Yamaha GRIZZLY 700 FI YFM7FGPW User manual

LIT-11616-20-11 3B4-28197-10
YFM7FGPW
SERVICE MANUAL

EBS00001
YFM7FGPW
SERVICE MANUAL
©2006 by Yamaha Motor Corporation, U.S.A.
First Edition, May 2006
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-11616-20-11

EBS00002
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle
repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe
and unfit for use.
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
vehicle 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 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.
NOTE:
_
• This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EBS00003
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the vehicle operator, a bystander or a person checking or repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

EBS00004
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “symbols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram 4is provided for removal and disassembly jobs.
2. Numbers 5are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8are given in addition
to the exploded diagram and the job instruction chart.

EBS00006
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1to 0indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Cooling system
6Fuel injection system
7Drive train
8Chassis
9Electrical
0Troubleshooting
Symbols Ato Hindicate the following
ACan be serviced with engine mounted
BFilling fluid
CLubricant
DSpecial tool
ETorque
FWear limit, clearance
GEngine speed
HElectrical data (Ω, V, A)
Symbols Ito Nin the exploded diagrams
indicate the types of lubricants and lubrication
points.
IApply engine oil
JApply gear oil
KApply molybdenum disulfide oil
LApply wheel bearing grease
MApply lithium-soap-based grease
NApply molybdenum disulfide grease
Symbols Oto Pin the exploded diagrams
indicate where to apply a locking agent Oand
when to install a new part P.
OApply the locking agent (LOCTITE®)
PReplace
12
34
56
78
90
AB
CD
EF
GH
IJK
LMN
OP
GEN
INFO SPEC
CHK
ADJ ENG
COOL
FI
DRIV
CHAS
–+
ELEC TRBL
SHTG
T
R
.
.
EGM
BLS M
LT
New

EBS00008
TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC 2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
ENGINE ENG 4
COOLING SYSTEM COOL 5
FUEL INJECTION SYSTEM FI 6
DRIVE TRAIN DRIV 7
CHASSIS CHAS 8
ELECTRICAL ELEC 9
TROUBLESHOOTING TRBL
SHTG
10
–+

CONTENTS
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION............................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
FEATURES......................................................................................................1-2
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................1-3
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM......1-4
EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM .....1-5
INSTRUMENT FUNCTIONS .....................................................................1-6
IMPORTANT INFORMATION .........................................................................1-9
PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-9
REPLACEMENT PARTS...........................................................................1-9
GASKETS, OIL SEALS AND O-RINGS ....................................................1-9
LOCK WASHERS/PLATES AND COTTER PINS ...................................1-10
BEARINGS AND OIL SEALS ..................................................................1-10
CIRCLIPS ................................................................................................1-10
CHECKING THE CONNECTIONS..........................................................1-11
SPECIAL TOOLS ..........................................................................................1-12
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................2-1
ENGINE SPECIFICATIONS ............................................................................2-5
CHASSIS SPECIFICATIONS ........................................................................2-12
ELECTRICAL SPECIFICATIONS .................................................................2-14
TIGHTENING TORQUES ..............................................................................2-16
ENGINE TIGHTENING TORQUES.........................................................2-16
CHASSIS TIGHTENING TORQUES.......................................................2-19
HOW TO USE THE CONVERSION TABLE..................................................2-22

GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-22
LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-23
ENGINE...................................................................................................2-23
COOLANT FLOW DIAGRAMS .....................................................................2-25
OIL FLOW DIAGRAMS.................................................................................2-26
CABLE ROUTING .........................................................................................2-28
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION..............................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM .........................................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART............................3-2
ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS .......................3-4
ENGINE SKID PLATES.............................................................................3-4
SEAT AND SIDE PANELS ........................................................................3-5
FRONT CARRIER AND FRONT GUARD .................................................3-6
FRONT FENDERS AND FRONT GRILL...................................................3-8
REAR CARRIER AND REAR FENDER ....................................................3-9
ELECTRICAL COMPONENTS TRAY...........................................................3-10
ELECTRICAL COMPONENTS TRAY 1/2 ...............................................3-10
ELECTRICAL COMPONENTS TRAY 2/2 ...............................................3-12
FOOTREST BOARDS ...................................................................................3-14
AIR FILTER CASE ........................................................................................3-15

