearing 1
17 Middle driven shaft 1
5-91
MIDDLE GEAR
EBS30203
REMOVING THE MIDDLE DRIVE SHAFT Coupling gear/middle shaft tool

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

then secure it in a vise.
2. Remove:
• Front drive shaft yoke nut "1"
• Washer
• Front drive shaft yoke "2"
TIP~~~~~~~~~~~~~~~~
3. Remove: Use the coupling gear/middle shaft tool "3" to
• Middle drive pinion gear nut hold the front drive shaft coupling sleeve.
• Middle drive pinion gear
• Shim(s)
Coupling gear/middle shaft tool
4. Remove:
90890-01229
• Middle driven gear "1"
Gear holder
• Circlip YM-01229
• Middle drive shaft "2"
TIP ~~~~~~~~~~~~~~~~
Press the middle drive shaft end and remove the
middle driven gear.
I
•
I I
1-- -1
fi t
- -2
3. Remove:
• Bearing housing assembly "1"
a. Clean the surface of the bearing housing as-
EBS30204 sembly.
REMOVING THE MIDDLE DRIVEN SHAFT b. Place the bearing housing assembly onto a
1. Remove: hydraulic press.
• Rear drive shaft yoke nut "1" ECB01900
• Washer NOTICE~~~~~~~~~~~~~
• Rear drive shaft yoke "2" • Never directly press the middle driven pin-
TIP~~~~~~~~~~~~~~~~ ion gear end with a hydraulic press, this will
Use the coupling gear/middle shaft tool "3" to result in damage to the middle driven pin-
hold the rear drive shaft coupling sleeve. ion gear thread.
5-92
MIDDLE GEAR
• Install a suitable socket "2" on the middle

driven pinion gear end to protect the thread Ring nut wrench
from damage. 90890-01430
Ring nut wrench
c. Press the middle driven pinion gear end and YM-38404
remove the bearing housing.
EC.801750
---,
NOTICE
--------------
The middle driven shaft bearing retainer has
left-hand threads. To loosen the retainer turn
it clockwise.
••••••••••••••••••••••••••••••••
4. Remove:
• Middle driven pinion gear bearing retainer
• Bearing
a. Wrap the bearing housing in a folded rag "1",
and then secure the bearing housing edge in
a vise.
b. Attach the bearing retainer wrench "2".
Bearing retainer wrench

90890-04128
YM-04128 3
EC801740
NOTICE
- - - - - - - - - - - - - - 6. Remove:
The middle driven pinion gear bearing retain- • Middle driven shaft "1"
er has left-hand threads. To loosen the re- (with bearing)
tainer, turn it clockwise.
EBS30205
c. Remove the bearing retainer and bearing. CHECKING THE PINION GEARS
1. Check:
••••••••••••••••••••••••••••••••
5. Remove:
• Drive pinion gear teeth
• Driven pinion gear teeth
• Oil seal "1"
Pitting/galling/wear ~ Replace.
• Middle driven shaft bearing retainer "2"
2. Check:
TIP - - - - - - - - - - - - - - - ~ • 0-ring
Attach the ring nut wrench "3". Damage~ Replace.
5-93
MIDDLE GEAR
• Bearings
Pitting/ damage ~ Replace. Ring nut wrench
90890-01430
EBS30206 Ring nut wrench
INSTALLING THE BEARING AND OIL SEALS YM-38404
1. Install:
• Bearing "1" EC.801760
---,
NOTICE
• O il seal "2" 1r..l"'f:i•n•4 -------------
(into the bearing housing "3") The middle driven shaft bearing retainer has
left-hand threads. To tighten the retainer turn
Installed depth "a" of bearing it counterclockwise.
0.9-1.4 mm (0.035-0.055 in)
Installed depth "b" of oil seal
1.0-1.5 mm (0.039-0.059 in)
0
c... -
2. Install:
• O il seal "1" ilM
(into the crankcase "2")
Installed depth "a" of oil seal

1.0-1.5 mm (0.039-0.059 in)
2
2. Install:
a 1 • Middle driven pinion gear bearing retainer "1"
-
~
,-
~
,.J
a. Wrap the bearing housing in a folded rag , and
then secure the bearing housing edge in a
2- - i - vise.
b. Attach the bearing retainer wrench "2".
I\._
I Bearing retainer wrench
90890-04128
ESS30207
YM-04128
INSTALLING THE MIDDLE DRIVEN SHAFT
1. Install:
c. Tighten the bearing retainer.
• Middle driven shaft bearing retainer "1"
Middle driven pinion gear bearing
Middle driven shaft bearing re-
retainer
tainer 130 Nm (13 m-kgf, 94 ft-lbf)
80 Nm (8.0 m-kgf, 58 ft-lbf) LOCTITE®
LOCTITE®
TIP - - - - - - - - - - - - - - - ~
Attach the ring nut wrench "2".
5-94
MIDDLE GEAR
ECB01770
NOTICE
- - - - - - - - - - - - -
The middle driven pinion gear bearing retain-
er has left-hand threads. To tighten the re-
tainer turn it counterclockwise.
5. Install:
• Rear drive shaft yoke "1"
• Washer
2 • Rear drive shaft yoke nut "2"
Rear drive shaft yoke nut (middle

••••••••••••••••••••••••••••••••
3. Install:
gear side)
190 Nm (19 m -kgf, 137 ft-lbf)
• Middle driven pinion gear shim(s) "1" LOCTITE®
• Bearing housing
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Install the shim(s) so that the tabs are positioned Use the coupling gear/middle shaft tool "3" to
as shown in the illustration. hold the rear drive shaft yoke.
Coupling gear/middle shaft tool

90890-01229
Gear holder
YM-01229
4. Install:
• Front drive shaft yoke "1"
• Washer
• Front drive shaft yoke nut "2"
Front drive shaft yoke nut (mid-

EBS30208
dle gear side)
INSTALLING THE MIDDLE DRIVE SHAFT
190 Nm (19 m -kgf, 137 ft-lbf)
LOCTITE® 1. Install:
• Circlip
• Middle driven gear "1"
TIP - - - - - - - - - - - - - - - (onto the middle drive shaft "2")
Use the coupling gear/middle shaft tool "3" to
hold the front drive shaft yoke. Installed depth "a" of middle
driven gear
Coupling gear/middle shaft tool 24.7-24.9 mm (0.972-0.980 in)
90890-01229
Gear holder
YM-01229
5-95
MIDDLE GEAR
EBS30209
MEASURING THE MIDDLE GEAR

BACKLASH
1. Measure:
• Middle gear backlash
Refer to "ALIGNING TH E MIDDLE GEAR" on
\2 page 5-97.
Middle gear backlash

0.10-0.30 mm (0.004-0.012 in)
2. Tighten:
• Bearing retainer bolts "1" i~Mi TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Temporarily install the crankcase (right).
Middle drive shaft bearing retain- b. Wrap a rag "1" around a screwdriver "2", and
er bolt then insert it into the installation hole "a" of the
29 Nm (2.9 m-kgf, 21 ft-lbf) crankcase (right) speed sensor to hold the
LOCTITE® middle driven gear.
TIP ~~~~~~~~~~~~~~~~
Stake the bearing retainer bolts at the cutouts "a"

in the bearing retainers "2". 1 @
D~ /
W---a
~~~rd_ 0 2
- J./.
c. Attach the final gear backlash band "3" and
dial gauge "4".
·~- 1
0 a 0 Final gear backlash band
90890-01511
3. Tighten: Middle drive gear lash tool
• Middle drive pinion gear nut "1" i~tMi YM-01230
Middle drive pinion gear nut

190 Nm (19 m-kgf, 137 ft-lbf)
TIP ~~~~~~~~~~~~~~~~
• Wrap the middle drive shaft in a folded rag, and

then secure it in a vise.
• Lock the threads with a drift punch.
b a
a. 39.3 mm (1.55 in)
b. 25.3 mm (1.00 in)
d. Measure the gear lash while rotating the mid-

dle driven shaft back and forth.
TIP ~~~~~~~~~~~~~~
Measure the gear lash at 4 positions. Rotate the

middle driven gear 90° each time.
5-96
MIDDLE GEAR
e. If the gear lash is incorrect, adjust the gear

lash by middle driven pinion gear shim(s) . a-
k-
-- '
•••••••••••••••••••••••••••••••• ...r ...

ESS30210 - -
ALIGNING THE MIDDLE GEAR
- n '
~
TIP ~~~~~~~~~~~~~~
Aligning the middle gear is necessary when any

] " -
)
-
of the following parts are replaced:
' \..
• Crankcase
,, - '
• Middle drive pinion gear '
• Middle driven pinion gear - -
• Middle driven shaft bearing housing
w e d
• Middle drive shaft bearing housing
b C
1. Select:
A
• Middle drive pinion gear shim(s) "1" - ~
• Middle driven pinion gear shim(s) "2" 1 "' ~II

~,
~
' 1
,, ,
)'n ~
~
~--
1
•
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I. -
~ D
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h
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- -
,=- ~
=
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I t
J B
A. Middle drive pinion gear shim thickness

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

on the bearing housing is either added to or
subtracted from "0 .9"
"b" = 17.0
"c" = 55.0
"d" = a numeral (usually a decimal number)
on the crankcase (left) specifies a thickness
of "65.0"
5-97
MIDDLE GEAR
"e" = a numeral (usually a decimal number) Hundredth Rounded value

on the crankcase (right) specifies a thickness
of "9.0" 0, 1, 2 0
"k" = 1.5 3,4, 5, 6, 7 5
Example: 8, 9 10
If the bearing housing is marked "+01 ",
"a" is 0.91 Shims are supplied in the following thickness-
es.
Middle drive pinion gear shim

Thickness (mm)
0.50 0.55 0.60 0.70 0.80 0.90 1.00
c. To find middle driven pinion gear shim thick-

ness "B", use the following formula.
Middle driven pinion gear shim thickness
"B" = "f" - "g" + "h" - ''i" - "j"
"b" is 17.0 "f" = a numeral (usually a decimal number) on

"c" is 55.0 the bearing housing is either added to or sub-
If the crankcase (left) is marked "64.96", tracted from "89.5"
"d" is 64.96 TIP ~~~~~~~~~~~~~~
After replacing any part in the middle driven pin-

ion gear assembly, the overall length of the as-
sembly w ill change. Therefore, be sure to
measure distance ''f" to select the correct m iddle
d driven pinion gear shim thickness.
If the crankcase (right) is marked "9.01 ", f

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

on the middle driven pinion gear is either add-
ed to or subtracted from "61 .0"
"h" = a numeral (usually a decimal number)
on the middle driven pinion gear is either add-
ed to or subtracted from "80.5"
"k" is 1.5 "i" = a numeral (usually a decimal number) on
Therefore, "A" is 1.38. the crankcase (right) specifies a thickness of
"A" = 9.0 1 + 64.96 + 0.91 - 55.0 - 17.0 - 1.5 "99.98"
= 1.38 "j" = a numeral (usually a decimal number) on
Round off hundredths digit and select appro- the crankcase (left) specifies a thickness of
priate shim(s). "8.12"
In the above example, the calculated shim Example:
thickness is 1.38 mm. The following chart in- If the bearing housing is marked "+03",
structs you, however, to round off 8 to 10. "f" is 89.53
5-98
MIDDLE GEAR
•
J
If the driven pinion gear is marked "+02", Therefore, "B" is 0.93.

"g" is 61 .02 "B" = 89.53 - 61.02 + 80.52 - 99.98 - 8.12 =
0.93
Round off hundredth digit and select appro-
priate shim(s) .
In the above example, the calculated shim
thickness is 0.93 mm. The chart instructs
you, however, to round off 3 to 5.
Hundredth Rounded value
0, 1, 2 0
3,4, 5, 6, 7 5
If the driven pinion gear is marked "+02", 8, 9 10
"h" is 80.52
Shims are supplied in the following thickness-
es.
Middle driven pinion gear shim

Thickness (mm)
0.10 0.15 0.20 0.30 0.40 0.50 0.60
TIP~~~~~~~~~~~~~~
• If the specified middle gear backlash cannot be

obtained with a calculated shim thickness, in-
If the crankcase (right) is marked "99.98", crease or decrease the shim thickness.
"i" is 99.98 • If the shim thickness is increased, the actual
middle gear backlash will increase and, if the
shim thickness is decreased, the actual middle
gear backlash will decrease.
If the crankcase (left) is marked "8.12",

"j" is 8.1 2
5-99
COOLING SYSTEM
01 L COOLER ...... .......... ......... .......... ......... ........ .......... ......... ......... .......... ......... 6-1
CHECKING THE OIL COOLER ....... ......... ......... ......... ......... .......... ......... .. 6-3
INSTALLING THE OIL COOLER ....... .......... ........ .......... ......... ......... ......... 6-3
RADIATOR .......... .......... ......... .......... ......... ......... .......... ........ .......... ......... ........ 6-4
CHECKING THE RADIATOR .... ......... .......... ........ ......... .......... ......... ......... 6-6
INSTALLING THE RADIATOR .......... ........ .......... ......... ......... ......... .......... . 6-6
THERMOSTAT ... .......... ......... .......... ......... ........ .......... ......... ......... .......... ......... 6-7
CHECKING THE THERMOSTAT ...... ......... ......... ......... ......... ......... .......... . 6-8
INSTALLING THE THERMOSTAT ..... ........ .......... ......... .......... ......... ......... 6-8
WATER PUMP .... .......... ......... .......... ......... ........ .......... ......... .......... ......... ....... 6-1 O
DISASSEMBLING THE WATER PUMP ........ ......... ......... .......... ......... ..... 6-13
CHECKING THE WATER PUMP ........ ......... .......... ......... ......... .......... ..... 6-13
ASSEMBLING THE WATER PUMP ... ........ .......... ......... .......... ......... ....... 6-13
INSTALLING THE AC MAGNETO COVER ........ .......... ......... ......... ........ 6-14
OIL COOLER
EBS20050
OIL COOLER
Removing the oil cooler
20 Nm (2.0 m·kgf, 14 ft·lbf)
~ 18 Nm (1.8 m·kgf, 13 ft·lbf)
18Nm 1.8m·k f, 13ft·lbf
17 Nm (1.7 m·kgf, 12 ft·lbf) ~ 30 Nm (3.0 m·kgf, 22 ft·lbf)

Seat frames
4-4.

4-10.
Rear panel (right)/Rear panel (left)/Center pas- Refer to "GENERAL CHASSIS (7)" on page
senger lower panel 4-20.
Heat shield 5-7.
Air filter case Refer to "AIR FILTER CASE" on page 7-6.
Drain.
page 3-14.
Drain.
page 3-9.
Water pump outlet pipe/Oil cooler inlet hose Refer to "WATER PUMP" on page 6-10.
6-1
OIL COOLER
Removing the oil cooler

20 Nm (2.0 m·kgf, 14 ft·lbf)
~ 18 Nm (1.8 m·kgf, 13 ft·lbf)
18Nm 1.8m·k f, 13ft·lbf
1 Oil filter cartridge 1

2 Oil filter cartridge union bolt 1
3 Oil cooler 1
4 Oil cooler outlet hose 1
5 Oil pipe (crankcase to cylinder head) 1
6 Oil pipe (AC magneto cover) 1
6-2
OIL COOLER
ESS30211
CHECKING THE OIL COOLER Oil filter cartridge union bolt

1. Check: 30 Nm (3.0 m-kgf, 22 ft-lbf)
• Oil cooler
Cracks/damage~ Replace. 4. Fill:
2. Check: • Cooling system
• Oil cooler outlet hose (with the specified amount of the recom-
• Oil pipe (crankcase to cylinder head) mended coolant)
• Oil pipe (AC magneto cover) Refer to "CHANGING THE COOLANT' on
Cracks/damage/wear~ Replace. page 3-9.
• Crankcase
EBS30212
INSTALLING THE OIL COOLER (with the specified amount of the recom-
1. Clean : mended engine oil)
• Mating surfaces of the oil cooler and the Refer to "CHANG ING T HE ENGINE OIL" on
crankcase page 3-14.
(with a cloth dampened with lacquer thinner) 5. Check:
2. Install: • Cooling system
• Oil cooler outlet hose "1" Leaks ~ Repair or replace any faulty part.
(to the oil cooler) 6. Measure:
• Radiator cap opening pressure
TIP ~~~~~~~~~~~~~~
Below the specified pressure ~ Replace the
Install the oil cooler outlet hose with the white radiator cap.
paint mark "a" facing in the direction shown in Refer to "CHECKING THE RADIATOR" on
the illustration. page 6-6.
3. Install:
• Gasket iltii
• Oil cooler "1"
• Oil filter cartridge union bolt "2"
TIP ~~~~~~~~~~~~~~~~
Fit the projection "a" on the oil cooler between

the projections "b" on the crankcase.
6-3
RADIATOR
ESS20051
RADIATOR
Removing the radiator
~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
' t!t
~~ , 8 Nm (0.8 m·kgf, 5.8 ft·lbf) ~
-=-::;::::::;,- ~ ~ - .
--------- ---------
-------------- J
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
------ -
_ __-/
,

Side frames 4-12.
Front fender/Instrument panel Refer to "GENERAL CHASSIS (6)" on page

4-15.
Seat frames
4-4.
Sound-deflection panel Refer to "GENERAL CHASSIS (4)" on page

4-10.
Center passenger lower panel/Center floor Refer to "GENERAL CHASSIS (7)" on page
board/ Floor board (left)/ Floor board (right) 4-20.
Electrical components tray 4-24.
Heat shield 5-7.
Drain.
page 3-9.
6-4
RADIATOR
Removing the radiator
10
'
5
~ @
12 .
2
~~ , 8 Nm (0.8 m·kgf, 5.8 ft·lbf) ~
----::::::::;;::::;:--, ~ ~
-:;:;;c-
3
---------------
J
--------- - - - - - - - - - - - - -
'
,
_ _-/
. 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
1 Radiator cap 1
2 Coolant reservoir hose 1
3 Coolant reservoir breather hose 1
4 Coolant reservoir cap 1
5 Coolant reservoir 1
6 Radiator inlet hose 1
7 Radiator inlet pipe 1
8 Radiator outlet hose 1
9 Radiator outlet pipe 1
10 Radiator fan motor coupler 1 Disconnect.
11 Radiator bracket 1
12 Radiator 1
13 Radiator fan 1
14 Radiator fan motor breather hose 1
6-5
RADIATOR
ESS30213
CHECKING THE RADIATOR

1. Check:
• Radiator fins
Obstruction~ Clean .
Apply compressed air to the rear of the radia-
tor.
Damage ~ Repair or replace.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Straighten any flattened fins with a thin , flat-head
screwdriver. b. Apply the specified pressure for ten seconds
and make sure there is no drop in pressure.
••••••••••••••••••••••••••••••••
/
/ I\ 4. Check:
• Radiator fan
-
- ,-
-
~ -"'' y Damage~ Replace.
Malfunction ~ Check and repair.
Refer to "COOLING SYSTEM" on page 9-27.
-
- '
- - EBS30214
I INSTALLING THE RADIATOR

1. Fill :
2. Check: • Cooling system
• Radiator hoses (with the specified amount of the recom-
• Radiator pipes mended coolant)
Cracks/damage/wear~ Replace. Refer to "CHANGING THE COOLANT' on
3. Measure: page 3-9.
• Radiator cap opening pressure 2. Check:
Below the specified pressure ~ Replace the • Cooling system
radiator cap. Leaks ~ Repair or replace any faulty part.
3. Measure:
Radiator cap opening pressure
107.9-137.3 kPa (1.1-1.4
kgf/cm 2 , 15.6-19.9 psi)
radiator cap.
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT Refer to "CHECKING THE RADIATOR" on
a. Install the radiator cap tester "1" and radiator page 6-6.
cap tester adapter "2" to the radiator cap "3".
Radiator cap tester

90890-01325
Mityvac cooling system tester kit
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
6-6
THERMOSTAT
EBS20052
THERMOSTAT
Removing the thermostat
1O Nm 1.0 m·k f, 7.2 ft·lbf 2

4 5
18 Nm 1.8 m·k f, 13 ft·lbf
Drain.
page 3-9.
1 Thermostat outlet hose 1
2 Thermostat cover 1
3 Thermostat 1
4 Coolant temperature sensor coupler 1 Disconnect.
5 Coolant temperature sensor 1
6-7
THERMOSTAT
EBS30215
• Thermostat housing (cylinder head)
CHECKING THE THERMOSTAT
• Thermostat outlet hose
1. Check:
• Thermostat
Does not open at 69-73 °c (156-163°F) ~ EBS30216
Replace. INSTALLING THE THERMOSTAT

1. Install:
• Copper washer il@1i
• Coolant temperature sensor
Coolant temperature sensor

18 Nm (1.8 m-kgf, 13 ft-lbf)
ECB01910
NOTICE
--------------
Use extreme care when handling the coolant
temperature sensor. Replace any part that
a. Suspend the thermostat "1" in a container "2" was dropped or subjected to a strong im-
filled with water. pact.
b. Slowly heat the water "3". 2. Install:
c. Place a thermometer "4" in the water. • Thermostat "1"
d. While stirring the water, observe the thermo- • 0-ring "2" ilt¥i
stat and thermometer indicated temperature. • Thermostat cover "3"
Thermostat cover bolt

-,---- 4
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
r--=_
= --_
--==
=~=:::!.//J__ 3 Install the thermostat with its breather hole "a"
1 facing up.
/1--- 2
21@@4 a
B- - - - - - ---.-
3 I 1
7mm
(0.28 in)
A - ~ _ _ _ _ _ _ __.._
71+2°C 85°C 3. Fill :
(159+3° F) (185°F) • Cooling system
A. Fully closed mended coolant)
B. Fully open Refer to "CHANGING THE COOLA NT ' on
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ page 3-9.
4. Check:
If the accuracy of the thermostat is in doubt, re-
• Cooling system
place it. A faulty thermostat could cause serious
Leak ~ Repair or replace any faulty part.
overheating or overcooling.
5. Measure:
••••••••••••••••••••••••••••••••
2. Check:
• Thermostat cover radiator cap.
6-8
THERMOSTAT
Refer to "CHECKING TH E RADIATOR" on

page 6-6.
6-9
WATER PUMP
EBS20053
WATER PUMP
Removing the water pump
---:J- J~
' '
~~~---,L~<Y~ \;::~ _:)

1.5 Nm 0.15 m·k f, 1.1 ft·lbf

~ 1O Nm (1.0 m·kgf, 7.2 ft·lbf) 1O Nm (1.0 m·kgf, 7.2 ft·lbf)

Seat frames
4-4.

4-10.
Center passenger lower panel/Center passen- Refer to "GENERAL CHASSIS (7)" on page
ger compartment panel/Rear panel (right) 4-20.
Side panel (right) 4-1 .
Heat shield 5-7.
Drain.
page 3-14.
Drain.
page 3-9.
6-10
WATER PUMP

' '
6
'
_:)
1.5 Nm 0.15 m·k f, 1.1 ft·lbf
1.0 m·k f, 7.2 ft·lbf

1 Water pump inlet hose 1

2 Water jacket joint 1
3 Water pump outlet hose 1
4 Water pump outlet pipe 1
5 Oil cooler inlet hose 1
6 Water pump breather hose 1
7 Water pump housing 1
8 Gasket 1
6-11
WATER PUMP

'
15
14 l~M 10 1O Nm (1.0 m·kgf, 7.2 ft·lbf)
11
---:J- )(i
,
'
tF-,--------,(_®e9® ~ - _:)
k f, 1 •1 ft· Ibf
SL..:.;C.:....:..C..:..:..:....>.:o:..:...1.;,,:s:....;mc:..:....:..:.·
1.0 m·k f, 7.2 ft·lbf

9 Dowel pin 2
11 AC magneto coupler 2 Disconnect.
13 AC magneto cover 1
14 AC magneto cover gasket 1
15 Dowel pin 2
16 Circlip 1
17 Impeller shaft 1
18 Mechanical seal (impeller side) 1
19 Mechanical seal (housing side) 1
20 Bearing 1
21 Oil seal 1
6-12
WATER PUMP
ESS30217 EBS30218
DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP

1. Remove: 1. Check:
• Mechanical seal (impeller side) "1" • Water pump housing cover
(from the impeller, with a thin, flat-head • AC magneto cover
screwdriver) • Impeller shaft
TIP ~~~~~~~~~~~~~~ • Oil cooler inlet hose
Do not scratch the impeller shaft. • Water pump outlet pipe
• Water pump outlet hose
Cracks/damage/wear~ Replace.
2. Check:
• Bearing
Rough movement ~ Replace.
EBS30219
ASSEMBLING THE WATER PUMP

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

8.1-8.7 mm (0.32-0.34 in)
3. Remove:
• Bearing "1" a
• Oil seal "2"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~ 2. Install:
Remove the bearing and oil seal from the inside • Mechanical seal (housing side) "1" iiMi
of the AC magneto cover. ECB01410
--,
NOTICE
- - - - - - - - - - - - - -
Never lubricate the mechanical seal (hous-
ing side) surface with oil or grease.
TIP ~~~~~~~~~~~~~~
Use the special tools and a press to press the

mechanical seal (housing side) straight in until it
touches the water pump housing.
6-13
WATER PUMP
TIP - - - - - - - - - - - - - - - ~
Mechanical seal installer
90890-04132 If the surface "a" of the mechanical seal (impeller
Water pump seal installer side) that contacts the mechanical seal (housing
YM-33221-A side) is dirty, clean it.
Middle driven shaft bearing driv-
er Impeller shaft tilt limit
90890-04058 0.15 mm (0.006 in)
Middle drive bearing installer 40
&50mm
YM-04058
,_-./-.-
1---
J-- 1 •~Mil
1 . Straightedge
2. Impeller
A. Push down 5. Install:

2. Mechanical seal installer • Impeller "1"
3. Middle driven shaft bearing driver • Circlip i@tMJ
3. Install : TIP - - - - - - - - - - - - - - - ~
• Mechanical seal (impeller side) "1" i@tMJ After installation, check that the impeller shaft ro-
tates smoothly.
TIP ~~~~~~~~~~~~~~~~
Before installing the mechanical seal (impeller /

side) , apply tap water or coolant onto its outer
surface.
1 em@ii EBS30220
INSTALLING THE AC MAGNETO COVER

1. Install:
• Dowel pins "1"
4. Measure:
• Impeller shaft tilt
• AC magneto cover gasket "2" i@f:ii
• AC magneto cover "3"
Out of specification ~ Repeat steps (3) and
(4) . TIP - - - - - - - - - - - - - - - ~
ECB01420
Align the slit "a" on the impeller shaft with the
NOTICE projection "b" on the oil pump driven sprocket.
-------------
Make sure the mechanical seal (impeller
side) is flush with the impeller.
6-14
WATER PUMP
2. Install:
• Dowel pins "1"
• Gasket "2" i~Mi
• Water pump housing "3"
TIP~~~~~~~~~~~~~~
Install the bolt "4" to the water pump housing,

and then install the water pump housing to the
AC magneto cover.
21~f4,j
3
3. Fill:
• Cooling system
mended coolant)
Refer to "CHANGING THE COOLANT' on
page 3-9.
4. Check:
• Cooling system
Leaks ~ Repair or replace any faulty part.
5. Measure:
Below the specified pressure~ Replace the
radiator cap.
Refer to "CHECKING THE RADIATOR" on
page 6-6.
6-15
FUEL SYSTEM
FUEL TANK ......... .......... ......... .......... ......... ......... .......... ........ .......... ......... ........ 7-1
REMOVING THE FUEL TANK ........... ........ ......... ......... .......... ......... ......... . 7-3
REMOVING THE FUEL PUMP .......... ........ ......... .......... ......... .......... ......... 7-3
CHECKING THE FUEL PUMP BODY ...... .......... ......... ......... ......... ......... ... 7-3
CHECKING THE FUEL TANK BREATHER HOSE JOINT ... .......... .......... 7-3
INSTALLING THE FUEL PUMP ........ ......... ......... ......... ......... .......... ......... . 7-4
INSTALLING THE FUEL TANK ......... ......... ......... .......... ......... ......... .......... 7-4
CHECKING THE FUEL PRESSURE ........ ......... ......... .......... ......... ......... .. 7-5
AIR FILTER CASE ........ ......... .......... ......... ......... .......... ........ ......... .......... ........ 7-6
INSTALLING THE AIR FILTER CASE ....... ......... .......... ......... .......... ......... 7-8
THROTTLE BODY ......... ......... .......... ......... ......... .......... ........ ......... .......... ........ 7-9
REMOVING THE THROTTLE BODY ASSEMBLY ......... ......... ......... ...... 7-12
CHECKING THE INJECTOR .... ......... .......... .......... ........ .......... ......... ...... 7-12
CHECKING THE THROTTLE BODY ........... ........ .......... .......... .......... ..... 7-12
CHECKING THE THROTTLE BODY JOINT ........ ......... .......... .......... ...... 7-12
INSTALLING THE THROTTLE BODY ASS EMBLY ....... ......... ......... ....... 7-12
ADJUSTING THE THROTTLE POSITION SENSOR ..... ......... ......... ....... 7-13
AIR INDUCTION SYSTEM .... ......... .......... ........ .......... ......... ......... .......... ....... 7-15
CHECKING THE AIR INDUCTION SYSTEM ........ ......... .......... ......... ...... 7-18
INSTALLING THE AIR INDUCTION SYSTEM ........ ......... .......... ......... .... 7-18
FUEL TANK
EBS20054
FUEL TANK
Removing the fuel tank
r.:'"'""'r-----------,
16 Nm 1.6 m·kgf, 12 ft·lbf 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
4
~ (6)
' ~
1
~ 3
6 -- ~
~ --
1--- 1
~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Seat frames
4-4.

