Yamaha YXR660FAS Service Manual

LIT-11616-17-23 5UG-F8197-10YXR660FASSERVICE MANUAL

CHANGING THE DIFFERENTIAL GEAR OIL ...3-35CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS ...3-36CHECKING

3 - 23CHKADJCHECKING THE COOLANT TEMPERATURE WARNINGLIGHT/CHECKING THE V-BELTCHECKING THE COOLANT TEMPERATURE WARNING LIGHT1 Coolant temperature indic

3 - 24CHKADJCHECKING THE V-BELT2. Check:• V-belt 1 Cracks/wear/scaling/chipping → Replace.Oil/grease → Check primary sheave andsecondary sheave.3. Me

3 - 25CHKADJCHECKING THE V-BELT/CLEANING THE SPARK ARRESTER5. Remove:• drive belt cover Refer to “PRIMARY AND SECONDARYSHEAVES” in chapter 4.• console

3 - 26CHKADJADJUSTING THE BRAKE PEDALCHASSISADJUSTING THE BRAKE PEDAL1. Check: • brake pedal free play a Out of specification → Adjust.NOTE:_ The end

3 - 27CHKADJADJUSTING THE PARKING BRAKEADJUSTING THE PARKING BRAKE1. Shift the drive select lever into low gear “L”.2. Remove:• driver seat• passenger

3 - 28CHKADJCHECKING THE BRAKE FLUID LEVELCHECKING THE BRAKE FLUID LEVEL1. Place the vehicle on a level surface.NOTE:When checking the brake fluid lev

3 - 29CHKADJCHECKING THE FRONT BRAKE PADS/CHECKING THE REAR BRAKEPADS/CHECKING THE BRAKE HOSES AND BRAKE PIPESCHECKING THE FRONT BRAKE PADS1. Remove:•

3 - 30CHKADJCHECKING THE BRAKE HOSES AND BRAKE PIPES/BLEEDING THE HYDRAULIC BRAKE SYSTEM2. Lift the hood up.3. Lift the cargo bed.4. Check:• front bra

3 - 31CHKADJBLEEDING THE HYDRAULIC BRAKE SYSTEM1. Bleed:• brake system▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Add the proper brake fluid to the

3 - 32CHKADJADJUSTING THE SELECT LEVER SHIFT ROD/ADJUSTING THE BRAKE LIGHT SWITCHADJUSTING THE SELECT LEVER SHIFT ROD1 Neutral2 High3 Low4 Reverse5 Se

VALVES AND VALVE SPRINGS...4-25REMOVING THE VALVES AND VALVE SPRINGS ...

3 - 33CHKADJADJUSTING THE BRAKE LIGHT SWITCH/CHECKING THE FINAL GEAR OIL LEVEL1. Check:• brake light operation timing Incorrect → Adjust.2. Adjust:• b

3 - 34CHKADJCHANGING THE FINAL GEAR OIL/CHECKING THE DIFFERENTIAL GEAR OILCHANGING THE FINAL GEAR OIL1. Place the vehicle on a level surface.2. Place

3 - 35CHKADJCHECKING THE DIFFERENTIAL GEAR OIL/CHANGING THE DIFFERENTIAL GEAR OIL3. Check:• oil levelOil level should be up to the brim of hole.Oil le

3 - 36CHKADJCHANGING THE DIFFERENTIAL GEAR OIL/CHECKINGTHE CONSTANT VELOCITY JOINT DUST BOOTS6. Fill:• differential gear caseNOTE:If gear oil is fille

3 - 37CHKADJCHECKING THE STEERING SYSTEM/ADJUSTING THE TOE-INCHECKING THE STEERING SYSTEM1. Place the vehicle on a level surface.2. Check:• steering a

3 - 38CHKADJADJUSTING THE TOE-INc. Measure distance È between the marks.d. Rotate the front tires 180° until the marksare exactly opposite one another

3 - 39CHKADJADJUSTING THE FRONT SHOCK ABSORBERS/ADJUSTING THE REAR SHOCK ABSORBERSADJUSTING THE FRONT SHOCK ABSORBERSWARNINGAlways adjust both shock a

3 - 40CHKADJCHECKING THE TIRESCHECKING THE TIRESWARNING• TIRE CHARACTERISTICS1) Tire characteristics influence the han-dling of vehicle’s. The tires l

3 - 41CHKADJCHECKING THE TIRES1. Measure:• tire pressure (cold tire pressure)Out of specification → Adjust.NOTE:• The tire pressure gauge 1 is include

3 - 42CHKADJCHECKING THE WHEELS/CHECKING AND LUBRICATING THE CABLESCHECKING THE WHEELS1. Check:• wheels 1 Damage/bends → Replace.NOTE:Always balance t

CRANKCASE ...4-66STARTER MOTOR, TIMING CHAIN AND OIL FILT

3 - 43CHKADJLUBRICATING THE PEDAL, ETC.LUBRICATING THE PEDAL, ETC.1. Lubricate the pivoting parts.Recommended lubricantLithium-soap-based grease

3 - 44CHKADJCHECKING AND CHARGING THE BATTERYEB305000ELECTRICALCHECKING AND CHARGING THE BATTERYWARNING_ Batteries generate explosive hydrogen gasand

3 - 45CHKADJCHECKING AND CHARGING THE BATTERYNOTE:_ Since MF batteries are sealed, it is not possi-ble to check the charge state of the battery bymeas

3 - 46CHKADJ6. Charge: • battery (refer to the appropriate charging methodillustration)WARNING_ Do not quick charge a battery. CAUTION:_ • Never remov

3 - 47CHKADJCHECKING AND CHARGING THE BATTERYCharging method using a variable-current (voltage) chargerMeasure the open-circuitvoltage prior to chargi

3 - 48CHKADJCHECKING AND CHARGING THE BATTERYCharging method using a constant voltage chargerMeasure the open-circuitvoltage prior to charging.Connect

3 - 49CHKADJCHECKING AND CHARGING THE BATTERY/CHECKING THE FUSES7. Install:• battery8. Connect:• battery leadsCAUTION:_ First, connect the positive ba

3 - 50CHKADJCHECKING THE FUSES4. Replace:• blown fuse▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Turn off the ignition.b. Install a new fuse of the

3 - 51CHKADJADJUSTING THE HEADLIGHT BEAM/CHANGING THE HEADLIGHT BULBADJUSTING THE HEADLIGHT BEAM1. Adjust:• headlight beam (vertically) Turn the adjus

3 - 52CHKADJCHANGING THE HEADLIGHT BULB/CHANGING THE TAIL/BRAKE LIGHT BULB5. Install:• headlight bulb holder (with bulb)• headlight bulb holder cover6

CHAPTER 5COOLING SYSTEMRADIATOR AND COOLANT RESERVOIR...5-1CHECKING THE RADIATOR...

3 - 53CHKADJCHANGING THE TAIL/BRAKE LIGHT BULB4. Install:• tail/brake light bulb holder (with bulb)5. Install:• cargo bed panelT R..7 Nm (0.7 m · kg,

4 - 1ENGENGINEENGINE REMOVALAIR DUCTS, MUFFLER AND EXHAUST PIPET R..11 Nm (1.1 m • kg, 8.0 ft • Ib)T R..20 Nm (2.0 m • kg, 14 ft • Ib)T R..14 Nm (1.4

4 - 2ENGENGINE REMOVALT R..11 Nm (1.1 m • kg, 8.0 ft • Ib)T R..20 Nm (2.0 m • kg, 14 ft • Ib)T R..14 Nm (1.4 m • kg, 10 ft • Ib)T R..10 Nm (1.0 m • kg

4 - 3ENGENGINE REMOVALSELECT LEVER UNIT AND COOLANT RESERVOIRT R..15 Nm (1.5 m • kg, 11 ft • Ib)T R..15 Nm (1.5 m • kg, 11 ft • Ib)T R..14 Nm (1.4 m •

4 - 4ENGENGINE REMOVALHOSES AND LEADSR..10 Nm (1.0 m • kg, 7.2 ft • Ib)1212436578914131011Order Job/Part Q’ty RemarksRemoving the hoses and leadsRemov

4 - 5ENGR..10 Nm (1.0 m • kg, 7.2 ft • Ib)1212436578914131011Order Job/Part Q’ty Remarks13 Reverse switch lead 1 Green/White14 Engine ground lead 1 Di

4 - 6ENGENGINE REMOVALENGINE MOUNTING BOLTSOrder Job/Part Q’ty RemarksRemoving the engine mounting boltsRemove the parts in the order listed.Front ski

4 - 7ENGENGINE REMOVALOrder Job/Part Q’ty Remarks1 Rubber damper nut (rear) 2NOTE:Remove the engine assembly from thetop of the vehicle.CAUTION:Instal

4 - 8ENGENGINE REMOVALINSTALLING THE ENGINE1. Install:• engine mounting bolt (rear) 1• rubber damper (rear) 2• rubber damper nut (front) 3• engine ass

4 - 9ENGCYLINDER HEAD COVERCYLINDER HEAD COVEROrder Job/Part Q’ty RemarksRemoving the cylinder head coverRemove the parts in the order listed.Driver s

REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT ...

4 - 10ENGCYLINDER HEAD COVEROrder Job/Part Q’ty Remarks8 Cylinder head cover 1 Refer to “REMOVING THE CYLINDER HEAD COVER” and “INSTALLING THE CYLINDE

4 - 11ENGCYLINDER HEAD COVERREMOVING THE CYLINDER HEAD COVER1. Align:•“I” mark(with stationary pointer)▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. T

4 - 12ENGCYLINDER HEAD COVERINSTALLING THE CYLINDER HEAD COVER1. Apply:• sealant (Quick Gasket®) 1 (to the mating surfaces of the cylinder headand cyl

4 - 13ENGROCKER ARMSROCKER ARMSOrder Job/Part Q’ty RemarksRemoving the rocker armsRemove the parts in the order listed.Cylinder head cover Refer to “C

4 - 14ENGROCKER ARMSOrder Job/Part Q’ty Remarks10 Wave washer 411 Locknut 512 Valve adjuster 5For installation, reverse the removal pro-cedure.

