YAMAHA YFM7FGPW SERVICE MANUAL
YFM7FGPW
SERVICE MANUAL
3B4-28197-E0
EBS00000
YFM7FGPW
SERVICE MANUAL
©2006 by Yamaha Motor Co., Ltd.
First edition, June 2006
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
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. (For CDN)
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant 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. (For CDN)
• 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!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death
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.
to
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 accompanied 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 4 is provided for removal and disassembly jobs.
2. Numbers 5 are 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 7 accompanies 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 8 are given in addition
to the exploded diagram and the job instruction chart.
12
GEN
INFO
34
SPEC
CHK
ENG
ADJ
56
COOL
78
DRIV
90
FI
CHAS
EBS00006
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1 to 0 indicate the subject of each
chapter.
General information
1
Specifications
2
Periodic checks and adjustments
3
Engine
4
Cooling system
5
Fuel injection system
6
Drive train
7
Chassis
8
Electrical
9
Troubleshooting
0
ELEC
–+
AB
CD
EF
T
.
R
.
GH
IJK
E
LMN
B
OP
LT
TRBL
SHTG
G
LS
M
M
New
Symbols A to H indicate the following
Can be serviced with engine mounted
A
Filling fluid
B
Lubricant
C
Special tool
D
Torque
E
Wear limit, clearance
F
Engine speed
G
Electrical data (Ω, V, A)
H
Symbols I to N in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Apply engine oil
I
Apply gear oil
J
Apply molybdenum disulfide oil
K
Apply wheel bearing grease
L
Apply lithium-soap-based grease
M
Apply molybdenum disulfide grease
N
Symbols O to P in the exploded diagrams
indicate where to apply a locking agent O and
when to install a new part P.
®
Apply the locking agent (LOCTITE
O
Replace
P
)
EBS00008
– +
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
ENGINE
COOLING SYSTEM
GEN
INFO
SPEC
CHK
ADJ
ENG
COOL
1
2
3
4
5
FUEL INJECTION SYSTEM
DRIVE TRAIN
CHASSIS
ELECTRICAL
TROUBLESHOOTING
FI
DRIV
CHAS
ELEC
TRBL
SHTG
6
7
8
9
10
CHAPTER 1
GENERAL INFORMATION
GEN
INFO
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
FEATURES
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
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
......................................................................................................1-2
..........................................................................................1-12
............................................................................1-1
.........................................................................1-9
VEHICLE IDENTIFICATION
EBS00009
GENERAL INFORMATION
VEHICLE IDENTIFICATION
EBS00010
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the front left side of the frame.
EBS00011
MODEL LABEL
The model label 1 is affixed at the location in
the illustration. This information will be needed
to order spare parts.
GEN
INFO
1 - 1
GEN
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 optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. 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 conditions 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 manner. 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.
INFO
1234 567 8 9
ECU (engine control unit)
1
Lean angle sensor
2
Fuel injection system relay
3
Engine trouble warning light
4
Intake air pressure sensor
5
TPS (throttle position sensor)
6
Intake air temperature sensor
7
Fuel injector
8
0ABCD
Fuel pump
9
Speed sensor
0
Crankshaft position sensor
A
Coolant temperature sensor
B
Spark plug
C
Ignition coil
D
1 - 2
GEN
FEATURES
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains
the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm
ingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens,
causing the fuel to be injected into the intake manifold only during the time the passage remains
open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the
greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector
is energized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature sensor, coolant temperature sensor, lean angle sensor and speed sensor enable the ECU
to determine the injection duration. The injection timing is determined through the signals from the
crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions.
Illustration is for reference only.
INFO
2
, 46.1 psi). Accord-
C
Fuel pump
1
Fuel injector
2
Ignition coil
3
ECU (engine control unit)
4
Speed sensor
5
Lean angle sensor
6
Coolant temperature sensor
7
Crankshaft position sensor
8
Intake air pressure sensor
9
Throttle body
0
1
B
É
A
9
È
0
2
Ê
4
5
6
7
3
8
Throttle position sensor
A
Intake air temperature sensor
B
Air filter case
C
Fuel system
È
Air system
É
Control system
Ê
1 - 3
FEATURES
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM
GEN
INFO
Speed information from
speed sensor
Battery
5. Electricity output
switched by EPS
control unit
6. Activates EPS motor
Engine starting RPM
information from ECU
4. EPS control unit
calculates assist power
3. Sends the torque
sensor signal
Steering stem
1. Operates steering
2. Twists torsion bar
EPS control unit
EPS motor
EPS unit
Torque sensor
CAUTION:
To prevent accidental damage to the EPS unit, it must not be disassembled.