4-10.
Side panel (right) 4-1 .
Outer passenger compartment panel/Rear pan- Refer to "GENERAL CHASSIS (7)" on page
el (right) 4-20.
1 Fuel tank breather hose 2
2 Fuel tank breather hose joint 1
3 Fuel pump coupler 1 Disconnect.
4 Fuel hose connector holder 1
5 Fuel hose 1
6 Fuel tank retainer 1
7-1
FUEL TANK
Removing the fuel tank

~---------,
16 Nm 1.6 m·kgf, 12 ft·lbf 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
/---- ~ '
11
i---- a
~ 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Damper 2
8 Fuel tank bracket 1
9 Fuel tank 1
10 Damper 2
11 Fuel pump 1
7-2
FUEL TANK
ESS30221
REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
t
• Fuel hose connector holder
• Fuel hose
EWB03050
A WARNING
Cover fuel hose connections with a cloth
2 3
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to EBS30222
spurt out when removing the hose. REMOVING THE FUEL PUMP
1. Remove:
ECB01560
NOTICE • Fuel pump bracket

--------------
A Itho ugh the fuel has been removed from
• Fuel pump
• Fuel pump gasket
the fuel tank, be careful when removing the EC.801450
----,
fuel hose, since there may be fuel remaining NOTICE
in it. - - - - - - - - - - - - - -
• Do not drop the fuel pump or give it a
strong shock.
TIP - - - - - - - - - - - - - - - ~
• Do not touch the base section of the fuel
• To disconnect the fuel hose from the fuel
sender.
pump, remove the fuel hose connector holder,
insert a slotted head screwdriver, etc., in the
EBS30223
slot part "a" of the fuel hose connector cover
CHECKING THE FUEL PUMP BODY
"1", slide the cover in the direction of the arrow,
1. Check:
and then disconnect the fuel hose. • Fuel pump body
• To disconnect the fuel hose from the injector Obstruction ~ Clean.
fuel rail, slide the fuel hose connector cover "2"
Cracks/damage ~ Replace the fuel pump.
on the end of the hose in direction of the arrow
shown , press the two buttons "3" on the sides EBS30224
of the connector, and then disconnect the CHECKING THE FUEL TANK BREATHER
hose. HOSE JOINT
• Before removing the hose, place a few rags in 1. Check:
the area under where it will be removed. • Fuel tank breather hose joint
Damage/faulty ~ Replace.
TIP ~~~~~~~~~~~~~~
• Check that air flows smoothly in the direction of

the arrow shown when the hose joint is posi-
tioned as shown in the illustration "A".
• Check that air does not flow in the direction of
the arrow shown when the hose joint is posi-
tioned as shown in the illustration "B".
7-3
FUEL TANK
a a
• •
S>i CQ f< 6 ¢ FWD
I a
b
a. upward EBS30226
INSTALLING THE FUEL TANK

EBS30225
1. Install:
INSTALLING THE FUEL PUMP
• Dampers "1"
1. Install:
TIP ~~~~~~~~~~~~~~
• Fuel pump gasket "1" l~t4\i Fit the projections "a" on the dampers into the
TIP ~~~~~~~~~~~~~~
holes "b" in the frame.
• Always use a new fuel pump gasket.
• Install the fuel pump gasket with the lip side "a"
facing upward.
iltN 1
~ b
/
/
2. Install:
\ •
•
Fuel tank "1"
Fuel tank bolts "2"
2. Install: • Fuel tank retainer "3"
• Fuel pump • Fuel tank retainer bolts "4"
• Fuel pump bracket TIP ~~~~~~~~~~~~~~~~
Fuel pump nut Finger tighten the fuel tank bolts and fuel tank re-
7 Nm (0.7 m-kgf, 5.1 ft-lbf) tainer bolts.
e 0 4
TIP ~~~~~~~~~~~~~~
0 4 0
• Do not damage the installation surfaces of the 0 0 00
fuel tank when installing the fuel pump. 0

• Install the fuel pump in the direction shown in 0
0
the illustration.
•
• Install the fuel pump bracket by aligning the 0
projections "a" on the fuel pump with the pro-

jection "b" on the fuel tank. ~2
• Tighten the nuts to specification in the proper
tightening sequence as shown . 3. Tighten:
• Fuel tank bolts "1"- "3"
• Fuel tank retainer bolts "4" , "5"
7-4
FUEL TANK
Fuel tank bolt

7 Nm (0.7 m-kgf, 5.1 ft-lbf)
Fuel tank retainer bolt
16 Nm (1.6 m-kgf, 12 ft-lbf)
TIP ~~~~~~~~~~~~~~
Tighten the bolts in the proper tightening se-

D
quence as shown .
2
EBS30227
CHECKING THE FUEL PRESSURE

0 1. Check:
0 • Fuel pressure
0
0
a. Remove the frame cross member.
•
Refer to "GENERAL CHASSIS (1O)" on page
4-28.
b. Disconnect the fuel hose "1" from the injector
4. Install : fuel rail.
• Fuel hose Refer to "REMOVING TH E T HROTTLE
• Fuel hose connector holder "1" BODY ASSEMBLY" on page 7-1 2.
• Fuel pump coupler c. Connect the pressure gauge "2" and adapter
ECB02010 "3" to the fuel injector rail and fuel hose.
NOTICE
------------- Pressure gauge
When installing the fuel hose, make sure that
90890-03153
it is securely connected, and that the fuel
Pressure gauge
hose holder is in the correct position, other- YU-03153
wise the fuel hose will not be properly in- Fuel pressure adapter
stalled. 90890-03176
TIP ~~~~~~~~~~~~~~
Fuel pressure adapter
YM-03176
• Install the fuel hose connector holder "1" se-
curely onto the fuel pump until a distinct "click"
is heard, and then make sure that it does not
come loose.
• To install the fuel hose onto the injector fuel
rail, slide the fuel hose connector cover "2" on
the end of the hose in direction of the arrow
shown .
d. Start the engine.

e. Measure the fuel pressure.
Out of specification ~ Replace the fuel
pump.
Fuel line pressure at idling

300--390 kPa (3.0-3.9 kgf/cm 2 ,
42.7-55.5 psi)
7-5
AIR FILTER CASE
EBS20055
AIR FILTER CASE

Removing the air filter case and air intake duct
r- - - . . /
,
•••
' 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
'
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
~ 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
-~
--..._ I
0.7 m·k f, 5.1 ft·lbf
'
' , I
'
'
'
'
,~;·:.:;;:.l, .•
.': ..,.:.·........·........
I : : ••••••• ;
...: .:: '.,".-r •• ,.......

..... , 'I'
,,
/\_
••••
,' -=-=-; •••• i •••••••••••••••••••••••••• ~~~~~·
_J

Side frames 4-12.
Front fender/Instrument panel Refer to "GENERAL CHASSIS (6)" on page

4-15.

4-1 .
Seat frames
4-4.

4-10.
Center passenger compartment panel/Floor Refer to "GENERAL CHASSIS (7)" on page
boards 4-20.
Heat shield 5-7.
7-6
AIR FILTER CASE
Removing the air filter case and air intake duct

r------.·/
i---12 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
10 5
/5
8 9 8
i~
11
. 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
4 7-'m_;,.;.;;.·k
,i_;_~.:....,..;;o.;.;;. t, 5 .1 ft·I bf
' ........ .. ..
'
' '' ,I
'
, ''
~·:-.. .:,:. ..··.. ·.
' · • • ••• 1
~
,
': /. /.' ··-1.........
................. ,,
...: :: ,
.' ..'.
-~~""'i····i·························-~~~~~-_______J
1 Air filter case cover 1

2 Air filter element holder 1
3 Air filter element 1
4 Air filter element frame 1
5 Intake air temperature sensor coupler 1 Disconnect.
6 Air filter case joint clamp screw 2 Loosen.
7 Air filter case joint 1
8 Air intake duct joint clamp screw 2 Loosen.
9 Air intake duct joint 1
10 Intake air temperature sensor 1
11 Air filter case 1
12 Air intake duct 1
7-7
AIR FILTER CASE
EBS30228
INSTALLING THE AIR FILTER CASE

1. Install:
• Air filter case joint "1"
(to the air filter case)
• Air filter case
TIP ~~~~~~~~~~~~~~
Align the projection "a" on the air filter case joint

with the slot "b" on the air intake silencer "2".
7-8
THROTTLE BODY
EBS20056
THROTTLE BODY
Removing the throttle body
.,....-,-------------,
11 ~ 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
2.8 Nm (0.28 m·kgf, 2.0 ft·lbf)
t"'ll-- 4 2.8 Nm 0.28 m·k f, 2.0 ft·lbf
10
a I (-',,,, __
' '
' '
''
''
' ''
' ,
2 -l_/
'
''
''
'
' ----- .------
3 '-:::
r;\· 5 ~ 6
/
\__;v~1)~ ~
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
°"''
,
'
'
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) -....;
'

page 4-28.
1 Intake air pressure sensor coupler 1 Disconnect.
2 Throttle position sensor coupler 1 Disconnect.
3 Throttle body breather hose 1
4 Fuel injector coupler 1 Disconnect.
5 ISC (Idle Speed Control) unit coupler 1 Disconnect.
6 Throttle cable housing cover 1
7 Throttle cable 1 Disconnect.
8 Fuel hose 1 Disconnect.
9 Cylinder head breather hose 1
10 Air intake silencer joint clamp screw 2 Loosen.
11 Air intake silencer joint 1
7-9
THROTTLE BODY
Removing the throttle body

.,....-,-------------,
~ 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
~~
2.8 Nm (0.28 m·kgf, 2.0 ft·lbf)
2.8 Nm 0.28 m·k f, 2.0 ft·lbf
' .................. , ) 13
:.' ',c,·--,, ', I 14
' '
' '
' '
''
''
''
' ,
J' 12
12
' ----- .------
~~
~. /
17
~ "O~S?<
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
....-- -~
°"''
-1
,
15
'
'
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
12 Throttle body joint clamp screw 2 Loosen.

13 Throttle body assembly 1
14 Throttle body joint 1
Air induction system solenoid hose (air intake si-
15 lencer to air induction system solenoid) 1 Disconnect.
16 Air filter case joint clamp screw 1 Loosen.

17 Air intake silencer 1
7-10
THROTTLE BODY
Disassembling the throttle body assembly

~ 3.6 Nm (0.36 m·kgf, 2.6 ft·lbf)
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
3.5 Nm 0.35 m·k f, 2.5 ft·lbf
1 Intake air pressure sensor 1

2 Intake air pressure sensor hose 1
3 Throttle position sensor 1
4 Injector fuel rail 1
5 Fuel injector 1
6 Throttle body 1
7-11
THROTTLE BODY
EBS30229 EBS30231
REMOVING THE THROTTLE BODY CHECKING THE THROTTLE BODY

ASSEMBLY 1. Check:
1. Disconnect: • Throttle body
• Fuel hose Cracks/damage~ Replace the throttle body.
EWB03050
2. Check:
AwARNING • Fuel passages
Cover fuel hose connections with a cloth Obstructions~ Clean .
when disconnecting them. Residual pres- TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
sure in the fuel lines could cause fuel to a. Wash the throttle body in a petroleum- based
spurt out when removing the hose. solvent.
ECB01700 Do not use any caustic carburetor cleaning
NOTICE solution.
-------------
• Be sure to disconnect the fuel hose by b. Blow out all of the passages with compressed
hand. Do not forcefully disconnect the air.
hose with tools. ••••••••••••••••••••••••••••••••
• Although the fuel has been removed from EBS30232
the fuel tank, be careful when removing the CHECKING THE THROTTLE BODY JOINT
fuel hose, since there may be fuel remain- 1. Check:
ing in it. • Throttle body joint "1"
TIP - - - - - - - - - - - - - - - ~
• To disconnect the fuel hose from the injector
fuel rail, slide the fuel hose connector cover "1"
on the end of the hose in direction of the arrow
shown , press the two buttons "2" on the sides
of the connector, and then disconnect the
hose.
• Before disconnecting the hose, place a few
rags in the area under where it will be discon-
nected.
EBS30233
INSTALLING THE THROTTLE BODY

t ASSEMBLY
1. Install:
• Throttle body joint "1"
TIP ~~~~~~~~~~~~~~
Align the projection "a" on the cylinder head with

the slot "b" in the throttle body joint.
1
EBS30230
CHECKING THE INJECTOR

1. Check:
• Injector:
Obstruction ~ Replace and check the fuel
pump/fuel supply system.
Deposit~ Replace.
Damage ~ Replace.
2. Check: 2. Install:
• Injector resistance • Throttle body joint clamps "1"
Refer to "CHECKING TH E FU EL INJ EC-
TOR" on page 9-108.
7-12
THROTTLE BODY
TIP ~~~~~~~~~~~~~~
Align the projections on the throttle body joint

with the gap in each throttle body joint clamp.
1
Du-
1
7
5. Install:
• Air intake silencer "1"
TIP ~~~~~~~~~~~~~~
Align the projection "a" on the air filter case joint

3. Install:
"2" with the slot "b" on the air intake silencer.
• Throttle body assembly "1"
TIP - - - - - - - - - - - - - - - ~
Align the projection "a" on the throttle body as-
sembly between the tabs "b" on the throttle body
joint.
6. Install:
• Air intake silencer joint "1"
TIP~~~~~~~~~~~~~~
Align the projection "a" on the throttle body as-
sembly between the tabs "b" on the air intake si-
4. Connect:
lencer joint.
• Fuel hose
ECB01920
NOTICE
-------------
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
the correct position, otherwise the fuel hose
r
will not be properly installed.
TIP ~~~~~~~~~~~~~~
• Connect the fuel hose securely onto the injec-

tor fuel rail until a distinct "click" in heard.
EBS30234
• To connect the fuel hose onto the injector fuel ADJUSTING THE THROTTLE POSITION
rail, slide the fuel hose connector cover "1" on
SENSOR
the end of the hose in direction of the arrow EWB03070
shown . AwARNING
• Handle the throttle position sensor with
special care.
• Never subject the throttle position sensor
to strong shocks. If the throttle position
sensor is dropped, replace it.
7-13
THROTTLE BODY
1. Check:
• Throttle position sensor
Refer to "CHECKING THE THROTTLE PO-
SIT ION SENSOR" on page 9-106.
2. Adjust:
• Throttle position sensor angle
a. Connect the test harness- TPS (3P) "1" to the
throttle position sensor and wire harness as
shown.
b. Connect the digital circuit tester (DC 20V) to
the test harness- TPS (3P).

90890-03204
YU-03204
Digital circuit tester
90890-03174
Model 88 Multimeter with ta-
chometer
YU-A1927
• Positive tester probe

yellow (wire harness color)
• Negative tester probe
black/blue (wire harness color)
c. Turn the main switch to" ~ " (on).

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

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

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

3.5 Nm (0.35 m-kgf, 2.5 ft-lbf)
7-14
AIR INDUCTION SYSTEM
ESS20057
2 3 4
1
1. Air intake silencer

2. Air induction system hose (air intake silencer
to air cut-off valve)
3. Air cut-off valve
4. Air induction system hose (air cut-off valve to
reed valve cover)
5. Reed valve
7-15
Removing the air cut-off valve
1 Air induction system solenoid coupler 1 Disconnect.

Air induction system hose (air cut-off valve joint
2 to reed valve cover) 1
Air induction system hose (air intake silencer to

3 air cut-off valve) 1
4 Air cut-off valve 1
7-16
Removing the reed valve
,''
'' ''
' '
'
'
'
''
'
''
'
'' '
'
' '
''
' '
----
'
'
\..--'-·..-,_.-... . . . . ..
a
~ 1O Nm (1.0 m·kgf, 7.2 ft·lbf)
Air induction system hose (air cut-off valve to Disconnect.

Refer to "AIR INDUCTION SYSTEM" on
reed valve cover)
page 7-15.
1 Reed valve cover 1
2 Reed valve assembly 1
3 Reed valve plate 1
7-17
EBS30235
2. Check:
CHECKING THE AIR INDUCTION SYSTEM
• Reed valve
• Reed valve stopper
Air injection
• Reed valve seat
The air induction system burns unburned ex-
Cracks/damage ~ Replace the reed valve
haust gases by injecting fresh air (secondary air)
assembly.
into the exhaust port, reducing the emission of
3. Check:
hydrocarbons. When there is negative pressure
• Air cut-off valve
at the exhaust port, the reed valve opens, allow-
ing secondary air to flow into the exhaust port.
4. Check:
The required temperature for burning the un-
• Air induction system solenoid
burned exhaust gases is approximately 600 to
Refer to "CHECKING THE AIR INDUCTION
700 °C (1112 to 1292 °F) .
SYSTEM SOLENOID" on page 9-108.
Air cut-off valve EBS30236
The air cut-off valve is controlled by the signals INSTALLING THE AIR INDUCTION SYSTEM
from the ECU in accordance with the combus- 1. Install:
tion conditions. Ordinarily, the air cut-off valve • Reed valve plate "1"
opens to allow the air to flow during idle and TIP ~~~~~~~~~~~~~~
closes to cut-off the flow when the vehicle is be- Align the notch "a" in the reed valve plate with
ing driven. However, if the coolant temperature the projection "b" of the reed valve seat on the
is below the specified value, the air cut-off valve cylinder head.
remains open and allows the air to flow into the
exhaust pipe until the temperature becomes a
higher than the specified value. 0
I IIi" a° ~
b --++-[@:....Jr'l 000000 00 ~..il.!-~
lJ 0000 6..1
+:---1
00000
r-
'.'
•
0
~
- Ir
~~
'
=c ~
-
~
J.fJ ' . '•

'
=?l ..
'
'
'
~ ~.LJ. _tgt
l=
~~
='~
~
A. From the air intake silencer

B. To the reed valve
1. Check:
• Hoses
Loose connections ~ Connect properly.
7-18
7-19
DRIVE TRAIN
TROUBLESHOOTING .. ......... ......... .......... ........ .......... ......... ......... .......... ......... 8-1
CHECKING NOISES .. ...... ......... ......... ........ ......... .......... ......... ......... ......... . 8-2
TROUBLESHOOTING CHART ......... ........ ......... .......... ......... ......... ......... .. 8-3
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES,

DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT ....... ......... ......... . 8-4
DISASSEMBLING THE UNIVERSAL JOINTS ....... ......... ........... ......... .... 8-10
DISASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ......... ......... .......... ......... ......... .......... ......... ......... .......... ..... 8-1 O
CHECKING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ......... ......... .......... ......... ......... .......... ......... ......... .......... ..... 8-11
ASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ......... ......... .......... ......... ......... .......... ......... .......... ......... ..... 8-11
REMOVING THE FRONT DRIVE SHAFT YOKE ... ........ .......... ......... ...... 8-12
REMOVING THE DIFFERENTIAL GEAR ASSEMBLY ..... ......... ......... .... 8-13
CHECKING THE FRONT DRIVE SHAFT ..... .......... .......... ......... .......... ... 8-13
CHECKING THE DIFFERENTIAL ASSEMBLY ..... ......... ......... .......... ..... 8-13
CHECKING THE DIFFERENTIAL MOTOR OPERATION ..... .......... ....... 8-13
ASSEMBLING THE FRONT DRIVE SHAFT ....... .......... ......... .......... ....... 8-14
ASSEMBLING THE DIFFERENTIAL ASSEMBLY ....... .......... ......... ........ 8-14
ASSEMBLING THE UNIVERSAL JOINT ..... .......... ........ .......... ......... ...... 8-15
MEASURING THE DIFFERENTIAL GEAR BACKLASH .. .......... ......... .... 8-16
ADJUSTING THE DIFFERENTIAL GEAR BACKLASH .. .......... ......... ..... 8-17
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES,

FINAL DRIVE ASS EMBLY AND REAR DRIVE SHAFT .... .......... .......... ...... 8-18
DISASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASS EM BLI ES ......... ......... .......... ......... .......... ......... ......... .......... ......... ..... 8-24
CHECKING THE REAR CONSTANT VELOCITY SHAFT
ASS EM BLI ES ......... .......... ......... ......... .......... ......... ......... .......... ......... ..... 8-24
ASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......... .......... ......... ......... .......... ......... ......... .......... ......... ..... 8-25
DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY .. ..... 8-26
CHECKING THE REAR DRIVE SHAFT ........ ......... ......... ......... .......... ..... 8-27
CHECKING THE FINAL DRIVE ASSEMBLY ....... .......... ......... .......... ...... 8-27
ADJUSTING THE RING GEAR STOPPER .......... .......... .......... ......... ...... 8-27
MEASURING THE FINAL GEAR BACKLASH ........ ......... ......... ......... ..... 8-27
ADJUSTING THE FINAL GEAR BACKLASH ...... .......... .......... .......... ..... 8-28
ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY ......... .... 8-29
INSTALLING THE FINAL DRIVE ASS EMBLY ...... ......... .......... .......... ..... 8-29
TROUBLESHOOTING
EBS20058
TROUBLESHOOTING
The following conditions may indicate damaged shaft drive components:
Symptoms Possible Causes
1. A pronounced hesitation or "jerky" movement A. Bearing damage.
during acceleration, deceleration, or sustained B. Improper gear backlash.
speed. (This must not be confused with engine C. Gear tooth damage.
surging or transmission characteristics.) 0. Broken drive shaft.
2. A "rolling rumble" noticeable at low speed; a high- E. Broken gear teeth.
pitched whine; a "clunk" from a shaft drive com- F. Seizure due to lack of lubrication.
ponent or area. G. Small foreign objects lodged between the moving
3. A locked-up condition of the shaft drive train parts.
mechanism, no power transmitted from the en-
gine to the front and/or rear wheels.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal vehicle operating noise. If there is reason to believe these compo-
nents are damaged, remove the components and check them.
8-1
TROUBLESHOOTING
ESS30237
CHECKING NOISES a. Clean the entire vehicle thoroughly, then dry
1. Investigate any unusual noises. it.
b. Apply a leak detection compound or dry pow-
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT der spray to the shaft drive.
The following "noises" may indicate a me-
c. Road test the vehicle for the distance neces-
chanical defect:
sary to locate the leak.
a. A "rolling rumble" noise during coasting, ac-
Leakage ~ Check the component housing,
celeration, or deceleration. The noise in-
gasket, and/or seal for damage.
creases with front and/or rear wheel speed,
Damage ~ Replace the component.
but it does not increase with higher engine or
TIP ~~~~~~~~~~~~~~
transmission speeds.
Diagnosis: Possible wheel bearing damage. • An apparent oil leak on a new or nearly new ve-
Refer to "TROUBLESHOOTING CHART' on hicle may be the result of a rust-preventative
page 8-3. coating or excessive seal lubrication.
b. A "whining" noise that varies with accelera- • Always clean the vehicle and recheck the sus-
tion and deceleration . pected location of an apparent leakage.
Diagnosis: Possible incorrect reassembly,
too little gear backlash .
Refer to "MEASURING THE DIFFERENTIAL
GEAR BACKLASH" on page 8-16 or "MEA-
SURING THE FINAL GEAR BACKLASH" on
page 8-27.
EWB02900
A WARNING
Insufficient gear backlash is extremely de-
structive to the gear teeth. If a test ride, fol-
lowing reassembly, indicates these
symptoms, stop riding immediately to mini-
mize gear damage.
c. A slight "thunk" evident at low speed opera-
tion . This noise must be distinguished from
normal vehicle operation.
Diagnosis: Possible broken gear teeth.
EWB02910
A WARNING
Stop riding immediately if broken gear teeth
are suspected. This condition could result in
the shaft drive assembly locking up, causing
a loss of control and possible injury to the
rider.
••••••••••••••••••••••••••••••••
2. Check:
• Drained oil
Drained oil shows large amounts of metal
particles ~ Check the bearing for seizure.
TIP~~~~~~~~~~~~~~
A small amount of metal particles in the oil is nor-
mal.
3. Check:
• O il leakage
8-2
TROUBLESHOOTING
EBS30238
TROUBLESHOOTING CHART
When basic conditions (a) and (b) described in "CHECKING NOISES" exist, check the following points:
YES~ Replace the wheel bearing . Refer to