ENGINE .........................................................................................................3-16
ADJUSTING THE VALVE CLEARANCE ................................................3-16
ADJUSTING THE ENGINE IDLING SPEED ...........................................3-19
ADJUSTING THE THROTTLE LEVER FREE PLAY ..............................3-20
ADJUSTING THE SPEED LIMITER........................................................3-22
CHECKING THE SPARK PLUG .............................................................3-23
CHECKING THE IGNITION TIMING.......................................................3-24
MEASURING THE COMPRESSION PRESSURE..................................3-25
CHECKING THE ENGINE OIL LEVEL....................................................3-28
CHANGING THE ENGINE OIL ...............................................................3-29
CLEANING THE AIR FILTER ELEMENT................................................3-31
CHECKING THE THROTTLE BODY JOINT...........................................3-33
CHECKING THE FUEL HOSE ................................................................3-34
CHECKING THE BREATHER HOSES ...................................................3-34
CHECKING THE COOLANT LEVEL.......................................................3-35
CHANGING THE COOLANT...................................................................3-35
CHECKING THE COOLING SYSTEM ....................................................3-39
CHECKING THE COOLANT TEMPERATURE WARNING LIGHT.........3-40
CHECKING THE V-BELT........................................................................3-41
CHECKING THE EXHAUST SYSTEM....................................................3-42
CLEANING THE SPARK ARRESTER ....................................................3-43
CHASSIS .......................................................................................................3-44
ADJUSTING THE FRONT BRAKE .........................................................3-44
ADJUSTING THE REAR BRAKE............................................................3-44
CHECKING THE BRAKE FLUID LEVEL.................................................3-46
CHECKING THE FRONT BRAKE PADS ................................................3-47
CHECKING THE REAR BRAKE PADS ..................................................3-48
CHECKING THE REAR BRAKE HOSE PROTECTORS ........................3-48
CHECKING THE BRAKE HOSES...........................................................3-49
BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-49
ADJUSTING THE SELECT LEVER CONTROL CABLE AND
SHIFT ROD ............................................................................................3-51
CHECKING THE FINAL GEAR OIL LEVEL ............................................3-53
CHANGING THE FINAL GEAR OIL........................................................3-53
CHECKING THE DIFFERENTIAL GEAR OIL LEVEL.............................3-55
CHANGING THE DIFFERENTIAL GEAR OIL ........................................3-55
CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS ..........3-56
CHECKING THE STEERING SYSTEM ..................................................3-57
ADJUSTING THE TOE-IN.......................................................................3-59
CHECKING THE FRONT AND REAR SHOCK ABSORBERS ...............3-60
ADJUSTING THE FRONT SHOCK ABSORBERS .................................3-61
ADJUSTING THE REAR SHOCK ABSORBERS....................................3-62
CHECKING THE TIRES..........................................................................3-62
CHECKING THE WHEELS .....................................................................3-65
CHECKING AND LUBRICATING THE CABLES ....................................3-65
LUBRICATING THE LEVERS AND PEDALS .........................................3-66

ELECTRICAL SYSTEM.................................................................................3-67
CHECKING AND CHARGING THE BATTERY.......................................3-67
CHECKING THE FUSES ........................................................................3-73
ADJUSTING THE HEADLIGHT BEAMS.................................................3-76
REPLACING THE HEADLIGHT BULBS .................................................3-76
CHAPTER 4
ENGINE
ENGINE REMOVAL ........................................................................................4-1
AIR DUCTS, MUFFLER AND EXHAUST PIPE ........................................4-1
SELECT LEVER UNIT ..............................................................................4-3
LEADS, CABLES AND HOSES ................................................................4-4
ENGINE MOUNTING BOLTS ...................................................................4-6
INSTALLING THE ENGINE.......................................................................4-8
INSTALLING THE SELECT LEVER UNIT ................................................4-9
CYLINDER HEAD..........................................................................................4-10
REMOVING THE CYLINDER HEAD.......................................................4-12
CHECKING THE CAMSHAFT SPROCKET............................................4-13
CHECKING THE TAPPET COVERS ......................................................4-13
CHECKING THE TIMING CHAIN TENSIONER......................................4-13
CHECKING THE CYLINDER HEAD .......................................................4-14
INSTALLING THE CYLINDER HEAD .....................................................4-15
ROCKER ARMS AND CAMSHAFT ..............................................................4-18
REMOVING THE ROCKER ARMS AND CAMSHAFT............................4-20
CHECKING THE CAMSHAFT.................................................................4-20
CHECKING THE DECOMPRESSION SYSTEM.....................................4-21
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........4-21
INSTALLING THE CAMSHAFT AND ROCKER ARMS ..........................4-22
VALVES AND VALVE SPRINGS..................................................................4-25
REMOVING THE VALVES AND VALVE SPRINGS ...............................4-26
CHECKING THE VALVES AND VALVE SPRINGS ................................4-27
INSTALLING THE VALVES AND VALVE SPRINGS ..............................4-31
CYLINDER AND PISTON..............................................................................4-34
REMOVING THE PISTON ......................................................................4-35
CHECKING THE CYLINDER AND PISTON ...........................................4-35
CHECKING THE PISTON RINGS...........................................................4-37
CHECKING THE PISTON PIN ................................................................4-38
INSTALLING THE PISTON AND CYLINDER .........................................4-39

