2014 SXS 700M2 M4 Service Manaul

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HOW TO USE THIS MANUAL
A Few Words About Safety
Service Information
The service and repair Informal.on conlalned In this manual IS Inlended for use by qual,red. professional technicians. Attempting
service Of repairs WithoUt the proper training. 1000s, and equipment could cause Injury to you or others. It could also damage the
vehide or create an unsafe cOf'lchlion.
ThIS manual describes the proper methods and procedures for performing service, mBtrllenance and repairs Some procedures
require the use 01 speoally designed tools and dedicated eqUipment Any person who Inlends to use a replacement part service
procedure or a 1001 thai is nol recommended by Honda must determine the nsks to their personal safely and the safe operal!on of
the vehicle
If you need to replace a part. use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of Infenor quality.
For You r Customer's Safety

Proper service and maintenance are essential 10 the customer s safety and the reliability of the vehICle Any error or oversight wMe
servicing a vehICle can result In faulty operation, damage to the vehiCle. or Injury to others.
AWARNING
Improper service and repairs can create an unsafe
condition that can cause your customer to be
senously hurt or killed
Follow the procedures and precautions in thiS
manual and other service matenals carefully.
For Your Safety

Because thiS manual IS Intended for the professIOnal service technICIan we do not provide warnings about many baSIC shop safety
prac!ICeS (e 9 . Hot parts-wear gloves). If you have not receIVed shop safety training or do not feel confident about your knowledge
of safe serviCing practice, we recommend that you do not attempt to perform the procedures descflbed In thiS manual.
Some of the most important general service safety precautions are given below However, we cannot warn you of every
concel'lable hazard thaI can arise In perforrmng set-up and pre--deilvery procedures Only you can deCide whether Of not you should
perform a given task
AWARNING
FaLlure 10 properly follov.'lnstructlons and
precautions can cause you to be senously hurt or
killed
Follow the procedures and precautions In thiS
manual carefully.
Important Safety Precautions

Make sure you have a clear understand.ng of a.1 baSIC shop safety practICes and that you are ...... eanng appropriate dontlng and
USing safety equipment. When performing any service tasi( be espeoa'ly careful of Ihe fOllOWing:
Read all of the Instructions before you begin, and make sure you have the 10015. the replacement or repa,r parts. and the skills
required to perform the tasks safely and completely.
Protect your eyes by USing proper safety glasses. goggles or face shields any\lme you hammer, drill, gnnd. pry or work around
pressunzed air or liqUids and springs or other slored--energy components. If there IS any doubt put on eye protectIon.
Use other protective wear when necessary for example gloves or safety shoes Handiing hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like It can hun you. Slop and put on gloves
Protect yourself and others whenever you have the vehicle up In the air Any tUTIe you lift the vehicle either .....Ith a holSt or a Jack
make sure that II is always securely supponed. Use jack stands
Make sure the engme IS off before you begin any servICing procedures unless the nSlructlon teUs you to do otherwise. This will
help elimmate several potential hazards
Carbon monoXide poisoning from engine exhaust. Be sure there is adequate ventilallon whenever you run the engine
, Bums from hot pans or COOlant. Let the engine and exhaust system cool before workmg In those areas
Inlury from mOVing pans If the ,nslructJC)n tells you to run the eng 00, be sure your hands. fingers and clothtng are oul of the way
Gasolme vapors and hydrogen gases from banenes are expiOStVe To reduce the poss:bility of a fire or eJl:plosk>n. be careful .... hen
working around gasoline or battenes.
Use only a nonflammable solvent not gasOl,ne, to clean parts.
Never drain or store gasoline In an open container.
Keep all cigarettes. sparks and names away from the battery and all fiJel-relaled parts
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How To Use This Manual
This manual describes the service procedures for Ihe SXS700.
Sections 1 and 3 apply to the whole vehicle. Section 2 illustrates procedures for removal/installation of components that may be
required to perform service described in the following sections.
Section 4 through 22 describe parts of the vehicle, grouped according to location.
If you are not familiar wilh this vehicle, read Technical Features in Section 1.
Follow the Maintenance Schedule recommendations to ensure thai the vehicle is in peak operating condition .
Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in
period.
Find the section you want, then turn to the table of contents on the first page of the section .
Most sections start with an assembly or system illustration , service information and troubleshooting for the section. The subsequent
pages give detailed procedure.
Refer to the troubleshooting In each section according to the malfunction or symptom. In case of an engine trouble , refer to PGM-Fl
section troubleshooting first.
Your safety. and the safety of others. is very Important. To help you make informed decisions we have provided safety
messages and other information throughout this manual. Of course. it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle.
You must use your own good Judgement.
You Will find important safety information in a variety of forms including :
Safety Labels - on the vehicle
Safety Messages - preceded by a safety alert symbol ! and one of three signal words . DANGER . WARNING. or CAUTION.
These signal words mean:
tfi.tVI3Mji You WILL be KILLED or SERIOUSLY HURT if you dan', follow instructions.
You CAN be HURT if you don't follow instructions.
Instructions - how to service this vehicle correctly and safely.
As you read this manual , you will find information that IS preceded by a [NOner symbol. The purpose of this message is to help
prevent damage to your vehicle. other property, or the environment.
Date of Issue: August. 2013

SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
I Replace the par1(s) with new ona(s) before assembly.
Use the recommend engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ralio of 1:1)
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NlGl #2 or
equivalent).
Example:
Molykote BR-2 plus manufactured by Dow Corning U.S.A.
___ _ _ _ _--;.~M~"~I~ti-~purpose M-2 manufactured by Mitsubishi 0'2'il.~J~a~p~a~n~==~~==~=
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NlGI #2 or
equivalent).
Example:
Molykote G-n Paste manufactured by Dow Corning U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocollimited, U.K.
_ __ _ _ _ _+--'-~R~O~C~OI Paste manufactured by Sumico Lubricant, Japan
Use silicone grease.
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
1
Use only DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use fork or suspension fluid.

CONTENTS
GENERAL INFORMATION
FRAME/BODY PAN ELS/EXHAUST SYSTEM
MAINTENANCE
PGM-FI SYSTEM
IGNITION SYSTEM
~ F=~
EL=E~C~T~R=IC~S~T=
A~R~
TE~R~=========================
~ F=~
FU~E~L~SY
~S~T~E~M===============================
o
w
F=~~~~~~==~=====================
LUBRICATION SYSTEM
m
z
F=~~~~~==~==========================
COOLING SYSTEM
~ F=~CY~L~I~N~D~E~R~H~E~A~D~N~A~L~V~E~/C~A~M~S~H~A~F=T~==============
~ ~==================================
W CYLINDER/PISTON
> ~============~====================
~ ALTERNATOR/STARTER CLUTCH
zw F=======~======~==================
SUB-TRANSMISSION/GEARSHIFT LINKAGE
z~ F=====~~======~~==============
CRANKCASE/CRANKSHAFT/BALANCER
w F=~==~~~==========================
ENGINE REMOVAL/INSTALLATION
DRIVETRAIN SYSTEM
STEERING SYSTEM
~ ~==================================
~ DRIVE SHAFT/FINAL GEAR
~ ~==~===============================
WHEEL/SUSPENSION
GF=~===================================
BRAKE SYSTEM
;1 BATTERY/CHARGING SYSTEM
wU F=~~~~~~~~~~======================
~~ LIGHTS/METERS/SWITCHES
~u l=~~~~~~~=============================
~w
u: WIRING DIAGRAM
INDEX

MEMO

1. GENERAL INFORMATION
SERVICE RULES . ............ 12 CABLE & HARNESS ROUTING ............. 1-17
MODEL IDENTIFICATION 1 2 EMISSION CONTROL SySTEMS 1-32
SPECIFICATIONS"""""""""" " """""" 1-4 LIFT AND SUPPORT POINTS

1-33
TORQUE VALUES .. .... ..... 1-9 TECHNICAL FEATURES ............. ......... 1-34
LUBRICATION & SEAL POINTS ............ 114
1-1
GENERAL INFORMATION
SERVICE RULES
1. Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts thai do not meet Honda's design
specifications may cause damage to the vehicle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the vehicle. Metric bolls, nuts and screws are not interchangeable with English fasteners.
4. Install new gaskets . O-rings , cotter pins. and lock plates when reassembling.
5. When tightening bolls or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in
Incremental sleps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as show in the Cable and Harness Routing (page 1- 17).
ABBREVIATION
Throughout this manual , the following abbreviations are used to identify the respective parts or systems .
tf. AfTAbb,ev. te~:~~ii~~~~;