1 - 4
FEATURES
EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM
Meter assembly
Multifunction display
Odometer/Tripmeter A/Tripmeter B/Clock/Fuel
meter/Gear position
Indicator and warning lights
EPS UNIT
Torque sensor
EPS motor
EPS warning/Engine trouble warning/Coolant
temperature warning/Reverse indicator/Neutral
indicator/Park indicator/High-range indicator/
Low-range indicator/Differential lock
• CO adjusting mode (For Europe and Oceania)
• FI and EPS self-diagnostic error codes
Coolant temperature sensor signal
Crankshaft position sensor signal
Speed sensor signal
GEN
INFO
EPS control unit
Battery
Engine rpm signal
Intake air temperature sensor signal
Throttle position sensor signal
Intake air pressure sensor signal
ECU
Fuel injector
Fuel pump
Ignition coil
Lean angle sensor signal
1 - 5
FEATURES
GEN
INFO
3
2
1
45
67
INSTRUMENT FUNCTIONS
EBU27291
Multifunction display
“CLOCK” button
1
“RESET” button
2
“SELECT” button
3
Speedometer
4
Fuel meter
5
Clock/Hour meter
6
Odometer/Tripmeter A/Tripmeter B
7
The multifunction display is equipped with the
following:
• a speedometer (which shows the riding
speed)
• an odometer (which shows the total distance traveled)
• two tripmeters (which show the distance
traveled since they were last set to zero)
• a clock
• an hour meter (which shows the total time
the key has been turned to “ON”)
• a fuel meter
• a self-diagnosis device
Odometer and tripmeter modes
Pushing the “SELECT” button switches the
display between the odometer mode “ODO”
and the tripmeter modes “A” and “B” in the following order:
ODO → TRIP A → TRIP B → ODO
To reset a tripmeter, select it by pushing the
“SELECT” button, and then push the “RESET”
button for at least three seconds. The tripmeters can be used to estimate the distance that
can be traveled with a full tank of fuel. This
information will enable you to plan future fuel
stops.
NOTE:
Holding in the “SELECT” button and then turning the key to “ON” switches the display
between “mph” and “km/h”.
1 - 6
GEN
FEATURES
Clock mode
Pushing the “CLOCK” button switches the display between the clock mode “CLOCK” and
the hour meter mode “HOUR” 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”
button 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.
INFO
1
2
3
Fuel meter
The fuel meter indicates the amount of fuel in
the fuel tank. The display segments of the fuel
meter disappear from “F” (full) towards “E”
(empty) as the fuel level decreases. When the
“E” segment disappears and the fuel level
warning indicator flashes, refuel as soon as
possible.
NOTE:
This fuel meter is equipped with a self-diagnosis system. If the electrical circuit is defective,
all the display segments and fuel level warning
indicator will start flashing. If this occurs, check
the electrical circuit.
Refer to “SIGNALING SYSTEM” in chapter 9.
Fuel level warning indicator
1
Fuel meter
2
“E” segment
3
1 - 7
1
GEN
FEATURES
Self-diagnosis device
This model is equipped with a self-diagnosis
device for various electrical circuits.
If any of those circuits are defective, the multifunction display will indicate a two-digit error
code. If the multifunction display indicates
such an error code, note the code number, and
check the vehicle.
ECB00810
CAUTION:
If the multifunction display indicates an error
code, the vehicle should be checked as soon
as possible in order to avoid engine damage.
Error code display
1
INFO
1 - 8
IMPORTANT INFORMATION
EBS00013
IMPORTANT INFORMATION
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
equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
GEN
INFO
EBS00014
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use oil and grease recommended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EBS00015
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, 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.
1 - 9
IMPORTANT INFORMATION
EBS00016
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.
EBS00017
BEARINGS AND OIL SEALS
Install bearings and oil seals 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.
Oil seal
1
GEN
INFO
CAUTION:
_
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
Bearing
1
EBS00018
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always 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.
Shaft
4
1 - 10
IMPORTANT INFORMATION
EBS00019
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect several times.
3. Check:
• all connections
Loose connection → Connect properly.
NOTE:
_
If the pin 1 on the terminal is flattened, bend it
up.
GEN
INFO
4. Connect:
• lead
• coupler
• connector
NOTE:
_
Make sure all connections are tight.
