Content      ..     4      5      6      7     ..

Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 6

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE

• After setting the toe-in to specification, run

Toe-in (with tires touching the

the vehicle slowly for some distance with

ground)

both hands lightly holding the handlebar

0.0-10.0 mm (0.00-0.39 in)

and check that the handlebar responds cor-

rectly. If not, turn either the right or left tie-

TIP

rod within the toe-in specification.

Before measuring the toe-in, make sure that the

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

tire pressure is correct.

a. Mark both tie-rods ends.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

This reference point will be needed during

a. Mark both front tire tread centers.

adjustment.

b. Face the handlebar straight ahead.

b. Loosen the tie-rod end locknuts “1” of both

c. Measure the width “A” between the marks.

tie-rods.

d. Rotate the front tires 180° until the marks are

c. The same number of turns should be given to

exactly opposite one another.

both the right and left tie-rods “2” until the

e. Measure the width “B” between the marks.

specified toe-in is obtained. This is to keep

f. Calculate the toe-in using the formula given

the length of the tie-rods the same.

below.

1

1

Toe-in = “B” - “A”

g. If the toe-in is incorrect, adjust it.

2

d. Tighten the tie-rod end locknuts to specifica-

tion.

Tie-rod end locknut (front wheel

side)

15 Nm (1.5 m·kgf, 11 ft·lbf)

Tie-rod end locknut (pitman arm

side)

15 Nm (1.5 m·kgf, 11 ft·lbf)

TIP

Adjust the tie-rod ends so that “A” and “B” are

equal.

C. Forward

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3. Adjust:

• Toe-in

EWB03750

WARNING

• Be sure that both tie-rods are turned the

same amount. If not, the vehicle will drift

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

right or left even though the handlebar is

4. Check:

positioned straight. This may lead to mis-

• Handlebar

handling and an accident.

3-22

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE

EBS30038

TIP

CHECKING THE ENGINE OIL LEVEL

After adjusting the toe-in, the handlebar should

1. Place the vehicle on a level surface.

be centered.

2. Check the engine oil level on a cold engine.

Refer to “INSTALLING THE HANDLEBAR”

TIP

on page 4-50.

If the engine was started before the oil level was

checked, be sure to warm up the engine suffi-

EBS30067

ciently, and then wait at least 10 minutes until

CHECKING THE ENGINE MOUNT

the oil settles for an accurate reading.

1. Check:

• Rubber damper

3. Remove:

Cracks/damage → Replace.

• Dipstick accessing cover

• Engine mounting bolts

Refer to “GENERAL CHASSIS (4)” on page

• Rubber damper nuts

4-11.

Loosen → Tighten.

4. Check:

Refer to “ENGINE REMOVAL (3)” on page

• Engine oil level

5-8.

The engine oil level should be between the

minimum level mark “a” and maximum level

EBS30068

CHECKING THE CONSTANT VELOCITY

mark “b”.

SHAFT ASSEMBLY DUST BOOTS

Below the minimum level mark → Add the

1. Check:

recommended engine oil to the proper level.

ECB01810

• Dust boots “1”

NOTICE

Damage → Replace.

Do not allow foreign materials to enter the

Refer to “FRONT CONSTANT VELOCITY

crankcase.

SHAFT ASSEMBLIES, DIFFERENTIAL AS-

SEMBLY AND FRONT DRIVE SHAFT” on

TIP

page 8-4 and “REAR CONSTANT VELOCI-

Insert the dipstick completely into the oil filler

TY SHAFT ASSEMBLIES, FINAL DRIVE

hole, and then remove it again to check the oil

ASSEMBLY AND REAR DRIVE SHAFT” on

level.

page 8-15.