AC MAGNETO...............................................................................................4-42
REMOVING THE AC MAGNETO ROTOR..............................................4-45
CHECKING THE STATOR COIL AND CRANKSHAFT POSITION
SENSOR ................................................................................................4-46
CHECKING THE STARTER CLUTCH ....................................................4-46
CHECKING THE TORQUE LIMITER......................................................4-47
INSTALLING THE AC MAGNETO ROTOR ............................................4-47
BALANCER GEARS AND OIL PUMP GEARS ............................................4-49
REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP
DRIVEN GEAR.......................................................................................4-51
CHECKING THE OIL PUMP DRIVE .......................................................4-51
CHECKING THE BALANCER DRIVE .....................................................4-51
INSTALLING THE BALANCER DRIVE GEAR, BALANCER DRIVEN
GEAR, AND OIL PUMP DRIVEN GEAR................................................4-52
PRIMARY AND SECONDARY SHEAVES....................................................4-53
PRIMARY SHEAVE.................................................................................4-55
SECONDARY SHEAVE ..........................................................................4-56
REMOVING THE PRIMARY AND SECONDARY SHEAVES .................4-57
DISASSEMBLING THE SECONDARY SHEAVE....................................4-57
CHECKING THE PRIMARY SHEAVE ....................................................4-58
CHECKING THE SECONDARY SHEAVE ..............................................4-58
ASSEMBLING THE PRIMARY SHEAVE ................................................4-59
ASSEMBLING THE SECONDARY SHEAVE..........................................4-60
INSTALLING THE PRIMARY AND SECONDARY SHEAVES................4-62
CLUTCH ........................................................................................................4-63
REMOVING THE CLUTCH .....................................................................4-65
CHECKING THE CLUTCH......................................................................4-66
INSTALLING THE CLUTCH....................................................................4-67
CRANKCASE ................................................................................................4-68
TIMING CHAIN AND OIL FILTER ...........................................................4-68
CRANKCASE ..........................................................................................4-70
CRANKCASE BEARINGS.......................................................................4-71
SEPARATING THE CRANKCASE..........................................................4-72
CHECKING THE TIMING CHAIN AND GUIDE.......................................4-72
CHECKING THE RELIEF VALVE ...........................................................4-72
CHECKING THE BEARINGS..................................................................4-73
CHECKING THE CRANKCASE ..............................................................4-73
ASSEMBLING THE CRANKCASE..........................................................4-73
INSTALLING THE SHIFT LEVER ...........................................................4-74

CRANKSHAFT AND OIL PUMP ...................................................................4-75
OIL PUMP ...............................................................................................4-76
REMOVING THE CRANKSHAFT ...........................................................4-77
CHECKING THE OIL PUMP ...................................................................4-77
CHECKING THE OIL STRAINER ...........................................................4-78
CHECKING THE CRANKSHAFT ............................................................4-78
ASSEMBLING THE OIL PUMP...............................................................4-79
INSTALLING THE CRANKSHAFT ..........................................................4-79
TRANSMISSION............................................................................................4-81
DRIVE AXLE ...........................................................................................4-83
REMOVING THE TRANSMISSION ........................................................4-85
CHECKING THE SHIFT FORKS.............................................................4-85
CHECKING THE SHIFT DRUM ..............................................................4-86
CHECKING THE TRANSMISSION .........................................................4-86
CHECKING THE SECONDARY SHAFT.................................................4-87
CHECKING THE STOPPER LEVER AND STOPPER WHEEL..............4-87
ASSEMBLING THE SHIFT FORK ASSEMBLY ...................................... 4-87
INSTALLING THE TRANSMISSION .......................................................4-88
MIDDLE GEAR ..............................................................................................4-89
MIDDLE DRIVE SHAFT ..........................................................................4-89
MIDDLE DRIVEN SHAFT........................................................................4-90
REMOVING THE MIDDLE DRIVE SHAFT .............................................4-92
REMOVING THE MIDDLE DRIVEN SHAFT...........................................4-93
CHECKING THE PINION GEARS ..........................................................4-95
SELECTING MIDDLE DRIVE AND DRIVEN GEAR SHIMS...................4-96
INSTALLING THE BEARING AND OIL SEALS ...................................... 4-99
INSTALLING THE MIDDLE DRIVEN SHAFT .......................................4-100
INSTALLING THE MIDDLE DRIVE SHAFT ..........................................4-102
MEASURING THE MIDDLE GEAR BACKLASH...................................4-102
CHAPTER 5
COOLING SYSTEM
RADIATOR ......................................................................................................5-1
CHECKING THE RADIATOR....................................................................5-3
INSTALLING THE RADIATOR..................................................................5-4
THERMOSTAT ................................................................................................5-5
CHECKING THE THERMOSTAT..............................................................5-6
INSTALLING THE THERMOSTAT............................................................5-6
WATER PUMP.................................................................................................5-7
DISASSEMBLING THE WATER PUMP....................................................5-9
CHECKING THE WATER PUMP ..............................................................5-9
ASSEMBLING THE WATER PUMP........................................................5-10