5. Check:
• continuity (with the pocket tester)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
_
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
1 - 11
GEN
SPECIAL TOOLS
EBS00021
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools; this will help prevent damage caused by the use of inappropriate
tools or improvised techniques. Special tools may differ by shape and part number from country to
country. In such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
For US and CDN
P/N. YM-, YU-, YS-, YK-, ACC-
Except for US and CDN
P/N. 90890-
Tool No. Tool name/How to use Illustration
Slide hammer bolt
Slide hammer bolt 6 mm
90890-01083
YU-01083-1
This tool is used to remove the rocker
arm shaft.
INFO
90890-01084
YU-01083-3
90890-01135
YU-01135-B
90890-01229
YM-01229
Weight
YU-01083-3
This tool is used to remove the rocker
arm shaft.
Crankcase separating tool
Crankcase separator
This tool is used to separate the crankcase.
Coupling gear/middle shaft tool
Gear holder
This tool is needed when removing or
installing the coupling gear nut.
90890-01243
YM-01253-1
Valve spring compressor attachment
Valve spring compressor adapter
(26 mm)
This tool is needed to remove and install
the valve assemblies.
1 - 12
GEN
SPECIAL TOOLS
Tool No. Tool name/How to use Illustration
Crankshaft installer pot
Installing pot
Pot installer
90890-01274
YU-90058
YU-90059
This tool is used to install the crankshaft.
Crankshaft installer bolt
Bolt
90890-01275
YU-90060
This tool is used to install the crankshaft.
Piston pin puller set
Piston pin puller
YU-90058/YU-90059
INFO
90890-01304
YU-01304
90890-01309
YU-90059
90890-01311
YM-08035-A
This tool is used to remove the piston pin.
Spacer
Pot spacer
This tool is used to install the crankshaft.
Tappet adjusting tool
Valve adjuster 3 mm & 4 mm
This tool is necessary for adjusting the
valve clearance.
YU-01304
ø35
1 - 13
GEN
SPECIAL TOOLS
Tool No. Tool name/How to use Illustration
Radiator cap tester
Radiator pressure tester
90890-01325
YU-24460-01
This tool is used to check the cooling system.
Locknut wrench
90890-01348
YM-01348
YU-24460-01
INFO
90890-01352
YU-33984
90890-01362
YU-33270-B
90890-01426
YU-38411
This tool is needed when removing or
installing the secondary sheave spring.
Radiator cap tester adapter
Radiator pressure tester adapter
YU-33984
This tool is used to check the cooling system.
Flywheel puller
Heavy duty puller
This tool is used to remove the AC magneto rotor.
Oil filter wrench
This tool is needed to loosen or tighten
the oil filter cartridge.
90890-01430
YM-38404
Ring nut wrench
This tool is needed to removing and
installing the middle driven shaft bearing
retainer.
1 - 14
GEN
SPECIAL TOOLS
Tool No. Tool name/How to use Illustration
Ball joint remover
90890-01474
YM-01474
These tools are used to removing or
installing the ball joints.
Gear lash measurement tool
Middle drive gear lash tool
90890-01475
YM-01475
This tool is used to measure the gear
lash.
Ball joint remover attachment set
Ball joint adapter set
90890-01480
YM-01480
These tools are used to removing or
installing the ball joints.
Final gear backlash band
Middle drive gear lash tool
90890-01511
YM-01230
This tool is needed when measuring the
final gear backlash.
INFO
90890-01514
YM-01514
90890-01701
YS-01880-A
90890-03079
YM-34483
90890-03081
YU-33223
90890-03112
YU-03112-C
Ball joint remover short shaft set
These tools are used to removing or
installing the ball joints.
Sheave holder
Primary clutch holder
This tool is needed to hold the primary
sheave when removing or installing the
sheave nuts.
Thickness gauge
Narrow gauge set
This tool is used to measure the valve
clearance.
Compression gauge
Engine compression tester
This tool is needed to measure engine
compression.
Pocket tester
Analog pocket tester
This instrument is needed for checking
the electrical systems.
1 - 15
GEN
SPECIAL TOOLS
Tool No. Tool name/How to use Illustration
Timing light
Inductive clamp timing light
90890-03141
YU-03141
This tool is necessary for checking ignition timing.
Pressure gauge
90890-03153
YU-03153
This tool is used to measure fuel pressure.
Belt tension gauge
Rear drive belt tension gauge
90890-03170
YM-03170
This tool is used to measure the steering
tension.
Digital circuit tester
Model 88 Multimeter with tachometer
90890-03174
YU-A1927
This tool is used to check the electrical
systems.