A

1

1

B

Recommended brand

YAMALUBE

Type

SAE 0W-30, 10W-30, 10W-40,

15W-40, 20W-40 or 20W-50

Recommended engine oil grade

API service SG type or higher,

JASO standard MA

1

1

A. Front

B. Rear

3-23

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE

0

10

30

50

70

90

110

130 ˚F

SAE 0W-30

SAE 10W-30

SAE 10W-40

2

SAE 15W-40

SAE 20W-40

SAE 20W-50

-20

-10

0

10

20

30

40

50 ˚C

ECB01820

5. Drain:

NOTICE

• Engine oil

• Engine oil also lubricates the clutch and the

(completely from the crankcase)

wrong oil types or additives could cause

6. If the oil filter cartridge is also to be replaced,

clutch slippage. Therefore, do not add any

perform the following procedure.

chemical additives or use engine oils with a

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

grade of “CD” or higher and do not use oils

a. Remove the oil filter cartridge “1” with the oil

labeled “ENERGY CONSERVING II”.

filter wrench “2”.

• Do not allow foreign materials to enter the

crankcase.

Oil filter wrench

90890-01426

5. Check the engine oil level again.

Oil filter wrench

ECB01830

YU-38411

NOTICE

Be sure the engine oil is at the correct level,

otherwise engine damage may result.

6. Install:

• Dipstick accessing cover

Refer to “GENERAL CHASSIS (4)” on page

4-11.

EBS30039

2

1

CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several min-

utes, and then turn it off.

b. Lubricate the O-ring “3” of a new oil filter car-

2. Remove:

tridge with a thin coat of engine oil.

• Dipstick accessing cover

ECB01280

Refer to “GENERAL CHASSIS (4)” on page

NOTICE

4-11.

Make sure the O-ring “3” is positioned cor-

3. Place a container under the engine oil drain

rectly in the groove of the oil filter cartridge.

bolt.

4. Remove:

• Dipstick “1”

• Engine oil drain bolt “2”

(along with the gasket)

c. Tighten the new oil filter cartridge to specifi-

cation with the oil filter wrench.

3-24

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE

2. Remove:

Oil filter cartridge

• Side panel (left)

15 Nm (1.5 m·kgf, 11 ft·lbf)

Refer to “GENERAL CHASSIS (1)” on page

4-1.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

• Footrest board (left)

7. Install:

Refer to “GENERAL CHASSIS (4)” on page

• Engine oil drain bolt

4-11.

(along with the gasket

New

)

3. Start the engine, warm it up for several min-

utes, and then turn it off.

Engine oil drain bolt

ECB02550

22 Nm (2.2 m·kgf, 16 ft·lbf)

NOTICE

When the engine is cold, the engine oil will

8. Fill:

have a higher viscosity, causing the engine

• Crankcase

oil pressure to increase. Therefore, be sure

(with the specified amount of the recom-

to measure the engine oil pressure after

mended engine oil)

warming up the engine.

Engine oil quantity

4. Remove:

Quantity (disassembled)

• Main gallery bolt “1”

2.60 L (2.75 US qt, 2.29 Imp.qt)

EWB03630

Without oil filter cartridge re-

WARNING

placement

The engine, muffler and engine oil are ex-

2.00 L (2.11 US qt, 1.76 Imp.qt)

tremely hot.

With oil filter cartridge replace-

ment

1

2.10 L (2.22 US qt, 1.85 Imp.qt)

9. Install:

• Dipstick

10.Start the engine, warm it up for several min-

utes, and then turn it off.

11.Check:

• Engine

(for engine oil leaks)

12.Check:

5.

Install:

• Engine oil level

• Oil pressure gauge “1”

Refer to “CHECKING THE ENGINE OIL

• Adapter “2”

LEVEL” on page 3-23.

Pressure gauge

13.Install:

90890-03153

• Dipstick accessing cover

Pressure gauge

Refer to “GENERAL CHASSIS (4)” on page

YU-03153

4-11.

Oil pressure adapter H

14.Check:

90890-03139

• Engine oil pressure

Refer to “MEASURING THE ENGINE OIL

1

2

PRESSURE” on page 3-25.

EBS30458

MEASURING THE ENGINE OIL PRESSURE

1. Check:

• Engine oil level

Refer to “CHANGING THE ENGINE OIL” on

page 3-24.

3-25

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE

ECB01600

6. Measure:

NOTICE

• Engine oil pressure

(at the following conditions)

Take care not to allow foreign material to en-

ter the differential case.

Oil pressure (hot)

50.0 kPa/1600 r/min (0.50

kgf/cm²/1600 r/min, 7.3 psi/1600

r/min)

Out of specification → Check.