4 - 15ENGROCKER ARMSREMOVING THE ROCKER ARMS1. Remove:• rocker arm shafts 1 • rocker arms 2 NOTE:Use a slide hammer bolt 3 and weight 4 toremove the r

4 - 16ENGROCKER ARMSd. Measure the outside diameter b of therocker arm shafts.Out of specification → Replace.e. Calculate the clearance by subtracting

4 - 17ENGCAMSHAFT AND CYLINDER HEADCAMSHAFT AND CYLINDER HEADOrder Job/Part Q’ty RemarksRemoving the camshaft and cylin-der headRemove the parts in th

4 - 18ENGCAMSHAFT AND CYLINDER HEADOrder Job/Part Q’ty Remarks7 Thermo switch 1 18 Cylinder head 19 Coolant outlet joint 110 Gasket 111 Cylinder head

4 - 19ENGCAMSHAFT AND CYLINDER HEADREMOVING THE CAMSHAFT AND CYLINDER HEAD1. Loosen:• camshaft sprocket bolts 1 2. Loosen:• timing chain tensioner cap

REAR BRAKE CALIPER ...8-31DISASSEMBLING THE FRONT BRAKE CALIPERS...

4 - 20ENGCAMSHAFT AND CYLINDER HEADCHECKING THE CAMSHAFT SPROCKET1. Check:• camshaft sprocketWear/damage → Replace the camshaftsprocket and timing ch

4 - 21ENGCAMSHAFT AND CYLINDER HEADb. Removing the screwdriver and slowlyrelease the timing chain tensioner rod.c. Make sure that the timing chain ten

4 - 22ENGCAMSHAFT AND CYLINDER HEADd. Place a 400 ~ 600 grit wet sandpaper onthe surface plate, and resurface the headusing a figure-eight sanding pat

4 - 23ENGCAMSHAFT AND CYLINDER HEADc. Temporarily install the camshaft sprocket onthe camshaft. (Do not install the bolts.)Then, install the timing ch

4 - 24ENGCAMSHAFT AND CYLINDER HEADc. With the screwdriver still inserted into thetiming chain tensioner, install the timingchain tensioner and gasket

4 - 25ENGVALVES AND VALVE SPRINGSVALVES AND VALVE SPRINGSOrder Job/Part Q’ty RemarksRemoving the valves and valve springsRemove the parts in the order

4 - 26ENGVALVES AND VALVE SPRINGSREMOVING THE VALVES AND VALVE SPRINGS1. Check:• valve sealingLeakage at the valve seat → Check thevalve face, valve s

4 - 27ENGVALVES AND VALVE SPRINGSCHECKING THE VALVES AND VALVE SPRINGS1. Measure:• stem-to-guide clearanceOut of specification → Replace the valveguid

4 - 28ENGVALVES AND VALVE SPRINGS3. Check:• valve facePitting/wear → Grind the face.• valve stem endMushroom shape or diameter larger thanthe body of

4 - 29ENGVALVES AND VALVE SPRINGS8. Measure:• valve seat width a Out of specification → Reface the valveseat.▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼

CHECKING THE BULBS AND BULB SOCKETS ...9-6TYPES OF BULBS ...

4 - 30ENGVALVES AND VALVE SPRINGSc. Install the valve into the cylinder head.d. Turn the valve until the valve face and valveseat are evenly polished,

4 - 31ENGVALVES AND VALVE SPRINGS11.Measure:• compressed spring force a Out of specification → Replace.bInstalled length12.Measure:• spring tilt a Out

4 - 32ENGVALVES AND VALVE SPRINGS3. Install:• valve cottersNOTE:Install the valve cotters while compressing thevalve spring with the valve spring comp

4 - 33ENGCYLINDER AND PISTONCYLINDER AND PISTONOrder Job/Part Q’ty RemarksRemoving the cylinder and pistonRemove the parts in the order listed.Water p

4 - 34ENGCYLINDER AND PISTONREMOVING THE PISTON1. Remove:• piston pin clips 1 • piston pin 2 • piston 3 NOTE:Before removing piston pin, deburr the cl

4 - 35ENGCYLINDER AND PISTONb. If out of specification, rebore or replace thecylinder, and replace the piston and pistonrings as a set.Standard Wear l

4 - 36ENGCYLINDER AND PISTONCHECKING THE PISTON RINGS1. Measure:• ring side clearanceUse a thickness gauge. Out of specification → Replace the pistona

4 - 37ENGCYLINDER AND PISTONCHECKING THE PISTON PIN1. Check:• piston pinBlue discoloration/grooves → Replace, thencheck the lubrication system.2. Meas

4 - 38ENGCYLINDER AND PISTON2. Position:• top ring• 2nd ring• oil ringOffset the piston ring end gaps as shown.aTop ring endbUpper oil ring rail endCO

4 - 39ENGCYLINDER AND PISTONINSTALLING THE CYLINDER1. Install:• cylinder• O-ring• bolts (M10)• bolts (M6)NOTE:Install the cylinder with one hand while

CHAPTER 10TROUBLESHOOTINGSTARTING FAILURE/HARD STARTING...10-1FUEL SYSTEM...

4 - 40ENGENGINE COOLING FAN AND A.C. MAGNETOENGINE COOLING FAN AND A.C. MAGNETOOrder Job/Part Q’ty RemarksRemoving the engine cooling fan and A.C. mag

4 - 41ENGENGINE COOLING FAN AND A.C. MAGNETOOrder Job/Part Q’ty Remarks3 Engine cooling fan 14 Air shroud 2 15 A.C. magneto coupler 2 Disconnect.6 Eng

4 - 42ENGOrder Job/Part Q’ty Remarks18 Starter idle gear 1For installation, reverse the removal pro-cedure.ENGINE COOLING FAN AND A.C. MAGNETO

4 - 43ENGENGINE COOLING FAN AND A.C. MAGNETOREMOVING THE A.C. MAGNETO1. Remove:• engine cooling fan pulley 1 NOTE:Use the sheave holder 2 to hold the

4 - 44ENGENGINE COOLING FAN AND A.C. MAGNETOCHECKING THE STARTER CLUTCH1. Check:• starter clutch 1 Cracks/damage → Replace.• starter clutch bolts 2 Lo

4 - 45ENGCHECKING THE ENGINE COOLING FAN1. Check:• engine cooling fan• air shroud 1• air shroud 2Cracks/damage → Replace.INSTALLING THE A.C. MAGNETO1.

4 - 46ENGENGINE COOLING FAN AND A.C. MAGNETO3. Install:• dowel pins• gasket• A.C. magneto cover NOTE:• When installing the A.C. magneto cover, usea lo

4 - 47ENG5. Connect:• A.C. magneto couplers6. Install:• engine cooling fan 1NOTE:Install the bolts in the holes in the collar of theengine cooling fan

4 - 48ENGBALANCER GEARS AND OIL PUMP GEARSBALANCER GEARS AND OIL PUMP GEARSOrder Job/Part Q’ty RemarksRemoving the balancer gears and oil pump gearsRe

4 - 49ENGOrder Job/Part Q’ty Remarks9Pin 4For installation, reverse the removal pro-cedure.BALANCER GEARS AND OIL PUMP GEARS

1 - 1GENINFOGENERAL INFORMATIONVEHICLE IDENTIFICATIONVEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 isstamped into the left side of

4 - 50ENGBALANCER GEARS AND OIL PUMP GEARSREMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR1. Straighten the lock washer tabs.2. Loosen:• bala

4 - 51ENGBALANCER GEARS AND OIL PUMP GEARSINSTALLING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR1. Install:• pins• springs• balancer drive gear(o

4 - 52ENGPRIMARY AND SECONDARY SHEAVESPRIMARY AND SECONDARY SHEAVEST R..100 Nm (10.0 m • kg, 72 ft • lb)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..10 Nm

4 - 53ENGPRIMARY AND SECONDARY SHEAVEST R..100 Nm (10.0 m • kg, 72 ft • lb)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R

4 - 54ENGPRIMARY AND SECONDARY SHEAVESPRIMARY SHEAVEOrder Job/Part Q’ty RemarksDisassembling the primary sheave Remove the parts in the order listed.1

4 - 55ENGPRIMARY AND SECONDARY SHEAVESSECONDARY SHEAVEOrder Job/Part Q’ty RemarksDisassembling the secondary sheaveRemove the parts in the order liste

4 - 56ENGPRIMARY AND SECONDARY SHEAVESREMOVING THE PRIMARY AND SECONDARY SHEAVES1. Loosen:• secondary sheave nut 1 • primary sheave nut 2 NOTE:• Use t

4 - 57ENGPRIMARY AND SECONDARY SHEAVESCHECKING THE PRIMARY SHEAVE1. Check:• weight outside diameter a Out of specification → Replace the weight.Weight

4 - 58ENGPRIMARY AND SECONDARY SHEAVESASSEMBLING THE PRIMARY SHEAVE1. Clean:• primary sliding sheave face 1 • primary fixed sheave face 2 • collar 3 •

4 - 59ENGPRIMARY AND SECONDARY SHEAVES3. Apply:• BEL-RAY assembly lube® (to the guide pin sliding grooves 1, and O-rings 2 )New4. Install:• spring sea

1 - 2GENINFOFEATURESFEATURESSELF-ADJUSTING PARKING BRAKE MECHANISMUsually, for vehicles equipped with a parking brake that must be adjusted manually,

4 - 60ENGPRIMARY AND SECONDARY SHEAVESINSTALLING THE PRIMARY AND SECONDARY SHEAVES1. Install:• secondary sheave assembly• V-belt• primary sheave assem

4 - 61ENGCLUTCHCLUTCHOrder Job/Part Q’ty RemarksRemoving the clutchRemove the parts in the order listed.Primary and secondary sheaves Refer to “PRIMAR

4 - 62ENGCLUTCHOrder Job/Part Q’ty RemarksDisassembling the clutch housingRemove the parts in the order listed.1 Oil seal 12 Circlip 13 Bearing housin

4 - 63ENGCLUTCHREMOVING THE CLUTCH1. Remove:• clutch housing assembly• gasket• dowel pinsNOTE:Working in crisscross pattern, loosen each bolt1/4 of a

4 - 64ENGCLUTCHb. When turning the clutch housing clockwiseÈ, the clutch housing should turn freely.If not, the one-way clutch assembly isfaulty.Repla

4 - 65ENGCLUTCH3. Install:• one-way clutch bearingNOTE:The one-way clutch bearing should beinstalled in the clutch carrier assembly with thearrow mark

4 - 66ENGCRANKCASECRANKCASESTARTER MOTOR, TIMING CHAIN AND OIL FILTEROrder Job/Part Q’ty RemarksRemove the starter motor, timing chain and oil filterR