CKP sensor
Clutch PC solenoid
ii
DLC Data
OTC
ECT sensor
ELR
EDT -sensor
IACV ~ Idle Air Control Valve
IAT sensor Intake Air
MAP sensor ; I
MCS
Indicator Lamp
OPS Protective Structure
PCM Control Module
(ECMITCM) i i Control McKlule ) _ _
PGM-FI
SCS connector Check
TP sensor Position sensor
VS sensor Vehicle Speed sensor
2WD. 4WD 2 Wheel Drive, 4 Wheel Drive
MODEL IDENTIFICATION
4 person type shown:
12
GENERAL INFORMATION
TYPE CODE
This manual covers following types of SXS700:
4 PERSON TYPE :
TYPE CODE REGION
AG, III AC U.S ,A. (50 stale model), Australia, New Zealand
eM, 111 eM Canada
2 PERSON TYPE :
TYPE CODe
II AG, IVAC
II eM, IVCM t: REGION
U.S.A. (50 stale model), Australia, New Zealand
Canada
Be sure to refer to the procedure for the appropriate version of the SXS700.
]
SERIAL NUMBERS/LABELS
t:r'y)
V.I.N. (Vehicle Identification Number)
EMISSION CQNTROllNFQRMATIQN
THROTTLE BODY IDENTIFICATION NUMBER
r ~BEL,lcaoad;
~
-/ -~ ~~
COLOR LABEL
-~A~
EMISSION CONTROL
INFORMATION LABEL
MANUFACTURERS LABEL
Icaoa? ooly)
MANUFACTURERS LABEL
1-3
GENERAL INFORMATION
SPECIFICATIONS
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overa!1 length 2.910 mrn (114.6 in)
Overall width 1,525 mm (60.0 in)
I - 1,985 mm (78 .1 in)- -
Overall height 4 person type:
2 person type: 1,970mm (77.6 in)
Wheelbase 1,950 mm (76.8 in)
Front tread 1.321 mm {52.a in)
Rear tread 1,270 mm (50.0 "in)
Seat height 868 mm (34.2 in)
Floor height 458 mm (1S.a in)
Ground clearance 270 mm (10.6 in)
Curb weight 4 person , AC type: 633 kg (1,396Jbs)
4 person , eM type: 634 kg (1,398Ibs)
2 person , AC type: 572 kg (1,2611bs)
2 person , eM type: 573 kg ( 1,263Ibs)
Maximum weight capacity 784 kg ( 1,728 Ibs)
I FRAME " Frame typ:oe= =_ _ _ _ _ _ _ _ _ _ _--';S~e"m:;'-;;I''''do;de;:'~'~p;;:'''';e'-----
Front su spension Double wish-bone
~F~'~O~"t~w~h~e~e~It~'"~v~el
'=====:======~32~oo~mm
5
(7.9 in) - -- - I
~ Front damper Double lube
Rear suspension _ _ -t--;Double wish-bone
Rear wheel travel 230 mm (9 1 in)
Rear damper Double tube
Front tire size is x B.OO-12NHS
Rear tire size 25 x 10.00-12NHS
Front rim size 12x6.0AT
Rear rim size 12x7.5AT
Front tire brand BLACKSTONE-OTR HP-007
Rear lire brand BLACKSTONE-OTR HP-007
Front brake Hydraulic disc brake
<
Rear brake Hydraulic disc brake
Casler angle 3" ,
Trail length 14 mm (0.55 in )
Camber angle 0"
Fuel tank capacity 30 liters (7.9 US gal, 6.6 Imp gal)
Fuel tank reserve capacity 4.51i1ers (1 .19 US gal , 0 .99 Imp gal)
ENGINE Cylinder arrangement Single cylinder, longitudinally installed
Bore and stroke 102 x 82.6 mm (4.02 x 3.25 in)
Displacement 675 cm (41 .2 cu-in) <
Compression ratio 9.2: 1
Valve train DHV
Intake valve opens at 1 mm (0.04 in) lift 3 0 BTDC -j
Intake valve closes at 1 mm (0.04 in) lift 40 0 ABDC
Exhaust valve opens at 1 mm (0.04 in) lift
Exhaust valve closes at 1 mm (0.04 in) lift
40 0 BBDC
0" TOC
i
r-~ubricalion system Forced pressure ~emi-dry sump)
Oil pump type Trochoid
Cooling system liquid cooled
Air filtrahon Oiled double urethane foam
t-~ngine dry weight _ f--?O.S kg (133.4Ib'1
! "UEL OELIVERY- Type _ PGM-FI (Programmed Fuel Injection)
SYSTEM I--Throttle bore 40 mm (1.6 in)
1-4
GENERAL INFORMATION
ITEM SPECIFICATIONS
DRIVETRAIN Transmission Automatic (Torque converter + 3-speed drive
system and reverse)==="",,,
Shift dutch (1st. 2nd and 3rd clutches) Multi-plate. wet (hydraulic clutch with electriC
controlled)
Primary reduction 1.333 (64/48 )
Secondary reduction Forward 2.562 (41116)
Reverse ::=:::;:j 3.153 (41113)
Final reduction Front 3.462 (45/13)
Rear 3.462 (45/13)
T ransmission ratio 15' - +-><
2."05"2 (39119)
2,d 1.416 (34/24)
3,d 0.933 (28130)
=====o-___-;R~,everse
Gearshift pattern Sub-transmission
2.138 (39119 x 25/24)
Reverse (R) - Neutral (N) - Drive (D)
o 3-speed automatic
R Fixed low ratio
Drive mode select pattern 2WD - 4WQ - 4WQ (Differential lock)
ELECTRICAL Ignition system Fun Transistorized Ignition