1

Engine oil pressure

Possible causes

• Faulty oil pump

• Clogged oil strainer

2

Below specification

• Leaking oil passage

• Broken or damaged

4. Check:

oil seal

• Differential gear oil filler bolt gasket

• Leaking oil passage

Damage → Replace.

Above specification

• Faulty oil filter

• Oil viscosity too high

5. Install:

• Differential gear oil filler bolt

7. Install:

(along with the gasket)

• Main gallery bolt

Differential gear oil filler bolt

• Gasket

New

23 Nm (2.3 m·kgf, 17 ft·lbf)

Main gallery bolt

35 Nm (3.5 m·kgf, 25 ft·lbf)

EBS30043

CHANGING THE DIFFERENTIAL GEAR OIL

LOCTITE®

1.

Place the vehicle on a level surface.

8. Install:

2.

Place a container under the differential case.

• Footrest board (left)

3.

Remove:

Refer to “GENERAL CHASSIS (4)” on page

• Differential gear oil filler bolt

4-11.

(along with the gasket)

• Side panel (left)

• Differential gear oil drain bolt “1”

Refer to “GENERAL CHASSIS (1)” on page

(along with the gasket)

4-1.

Completely drain the differential case of its

oil.

EBS30042

CHECKING THE DIFFERENTIAL GEAR OIL

LEVEL

1. Place the vehicle on a level surface.

2. Remove:

• Differential gear oil filler bolt “1”

(along with the gasket)

3. Check:

• Differential gear oil level

1

The differential gear oil level should be up to

the brim “2” of the hole.

4.

Install:

Below the brim → Add the recommended dif-

• Differential gear oil drain bolt

ferential gear oil to the proper level.

(along with the gasket

New

)

Type

Yamaha Friction Modified Plus

Differential gear oil drain bolt

Shaft Drive Oil (Part No.: ACC-

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

SHFTL-PL-32) or SAE 80 API

GL-4 Hypoid gear oil

3-26

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE

5. Fill:

• Differential case

1

(with the specified amount of the recom-

mended differential gear oil)

2

Type

Yamaha Friction Modified Plus

Shaft Drive Oil (Part No.: ACC-

SHFTL-PL-32) or SAE 80 API

GL-4 Hypoid gear oil

Quantity (disassembled)

4. Check:

0.23 L (0.24 US qt, 0.20 Imp.qt)

• Final gear oil level check bolt gasket

Quantity

0.22 L (0.23 US qt, 0.19 Imp.qt)

Damage → Replace.

5. Install:

ECB01600

• Final gear oil level check bolt

NOTICE

(along with the gasket)

Take care not to allow foreign material to en-

ter the differential case.

Final gear oil level check bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

6. Check:

• Oil level

EBS30041

Refer to “CHECKING THE DIFFERENTIAL

CHANGING THE FINAL GEAR OIL

GEAR OIL LEVEL” on page 3-26.

1.

Place the vehicle on a level surface.

7. Install:

2.

Place a container under the final drive case.

• Differential gear oil filler bolt

3.

Remove:

(along with the gasket)

• Final gear oil filler bolt “1”

(along with the gasket)

Differential gear oil filler bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)

EBS30040

1

CHECKING THE FINAL GEAR OIL LEVEL

1. Place the vehicle on a level surface.

2. Remove:

• Final gear oil level check bolt “1”

(along with the gasket)

3. Check:

• Final gear oil level

4.

Remove:

The final gear oil level should be up to the

• Final gear oil level check bolt

brim “2” of the hole.

(along with the gasket)

Below the brim → Add the recommended fi-

• Final gear oil drain bolt “1”

nal gear oil to the proper level.

(along with the gasket)

Type

Completely drain the final drive case of its oil.

Yamaha Friction Modified Plus

Shaft Drive Oil (Part No.: ACC-

SHFTL-PL-32) or SAE 80 API

1

GL-4 Hypoid gear oil

ECB01690

NOTICE

Take care not to allow foreign material to en-

ter the final drive case.