1. Elevate and spin both wheels. Feel "STEERING KNUCKLES" on page 4-65
for wheel bearing damage. and "REAR KNUCKLES AND STABILIZ-
ER" on page 4-73.
NO j,
2. Check the wheel nuts and axle nuts NO~ Torque to specification . Refer to "FRONT
for tightness. AND REAR WHEELS" on page 4-33.
YES j,
NO~ Constant velocity shaft bearings and differ-

3. Check the front constant velocity
ential bearings are probably not damaged.
shaft assemblies. Feel for bearing
Repeat the test or remove the individual
damage.
components.
YES j,
NO~ Adjust per instructions. Refer to "ADJUST-

4. Check the parking brake adjust-
ING THE PARKING BRAKE LEVER" on
ment.
page 3-21 .
YES j,
NO~ Constant velocity shaft bearings and final

5. Check the rear constant velocity
gear bearings are probably not damaged.
shaft assemblies. Feel for bearing
Repeat the test or remove the individual
damage.
components.
YES j,
Remove the shaft drive components.
8-3
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE SHAFT
EBS20059
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL

ASSEMBLY AND FRONT DRIVE SHAFT
Removing the front constant velocity shaft assemblies, differential assembly, and front drive shaft
150 Nm 15 m·k f, 108 ft·lbf
.......... ;
--
'
..
'
'
"
'"
'
'
:' _.,....--'-- a:;__-,,
~ 60 Nm (6.0 m·kgf, 43 ft·lbf)
Side frames Refer to "GENERAL CHASSIS (5)" on page

4-12.
Front fender/Instrument panel/Front guard Refer to "GENERAL CHASSIS (6)" on page

4-15.
Sound-deflection panel Refer to "GENERAL CHASSIS (4)" on page

4-10.
Center passenger compartment panel/Center Refer to "GENERAL CHASSIS (7)" on page
floor board 4-20.
Front skid plate Refer to "GENERAL CHASSIS (1 )" on page

4-1 .
Heat shield 5-7.
Refer to "STEERING KNUCKLES" on page
Steering knuckles 4-65.
Drain.
Differential gear oil Refer to "CHANGING THE DIFFERENTIAL
GEAR OIL'.' on page 3-17.
8-4
Removing the front constant velocity shaft assemblies, differential assembly, and front drive shaft
150 Nm 15 m·k f, 108 ft·lbf
--
'
" .,. ., "
..
-'
I
'
'
"
'"
'
'
'
: _.,---'-~a::__-(
5
1
~ 60 Nm (6.0 m·kgf, 43 ft·lbf)
1 Front constant velocity shaft assembly 2

2 Differential motor coupler 1 Disconnect.
3 Differential assembly breather hose 1 Disconnect.
4 Differential assembly 1
5 Support bearing bracket 1
6 Front drive shaft (differential side) 1
7 Dust seal 1
8 Universal joint 2
9 Universal joint yoke 2
10 Front drive shaft (middle gear side) 1
11 Support bearing housing 1
12 Support bearing rubber 1
13 Oil seal 1
14 Oil seal 1
15 Bearing 1
8-5
Disassembling the front constant velocity shaft assemblies
61~-
7
[ID
41~-
1~m 2 •
3
1~t4W 1
"
•
1~t4W8
/
l~@i 9
A: Wheel side
B: Differential side

the front constant velocity shaft assemblies.
1 Boot band 1
2 Boot band 1
3 Dust boot 1
4 Clip 1
5 Double offset joint 1
6 Circlip 1
7 Ball bearing 1
8 Boot band 1
9 Boot band 1
8-6
Disassembling the front constant velocity shaft assemblies
13
A: Wheel side
B: Differential side
10 Dust boot 1
11 Constant velocity joint 1
12 Clip 1
13 Constant velocity shaft 1
8-7
Disassembling the differential assembly
1
11 Nm (1.1 m·kgf, 8.0 ft·lbf)
62 Nm (6.2 m·kgf, 45 ft·lbf)
10
6
9
["aj 24 Nm (2.4 m·kgf, 17 ft·lbf) I
I~ 23 Nm (2.3 m·kgf, 17 ft·lbf) I
15\!1O Nm (1.0 m·kgf, 7.2 ft·lbf) I ~ 24 Nm (2.4 m·kgf, 17 ft·lbf)
* SAE 80 API GL-4 Hypoid gear oil
1 Differential motor 1
2 Front drive shaft yoke nut (differential case side) 1
3 Front drive shaft yoke (differential case side) 1
4 Bracket 1
5 Differential case cover 1
6 Differential gear assembly 1
Refer to "ADJUSTING THE DIFFEREN-
7 Differential gear assembly shim
TIAL GEAR BACKLASH" on page 8-17.
8 Bearing 1
9 Bearing 1
10 Oil seal 1
8-8
Disassembling the differential assembly
11 Nm (1.1 m·kgf, 8.0 ft·lbf)
62 Nm (6.2 m·kgf, 45 ft·lbf)
11
13
12
14 fl
["aj 24 Nm (2.4 m·kgf, 17 ft·lbf) I
I~ 23 Nm (2.3 m·kgf, 17 ft·lbf) I

~
rii
"""-,l-1O-N-m-(1-.0-m-·-kg-f,-7-.2-ft-·lb-f)-,-!_ _,i, ~ 24 Nm (2.4 m·kgf, 17 ft·lbf)
11 Clip 1
12 Differential pinion gear 1
13 Bearing 1
14 Bearing 1
15 Oil seal 2
16 Differential case 1
8-9
EBS30239
DISASSEMBLING THE UNIVERSAL JOINTS

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
universal joint yoke "3", press the bearing "4"
into the pipe as shown.
TIP ~~~~~~~~~~~~~~
It may be necessary to lightly tap the universal

joint yoke with a punch. 4
-· 1 3
,, ,, 0
,,"
o I
A. Differential side
I -:t----2
2. Remove:
• Boot band "1"
TIP ~~~~~~~~~~~~~~
Use the boot band installation tool "2".

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

e. Remove the universal joint.
••••••••••••••••••••••••••••••••
ESS30240
2
1
DISASSEMBLING THE FRONT CONSTANT
VELOCITY SHAFT ASSEMBLIES
front constant velocity shaft assemblies.
1. Remove:
• Boot bands B. Wheel side
• Clip "1" 3. Remove:
• Double offset joint "2" • Dust boot
• Circlip "3" • Constant velocity joint
• Ball bearing "4" • Clip
• Dust boot "5" TIP ~~~~~~~~~~~~~~~
TIP ~~~~~~~~~~~~~~
Secure the constant velocity shaft in a vise, and
Before removing the clip, slide the dust boot then remove the constant velocity joint using
away from the double offset joint. hammers.
8-10
< 3
B. Wheel side
EBS3024 1
t--1---3
CHECKING THE FRONT CONSTANT
1. Check:
• Double offset joint splines
• Constant velocity joint splines
• Constant velocity shaft splines
Wear/damage ~ Replace.
2. Check:
• Dust boots
ECB01590
NOTICE
-------------
A Iways use a new boot band.
(
3. Check:
• Balls and ball races
• Inner surface of double offset joint
Pitting/wear/damage ~ Replace. A. Wheel side
ESS30242
ASSEMBLING THE FRONT CONSTANT

•2.•••••••••••••••••••••••••••••••
Install:
VELOCITY SHAFT ASSEMBLIES • Dust boot
The following procedure applies to both of the • Ball bearing "1"
1. Install:
• Circlip "2" ilf:ii
• Double offset joint "3"
• Clip "1"il@:i • Clip "4" iltii
• Constant velocity joint "2"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Constant velocity shaft "3"
• Dust boot • Securely install the circlip into the groove in the
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT constant velocity shaft.
a. Install a new clip. • Securely install the clip into the groove in the
b. Install the constant velocity joint. double offset joint.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Install the clip into the groove in the constant
velocity shaft as shown.
• Secure the constant velocity joint in a vise, and
then fit the constant velocity shaft into the con-
stant velocity joint using a plastic hammer.
8-11
l~f:i,Jj
1 5 --- 3 l~tMI
··- ----···- 2 l~r:w,
21IM
a. Install the dust boots.
b. Install the dust boot bands "4" and "5".
TIP~~~~~~~~~~~~~~

41~t4W 90890-01526
YM-01526
B. Differential side
3. Apply:
• Molybdenum disulfide grease
(into the double offset joint, constant velocity 6
joint, and dust boots)
4
I
60-80 g (2.1 - 2.8 oz) per dust
boot (wheel side)
35-55 g (1.2-1.9 oz) per dust
boot (differential side)
••••••••••••••••••••••••••••••••
5. Check:
TIP ~~~~~~~~~~~~~~
Molybdenum disulfide grease is included in the • Thrust movement free play

repair kit. Excessive play ~ Replace the constant ve-
locity shaft assembly.
4. Install:
• Dust boots "1"
• Boot bands "2", "3", "4", "5" ii&
TIP ~~~~~~~~~~~~~~
The dust boots should be fastened with the boot

bands "3" and "5" at the grooves in the constant
\11
velocity shaft.
EBS30243
REMOVING THE FRONT DRIVE SHAFT

YOKE
1. Remove:
• Front drive shaft yoke
8-12
TIP ~~~~~~~~~~~~~~ 2. Check:
Use the universal joint holder "1" to hold the front • Support bearing
drive shaft yoke, then loosen the front drive shaft Damage~ Replace.
yoke nut. 3. Check:
• Support bearing housing
• Support bearing rubber
Universal joint holder
90890-04062
Universal joint holder EBS30246
YM-04062 CHECKING THE DIFFERENTIAL ASSEMBLY

1. Check:
• Differential case
• Differential case cover
TIP ~~~~~~~~~~~~~~
When the differential case and/or the differential

case cover are replaced , be sure to adjust the
7
1
shim of the differential gear assembly.
2. Check:
• Gear teeth
ESS30244 Pitting/galling/wear ~ Replace.
REMOVING THE DIFFERENTIAL GEAR TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~
ASSEMBLY When the differential pinion gear and/or the dif-
1. Remove: ferential assembly are replaced , be sure to ad-
• Differential gear assembly "1" just the shim of the differential gear assembly.
ECB01570
NOTICE
-------------
The ring gear and differential gear are as-
3. Check:
• Bearings
sembled into a proper unit at the factory by Damage~ Replace.
means of specialized equipment. Do not at- EBS30247
tempt to disassemble this unit. Disassembly CHECKING THE DIFFERENTIAL MOTOR
will result in the malfunction of the unit. OPERATION
1. Check:
• Differential motor operation
Does not operate ~ Replace.
1 EC.801930
NOTICE
-------------
Do not disassemble the differential motor or
remove the differential motor pinion gear.
a. Connect two C-size batteries to the differen-
tial motor terminals "1" (as shown in the illus-
ESS30245 trations) .
ECB01940
CHECKING THE FRONT DRIVE SHAFT
NOTICE
1. Check: -------------
• Do not use a 12 V battery to operate the dif-
• Drive shaft splines
• Coupling sleeve splines ferential motor pinion gear.
Wear/damage ~ Replace. • Do not connect the batteries to the differen-
EWB03040 tial motor when it is installed in the differen-
~ WARNING tial case. The differential motor should be
Do not attempt to straighten a bent shaft; checked when it is removed from the differ-
this may dangerously weaken it. ential case.
8-13
3V Installed depth of oil seal "a"
,---,,+ I + -0.5-0.5 mm (-0.020-0.020 in)
1 a 4
t-----1-/
,.,..__ (~
1-==i
3V
I +
A. Check that the differential motor pinion gear

"2" turns counterclockwise.
B. Check that the differential motor pinion gear
"2" turns clockwise.
3. Differential case
4. Differential case cover
ESS30248
ASSEMBLING THE FRONT DRIVE SHAFT 2. Measure:

1. Install: • Gear backlash
• Oil seal "1" Refer to "MEASURING THE DIFFERENTIAL
• Oil seal "2" GEAR BACKLASH" on page 8-16.
3. Install:
Installed depth of oil seal "a" • Differential motor
1.0-1.5 mm (0.039-0.059 in) TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Slide the shift fork sliding gear "1", which is in-
stalled to the differential case cover, to the
a l ~1 right front constant velocity shaft assembly
t '
I I
•.C side as shown in the illustration to put it into
the 2WD mode.
el
I
j
I
~
3
1
I
~ ()! '" n
J 2
a t
3. Support bearing housing
ESS30249
ASSEMBLING THE DIFFERENTIAL

ASSEMBLY
b. Connect two C-size batteries to the differen-
1. Install:
tial motor terminal "2" to operate the differen-
• Oil seals "1"
tial motor pinion gear "3". Operate the
• Oil seal "2"
differential motor pinion gear until the mark
8-14
"a" on the differential motor pinion gear is
aligned with the mark "b" on the differential
motor case.
EC8016SO
NOTICE
- - - - - - - - - - - - -
Do not use a 12 V battery to operate the dif-
ferential motor pinion gear.
2 II '
lf;.c~=80s=o..=c80~ @
5. Install:
0
• Front drive shaft yoke
• Washer
• Front drive shaft yoke nut
+ I +1...........
Front drive shaft yoke nut
3V 62 Nm (6.2 m-kgf, 45 ft-lbf)
c. Insert 6 mm bolts "4" into the differential mo- TIP_~~~~~~~~~~~~~

tor "5" and use them as a guide to set the mo-
tor on the differential case cover "6" so that • Apply locking agent (LOCTIT E®) to the nut
threads.
the shift fork sliding gear "7" does not move.
ECB0l9S0 • Use the universal joint holder "1" to hold the
NOTICE front drive shaft yoke, then tighten the front
-------------
1f the position of the shift fork sliding gear is drive shaft yoke nut.
moved, the position of the differential gear
assembly and the indicator light display may Universal joint holder
differ, and the 2WD or differential lock mode 90890-04062
may not be activated. Universal joint holder
YM-04062
1
7
d. Remove the 6 mm bolts, and then install the
motor with the differential motor bolts. EBS30250
ASSEMBLING THE UNIVERSAL JOINT

Differential motor bolt 1. Install:
11 Nm (1.1 m-kgf, 8.0 ft-lbf) • Universal joint
••••••••••••••••••••••••••••••••
4. Check:
a. Install the universal joint into the front drive
shaft yoke.
• Differential assembly operation
Unsmooth operation ~ Replace the differen-
tial assembly.
Insert the double offset joint into the differen-
tial assembly, and turn the gears back and
forth.
8-15
EBS30251
MEASURING THE DIFFERENTIAL GEAR

BACKLASH
1. Secure the differential case in a vise or anoth-
er supporting device.
2. Remove:
• Drain plug
-- ·- - • Gasket
3. Install:
• Ring gear fix bolt (M 10) "1"
(into the drain plug hole)
b. Apply lithium-soap-based grease to the bear-
ings. Ring gear fix bolt (M10)
c. Install the bearing "1" onto the front drive 90890-01527
shaft yoke. Ring gear fix bolt (M10)
EC8 01670
YM-01527
NOTICE
------------- ECB01250
The needles can easily fall out of their races, ---,
NOTICE
so check each bearing carefully. Slide the -------------
universal joint driven yoke assembly back Finger tighten the bolt until it holds the ring
and forth on the bearings. If a needle is out of gear. Otherwise, the ring gear will be dam-
place, the yoke will not go all the way onto aged.
the bearings. 4. Attach :
• Gear lash measurement tool "2"
1 • Dial gauge "3"
Gear lash measurement tool

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

yoke using a suitable socket.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
The bearing must be inserted far enough into the 0
universal joint yoke and front drive shaft yoke so
that the circlip can be installed.
e. Install new circlips "2" i~M into the groove

-a
a. Measuring point is 31.0 mm (1.22 in)
of each bearing .
5. Measure:
• Gear backlash
2
Gently rotate the differential pinion gear from
engagement to engagement.
Differential gear backlash

0.05-0.25 mm (0.002-0.01 O in)
TIP - - - - - - - - - - - - - - -
Measure the gear backlash at four positions. Ro-
tate the differential pinion gear 90° each time.
8-16
EBS30252
ADJUSTING THE DIFFERENTIAL GEAR

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

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

••••••••••••••••••••••••••••••••
8-17
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
EBS20060
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE

ASSEMBLY AND REAR DRIVE SHAFT
Removing the rear constant velocity shaft assemblies, final drive assembly, and rear drive shaft
105 Nm (10.5 m·kgf, 76 ft·lbf)
-------
----------
(4)
105 Nm (10.5 m·kgf, 76 ft·lbf)

Refer to "REAR KNUCKLES AND STABI-
Rear knuckles LIZER" on page 4-73.
Parking brake caliper Refer to "PARKING BRAKE" on page 4-50.
Refer to"ENGINE REMOVAL (1 )" on page
Muffler 5-2.
Drain.
Final gear oil Refer to "CHANGING THE FINAL GEAR
OIL'.' on page 3-16.
1 Rear constant velocity shaft assembly 2
2 Final drive assembly breather hose 1 Disconnect.
3 Final drive assembly bracket (upper side) 1
4 Final drive assembly 1
5 Spring 1
8-18
Removing the rear constant velocity shaft assemblies, final drive assembly, and rear drive shaft
105 Nm (10.5 m·kgf, 76 ft·lbf)
(4)
~-33-Nm-(3-.3-m-·-kg_f_
, 2-4-ft--l-bf-;)
.
--.J
@7~ =
'
/-- -------..__,,
~~ ©)
33 Nm 3.3 m·kgf, 24 ft·lbf)
11
105 Nm (10.5 m·kgf, 76 ft·lbf)
6 Rear drive shaft 1

7 Damper 1
8 Rear drive shaft coupling sleeve 1
9 Dust seal 1
10 Dust seal 1
11 Final drive assembly bracket (lower side) 1
8-19
Disassembling the rear constant velocity shaft assemblies
61~-
7
41~-
1~m 2
3
1~t4W1
l~@i 9
A: Wheel side
B: Final drive side

the rear constant velocity shaft assemblies.
1 Boot band 1
2 Boot band 1
3 Dust boot 1
4 Clip 1
5 Double offset joint 1
6 Circlip 1
7 Ball bearing 1
8 Boot band 1
9 Boot band 1
10 Dust boot 1
11 Constant velocity joint 1
12 Clip 1
8-20
Disassembling the rear constant velocity shaft assemblies
13
•
A: Wheel side
B: Final drive side

13 Constant velocity shaft 1
8-21
Disassembling the final drive assembly
23 Nm (2.3 m·kgf, 17 ft·lbf)
*
13
111~·
10
I. V 1~&12
'
52 Nm 5.2 m·k f, 38 ft·lbf

16Nm 1.6m·k f,12ft·lbf a
26 Nm (2.6 m·kgf, 19 ft·lbf)
97 Nm 9.7 m·k f, 70 ft·lbf

Parking brake disc Refer to "PARKING BRAKE" on page 4-50.
1 Final drive pinion gear assembly 1
2 Rear drive shaft yoke (final drive assembly side) 1
3 Final drive pinion gear 1
4 Final drive pinion gear shim
5 Collar 1
6 Oil seal 1
7 Bearing 1
8 Final drive pinion gear bearing housing 1
9 Ring gear stopper 1
10 Final drive case cover 1
11 Final drive case cover gasket 1
12 Oil seal 1
13 Final drive ring gear 1
8-22
Disassembling the final drive assembly
23 Nm (2.3 m·kgf, 17 ft·lbf)
20
*
16
14
,,,,,,,"",,,.
*~---------,
52 Nm 5.2 m·k f, 38 ft·lbf
16Nm 1.6m·k f,12ft·lbf a
26 Nm (2.6 m·kgf, 19 ft·lbf)
97 Nm 9.7 m·k f, 70 ft·lbf
* SAE 80 API GL-4 Hy po id gear oil

Final drive ring gear shim (final drive case cover
14 side)
15 Final drive ring gear shim (final drive case side)
16 Bearing 1
17 Bearing 1
18 Bearing 1
19 Dowel pin 2
20 Final drive case 1
21 Oil seal 1
8-23
EBS30253
DISASSEMBLING THE REAR CONSTANT

rear constant velocity shaft assemblies. 2
1. Remove: 1
• Boot bands
• Clip "1"
• Double offset joint "2"
• Circlip "3"
• Ball bearing "4"
B. Wheel side
• Dust boot "5"
TIP ~~~~~~~~~~~~~~ 3. Remove:
Before removing the clip, slide the dust boot • Dust boot
away from the double offset joint. • Constant velocity joint
• Clip
TIP - - - - - - - - - - - - - - -
Secure the constant velocity shaft in a vise, and
then remove the constant velocity joint using
hammers.
3
B. Wheel side
EBS30254
CHECKING THE REAR CONSTANT

A. Final drive side rear constant velocity shaft assemblies.
2. Remove: 1. Check:
• Boot bands "1" • Double offset joint splines
Use the boot band installation tool "2". • Constant velocity joint splines
• Constant velocity shaft splines
Boots band installation tool Wear/damage ~ Replace.
90890-01526 2. Check:
Boots band installation tool • Dust boots
YM-01526 Cracks/damage ~ Replace.
ECB01590
NOTICE
-------------
A Iways use a new boot band.
3. Check:
• Balls and ball races
• Inner surface of double offset joint
Pitting/wear/damage ~ Replace.
8-24
EBS30255
2. Install:
ASSEMBLING THE REAR CONSTANT
• Dust boot
• Ball bearing "1"
rear constant velocity shaft assemblies. • Circlip "2" ii&
1. Install: • Double offset joint "3"
• Clip "1" ilt¥i • Clip "4" ilt¥i

• Constant velocity joint "2" TIP ~~~~~~~~~~~~~~
• Constant velocity shaft "3" • Securely install the circlip into the groove in the
• Dust boot constant velocity shaft.
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT • Securely install the clip into the groove in the
a. Install the clip. double offset joint.
b. Install the constant velocity joint.
TIP~~~~~~~~~~~~~~
• Install the clip into the groove in the constant

velocity shaft as shown.
• Secure the constant velocity joint in a vise, and 21IM
then fit the constant velocity shaft into the con-
stant velocity joint using a plastic hammer.
< 3
4iltN
3
B. Final drive side
3. Apply:
• Molybdenum disulfide grease
ilt4W1 (into the double offset joint, constant velocity
joint, and dust boots)

l 60-80 g (2.1-2.8 oz) per dust
boot (wheel side)
55-75 g (1.9-2.6 oz) per dust
boot (final drive side)
TIP~~~~~~~~~~~~~~
Molybdenum disulfide grease is included in the

repair kit.
4. Install:
• Dust boots "1"
A. Wheel side
• Boot bands "2", "3", "4", "5" ilt¥i
8-25
EBS30256
TIP ~~~~~~~~~~~~~~
DISASSEMBLING THE FINAL DRIVE PINION
The dust boots should be fastened with the boot GEAR ASSEMBLY
bands "3" and "5" at the grooves in the constant 1. Remove:
velocity shaft. • Rear drive shaft yoke nut
• Washer
• Rear drive shaft yoke "1"
TIP - - - - - - - - - - - - - - -
1 5 l~f4ij 31~@4 1 2 l~f4ij • Secure the final drive assembly in a vise.
• Use the coupling gear holding tool (35) "2" to
hold the rear drive shaft yoke.

90890-01571
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT YM-01571
a. Install the dust boots.
b. Install the dust boot bands "4" and "5".