4 - 67ENGCRANKCASEOrder Job/Part Q’ty Remarks5 Oil pipe assembly/O-ring 1/26 Oil pipe adapter/O-ring 1/17 Relief valve assembly 18 Speed sensor 19 Shi

4 - 68ENGCRANKCASECRANKCASEOrder Job/Part Q’ty RemarksSeparating the crankcaseRemove the parts in the order listed.1 Shift lever cover/gasket 1/1Refer

4 - 69ENGCRANKCASECRANKCASE BEARINGST R..10 Nm (1.0 m kg, 7.2 ft Ib)LSEEEE4444312444NewE4E4Order Job/Part Q’ty RemarksRemoving the crankcase beari

EBS00001YXR660FAS SERVICE MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. First Edition, July 2003All rights reserved. Any reproduction or unauthoriz

1 - 3GENINFOFEATURESParking Brake Operation1 Parking brake arm2 Parking brake arm shaft3 Set bolt4 Adjusting bolt sleeve5 Brake caliper piston6 Brake

4 - 70ENGCRANKCASESEPARATING THE CRANKCASE1. Separate:• right crankcase• left crankcase ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Remove the crank

4 - 71ENGCRANKCASECHECKING THE RELIEF VALVE1. Check:• relief valve 1• spring 2Damage/wear → Replace the defectivepart(s).CHECKING THE CRANKCASE1. Tho

4 - 72ENGCRANKCASE3. Fit the left crankcase onto the right case.Tap lightly on the case with a soft hammer.CAUTION:Before installing and torquing the

4 - 73ENGCRANKSHAFT AND OIL PUMPCRANKSHAFT AND OIL PUMPOrder Job/Part Q’ty RemarksRemoving the crankshaft and oil pumpRemove the parts in the order li

4 - 74ENGCRANKSHAFT AND OIL PUMPOIL PUMPOrder Job/Part Q’ty RemarksDisassembling the oil pumpRemove the parts in the order listed.1 Rotor cover 12 Pin

4 - 75ENGCRANKSHAFT AND OIL PUMPREMOVING THE CRANKSHAFT1. Remove:• crankshaft Use a crankcase separating tool 1.Crankcase separating toolP/N. YU-01135

4 - 76ENGCRANKSHAFT AND OIL PUMPCHECKING THE RELIEF VALVE1. Check:• relief valve body 1 • relief valve 2 • spring 3 • O-ring 4 Damage/wear → Replace

4 - 77ENGCRANKSHAFT AND OIL PUMPCHECKING THE CRANKSHAFT1. Measure:• crank width A Out of specification → Replace the crank-shaft.• side clearance D Ou

4 - 78ENGCRANKSHAFT AND OIL PUMPINSTALLING THE CRANKSHAFT AND BALANCER 1. Install:• crankshaftNOTE:Hold the connecting rod at the Top Dead Cen-ter (TD

4 - 79ENGTRANSMISSIONTRANSMISSIONOrder Job/Part Q’ty RemarksRemoving the transmissionRemove the parts in the order listed.Crankcase separation Refer t

1 - 4GENINFOFEATURESParking Brake Adjustment1 Brake caliper piston2 Nut3 Adjusting bolt4 Adjusting bolt sleeveWhen the brake pedal is operated, the br

4 - 80ENGTRANSMISSIONDRIVE AXLE ASSEMBLY Order Job/Part Q’ty RemarksDisassembling the drive axle assemblyRemove the parts in the order listed.1 Clutch

4 - 81ENGTRANSMISSIONREMOVING THE TRANSMISSION1. Remove:• shift drum 1• shift fork assembly 2▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Pull out th

4 - 82ENGTRANSMISSION3. Check:• shift fork movement(on the guide bar)Unsmooth operation → Replace the shiftfork and the guide bar.4. Check:• springsCr

4 - 83ENGTRANSMISSION2. Check:• gear movementUnsmooth → Repeat steps #1 or replacethe defective parts.3. Check:• circlipBends/looseness/damage → Repl

4 - 84ENGTRANSMISSIONASSEMBLING THE SHIFT FORK ASSEMBLY1. Install:• guide bar 1• shift fork 2 2• long spring 3• shift fork 1 4• short spring 5INSTALLI

4 - 85ENGMIDDLE GEARMIDDLE GEARMIDDLE DRIVE SHAFTOrder Job/Part Q’ty RemarksRemoving the middle drive shaftRemove the parts in the order listed.Crankc

4 - 86ENGMIDDLE GEARMIDDLE DRIVEN SHAFTOrder Job/Part Q’ty RemarksRemoving the middle driven shaftRemove the parts in the order listed.Crankcase separ

4 - 87ENGMIDDLE GEAROrder Job/Part Q’ty Remarks10 Bearing retainer 111 Middle driven shaft 1For installation, reverse the removal pro-cedure.

4 - 88ENGMIDDLE GEARREMOVING THE MIDDLE DRIVE SHAFT 1. Straighten:• punched portion of the nut (middle drivepinion gear)2. Loosen:• middle drive pinio

4 - 89ENG2. Remove:• universal joint▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Remove the circlips 1.b. Place the universal joint in a press.c. Wit

1 - 5GENINFOIMPORTANT INFORMATIONEB101000IMPORTANT INFORMATIONPREPARATION FOR REMOVAL PROCEDURES1. Remove all dirt, mud, dust and foreignmaterial befo

4 - 90ENGMIDDLE GEAR4. Remove:• bearing housing assembly 1 ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Clean the outside of the bearing housingassem

4 - 91ENGMIDDLE GEAR6. Remove:• drive shaft coupling• oil seal 1 • bearing retainer 2 • bearingNOTE:Attach the ring nut wrench 3.CAUTION:The middle dr

4 - 92ENGMIDDLE GEARSELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMSWhen the drive and driven gear, bearing hous-ing assembly and/or crankcase replace

4 - 93ENGMIDDLE GEARExample:1) If the bearing housing is marked “+02”,... a is 7.52,2) b is 173) c is 554) If the crankcase (left) is marked “64.98

4 - 94ENGMIDDLE GEARg = a numeral (usually a decimal number) onthe middle driven pinion gear is eitheradded to or subtracted from “80.5”.h = a numeral

4 - 95ENGMIDDLE GEARINSTALLING THE MIDDLE DRIVEN SHAFT1. Install:• bearing retainer 1NOTE:Attach the ring nut wrench 2.CAUTION:The middle driven shaft

4 - 96ENGMIDDLE GEAR3. Install:• shims 1• bearing housing NOTE:Install the shims so that the tabs are positionedas shown in the illustration.4. Instal

4 - 97ENGMIDDLE GEARd. Press each bearing into the universal jointusing a suitable socket.NOTE:The bearing must be inserted far enough intothe univers

4 - 98ENGMIDDLE GEARMEASURING THE MIDDLE GEAR BACKLASH1. Measure:• gear lash▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Temporary install the left c

5 - 1COOLCOOLING SYSTEMRADIATOR AND COOLANT RESERVOIR98105321467T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..28 Nm (2.8 m • kg, 20 ft • Ib)1211Order Job/Pa

1 - 6GENINFOIMPORTANT INFORMATIONEB101030LOCK WASHERS/PLATES AND COTTER PINS1. Replace all lock washers/plates 1 and cot-ter pins after removal. Bend

5 - 2COOL98105321467T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..28 Nm (2.8 m • kg, 20 ft • Ib)1211Order Job/Part Q’ty Remarks11 Coolant reservoir 112 Cool

5 - 3COOLRADIATOR AND COOLANT RESERVOIRCHECKING THE RADIATOR1. Check:• radiator finsObstruction → Clean.Apply compressed air to the rear of the radi-a

5 - 4COOLRADIATOR AND COOLANT RESERVOIRINSTALLING THE RADIATOR 1. Fill:• cooling system(with the specified amount of the recom-mended coolant)Refer to

5 - 5COOLWATER PUMPWATER PUMP67NewLS81LS5NewT R..10 Nm (1.0 m • kg, 7.2 ft • Ib)243NewOrder Job/Part Q’ty RemarksRemoving the water pumpRemove the par

5 - 6COOLWATER PUMPOrder Job/Part Q’ty RemarksDisassembling the water pump Remove the parts in the order listed.1 Water pump housing cover 12 Gasket 1

5 - 7COOLWATER PUMPDISASSEMBLING THE WATER PUMP 1. Remove:• rubber damper holder 1 • rubber damper 2 (from the impeller, with a thin, flatheadscrewdri

5 - 8COOLWATER PUMP3. Measure:• impeller shaft tiltOut of specification → Replace.1Straightedge2ImpellerMax. impeller shaft tilt0.15 mm (0.006 in)ASSE

5 - 9COOLWATER PUMP3. Install:• rubber damper 1• rubber damper holder 2NOTE:Before installing the rubber damper, apply tapwater or coolant onto its ou

5 - 10COOLOIL COOLEROIL COOLERLSLSNewNewR..7 Nm (0.7 m • kg, 5.1 ft • Ib)R..7 Nm (0.7 m • kg, 5.1 ft • Ib)1223(4)76845Order Job/Part Q’ty RemarksRemov

5 - 11COOLOIL COOLERLSLSNewNewR..7 Nm (0.7 m • kg, 5.1 ft • Ib)R..7 Nm (0.7 m • kg, 5.1 ft • Ib)1223(4)76845Order Job/Part Q’ty Remarks8 Oil cooler in

1 - 7GENINFOCHECKING OF CONNECTIONSEB801000CHECKING OF CONNECTIONSCheck the connectors for stains, rust, mois-ture, etc.1. Disconnect:• Connector2. Ch

5 - 12COOLOIL COOLERCHECKING THE OIL COOLER1. Check:• oil coolerObstruction → Clean.Apply compressed air to the rear of the oilcooler.Damage → Repair

6 - 1FUELFUEL SYSTEMFUEL PUMP AND FUEL TANK453629111T R..30 Nm (3.0 m • kg, 22 ft • Ib)787102T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)Order Job/Part Q’ty Re

6 - 2FUEL453629111T R..30 Nm (3.0 m • kg, 22 ft • Ib)787102T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)Order Job/Part Q’ty Remarks10 Fuel tank cap 111 Fuel tan

6 - 3FUELEAS00506CHECKING THE FUEL PUMP OPERATION1. Remove:• driver seat• passenger seat• console• right protectorRefer to “SEATS, ENCLOSURE, HOODAND

6 - 4FUELCARBURETORCARBURETOR4314121181362917105Order Job/Part Q’ty RemarksRemoving the carburetorRemove the parts in the order listed.Driver seat/pas