Starting system Electric starter motor
Charging system Tnple phase outpui',a""'-'."'''''a''''o'''- -- -
Regulatorlrectifier FET shorted , triple phase full wave rectification
Ughting system Battery
PGMFI SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
ECT sensor resistance (40~~CP./1~04~~F'!)=======:_;- 1.0 1.31<.0
IAT sensor resis tance (20 C/68"F,- ) _ _ _ _ __ _ ...J.t 2.2 2.7 kO
IGNITION SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
r
~park plug BKRSE-ll (NGK), KI6PR-=-Ul1 (DEN SO)
Spark plug gap 1.00 - 1.10 mm (0.039 - 0.043 in)
~gnition coil peak voltage - 100 V minimum
- - -0;';.7 V minimum
CKP sensor pea~k~'~O~"a~g~.~=====__
r Ignition timing ____"' S__ ' -."BTDC at idle
ELECTRIC STARTER SPECIFICATIONS
IT
TEEMM' - - - - --::..._+-. ' [======~~Unit:
STANDA,!O mm (in )
SERVICE LIMIT
Starter motor brush length I 12.0 (0.47) _ _ _~",
6 ",
5 (0.26)
FUEL SYSTEM SPECIFICATIONS

ITEM T - - - -..S'"P"E"C""I FICATIONS
Throttle body identificat';,o
;","',"u;;;m"be;;;C,- - - - t GQ6JA
Idle speed t- 1,400:1 100 rpm
Accelerator pedal freeplay + 5 10 mm (3/ 16 318 in)
Fuel injector resistance (2"0. C ,' I6""'8" F")- - - -- 11 .1 12.30
Fuel pressure 331 - 367 kPa (3.4 3.7 kgf/cm 2, 48 - 53 psi)
Fuel pump now (at 12 V) 356 cm3( 12.0 us o 12.51mp oz ) minimumJl0 seconds

15
GENERAL INFORMATION
LUBRICATION SYSTEM SPECIFICATIONS
,I
II
i I oil
I I i SG or higher
(except oils labeled as energy conserving
on the circular API service label)
JASO T 903 standard: MA
SAE 10W-30
il pump rotor I I
I
I
COOLING SYSTEM SPECIFICATIONS
"
" iii
ill
CYLINDER HEADNALVE/CAMSHAFT SPECIFICATIONS