90890-01526
YM-01526
6 2. Remove:
• Final drive pinion gear "1"
4 TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Clean the outside surface of the final drive
p1n1on gear.
b. Place the final drive gear in a hydraulic press.
ECB01580
NOTICE
- - - - - - - - - - - - -
••••••••••••••••••••••••••••••••
5. Check:
• Never directly press the gear end with a hy-
draulic press, this will result in damage to
• Thrust movement free play the gear thread.
Excessive play ~ Replace the constant ve- • Install the suitable socket on the gear end
locity shaft assembly. to protect the thread from damage.
c. Press the gear end and remove the final drive
pinion gear.
8-26
TIP ~~~~~~~~~~~~~~
• Apply Yamaha bond No.1215 to the ring gear

stopper threads.
• Apply LOCTIT E® to the nut threads.
2. Adjust:
• Ring gear stopper clearance
a. Finger tighten the ring gear stopper until it
contacts the ring gear "2".
2. Suitable socket
2 --i-
EBS30257
CHECKING THE REAR DRIVE SHAFT

1. Check:
• Drive shaft splines
• Coupling sleeve splines
Wear/damage ~ Replace.
EWB03040
A WARNING b. Turn the ring gear stopper 120° counterclock-

Do not attempt to straighten a bent shaft; wise.
this may dangerously weaken it. l
EBS30258
I~
CHECKING THE FINAL DRIVE ASSEMBLY
1. Check:
• Final drive case
• Final drive case cover
TIP~~~~~~~~~~~~~~~
When the final drive case and/or the final drive
case cover are replaced, be sure to adjust the c. Tighten the ring gear stopper nut "3".
shim of the final drive pinion gear and/or ring
gear. Ring gear stopper nut
16 Nm (1.6 m-kgf, 12 ft-lbf)
2. Check: LOCTITE®
• Gear teeth
Pitting/ galling/ wear ~ Replace the final drive
pinion gear and ring gear as a set. EBS30260
TIP ~~~~~~~~~~~~~~ MEASURING THE FINAL GEAR BACKLASH

When the final drive pinion gear and ring gear 1. Remove:
are replaced, be sure to adjust the shim of the fi- • Filler plug
nal drive pinion gear and/or ring gear. • Gasket
2. Install:
3. Check: • Ring gear fix bolt (M 1O x 1.5) "1"
• Bearings (into the drain plug hole)
Damage ~ Replace.
Ring gear fix bolt (M1 O x 1.5)
EBS30259
90890-01572
ADJUSTING THE RING GEAR STOPPER
Ring gear fix bolt (M1 O x 1.5)
1. Install:
YM-01572
• Ring gear stopper "1"
• Nut
8-27
ECB0l2SO
• Final drive ring gear shim (final drive case
NOTICE
------------- cover side) "3"
Finger tighten the bolt until it holds the ring • Final drive ring gear shim (final drive case
gear. Otherwise, the ring gear will be dam- side) "4"
aged.
2. Adjust:
3. Attach: • Gear backlash
• Gear lash measurement tool "1" TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Select a suitable shim(s) using the following
• Dial gauge "2"
chart.
Gear lash measurement tool Final gear backlash is in-
Thinner shim
90890-01467 creased.
Gear lash measurement tool Final gear backlash is de-
YM-01467 Thicker shim
creased.
b. If increased by more than 0.2 mm (0.008 in):

Reduce the final drive ring gear shim (final
drive case cover side) "3" thickness by 0.2
mm (0.008 in) for every 0.2 mm (0.008 in) that
the final drive ring gear shim (final drive case
side) "4" is increased .
c. If reduced by more than 0.2 mm (0.008 in) :
Increase the final drive ring gear shim (final
drive case cover side) "3" thickness by 0.2
mm (0.008 in) for every 0.2 mm (0.008 in) that
a. Measuring point is 31.5 mm (1.24 in) the final drive ring gear shim (final drive case
side) "4" is decreased.
4. Measure:
• Gear backlash Final drive ring gear shims (final
Gently rotate the final drive pinion gear from drive case cover side) "3"
engagement to engagement. Thickness (mm)
0.2 0.3
Final gear backlash
0.13-0.23 mm (0.005-0.009 in) TIP ~~~~~~~~~~~~~~
Be sure to use one of each of the final drive ring
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~ gear shim (final drive case cover side) "3" and fi-
Measure the gear backlash at four positions. Ro- nal drive ring gear shim (final drive case side) "4"
tate the final drive pinion gear 90° each time. to obtain the shim thickness.
ESS30261
Final drive ring gear shims (final
ADJUSTING THE FINAL GEAR BACKLASH
drive case side) "4"
1. Remove:
Thickness (mm)
• Final drive ring gear "1" 0.2 0.3
• Bearings "2"
8-28
EBS30262
ASSEMBLING THE FINAL DRIVE PINION Final drive assembly bracket bolt
GEAR ASSEMBLY (upper side)
1. Apply: 33 Nm (3.3 m-kgf, 24 ft-lbf)
• Sealant
(onto the washer contact surface and splines • Final drive assembly "2"
of the final drive pinion gear)
Final drive assembly nut (upper
Yamaha bond No. 1215 side)
90890-85505 105 Nm (10.5 m-kgf, 76 ft-lbf)
• Final drive assembly bracket (lower side) "3"
Final drive assembly nut (lower

side)
105 Nm (10.5 m-kgf, 76 ft-lbf)

(lower side)
33 Nm (3.3 m-kgf, 24 ft-lbf)
TIP ~~~~~~~~~~~~~~
2. Install : Tighten the bolts and nuts to specification in the
• Rear drive shaft yoke (final drive case side) proper tightening sequence shown.
"1"
Rear drive shaft yoke nut (final

drive assembly side)
97 Nm (9. 7 m-kgf, 70 ft-lbf)
LOCTITE®
¢FWD
TIP ~~~~~~~~~~~~~~
2..,_
• Secure the rear differential assembly in a vise.
• Use the coupling gear holding tool (35) "2" to 0n 2
n
hold the rear drive shaft yoke.

90890-01571
YM-01571
EBS30263
INSTALLING THE FINAL DRIVE ASSEMBLY

1. Install
• Final drive assembly bracket (upper side) "1"
8-29
ELECTRICAL SYSTEM
IGNITION SYSTEM ...... ......... ........ ........ ......... ........ ......... ......... ....... ......... ....... 9-1
CIRCU IT DIAGRAM ......... .......... ......... ......... ........ ......... .......... ......... ......... 9-1
TROUBLESHOOTING ... .......... ......... ........ .......... ......... ......... .......... ......... . 9-3
ELECTRIC STARTING SYSTEM .... ......... ....... ......... ......... ........ ......... ....... ...... 9-5
CIRCU IT DIAGRAM ......... .......... ......... ......... ........ ......... .......... ......... ......... 9-5
STARTING CIRCU IT CUT-OFF SYSTEM OPERATION ......... ......... ........ 9-7
TROUBLESHOOTING ... .......... ......... ........ .......... ......... ......... .......... ......... . 9-8
CHARGING SYSTEM ... ......... ......... .......... ........ .......... ......... .......... ......... ....... 9-11
CIRCU IT DIAGRAM .......... .......... ......... .......... .......... ......... ......... ......... .... 9-11
TROUBLESHOOTING ... .......... ......... ......... ......... .......... ......... ......... ........ 9-13
LIGHTING SYSTEM ..... ......... ......... .......... ........ .......... ......... .......... ......... ....... 9-15
CIRCU IT DIAGRAM .......... .......... ......... .......... ......... .......... ......... ......... .... 9-15
TROUBLESHOOTING ... .......... ......... ......... ......... ......... .......... ......... ........ 9-17
SIGNALING SYSTEM .. ......... ......... .......... ........ .......... ......... ......... .......... ....... 9-19
CIRCU IT DIAGRAM .......... .......... ......... .......... ......... .......... ......... ......... .... 9-19
COOLING SYSTEM ....... .......... .......... ........... .......... .......... .......... .......... ......... 9-27
CIRCU IT DIAGRAM .......... .......... ......... .......... ......... .......... ........ .......... .... 9-27
FUEL INJECTION SYSTEM .. ......... .......... ........ .......... ......... ......... .......... ....... 9-31
CIRCU IT DIAGRAM .......... .......... ......... .......... ......... .......... ........ .......... .... 9-31
ECU SELF-DIAGNOSTIC FUNCTION ....... ......... .......... ......... .......... ....... 9-33
TROUBLESHOOTING METHOD ........ ......... .......... ........ .......... .......... ..... 9-33
YAMAHA DIAGNOSTIC TOOL ......... ......... ......... .......... ......... ......... ........ 9-34
TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM) ..... ....... 9-35
FU EL PUMP SYSTEM .. ......... ......... .......... ........ .......... ......... ......... .......... ....... 9-65
CIRCU IT DIAGRAM .......... .......... ......... .......... ......... .......... ........ .......... .... 9-65
2WD/4WD SELECTING SYSTEM .. .......... ........ ......... .......... ......... .......... ....... 9-69
CIRCU IT DIAGRAM .......... .......... ......... .......... ......... .......... ........ .......... .... 9-69
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) .... ....... 9-73
CIRCUIT DIAGRAM .......... ......... .......... ......... ......... ......... ......... .......... ..... 9-73
EPS CONTROL UNIT'S SELF-DIAGNOSTIC FUNCTION ... ......... ......... 9-75
EPS WARNING LIGHT DURING NORMAL OPERATION ...... ......... ....... 9-75
DIAGNOSTIC MODE ........ ......... .......... ......... ......... ......... ......... .......... ..... 9-76
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM) ...... ......... ....... 9-78
TROUBLESHOOTING DETAILS (EPS SYSTEM) .......... ......... ......... ...... 9-79
ELECTRICAL COMPONENTS ........ .......... ......... .......... ........ ......... .......... ...... 9-83
CHECKING THE SWITCHES .. .......... ........ .......... ......... .......... .......... ...... 9-89
CHECKING THE BULBS AND BULB SOCKETS .. ........ .......... .......... ..... 9-92
REPLACING THE HEADLIGHT BULBS ....... .......... ........ ......... .......... ..... 9-93
ADJUSTING THE HEADLIGHT BEAMS ....... ......... ......... ........... ......... .... 9-94
CHECKING THE FUSES ......... .......... ........ .......... .......... ......... .......... ...... 9-94
CHECKING AND CHARGING THE BATTERY .... .......... .......... .......... ..... 9-95
CHECKING THE RELAYS ........ .......... ......... .......... ........ .......... .......... ..... 9-97
CHECKING THE SPARK PLUG CAP .......... ......... ........ .......... ......... ..... 9-100
CHECKING THE IGNITION COIL ...... ........ ......... .......... ......... .......... ..... 9-100
CHECKING THE IGNITION SPARK GAP .... .......... ......... ......... ......... .... 9-101
CHECKING THE CRANKSHAFT POSITION SENSOR .......... ......... ..... 9-101
CHECKING THE LEAN ANGLE SENSOR ... ........ .......... .......... ......... .... 9-102
CHECKING THE STARTER MOTOR OPERATION ..... .......... .......... .... 9-102
CHECKING THE STATOR COIL ........ ......... .......... ........ .......... ......... .... 9-103
CHECKING THE RECTIFIER/REGULATOR ...... ......... .......... ......... ...... 9-103
CHECKING THE FUEL SENDER ....... ......... ........ .......... ......... .......... .... 9-103
CHECKING THE FUEL METER/FUEL LEVEL WARNING LIGHT .. ..... 9-104
CHECKING THE SPEED SENSOR ... ......... ......... ......... .......... ......... ..... 9-104
CHECKING THE PARKING BRAKE BUZZER ..... .......... ......... .......... .... 9-105
CHECKING THE RADIATOR FAN MOTOR ....... ......... .......... ......... ...... 9-105
CHECKING THE RADIATOR FAN MOTOR CIRCUIT BREAKER ....... 9-105
CHECKING THE COOLANT TEMPERATURE SENSOR ...... .......... ..... 9-106
CHECKING THE THROTTLE POSITION SENSOR ..... ......... .......... ..... 9-106
CHECKING THE INTAKE AIR PRESSURE SENSOR .......... ......... ...... 9-107
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ... ......... ...... 9-107
CHECKING THE FUEL INJECTOR ... .......... ........ .......... .......... ......... .... 9-108
CHECKING THE AIR INDUCTION SYSTEM SOLENOID ...... ......... ..... 9-108
CHECKING THE DIFFERENTIAL MOTOR POSITION SWITCH .... ..... 9-109
CHECKING THE EPS MOTOR (for EPS models) ......... ......... ......... ..... 9-109
CHECKING THE EPS TORQUE SENSOR (for EPS models) .. ......... ... 9-11 O
IGNITION SYSTEM
1. Crankshaft position sensor

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
21. ECU (Engine Control Unit)
22. Ignition coil
23.Spark plug
30.Lean angle sensor
34.Joint coupler
60. Ignition fuse
B. Wire harness
C. Negative battery sub-wire harness
9-2
IGNITION SYSTEM
EBS30265
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• Before troubleshooting , remove the following part(s):

1. Hood
2. Side panel (right)
3. Rear panel (right)
1. Check the fuses. NG~

(Main and ignition)
Replace the fuse(s) .
Refer to "CHECKING THE FUS-
ES" on page 9-94.
OKt
2. Check the battery. NG~

Refer to "CHECKING AND • Clean the battery terminals.
CHARG ING THE BATTERY" on • Recharge or replace the battery.
page 9-95.
OKt
3. Check the spark plug. NG~

Refer to "CHECKING THE SPARK Re-gap or replace the spark plug.
PLUG" on page 3-5.
OKt
4. Check the ignition spark gap. OK~

Refer to "CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP" on page 9-101 .
NG j,
5. Check the spark plug cap. NG~

Refer to "CHECKING THE SPARK Replace the spark plug cap.
PLUG CAP" on page 9-100.
OKt
6. Check the ignition coil. NG~

Refer to "CHECKING THE IGNI- Replace the ignition coil.
TION COIL:' on page 9-100.
OKt
7. Check the crankshaft position sen- NG~

sor.
Replace the crankshaft position sen-
Refer to "CHECKING THE CRANK-
sor/stator assembly.
SHAFT POSITION SENSOR" on
page 9-101.
OKt
8. Check the main switch . NG~

Refer to "CHECKING THE Replace the main switch.
SWITCHES" on page 9-89.
OKt
9-3
IGNITION SYSTEM
9. Check the lean angle sensor. NG~

Refer to "CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR" on page 9-102.
OKt
1a .Check the entire ignition system NG~

w1nng. Properly connect or replace the wire har-
Refer to "CIRCU IT DIAGRAM" on ness.
page 9-1 .
OKt
Replace the ECU.
9-4
ELECTRIC STARTING SYSTEM

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
11. Starter relay
12. Starter motor
17. Gear position switch
34.Joint coupler
56.Brake light switch
60. Ignition fuse
62.Signaling system fuse
B. Wire harness
9-6
ESS30267
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the main switch is set to "o" (start) , the starter motor can only operate if at least one of the following
conditions is met:
• The transmission is in neutral (the neutral circuit of the gear position switch is closed).
• The brake pedal is pressed (the brake light switch circuit is closed).
/ "\
_L 11
-- "-
I
-lb-
-
.... t- e (±)
10
1
::>
5 (
3 <
.... t-
6
4
.)
8
l
-t---< t-19
1. Battery
2. Main fuse
3. Ignition fuse
4. Main switch
6. Signaling system fuse
7. Brake light switch
10. Starter relay
11.Starter motor
9-7
EBS30268
TROUBLESHOOTING
The starter motor fails to turn.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

1. Hood
2. Air intake silencer

(Main, ignition, and signaling sys-
tem) Replace the fuse(s) .
ES" on page 9-94.
OKt

page 9-95.
OKt
3. Check the starter motor operation. OK~

Starter motor is OK. Perform the electric
Refer to "CHECKING THE START-
starting system troubleshooting , starting
ER MOTOR OPERATION" on page
with step 5.
9-102.
NG j,
4. Check the starter motor. NG~

Refer to "CHECKING THE START- Repair or replace the starter motor.
ER MOTOR" on page 5-43.
OKt
5. Check the starter relay. NG~

Refer to "CHECKING THE RE- Replace the starter relay.
LAYS" on page 9-97.
OKt
6. Check the load control relay. NG~

Refer to "CHECKING THE RE- Replace the load control relay.
LAYS" on page 9-97.
OKt
OKt
8. Check the brake light switch. NG~

Refer to "CHECKING THE Replace the brake light switch .
OKt
9-8
9. Check the gear position switch. NG~

Refer to "CHECKING THE Replace the gear position switch .
OKt
1a .Check the entire starting system NG~
page 9-5.
OKt
Replace the ECU.
9-9
9-10
CHARGING SYSTEM
2. AC magneto
3. Rectifier/regulator
5. Frame ground
8. Battery
9. Main fuse
B. Wire harness
9-12
CHARGING SYSTEM
EBS30270
TROUBLESHOOTING
The battery is not being charged.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• Before troubleshooting , remove the following part(s) :

1. Hood
1. Check the fuse. NG~

(Main)
Replace the fuse.
Refer to "CHECKING TH E FUS-
ES" on page 9-94.
OKt

page 9-95.
OKt
3. Check the stator coil. NG~

Replace the crankshaft position sen-
Refer to "CH ECKING THE STATOR
sor/stator assembly.
COIL:' on page 9-103.
OKt
4. Check the rectifier/regu lator. NG~

Refer to "CHECKING TH E RECTI-
Replace the rectifier/regulator.
FIER/REGULATOR" on page
9-103.
OKt
5. Check the entire charging system NG~

w1nng . Properly connect or replace the wire har-
page 9-11 .
OKt
The charging system circuit is OK.
9-13
CHARGING SYSTEM
9-14
LIGHTING SYSTEM

5. Frame ground
6. Main switch
8. Battery
9. Main fuse
52.Light switch
53. Headlight relay
54. Headlight
57. Tail/brake light
60. Ignition fuse
63. Headlight fuse
B. Wire harness
9-16
LIGHTING SYSTEM
EBS30272
TROUBLESHOOTING
Any of the following fail to light: headlight or taillight.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

1. Cargo bed panel (left)
2. Cargo bed panel (right)
3. Hood
1. Check the condition of each bulb NG~

and bu lb socket.
Refer to "CHECKING THE BULBS Replace the bulb(s) and bulb socket(s) .
AND BULB SOCKETS" on page
9-92.
OKt

(Main, ignition, and headlight)
Replace the fuse(s) .
ES" on page 9-94.
OKt

page 9-95.
OKt
Refer to "CHECKING THE Replace the main switch .
OKt
5. Check the light switch . NG~

Refer to "CHECKING THE Replace the light switch .
OKt
6. Check the headlight relay. NG~

Refer to "CHECKING THE RE- Replace the headlight relay.
LAYS" on page 9-97.
OKt

LAYS" on page 9-97.
OKt
9-17
LIGHTING SYSTEM
8. Check the entire lighting system NG~

page 9-15.
OKt
The lighting system circuit is OK.
9-18
SIGNALING SYSTEM

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
26.Coolant temperature sensor
27.Speed sensor
31 . Parking brake switch
32. Parking brake buzzer
33. Reverse switch
34.Joint coupler
35.Seat belt switch
36. Indicator assembly
37. Helmet indicator light
38. Seat belt indicator light
39.Meter assembly
40.Multi-function meter
42.Coolant temperature warning light
43. Park indicator light
44. Reverse indicator light
45. Neutral indicator light
46. High-range indicator light
47.Low-range indicator light
49. Fuel sender
57. Tail/brake light
60. Ignition fuse
61.Backup fuse
68.Backup light
69.Backup light relay
A. Optional
B. Wire harness
9-20
SIGNALING SYSTEM
ESS30274
TROUBLESHOOTING
• Any of the following fail to light: warning light, brake light or an indicator light.
• The fuel meter fails to come on.
• The speedometer fails to operate.
• The parking brake buzzer fails to sounds.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

1. Hood
2. Cargo bed panel (left)
3. Cargo bed panel (right)
4. Outer/center passenger seat frame
5. Sound-deflection panels
6. Outer passenger compartment panel/Center passenger compartment panel
9. Fuel tank
1O.Air intake silencer
11.Sun top
12.Side frames
13.Front fender

(Main, ignition, signaling system ,
and backup) Replace the fuse(s) .
ES" on page 9-94.
OKt

page 9-95.
OKt

OKt

LAYS" on page 9-97.
OKt
9-21
SIGNALING SYSTEM
5. Check the entire signaling system NG~

page 9-19.
OKt
Check the condition of each of the sig-

naling system circu its. Refer to
"Checking the signaling system".
Checking the signaling system

The tail/brake lights fail to come on.
1. Check the tail/brake light bu lbs and NG~

sockets.
Replace the tail/brake light bulb, socket or
Refer to "CHECKING TH E BULBS
both.
AND BULB SOCKETS" on page
9-92.
OKt
2. Check the brake light switch. NG~

Refer to "CHECKING TH E Replace the brake light switch .
OKt

page 9-19.
OKt
This circuit is OK.
The neutral. high-range. and/or low-range indicator light fails to come on .
1. Check the gear position switch. NG~

Refer to "CHECKING TH E Replace the gear position switch .
OKt

page 9-19.
OKt
Replace the meter assembly or ECU.
9-22
SIGNALING SYSTEM
The reverse indicator light fails to come on.
1. Check the reverse switch. NG~

Refer to "CHECKING THE Replace the reverse switch.
OKt

page 9-19.
OKt
The park indicator light fails to come on.
1. Check the parking brake switch. NG~

Refer to "CHECKING THE Replace the parking brake switch .
OK t

page 9-19.
OK t
The coolant temperature warning light fails to come on.
1. Check the coolant temperature sen- NG~

sor.
Refer to "CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR"
on page 9-106.
OKt

page 9-19.
OK t
The fuel meter fails to come on.
1. Check the fuel sender. NG~

Refer to "CHECKING THE FUEL Replace the fuel pump assembly.
SENDER" on page 9-103.
OK t
9-23
SIGNALING SYSTEM

page 9-19.
OKt
Replace the meter assembly.
The speedometer fails to come on.
1. Check the speed sensor. NG~

Refer to "ELECTRICAL COMPO- Replace the speed sensor.
NENTS" on page 9-83.
OKt

page 9-19.
OKt
The helmeVseat belt indicator light fails to come on.
1. Check the seat belt switch. NG~

Refer to "CHECKING THE Replace the driver seat belt buckle.
OKt

page 9-19.
OKt
Replace the ind icator light assembly or

ECU.
9-24
SIGNALING SYSTEM
The parking brake buzzer fails to sound.
1. Check the parking brake buzzer. NG~

Refer to "CHECKING THE PARK-
Replace the parking brake buzzer.
ING BRAKE BUZZER" on page
9-105 .
OK t
page 9-19.
OKt
Replace the ECU.
9-25
SIGNALING SYSTEM
9-26
COOLING SYSTEM
5. Frame ground
6. Main switch
8. Battery
9. Main fuse
34.Joint coupler
58. Radiator fan motor fuse
60. Ignition fuse
65. Radiator fan motor
66. Radiator fan motor circuit breaker
B. Wire harness
9-28
COOLING SYSTEM
EBS30276
TROUBLESHOOTING
The radiator fan motor fails to turn.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

1. Hood
2. Skid plate
3. Frame cross member

(Main, ignition , and radiator fan mo-
tor) Replace the fuse(s) .
ES" on page 9-94.
OKt

page 9-95.
OKt

OKt
4. Check the radiator fan motor. NG~

Refer to "CHECKING THE RADIA- Replace the radiator fan motor.
TOR FAN MOTOR" on page 9-105.
OKt
5. Check the radiator fan motor relay. NG~

Refer to "CHECKING THE RE- Replace the radiator fan motor relay.
LAYS" on page 9-97.
OKt
6. Check the radiator fan motor circuit NG~

breaker.
Replace the radiator fan motor circuit
Refer to "CHECKING THE RADIA-
breaker.
TOR FAN MOTOR CIRCU IT
BREAKER" on page 9-105 .
OKt
7. Check the coolant temperature sen- NG~

sor.
Refer to "CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR"
on page 9-106.
OKt
9-29
COOLING SYSTEM
8. Check the entire cooling system NG~

page 9-27.
OKt
Replace the ECU.
9-30
FUEL INJECTION SYSTEM

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
14.Air induction system solenoid
19. Yamaha diagnostic tool coupler
20. ISC (Idle Speed Control) unit
22. Ignition coil
23.Spark plug
24. Fuel injector
25. Intake air temperature sensor
27.Speed sensor
28.TPS (throttle position sensor)
29. Intake air pressure sensor
30.Lean angle sensor
34.Joint coupler
39.Meter assembly
41. Engine trouble warning light
SO.Fuel pump
60. Ignition fuse
61.Backup fuse
B. Wire harness
9-32
EBS30278
ECU SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system , it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is
stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
comes on when the main switch is being turned to start the engine.
• If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an appro-
priate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminat-
ing the engine trouble warning light.
• After the engine has been stopped, the lowest fault code number appears on the multi-function meter
display. Once a fault code has been displayed , it remains stored in the memory of the ECU until it is
deleted.
Engine trouble warning light indication and fuel injection system operation
Warning light indication ECU operation Fuel injection operation Vehicle operation
Warning provided when
Flashing* Operation stopped Cannot be operated
unable to start engine
Operated with substitute
Can or cannot be operat-
characteristics in accor-
Remains on Malfunction detected ed depending on the fault
dance with the descrip-
code
tion of the malfunction
* The warning light flashes when any one of the conditions listed below is present and the main switch
is turned to " O " (on) :
Fuel injector
12: Crankshaft position sensor 39:
(open or short-circuit)
Lean angle sensor Lean angle sensor
30: 41:
(latch up detected) (open or short-circuit)
ECU internal malfunction
33: Faulty ignition 50:
(faulty ECU memory)
Checking for a defective engine trouble warning light bulb

The engine trouble warning light comes on for around 2 seconds after the main switch has been turned
to " O " (on). If the warning light does not come on under these conditions, the warning light (LED) may
be defective.
ECU detects an abnormal signal from a sensor

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions that
are appropriate for the type of malfunction .
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue to operate or stop operating, depending on the conditions.
EBS30279
TROUBLESHOOTING METHOD
The engine operation is not normal and the engine trouble warning light comes on.
1. Check:
• Fault code number
9-33
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Check the fault code number displayed on the multi-function meter.
b. Identify the faulty system w ith the fault code.
c. Identify the probable cause of the malfunction .
••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
2. Check and repair the probable cause of malfunction .
Fault code No. No fault code No.
Check and repair. Refer Check and repair.
to "TROUBLESHOOT-
ING DETAILS (FUEL
INJECTION SYS-
TEM)" on page 9-35.
Monitor the operation of
the sensors and actua-
tors in the diagnostic
mode.
Refer to "TROUBLE-
SHOOTING DETAILS
(FUEL INJECTION
SYSTEM)" on page
9-35 and "SELF-DIAG-
NOSTIC FUNCTION
AND DIAGNOSTIC
CODE TABLE" on page
10-7.
3. Perform the reinstatement action for the fuel injection system .