INFO
90890-03176
YM-03176
90890-04019
YM-04019
90890-04058
YM-04058
90890-04064
YM-04064-A
90890-04065
YM-04065-A
Fuel pressure adapter
This tool is used to measure fuel pressure.
Valve spring compressor
This tool is used to remove or install the
valve assemblies.
Middle driven shaft bearing driver
Bearing driver 40 mm
This tool is used to install the water pump
seal.
Valve guide remover (ø6)
Valve guide remover (6.0 mm)
This tool is needed to remove and install
the valve guides.
Valve guide installer (ø6)
Valve guide installer (6.0 mm)
This tool is needed to install the valve
guides.
1 - 16
GEN
SPECIAL TOOLS
Tool No. Tool name/How to use Illustration
Valve guide reamer (ø6)
90890-04066
YM-04066
90890-04081
YM-91044
Valve guide reamer (6.0 mm)
This tool is needed to rebore the new
valve guides.
Spacer (crankshaft installer)
Pot spacer
YM-91044
This tool is used to install the crankshaft.
Extension
INFO
90890-04082
90890-04086
YM-91042
90890-04128
YM-04128
90890-04130
YM-04059
This tool is used to measure engine compression.
Universal clutch holder
This tool is needed to hold the clutch carrier when removing or installing the carrier nut.
Bearing retainer wrench
Middle gear bearing retainer
This tool is needed when removing or
installing the bearing retainers.
Adapter (M16)
Adapter #13
90890-04132
YM-33221-A
This tool is used to install the crankshaft.
Mechanical seal installer
Water pump seal installer
This tool is used to install the water pump
seal.
1 - 17
GEN
SPECIAL TOOLS
Tool No. Tool name/How to use Illustration
Sheave spring compressor
90890-04134
YM-04134
This tool is needed when removing or
installing the secondary sheave spring.
Sheave fixed block
Sheave fixed bracket
90890-04135
YM-04135
INFO
90890-06754
YM-34487
90890-06760
YU-39951-B
90890-85505
This tool is needed when removing or
installing the secondary sheave spring.
Ignition checker
Opama pet-4000 spark checker
This instrument is necessary for checking
the ignition system components.
Digital tachometer
This tool is needed for checking engine
rpm.
Yamaha bond No. 1215
(Three bond No.1215
This bond is used on crankcase mating
surfaces, etc.
®
)
1 - 18
CHAPTER 2
SPECIFICATIONS
SPEC
GENERAL SPECIFICATIONS
ENGINE SPECIFICATIONS
CHASSIS SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES.........................................................2-16
CHASSIS TIGHTENING TORQUES.......................................................2-19
HOW TO USE THE CONVERSION TABLE
GENERAL TIGHTENING TORQUE SPECIFICATIONS
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE...................................................................................................2-23
........................................................................2-1
............................................................................2-5
........................................................................2-12
.................................................................2-14
..............................................................................2-16
..................................................2-22
...............................2-22
....................................2-23
COOLANT FLOW DIAGRAMS
OIL FLOW DIAGRAMS
CABLE ROUTING
.................................................................................2-26
.........................................................................................2-28
.....................................................................2-25
GENERAL SPECIFICATIONS
EBS01001
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
3B42, 3B46 (For CDN)
Model code
Dimensions
Overall length 2,065 mm (81.3 in)
Overall width 1,180 mm (46.5 in)
Overall height 1,240 mm (48.8 in)
Seat height 905 mm (35.6 in)
Wheelbase 1,250 mm (49.2 in)
Minimum ground clearance 275 mm (10.8 in)
Minimum turning radius 3,200 mm (126.0 in)
Basic weight
With oil and fuel 294.0 kg (648 lb)
Engine
