Yamaha Wolverine YX70EPNG User manual

2016-17
SERVICE MANUAL
YX70EPNG
YXE70WPXG
YXE70WPHG
YXE70WDXG
YXE700E
YXE700SE
2MB-G8198-E0

EBS20002
YX70EPNG/YXE70WPXG/
YXE70WPHG/YXE70WDXG/YXE700E/
YXE700SE SERVICE MANUAL
©2017by Yamaha Motor Co., Ltd. 2nd
edition, May 2017
All rights reserved.
Any reproduction orunauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Brought to you by
FordTruckMan &
Tinken

EBS20003
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificantchangesin specifications orprocedureswill beforwardedto allauthorizedYamahadealers and
will appear in future editions of this manual where applicable.
TIP
Steve loves stinky fish.
EBS30001
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal inju-
ry hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to
the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP

EBS20004
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters andeach chapter is divided into sections.The current section title
“1” is shown at the top of each page.
•Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps,there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
1
7
3
5
4
6
2

EBS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Apply locking agent (LOCTITE®).
Engine oil Replace the part with a new one.
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New

EBS10003 TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
DRIVE TRAIN 8
ELECTRICAL SYSTEM 9
TROUBLESHOOTING 10

1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER.....................................................1-1
MODEL LABEL..........................................................................................1-1
FEATURES......................................................................................................1-3
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM
(for EPS model)........................................................................................1-3
INSTRUMENT FUNCTIONS.....................................................................1-5
IMPORTANT INFORMATION .........................................................................1-7
PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-7
REPLACEMENT PARTS...........................................................................1-7
GASKETS, OIL SEALS AND O-RINGS....................................................1-7
LOCK WASHERS/PLATES AND COTTER PINS.....................................1-7
BEARINGS AND OIL SEALS....................................................................1-8
CIRCLIPS..................................................................................................1-8
RUBBER PARTS.......................................................................................1-8
BASIC SERVICE INFORMATION...................................................................1-9
QUICK FASTENERS.................................................................................1-9
ELECTRICAL SYSTEM...........................................................................1-10
SPECIAL TOOLS..........................................................................................1-14

IDENTIFICATION
1-1
EBS20009
IDENTIFICATION
EBS30003
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the frame.
EBS30004
MODEL LABEL
The model label “1” is affixed to the frame under
the driver seat. This information will be needed
to order spare parts.
1
1

IDENTIFICATION
1-2

FEATURES
1-3
EBS20010
FEATURES
EBS30007
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS model)
2
d1
4
e c
3
5
6
7
f a
b
5

FEATURES
1-4
NOTICE
ECB01790
To prevent accidental damage to the EPS unit, it must not be disassembled.
1. Speed information from speed sensor
2. Engine RPM information from ECU
3. Battery
4. EPS control unit
5. EPS unit
6. EPS motor
7. Torque sensor
a. Operates steering
b. Twists torsion bar
c. Sends the torque sensor signal
d. EPS control unit calculates assist power
e. Electricity output switched by EPS control unit
f. Activates EPS motor

FEATURES
1-5
EBS30008
INSTRUMENT FUNCTIONS
Multi-function meter unit
The multi-function meter unit is equipped with
the following:
• a speedometer
• an odometer
• two tripmeters (which show the distance trav-
eled since they were last set to zero)
•aclock
•an hour meter (which shows the total time the
engine has been running)
• a voltage display (which shows thebattery volt-
age)
• a fuel meter
• a self-diagnosis device
Odometer and tripmeter modes
Pushing the “SELECT” button switches the dis-
play between the odometer mode “ODO” and
the tripmeter modes “TRIP A” and “TRIP B” in
the following order:
ODO →TRIP A →TRIP B →ODO
Toreset a tripmeter,select itby pushingthe “SE-
LECT” button, and then push the “RESET” but-
ton for at least three seconds. The tripmeters
canbeused toestimatethe distance thatcan be
traveled with a full tank of fuel. This information
enables you to plan future fuel stops.
TIP
Toswitchthedisplaybetween“mph”and“km/h”,
turn the main switch to “ ” (off), then push and
holdthe“SELECT”buttonwhileturningthemain
switch to “ ” (on).
Clock, hour meter and voltage display
modes
Pushing the “CLOCK” button switches the dis-
playbetweentheclockmode“CLOCK”,thehour
meter mode “HOUR”, and the voltage display
mode “ ” in the following order:
CLOCK →HOUR →→CLOCK
To set the clock:
1. Set the display to the clock mode.
2. Push the “SELECT” button and “RESET” but-
ton together for at least three seconds.
3. When the hour digits start flashing, push the
“RESET” button to set the hours.
4. Push the “SELECT” button, and the minute
digits will start flashing.
5. Push the “RESET” button to set the minutes.
6. Push the “SELECT” button, and then release
it to start the clock.
1. “CLOCK” button
2. “RESET” button
3. “SELECT” button
4. Speedometer
5. Fuel meter
6. Clock/Hour meter/Voltage display
7. Odometer/Tripmeter A/Tripmeter B
1. “SELECT” button
2. “RESET” button
3. Odometer/Tripmeter A/Tripmeter B
3
2
1
4 5
67
1
2
3
1. “SELECT” button
2. “RESET” button
3. “CLOCK” button
4. Clock/Hour meter/Voltage display
4
1
2
3