Refer to "Confirmation of service completion" of table in "TROUBLESHOOTING DETAILS (FUEL
INJ ECTION SYSTEM)" on page 9-35.
4. Turn the main switch to "o "
(off) and back to " O " (on) , then check that no fault code number is dis-
played .
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
If another fault code are displayed, repeat steps (1) to (4) until no fault code number is displayed.
5. Erase the malfunction history in the diagnostic mode (code No. 62) . Refer to "SELF-DIAGNOSTIC
FUNCTION AND DIAGNOSTIC CODE TABLE" on page 10-7.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Turning the main switch to "O " (off) will not erase the malfunction history.
The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode.
Refer to ''TROUBLESHOOTING DETAILS (FUEL INJ ECTION SYSTEM)" on page 9-35 and "SELF-
DIAGNOSTIC FUNCTION AND DIAGNOSTIC COD E TABLE" on page 10-7.
01: Throttle position sensor signal (throttle angle)
30: Ignition coil
36: Injector
48: Air induction system solenoid
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair inner parts of the engine.
EBS30280
YAMAHA DIAGNOSTIC TOOL

This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.
9-34
Yamaha diagnostic tool (US)

90890-03234
Connecting the Yamaha diagnostic tool

Remove the protective cap, and then connect the Yamaha diagnostic tool to the coupler "1".
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter
and indicators will be different from the normal operation.
ESS30281
TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM)

This section describes the measures per fault code number displayed on the multi-function meter dis-
play. Check and service the items or components that are the probable cause of the malfunction fol-
lowing the order given.
After the check and service of the malfunctioning part has been completed , reset the multi-function me-
ter display according to the "Confirmation of service completion".
Fault code No.:
Fault code number displayed on the multi-function meter when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to "SELF-D IAGNOS-
TIC FUNCTION AND DIAGNOSTIC COD E TABLE" on page 10-7.
9-35
Fault code No. 12

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

Item
crankshaft position sensor.
Unable to start engine
Fail-safe system
Unable to drive vehicle
Diagnostic code No. -
Indicated -
Procedure -
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of crankshaft posi- Improperly connected ~ Con- Crank the engine.
tion sensor coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played ~ Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and ~ Go to item 2.
check the pins (bent or broken
terminals and locking condition
of the pins).
2 Connection of ECU coupler. Improperly connected ~ Con- Crank the engine.
Check the locking condition of nect the coupler securely or re- Fault code number is not dis-
the coupler. place the wire harness. played ~ Service is finished.
Disconnect the coupler and Fault code number is displayed
check the pins (bent or broken ~ Go to item 3.
of the pins).
3 Wire harness continuity. Open or short circuit ~ Replace Crank the engine.
the wire harness. Fault code number is not dis-
Between crankshaft position played ~ Service is finished.
sensor coupler and ECU cou- Fault code number is displayed
pier. ~ Go to item 4.
gray-gray
Between crankshaft position
sensor coupler and joint cou-
pier.
black/blue- black/blue
Between joint coupler and ECU
coupler.
4 Installed condition of crank- Improperly installed sensor ~ Crank the engine.
shaft position sensor. Reinstall or replace the sensor. Fault code number is not dis-
Check for looseness or pinch- played ~ Service is finished.
,ng. Fault code number is displayed
~ Go to item 5.
5 Defective crankshaft position Check the crankshaft position Crank the engine.
sensor. sensor. Fault code number is not dis-
Refer to "CHECKING THE played ~ Service is finished.
CRANKSHAFT POSITION Fault code number is displayed
SENSOR" on page 9-101. ~ Go to item 6.
Replace if defective.
6 Malfunction in ECU. Replace the ECU.
9-36
Fault code No. 13

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

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 03
Indicated Displays the intake air pressure.
Turn and hold the main switch in the"()" (start) position, then press the
Procedure
accelerator pedal. (If the display value changes, the performance is OK.)
1 Connection of intake air pres- Improperly connected ~ Con- Turn the main switch to " ~ "
sure sensor coupler. nect the coupler securely or re- (on).
Check the locking condition of place the wire harness. Fault code number is not dis-
the coupler. played ~ Service is finished.
of the pins).
2 Connection of ECU coupler. Improperly connected ~ Con- Turn the main switch to " ~ "
Check the locking condition of nect the coupler securely or re- (on).
the coupler. place the wire harness. Fault code number is not dis-
Disconnect the coupler and played ~ Service is finished.
check the pins (bent or broken Fault code number is displayed
terminals and locking condition ~ Go to item 3.
of the pins).
3 Wire harness continuity. Open or short circuit ~ Replace Turn the main switch to " ~ "
the wire harness. (on).
Between intake air pressure Fault code number is not dis-
sensor coupler and ECU cou- played ~ Service is finished.
pier. Fault code number is displayed
pink- pink ~ Go to item 4.
Between intake air pressure
pier.
blue- blue
coupler.
blue- blue
4 Installed condition of intake air Improperly installed sensor ~ Turn the main switch to " ~ "
pressure sensor. Reinstall or replace the sensor. (on).
Check for looseness or pinch- Fault code number is not dis-
,ng. played ~ Service is finished.
Fault code number is displayed
~ Go to item 5.
9-37
Fault code No. 13
Item Intake air pressure sensor: open or short circuit detected.

5 Defective intake air pressure Execute the diagnostic mode. Turn the main switch to " ~ "
sensor. (Code No. 03) (on).
When engine is stopped: Fault code number is not dis-
Atmospheric pressure at the played ~ Service is finished.
current altitude and weather Fault code number is displayed
conditions is indicated. ~ Go to item 6.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
1000 m (3300 ft) above sea lev-
el: Approx. 90 kPa (675.1
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. ~
Check the intake air pressure
sensor.
Refer to "CHECKING THE IN-
TAKE AIR PRESSURE SEN-
SOR" on page 9-107.
9-38
Fault code No. 14

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

Item
tached hose).
Fail-safe system
Indicated Displays the intake air pressure.
Turn and hold the main switch in the"()" (start) position, then press the
Procedure
accelerator pedal. (If the display value changes, the performance is OK.)
1 Condition of intake air pressure Clogged or detached hose ~ Start the engine and let it idle
sensor hose. Repair or replace the sensor for approximately 5 seconds.
Check the intake air pressure hose. Fault code number is not dis-
sensor hose condition. played ~ Service is finished.
~ Go to item 2.
2 Defective intake air pressure Execute the diagnostic mode.

sensor. (Code No. 03)
When engine is stopped:
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. ~
Check the intake air pressure
sensor.
TAKE AIR PRESSURE SEN-
SOR" on page 9-107.
9-39
Fault code No. 15

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
"15" first.
Fault code No. 15
Item Throttle position sensor: open or short circuit detected.

Fail-safe system
Throttle position sensor signal
Indicated
• 14-20 (fully closed position)
Procedure Check with throttle valve fully closed.
1 Connection of throttle position Improperly connected ~ Con- Turn the main switch to " 0 "
sensor coupler. nect the coupler securely or re- (on).
of the pins).
2 Connection of ECU coupler. Improperly connected ~ Con- Turn the main switch to " 0 "
of the pins).
3 Wire harness continuity. Open or short circuit ~ Replace Turn the main switch to " 0 "
Between throttle position sensor Fault code number is not dis-
coupler and ECU coupler. played ~ Service is finished.
yellow- yellow Fault code number is displayed
Between throttle position sensor ~ Go to item 4.
coupler and joint coupler.
blue- blue
coupler.
blue- blue
4 Installed condition of throttle po- Improperly installed sensor ~ Turn the main switch to " 0 "
sition sensor. Reinstall or adjust the sensor. (on).
Check for looseness or pinch- Refer to "ADJUSTING THE Fault code number is not dis-
,ng. THROTILE POSITION SEN- played ~ Service is finished.
SOR" on page 7-13. Fault code number is displayed
~ Go to item 5.
5 Throttle position sensor resis- Measure the throttle position Turn the main switch to " 0 "
tance. sensor resistance. (on).
Refer to "CHECKING THE Fault code number is not dis-
THROTILE POSITION SEN- played ~ Service is finished.
SOR" on page 9-106. Fault code number is displayed
~ Go to item 6.
9-40
Fault code No. 15
Item Throttle position sensor: open or short circuit detected.

6 Defective throttle position sen- Check throttle position sensor Turn the main switch to " 0 "
sor. signal. (on).
Execute the diagnostic mode. Fault code number is not dis-
(Code No. 01) played ~ Service is finished.
When the throttle valve is fully Fault code number is displayed
closed: ~ Goto item 7.
A value of 14-20 is indicated.
An indicated value is out of the
specified range ~ Replace the
throttle position sensor.
Fault code No. 16

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• If fault code numbers "15" and "16" are both indicated, take the actions specified for fault code number
"15" first.
"16" first.
Fault code No. 16
Item Throttle position sensor: stuck throttle position sensor is detected.

Fail-safe system
Throttle position sensor signal
Indicated
• 14-20 (fully closed position)
Procedure Check with throttle valve fully closed.
1 Installed condition of throttle po- Improperly installed sensor ~ Turn the main switch to " 0 "
sition sensor. Reinstall or adjust the sensor. (on), then press the accelerator
Check for looseness or pinch- Refer to "ADJUSTING THE pedal.
,ng. THROTILE POSITION SEN- Fault code number is not dis-
SOR" on page 7-13. played ~ Service is finished.
~ Go to item 2.
2 Defective throttle position sen- Check throttle position sensor Turn the main switch to " 0 "
sor. signal. (on), then operate the throttle.
Execute the diagnostic mode. Fault code number is not dis-
(Code No. 01) played ~ Service is finished.
When the throttle valve is fully Fault code number is displayed
closed: ~ Go to item 3.
A value of 14-20 is indicated.
An indicated value is out of the
specified range ~ Replace the
throttle position sensor.
9-41
Fault code No. 21

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
If fault code numbers "21 " and "37" are both indicated , take the actions specified for fault code number
"21 " first.
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.

Fail-safe system
Indicated Displays the coolant temperature.
Compare the actually measured coolant temperature with the meter dis-
Procedure
play value.
1 Connection of coolant tempera- Improperly connected ~ Con- Turn the main switch to " 0 "
ture sensor coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
Between coolant temperature Fault code number is not dis-
green/yellow-green/yellow ~ Go to item 4.
Between coolant temperature
pier.
coupler.
4 Installed condition of coolant Improperly installed sensor ~ Turn the main switch to " 0 "
temperature sensor. Reinstall or replace the sensor. (on).
~ Go to item 5.
9-42
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.

5 Defective coolant temperature Execute the diagnostic mode. Turn the main switch to " ~ "
When engine is cold: Fault code number is not dis-
Displayed temperature is close played ~ Service is finished.
to the ambient temperature. Fault code number is displayed
The displayed temperature is ~ Go to item 6.
not close to the ambient tern-
perature ~ Check the coolant
temperature sensor.
Refer to "CHECKING THE
COOLANT TEMPERATURE
SENSOR" on page 9-106.
9-43
Fault code No. 22

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
"22" first.
Fault code No. 22

Item Intake air temperature sensor: open or short circuit detected.
Fail-safe system
Indicated Displays the intake air temperature.
Compare the actually measured intake air temperature with the indicated
Procedure
value.
1 Connection of intake air tern- Improperly connected ~ Con- Turn the main switch to " 0 "
perature sensor coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
Between intake air temperature Fault code number is not dis-
brown/white- brown/white ~ Go to item 4.
Between intake air temperature
pier.
coupler.
4 Installed condition of intake air Improperly installed sensor ~ Turn the main switch to " 0 "
temperature sensor. Reinstall or replace the sensor. (on).
~ Go to item 5.
9-44
Fault code No. 22

Item Intake air temperature sensor: open or short circuit detected.
5 Defective intake air temperature Execute the diagnostic mode. Turn the main switch to " ~ "
When engine is cold: Fault code number is not dis-
Displayed temperature is close played ~ Service is finished.
to the ambient temperature. Fault code number is displayed
The displayed temperature is ~ Go to item 6.
not close to the ambient tern-
perature. ~ Check the intake
air temperature sensor.
TAKE AIR TEMPERATURE
9-45
Fault code No. 30

Fault code No. 30
Item Latch up detected.
Fail-safe system
Lean angle sensor output voltage
Indicated • 3.6-4.4 (upright)
• 0.7- 1.3 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
1 The vehicle has overturned. Raise the vehicle upright. Turn the main switch to " ~ "
(on), then to "O" (off), and then
back to " ~ " (on).
Fault code number is not dis-
played ~ Service is finished.
~ Go to item 2.
2 Installed condition of lean an- Check the installed direction Turn the main switch to " ~ "
gle sensor. and condition of the sensor. (on), then to "O" (off), and then
back to " ~ " (on).
~ Go to item 3.
3 Defective lean angle sensor. Execute the diagnostic mode. Turn the main switch to " ~ "
(Code No. 08) (on) then to "O" (off), and then
An indicated value is out of the back to " ~ " (on).
specified range ~ Check the Fault code number is not dis-
lean angle sensor. played ~ Service is finished.
Replace if defective. Fault code number is displayed
Refer to "CHECKING THE ~ Go to item 4.
LEAN ANGLE SENSOR" on
page 9-102.
9-46
Fault code No. 33

Fault code No. 33
Ignition coil: open or short circuit detected in the primary lead of the
Item
ignition coil.
Fail-safe system
Actuates the ignition coil five times at one-second intervals.
Actuation The "CHECK" indicator and " 0 " on the Yamaha diagnostic tool screen
come on each time the ignition coil is actuated.
Check that a spark is generated five times.
Procedure
• Connect an ignition checker.
1 Connection of ignition coil con- Improperly connected ~ Con- Start the engine and let it idle
nector. nect the connector securely or for approximately 5 seconds.
Check the locking condition of replace the wire harness. Fault code number is not dis-
the connector. played ~ Service is finished.
Disconnect the connector and Fault code number is displayed
of the pins).
2 Connection of ECU coupler. Improperly connected ~ Con- Start the engine and let it idle
Check the locking condition of nect the coupler securely or re - for approximately 5 seconds.
of the pins).
3 Wire harness continuity. Open or short circuit ~ Replace Start the engine and let it idle
the wire harness. for approximately 5 seconds.
Between ignition coil connector Fault code number is not dis-
and ECU coupler. played ~ Service is finished.
orange-orange Fault code number is displayed
~ Go to item 4.
4 Installed condition of ignition Improperly installed ignition coil Start the engine and let it idle
coil. ~ Reinstall or replace the igni- for approximately 5 seconds.
Check for looseness or pinch- tion coil. Fault code number is not dis-
~ Go to item 5.
5 Defective ignition coil. Measure the primary coil resis- Start the engine and let it idle
tance of the ignition coil. for approximately 5 seconds.
Replace if out of specification. Fault code number is not dis-
Refer to "CHECKING THE IG- played ~ Service is finished.
N IT ION COi i.'.' on page 9-100. Fault code number is displayed
~ Go to item 6.
6 Malfunction in ECU. Execute the diagnostic mode.

(Code No. 30)
No spark ~ Replace the ECU.
9-47
Fault code No. 37

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

• If fault code numbers "16" and "37" are both indicated , take the actions specified for fault code number
"16" first.
• If fault code numbers "21 " and "37" are both indicated, take the actions specified for fault code number
"21 " ti rst.
"22" first.
"46" first.
"42" first.
Fault code No. 37

Component other than ISC (Idle Speed Control) unit is defective
A
(ISC operating sound is heard).
Item
Defective ISC (Idle Speed Control) unit (ISC operating sound is
B
not heard).
Fail-safe system
Actuates and fully closes the ISC valve, then opens it to the stand-by
opening position when the engine is started.
Actuation This operation takes approximately 3 seconds until it is completed.
The "CHECK" indicator and " 0 " on the Yamaha diagnostic tool screen
come on during the operation.
Procedure The operating sound can be heard when ISC valve operates.
A-1 Locate the malfunction. Execute the diagnostic mode. ISC operating sound is heard ~
(Code No. 54) Go to item A-2.
Fully closes the ISC (Idle Speed ISC operating sound is not
Control) valve, and then fully heard ~ Go to item B-2 for the
opens the valve. defective ISC (Idle Speed Con-
trol) unit.
A-2 Incorrect speed sensor signal. Check the speed sensor. Start the engine and let it idle
Execute the diagnostic mode. for approximately 10 seconds.
(Code No. 07) Fault code number is not dis-
Rotate the rear wheel by hand played ~ Service is finished.
and check that the indicated Fault code number is displayed
value increases. ~ Go to item A-3.
Value does not increase ~ Go
to fault code No. 42.
A-3 Throttle valve does not fully Check the throttle body. Start the engine and let it idle
close. Refer to "THROTTLE BODY" on for approximately 10 seconds.
page 7-9. Fault code number is not dis-
Check the throttle cable. played ~ Service is finished.
Refer to "ADJUSTING THE AC- Fault code number is displayed
CELERATOR PEDAL FREE ~ Go to item A-4.
PLAY" on page 3-22.
9-48
Fault code No. 37

A
Item
B
not heard).
A-4 ISC valve is not moving correct- Replace the throttle body as- Start the engine and let it idle
ly. sembly. for approximately 10 seconds.
~ Go to item A-5.
A-5 Malfunction in ECU. Replace the ECU.
9-49
Fault code No. 37

A
Item
B
not heard).
Fail-safe system
Actuates and fully closes the ISC valve, then opens it to the stand-by
opening position when the engine is started.
Actuation This operation takes approximately 3 seconds until it is completed.
come on during the operation.
Procedure The operating sound can be heard when ISC valve operates.
B- 1 Locate the malfunction. Execute the diagnostic mode. ISC operating sound is heard ~
(Code No. 54) Go to item A-2 for the compo-
Fully closes the ISC (Idle Speed nent other than ISC (Idle Speed
Control) valve, and then fully Control) unit is defective.
opens the valve. ISC operating sound is not
heard ~ Go to B-2.
B-2 Connection of ISC (Idle Speed Improperly connected ~ Con- Execute the diagnostic mode.
Control) unit coupler. nect the coupler securely or re- (Code No. 54)
Check the locking condition of place the wire harness. ISC operating sound is heard ~
the coupler. Go to B-8.
Disconnect the coupler and ISC operating sound is not
check the pins (bent or broken heard ~ Go to B-3.
of the pins).
B-3 Connection of ECU coupler. Improperly connected ~ Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code No. 54)
the coupler. place the wire harness. ISC operating sound is heard ~
Disconnect the coupler and Go to B-8.
check the pins (bent or broken ISC operating sound is not
terminals and locking condition heard ~ Go to item B-4.
of the pins).
B-4 Wire harness continuity. Open or short circuit ~ Replace Execute the diagnostic mode.
the wire harness. (Code No. 54)
Between ISC (Idle Speed Con- ISC operating sound is heard ~
trol) unit coupler and ECU cou- Go to B-8.
pier. ISC operating sound is not
red/green - red/green heard ~ Go to item B-5.
pink/blue- pink/blue
white/green- white/green
brown/blue-brown/blue
Between ISC (Idle Speed Con-
trol) unit coupler and joint cou-
pier.
red/white-red/white
red/white-red/white
9-50
Fault code No. 37

A
Item
B
not heard).
B-5 Installed condition of ISC (Idle Improperly installed ISC (Idle Execute the diagnostic mode.
Speed Control) unit. Speed Control) unit ~ Reinstall (Code No. 54)
Check for looseness or pinch- the ISC (Idle Speed Control) ISC operating sound is heard ~
,ng. unit. Go to B-8.
ISC operating sound is not
heard ~ Go to item B-6.
B-6 ISC valve is not moving correct- Replace the throttle body as- Execute the diagnostic mode.
ly. sembly. (Code No. 54)
ISC operating sound is heard ~
Go to B-8.
ISC operating sound is not
heard ~ Go to item B-7.
B-7 Malfunction in ECU. Replace the ECU.
B-8 Delete the fault code. Start the engine and let it idle
for approximately 10 seconds.
Check that the fault code num-
ber is not displayed.
9-51
Fault code No. 39

Fault code No. 39
Item Injector: open or short circuit detected.
Fail-safe system
Actuates injector five times at one-second intervals.
Actuation The "CHECK" indicator and ",a" on the Yamaha diagnostic tool screen
come on each time the fuel injector is actuated.
Check that injector is actuated five times by listening for the operating
Procedure
sound.
1 Connection of injector coupler. Improperly connected ~ Con- Execute the diagnostic mode.
the coupler. place the wire harness. Operating sound ~ Go to item
Disconnect the coupler and 6.
check the pins (bent or broken No operating sound ~ Go to
terminals and locking condition item 2.
of the pins).
2 Defective injector. Measure the injector resistance. Execute the diagnostic mode.
Replace if out of specification. (Code No. 36)
Refer to "CHECKING THE Operating sound ~ Go to item
FUEL INJECTOR" on page 6.
9-108. No operating sound ~ Go to
item 3.
3 Connection of ECU coupler. Improperly connected ~ Con- Execute the diagnostic mode.
the coupler. place the wire harness. Operating sound ~ Go to item
Disconnect the coupler and 6.
check the pins (bent or broken No operating sound ~ Go to
terminals and locking condition item 4.
of the pins).
4 Wire harness continuity. Open or short circuit ~ Replace Execute the diagnostic mode.
the wire harness. (Code No. 36)
Between injector coupler and Operating sound ~ Go to item
ECU coupler. 6.
red-red No operating sound ~ Go to
Between injector coupler and item 5.
joint coupler.
red/blue-red/blue
6 Delete the fault code. Start the engine and let it idle
for approximately 5 seconds.
9-52
Fault code No. 41

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

Fail-safe system
Indicated • 3.6-4.4 (upright)
• 0.7- 1.3 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
1 Connection of lean angle sen- Improperly connected ~ Con- Turn the main switch to " ~ "
sor coupler. nect the coupler securely or re- (on), then to "O" (off), and then
Check the locking condition of place the wire harness. back to " ~ " (on).
the coupler. Fault code number is not dis-
of the pins).
Check the locking condition of nect the coupler securely or re- (on), then to "O" (off), and then
the coupler. place the wire harness. back to " ~ " (on).
Disconnect the coupler and Fault code number is not dis-
check the pins (bent or broken played ~ Service is finished.
terminals and locking condition Fault code number is displayed
of the pins). ~ Go to item 3.
the wire harness. (on), then to " O" (off), and then
Between lean angle sensor back to " ~ " (on).
coupler and ECU coupler. Fault code number is not dis-
yellow/green- yellow/green played ~ Service is finished.
Between lean angle sensor Fault code number is displayed
coupler and joint coupler. ~ Go to item 4.
blue- blue
coupler.
blue- blue
4 Defective lean angle sensor. Execute the diagnostic mode. Turn the main switch to " U "
(Code No. 08) (on), then to "O" (off), and then
An indicated value is out of the back to " ~ " (on).
specified range ~ Check the Fault code number is not dis-
lean angle sensor. played ~ Service is finished.
Replace if defective. Fault code number is displayed
Refer to "CHECKING THE ~ Go to item 5.
LEAN ANGLE SENSOR" on
page 9-102.
9-53
Fault code No. 42

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

Speed sensor: no normal signals are received from the speed sen-
Item
sor.
Fail-safe system
Vehicle speed pulse
Indicated
0- 999
Check that the number increases when the rear wheels are rotated. The
Procedure
number is cumulative and does not reset each time the wheel is stopped.
1 Connection of speed sensor Improperly connected ~ Con- Turn the main switch to " 0 "
coupler. nect the coupler securely or re- (on), and then rotate the rear
Check the locking condition of place the wire harness. wheel by hand.
the coupler. Fault code number is not dis-
Disconnect the coupler and played ~ Go to item 6.
of the pins).
Check the locking condition of nect the coupler securely or re- (on), and then rotate the rear
the coupler. place the wire harness. wheel by hand.
Disconnect the coupler and Fault code number is not dis-
check the pins (bent or broken played ~ Go to item 6.
terminals and locking condition Fault code number is displayed
of the pins). ~ Go to item 3.
the wire harness. (on), and then rotate the rear
Between speed sensor coupler wheel by hand.
and ECU coupler. Fault code number is not dis-
white- white played ~ Go to item 6.
Between speed sensor coupler Fault code number is displayed
and joint coupler. ~ Go to item 4.
blue- blue
coupler.
blue- blue
4 Defective speed sensor. Execute the diagnostic mode. Turn the main switch to " ~ "
(Code No. 07) (on), and then rotate the rear
While the rear wheels and wheel by hand.
stopped, check that the indicat- Fault code number is not dis-
ed value does not change. played ~ Go to item 6.
Rotate the rear wheel by hand Fault code number is displayed
and check that the indicated ~ Go to item 5.
value increases.
Malfunction ~ Replace the
speed sensor.
9-54
Fault code No. 42

Speed sensor: no normal signals are received from the speed sen-
Item
sor.
6 Delete the fault code. Start the engine, and input the
vehicle speed signals by operat-
ing the vehicle at 20 to 30 km/h
(12 to 19 mph).
9-55
Fault code No. 43

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

Item
and fuel pump.
Fail-safe system
Diagnostic code No. 09, 50
Fuel system voltage (battery voltage)
Indicated
Approximately 12.0
09 Turn the main switch to " ~ "(on) , and then compare the actually mea-
Procedure sured battery voltage with the display value. (If the actually measured
battery voltage is low, recharge the battery.)
Actuates the fuel injection system relay five times at one-second inter-
vals.
Actuation come on each time the relay is actuated.
50 (When the relay is on, the "CHECK" indicator and" 0 " on the Yamaha di-
agnostic tool screen go off. When the relay is off, the "CHECK" indicator
and" 0 " on the Yamaha diagnostic tool screen come on.)
Check that the fuel injection system relay is actuated five times by listen-
Procedure
ing for the operating sound.
1 Connection of fuel injection sys- Improperly connected ~ Con- Start the engine and let it idle
tern relay coupler. nect the coupler securely or re- for approximately 5 seconds.
of the pins).
2 Connection of ECU coupler. Improperly connected ~ Con- Start the engine and let it idle
Check the locking condition of nect the coupler securely or re- for approximately 5 seconds.
of the pins).
9-56
Fault code No. 43
Fuel system voltage: incorrect voltage supplied to the fuel injector

Item
and fuel pump.
3 Wire harness continuity. Open or short circuit ~ Replace Start the engine and let it idle
the wire harness. for approximately 5 seconds.
Between fuel injection system Fault code number is not dis-
relay coupler and ECU coupler. played ~ Service is finished.
blue/red- blue/red Fault code number is displayed
Between fuel injection system ~ Go to item 4.
relay coupler and joint coupler.
red/blue-red/blue
coupler.
red/blue-red/blue
Between ECU coupler and joint
coupler.
red/white-red/white
Between joint coupler and back-
up fuse.
red/white-red/white
Between main switch coupler
and ECU coupler.
brown/red- brown/ red
4 Defective fuel injection system Execute the diagnostic mode. Start the engine and let it idle
relay. (Code No. 50) for approximately 5 seconds.
No operating sound ~ Replace Fault code number is not dis-
the fuel injection system relay. played ~ Service is finished.
~ Go to item 5.
5 Defective fuel injection system Execute the diagnostic mode. Start the engine and let it idle
relay. (Code No. 09) for approximately 5 seconds.
Fuel system voltage is below 3 Fault code number is not dis-
V ~ Replace the fuel injection played ~ Service is finished.
system relay. Fault code number is displayed
~ Go to item 6.
9-57
Fault code No. 44

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

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
"46" first.
Fault code No. 46

Item Charging voltage is abnormal.
Fail-safe system
Indicated -
Procedure -
1 Malfunction in charging system. Check the charging system. Start the engine and let it idle
Refer to "CHARGING SYS- for approximately 5 seconds.
TEM" on page 9-11. Fault code number is not dis-
Defective rectifier/regulator or played ~ Service is finished.
AC magneto ~ Replace. Fault code number is displayed
Defective connection in the ~ Repeat the maintenance job.
charging system circuit ~ Prop-
erly connect or replace the wire
harness.
9-58
Fault code No. 50

Fault code No. 50
Faulty ECU (Engine Control Unit) memory. (When this malfunction is
Item
detected in the ECU, the fault code number might not appear.)
Fail-safe system
Indicated -
Procedure -
1 Malfunction in ECU. Replace the ECU. Turn the main switch to " ~ "
(on).
9-59
Fault code No. Er-1

Fault code No. Er-1
ECU (Engine Control Unit) internal malfunction (output signal error):

Item signals cannot be transmitted between the ECU and the multi-func-
tion meter.
Able to start engine (unable when ECU is malfunctioning)
Fail-safe system
Able to drive vehicle (unable when ECU is malfunctioning)
Indicated -
Procedure -
1 Connection of meter assembly Improperly connected ~ Con- Turn the main switch to " 0 "
coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
Between meter assembly cou- Fault code number is not dis-
pier and ECU coupler. played ~ Service is finished.
yellow/blue-yellow/blue Fault code number is displayed
~ Go to item 4.
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to " 0 "
(on).
~ Go to item 5.
9-60
Fault code No. Er-2

Fault code No. Er-2

Item
no signals are received from the ECU within the specified duration.
Fail-safe system
Indicated -
Procedure -
1 Connection of meter assembly Improperly connected ~ Con- Turn the main switch to " ~ "
of the pins).
of the pins).
yellow/blue- yellow/blue Fault code number is displayed
~ Go to item 4.
(on).
~ Go to item 5.
9-61
Fault code No. Er-3

Fault code No. Er-3

Item
data from the ECU cannot be received correctly.
Fail-safe system
Indicated -
Procedure -
of the pins).
of the pins).
~ Go to item 4.
(on).
~ Go to item 5.
9-62
Fault code No. Er-4

Fault code No. Er-4
ECU (Engine Control Unit) internal malfunction (input signal error):

Item
non-registered data has been received from the meter assembly.
Fail-safe system
Indicated -
Procedure -
of the pins).
of the pins).
~ Go to item 4.
4 Defective meter assembly. Replace the meter assembly. Tu rn the main switch to " 0 "
(on).
~ Go to item 5.
9-63
9-64
FUEL PUMP SYSTEM
5. Frame ground
6. Main switch
8. Battery
9. Main fuse
34.Joint coupler
SO.Fuel pump
60. Ignition fuse
B. Wire harness
9-66
FUEL PUMP SYSTEM
EBS30283
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

1. Outer passenger seat frame
2. Sound-deflection panels
3. Outer passenger compartment panel
6. Fuel tank

(Main, ignition, and fuel injection
system) Replace the fuse(s) .
ES" on page 9-94.
OKt

page 9-95.
OKt

OKt
4. Check the fuel injection system re- NG~

lay.
Replace the fuel injection system relay.
Refer to "CHECKING THE RE-
LAYS" on page 9-97.
OKt
5. Check the fuel pump. NG~

Refer to "CHECKING THE FUEL Replace the fuel pump assembly.
PUMP BODY" on page 7-3.
OKt
6. Check the entire fuel pump system NG~

page 9-65.
OKt
Replace the ECU.
9-67
FUEL PUMP SYSTEM
9-68
2WD/4WD SELECTING SYSTEM

5. Frame ground
6. Main switch
8. Battery
9. Main fuse
16. Differential motor
18.0n-Command four-wheel-drive switch
34.Joint coupler
39.Meter assembly
48.0n-Command differential gear lock indicator
light
51.Differential motor relay 2
59.Differential motor fuse
60. Ignition fuse
B. Wire harness
9-70
EBS30285
TROUBLESHOOTING
• The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential
gear lock indicator fails to come on .
• The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential
gear lock indicator flashes.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

1. Hood
2. Skid plate
The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential gear

lock indicator fails to come on .