6 - 5FUEL4314121181362917105Order Job/Part Q’ty Remarks12 Throttle cable end 113 Throttle cable 114 Carburetor joint (intake manifold) 1For installati

6 - 6FUELCARBURETOROrder Job/Part Q’ty RemarksDisassembling the carburetorRemove the parts in the order listed.NOTE:Before disassembling the carbureto

6 - 7FUELCARBURETOROrder Job/Part Q’ty Remarks9 Pilot air jet 10 Drain screw 1A Float chamber 1B Float 1 Refer to “ASSEMBLING THE CARBURE-TOR”.C Needl

6 - 8FUELCARBURETORDISASSEMBLING THE CARBURETORNOTE:Before disassembling the carburetor, makesure to note the number of times the pilotscrew is turned

6 - 9FUELCARBURETOR4. Check:• piston valve 1 Scratches/wear/damage → Replace.• rubber diaphragm 2 Tears → Replace.5. Check:• vacuum chamber cover 1 •

1 - 8GENINFOSPECIAL TOOLSEB102001SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Useonly the ap

6 - 10FUELCARBURETOR8. Check:• free movement (piston valve)Sticks → Replace the piston valve guideand the piston valve.Insert the piston valve into t

6 - 11FUELCARBURETORADJUSTING THE FUEL LEVEL 1. Measure:• fuel level a Out of specification → Adjust. ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Pl

7 - 1DRIVDRIVE TRAINTROUBLESHOOTINGThe following conditions may indicate damaged shaft drive components:NOTE:Areas A, B, and C above may be extremely

7 - 2DRIVTROUBLESHOOTINGCAUTION:Too little gear lash is extremely destructiveto the gear teeth. If a test ride followingreassembly indicates this cond

7 - 3DRIVTROUBLESHOOTINGTroubleshooting chart When basic condition “a” and “b” exist, check the following points: Elevate and spin both wheels. Feel f

7 - 4DRIVFRONT CONSTANT VELOCITY JOINTS, DIFFERENTIALGEAR AND DRIVE SHAFTFRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFTLSLS65324T R

7 - 5DRIVFRONT CONSTANT VELOCITY JOINTS, DIFFERENTIALGEAR AND DRIVE SHAFTLSLS65324T R..55 Nm (5.5 m • kg, 40 ft • Ib)T R..55 Nm (5.5 m • kg, 40 ft • I

7 - 6DRIVFRONT CONSTANT VELOCITY JOINTS, DIFFERENTIALGEAR AND DRIVE SHAFTOrder Job/Part Q’ty RemarksDisassembling the constant velocity jointRemove th

7 - 7DRIVFRONT CONSTANT VELOCITY JOINTS, DIFFERENTIALGEAR AND DRIVE SHAFTOrder Job/Part Q’ty RemarksDisassembling the differential gearRemove the part

7 - 8DRIVFRONT CONSTANT VELOCITY JOINTS, DIFFERENTIALGEAR AND DRIVE SHAFTOrder Job/Part Q’ty RemarksB Shim (right)C Differential gear assembly 1D Shim

1 - 9GENINFOSPECIAL TOOLS90890-01311YM-08035-ATappet adjusting tool This tool is necessary for adjusting the valve clearance.90890-01312YM-01312-AFuel

7 - 9DRIVFRONT CONSTANT VELOCITY JOINTS, DIFFERENTIALGEAR AND DRIVE SHAFTDISASSEMBLING THE UNIVERSAL JOINT1. Remove:• universal joint▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼

7 - 10DRIVFRONT CONSTANT VELOCITY JOINTS, DIFFERENTIALGEAR AND DRIVE SHAFTCHECKING THE CONSTANT VELOCITY JOINTS1. Check:• double off-set joint spline•

7 - 11DRIVFRONT CONSTANT VELOCITY JOINTS, DIFFERENTIALGEAR AND DRIVE SHAFT3. Check:• front drive shaftBends → Replace.• torque limiterLoose → Replace

7 - 12DRIVFRONT CONSTANT VELOCITY JOINTS, DIFFERENTIALGEAR AND DRIVE SHAFT2. Install:• dust boots 1 • boot bands 2, 3▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼

7 - 13DRIVFRONT CONSTANT VELOCITY JOINTS, DIFFERENTIALGEAR AND DRIVE SHAFTb. Connect two C size batteries to the gearmotor terminal 2 to operate the p

7 - 14DRIVFRONT CONSTANT VELOCITY JOINTS, DIFFERENTIALGEAR AND DRIVE SHAFT4. Check:• differential gear operationUnsmooth operation → Replace the diffe

7 - 15DRIVFRONT CONSTANT VELOCITY JOINTS, DIFFERENTIALGEAR AND DRIVE SHAFT3. Install:• a bolt of the specified size 1 (into the drain plug hole)CAUTIO

7 - 16DRIVFRONT CONSTANT VELOCITY JOINTS, DIFFERENTIALGEAR AND DRIVE SHAFT2. Adjust:• gear lash▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Select th

7 - 17DRIV3. Measure the starting torque of the frontwheel (i.e., differential gear preload) with atorque wrench.NOTE:• Repeat this step several times

7 - 18DRIVREAR CONSTANT VELOCITY JOINTS, FINAL DRIVEGEAR AND DRIVE SHAFTREAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT3146512T R..70

1 - 10GENINFOSPECIAL TOOLS90890-01430YM-38404Ring nut wrenchThis tool is needed to removing and installing the middle driven shaft bearing retainer.90

7 - 19DRIV3146512T R..70 Nm (7.0m • kg, 51 ft • Ib)LSLSLSOrder Job/Part Q’ty Remarks1 Rear constant velocity joint 2NOTE:Remove the constant velocity

7 - 20DRIVREAR CONSTANT VELOCITY JOINTS, FINAL DRIVEGEAR AND DRIVE SHAFTOrder Job/Part Q’ty RemarksDisassembling the rear constant velocity jointRemov

7 - 21DRIVREAR CONSTANT VELOCITY JOINTS, FINAL DRIVEGEAR AND DRIVE SHAFTOrder Job/Part Q’ty RemarksDisassembling the final gear caseRemove the parts i

7 - 22DRIVREAR CONSTANT VELOCITY JOINTS, FINAL DRIVEGEAR AND DRIVE SHAFTOrder Job/Part Q’ty RemarksB Bolt 2NOTE:Working in a crisscross pattern, loose

7 - 23DRIVREAR CONSTANT VELOCITY JOINTS, FINAL DRIVEGEAR AND DRIVE SHAFTOrder Job/Part Q’ty RemarksM Bearing 1 Refer to “REMOVING THE FINAL DRIVE ROLL

7 - 24DRIVREAR CONSTANT VELOCITY JOINTS, FINAL DRIVEGEAR AND DRIVE SHAFTASSEMBLING THE REAR CONSTANT VELOCITY JOINTS1. Apply:• molybdenum disulfide gr

7 - 25DRIVREAR CONSTANT VELOCITY JOINTS, FINAL DRIVEGEAR AND DRIVE SHAFT2. Remove: • final drive pinion gear bearing housingassembly 1 ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼

7 - 26DRIV2. Remove:• roller bearing (final drive pinion gear) 1 ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Heat the main housing only to 150 °C(30

7 - 27DRIVSelecting the final drive pinion gear shim1. Select:• final drive pinion gear shim(s) 1 ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. To fin

7 - 28DRIVREAR CONSTANT VELOCITY JOINTS, FINAL DRIVEGEAR AND DRIVE SHAFTShims are supplied in the following thick-nesses.▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲

1 - 11GENINFOSPECIAL TOOLSCompressor90890-04019YM-04019Attachment90890-01243YM-01253-1Valve spring compressorValve spring compressor attachmentThis to

7 - 29DRIVREAR CONSTANT VELOCITY JOINTS, FINAL DRIVEGEAR AND DRIVE SHAFT6) Round off the hundredth digit and select theappropriate shim(s).In the exam

7 - 30DRIVREAR CONSTANT VELOCITY JOINTS, FINAL DRIVEGEAR AND DRIVE SHAFTc. Remove the final gear case assembly.d. Measure the thrust clearance. Calcul

7 - 31DRIVREAR CONSTANT VELOCITY JOINTS, FINAL DRIVEGEAR AND DRIVE SHAFTCHECKING THE DRIVE SHAFT1. Check:• drive shaft (splines) 1 • coupling gear (sp

7 - 32DRIVREAR CONSTANT VELOCITY JOINTS, FINAL DRIVEGEAR AND DRIVE SHAFTMEASURING AND ADJUSTING THE FINAL GEAR LASHMeasuring the final gear lash 1. Se

7 - 33DRIVREAR CONSTANT VELOCITY JOINTS, FINAL DRIVEGEAR AND DRIVE SHAFTAdjusting the final gear lash 1. Remove:• ring gear bearing housing 1 • ring g

7 - 34DRIVREAR CONSTANT VELOCITY JOINTS, FINAL DRIVEGEAR AND DRIVE SHAFT2. Install:• ring gear bearing housing• M8 bolts (ring gear bearing housing) 1

7 - 35DRIVREAR CONSTANT VELOCITY JOINTS, FINAL DRIVEGEAR AND DRIVE SHAFT4. Install: • drive shaft coupling nut▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼

8 - 1CHASCHASSISSEATS, ENCLOSURE, HOOD AND CARGO BEDFRONT BUMPER AND HOOD4321T R..32 Nm (3.2 m • kg, 23 ft • Ib)T R..59 Nm (5.9 m • kg, 43 ft • Ib)T R

8 - 2CHASSEATS, ENCLOSURE, HOOD AND CARGO BEDSEATS, CONSOLE AND INSTRUMENT PANELS(16)(5)(9)(7)123456141312129108711T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)

8 - 3CHAS(16)(5)(9)(7)123456141312129108711T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..35 Nm (3.5 m • kg, 25 ft • Ib)Order Job/Part Q’ty Remarks11 Auxilia

1 - 12GENINFOSPECIAL TOOLS90890-04134YM-04134Sheave spring compressorThis tool is needed when removing or installing the secondary sheave spring.90890

8 - 4CHASSEATS, ENCLOSURE, HOOD AND CARGO BEDPANELS AND FOOTREST COVER1(12)56810324131112(8)(8)(4)(6)(4)(6)(4)(4)679T R..7 Nm (0.7 m • kg, 5.1 ft • Ib