Engine type Liquid-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 686.0 cm
Bore × stroke 102.0 × 84.0 mm (4.02 × 3.31 in)
Compression ratio 9.20 : 1
Standard compression pressure (at sea level) 450 kPa (4.50 kg/cm
Starting system Electric starter
Lubrication system
3B43, 3B47 (For Europe)
3B44 (For Oceania)
3
(41.86 cu. in)
2
, 64.0 psi)
Wet sump
SPEC
2 - 1
Item Standard
Oil type or grade
Engine oil
For CDN
0° 10° 30° 50° 70° 90° 110°
YAMALUBE4 (20W40) or SAE 20W40
YAMALUBE4 (10W30) or SAE 10W30
SAE 5W30
-20° -10° 0° 10° 20° 30° 40°
For Europe and Oceania
GENERAL SPECIFICATIONS
API service SE, SF, SG type or higher
130°F
50°C
JASO standard MA
SPEC
Final gear oil SAE 80 API GL-4 Hypoid gear oil
Differential gear oil SAE 80 API GL-4 Hypoid gear oil
Oil quantity
Engine oil
Periodic oil change 2.00 L (1.76 Imp qt, 2.11 US qt)
With oil filter replacement 2.10 L (1.85 Imp qt, 2.22 US qt)
Total amount 2.40 L (2.11 Imp qt, 2.54 US qt)
Final gear oil
Periodic oil change 0.20 L (0.18 Imp qt, 0.21 US qt)
Total amount 0.25 L (0.22 Imp qt, 0.26 US qt)
Differential gear case oil
Periodic oil change 0.215 L (0.19 Imp qt, 0.23 US qt)
Total amount 0.23 L (0.20 Imp qt, 0.24 US qt)
Radiator capacity (including all routes)
Air filter
1.99 L (1.75 Imp qt, 2.10 US qt)
Wet type element
Fuel
Type Regular unleaded gasoline only (For CDN and
Europe)
Unleaded gasoline only (For Oceania)
Fuel tank capacity 20.0 L (4.40 Imp gal, 5.28 US gal)
Fuel reserve amount 4.5 L (0.99 Imp gal, 1.19 US gal)
Fuel injector
Type/quantity 297500-1010/1
Manufacturer DENSO
2 - 2
GENERAL SPECIFICATIONS
Item Standard
Spark plug
Type/manufacturer CPR7EA-9/NGK
Spark plug gap 0.8 ~ 0.9 mm (0.031 ~ 0.035 in)
Clutch type
Transmission
Primary reduction system V-belt
Secondary reduction system Shaft drive
Secondary reduction ratio 41/21 × 24/18 × 33/9 (9.544)
Transmission type V-belt automatic
Operation Left hand operation
Single speed automatic 2.380 ~ 0.700 : 1
Sub transmission ratio low 31/16 (1.938)
high 29/25 (1.160)
Reverse gear 23/14 × 28/23 (2.000)
Chassis
Frame type Steel tube frame
Caster angle 5.0°
Camber angle 0°
Kingpin angle 11.0°
Kingpin offset 0 mm (0 in)
Trail 26.0 mm (1.02 in)
Tread front (STD) 940.0 mm (37.01 in)
Tread rear (STD) 915.0 mm (37.01 in)
Toe-in (with tires touching the ground) 0 ~ 10.0 mm (0 ~ 0.39 in)
Tire
Type front Tubeless
rear Tubeless
Size front AT25 × 8-12
rear AT25 × 10-12
Manufacturer/model front DUNLOP/KT421 (For CDN and Europe)
rear DUNLOP/KT425 (For CDN and Europe)
Tire pressure (cold tire)
Maximum load* 220.0 kg (485 lb)
Off-road riding front 32 ~ 38 kPa (0.32 ~ 0.38 kg/cm
rear 27 ~ 33 kPa (0.27 ~ 0.33 kg/cm
*Load is total weight of cargo, rider, accessories, and tongue
Brake
Front brake type Dual disc brake
operation Right hand operation
Rear brake type Dual disc brake
operation Left hand and right foot operation
Wet, centrifugal automatic
CHENG SHIN/C828-4P (For Oceania)
CHENG SHIN/C828-4P (For Oceania)
SPEC
2
, 4.6 ~ 5.5 psi)
2
, 3.9 ~ 4.8 psi)
2 - 3
GENERAL SPECIFICATIONS
Item Standard
Suspension
Front suspension Double wishbone
Rear suspension Double wishbone
Shock absorber
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/oil damper
Wheel travel
Front wheel travel 180 mm (7.1 in)
Rear wheel travel 230 mm (9.1 in)
Electrical system
Ignition system Transistorized coil ignition (digital)
Generator system AC magneto
Battery type YTX20L-BS
Battery capacity 12 V 18.0 Ah
Bulb type
Bulb voltage/wattage × quantity
Headlight 12 V 35.0 W/35.0 W × 2
Tail/brake light 12 V 21.0/5.0 W × 1
Indicator light
Neutral indicator light LED
Reverse indicator light LED
Coolant temperature warning light LED
Engine trouble warning light LED
EPS warning light LED
Park indicator light LED
On-command four-wheel drive/differential
gear lock indicator
High-range indicator light LED
Low-range indicator light LED
Differential gear lock indicator light LED
Halogen bulb
LCD
SPEC
2 - 4
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