3-27

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE

5. Install:

• Radiator outlet hose “5”

• Final gear oil drain bolt

• Water jacket joint “6”

• Water pump outlet hose “7”

(along with the gasket

New

)

• Water pump outlet pipe “8”

Final gear oil drain bolt

• Water pump housing “9”

23 Nm (2.3 m·kgf, 17 ft·lbf)

• Water pump inlet hose “10”

• Cooling water hose joint “11”

6. Fill:

• Oil cooler inlet hose “12”

• Final drive case

• Oil cooler outlet hose “13”

(with the specified amount of the recom-

• Oil cooler “14”

mended final gear oil)

Cracks/damage → Replace.

Coolant leakage → Replace any damaged

Type

hose and pipe

Yamaha Friction Modified Plus

Refer to “RADIATOR” on page 6-4 and “WA-

Shaft Drive Oil (Part No.: ACC-

TER PUMP” on page 6-10.

SHFTL-PL-32) or SAE 80 API

GL-4 Hypoid gear oil

Quantity (disassembled)

0.25 L (0.26 US qt, 0.22 Imp.qt)

Quantity

2

0.20 L (0.21 US qt, 0.18 Imp.qt)

ECB01690

NOTICE

3

Take care not to allow foreign material to en-

ter the final drive case.

7. Check:

• Oil level

4

Refer to “CHECKING THE FINAL GEAR OIL

1

LEVEL” on page 3-27.

8. Install:

• Final gear oil level check bolt

(along with the gasket)

• Final gear oil filler bolt

(along with the gasket)

5

Final gear oil level check bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Final gear oil filler bolt

9

6

10

11

23 Nm (2.3 m·kgf, 17 ft·lbf)

7

13

EBS30034

CHECKING THE COOLING SYSTEM

1. Remove:

• Front fenders

Refer to “GENERAL CHASSIS (3)” on page

8

14

12

4-8.

• Footrest board (left)

Refer to “GENERAL CHASSIS (4)” on page

3.

Install:

4-11.

• Footrest board (left)

2. Check:

Refer to “GENERAL CHASSIS (4)” on page

• Radiator “1”

4-11.

• Radiator inlet hose “2”

• Front fenders

• Coolant reservoir “3”

Refer to “GENERAL CHASSIS (3)” on page

• Coolant reservoir hose “4”

4-8.

3-28

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE

EBS30035

CHECKING THE COOLANT LEVEL

1

1. Place the vehicle on a level surface.

TIP

The coolant level must be checked on a cold en-

a

gine since the level varies with engine tempera-

ture.

2. Check:

• Coolant level

The coolant level should be between the

EBS30036

maximum level mark “a” and minimum level

CHANGING THE COOLANT

mark “b”.

1. Remove:

Below the minimum level mark → Add the

• Side panel (left)

recommended coolant to the proper level.

ECB01300

• Side panel (right)

NOTICE

Refer to “GENERAL CHASSIS (1)” on page

4-1.

• Adding water instead of coolant lowers the

• Upper panel

antifreeze content of the coolant. If water is

Refer to “GENERAL CHASSIS (2)” on page

used instead of coolant check, and if nec-

4-6.

essary, correct the antifreeze concentra-

• Footrest board (left)

tion of the coolant.

Refer to “GENERAL CHASSIS (4)” on page

• Use only distilled water. However, if dis-

4-11.

tilled water is not available, soft water may

2. Remove:

be used.

• Coolant reservoir cap “1”

1

a

b

3. If the coolant is at or below the minimum level

3. Disconnect:

mark, remove the side panel (left).

• Coolant reservoir hose “2”

Refer to “GENERAL CHASSIS (1)” on page

4-1.

4. Remove the reservoir cap “1”, add coolant or

distilled water to the maximum level mark “a”,

install the reservoir cap and then install the

side panel (left).