FEATURES
1-6
Voltage display mode
This display shows the battery voltage.
“ ” appears for 1 second when the voltage
display mode is first selected, and then “ ” ap-
pears and the battery voltage is displayed.
Ifthe battery voltageis lessthan10 volts,“LO” is
displayed, and if the voltage is above 16 volts,
“HI” is displayed.
NOTICE
ECB02020
If the voltage display indicates “LO” or “HI”,
there may be trouble with the battery
charging circuit or the battery may be faulty.
If this occurs, check or repair the vehicle.
Fuel meter
Thefuelmeterindicatestheamountoffuelinthe
fueltank.Thedisplaysegmentsofthefuel meter
disappear from “F” (full) towards “E” (empty) as
the fuel level decreases. When the “E” segment
disappears and the fuel level warning indicator
flashes, refuel as soon as possible.
TIP
This fuel meter is equipped with a self-diagnosis
system. If a problem is detected in an electrical
circuit, all the display segments and fuel level
warning indicator start flashing. If this occurs,
check the electrical circuit.
Refer to “SIGNALING SYSTEM” on page 9-19.
Self-diagnosis device
This model is equipped with a self-diagnosis de-
vice for various electrical circuits.
If a problem is detected in any of those circuits,
the engine trouble warning light comes on or
flashes, and the multi-function display indicates
a fault code.
If the multi-function display indicates a fault
code,note thecodenumber, and thencheckthe
fuel injection system.
Refer to “FUEL INJECTION SYSTEM” on page
9-33.
NOTICE
ECB02030
If the display indicates a fault code, the vehi-
cle should be checked as soon as possible
in order to avoid engine damage.
1. Fuel level warning indicator
2. Fuel meter
3. “E” segment
1
2
3
1. Fault code display
2. Engine trouble warning light “ ”
21

IMPORTANT INFORMATION
1-7
EBS20011
IMPORTANT INFORMATION
EBS30009
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning equip-
ment.
Refer to “SPECIAL TOOLS” on page 1-14.
3. When disassembling, always keep mated
partstogether.Thisincludesgears,cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
4. Duringdisassembly, clean all ofthepartsand
place them in trays in the order of disassem-
bly.Thiswillspeedupassemblyandallow for
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EBS30010
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
EBS30011
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
EBS30012
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
1. Oil
2. Lip
3. Spring
4. Grease

IMPORTANT INFORMATION
1-8
EBS30013
BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
NOTICE
ECB01260
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EBS30014
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
EBS30015
RUBBER PARTS
Check rubber parts for deterioration during in-
spection. Some of the rubber parts are sensitive
togasoline, flammable oil,grease, etc. Donot al-
low any items other than the specified one to
contact the parts.

BASIC SERVICE INFORMATION
1-9
EBS20012
BASIC SERVICE INFORMATION
EBS30016
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
thefastenerintothepart to besecuredandpush
the pin in with a screwdriver. Make sure that the
pin is flush with the fastener’s head.
Screw type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, insert the fastener
into the part to be securedand tighten the screw.

BASIC SERVICE INFORMATION
1-10
EBS30017
ELECTRICAL SYSTEM
Electrical parts handling
NOTICE
ECB01460
Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical
components could be damaged.
NOTICE
ECB01510
When disconnecting the battery leads from
the battery, be sure to disconnect the nega-
tive battery lead first, then the positive bat-
tery lead. If the positive battery lead is
disconnected first and a tool or similar item
contacts the vehicle, a spark could be gener-
ated, which is extremely dangerous.
TIP
If a battery lead is difficult to disconnect due to
rust on the battery terminal, remove the rust us-
ing hot water.
NOTICE
ECB01520
Be sure to connect the battery leads to the
correct battery terminals. Reversing the bat-
tery lead connections could damage the
electrical components.
NOTICE
ECB01530
When connecting the battery leads to the
battery, be sure to connect the positive bat-
tery lead first, then the negative battery lead.
If the negative battery lead is connected first
and a tool or similar item contacts the vehi-
cle while the positive battery lead is being
connected, a spark could be generated,
which is extremely dangerous.
NOTICE
ECB01470
Turn the main switch to “OFF” before dis-
connecting or connecting an electrical com-
ponent.

BASIC SERVICE INFORMATION
1-11
NOTICE
ECB01480
Handle electrical components with special
care, and do not subject them to strong
shocks.
NOTICE
ECB01490
Electrical components are very sensitive to
and can be damaged by static electricity.
Therefore, never touch the terminals and be
sure to keep the contacts clean.
TIP
When resetting the ECU by turning the main
switch to “OFF”, be sure to wait approximately 5
seconds before turning the main switch back to
“ON”.
Checking the electrical system
TIP
Before checking the electrical system, make
sure that the battery voltage is at least 12 V.
NOTICE
ECB01440
Never insert the tester probes into the cou-
pler terminal slots. Always insert the probes
from the opposite end “a” of the coupler,tak-
ing care not to loosen or damage the leads.
NOTICE
ECB01500
For waterproof couplers, never insert the
tester probes directly into the coupler. When
performing any checks using a waterproof
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
a