CHAPTER 6
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM............................................................................6-1
CIRCUIT DIAGRAM ..................................................................................6-3
ECU SELF-DIAGNOSTIC FUNCTION......................................................6-5
SELF-DIAGNOSTIC FUNCTION TABLE ..................................................6-6
TROUBLESHOOTING CHART .................................................................6-7
DIAGNOSTIC MODE ................................................................................6-8
TROUBLESHOOTING DETAILS ............................................................6-12
CHECKING THE INTAKE AIR PRESSURE SENSOR ...........................6-26
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....................6-26
FUEL TANK...................................................................................................6-28
REMOVING THE FUEL TANK ................................................................6-30
REMOVING THE FUEL PUMP ...............................................................6-30
CHECKING THE FUEL PUMP BODY.....................................................6-31
CHECKING THE ROLLOVER VALVE ....................................................6-31
INSTALLING THE FUEL PUMP..............................................................6-31
INSTALLING THE FUEL HOSE ..............................................................6-32
THROTTLE BODY.........................................................................................6-33
REMOVING THE THROTTLE BODY ASSEMBLY .................................6-36
CHECKING THE FUEL INJECTOR ........................................................6-36
CHECKING THE THROTTLE BODY ......................................................6-36
INSTALLING THE THROTTLE BODY ASSEMBLY................................6-37
CHECKING THE FUEL PUMP AND PRESSURE REGULATOR
OPERATION ..........................................................................................6-38
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR ................................................................................................6-39
CHAPTER 7
DRIVE TRAIN
TROUBLESHOOTING.....................................................................................7-1
CHECKING NOISES .................................................................................7-1
TROUBLESHOOTING CHART .................................................................7-3

FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR........7-4
REMOVING THE DIFFERENTIAL GEAR ASSEMBLY........................... 7-10
CHECKING THE FRONT CONSTANT VELOCITY JOINTS...................7-10
CHECKING THE DIFFERENTIAL GEARS .............................................7-11
CHECKING THE DIFFERENTIAL GEAR MOTOR .................................7-11
ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS ..............7-12
ASSEMBLING THE DIFFERENTIAL GEARS.........................................7-13
MEASURING THE DIFFERENTIAL GEAR LASH ..................................7-14
ADJUSTING THE DIFFERENTIAL GEAR LASH....................................7-15
CHECKING THE DIFFERENTIAL GEAR OPERATION .........................7-16
REAR CONSTANT VELOCITY JOINTS AND FINAL DRIVE GEAR ...........7-17
ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS.................7-24
DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY.......7-25
POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR ...7-25
ADJUSTING THE FINAL DRIVE PINION GEAR BACKLASH ................7-25
ADJUSTING THE FINAL DRIVEN PINION GEAR BACKLASH .............7-27
MEASURING THE FINAL DRIVEN PINION GEAR THRUST
WASHER CLEARANCE.........................................................................7-29
MEASURING THE WHEEL GEAR THRUST CLEARANCE ...................7-30
CHECKING THE REAR DRIVE SHAFT..................................................7-31
CHECKING THE FINAL DRIVE ASSEMBLY..........................................7-31
MEASUREMENT THE FINAL GEAR LASH............................................7-32
ADJUSTING THE FINAL GEAR LASH ...................................................7-33
ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY.............7-34
ASSEMBLING THE FINAL GEAR CASE................................................7-35
CHAPTER 8
CHASSIS
FRONT AND REAR WHEELS ........................................................................8-1
FRONT WHEELS ......................................................................................8-1
REAR WHEELS ........................................................................................8-3
CHECKING THE WHEELS .......................................................................8-5
CHECKING THE WHEEL HUBS...............................................................8-5
CHECKING THE BRAKE DISCS ..............................................................8-6
INSTALLING THE BRAKE DISCS ............................................................8-6
INSTALLING THE WHEEL HUBS.............................................................8-6
INSTALLING THE WHEELS .....................................................................8-7