(Main, ignition, signaling system ,
and differential motor) Replace the fuse(s) .
ES" on page 9-94.
OKt

Refer to "CHECKING AND • Clean the battery term inals.
page 9-95.
OKt

OKt
4. Check the On-Command four- NG~
wheel-drive switch . Replace the On-Command four-wheel-
Refer to"CHECKING THE drive switch.
OKt
5. Check the differential motor relay 1. NG~

Refer to "CHECKING THE RE- Replace the differential motor relay 1.
LAYS" on page 9-97.
OKt
6. Check the differential motor relay 2. NG~

Refer to "CHECKING THE RE- Replace the differential motor relay 2.
LAYS" on page 9-97.
OKt

LAYS" on page 9-97.
OKt
9-71
8. Check the differential motor opera- NG~

tion .
Refer to "CHECKING THE DIF- Replace the differential motor.
FERENTIAL MOTOR OPERATION"
on page 8-13.
OKt
9. Check the entire 2WD/4WD select- NG~
ing system wiring . Properly connect or replace the 2WD/4WD
Refer to "CIRCU IT DIAGRAM" on selecting system wiring .
page 9-69.
OKt
The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential gear

lock indicator flashes.
1. Check the differential motor posi- NG~
tion switch.
Refer to "CHECKING THE DIF- Replace the differential motor.
FERENTIAL MOTOR POSITION
SWITCH" on page 9-109.
OKt
2. Check the entire 2WD/4WD select- NG~
ing system wiring . Properly connect or replace the 2WD/4WD
Refer to "CIRCU IT DIAGRAM" on selecting system wiring.
page 9-69.
OKt
Replace the ECU.
9-72
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)

5. Frame ground
6. Main switch
8. Battery
9. Main fuse
10.EPS fuse
28.Speed sensor
35.Joint coupler
36.EPS unit
37.EPS motor
38.EPS torque sensor
39. EPS self-diagnosis signal connector
40.EPS (electric power steering) control unit
45.Meter assembly
55. EPS warning light
67.lgnition fuse
B. Wire harness
D. EPS (electric power steering) control unit
9-74
ESS30287
EPS CONTROL UNIT'S SELF-DIAGNOSTIC FUNCTION

The EPS control unit is equipped with a self-diagnostic function . If this function detects a malfunction in
the EPS system, it lights the EPS warning light to alert the rider that a malfunction has occurred in the
system. Once a malfunction has been detected, it becomes stored in the EPS control unit memory in
the form of a fault code.
• The EPS warning light comes on when the main switch is turned to " O " (on), and then goes off once
the engine is started . If the warning light remains on or comes on after the engine is started , the EPS
system may be defective.
• The electrical circuit of the warning light can be checked by turning the main switch to " O " (on). If the
warning light does not come on , the electrical circuit may be defective.
1. EPS warning light

' 1
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
If the steering usage is too heavy (i.e., excessive steering use when the vehicle is traveling at a slow
speed) , the power assist is reduced to protect the EPS motor from overheating.
EBS30288
EPS WARNING LIGHT DURING NORMAL OPERATION

The EPS warning light comes on initially for 2 seconds after the main switch is turned to " O " (on). How-
ever, the warning light remains on until the engine is started.
In addition, if a malfunction is detected while the warning light comes on initially, the warning light re-
mains on.
Furthermore, the warning light comes on whenever a malfunction has occurred.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
The EPS system does not operate while the EPS warning light is on.
e
a d
g •
f I
b
g
f
C
h
a. Main switch f. Off
b. EPS warning light (no malfunction detected) g. Comes on.
c. EPS warning light (malfunction detected) h. Initial lighting: 2 seconds
d. " O " (ott) 1. Goes off.
e. " ~ " (on)
9-75
EBS30289
DIAGNOSTIC MODE
Setting the diagnostic mode (present and past malfunctions)

1. Disconnect the EPS self-diagnosis signal connector "1".
2. Turn the main switch to " 0 " (on).
3. Select the signaling mode by grounding the EPS self-diagnosis signal connector (male side) to the
EPS control unit "2" or disconnecting it from the unit as follows.
~~ ~
2
' ~
r/Xb?
' ,~·I
l.
'P'
0 /,~
• Present malfunction signaling mode

Ground the connector "1" quickly* to the EPS control unit "2" over 2 times.
* Quickly = from 20 to 76 ms interval
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• Because the "quickly" intervals are approximately the same as the intervals when sliding the connec-
tor "1" across the area "a" of the EPS control unit "2", this method can also be used to set the diag-
nostic mode.
• To set the diagnostic mode, this step should be started within 5 seconds and completed within 1O sec-
onds after the main switch is turned to "ON".
The EPS warning light starts to show present fault codes.
• Past malfunction signaling mode
While the present malfunction mode is activated, briefly disconnect the connector "1", ground it
again, and leave it grounded. The signaling mode is activated after 5 seconds.
The EPS warning light starts to show past fault codes.
4. Turn the main switch to "O " (off) to cancel the diagnostic mode.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• The diagnostic mode can also be canceled by riding the vehicle at speeds above 2 km/h (1 .2 mi/h).
• When the diagnostic mode is selected and during the initial lighting of the EPS warning light, the EPS
control unit does not receive input from the EPS self-diagnosis signal connector.
5. Connect the EPS self-diagnosis signal connector.
Identifying fault codes

When the diagnostic mode is activated, the fault codes determined by the fail-safe specifications are
signaled by the EPS warning light as follows.
• Present malfunction signaling mode: Currently detected fault codes are signaled.
• Past malfunction signaling mode: Both previously detected fau lt codes and currently detected fault
codes are signaled.
Signaling method
Example 1 : Fault code No. 23
9-76
5
d d •
a g I g
I
j k
b h
e A
- - --- - ~
V B- -
C
f ~
- - - ~ ~
•
5
.
I ·I· •I I I I
2 1 3
-Y
0.5 X 3 0.5 X 5
a. EPS self-diagnosis signal connector B. Display of the present malfunctions stops
b. Diagnostic mode when the past malfunction display mode is
c. EPS warning light selected.
d. Disconnected
e. On
f. Off
g. Grounded
h. Normal mode (diagnostic mode not activated)
1. Mode selection judgment
J. Present malfunction signaling mode
k. Past malfunction signaling mode
A. The EPS warning light comes on for 5
seconds during the diagnostic mode selection
judgment.
After the mode selection judgment is completed (present or past malfunction mode) , the current fault
code signaling stops immediately, and then the first code of the mode is signaled 2 seconds later.
When a fault code is signaled , the EPS warning light goes off for 1 second between the units of 10 and
the units of 1 for the code. After a fault code is signaled, the warning light goes off for 3 seconds, and
then the next code is signaled.
Example 2: No malfunctions are detected
a C
f
d A
b e
5 1.5 1.5 1.5 .1.~1 ) .5, 1) .5. ~ l l j

g
a. EPS self-diagnosis signal connector A. The EPS warning light comes on for 5
b. EPS warning light seconds during the diagnostic mode selection
c. Disconnected judgment.
d. Comes on
e. Goes off
f. Grounded
g. Mode selection judgment
9-77
After the mode selection judgment is completed (present display or past malfunction mode) , the current
fault code signaling stops immediately, and then the EPS warning light starts flashing at 1.5-second in-
tervals.
Deleting fault codes

To delete fault codes, ground the EPS self-diagnosis signal connector 3 or more times within 5 seconds
while the present or past malfunction mode is activated. The currently selected mode remains active
after the fault codes of that mode are deleted.
b
a C
T2 ·I
a. EPS self-diagnosis signal connector c. Grounded
b. Disconnected
T1 : Connector grounded - - - - 0.1 ~ T1 ~ 1.6 seconds

T2: Fault codes deleted - - - - - Maximum 1.5 seconds required
EBS30290
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)

Fault code Probable cause of mal-
Item Symptom
No. function
• Open or short circuit in
11 wire harness.
13 EPS torque sensor
No normal signals are received from • Malfunction in torque sen-
15 the torque sensor. sor.
16 • Malfunction in EPS control
unit.
wire harness.
No normal signals are received from • Malfunction in speed sen-
21 Speed sensor
the speed sensor. sor.
• Malfunction in EPS control
unit.
wire harness.
No normal signals are received from
22 Engine speed signal
the ECU.
• Malfunction in ECU.
unit.
41 wire harness.
42 EPS motor
No normal signals are received from
• Malfunction in EPS motor.
43 the EPS motor.
45 unit.
Relay contacts in the EPS control unit Malfunction in EPS control
52 EPS control unit
are welded together. unit.
9-78
Fault code Probable cause of mal-

Item Symptom
No. function
• Faulty battery.
• Malfunction in the
charging system.
53 EPS control unit Battery voltage has dropped. Refer to "CHARGING
unit.
Relay contacts in the EPS control unit Malfunction in EPS control
54 EPS control unit
are welded together. unit.
• Malfunction in the
charging system.
Battery voltage has increased.
Refer to "CHARGING
55 EPS control unit Abnormality exists between the EPS
and the ECU.
unit.
ESS30291
TROUBLESHOOTING DETAILS (EPS SYSTEM)

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
The malfunction history is stored even if the main switch is turned to "O" (off), therefore, be sure to
erase the history (present and past malfunction signaling modes) after repairing the cause of the EPS
system malfunction. The malfunction history must be erased in the diagnostic mode. Refer to "DIAG-
NOSTIC MODE" on page 9-76.
Fault code No. 11 , 13, 15, 16

Fault code No. 11 , 13, Symptom EPS torque sensor: no normal signals are received from the
15, 16 EPS torque sensor.
Order Item/components and probable cause Check or maintenance job Reinstatement

method
1 Connections • Check the locking condition of the Turning the main
• EPS torque sensor coupler coupler. switch to "O"
• Disconnect the coupler and check (off).
the pins (bent or broken terminals
and locking condition of the pins).
• If there is a malfunction, connect
the coupler securely or replace the
wire harness.
2 Open or short circuit in EPS torque sen- • Replace if there is an open or short
sor lead. circuit.
• Between EPS torque sensor cou-
pier and EPS control unit coupler.
white- white
red- red
green-green
black-black
3 Defective EPS torque sensor. • Replace if defective.
Refer to "CHECKING THE EPS
TORQUE SENSOR (for EPS mod-
els)" on page 9-110.
4 Malfunction in EPS control unit. Replace the EPS control unit.
9-79
Fault code No. 21

Fault code No. 21 Symptom Speed sensor: no normal signals are received from the speed
sensor.

method
1 Connections • Check the locking condition of the Starting the en-
• Speed sensor coupler coupler. gine and activat-
• EPS control unit coupler at the wire • Disconnect the coupler and check ing the vehicle
harness the pins (bent or broken terminals speed sensor by
and locking condition of the pins). operating the ve-
• If there is a malfunction, connect hicle above 5
the coupler securely or replace the km/h (3 mi/h), or
wire harness. turning the main
2 Open or short circuit in wire harness. • Replace if there is an open or short switch to "O "
circuit. (off), then to " O "
• Between speed sensor coupler (on), and then
and joint coupler. deleting the fault
white- white codes. Refer to
"DIAGNOSTIC
• Between joint coupler and EPS
control unit coupler. MODE" on page
white- white 9-76.
3 Defective speed sensor. • Replace if defective.

Refer to "CHECKING THE SPEED
Fault code No. 22

Fault code No. 22 Symptom No normal signals are received from the ECU.

method
• EPS control unit coupler at the wire coupler. switch to "O "
harness • Disconnect the coupler and check (off).
• ECU coupler at the wire harness the pins (bent or broken terminals
wire harness.
2 Open or short circuit in wire harness. • Replace if there is an open or short
circuit.
• Between ECU coupler and EPS
control unit coupler.
orange/white- orange/white
9-80
Fault code No. 41, 42, 43, 45

Fault code No. 41, 42, Symptom EPS motor: no normal signals are received from the EPS motor.
43,45
method
• EPS motor coupler coupler. switch to "O "
• Disconnect the coupler and check (off).
the pins (bent or broken terminals
wire harness.
2 Open or short circuit in EPS motor lead. • Replace if there is an open or short
circuit.
• Between EPS motor and EPS con-
trol unit coupler.
red-red
black-black
3 Defective EPS motor. Replace if defective.
Refer to "CHECKING THE EPS MO-
TOR (for EPS models)" on page
9-109.
Fault code No. 52

Fault code No. 52 Symptom Relay contacts in the EPS control unit are welded together.

method
1 Malfunction in EPS control unit. Replace the EPS control unit. Turning the main
switch to "O "
(off).
Fault code No. 53

Fault code No. 53 Symptom Battery voltage has dropped.

method
1 Faulty battery. Replace or charge the battery. Turning the main
Refer to "CHECKING AND switch to "O "
CHARGING THE BATIERY" on (off).
page 9-95.
2 Malfunction in rectifier/regulator or Replace if defective.
charging system. Refer to "CHECKING THE RECTIFI-
ER/REGULATOR" on page 9-103.
9-81
Fault code No. 54

Fault code No. 54 Symptom Relay contacts in the EPS control unit are welded together.

method
1 Malfunction in EPS control unit. Replace the EPS control unit. Turning the main
switch to "O "
(off).
Fault code No. 55

Fault code No. 55 Symptom Battery voltage has increased.
Abnormality exists between the EPS and the ECU.

method
1 Faulty battery. Replace the battery. Turning the main
Refer to "CHECKING AND switch to "O "
CHARGING TH E BATIERY" on (off).
page 9-95.
2 Malfunction in rectifier/regulator. Replace if defective.
Refer to "CHECKING THE RECTIFI-
ER/REGULATOR" on page 9- 103.
3 Malfunction in EPS con trol unit. Replace the EPS control unit.
9-82
ELECTRICAL COMPONENTS
EBS20084
7
5
4
10
3
11
13
14
21
15
20
19 16
18 17
9-83
1. Radiator fan motor

2. Lean angle sensor
3. Parking brake buzzer
4. Parking brake switch
5. Ignition coil
6. Intake air pressure sensor
7. TPS (throttle position sensor)
8. Fuel injector
9. ISC (Idle Speed Control)
10. Air induction system solenoid
11. Coolant temperature sensor
12. Reverse switch
14. Speed sensor
17. Fuel sender
18. Fuel pump
19. Seat belt switch
21. Differential motor
9-84
4 5 6
2
13
() . 11
10
12
9-85
1. Auxiliary DC jack
2. Battery
3. Meter assembly
4. Indicator light assembly
5. Main switch
6. On-Command four-wheel-drive switch
7. Light switch
8. EPS torque sensor (for EPS models)
9. EPS motor (for EPS models)
10. EPS (electric power steering) control unit (for
EPS models)
11. Radiator fan motor circuit breaker
13. Rectifier/regulator
9-86
10
~ 13 11
16 15
14
0
12
12
9-87

4. Headlight relay
8. Spare fuse
9. Starter relay
10. EPS fuse (for EPS models)
11 . Main fuse
12. Fuse box
13. Radiator fan motor fuse
14. Headlight fuse
15. Signaling system fuse
16. Auxiliary DC jack fuse
17. Differential motor fuse
18. Ignition fuse
19. Backup fuse
9-88
EBS30292
CHECKING THE SWITCHES
4
1../W B G/R
.. . . . . . .............. . ~ ~ 2WD (} f-( )
4WD
'I • • • • • • • • • • • • • • • • • Br/R RIB UY Br/R DIFF LOCK 0- f-(l
'' ''
.' ,'
~
Br Y
'
:,' © (off)
' '
: :
: C>-----ifO
(8) :
6
0 (on)
'' ·-----------------
' ' ? (start)
..'' ----- -------------' --------------------'
5
T
G/W
..
'
'
'
'
'
'
11
..' - --=-- - -
'
8 :6
Br L Y
© (off)
-
--- --- --- - - - - - - --- - - - - - - - - - ----------- - - - ~
'.. -------------------------- -·
9-89

2. Parking brake switch
3. Main switch
4. On-Command four-wheel-drive switch
5. Reverse switch
7. Seat belt switch
8. Light switch
9-90
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
ECB01430
NOTICE
--------------------------------
Never insert the tester probes into the coupler terminal slots "a". Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
YU-03112-C
TIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~
• Before checking for continuity, set the pocket tester to "O" and to the "Q x 1" range.
• When checking for continuity, switch back and forth between the switch positions a few times.
- -
00
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions "a" are shown in the far left column and the switch lead colors "b" are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
"0 - 0 ". There is continuity between the brown/red and red/black leads when the switch is set to
" O "(on).
b
Br/R RIB UY Br/R
© (off)
a O (on)
6? (start)
~ Br/R R/B
CD UY Br/A
9-91
EBS30293 EWB02860
CHECKING THE BULBS AND BULB & WARNING

SOCKETS Since the headlight bulb gets extremely hot,
TIP ~~~~~~~~~~~~~~ keep flammable products and your hands
Do not check any of the lights that use LEDs. away from the bulb until it has cooled down.
EC.801960
Check each bulb and bulb socket for damage or
NOTICE
wear, proper connections, and also for continuity
between the terminals.
-------------
• Be sure to hold the socket firmly when re-
Damage/wear ~ Repair or replace the bulb, moving the bulb. Never pull the lead, other-
bulb socket or both. wise it may be pulled out of the terminal in
Improperly connected ~ Properly connect. the coupler.
No continuity ~ Repair or replace the bulb, bulb • Avoid touching the glass part of a headlight
socket or both . bulb to keep it free from oil, otherwise the
transparency of the glass, the life of the
Types of bulbs bulb, and the luminous flux will be adverse-
The bulbs used on this vehicle are shown in the ly affected. If the headlight bulb gets soiled,
illustration. thoroughly clean it with a cloth moistened
• Bulbs "a" and "b" are used for the headlights with alcohol or lacquer thinner.
and usually use a bulb holder that must be de- 2. Check:
tached before removing the bulb. The majority • Bulb (for continuity)
of these types of bulbs can be removed from (with the pocket tester)
their respective socket by turning them coun- No continuity ~ Replace.
terclockwise.
• Bulbs "c" are used for tail/brake lights and can Pocket tester
be removed from the socket by pushing and 90890-03112
turning the bulb counterclockwise. Analog pocket tester
YU-03112-C
a b
TIP - - - - - - - - - - - - - - - ~
Before checking for continuity, set the pocket
tester to "O" and to the "Q x 1" range.
a. Connect the positive tester probe to terminal
"1" and the negative tester probe to terminal
"2", and check the continuity.
b. Connect the positive tester probe to terminal
"1" and the negative tester probe to terminal
"3", and check the continuity.
C c. If either of the readings indicate no continuity,
replace the bulb .
••••••••••••••••••••••••••••••••
0
Checking the condition of the bulbs

bulbs. 2
1. Remove:
• Bulb
9-92
Checking the condition of the bulb sockets 3. Disconnect:

The following procedure applies to all of the bulb • Headlight coupler "1"
sockets.
1. Check:
• Bulb socket (for continuity)
(with the pocket tester)
""
No continuity ~ Replace.
Pocket tester
90890-03112
YU-03112-C
4. Remove:
TIP ~~~~~~~~~~~~~~
• Headlight bulb holder "1"
Check each bulb socket for continuity in the • Headlight bulb "2"
same manner as described in the bulb section ; EWB02860
however, note the following. AwARNING

TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT Since the headlight bulb gets extremely hot,
a. Install a good bulb into the bulb socket. keep flammable products and your hands
b. Connect the pocket tester probes to the re- away from the bulb until it has cooled down.
spective leads of the bulb socket.
c. Check the bulb socket for continuity. If any of TIP - - - - - - - - - - - - - - - ~
the readings indicate no continuity, replace Unhook the headlight bulb holder, and then re-
move the defective bulb.
the bulb socket.
EBS30294
REPLACING THE HEADLIGHT BULBS

headlight bulbs.
1. Remove:
• Headlight rear cover "1"
5. Install:
• Headlight bulb i@M
Secure the new headlight bulb with the head-
light bulb holder.
ECB01350
NOTICE - -------------
Avoid touching the glass part of the head-
2. Remove: light bulb to keep it free from oil, otherwise
• Headlight bulb holder cover "1" the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
6. Install:
• Headlight bulb holder
7. Connect:
• Headlight coupler
8. Install:
• Headlight bulb holder cover
9-93
ECB01970
NOTICE
-------------
ECB01980
NOTICE
-
-- - - - - - - - - - - -
Make sure the headlight bulb holder cover is To avoid a short circuit, always set the main
securely fitted over the bulb holder and seat- switch to "OFF" when checking or replacing
ed properly. a fuse.
TIP ~~~~~~~~~~~~~~ 1. Remove:

Pass the headlight lead "1" through the slot "a" in • Hood
the headlight unit as shown, and then reinstall Refer to "GENERAL CHASSIS (6)" on page
the bulb holder cover. 4-15.
2. Check:
• Fuse
Amperage
No. Fuses Q'ty
rating
1 EPS (for EPS models) 40.0 A 1
2 Main 40.0 A 1
3 Radiator fan motor 25.0 A 1
4 Headlight 15.0 A 1
5 Backup 10.0 A 1
9. Install: 6 Fuel injection system 10.0 A 1
• Headlight rear cover 7 Ignition 10.0 A 1
EBS30295 8 Differential motor 10.0 A 1
ADJUSTING THE HEADLIGHT BEAMS 9 Signaling system 10.0 A 1
The following procedure appl ies to both of the
10 Auxiliary DC jack 10.0 A 1
headlights.
1. Adjust: 11 Spare 25.0 A 1
• Headlight beam (vertically) 12 Spare 15.0 A 1
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 13
a. Turn the adjusting screw "1" in direction "a" or Spare 10.0 A 2
"b". 14
Direction "a"
Headlight beam is raised.
Direction "b"
Headlight beam is lowered.
a. Connect the pocket tester to the fuse and
check the continuity.
TIP~~~~~~~~~~~~~~
Set the pocket tester selector to "Q x 1".
EBS30296 Pocket tester