Unit: mm (in
ITEM , LIMIT
I , I
Valve IN 1 , '5'~(00061 -
EX 1,32 I, 1 (0,013 I -
Valve IN 161) 5,45 1,2'

~:I~:gUide
~X
IN
~~ i:55'5) ~5)
EX 0,14 0,006)
Valve gUI.~e.l . i 18, 15.25~0~~~ -
above 1 I head 73--=--,-" 58,- ,
Valve ,eal wldlh ' ~~EX ,00 ~(~~~t"39 - 0,043) 1.4 1,06)
~-
Valve spring Free length 37.20 . 36,3 1.43
4' ,2U11.74 43,
"OeKei aim >-"
ffi -
"",
I Shaft 0.0, INIEX 1' 964 - 1 Taf ,0:4718)
clearance INIEX 0.016 0.054 m.1 0,08 (0,00
~am loDe nelgm IN S- 34("3" (1,000
cam fol!o~~~a I,''''''
"' , - 30,1430 \ "ou00 - '

J'7~R';:6)
~~
CamlOik ; _ ORR," 1,46
~482
" bOle 10, , ) - ',526 1-1, 22,54 ~.
- 0,059 (0, J011
" INIEX 007 (11.003)
"
'(0,002) _
,,1-6
GENERAL INFORMATION
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERV IC E LIMIT
Cylinder 1.0. 102.000 -102.015 (4.0157 - 4.0163)
'0205 (40': J
Out-af-round - 0.05 (0.002)
Taper - 0.05 (0 .002 )
Warpage 0.05 (O.D02)
Piston, Piston 0.0. at 20 (0.8) from bottom r-~?1.960 101.990 (4 . 014~O153 ) 101.90 (4.012)
piston pin , Piston pin hole 1.0. 23.002 - 23.008 (0.9056 - 0.9058) 23 .03 (0.907)
piston ring Piston pin 0 .0. 22.994 23.000 (0.9053 0.9055) 2298 (0.905)
Piston-la-piston pin clearance 0.002 0.014 (0.0001 0.0006) , 0.04 (0 .002)
Piston ring end gap Top 0.25 0.35 (0.0'0 0.014) 0.5 (0.02 )
Second 0.40 0.55 (0.016 0.022) 0.7 (0.03)
Oil (side rail) 0 .20 0.70 (0.008
0.028) 0 .9 (0.04)
,
Piston ring-la-ring Top 0.045 0.080 (0.0018 0.0031 ) 0.095 (0.0037)
groove clearance Second 0.025 0.060 (O.D01O 0.0024) 0 .075 (0.0030)
Cylinder-to-piston c learance 0.010 0,055 (0.0004 0.0022) 0.19 (0 .007)
Co_nnecting rod small end t.O. 23.030 23.050 (0.9067 0.9075) 23.06 (0.908)
Connecting rod-to-piston pin clearance 0.030 0.056 (0.0012 0.0022) 0.08 (0.003)
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

Unit" mm (in)
ITEM STANDARD SERVICE LIMIT
Starter driven gear boss 0 .0 . _ 51 .705 - 51 .718(2.0356 - 2.0361)
~ Torque limiler slip torque 53 84 N' m (5.4 8 .6 kgf-m,
39 - 62 IbUt)
SUB-TRANSMISSION/GEARSHIFT LINKAGE SPECIFICATIONS

Unit: mm (in )
ITEM STANDARD SERV ICE LIMIT
Shift fork t.o. _____+-.;.'",'."00,,,0.,,-,,':';'7,.0,,2.;,1 (0.4331 - 0.4 339) _ - ! -11 .04 (0.435)
Claw thickness 4.93 5.00 (0.194 - 0.197) 4.5 (0.18)
S~h=
aft
~ O~.D~._ _ _ _ _ _ _ _~~,0
~.~
9B~B~'~0~
.9=8~
4~(0~.4~3~
'~7 _-~
0~.4~
32~4~)_ _~_,~0~ 6 (0.431 )
.9=
CRANKCASE/CRANKSHAFT/BALANCER SPECIFICATIONS
Unit: mm (in)
Crankshaft Runout 0.05 (0.002) 0.15 (0.006)
Big end side clearance 0.05 - 0 .65 (0 .002 - 0.026) 0.8 (0.03)
Big end radial clearance 0.006 0.Q18 (0.0002 0.0007) 0 .05 (0.002 )
DRIVETRAIN SYSTEM SPECIFICATIONS