8 - 5CHAS1(12)56810324131112(8)(8)(4)(6)(4)(6)(4)(4)679T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..16 Nm (1.6 m • kg, 11 ft • Ib)T R..32 Nm (3.2 m • kg, 2

8 - 6CHASSEATS, ENCLOSURE, HOOD AND CARGO BEDCARGO BED423NewNew1123T R..16 Nm (1.6 m • kg, 11 ft • Ib)T R..16 Nm (1.6 m • kg, 11 ft • Ib)Order Job/Par

8 - 7CHAS5542143673(9)(12)(12)(9)T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..11 Nm (

8 - 8CHASSEATS, ENCLOSURE, HOOD AND CARGO BEDSKID PLATEST R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)312(11)(7)(4)(4)(7)(11)(

8 - 9CHASSEATS, ENCLOSURE, HOOD AND CARGO BEDENCLOSURE AND SEAT BELTST R..64 Nm (6.4 m • kg, 46 ft • Ib)T R..64 Nm (6.4 m • kg, 46 ft • Ib)T R..64 Nm

8 - 10CHASFRONT WHEELS AND BRAKE DISCSFRONT WHEELS AND BRAKE DISCS4653NewLTLT21T R..48 Nm (4.8 m • kg, 35 ft • Ib)T R..30 Nm (3.0 m • kg, 22 ft • Ib)T

8 - 11CHASFRONT WHEELS AND BRAKE DISCS4653NewLTLT21T R..48 Nm (4.8 m • kg, 35 ft • Ib)T R..30 Nm (3.0 m • kg, 22 ft • Ib)T R..55 Nm (5.5 m • kg, 40 ft

8 - 12CHASFRONT WHEELS AND BRAKE DISCSCHECKING THE FRONT WHEEL1. Check:• wheel2. Measure:• wheel runoutOver the specified limit → Replace thewheel or

8 - 13CHASFRONT WHEELS AND BRAKE DISCSCHECKING THE FRONT BRAKE DISC1. Check:• brake discGalling/damage → Replace.2. Measure:• brake disc deflectionOut

EBS00002NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealersand their qualified mechanics. It is not possibl

2 - 1SPECSPECIFICATIONSGENERAL SPECIFICATIONSItem StandardModel code5UG1DimensionsOverall length 2,885 mm (113.6 in)Overall width 1,385 mm (54.5 in)Ov

8 - 14CHASREAR WHEELS AND BRAKE DISCREAR WHEELS AND BRAKE DISCREAR WHEELSNew1342T R..260 Nm (26.0 m • kg, 190 ft • lb)T R..55 Nm (5.5 m • kg, 40 ft •

8 - 15CHASREAR WHEELS AND BRAKE DISCREAR BRAKE DISC(6)1T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)Order Job/Part Q’ty RemarksRemoving the rear brake discRemo

8 - 16CHASREAR WHEELS AND BRAKE DISCCHECKING THE REAR WHEEL1. Check:• wheelRefer to “CHECKING THE FRONTWHEEL”.2. Measure:• wheel runoutRefer to “CHECK

8 - 17CHASREAR WHEELS AND BRAKE DISCINSTALLING THE REAR WHEEL HUB1. Install:• axle nutRefer to “INSTALLING THE FRONTWHEEL HUB”.NewINSTALLING THE REAR

8 - 18CHASFRONT AND REAR BRAKESFRONT AND REAR BRAKESFRONT BRAKE PADS3421T R..48 Nm (4.8 m • kg, 35 ft • Ib)T R..18 Nm (1.8 m • kg, 13 ft • Ib)Order Jo

8 - 19CHASFRONT AND REAR BRAKESREAR BRAKE PADST R..17 Nm (1.7 m • kg, 12 ft • Ib)476578123T R..40Nm (4.0 m • kg, 29 ft • Ib)Order Job/Part Q’ty Remark

8 - 20CHASFRONT AND REAR BRAKESCAUTION:Disc brake components rarely require dis-assembly. DO NOT:• disassemble components unless abso-lutely necessary

8 - 21CHASFRONT AND REAR BRAKES2. Install:• brake pads• brake pad springNOTE:Always install new brake pads and brake padspring as a set.▼▼▼▼ ▼ ▼▼▼▼ ▼

8 - 22CHASFRONT AND REAR BRAKES1. Measure:• brake pad wear limit a Out of specification → Replace the brakepads as a set.Brake pad wear limit1.5 mm (0

8 - 23CHASe. Install the brake pad holding bolts, the brakecaliper, and the brake caliper mountingbolts.▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲3.

2 - 2SPECGENERAL SPECIFICATIONSDifferential gear case oilPeriodic oil change 0.32 L (0.28 Imp qt, 0.34 US qt)Total amount 0.33 L (0.29 Imp qt, 0.35 US

8 - 24CHASFRONT AND REAR BRAKESBRAKE MASTER CYLINDER74565T R..19 Nm (1.9 m • kg, 13 ft • Ib)T R..16 Nm (1.6 m • kg, 11 ft • Ib)T R..27 Nm (2.7 m • kg,

8 - 25CHASFRONT AND REAR BRAKES36214T R..9 Nm (0.9 m • kg, 6.5 ft • Ib)NewNew5NewOrder Job/Part Q’ty RemarksDisassembling the brake master cyl-inder R

8 - 26CHASFRONT AND REAR BRAKESCHECKING THE MASTER CYLINDER1. Check:• brake master cylinder 1 Wear/scratches → Replace the brake mas-ter cylinder asse

8 - 27CHASFRONT AND REAR BRAKESINSTALLING THE BRAKE MASTER CYLINDER 1. Install:• brake master cylinder2. Install:• brake pipe• copper washers• brake h

8 - 28CHASFRONT AND REAR BRAKES4. Air bleed:• brake systemRefer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.5. Check:• brake fluid levelBrake

8 - 29CHASFRONT AND REAR BRAKESFRONT BRAKE CALIPEROrder Job/Part Q’ty RemarksRemoving the front brake caliperRemove the parts in the order listed.Brak

8 - 30CHASFRONT AND REAR BRAKESNewNew5667741T R..18 Nm (1.8 m • kg, 13 ft • Ib)38T R..6 Nm (0.6 m • kg, 4.3 ft • Ib)2Order Job/Part Q’ty RemarksDisass

8 - 31CHASFRONT AND REAR BRAKESREAR BRAKE CALIPERT R..27 Nm (2.7 m • kg, 19 ft • Ib)T R..40 Nm (4.0m • kg, 29 ft • Ib)T R..7 Nm (0.7 m • kg, 5.1 ft •

8 - 32CHAST R..27 Nm (2.7 m • kg, 19 ft • Ib)T R..40 Nm (4.0m • kg, 29 ft • Ib)T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)12345678910NewOrder Job/Part Q’ty Re

8 - 33CHASFRONT AND REAR BRAKEST R..5 Nm (0.5 m • kg, 3.6 ft • Ib)T R..17 Nm (1.7 m • kg, 12 ft • Ib)T R..22 Nm (2.2 m • kg, 16 ft • Ib)LSLS1234567890

2 - 3SPECGENERAL SPECIFICATIONSTire pressure (cold tire)Maximum load* 397 kg (876 lb)Off-road riding front 63 ~ 77 kPa (0.63 ~ 0.77 kg/cm2, 9 ~ 11 psi

8 - 34CHAST R..5 Nm (0.5 m • kg, 3.6 ft • Ib)T R..17 Nm (1.7 m • kg, 12 ft • Ib)T R..22 Nm (2.2 m • kg, 16 ft • Ib)LSLS1234567890ABCDEFGA4NewNewOrder

8 - 35CHASFRONT AND REAR BRAKESEBS00427DISASSEMBLING THE FRONT BRAKE CALIPERS1. Remove: • brake caliper pistons • dust seals 1 • caliper piston seals

8 - 36CHASFRONT AND REAR BRAKESEB702040CHECKING THE FRONT AND REAR BRAKE CALIPERSWARNINGAll internal brake components should becleaned in new brake fl

8 - 37CHASFRONT AND REAR BRAKESEBS00431ASSEMBLING THE FRONT BRAKE CALIPERSThe following procedure applies to both of thefront brake calipers.WARNING_

8 - 38CHASEBS00432ASSEMBLING THE REAR BRAKE CALIPERWARNING_ • All internal brake components should becleaned and lubricated with new brakefluid only b

8 - 39CHASFRONT AND REAR BRAKES4. Install:• parking brake arm shaft 1• parking brake arm 2• set bolt 3• parking brake arm nut 4▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼

8 - 40CHASFRONT AND REAR BRAKES6. Install:• brake pad holding boltsT R..17 Nm (1.7 m · kg, 12 ft · lb)EBS00434INSTALLING THE FRONT BRAKE CALIPERSThe f

8 - 41CHASFRONT AND REAR BRAKESWARNING_ • Use only the designated quality brakefluid: other brake fluids may deterioratethe rubber seals, causing leak

8 - 42CHAS2. Fill: • brake reservoirCAUTION:_ Brake fluid may damage painted surfacesor plastic parts. Always clean up spilledbrake fluid immediately.

8 - 43CHASPEDAL ASSEMBLY56NewT R..16 Nm (1.6 m • kg, 11 ft • Ib)23741Order Job/Part Q’ty RemarksRemoving the pedal assemblyRemove the parts in the ord

2 - 4SPECENGINE SPECIFICATIONSENGINE SPECIFICATIONSItem Standard LimitCylinder headWarp limit ---- 0.03 mm (0.0012 in)CylinderBore size 100.005 ~ 100.