CHECKING THE FUSES 90890-03112
The following procedure applies to all of the fus- Analog pocket tester
es. YU-03112-C
9-94
b. If the pocket tester indicates "oo", replace the • Eyes - Flush with water for 15 minutes and
fuse. get immediate medical attention.
••••••••••••••••••••••••••••••••
3. Replace:
INTERNAL
• Drink large quantities of water or milk fol-
• Blown fuse lowed with milk of magnesia, beaten egg or
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT vegetable oil. Get immediate medical atten-
a. Turn the main switch to " O " (off). tion.
b. Install a new fuse of the correct amperage EC.801990
rating. NOTICE
c. Set on the switches to verify if the electrical -------------
• This is a VRLA (Valve Regulated Lead Acid)
circuit is operational. battery. Never remove the sealing caps be-
d. If the fuse immediately blows again, check cause the balance between cells will not be
the electrical circuit. maintained and battery performance will
EWB028SO
A WARNING deteriorate.
• Charging time, charging amperage and
Never use a fuse with an amperage rating
charging voltage for a VRLA (Valve Regu-
other than that specified. Improvising or us-
lated Lead Acid) battery are different from
ing a fuse with the wrong amperage rating
those of conventional batteries. The VRLA
may cause extensive damage to the electri-
(Valve Regulated Lead Acid) battery should
cal system, cause the lighting and ignition
be charged according to the appropriate
systems to malfunction and could possibly
charging method. If the battery is over-
cause a fire.
charged, the electrolyte level will drop con-
••••••••••••••••••••••••••••••••
4. Install :
siderably. Therefore, take special care
when charging the battery.
• Hood TIP ~~~~~~~~~~~~~~
Since VRLA batteries are sealed, it is not possi-
4-1 5.
ble to check the charge state of the battery by
ESS30297 measuring the specific gravity of the electrolyte.
CHECKING AND CHARGING THE BATTERY Therefore, the charge of the battery has to be
EWB02830
checked by measuring the voltage at the battery
A WARNING
terminals.
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi- 1. Remove:
sonous and highly caustic sulfuric acid. • Hood
Therefore, always follow these preventive Refer to "GENERAL CHASSIS (6)" on page
measures: 4-15.
• Wear protective eye gear when handling or 2. Disconnect:
working near batteries. • Battery leads
• Charge batteries in a well-ventilated area. (from the battery terminals)
ECB01340
• Keep batteries away from fire, sparks or
NOTICE
open flames (e.g., welding equipment, -------------
lighted cigarettes). First, disconnect the negative battery lead
• DO NOT SMOKE when charging or han- "1 ", and then positive battery lead " 2" .
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
. .
1n1ury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
•Skin-Wash with water.
9-95
3. Remove:
• Battery
4. Check:
• Battery charge
a. Connect a pocket tester to the battery termi-
nals. I
• Positive tester probe ~ ,o ~-+----1----+----'---!,-;'-

I
--1
I
positive battery terminal
• Negative tester probe ~
~-~-~-~~~'-~-
100 75 50 30 25 20 0
B
negative battery terminal
A. Open-circuit voltage (V)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ B. Charging condition of the battery(%)
• The charge state of a VRLA (Valve Regulated C. Ambient temperature 20 °C (68 °F)
Lead Acid) battery can be checked by measur-
ing its open-circuit voltage (i.e., the voltage ••••••••••••••••••••••••••••••••
5. Charge:
when the positive battery terminal is discon-
• Battery
nected) .
(refer to the appropriate charging method)
• No charging is necessary when the open-cir- EWB02840
cuit voltage equals or exceeds 12.8 V. & WARNING
b. Check the charge of the battery, as shown in Do not quick charge a battery.
the charts and the following example. EC B02000
NOTICE
Example
Open-circuit voltage = 12.0 V --------------
• Do not use a high-rate battery charger
Charging time = 6.5 hours
since it forces a high-amperage current
Charge of the battery = 20- 30o/o
into the battery quickly and can cause bat-
tery overheating and battery plate damage.
A
13.0
• If it is impossible to regulate the charging
current on the battery charger, be careful
12.5
not to overcharge the battery.
12.0 • When charging a battery, be sure to remove
it from the vehicle. (If charging has to be
11.5
done with the battery mounted on the vehi-
cle, disconnect the negative battery lead
5 6.5 10 B from the battery terminal.)
D • To reduce the chance of sparks, do not
A. Open-circuit voltage (V) plug in the battery charger until the battery
B. Charging time (hours) charger leads are connected to the battery.
C. Relationship between the open-circuit voltage • Before removing the battery charger lead
and the charging time at 20 °C (68 °F) clips from the battery terminals, be sure to
D. These values vary with the temperature, the turn off the battery charger.
condition of the battery plates, and the • Make sure the battery charger lead clips are
electrolyte level. in full contact with the battery terminal and
that they are not shorted. A corroded bat-
tery charger lead clip may generate heat in
the contact area and a weak clip spring may
cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot
batteries can explode!
9-96
• As shown in the following illustration, the 12.8 V or more --- Charging is complete.
open-circuit voltage of a VRLA (Valve Reg- 12.7 V or less --- Recharging is required.
ulated Lead Acid) battery stabilizes about Under 12.0 V --- Replace the battery.
30 minutes after charging has been com-
pleted. Therefore, wait 30 minutes after ••••••••••••••••••••••••••••••••
6. Install:
charging is completed before measuring
the open-circuit voltage. • Battery
7. Connect:
A ·--·
C • Battery leads
18
D (to the battery terminals)
17 ECB01330
16 NOTICE
15
\
--------------
14 '-
First, connect the positive battery lead "1 ",
13 and then the negative battery lead "2".
12
11
10
o ,o 20 30 40 so Go B
4E
A. Open-circuit voltage (V)
B. Time (minutes)
C. Charging
D. Ambient temperature 20 °C (68 °F)
E. Check the open-circuit voltage.
Charging method using a constant volt- 8. Check:
age charger • Battery terminals
a. Measure the open-circuit voltage prior to Dirt~ Clean with a w ire brush .
charging . Loose connection~ Connect properly.
9. Install:
TIP - - - - - - - - - - - - - - - ~
• Hood
Voltage should be measured 30 minutes after
Refer to "GENERA L C HASSIS (6)" on page
the engine is stopped.
4-15.
b. Connect a charger and ammeter to the bat-
EBS30298
tery and start charging . CHECKING THE RELAYS
c. Make sure that the current is higher than the Check each switch for continuity with the pocket
standard charging current written on the bat- tester. If the continuity reading is incorrect, re-
tery. place the relay.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~
If the current is lower than the standard charging Pocket tester
current written on the battery, this type of battery 90890-03112
charger cannot charge the VALA (Valve Regu- Analog pocket tester
YU-03112-C
lated Lead Acid) battery. A variable voltage
charger is recommended. 1. Disconnect the relay from the wire harness.
d. Charge the battery until the battery's 2. Connect the pocket tester (Q x 1) and battery
charging voltage is 15 V. (12 V) to the relay terminal as shown.
TIP ~~~~~~~~~~~~~~ Check the relay operation.
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes.
9-97
Starter relay Headlight relay

3 First step:
- - - -~ --------------;
••
R • 1 ~
3r~I~
•
•
,,
~
/
>= '''"
' >=
'- ~ 2 ---
'
'
B '
'
~ 2 ,' 1 B G Y
----\S~ ~-------------· y
L
1. Positive battery terminal

2. Negative battery terminal 1 . Positive tester probe
3. Positive tester probe 2. Negative tester probe
4. Negative tester probe 3. Negative tester probe
Result Result
Continuity Continuity
(between "3" and "4") (between "1" and "2")
No continuity
Load control relay (between "1" and "3")
I Second step:
3~ =
I 11
4 -i--!L
1
+ I
(
1- 3~
I
=
l? .... I
5 ---r--!L 11
1
+ I
(
I-
4 ~I.....,, I
r,:::::::! I
~-;.
1 ....
2~ ~-;.
B
1
B G Y
y

2. Negative battery terminal 1. Positive battery terminal
3. Positive tester probe 2. Negative battery terminal
4. Negative tester probe 3. Positive tester probe
4. Negative tester probe
Result 5. Negative tester probe
Continuity
(between "3" and "4") Result
No continuity
(between "3" and "4")
Continuity
9-98
Radiator fan motor relay Differential motor relay 1
3
t- ~ 1 (
I-
First step:
2
21 ·.- ~
1
-
+ I
2
Y/B B Br/R
R Br/R
BN
2. Negative battery terminal 1 . Positive tester probe
3. Positive tester probe 2. Negative tester probe
4. Negative tester probe 3. Negative tester probe
Result Result
Continuity Continuity
(between "3" and "4") (between "1 " and "2")
No continuity
(between "1 " and "3 ")
Fuel injection system relay
3 -L Second step:
4 ll l
+ I I-
(
3
2
J? \
.....
1
5~
41--t
~___,_____,....______../
+
2 \
1
Y/B B Br/R
Br/R
B/Y

2. Negative battery terminal 1. Positive battery terminal
3. Positive tester probe 2. Negative battery terminal
4. Negative tester probe 3. Positive tester probe
Result 5. Negative tester probe
Continuity
(between "3" and "4") Result
No continuity
(between "3 " and "4")
Continuity
(between "3 " and "5 ")
9-99
Differential motor relay 2 TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT

a. Remove the spark plug cap from the spark
First step: plug lead .
b. Connect the pocket tester (Q x 1k) to the
spark plug cap as shown.
Pocket tester
90890-03112
G/R B Br/R YU-03112-C
Br/R
Br/8
1. Positive tester probe --T nx1k

2. Negative tester probe l'
GJ § ~
Result
Continuity '
No continuity
(between "1" and "3") c. Measure the spark plug cap resistance .
Second step: ••••••••••••••••••••••••••••••••

EBS30300
3~
I
- CHECKING THE IGNITION COIL
r
5~ I
)
- I- 1. Check:
+ I
4 ~ ILj ~
• Primary coil resistance
I Out of specification ~ Replace.
2~ \
1
Primary coil resistance
G/R B Br/R 2.16-2.64 Q
Br/R
Br/8 TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Disconnect the ignition coil connectors from
1. Positive battery terminal the ignition coil terminals.
2. Negative battery terminal b. Connect the pocket tester (Q x 1) to the igni-
3. Positive tester probe tion coil as shown.
Pocket tester
90890-03112
Result YU-03112-C
No continuity
(between "3" and "4") • Positive tester probe ~
Continuity orange "1"
(between "3" and "5") • Negative tester probe ~
brown/ red "2"
EBS30299
CHECKING THE SPARK PLUG CAP

1. Check:
• Spark plug cap resistance
Resistance
7.5-12.5 kQ
9-100
Minimum ignition spark gap

6.0 mm (0.24 in)
2 TIP ~~~~~~~~~~~~~~
If the ignition spark gap is within specification ,

the ignition system circuit is operating normally.
0 0
-- ~
1 a. Disconnect the spark plug cap from the spark
plug.
c. Measure the primary coil resistance. b. Connect the ignition checker "1" as shown .
••••••••••••••••••••••••••••••••
2. Check: Ignition checker
90890-06754
• Secondary coil resistance
Oppama pet-4000 spark checker
Out of specification ~ Replace. YM-34487
Secondary coil resistance
8.64-12.96 k.Q
a. Disconnect the spark plug cap from the igni-
tion coil.
b. Connect the pocket tester (Q x 1k) to the ig-
nition coil as shown .
Pocket tester 2
90890-03112 1
2. Spark plug cap
YU-03112-C
c. Measure the ignition spark gap "a".
• Positive tester probe ~ d. Crank the engine by turning the main switch
brown/ red "1" to "o" (start) and gradually increase the
• Negative tester probe ~ spark gap until a misfire occurs.
Spark plug lead "2"
••••••••••••••••••••••••••••••••
EBS30302
CHECKING THE CRANKSHAFT POSITION

2
SENSOR
1. Disconnect:
• Crankshaft position sensor coupler
(from the wire harness)
0
2. Check:
• Crankshaft position sensor resistance
1
Out of specification ~ Replace the crank-
shaft position sensor/stator assembly.
c. Measure the secondary coil resistance.
Crankshaft position sensor resis-
•••••••••••••••••••••••••••••••• tance
ESS30301
408-612 .Q
CHECKING THE IGNITION SPARK GAP
1. Check: TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
• Ignition spark gap a. Connect the pocket tester (Q x 100) to the
Out of specification ~ Perform the ignition crankshaft position sensor coupler as shown.
system troubleshooting, starting with step 5.
Refer to "T ROUBLESHOOTING" on page
9-3.
9-101
• Positive tester probe ~

Pocket tester yellow/green (wire harness color)
90890-03112 • Negative tester probe ~
Analog pocket tester black/blue (wire harness color)
YU-03112-C
1
gray "1"
black "2"
c. Turn the main switch to " 0 " (on) .

d. Turn the lean angle sensor to 65°.
Gy B
e. Measure the lean angle sensor output volt-
7 --'---'~ age.
1 2
••••••••••••••••••••••••••••••••
b. Measure the crankshaft position sensor re- EBS30304
sistance. CHECKING THE STARTER MOTOR

OPERATION
••••••••••••••••••••••••••••••••
EBS30303
1. Check:
CHECKING THE LEAN ANGLE SENSOR
• Starter motor operation
1. Remove: Does not operate ~ Perform the electric
• Lean angle sensor starting system troubleshooting, starting with
2. Check: step 4.
• Lean angle sensor output voltage Refer to "TROUBLESHOOTING" on page
9-8.
a. Connect the positive battery terminal "1" and
Less than 65°: 3.55-4.45 V starter motor lead "2" with a jumper lead "3".
EWB02920
More than 65°: 0.65- 1.35 V
& WARNING
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT • A wire that is used as a jumper lead must
a. Connect the test harness- lean angle sensor have at least the same capacity of the bat-
(3P) "1" between the lean angle sensor and tery lead, otherwise the jumper lead may
wire harness as shown. burn.
b. Connect the pocket tester (DC 20 V) to the • This check is likely to produce sparks,
test harness- lean angle sensor (3P). therefore, make sure no flammable gas or
fluid is in the vicinity.
Test harness- lean angle sensor
(3P)
90890-03213 3
Test harness- lean angle sensor 2
(3P)
YU-03213
Pocket tester
I ---- ---------------'
(1+- - - - ~ ' '
~=i:':::::::;i 1 ;
90890-03112
M ~ e
YU-03112-C
b. Check the starter motor operation .

••••••••••••••••••••••••••••••••
9-102
EBS30305
CHECKING THE STATOR COIL Charging voltage

1. Disconnect: above 14 Vat 5000 r/min
• Stator coil couplers
(from the wire harness) TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
2. Check: a. Connect the engine tachometer to the spark
• Stator coil resistance plug lead.
Out of specification ~ Replace the crank- b. Connect the pocket tester (DC 20 V) to the
shaft position sensor/stator assembly. battery as shown.
Stator coil resistance Pocket tester

0.09-0.13 n 90890-03112
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT YU-03112-C
a. Connect the digital circuit tester to the stator
coil coupler as shown. • Positive tester probe ~
positive battery terminal "1"
Digital circuit tester • Negative tester probe ~
90890-03174 negative battery terminal "2"
Model 88 Multimeter with ta-
chometer
YU-A1927

white "1"
white "2"

white "1"
white "3" c. Start the engine and let it run at approximate-
ly 5000 r/min.
• Positive tester probe ~ d. Measure the charging voltage.
white "2"
• Negative tester probe ~ ••••••••••••••••••••••••••••••••
EBS30307
white "3"
CHECKING THE FUEL SENDER
1. Disconnect:
• Fuel pump coupler
/
' (from the wire harness)
2. Remove:
• Fuel pump assembly
__........_ (from the fuel tank)
3. Check:
• Fuel sender resistance
Out of specification ~ Replace the fuel pump
3 2
assembly.
b. Measure the stator coil resistance.
Sender unit resistance (full)
•••••••••••••••••••••••••••••••• 19.00-21.00 n
EBS30306
Sender unit resistance (empty)
CHECKING THE RECTIFIER/REGULATOR 139.00-141.00 n
1. Check:
• Charging voltage TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
Out of specification ~ Replace the rectifi- a. Connect the pocket tester (Q x 1O or Q x 100)
er/regulator. to the fuel sender terminals as shown.
9-103
Warning light comes on for a few seconds,

Pocket tester then goes off ~ Warning light is OK.
90890-03112 Warning light does not come on ~ Replace
the meter assembly.
YU-03112-C
Warning light flashes eight times, then goes
off for 3 seconds in a repeated cycle (mal-
orange/black "1" function detected in fuel sender) ~ Replace
• Negative tester probe ~ the fuel pump assembly.
black/white "2"
1
0
n
LI
EBS30309
CHECKING THE SPEED SENSOR

b. Move the fuel sender float to minimum "3" 1. Check:
and maximum "4" level positions. • Speed sensor output voltage
Output voltage reading cycle

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

90890-03208
'
,, ,,."'
.,.: };=.:::============= =
' ' --'
> YU-03208
3-----\_,- Pocket tester
90890-03112
YU-03112-C

c. Measure the fuel sender resistance. white (wire harness color)
••••••••••••••••••••••••••••••••
EBS30308
CHECKING THE FUEL METER/FUEL LEVEL

WARNING LIGHT
This model is equipped with a self-diagnosis de-
vice for the fuel level detection circuit.
1. Check:
• Fuel meter/fuel level warning light "1"
(Turn the main switch to " 0 " [on].)
9-104
• Positive battery terminal ~

\ blue "1"
• Negative battery terminal ~
black "2"
L
Bl+-- - - - - - - ,
c. Turn the main switch to" O " (on). L-~

d. Elevate the rear wheels and slowly rotate
them.
e. Measure the voltage (DC 20 V) of white and 1
7 12V
black/blue. With each full rotation of the rear

c. Check the radiator fan motor movement.
wheels, the voltage reading should cycle
from 0.6 V to 4.8 V to 0.6 V to 4.8 V.
EBS30311
CHECKING THE RADIATOR FAN MOTOR

EBS30354
CIRCUIT BREAKER
CHECKING THE PARKING BRAKE BUZZER 1. Remove:
1. Check: • Radiator fan motor circuit breaker
• Parking brake buzzer (from the wire harness)
Does not sound ~ Replace.
a. Disconnect the parking brake buzzer coupler
from the wire harness.
b. Connect the battery to the parking brake
buzzer coupler as shown.
• Positive battery terminal ~
brown "1"
• Negative battery terminal ~
pink "2"
0 2. Check:
• Radiator fan motor circuit breaker resistance
Out of specification ~ Replace the radiator
/\ fan motor circuit breaker.
IP D-1
B r I}
Radiator fan motor circuit break-
I I
er resistance
+ I I- 0-0.05 .Q at 25 °C (77 °F)
12V
a. Connect the digital circuit tester to the radia-
c. Check the parking brake buzzer sound.
tor fan motor circuit breaker as shown .
••••••••••••••••••••••••••••••••
ESS30310 Digital circuit tester
CHECKING THE RADIATOR FAN MOTOR 90890-03174
1. Check: Model 88 Multimeter with ta-
• Radiator fan motor chometer
Faulty/rough movement~ Replace. YU-A1927
a. Disconnect the radiator fan motor coupler
from the wire harness.
b. Connect the battery (DC 12 V) as shown.
9-105
.
,. ' ' ., ;·
-
' .
~
''
'
''
'
3 II
~~ .. 4
~ (§) ~
c==Ql
I
I
t~J~ .,
--·1 I ft--_
2
b. Measure the radiator fan motor circuit break- d. Heat the coolant or let it cool down to the
er resistance. specified temperatures.
••••••••••••••••••••••••••••••••
EBS30312
e. Measure the coolant temperature sensor re-
sistance.
CHECKING THE COOLANT TEMPERATURE
SENSOR
••••••••••••••••••••••••••••••••
3. Install:
1. Remove: • Coolant temperature sensor
• Coolant temperature sensor
EWB02950
Coolant temperature sensor
A WARNING 18 Nm (1.8 m-kgf, 13 ft-lbf)
• Handle the coolant temperature sensor
with special care. EBS30313
• Never subject the coolant temperature sen- CHECKING THE THROTTLE POSITION
sor to strong shocks. If the coolant tem- SENSOR
perature sensor is dropped, replace it. 1. Remove:
2. Check: (from the throttle body)
• Coolant temperature sensor resistance EWB03070
Out of specification ~ Replace. A WARNING

• Handle the throttle position sensor with
Coolant temperature sensor re- special care.
sistance
• Never subject the throttle position sensor
2320-2590 n at 20 °c (2320-
2590 n at 68 °F) to strong shocks. If the throttle position
sensor is dropped, replace it.
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 2. Check:
a. Connect the pocket tester (n x 1k or n x 100)
• Throttle position sensor maximum resistance
to the coolant temperature sensor terminals Out of specification ~ Replace the throttle
as shown. position sensor.
Pocket tester Resistance
90890-03112
2.64-6.16 kn
YU-03112-C TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Connect the pocket tester (n x 1k) to the
b. Immerse the coolant temperature sensor "1" throttle position sensor terminals as shown.
in a container filled with coolant "2".
TIP ~~~~~~~~~~~~~~~~ Pocket tester
Make sure the coolant temperature sensor ter- 90890-03112
minals do not get wet.
YU-03112-C
c. Place a thermometer "3" in the coolant.
blue "1"
black/blue "2"
9-106
Test harness S- pressure sensor

1 2
5S7 (3P)
90890-03211
Test harness S- pressure sensor
5S7 (3P)
YU-03211
Pocket tester
90890-03112
YU-03112-C
b. Measure the throttle position sensor maxi-
mum resistance. • Positive tester probe ~
••••••••••••••••••••••••••••••••
3. Install:
pink (wire harness color)
TIP~~~~~~~~~~~~~~
When installing the throttle position sensor, ad-

just its angle properly. Refer to "ADJUSTING
THE THROTTLE POSITION SENSOR" on page
7-1 3.
ESS30314
CHECKING THE INTAKE AIR PRESSURE

SENSOR
EWB03210
A WARNING c. Turn the main switch to " ~ " (on).

• Handle the intake air pressure sensor with d. Measure the intake air pressure sensor out-
special care. put voltage.
• Never subject the intake air pressure sen-
sor to strong shocks. If the intake air pres- ••••••••••••••••••••••••••••••••
EBS30315
sure sensor is dropped, replace it. CHECKING THE INTAKE AIR
1. Check: TEMPERATURE SENSOR
• Intake air pressure sensor output voltage 1. Remove:
Out of specification ~ Replace. • Intake air temperature sensor
(from the air filter case.)
Intake air pressure sensor output EWB02940
voltage A WARNING
3.59-3.68 V • Handle the intake air temperature sensor
with special care.
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT • Never subject the intake air temperature
a. Connect the test harness S- pressure sensor
sensor to strong shocks. If the intake air
5S7 (3P) "1" between the intake air pressure
temperature sensor is dropped, replace it.
sensor and wire harness as shown.
b. Connect the pocket tester (DC 20 V) to the 2. Check:
test harness S- pressure sensor 5S7 (3P). • Intake air temperature sensor resistance
Intake air temperature sensor re-

sistance
5400-6600 Q at O 0 c (5400-6600
Q at 32 °F)
9-107
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT • Positive tester probe

a. Connect the pocket tester (Q x 1k or Q x 100) Injector terminal "1"
to the intake air temperature sensor terminals • Negative tester probe
as shown. Injector terminal "2"
Pocket tester
90890-03112
Analog pocket tester 1 2
~
YU-03112-C
b. Immerse the intake air temperature sensor

"1" in a container filled with water "2".
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Make sure that the intake air temperature sensor
terminals do not get wet.
c. Measure the fuel injector resistance.
c. Place a thermometer "3" in the water.
••••••••••••••••••••••••••••••••
3
,_ ~
/~ EBS303 17
CHECKING THE AIR INDUCTION SYSTEM

SOLENOID
I
--- I
,~ ·1
1
7
~ (§) ~
1. Check:
• Air induction system solenoid resistance
-- 1
~
·1 )
__ Jt-2 Solenoid resistance
20-24 Q
d. Heat the water or let it cool down to the spec- TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT

ified temperatures. a. Disconnect the air induction system solenoid
e. Measure the intake air temperature sensor coupler from the wire harness.
resistance. b. Connect the pocket tester (Q x 1) to the air in-
duction system solenoid terminals as shown .
••••••••••••••••••••••••••••••••
ESS303 16
Pocket tester
CHECKING THE FUEL INJECTOR
90890-03112
1. Check: Analog pocket tester
• Fuel injector resistance YU-03112-C
Out of specification ~ Replace the fuel injec-
tor. • Positive tester probe ~
Air induction system solenoid terminal "1"
Resistance • Negative tester probe ~
11.5-12.5 Q Air induction system solenoid terminal "2"
a. Disconnect the fuel injector coupler from wire
2 1
harness.
b. Connect the pocket tester (Q x 1) to the fuel
injector terminals as shown .
Pocket tester
90890-03112
YU-03112-C C
c. Measure the air induction system solenoid re-
sistance .
••••••••••••••••••••••••••••••••
9-108
ESS30318
g. Check the differential motor position switch
CHECKING THE DIFFERENTIAL MOTOR
no continuity.
POSITION SWITCH
1. Check: ••••••••••••••••••••••••••••••••
EBS30319
• Differential motor position switch
CHECKING THE EPS MOTOR (for EPS
models)
Pocket tester 1. Remove:
90890-03112 • EPS unit
Analog pocket tester 2. Check:
YU-03112-C • EPS motor
Out of specification ~ Replace the EPS unit.
TIP ~~~~~~~~~~~~~~ TIP ~~~~~~~~~~~~~~
Check the differential motor position switch for The pocket tester and the analog pocket tester
continuity between the terminals "1" and "3" and readings are shown in the following table.
between the terminals "2" and "3" when the On-
Command four-wheel-drive switch is set to the
Continuity
"2WD", "4WD", and "DIFF LOCK" positions. Positive tester probe ~ red "1"
Negative tester probe ~ black
2WD position "2"
No continuity No continuity
(between "1" and "3") Positive tester probe ~ red "1"
(between "2" and "3") Negative tester probe ~ EPS
4 WD position motor body " 3"
Continuity No continuity
(between "2" and "3") Positive tester probe ~ black
No continuity "2"
(between "1" and "3") Negative tester probe ~ EPS
DIFF LOCK position motor body " 3"
Continuity
No continuity
) 0
a. Connect the pocket tester (Q x 1) to the EPS
motor coupler terminal and EPS motor body.
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT Pocket tester

a. Turn the main switch to " ~ " (on). 90890-03112
b. Set the On-Command four-wheel-drive Analog pocket tester
switch to "2WD", "4WD", or "DIFF LOCK" po- YU-03112-C
sition.
c. Turn the main switch to " o"
(off). b. Check the EPS motor for continuity.
d. Disconnect the differential motor coupler. c. Check the EPS motor for no continuity.
e. Connect the pocket tester (Q x 1) to the differ- ••••••••••••••••••••••••••••••••
ential motor terminals.
f. Check the differential motor position switch
continuity.
9-109
EBS30320
CHECKINGTHEEPSTORQUESENSOR(~r
EPS models)
1. Remove:
• EPS unit
ECB01660
NOTICE
-------------
Make sure do not remove the torque sensor
and its protector from the EPS unit.
2. Check:
• EPS torque sensor resistance
O ut of specification ~ Replace the steering
column.
EPS torque sensor

Coil resistance
0.875-1.625 kQ (for EPS mod-
els)
a. Connect the pocket tester (Q x 1k) to the EPS
torque sensor coupler terminals as shown.
Pocket tester
90890-03112
YU-03112-C

red "1"
black "2"
b. Measure the EPS torque sensor resistance .