Coolant reservoir (up to the maxi-

mum level mark)

0.25 L (0.26 US qt, 0.22 Imp.qt)

2

4. Drain:

• Coolant

(from the coolant reservoir)

5. Connect:

• Coolant reservoir hose

3-29

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE

6. Remove:

Coolant drain bolt

• Radiator cap “1”

EWB02770

8 Nm (0.8 m·kgf, 5.8 ft·lbf)

WARNING

10.Fill:

A hot radiator is under pressure. Therefore,

• Cooling system

do not remove the radiator cap when the en-

(with the specified amount of the recom-

gine is hot. Scalding hot fluid and steam may

mended coolant)

be blown out, which could cause serious in-

jury. When the engine has cooled, open the

Recommended antifreeze

radiator cap as follows:

High-quality ethylene glycol an-

Place a thick rag or a towel over the radiator

tifreeze containing corrosion in-

cap and slowly turn the radiator cap counter-

hibitors for aluminum engines

clockwise toward the detent to allow any re-

Mixing ratio

sidual pressure to escape. When the hissing

1:1 (antifreeze:water)

sound has stopped, press down on the radi-

Radiator (including all routes)

ator cap and turn it counterclockwise to re-

1.76 L (1.86 US qt, 1.55 Imp.qt)

Coolant reservoir (up to the maxi-

move.

mum level mark)

0.25 L (0.26 US qt, 0.22 Imp.qt)

Handling notes for coolant

Coolant is potentially harmful and should be

handled with special care.

EWB02780

WARNING

1

• If coolant splashes in your eyes, thorough-

ly wash them with water and consult a doc-

tor.

7. Remove:

• If coolant splashes on your clothes, quickly

• Coolant drain bolt “1”

wash it away with water and then with soap

(along with the copper washer)

and water.

TIP

• If coolant is swallowed, induce vomiting

and get immediate medical attention.

Place a container under the engine, and then re-

ECB01310

move the coolant drain bolt. (Use a trough “2” or

NOTICE

a similar

object as shown to prevent coolant

from spilling

on the engine guard.)

• Adding water instead of coolant dilutes the

antifreeze concentration of the coolant. If

water is used instead of coolant; check,

and if necessary, correct the antifreeze

1

concentration of the coolant.

• Use only distilled water. However, if dis-

tilled water is not available, soft water may

be used.

2

• If coolant comes into contact with painted

surfaces, immediately wash them with wa-

ter.

• Do not mix different types of antifreeze.

8. Drain:

• Coolant

11.Install:

(from the engine and radiator)

• Radiator cap

9. Install:

12.Fill:

• Coolant drain bolt

• Coolant reservoir

(with the recommended coolant to the maxi-

(along with the copper washer

New

)

mum level mark “a”)

3-30

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE

13.Install:

Thermostat cover air bleed bolt

• Coolant reservoir cap “1”

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

1

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

15.Start the engine, warm it up for ten minutes,

a

and then rev the engine five times.

16.Pour the recommended coolant into the radi-

ator until it is full.

17.Stop the engine and allow it to cool. If the

coolant level has dropped after the engine

has cooled, add sufficient coolant until it

reaches the top of the radiator, and then in-

14.Bleed:

stall the radiator cap.

• Cooling system

18.Check:

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a.

Loosen the water pump air bleed bolt “2”,

• Coolant level

without removing it, to allow all of the air to es-

Refer to “CHECKING THE COOLANT LEV-

cape from the air bleed bolt hole.

EL” on page 3-29.

19.Start the engine, and then check for coolant

leakage.

20.Install:

• Footrest board (left)

Refer to “GENERAL CHASSIS (4)” on page

4-11.

• Upper panel

Refer to “GENERAL CHASSIS (2)” on page

2

4-6.

• Side panel (left)

b.

When coolant begins to flow out of the bolt

• Side panel (right)

hole, tighten the water pump air bleed bolt to

Refer to “GENERAL CHASSIS (1)” on page

specification.

4-1.

EBS30053

Water pump air bleed bolt

CHECKING AND LUBRICATING THE

8 Nm (0.8 m·kgf, 5.8 ft·lbf)

CABLES

The following procedure applies to all of the in-

c.

Loosen the thermostat cover air bleed bolt

ner and outer cables.

“3”, without removing it, to allow all of the air

EWB02820

to escape from the air bleed bolt hole.

WARNING

Damaged outer cable may cause the cable to

corrode and interfere with its movement. Re-

place damaged outer cable and inner cables

3

as soon as possible.

1. Check:

• Outer cable

Damage → Replace.

2. Check:

• Cable operation

d.