8 - 44CHAS23439517768LSOrder Job/Part Q’ty RemarksDisassembling the pedal assemblyRemove the parts in the order listed.1 Spring 12 Circlip 13 Washer 2

8 - 45CHASSTEERING SYSTEMSTEERING SYSTEMSTEERING COLUMN AND STEERING ASSEMBLY123T R..48 Nm (4.8 m • kg, 35 ft • Ib)T R..21 Nm (2.1 m • kg, 15 ft • Ib)

8 - 46CHASSTEERING SYSTEM243189AB765C2413NewNewNewT R..40 Nm (4.0 m • kg, 29 ft • Ib)0Order Job/Part Q’ty RemarksDisassembling the steering assem-blyR

8 - 47CHAS243189AB765C2413NewNewNewT R..40 Nm (4.0 m • kg, 29 ft • Ib)0Order Job/Part Q’ty RemarksC Steering assembly 1 Refer to “ASSEMBLING THE STEER

8 - 48CHASSTEERING SYSTEMDISASSEMBLING THE STEERING ASSEMBLY1. Remove:• oil seal • circlip • pinion gear with bearing 1NOTE:Lightly tap on the steerin

8 - 49CHASSTEERING SYSTEM3. Check:• rack gear teeth 1• pinion gear teeth 2Wear/damage → Replace the steeringassembly.NOTE:The wear pattern on the rac

8 - 50CHASSTEERING SYSTEM2. Install:• steering assembly• bearing• circlips• pinion gear• oil sealNOTE:After centering the rack gear, make two align-me

8 - 51CHASSTEERING SYSTEMTIE-ROD AND STEERING KNUCKLE36897425New3NewNewLS1T R..30 Nm (3.0 m • kg, 22 ft • Ib)T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..3

8 - 52CHASSTEERING SYSTEMREMOVING THE STEERING KNUCKLES1. Remove:• steering knuckle 1 NOTE:Use a general puller to separate the ball joints2 from the

8 - 53CHASSTEERING SYSTEMd. Install the body 3, short bolt 5, removerwasher 6 and remover spacer 7 onto theball joint.NOTE:• Remover washer 6 must be

2 - 5SPECENGINE SPECIFICATIONSCam chainCam chain type/No. of links 92RH2010J/126M ----Cam chain adjustment method Automatic ----Rocker arm/rocker arm

8 - 54CHASSTEERING SYSTEMh. Attach the assembled ball joint remover/installer, new ball joint B and installerattachment 8 to the steering knuckle C.NO

8 - 55CHASSTEERING SYSTEMh. Install the new oil seals.NOTE:When installing the oil seals, the “seal side” ofthe oil seal faces out.▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲

8 - 56CHASFRONT ARMS AND FRONT SHOCK ABSORBERFRONT ARMS AND FRONT SHOCK ABSORBER68843445516961011976NewLSNew4LS8T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R

8 - 57CHAS68843445516961011976NewLSNew4LS8T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..45 Nm (4.5 m • kg, 32 ft • Ib)T R

8 - 58CHASFRONT ARMS AND FRONT SHOCK ABSORBERREMOVING THE FRONT ARMS 1. Check:• front arm free play▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Check

8 - 59CHASFRONT ARMS AND FRONT SHOCK ABSORBERc. Install the body 3, long bolt 4, removerwasher 5 and remover spacer 6 onto balljoint.NOTE:Remover wash

8 - 60CHASFRONT ARMS AND FRONT SHOCK ABSORBERj. Apply lithium-soap base grease to the newball joint A.k. Install a new rubber boot and new circlip.NOT

8 - 61CHASFRONT ARMS AND FRONT SHOCK ABSORBERINSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER1. Install:• front arms• front shock absorber▼▼▼▼ ▼ ▼▼▼

8 - 62CHASREAR KNUCKLE AND STABILIZERREAR KNUCKLE AND STABILIZER675678533124334LST R..45 Nm (4.5 m • kg, 32 ft • Ib)T R..56 Nm (5.6 m • kg, 40 ft • Ib

8 - 63CHASREAR KNUCKLE AND STABILIZERCHECKING THE REAR KNUCKLE1. Check:• rear knuckleDamage/pitting → Replace.2. Check:• rear wheel bearingsBearings a

2 - 6SPECENGINE SPECIFICATIONSStem-to-guide clearance IN 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)0.08 mm (0.0031 in)EX 0.025 ~ 0.052 mm (0.0010 ~ 0.0020

8 - 64CHASREAR ARMS AND REAR SHOCK ABSORBERREAR ARMS AND REAR SHOCK ABSORBER355224363655T R..45 Nm (4.5 m • kg, 32 ft • Ib)11T R..45 Nm (4.5 m • kg, 3

8 - 65CHASREAR ARMS AND REAR SHOCK ABSORBERCHECKING THE REAR ARMS1. Check:• rear arms 1 Bends/damage → Replace.2. Check:• bushings 2 Wear/damage → Rep

8 - 66CHASREAR ARMS AND REAR SHOCK ABSORBERINSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER1. Install:• rear arms• rear shock absorber▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼

9 - 1– +ELECEB800000ELECTRICALELECTRICAL COMPONENTS1Diode 12Thermo switch 23Diode 24Circuit breaker (radiator fan motor)5Carburetor heater6Thermo swit

9 - 2– +ELECELECTRICAL COMPONENTS1 Rectifier/regulator2 Auxiliary DC jack3 Indicator light assembly 14 Indicator light assembly 25 On-Command four-whe

9 - 3– +ELECCHECKING THE SWITCHCHECKING THE SWITCHCHECKING THE SWITCHUse a pocket tester to check the terminals forcontinuity. If the continuity is fa

9 - 4– +ELECCHECKING THE SWITCHCHECKING THE SWITCH CONTINUITYRefer to “CHECKING THE SWITCH” and check for continuity between lead terminals.Poor conne

9 - 5– +ELECCHECKING THE SWITCH1 Fuse2 Brake light switch3 On-Command four-wheel drive switch and differential gear lock switch4 Main switch5 Light sw

9 - 6– +ELECCHECKING THE BULBS AND BULB SOCKETSEB801020CHECKING THE BULBS AND BULB SOCKETSCheck each bulb and bulb socket for damageor wear, proper co

9 - 7– +ELECCHECKING THE BULBS AND BULB SOCKETSWARNINGSince the headlight bulb gets extremelyhot, keep flammable products and yourhands away from the

2 - 7SPECENGINE SPECIFICATIONSPistonPiston to cylinder clearance 0.050 ~ 0.070 mm (0.0020 ~ 0.0028 in)0.15 mm (0.0059 in)Piston size “D” 99.945 ~ 99.9

9 - 8– +ELECCHECKING THE BULBS AND BULB SOCKETSCHECKING THE CONDITION OF THE BULB SOCKETSThe following procedure applies to all of thebulb sockets.1.

9 - 9– +ELECIGNITION SYSTEMEB802000IGNITION SYSTEMCIRCUIT DIAGRAM(BLACK)BRWWW2WD4WDLOCKONOFFOFFSTARTRY/LL/BSbG/WW/BG/R(BLACK) (BLACK)(BLACK)(GRAY)(GRA

9 - 10– +ELECIGNITION SYSTEMEB802010TROUBLESHOOTINGProcedureCheck:1. Fuses (main, ignition)2. Battery3. Spark plug4. Ignition spark gap5. Spark plug c

9 - 11– +ELECIGNITION SYSTEMCORRECT3. Spark plug• Check the spark plug condition.• Check the spark plug type.• Check the spark plug gap.Refer to “CHEC

9 - 12– +ELECIGNITION SYSTEM6. Ignition coil resistance• Disconnect the ignition coil connector fromthe wire harness.• Connect the pocket tester (Ω ×

9 - 13– +ELECIGNITION SYSTEMMEETSSPECIFICATION8. Pickup coil resistance• Disconnect the A.C. magneto coupler fromthe wire harness.• Connect the pocket

9 - 14– +ELECIGNITION SYSTEMCORRECT10.Wiring connection• Check the connections of the entire igni-tion system.Refer to “CIRCUIT DIAGRAM”.Replace the C

9 - 15– +ELECELECTRIC STARTING SYSTEMEB803000ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM(BLACK)BRWWW2WD4WDLOCKONOFFOFFSTARTRY/LL/BSbG/WW/BG/R(BLACK) (BLAC

9 - 16– +ELECELECTRIC STARTING SYSTEMSTARTING CIRCUIT OPERATIONThe starting circuit on this model consists ofthe starter motor, starter relay, brake l

9 - 17– +ELECELECTRIC STARTING SYSTEMEB803020TROUBLESHOOTINGProcedureCheck:1. Fuses (main, ignition, signaling system)2. Battery3. Starter motor4. Sta

2 - 8SPECENGINE SPECIFICATIONSOil ringDimensions (B × T) 2.5 × 3.4 mm(0.0984 × 0.1339 in)----End gap (installed) 0.20 ~ 0.70 mm(0.0079 ~ 0.0276 in)---

9 - 18– +ELECELECTRIC STARTING SYSTEM TURNS3. Starter motor• Connect the battery (+) terminal 1 andstarter motor cable 2 using a jumper lead3 .• Check

9 - 19– +ELECELECTRIC STARTING SYSTEMCORRECT6. Gear position switchRefer to “CHECKING THE SWITCH”.*INCORRECTReplace the gear position switch.CORRECT7.

9 - 20– +ELECELECTRIC STARTING SYSTEMSTARTER MOTOROrder Job/Part Q’ty RemarksRemoving the starter motorRemove the parts in the order listed.1 Starter

9 - 21– +ELECELECTRIC STARTING SYSTEMCHECKING THE STARTER MOTOR1. Check:• commutatorDirty → Clean it with #600 grit sandpaper.2. Measure:• commutator

9 - 22– +ELECELECTRIC STARTING SYSTEM5. Measure:• brush length a (each)Out of specification → Replace the brush. 6. Measure:• brush spring forceFatigu

9 - 23– +ELECCHARGING SYSTEMEB804000CHARGING SYSTEMCIRCUIT DIAGRAM (BLACK)BRWWW2WD4WDLOCKONOFFOFFSTARTRY/LL/BSbG/WW/BG/R(BLACK) (BLACK)(BLACK)(GRAY)(G

9 - 24– +ELECCHARGING SYSTEMEB804010TROUBLESHOOTINGProcedureCheck:1. Fuse (main)2. Battery3. Charging voltage4. Charging coil resistance5. Wiring conn

9 - 25– +ELECCHARGING SYSTEMOUT OFSPECIFICATION • Start the engine and accelerate to about1,000 r/min.Charging voltage14 V at 1,000 r/minNOTE:Use a fu

9 - 26–+ELECLIGHTING SYSTEMEB805000LIGHTING SYSTEMCIRCUIT DIAGRAM(BLACK)BRWWW2WD4WDLOCKONOFFOFFSTARTRY/LL/BSbG/WW/BG/R(BLACK) (BLACK)(BLACK)(GRAY)(GRA

9 - 27–+ELECLIGHTING SYSTEMEB805010TROUBLESHOOTINGProcedureCheck:1. Fuses (main, lighting system)2. Battery3. Main switch4. Light switch5. Wiring conn

2 - 9SPECENGINE SPECIFICATIONSTransmissionMain axle deflection limit ---- 0.06 mm (0.0024 in)Drive axle deflection limit ---- 0.06 mm (0.0024 in)Shift