Unit: mm (in)
Oil pressure at Line 785 kPa (8 .0 kgf/cm 2, 114 psi)
5,000 rpm 1st, 2nd and 3rd clutch 785 kPa (8 .0 kgf/cm 2, 114 psi )
Shift clutch (1 st, Initial clearance 0.7 - 0.9 (0.03 - 0.04)
2nd and 3rd) Disc thickness _ _t-:' 'ii.8c.c8~2Ci.0",0c:(0:c.0:c7>i4.--i0c;.Oiii7Ci9f-)_ _ _ _ _ _w"'o:c;'"n,out lining
Plate thickness 1.95 - 2.05 0.077 - 0 .081 ) discoloration
Return spring free length 33.8 (1 .33) 31 .B (1.25)
EDT sensor resistance (20 C/6B F) 2.5 - 2.8 kO
Q
STEERING SYSTEM SPECIFICATIONS

Steering wheel Rotational play 0 10 mm (0 2/5 in)
Initial turni""9~'o"
ado----+-'i13.7 N (1 .4 kgf. 3.1 fbf)
Wheel turning radius angle Inward: 41 , Outward: 33 (reference)
' -T"oe
"'--_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _-"-_T"o"'e"' -in: 0 10 mm (0 2/5 in)
1-7
GENERAL INFORMATION
DRIVE SHAFT/FINAL GEAR SPECIFICATIONS
Unit' mm (in)
ITE M STANDARD SERVICE LIMIT
,
I Front final Oil capacity I At draining 665 em:! (22.5 US OZ, 23.4 Imp oz)
drive AI disassembly 760 em (25.7 US OZ, 26.8 Imp ozt
_ ~ecommended oil Hypoid gear oil, SAE #80
Gear backlash 0.05 0.25 (0.002 0.010) 0.4 (0.02)
Backlash difference 0.2 (0.01 )
Rear final Oil capacity AI draining 140 em (4.7 US OZ, 4.91mp oz)
drive At disassembly 170 em (5.7 US OZ, 6.0 Imp oz)
- Recommended oil Hypoid gear oil, SAE #80
Gear backlash 0.05 0.25 (0.002 0.010) 0:4 (0.02)
Backlash difference 0.2 (0.01)
Rin9_gear-to-stop pin clearance 0.3 0.6 (0.01 0.02)
WHEEUSUSPENSION SPECIFICATIONS
Minimum lire Front/rear 4 mm (0.2 in)
tread depth
Cold tire Upto300kg(661Ibs) Front 70 kPa (0.7 kgf/cm 2 , 10 psi)
pressure load Rear 80 kPa 0.8 kgflcm , 12 psi)
Up to maximum I Front 70 kPa 0.7 kgf/cm , 10 psi)
weight capacity Rear 120 kPa (1.2 kgf/cm , 18 psi
-
BRAKE SYSTEM SPECIFICATIONS
Unit: mm (in
Recommended brake fluid Honda DOT 4 brake fluid
Brake disc thickness Front 11.8 12.2 (0.46 0.48) 10.0 (0.39)
Rear 7.3 7 .7 (0.29--=-0 .30)
I
6.0( 0.24)
Brake disc runout - 0.30 (0.012)
Brake pedal height (from accelerator pedat) 25 40 (1 1-3/S)
Parking brake lever free play
--
40 60 ( 1-9/16 2-318) , -
BATTERY/CHARGING SYSTEM SPECIFICATIONS
,
- ITEM SPECIFICATIONS
I
B'tt~,cePt Type YTX14-BS
CM type Capacity 12V-12 Ah/10HR
Current leakage 0.1 rnA max.
r-Voltage Fully charged_ 13.0 13.2 V
Needs
- I
(20"CI Below 12.3 V
68"F) charging
Charging Normal 1.4A/S-10h
current Quick 6.0Al1 .0h
f eM type Type GYZ16H
Capacity 12V-16 Ahl10HR
r-turrent leakage 0 .1 rnA max.
Voltage Fully charged 13.0 13.2 V
(20 CI Needs Below 12.3 V
68"F) charging
Charging Normal 1.6A/S 10 h
current Quick 8.0 Al1 .0 h
Alternator Capacity O.4S kW/S,OOO rpm
Charging coil resistance (20"C/68F) 0.1 1.0 n
'--- -
1-8
GENERAL INFORMATION
LIGHTS/METERS/SWITCHES SPECIFICATIONS
ITEM - --- SPECIFICATIONS
'B"u"'bC---~'H"'eadlight 12V - 37.SWx2
Brake/taillight LED
t
Neutral indica~to:;;,;-_ __ __
Reverse indicator
LED
LED
~igh coolant/oil temperature indicator LED
MIL LED
Oifferential lock indicator LED
~Seat belt indicator LED
Parl<ing brake indicator LED
Fuse Main 40A
Sub-fus"e'---_ _ __ ISAx3, 10Ax3
TORQUE VALUES
STANDARD TORQUE VALUES
FASTENER TYPE N' m (kgf-m, Ib"f.~ ) _ _,