When coolant begins to flow out of the bolt

Rough movement → Lubricate.

hole, tighten the thermostat cover air bleed

bolt to specification.

Recommended lubricant

Engine oil or a suitable cable lu-

bricant

3-31

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE

TIP

2.

“H” (high)

Hold the cable end upright and pour a few drops

3.

“L” (low)

4.

“R” (reverse)

of lubricant into the cable sheath or use a suit-

able lubricating device.

5.

“P” (park)

6. Drive select lever shift control cable

3. Apply:

7. Drive select lever shift rod

• Lithium-soap-based grease

1. Adjust:

(onto end of the cable)

• Brake pedal free play

EBS30464

Refer to “ADJUSTING THE REAR DISC

LUBRICATING THE LEVERS

BRAKE” on page 3-12.

Lubricate the pivoting point and metal-to-metal

2. Remove:

moving parts of the levers.

• Handle mounted light cover

Refer to “REPLACING THE HANDLE

Recommended lubricant

MOUNTED LIGHT BULB” on page 3-34.

Silicone grease

• Side panel (left)

EBS30465

Refer to “GENERAL CHASSIS (1)” on page

LUBRICATING THE PEDAL

4-1.

Lubricate the pivoting point and metal-to-metal

3. Adjust:

moving parts of the pedal.

• Drive select lever shift control cable

• Drive select lever shift rod

Recommended lubricant

Lithium-soap-based grease

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

Drive select lever shift control cable:

EBS30462

a. Make sure that the drive select lever is in “N”

ADJUSTING THE DRIVE SELECT LEVER

(neutral).

CONTROL CABLE AND SHIFT ROD

b. Squeeze the brake lever 15-25 mm (0.59-

ECB02700

0.98 in) “a”, loosen the locknut “1”, and then

NOTICE

adjust the shift control cable “2” with the ad-

Before moving the drive select lever, bring

juster “3” so that the drive select lever can be

the vehicle to a complete stop and return the

shifted to “R” (reverse) from “N” (neutral), and

throttle lever to its closed position. Other-

to “P” (park) from “R” (reverse).

wise the transmission may be damaged.

1

4

2

a

5

3

7

2

1

3

6

1.

“N” (neutral)

3-32

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE

EBS30446

c. Release the brake lever so that “a” is 0 mm (0

ADJUSTING THE THROTTLE LEVER FREE

in), and then verify that the drive select lever

PLAY

cannot be shifted to “R” (reverse) from “N”

1. Check:

(neutral), or to “P” (park) from “R” (reverse).

• Throttle lever free play “a”

d. If the operation of the drive select lever is in-

Out of specification → Adjust.

correct, repeat steps (a) to (c).

e. Tighten the locknut.

Throttle lever free play

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3.0-5.0 mm (0.12-0.20 in)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

Drive select lever shift rod:

a.

Make sure the drive select lever and trans-

mission are in “N” (neutral).

b.

Loosen both locknuts “1”.

2WD

4WD

c.

Adjust the length “a” of the shift rod to 410

mm (16.1 in).

N

a

2.

Remove:

a

•

Storage compartment

Refer to “GENERAL CHASSIS (5)” on page

4-17.

N

3. Adjust:

1

• Throttle lever free play

d.

Tighten the locknuts.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

Throttle body side

Drive select lever shift rod lock-

a. Slide back the rubber cover “1”.

nut (select lever unit side)

b. Loosen the locknut “2” on the throttle body

8 Nm (0.8 m·kgf, 5.8 ft·lbf)

side.

Drive select lever shift rod lock-

nut (shift arm side)

c. Turn the adjusting nut “3” in direction “a” or “b”

8 Nm (0.8 m·kgf, 5.8 ft·lbf)

until the correct free play is obtained.

e.

Start the engine, and then check that the

Direction “a”

drive select lever can be shifted to each shift

Free play is increased.

Direction “b”

position and that the appropriate indicator

Free play is decreased.

light comes on when the lever is in each po-

sition.

TIP

If the neutral indicator light does not come on

when the drive select lever is in the “N” (neutral)

position, stop the engine. Then, with the drive

b

select lever in the “N” (neutral) position and with-

out opening the throttle, start the engine and

check that the neutral indicator light comes on.

a

f. Adjust the shift control cable again if neces-

2

3

1

sary.

d. Tighten the locknut.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

e. Slide the rubber cover to its original position.