9 - 28– +ELECLIGHTING SYSTEMCORRECT4. Light switchRefer to “CHECKING THE SWITCH”.*INCORRECTReplace the light switch.EB805013CORRECT5. Wiring connectio

9 - 29– +ELECLIGHTING SYSTEMEB805020CHECKING THE LIGHTING SYSTEM1. If the headlights fail to come on:CONTINUITY1. Bulb and bulb socket• Check the bulb

9 - 30– +ELECLIGHTING SYSTEMEB8050212. If the taillights fail to come on:CONTINUITY1. Bulb and bulb socket• Check the bulb and bulb socket for conti-n

9 - 31– +ELECLIGHTING SYSTEM

9 - 32– +ELECSIGNALING SYSTEMEB806000SIGNALING SYSTEMCIRCUIT DIAGRAM(BLACK)BRWWW2WD4WDLOCKONOFFOFFSTARTRY/LL/BSbG/WW/BG/R(BLACK) (BLACK)(BLACK)(GRAY)(

9 - 33– +ELECSIGNALING SYSTEM3 Main switch6 Battery7 Main fuse0 Brake light switchB Reverse switchC C.D.I. unitP Gear position switchQ Parking brake s

9 - 34– +ELECSIGNALING SYSTEMEB806010TROUBLESHOOTINGProcedureCheck:1. Fuses (main, signaling system)2. Battery3. Main switch4. Wiring connections (the

9 - 35– +ELECSIGNALING SYSTEMEB806011CORRECT4. Wiring connections• Check the connections of the entire signalsystem.Refer to “CIRCUIT DIAGRAM”.Check t

9 - 36– +ELECSIGNALING SYSTEMCHECKING THE SIGNAL SYSTEM1. If the brake lights fail to come on:CONTINUITY1. Bulb and bulb socket• Check the bulb and bu

9 - 37– +ELECSIGNALING SYSTEMEB8060242. If the neutral indicator light fails to come on:CONTINUITY1. Bulb and bulb socket• Check the bulb and bulb soc

2 - 10SPECENGINE SPECIFICATIONSCooling systemRadiator coreWidth 380 mm (14.96 in) ----Height 238 mm (9.37 in) ----Thickness 24 mm (0.94 in) ----Radiat

9 - 38– +ELECSIGNALING SYSTEM3. If the parking brake indicator light fails tocome on:CONTINUITY1. Bulb and bulb socket• Check the bulb and bulb socket

9 - 39– +ELECSIGNALING SYSTEM4. If the reverse indicator light fails to come on:CONTINUITY1. Bulb and bulb socket• Check the bulb and bulb socket for

9 - 40– +ELECSIGNALING SYSTEM5. If the coolant temperature warning light does not come on when the main switch to “ON”, or if thecoolant temperature w

9 - 41– +ELECSIGNALING SYSTEM3. Voltage• Connect the pocket tester (DC 20 V) to theindicator light assembly 1 coupler. Tester (+) lead → Brown termina

9 - 42– +ELECSIGNALING SYSTEM6. If the differential gear lock indicator lightfails to come on:CONTINUITY1. Bulb and bulb socket• Check the bulb and bu

9 - 43– +ELECSIGNALING SYSTEM4. Voltage• Connect the pocket tester (DC 20 V) to theindicator light assembly 1 coupler.Tester (+) lead → Brown terminal

9 - 44– +ELECSIGNALING SYSTEM7. If the four-wheel drive indicator light fails tocome on:CONTINUITY1. Bulb and bulb socket• Check the bulb and bulb soc

9 - 45– +ELECSIGNALING SYSTEM4. Voltage• Connect the pocket tester (DC 20 V) to theindicator light assembly 1 coupler.Tester (+) lead → Brown terminal

9 - 46– +ELECCOOLING SYSTEMCOOLING SYSTEMCIRCUIT DIAGRAM(BLACK)BRWWW2WD4WDLOCKONOFFOFFSTARTRY/LL/BSbG/WW/BG/R(BLACK) (BLACK)(BLACK)(GRAY)(GRAY)(BLACK)

9 - 47– +ELECCOOLING SYSTEMTROUBLESHOOTINGProcedureCheck:1. Fuse (main)2. Battery3. Main switch4. Radiator fan motor5. Circuit breaker (radiator fan m

EBS00004HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “symbols”)1st title 1: Thi

2 - 11SPECENGINE SPECIFICATIONSCylinder head tightening sequence

9 - 48– +ELECCOOLING SYSTEMTURNS4. Radiator fan motor• Disconnect the radiator fan motor coupler.• Connect the battery (12 V) as shown.Battery (+) lea

9 - 49– +ELECCOOLING SYSTEMGOODCONDITION6. Thermo switch 3• Remove the thermo switch 3 from the radi-ator.• Connect the pocket tester (Ω × 1) to thet

9 - 50– +ELECCOOLING SYSTEMEB803028CORRECT7. Wiring connection• Check the connections of the entire start-ing system.Refer to “CIRCUIT DIAGRAM”.This c

9 - 51– +ELEC2WD/4WD SELECTING SYSTEM2WD/4WD SELECTING SYSTEMCIRCUIT DIAGRAM(BLACK)BRWWW2WD4WDLOCKONOFFOFFSTARTRY/LL/BSbG/WW/BG/R(BLACK) (BLACK)(BLACK

9 - 52– +ELEC2WD/4WD SELECTING SYSTEMEB803020TROUBLESHOOTINGProcedureCheck:1. Fuses (main, four-wheel drive)2. Battery3. Main switch4. Four-wheel driv

9 - 53– +ELEC2WD/4WD SELECTING SYSTEMCONTINUITY4. Four-wheel drive relay 1• Remove the four-wheel drive relay 1 fromthe wire harness.• Connect the poc

9 - 54– +ELEC2WD/4WD SELECTING SYSTEMCONTINUITY6. Four-wheel drive relay 3• Remove the four-wheel drive relay 3 fromthe wire harness.• Connect the poc

9 - 55– +ELEC2WD/4WD SELECTING SYSTEMCORRECT8. Gear motor• Disconnect the gear motor coupler.• Remove the gear motor from the differen-tial gear case.

9 - 56– +ELECCARBURETOR HEATING SYSTEMCARBURETOR HEATING SYSTEMCIRCUIT DIAGRAM(BLACK)BRWWW2WD4WDLOCKONOFFOFFSTARTRY/LL/BSbG/WW/BG/R(BLACK) (BLACK)(BLA

9 - 57– +ELECCARBURETOR HEATING SYSTEMTROUBLESHOOTING ProcedureCheck:1. Fuses (main, carburetor heater) 2. Battery 3. Main switch 4. Thermo switch 25.

2 - 12SPECCHASSIS SPECIFICATIONSCHASSIS SPECIFICATIONSItem Standard LimitSteering systemType Rack and pinion ----Front suspensionShock absorber travel

9 - 58– +ELECCARBURETOR HEATING SYSTEMGOODCONDITION4. Thermo switch 2• Remove the thermo switch 2 from the wireharness.• Connect the pocket tester (Ω

9 - 59– +ELECCARBURETOR HEATING SYSTEMCORRECT5. Carburetor heater• Remove the carburetor heater from thecarburetor.• Connect the pocket tester (Ω × 1

10 - 1TRBLSHTGEBS00537TROUBLESHOOTINGNOTE:_ The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,howe

10 - 2TRBLSHTGSTARTING FAILURE/HARD STARTING/POOR IDLE SPEEDPERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCECOMPRESSION SYSTEMCylinder and cylinder

10 - 3TRBLSHTGFAULTY DRIVE TRAINEBS00540FAULTY DRIVE TRAINThe following conditions may indicate damaged shaft drive components:NOTE:_ Areas A, B, and

10 - 4TRBLSHTGFAULTY GEAR SHIFTING/FAULTY CLUTCH PERFORMANCEEBS00542FAULTY GEAR SHIFTINGHARD SHIFTINGRefer to “CLUTCH SLIPPING”.SHIFT LEVER DOES NOT M

10 - 5TRBLSHTGFAULTY CLUTCH PERFORMANCE/OVERHEATING/FAULTY BRAKE/SHOCK ABSORBER MALFUNCTIONPOOR SPEED PERFORMANCEV-belt• Oil or grease on the V-beltPr

10 - 6TRBLSHTGUNSTABLE HANDLING/LIGHTING SYSTEMEBS00552UNSTABLE HANDLINGUNSTABLE HANDLINGSteering wheel• Improperly installed or bentSteering• Incorre

2 - 13SPECCHASSIS SPECIFICATIONSFront disc brakeType Dual ----Disc outside diameter × thickness 200 × 3.5 mm (7.87 × 0.14 in) ----Pad thickness inner

YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPANPRINTED IN U.S.A.

YXR660FAS WIRING DIAGRAM(BLACK)BRWWW2WD4WDLOCKONOFFOFFSTARTRY/LL/BSbG/WW/BG/R(BLACK) (BLACK)(BLACK)(GRAY)(GRAY)(BLACK)(BLACK)(BLACK)RW/GW/LW/R(BLACK)B

2 - 14SPECELECTRICAL SPECIFICATIONSELECTRICAL SPECIFICATIONSItem Standard LimitVoltage12 V ----Ignition systemIgnition timing (BTDC) 12°/ 1,500 r/min

2 - 15SPECELECTRICAL SPECIFICATIONSElectric starter systemType Constant mesh type ----Starter motorModel/manufacturer SM-13/MITSUBA ----Output 0.8 kW

2 - 16SPECTIGHTENING TORQUESEBS01005TIGHTENING TORQUESENGINE TIGHTENING TORQUESPart to be tightened Part nameThread sizeQ’tyTightening torqueRemarksNm

2 - 17SPECTIGHTENING TORQUESCrankcase Bolt M8 3 26 2.6 19Bolt M6 14 10 1.0 7.2Bolt M6 1 10 1.0 7.2Sealant (Quick Gasket®) Yamaha bond No.1215Bearing h

2 - 18SPECTIGHTENING TORQUESPrimary sheave assembly Nut M16 1 120 12.0 85Primary pulley sheave cap Screw M4 8 3 0.3 2.2Secondary sheave assembly N

2 - 19SPECTIGHTENING TORQUESEBS01006CHASSIS TIGHTENING TORQUESPart to be tightened Thread sizeTightening torqueRemarksNm m · kg ft · lbRubber damper a