FRONT AND REAR BRAKES.........................................................................8-8
FRONT BRAKE PADS ..............................................................................8-8
REAR BRAKE PADS.................................................................................8-9
REPLACING THE FRONT AND REAR BRAKE PADS...........................8-10
FRONT BRAKE MASTER CYLINDER....................................................8-12
REAR BRAKE MASTER CYLINDER ......................................................8-15
CHECKING THE MASTER CYLINDERS................................................8-18
ASSEMBLING THE FRONT AND REAR BRAKE MASTER
CYLINDERS ...........................................................................................8-18
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................8-19
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................8-21
FRONT BRAKE CALIPERS ....................................................................8-23
REAR BRAKE CALIPERS.......................................................................8-25
DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS ..........8-27
CHECKING THE FRONT AND REAR BRAKE CALIPERS ....................8-27
ASSEMBLING THE FRONT AND REAR BRAKE CALIPERS ................8-28
INSTALLING THE FRONT AND REAR BRAKE CALIPERS ..................8-29
STEERING SYSTEM.....................................................................................8-31
HANDLEBAR...........................................................................................8-31
REMOVING THE HANDLEBAR GRIPS..................................................8-33
CHECKING THE HANDLEBAR ..............................................................8-33
INSTALLING THE HANDLEBAR ............................................................8-33
INSTALLING THE HANDLEBAR GRIPS ................................................8-34
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................8-34
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................8-35
INSTALLING THE THROTTLE LEVER ASSEMBLY ..............................8-35
STEERING STEM ...................................................................................8-36
CHECKING THE STEERING STEM .......................................................8-38
INSTALLING THE STEERING STEM .....................................................8-38
INSTALLING THE PITMAN ARM............................................................8-40
TIE-RODS AND STEERING KNUCKLES ...............................................8-41
REMOVING THE STEERING KNUCKLES .............................................8-43
CHECKING THE TIE-RODS ...................................................................8-43
CHECKING THE STEERING KNUCKLES..............................................8-43
INSTALLING THE TIE-RODS .................................................................8-46
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES .............8-47
REMOVING THE FRONT ARMS ............................................................8-49
CHECKING THE FRONT ARMS.............................................................8-49
CHECKING THE FRONT SHOCK ABSORBERS...................................8-51
INSTALLING THE FRONT ARMS AND FRONT SHOCK
ABSORBERS .........................................................................................8-51
REAR KNUCKLES AND STABILIZER .........................................................8-52
CHECKING THE REAR KNUCKLES ......................................................8-54
CHECKING THE STABILIZER................................................................8-54

REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES .................8-55
CHECKING THE REAR ARMS ...............................................................8-57
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................8-57
INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER
ASSEMBLIES.........................................................................................8-58
CHAPTER 9
ELECTRICAL
ELECTRICAL COMPONENTS........................................................................9-1
CHECKING SWITCH CONTINUITY................................................................9-4
CHECKING THE SWITCHES..........................................................................9-5
CHECKING THE BULBS AND BULB SOCKETS ..........................................9-7
TYPES OF BULBS ....................................................................................9-7
CHECKING THE CONDITION OF THE BULBS .......................................9-8
CHECKING THE CONDITION OF THE BULB SOCKETS .......................9-9
IGNITION SYSTEM .......................................................................................9-10
CIRCUIT DIAGRAM ................................................................................9-10
TROUBLESHOOTING ............................................................................9-11
ELECTRIC STARTING SYSTEM ..................................................................9-16
CIRCUIT DIAGRAM ................................................................................9-16
STARTING CIRCUIT OPERATION.........................................................9-17
TROUBLESHOOTING ............................................................................9-18
STARTER MOTOR........................................................................................9-22
CHECKING THE STARTER MOTOR .....................................................9-24
ASSEMBLING THE STARTER MOTOR.................................................9-26
CHARGING SYSTEM....................................................................................9-27
CIRCUIT DIAGRAM ................................................................................9-27
TROUBLESHOOTING ............................................................................9-28
LIGHTING SYSTEM ......................................................................................9-30
CIRCUIT DIAGRAM ................................................................................9-30
TROUBLESHOOTING ............................................................................9-31
CHECKING THE LIGHTING SYSTEM....................................................9-32
SIGNALING SYSTEM ...................................................................................9-34
CIRCUIT DIAGRAM ................................................................................9-34
TROUBLESHOOTING ............................................................................9-36
CHECKING THE SIGNALING SYSTEM .................................................9-37