••••••••••••••••••••••••••••••••
9-110
9-111
TROUBLESHOOTING
TROUBLESHOOTING .. ......... ......... .......... ........ .......... ......... ......... .......... ....... 10-1
GENERAL INFORMATION ....... .......... ......... ........ ......... .......... ......... ....... 10-1
STARTING FAILURES .... .......... ......... ........ .......... ......... .......... ......... ....... 10-1
INCORRECT ENGINE IDLING SPEED ....... ......... ......... ......... ......... ....... 10-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........ ......... ........ 10-2
FAULTY DRIVE TRAIN .. .......... ......... ........ .......... ......... .......... ......... ........ 10-3
FAULTY GEAR SHIFTING ....... ......... ......... ......... ......... ......... .......... ........ 10-4
SHIFT LEVER DOES NOT MOVE ...... ......... ........ ......... ......... ......... ........ 10-4
JUMPS OUT OF GEAR .. .......... ......... ........ .......... ......... .......... ......... ........ 10-4
FAULTY CLUTCH PERFORMANCE ........ .......... ......... ......... ......... ......... 10-4
OVERHEATING ..... ......... ......... .......... ........ .......... ......... ......... .......... ....... 10-4
OVER COOLING .... ......... .......... ......... ......... ......... ......... .......... ......... ........ 10-5
POOR BRAKING PERFORMANCE .... .......... ......... ........ .......... ......... ...... 10-5
FAULTY SHOCK ABSORBER ASSEMBLY ......... ......... .......... ......... ....... 10-5
UNSTABLE HANDLING .. ......... .......... ........ ......... .......... ......... .......... ....... 10-5
FAULTY LIGHTING OR SIGNALING SYSTEM ... .......... ......... ......... ....... 10-5
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE .. ........ 10-7

SELF-DIAGNOSTIC FUNCTION TABLE ...... ......... ......... ......... ......... ...... 10-7
COMMUNICATION ERROR WITH THE METER ......... ......... .......... ....... 10-7
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ........... ......... ....... 10-8
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ...... .......... ...... 10-9
TROUBLESHOOTING
EBS20085
Electrical system
TROUBLESHOOTING 1. Battery
ESS3032 1
• Discharged battery
GENERAL INFORMATION • Faulty battery
TIP ~~~~~~~~~~~~~~~~ 2. Fuse(s)
• Blown, damaged or incorrect fuse
The following guide for troubleshooting does not
• Improperly installed fuse
cover all the possible causes of trouble. It should
3. Spark plug
be helpful, however, as a guide to basic trouble-
• Incorrect spark plug gap
shooting. Refer to the relative procedure in this
• Incorrect spark plug heat range
manual for checks, adjustments, and replace-
• Fouled spark plug
ment of parts.
• Worn or damaged electrode
• Worn or damaged insulator
EBS30322
STARTING FAILURES • Faulty spark plug cap

4. Ignition coil
Engine • Cracked or broken ignition coil body
1. Cylinder and cylinder head • Broken or shorted primary or secondary coils
• Loose spark plug • Faulty spark plug lead
• Loose cylinder head or cylinder 5. Ignition system
• Damaged cylinder head gasket • Faulty EC U
• Damaged cylinder gasket • Faulty crankshaft position sensor
• Worn or damaged cylinder • Broken AC magneto rotor woodruff key
• Incorrect valve clearance 6. Switches and wiring
• Improperly sealed valve • Faulty main switch
• Incorrect valve-to-valve-seat contact • Broken or shorted wiring
• Incorrect valve timing • Faulty gear position switch
• Faulty valve spring • Improperly grounded circuit
• Seized valve • Loose connections
2. Piston and piston ring(s) • Faulty brake light switch
• Improperly installed piston ring 7. Starting system
• Damaged, worn or fatigued piston ring • Faulty starter motor
• Seized piston ring • Faulty starter relay
• Seized or damaged piston • Faulty starter clutch
3. Air filter EBS30323
• Improperly installed air filter INCORRECT ENGINE IDLING SPEED
• Clogged air filter element
4. Crankcase and crankshaft Engine
• Improperly assembled crankcase 1. Cylinder and cylinder head
• Seized crankshaft • Incorrect valve clearance
• Damaged valve train components
Fuel system 2. Air filter
1. Fuel tank • Clogged air filter element
• Empty fuel tank
• C logged fuel tank breather hose joint Fuel system
• Clogged fuel tank breather hose joint hose 1. Throttle body
• Deteriorated or contaminated fuel • Damaged or loose throttle body joint
2. Fuel pump • Faulty ISC (Idle Speed Control) unit
• Faulty fuel pump • Improper throttle cable free play
• Faulty fuel injection system relay • Flooded throttle body
• Clogged or damaged fuel hose • Faulty air induction system
3. Throttle body
• Deteriorated or contaminated fuel
• Sucked-in air
10-1
TROUBLESHOOTING
Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Spark plug
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
3. Ignition coil
• Broken or shorted primary or secondary coils
• Faulty spark plug lead
• Cracked or broken ignition coil
4. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken AC magneto rotor woodruff key
ESS30324
POOR MEDIUM-AND-HIGH-SPEED
PERFORMANCE
Refer to "STARTING FAILURES" on page 10-1.
Engine
1. Air filter
• Clogged air filter element
Fuel system
1. Fuel pump
• Faulty fuel pump
10-2
TROUBLESHOOTING
EBS30325
FAULTY DRIVE TRAIN

The following conditions may indicate damaged shaft drive components:
Symptoms Possible Causes
1. A pronounced hesitation or "jerky" movement A. Bearing damage.
during acceleration, deceleration, or sustained B. Improper gear backlash.
speed. (This must not be confused with engine C. Gear tooth damage.
surging or transmission characteristics.) 0. Broken drive shaft.
2. A "rolling rumble" noticeable at low speed; a high- E. Broken gear teeth.
pitched whine; a "clunk" from a shaft drive com- F. Seizure due to lack of lubrication.
ponent or area. G. Small foreign objects lodged between the moving
3. A locked-up condition of the shaft drive mecha- parts.
nism, no power transmitted from the engine to the
front and/or rear wheels.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal vehicle operating noise. If there is reason to believe these compo-
nents are damaged, remove the components and check them.
10-3
TROUBLESHOOTING
EBS30326
Poor starting performance
FAULTY GEAR SHIFTING
1. V-belt
• V-belt slips
Shifting is difficult
• Oil or grease on the V-belt
Refer to "FAULTY CLUTCH PER FORMANCE"
2. Primary and secondary sheave
on page 10-4.
• Faulty operation
ESS30327 • Worn pin groove
SHIFT LEVER DOES NOT MOVE • Worn pin
3. Clutch shoe
Shift drum and shift forks • Bent, damaged or worn clutch shoe
• Foreign object in a shift drum groove
• Seized shift fork Poor speed performance
• Bent shift fork guide bar 1. V-belt
• Oil or grease on the V-belt
Transmission 2. Primary pulley weight(s)
• Seized transmission gear • Faulty operation
• Foreign object between transmission gears • Worn primary pulley weight
• Improperly assembled transmission 3. Primary fixed sheave
EBS30328
• Worn primary fixed sheave
JUMPS OUT OF GEAR 4. Primary sliding sheave
• Worn primary sliding sheave
Shift forks 5. Secondary fixed sheave
• Worn shift fork • Worn secondary fixed sheave
6. Secondary sliding sheave
Shift drum • Worn secondary sliding sheave
• Incorrect axial play
EBS30330
• Worn shift drum groove
OVERHEATING
Transmission
Engine
• Worn gear dog
1. Clogged coolant passages
EBS30329 2. Cylinder head and piston
FAULTY CLUTCH PERFORMANCE • Heavy carbon buildup
3. Engine oil
Engine operates but vehicle will not move • Incorrect oil level
1. V-belt • Incorrect oil viscosity
• Bent, damaged or worn V-belt • Inferior oil quality
• Slipping V-belt
2. Primary sheave cam and primary sheave Cooling system
slider 1. Coolant
• Damaged or worn primary sheave cam • Low coolant level
• Damaged or worn primary sheave slider 2. Radiator
3. Clutch spring(s) • Damaged or leaking radiator
• Damaged clutch spring • Faulty radiator cap
4. Transmission gear(s) • Bent or damaged radiator fin
• Damaged transmission gear 3. Water pump
• Damaged or faulty water pump
Clutch slips 4. Thermostat
1. Clutch spring(s) • Thermostat stays closed
• Damaged, loose or worn clutch spring 5. Oil cooler
2. Clutch shoe(s) • Clogged or damaged oil cooler
• Damaged or worn clutch shoe 6. Hose(s) and pipe(s)
3. Primary sliding sheave • Damaged hose
• Seized primary sliding sheave • Improperly connected hose
10-4
TROUBLESHOOTING
• Damaged pipe • Bent or damaged damper rod

• Improperly connected pipe
EBS30334
UNSTABLE HANDLING
Fuel system
1. Steering wheel
1. Throttle body • Bent or improperly installed steering wheel
• Faulty throttle body 2. Steering components
• Damaged or loose throttle body joint
• Incorrect toe-in
2. Air filter • Bent steering shaft
• Clogged air filter element • Improperly installed steering shaft
• Damaged bearing or bearing race
Chassis
• Bent tie-rods
1. Brake(s)
• Deformed steering knuckles
• Dragging brake
3. Shock absorber assembly(-ies)
• Faulty shock absorber spring
Electrical system
• Leaking oil or gas
1. Spark plug
4. Tire(s)
• Uneven tire pressures (left and right)
• Incorrect tire pressure
2. Ignition system
• Uneven tire wear
• Faulty ECU
5. Wheel(s)
3. Radiator fan
• Incorrect wheel balance
• Faulty fan motor
• Damaged wheel bearing
• Disconnected circuit breaker terminal
• Bent or loose wheel axle
• Faulty coolant temperature sensor
• Excessive wheel runout
EBS30331 6. Frame
OVERCOOLING • Bent frame
• Damaged frame
Cooling system
1. Thermostat EBS30335
• Thermostat stays open FAULTY LIGHTING OR SIGNALING SYSTEM
EBS30332 Headlight does not come on

POOR BRAKING PERFORMANCE • Wrong headlight bulb
• Worn brake pad • Too many electrical accessories
• Worn brake disc • Hard charging
• Air in hydraulic brake system • Incorrect connection
• Leaking brake fluid • Improperly grounded circuit
• Faulty brake caliper kit • Poor contacts (main or light switch)
• Faulty brake caliper seal • Burnt-out headlight bulb
• Loose union bolt
• Damaged brake hose Headlight bulb burnt out
• Oil or grease on the brake disc • Wrong headlight bulb
• Oil or grease on the brake pad • Faulty battery
• Incorrect brake fluid level • Faulty rectifier/regulator
EBS30333
• Improperly grounded circuit
FAULTY SHOCK ABSORBER ASSEMBLY • Faulty main switch
• Faulty light switch
Leaking oil • Headlight bulb life expired
• Bent, damaged or rusty damper rod
• Cracked or damaged shock absorber Tail/brake light does not come on
• Damaged oil seal lip • Wrong tail/brake light bulb
• Too many electrical accessories
Malfunction • Incorrect connection
• Fatigued or damaged shock absorber spring • Burnt-out tail/brake light bulb
10-5
TROUBLESHOOTING
Tail/brake light bulb burnt out

• Wrong tail/brake light bulb
• Faulty battery
• Faulty brake light switch
• Tail/brake light bulb life expired
• Faulty rectifier/regulator
• Improperly grounded circuit
10-6
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EBS20086

EBS30336
SELF-DIAGNOSTIC FUNCTION TABLE

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
For details of the fault code, refer to ''TROUBLESHOOTING METHOD" on page 9-33.
Fault code
Item
No.
Crankshaft position sensor: no normal signals are received from the crankshaft position sen-
12
sor.
13 Intake air pressure sensor: open or short circuit detected.
14 Intake air pressure sensor: hose system malfunction (clogged or detached hose).
15 Throttle position sensor: open or short circuit detected.
16 Throttle position sensor: stuck throttle position sensor is detected.
21 Coolant temperature sensor: open or short circuit detected.
22 Intake air temperature sensor: open or short circuit detected.
30 Latch up detected.
33 Ignition coil: open or short circuit detected in the primary lead of the ignition coil.
Component other than ISC (Idle Speed Control) unit is defective (ISC operating sound is
37 heard).
Defective ISC (Idle Speed Control) unit (ISC operating sound is not heard).
39 Injector: open or short circuit detected.
41 Lean angle sensor: open or short circuit detected.
42 Speed sensor: no normal signals are received from the speed sensor.
43 Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump.
44 EE PROM fault code number: an error is detected while reading or writing on EEPROM.
46 Charging voltage is abnormal.
Faulty ECU (Engine Control Unit) memory. (When this malfunction is detected in the ECU, the
50
fault code number might not appear.)
EBS30337
COMMUNICATION ERROR WITH THE METER

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
For details of the fault code, refer to ''TROUBLESHOOTING METHOD" on page 9-33.
Fault code
Item
No.
ECU (Engine Control Unit) internal malfunction (output signal error): signals cannot be trans-
Er-1
mitted between the ECU and the multi-function meter.
ECU (Engine Control Unit) internal malfunction (output signal error): no signals are received
Er-2
from the ECU within the specified duration.
ECU (Engine Control Unit) internal malfunction (output signal error): data from the ECU cannot
Er-3
be received correctly.
ECU (Engine Control Unit) internal malfunction (input signal error): non-registered data has
Er-4
been received from the meter.
10-7
EBS30338
DIAGNOSTIC CODE: SENSOR OPERATION TABLE

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
The diagnostic code numbers cannot be displayed on the multi-function meter. To display the diagnos-
tic code numbers, use the Yamaha diagnostic tool.
Diagnostic
Item Display Procedure
code No.
01 Throttle position sensor sig-
nal
• Fully closed position 14- 20 Check with throttle valve fully
closed.
03 Intake air pressure Displays the intake air pres- Turn and hold the main
sure. switch in the " O " (start) po-
sition, then press the accel-
erator pedal. (If the display
value changes, the perfor-
mance is OK.)
05 Intake air temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured intake air temperature
ambient temperature. with the display value.
When engine is hot: Displays
ambient temperature 20 °C
(68 °F).
06 Coolant temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured coolant temperature
ambient temperature. with the display value.
When engine is hot: Displays
current coolant temperature.
07 Vehicle speed pulse 0- 999 Check that the number in-
creases when the rear
wheels are rotated. The
number is cumulative and
does not reset each time the
wheel is stopped.
08 Lean angle sensor Lean angle sensor output Remove the lean angle sen-
voltage sor and incline it more than
3.6-4.4 65 degrees.
• Upright
• Overturned 0.7-1.3
09 Fuel system voltage (battery Approximately 12.0 Turn the main switch to " O "
voltage) (on), and then compare the
actually measured battery
voltage with the display val-
ue. (If the actually measured
battery voltage is low, re-
charge the battery.)
21 Gear position switch Shift the transmission.
• Transmission is in neutral ON
• Transmission is in gear OFF
60 EEPROM fault code display
• No history 00 -
• No malfunctions detected
(If the fault code 44 is indi-
cated, the ECU is defec-
tive.)
10-8
Diagnostic
Item Display Procedure
code No.
61 Malfunction history code dis-
play
• No history 00 -
• History exists Fault codes 12- 50 -
• (If more than one code
number is detected, the
display alternates every
two seconds to show all the
detected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
62 Malfunction history code era-
sure
• No history 00 -
• History exists • Displays the total number Save the malfunction history
of malfunctions, including to the computer, and then
the current malfunction, delete the fault codes.
that have occurred since
the history was last erased.
(For example, if there have
been three malfunctions,
"03" is displayed.)
70 Control number 0- 254 [-] -
EBS30339
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Ignition coil Actuates the ignition coil five Check that a spark is gener-
times at one-second inter- ated five times.
vals. • Connect an ignition check-
The "CHECK" indicator and er.
" 0 " on the Yamaha diag-
nostic tool screen come on
each time the ignition coil is
actuated.
36 Injector Actuates the injector five Check that the injector is ac-
times at one-second inter- tuated five times by listening
vals. for the operating sound.
The "CHECK" indicator and
"a " on the Yamaha diag-
each time the fuel injector is
actuated.
48 Air induction system solenoid Actuates the air induction Check that the air induction
system solenoid five times at system solenoid is actuated
one-second intervals. five times by listening for the
The "CHECK" indicator and operating sound.
each time the air induction
system solenoid is actuated.
10-9
Diagnostic
Item Actuation Procedure
code No.
50 Fuel injection system relay Actuates the fuel injection Check that the fuel injection
system relay five times at system relay unit is actuated
one-second intervals. five times by listening for the
The "CHECK" indicator and operating sound.
each time the relay is actuat-
ed.
(When the relay is on, the
"CHECK" indicator and " ,a"
on the Yamaha diagnostic
tool screen go off. When the
relay is off, the "CHECK" in-
dicator and " 0 " on the
Yamaha diagnostic tool
screen come on.)
51 Radiator fan motor relay Actuates the radiator fan mo- Check that the radiator fan
tor relay five times at five- motor relay is actuated five
second intervals. (2 seconds times by listening for the op-
on, 3 seconds off) erating sound.
each time the relay is actuat-
ed.
(When the relay is on, the
"CH ECK" indicator and ",a "
on the Yamaha diagnostic
tool screen go off. When the
relay is off, the "CHECK" in-
dicator and " 0 " on the
Yamaha diagnostic tool
screen come on.)
54 ISC valve Actuates and fully closes the The operating sound can be
ISC valve, then opens it to heard when ISC valve oper-
the stand-by opening posi- ates.
tion when the engine is start-
ed.
This operation takes approxi-
mately 3 seconds until it is
completed.
during the operation.
10-10
EBS20008
55.Auxiliary DC jack EBS30002
WIRING DIAGRAM (1) 56.Brake light switch COLOR CODE

YXM70VDXGNXM70VDHG 2016-2018 57.Tai l/brake light B Black
1. Crankshaft position sensor 58. Radiator fan motor fuse Br Brown
2. AC magneto 59. Differential motor fuse G Green
3. Rectifier/regulator 60.Ignition fuse Gy Gray
4. Load control relay 61.Backup fuse L Blue
62. Signaling system fuse Lg Light green
5. Frame ground
6. Main switch 63. Headlight fuse 0 Orange
p Pink
7. Engine ground 64.Auxiliary DC jack fuse
R Red
8. Battery 65.Radiator fan motor
Sb Sky blue
9. Main fuse 66. Radiator fan motor circuit
breaker
w White
10. Fuel injection system fuse y Yellow
11. Starter relay 67. Radiator fan motor relay B/G Black/Green
12. Starter motor 68.Backup light B/L Black/Blue
13. Fuel injection system relay 69.Backup light relay B/R Black/Red
14.Air induction system solenoid A. Optional B/W Black/White
15. Differential motor relay 1 B. Wire harness B/Y Black/Yellow
16. Differential motor C. Negative battery sub-wire har- Br/B Brown/Black
17. Gear position switch ness Br/L Brown/Blue
18. On-Command four-wheel-drive Br/R Brown/Red
switch Br/W Brown/White
19. Y amaha diagnostic tool coupler Br/Y Brown/Yellow
20. ISC (Idle Speed Control) unit G/R Green/Red
21. ECU (Engine Control Unit) G/W Green/White
22. Ignition coil G/Y Green/Yellow
23. Spark plug Gy/G Gray/Green
24. Fuel injector UB Blue/Black
UR Blue/Red
26. Coolant temperature sensor uw Blue/White
UY Blue/Yellow
27. Speed sensor
0/B Orange/Black
28.TPS (throttle position sensor)
0/L Orange/Blue
29. Intake air pressure sensor P/L Pink/Blue
30. Lean angle sensor P/W Pink/White
31. Parking brake switch RIB Red/Black
32. Parking brake buzzer RIG Red/Green
33. Reverse switch R/L Red/Blue
34. Joint coupler R/W Red/White
35. Seat belt switch R/Y Red/Yellow
36. Indicator light assembly W/B White/Black
37. Helmet indicator light WIG White/Green
38. Seat belt indicator light W/R White/Red
39. Meter assembly Y/B Yellow/Black
40. Multi-function meter Y/G Yellow/Green
41. Engine trouble warning light Y/L Yellow/Blue
42. Coolant temperature warning Y/R Yellow/Red
light Y/W Yellow/White
43. Parking brake indicator light
47. Low-range indicator light
48. On-Command differential gear
lock indicator light
49.Fuel sender
50. Fuel pump
52. Light switch
53. Headlight relay
54. Headlight
EBS20121 53. Low-range indicator light EBS30583
WIRING DIAGRAM (2) 54.On-Command differential gear COLOR CODE

YXM70VPXG/YXM70VPHG/YXM lock indicator light B Black
70VPSG 2016-2018 Br Brown
55.EPS warning light
1. Crankshaft position sensor 56.Fuel sender G Green
2. AC magneto 57.Fuel pump Gy Gray
3. Rectifier/regulator 58. Differential motor relay 2 L Blue
59. Light switch Lg Light green
60. Headlight relay 0 Orange
5. Frame ground
61 . Headlight p Pink
6. Main switch
R Red
7. Engine ground 62.Auxiliary DC jack
Sb Sky blue
8. Battery
9. Main fuse 64. Tail/brake light
w White
y Yellow
10. EPS fuse 65. Radiator fan motor fuse B/G Black/Green
11. Fuel injection system fuse 66. Differential motor fuse B/L Black/Blue
12. Starter relay 67. Ignition fuse B/R Black/Red
13. Starter motor 68.Backup fuse B/W Black/White
14. Fuel injection system relay 69. Signaling system fuse B/Y Black/Yellow
15. Air induction system solenoid 70. Headlight fuse Br/B Brown/Black
16. Differential motor relay 1 71 .Auxiliary DC jack fuse Br/L Brown/Blue
17. Differential motor 72. Radiator fan motor Br/R Brown/Red
18. Gear position switch 73. Radiator fan motor circuit Br/W Brown/White
19. On-Command four-wheel-drive breaker Br/Y Brown/Yellow
switch 74. Radiator fan motor relay G/R Green/Red
20. Yamaha diagnostic tool coupler 75. Backup light G/W Green/White
21. I SC (Idle Speed Control} unit 76. Backup light relay G/Y Green/Yellow
22. ECU (Engine Control Unit) A. Optional Gy/G Gray/Green
23. Ignition coil B. Wire harness UB Blue/Black
UR Blue/Red
24. Spark plug
25. Fuel injector
C. Negative battery sub-wire har-
ness uw Blue/White
D. EPS (electric power steering) UY Blue/Yellow
control unit 0/B Orange/Black
27. Coolant temperature sensor
0/L Orange/Blue
28. Speed sensor 0/W Orange/White
29. TPS (throttle position sensor) P/L Pink/Blue
30. Intake air pressure sensor P/W Pink/White
31. Lean angle sensor R/B Red/Black
32. Parking brake switch RIG Red/Green
33. Parking brake buzzer R/L Red/Blue
34. Reverse switch R/W Red/White
35. Joint coupler R/Y Red/Yellow
36. EPS unit W/B White/Black
37. EPS motor WIG White/Green
38. EPS torque sensor W/R White/Red
39. EPS self-diagnosis signal con Y/B Yellow/Black
nector Y/G Yellow/Green
40. EPS (electric power steering) Y/L Yellow/Blue
control unit Y/R Yellow/Red
41. Seat belt switch Y/W Yellow/White
42. Indicator light assembly
43. Helmet indicator light
44. Seat belt indicator light
45. Meter assembly
46. Multi-function meter
47. Engine trouble warning light
48. Coolant temperature warning
light
49. Parking brake indicator light

Yamaha 2016-2018 Viking Service Manual

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Yamaha 2016-2018 Viking Service Manual

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Available Formats

BASE / HUNTER

EPS / EPS HUNTER / EPS SPECIAL

IMPORTANT MANUAL INFORMATION

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

A NOTICE indicates special precautions that must be taken to avoid damage to

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

HOW TO USE THIS MANUAL

A.tie, sanciflO lhe !jlD2ed a,e,as, deal'I N CUC9'

The following symbols are not relevant to every vehicle.

SYMBOL DEFINITION SYMBOL DEFINITION

.. Serviceable with engine mounted -1 Gear oil

~ Special tool -Q>I Wheel bearing grease

Wear limit, clearance

PERIODIC CHECKS AND

VEHICLE IDENTIFICATION NUMBER

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

The multi-function meter unit is equipped with

Pushing the "CLOCK" button switches the dis-

oett:c 1r.=--~-~-~- ""m'I

1. Fuel level warning indicator

The fuel meter indicates the amount of fuel in the

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND 0-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS RUBBER PARTS

BASIC SERVICE INFORMATION

To remove the quick fastener, push its pin with a

To remove the quick fastener, loosen the screw

To install the quick fastener, push its pin so that

To install the quick fastener, insert the fastener

NOTICE Checking the electrical system

• If there is no continuity, clean the terminals.

Tappet adjusting tool 90890-01311 3-4

Oil filter wrench 3-14

Boots band installation tool 4-63, 8-10, 8-12 '

Ball joint remover adapter set 4-67 4-71

Base plate 35mm 4-67 4-71

Ball joint installer attachment 39mm 4-67 4-71

Compression gauge 90890-03081

Slide hammer bolt 5-21 5-23

Valve spring compressor attachment 5-25 5-30

Valve guide remover (06) 5-26

Valve guide installer (06) 5-26

Valve guide reamer (06) 5-26

Piston pin puller set 90890-01304 5-32

Sheave holder 5-38 5-38 5-39

Flywheel puller 5-38

Digital circuit tester 5-43 7-14

Sheave fixed block 5-58 5-62

Locknut wrench 5-58 5-62

Crankcase separating tool 5-78

Crankshaft installer pot 5-80

Adapter (M16) 5-80

Coupling gear/middle shaft tool 2 x22x1. 5-92 5-92 5-95

Bearing retainer wrench 5-93 5-94

Ring nut wrench 5-93 5-94

Radiator cap tester 90890-01325 6-6

Mechanical seal installer 6-14

Middle driven shaft bearing driver 6-14

Pressure gauge 7-5