ft~ FASTENER TYPE ----~'N m (kgf 'm , Ibf.ft)
5 mm hex bolt and nut 5 (0.5, 3.7) 5 mm screw 4 (OA. 3.0)
6 mm hex bolt and nut 10(1 .0, 7) - 6 mm screw 9 (0.9. 6.6 )
8 mm hex bolt and nut 22 (2 . 2~ f 6 mm flange bolt (8 mm head. small flange) 10 (1.0, 7)
6 mm flange bolt (8 mm head, large flange )
+
10 mm hex bolt and nut 34 (3.5, 25) 12 (1 .2. 9)
12 mm hex bolt and nul 54 (5.5.40) 6 mm flange bolt (10 mm head) and nut _ _ 12 (1 .2. 9)
8 mm flange bolt and nut 27 (2.8. 20)
10 mm flange bolt and nut 39 (4 .0. 29)
ENGINE & FRAME TORQUE VALUES
TORQUE
REMARKS
-'=;>.e.....'--,_ ..
N "m. (kg f'm , IbHt)
64 (6.5. 47) -t----
32 (3.3 . 24 )
B (0 .8 . 5.9) _---+_ _ ;
B (O.B. 5.9)
8 (O.B. 5.9)
9 (0.9. 6 .6)
= :;::=~==~;98 (0(0.9.B. 65.9) ;