3-33

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE

TIP

Speed limiter length

If the free play cannot be adjusted here, adjust it

12 mm (0.5 in)

at the handlebar side of the cable.

2. Adjust:

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

• Speed limiter length “a”

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

Handlebar side

a. Loosen the locknut “1”.

a. Slide back the rubber cover “1”.

b. Turn the adjuster “2” in direction “b” or “c” until

b. Loosen the locknut “2”.

the specified speed limiter length is obtained.

c. Turn the adjusting bolt “3” in direction “a” or

“b” until the correct free play is obtained.

Direction “b”

Speed limiter length is decreased.

Direction “a”

Direction “c”

Free play is increased.

Speed limiter length is increased.

Direction “b”

Free play is decreased.

a

2

3

2

1

b

b

a

2WD

4WD

c

1

c. Tighten the locknut.

EWB03830

WARNING

d.

Tighten the locknut.

e.

Slide the rubber cover to its original position.

• Particularly for a beginner rider, the speed

EWB03810

limiter should be screwed in completely.

WARNING

Screw it out little by little as their riding

After adjusting the throttle cable free play,

technique improves. Never remove the

start the engine and turn the handlebar to the

speed limiter for a beginning rider.

right and to the left to ensure that this does

• For proper throttle lever operation, do not

not cause the engine idling speed to change.

turn out the adjuster more than the speci-

fied length. Also, always adjust the throttle

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

cable free play to within specification.

4. Install:

• Storage compartment

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Refer to “GENERAL CHASSIS (5)” on page

EBS30593

4-17.

REPLACING THE HANDLE MOUNTED LIGHT

BULB

EBS30463

1. Remove:

ADJUSTING THE SPEED LIMITER

• Quick fastener “1”

The speed limiter keeps the throttle from becom-

• Handle mounted light cover “2”

ing fully-opened even when the throttle lever is

applied to the maximum position. Screwing in

the adjusting screw stops the engine speed from

increasing.

1. Measure:

• Speed limiter length

Out of specification → Adjust.

3-34

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE

ECB02990

NOTICE

Avoid touching the glass part of the handle

2

mounted light bulb to keep it free from oil,

otherwise the transparency of the glass, the

1

life of the bulb and the luminous flux will be

adversely affected. If the handle mounted

light bulb gets soiled, thoroughly clean it

with a cloth moistened with alcohol or lac-

1

quer thinner.

2.

Remove:

5. Install:

• Handle mounted light bulb cover “1”

• Handle mounted light bulb holder

TIP

Install the handle mounted light bulb holder by

pushing it in and turning it clockwise.

6. Install:

• Cover at the rear of the handle mounted light

7. Install:

• Handle mounted light cover “1”

1

• Quick fastener

3.

Remove:

• Handle mounted light bulb holder “1”

• Handle mounted light bulb

EWB03940

WARNING

Since the handle mounted light bulb gets ex-

tremely hot, keep flammable products and

1

your hands away from the bulb until it has

cooled down.

EBS30594

TIP

ADJUSTING THE HEADLIGHT AND HANDLE

Remove the handle mounted light bulb holder by

MOUNTED LIGHT BEAMS

pushing it in and turning it counterclockwise, and

1. Adjust:

then remove the defective bulb.

• Headlight and handle mounted light beam

(vertically)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Turn the adjusting screw “1” in direction “a” or

1

“b”.

Direction “a”

Light beam is raised.

Direction “b”

Light beam is lowered.

4. Install:

• Handle mounted light bulb

New

Secure the new handle mounted light bulb

with the handle mounted light bulb holder.

3-35

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE

A

a

b

1

B

b

a

1

A. Headlight (left and right)

B. Handle mounted light

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

3-36

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------

GENERAL CHASSIS (1)

EBS20024

GENERAL CHASSIS (1)

Removing the skid plates

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

3

2

1

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

1

Front skid plate

1

2

Center skid plate

1

3

Rear skid plate

1

4-1

Content      ..     4      5      6      7     ..