2 - 20SPECTIGHTENING TORQUESSteering knuckle and front lower arm M12 30 3.0 22Tie-rod locknut M12 40 4.0 29Steering knuckle and tie-rod M12 39 3.9

EBS00006SYMBOLSThe following symbols are not relevant toevery vehicle. Symbols 1 to 0 indicate the subject of eachchapter.1General information 2Specif

2 - 21SPECTIGHTENING TORQUESFront bumper and frame M10 32 3.2 23M12 59 5.9 43Hood stopper and frame M8 16 1.6 11Upper instrument panel and frame M6 7

2 - 22SPECHOW TO USE THE CONVERSION TABLE/GENERAL TIGHTENING TORQUE SPECIFICATIONSEBS00022HOW TO USE THE CONVERSION TABLEAll specification data in thi

2 - 23SPECLUBRICATION POINTS AND LUBRICANT TYPESEBS00024LUBRICATION POINTS AND LUBRICANT TYPESENGINELubrication points LubricantOil seal lipsLSBearing

2 - 24SPECCOOLANT FLOW DIAGRAMSCOOLANT FLOW DIAGRAMS1 Radiator2 Thermo switch 33 Radiator outlet hose4 Radiator inlet hose5 Radiator outlet pipe6 Radi

2 - 25SPECCOOLANT FLOW DIAGRAMS1 Coolant breather hose2 Coolant breather pipe3 Radiator outlet pipe4 Water pump inlet hose5 Water pump outlet pipe6 Wa

2 - 26SPECCOOLANT FLOW DIAGRAMS1 Coolant outlet hose2 Radiator inlet pipe21

2 - 27SPECOIL FLOW DIAGRAMSOIL FLOW DIAGRAMS1 Camshaft2 Oil delivery pipe 23 Oil delivery pipe 34 Crankshaft4123

2 - 28SPECOIL FLOW DIAGRAMS1 Oil delivery pipe 12 Oil delivery pipe 23 Oil delivery pipe 34 Oil pump5 Oil strainer45321

2 - 29SPECOIL FLOW DIAGRAMS1 Oil filter cartridge2 Oil pipe adapter3 Oil delivery pipe 24 Oil delivery pipe 15 Drive axle6 Relief valve7 Oil pump8 Oil

2 - 30SPECOIL FLOW DIAGRAMS1 Oil outlet pipe2 Oil inlet pipe3 Oil outlet hose4 Oil inlet hose5 Oil cooler inlet pipe 26 Oil cooler outlet pipe 25 6AA1

2 - 31SPECOIL FLOW DIAGRAMS1 Oil cooler2 Oil cooler inlet pipe 23 Oil cooler outlet pipe 24 Oil cooler inlet hose5 Oil cooler outlet hose6 Oil cooler

2 - 32SPECCABLE ROUTINGCABLE ROUTING1 Left headlight lead2 Wire harness3 Throttle cable4 Brake light switch lead5 Radiator fan motor breather hose6 St

2 - 33SPECCABLE ROUTINGÈ 30 ~ 60 mm (1.18 ~ 2.36 in)É 160 ~ 190 mm (6.30 ~ 7.48 in)Ê Fasten the wire harness to the frame with theplastic bands.Ë Pull

2 - 34SPECCABLE ROUTING1 Float chamber breather hose2 Throttle cable3 Parking brake cable4 Thermo switch 15 Vacuum hose6 Spark plug cap7 Wire harness8

2 - 35SPECCABLE ROUTINGÍ Fasten the parking brake cable to the air ductassembly 2 with the plastic band.Î Fasten the parking brake cable and float cha

2 - 36SPECCABLE ROUTING1 Main switch2 Starter (choke) knob3 Starter (choke) cable4 Rectifier/regulator5 Wire harness6 Coolant reservoir breather hose7

2 - 37SPECCABLE ROUTINGÈ 70 ~ 80 mm (2.76 ~ 3.15 in)É Fasten the wire harness withthe plastic bands.Ê Fasten the wire harness to theframe with the pla

2 - 38SPECCABLE ROUTINGÒ 70 ~ 90 mm (2.76 ~ 3.54 in)Ó Fasten the throttle cable withthe plastic band.Ô Fasten the radiator inlet pipewith the plastic

2 - 39SPECCABLE ROUTING1 Ignition coil lead2 Spark plug lead3 Final gear case breather hose4 Vacuum hose5 Fuel hoses6 Air vent hoses7 Starter (choke)

2 - 40SPECCABLE ROUTINGÈ Fasten the spark plug lead with the plasticholder.É 20 ~ 30 mm (0.79 ~ 1.18 in)Ê Pass the final gear case breather hose throu

EBS00008TABLE OF CONTENTSGENERAL INFORMATIONGEN INFO1 SPECIFICATIONSSPEC2 PERIODIC CHECKS AND ADJUSTMENTSCHK ADJ3 ENGINEENG4 COOLING SYSTEMCOOL5 FUEL

2 - 41SPECCABLE ROUTINGÒ Fasten the parking brake cable with the metalholder.Ó Fasten the wire harness, ignition coil lead, andrear brake hose with th

2 - 42SPECCABLE ROUTING1 Throttle cable2 Rear brake pipe3 A.C. magneto couplers4 Starter (choke) cable5 Rear brake hose6 Fuel hose7 Vacuum hose8 Spark

2 - 43SPECCABLE ROUTINGÍ Fasten the fuel hose and vacuum hose with theplastic clip.Î Make sure that the spark plug lead does notcontact the frame. Ï F

2 - 44SPECCABLE ROUTING1 Battery2 Negative battery lead3 Rectifier/regulator4 Starter (choke) cable5 Indicator light assembly couplers6 On-Command fou

2 - 45SPECCABLE ROUTINGK Four-wheel drive relay 3L Differential gear lock indicator light relayM Four-wheel drive indicator light relayN Fuse boxO Pos

2 - 46SPECCABLE ROUTINGË Fasten the throttle cable with the plastic holder.Ì Fasten the left headlight lead, differential gearcase breather hose, and

2 - 47SPECCABLE ROUTING1 Auxiliary DC jack2 Auxiliary DC jack lead3 Coolant reservoir breather hose4 Throttle cable5 Radiator fan motor breather hose6

2 - 48SPECCABLE ROUTINGÌ Fasten the wire harness and ground lead withthe plastic band.Í Fasten the differential gear case breather hose,coolant reserv

3 - 1CHKADJEB300000PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjust

3 - 2CHKADJPERIODIC MAINTENANCE/LUBRICATION* Since these items require special tools, data and technical skills have a Yamaha dealer perform the ser-v

CONTENTSCHAPTER 1GENERAL INFORMATIONVEHICLE IDENTIFICATION...1-1VEHICLE IDENT

3 - 3CHKADJADJUSTING THE VALVE CLEARANCEENGINEADJUSTING THE VALVE CLEARANCENOTE:• The valve clearance must be adjusted whenthe engine is cool to the t

3 - 4CHKADJADJUSTING THE VALVE CLEARANCE7. Remove:• engine cooling fan 118. Remove:• timing plug 1 9. Check:• valve clearanceOut of specification → Ad

3 - 5CHKADJADJUSTING THE VALVE CLEARANCE10.Adjust:• valve clearance ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Loosen the locknut 1.b. Insert a thi

3 - 6CHKADJADJUSTING THE TIMING CHAINAdjustment free.ADJUSTING THE IDLING SPEED 1. Start the engine and let it warm up for sev-eral minutes.2. Remove:

3 - 7CHKADJADJUSTING THE IDLING SPEED/ADJUSTING THE THROTTLE CABLE7. Detach:• tachometer8. Lower the cargo bed.9. Install:• console• passenger seat• d

3 - 8CHKADJADJUSTING THE THROTTLE CABLE/ADJUSTING THE STARTER CABLE5. Remove:• throttle valve cover6. Install:• console• passenger seat• driver seatAD

3 - 9CHKADJADJUSTING THE STARTER CABLE/CHECKING THE SPARK PLUG3. Install:• console• passenger seat• driver seatRefer to “SEATS, ENCLOSURE, HOODAND CAR

3 - 10CHKADJCHECKING THE IGNITION TIMINGCHECKING THE IGNITION TIMINGNOTE:Engine idling speed and throttle cable free playshould be adjusted properly b

3 - 11CHKADJCHECKING THE IGNITION TIMING/MEASURING THE COMPRESSION PRESSURE6. Check:• ignition timing▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. War

3 - 12CHKADJMEASURING THE COMPRESSION PRESSURE5. Remove:• spark plug6. Attach:• adapter• compression gauge 1 7. Measure:• compression pressureAbove th

LUBRICATION POINTS AND LUBRICANT TYPES ...2-23ENGINE...

3 - 13CHKADJMEASURING THE COMPRESSION PRESSURE/CHECKING THE ENGINE OIL LEVELWARNINGWhen cranking the engine, ground thespark plug lead to prevent spar

3 - 14CHKADJCHECKING THE ENGINE OIL LEVEL/CHANGING THE ENGINE OIL5. Stop the engine and check the oil levelagain.NOTE:Wait a few minutes until the oil

3 - 15CHKADJCHANGING THE ENGINE OILb. Lubricate the O-ring 3 of the new oil filtercartridge with a thin coat of lithium-soap-based grease.CAUTION:Make

3 - 16CHKADJCHANGING THE ENGINE OIL/CLEANING THE AIR FILTER11.Check:• engine oil pressure▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Slightly loosen

3 - 17CHKADJCLEANING THE AIR FILTER2. Remove:• air filter case cover 1 3. Remove:• air filter element assembly 1 • air filter element cap• air filter

3 - 18CHKADJCLEANING THE AIR FILTER/CHECKING THE COOLANT LEVELc. Apply Yamaha foam air filter oil or otherquality foam air filter oil.d. Squeeze out t

3 - 19CHKADJCHECKING THE COOLANT LEVEL/CHANGING THE COOLANT4. Start the engine, warm it up for several min-utes, and then turn it off.5. Check:• coola

3 - 20CHKADJCHANGING THE COOLANT8. Remove:• radiator cap 1 WARNINGA hot radiator is under pressure. Therefore,do not remove the radiator cap when thee

3 - 21CHKADJCHANGING THE COOLANT14.Connect:• water pump inlet hose• coolant outlet hose15.Remove:• air bleed bolt 116.Fill:• cooling system(with the s

3 - 22CHKADJCHANGING THE COOLANTCAUTION:• Adding water instead of coolant lowersthe antifreeze content of the coolant. Ifwater is used instead of cool