COOLING SYSTEM.......................................................................................9-45
CIRCUIT DIAGRAM ................................................................................9-45
TROUBLESHOOTING ............................................................................9-46
FUEL PUMP SYSTEM...................................................................................9-50
CIRCUIT DIAGRAM ................................................................................9-50
TROUBLESHOOTING ............................................................................9-51
2WD/4WD SELECTING SYSTEM.................................................................9-53
CIRCUIT DIAGRAM ................................................................................9-53
TROUBLESHOOTING ............................................................................9-54
EPS (ELECTRIC POWER STEERING) SYSTEM.........................................9-58
CIRCUIT DIAGRAM ................................................................................9-58
EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION .....................9-59
EPS WARNING LIGHT DURING NORMAL OPERATION......................9-60
DIAGNOSTIC MODE ..............................................................................9-61
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)......................9-64
TROUBLESHOOTING DETAILS (EPS SYSTEM) ..................................9-65
CHECKING THE EPS MOTOR...............................................................9-69
CHECKING THE EPS TORQUE SENSOR.............................................9-69
CHAPTER 10
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING .....................................................10-1
FUEL SYSTEM........................................................................................10-1
ELECTRICAL SYSTEM...........................................................................10-1
COMPRESSION SYSTEM......................................................................10-2
POOR IDLE SPEED PERFORMANCE .........................................................10-2
POOR IDLE SPEED PERFORMANCE...................................................10-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE................................10-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE .........................10-2
FAULTY DRIVE TRAIN.................................................................................10-3
FAULTY GEAR SHIFTING............................................................................10-4
HARD SHIFTING.....................................................................................10-4
SHIFT LEVER DOES NOT MOVE ..........................................................10-4
JUMPS OUT OF GEAR...........................................................................10-4

FAULTY CLUTCH PERFORMANCE ............................................................10-4
ENGINE OPERATES BUT VEHICLE WILL NOT MOVE ........................10-4
CLUTCH SLIPPING ................................................................................10-4
POOR STARTING PERFORMANCE......................................................10-4
POOR SPEED PERFORMANCE............................................................10-5
OVERHEATING.............................................................................................10-5
OVERHEATING ......................................................................................10-5
OVERCOOLING ............................................................................................10-5
COOLING SYSTEM ................................................................................10-5
FAULTY BRAKE ...........................................................................................10-5
POOR BRAKING EFFECT......................................................................10-5
SHOCK ABSORBER MALFUNCTION .........................................................10-6
MALFUNCTION.......................................................................................10-6
UNSTABLE HANDLING................................................................................10-6
UNSTABLE HANDLING ..........................................................................10-6
LIGHTING SYSTEM ......................................................................................10-6
HEADLIGHT DOES NOT COME ON ......................................................10-6
BULB BURNT OUT .................................................................................10-6

1 - 1
GEN
INFO
EBS00009
GENERAL INFORMATION
VEHICLE IDENTIFICATION
EBS00010
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is
stamped into the front left side of the frame.
EBS00011
MODEL LABEL
The model label 1is affixed at the location in
the illustration. This information will be needed
to order spare parts.
VEHICLE IDENTIFICATION

1 - 2
GEN
INFO
FEATURES
EAS20170
FEATURES
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-
mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera-
ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the
combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies with the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating con-
ditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man-
ner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions.
1ECU (engine control unit)
2Lean angle sensor
3Fuel injection system relay
4Engine trouble warning light
5Intake air pressure sensor
6TPS (throttle position sensor)
7Intake air temperature sensor
8Fuel injector
9Fuel pump
0Speed sensor
ACrankshaft position sensor
BCoolant temperature sensor
CSpark plug
DIgnition coil
1234 567 8 9
0ABCD
1