.6) ;
30(3.1. 22)
9 (0 .9. 6 .6)
9 (0.9. 6 .6)
-==t=~=~99 (0.9,
(0 .9, 66 .6)
6)
~-ii~---+~_ 9 (0 .9. 6.6)
12(1 .2, 9)
8 (0 .8, 5.9)
--==~=~=~8
_ 5.9)
(O.B. 59)
B (OB.
8 (0.8 , 5.9)
, _ _' -- iB(0 .8 . 5.9)-
:- 14 (1 .4, 10)
12 (1.2, 9)
B (0 8, 5.9)
8(0.8, -==::::==-___
5.9f)
49 (5.0. 36)
1
I
1-9
GENERAL INFORMATION
THREAD TORQUE
ITEM Q"lY REMARKS
OIA. (mm) N'm (kgf-m, IbHt)
Upper middle OPS mounting nul 49(5.0 , 36)
~ear upperOPS mounting nut (4 person type
6
4
10
10 49(5.0 , 36) 1
only)
Rear side OPS mounting nut (4 person type 8 10 49(5.0,36)
only)
~-
Rear lower OPS mounting bolt (4 person type 6 10 49(5.0, 36)
only)
I
Front seat bell anchor bolt 4 7/ 16" 32 (3.3, 24)
2 7116" 32 (3.3, 24)
(4 person type 2 7116" 32 (3.3, 24 )
onl~)
Rear seat belt retractor nut (4 person ty po 4 7116" 32 (3.3, 24 )
onl ~)
Front seal bell buckle bolt
- 2 7/16"
- :- 32 (3.3, 24)
Muffler band bolt 2 8 2~2.2, 16)
Exhaust pipe cover band screw
- -
_-==~:;~::::~~
6 4 (0.4.
Muffler fronl cover band screw
- r- 3 1.5 (0.2, 1.1)
I
~mer rear cover band screw 2 3.2 (O.3,3.0,
2.4)
Frame jOint nut 8 10 56 (5.7, 41) ' Qnly for proper torque
confirmation
(page 1-34)
MAINTENAN CE
- - -- T TORQUE
ITEM a'TY REMARKS
01 N'm (kgf-m, fbI-ttl
Sparl< plug 1 22 (2.2 , 16
Valve adj~US~I~
;"~g:SsCrc'''e';;w,,'ociCkk<i";Uutt 4 17 (1.7,13)
Timing hOI"e2ca"p"'::c~_ _ ~ 1 10(1 .0, 7)
Crankshaft"h", ol;;.
eac.-__ 1 12 (1 .2, 9)
I
1
I
.,
25(2518)
I
1 18 (1.8, 13)
I I
,
. 12 (1 .2, 9 )
j
12 (1 .2 , 9)
12 (1.2, 9)
12 (1 .2 , 9)
22 (2.2. 16)
22 (2.2, 16)
See page 3-21
24(2.4 , 18)
44 (4.5, 32)
PGM-FI SYSTEM
THREAD TORQUE ~
ITEM
DIA . (mm) N'm (kgfom. Ibf-ftl~ REMARKS ~
Sensor Unit mounting SCl"ew 5 3.4(0.3, 2.5) ~ j
ECTsensor - 10 12 (1.2 , 9) ~
VS sensor boll _ _ _ __ 6 _ - , - _- ,1.0."(1",
.0,,,,7) _ __ _ __ _
IGNITION SYSTEM
- - - - ,- Q
ITEM
- 'T
- y- , - THREAD TORQUE
REMARKS
1
_+--,"
O"IA"", (m
"=m )-+- "N,,'m
"+,(ki'!i
gfom, Ibf.ft) +-_ __ _ _ __
Timing ho~I.~ca=p______ - '_-L_ - ,14 10 (1 .0, 7,L)_ _-'-_ _ __ _ __
1-10
GENERAL INFORMATION
FUEL SYSTEM
THREAD TORQUE
ITEM C 'TY REMARKS
DIA. (mm) N'm (kgfrn. Ibf-ft)
Air cleaner housing mounting washer-screw 1 6 a l.a. 5.9)
Insulator band screw 2 5 - See p 3ge7-21
Throttle cable holder screw _ _-+_''c - - - --;5'-------;:3.4 (0 .3, 2.5)
Fuel injector joint mounting bolt _+-~2----,, 5 ----,, 5.1 (0.5,3.8)
IACV holder plale mountingcto~"'~s~
"~e~w_ _~__2~___ 2.1 CO.2, 1.5) _-"-_ _ _ _ _ _ _---"
LUBRICATION SYSTEM
ITEM a 'TY THREAD TORQUE REMARKS

...--____---J_--.-_+-..O"'tA"'.,6(mmJ_ f-- N-m (kgf-m, Ibf ...
ft)' - t - == ====---j
Oil pump driven sprocket bolt 12 (1.2. 9) Apply locking agent.
COOLING SYSTEM
TORQUE
THREAD
ITEM O'TV REMARKS
OrA. (mm)
N'm (kgf-m, Ibf-ft)
t-
Coolant bleed bolt (at thermostat cover) _ _+-_-'----'
1 __~----O'i+,i_i''i'j,,-+-------
6 12 (1 .2, 9)
Radiator mounting bolt 2 5 8.4 (0,9 , 6.2)
Fan motor mounting bolt 3 5 5.2 (0.5, 3.8)
Cooling fan mounting nut 5 2.7 (0.3, 2.0) Apply locking agent.
CYLINDER HEADfVALVE /CAMSHAFT

THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N-m (kgf-m , IbHt)
Cylinder head cover cap nul
10 65 (6.6, 48) Apply engine oiL
CYLINDER/PISTON
ITEM C'TY THREAD TORQUE REMARKS

DIA. (m
C" .....m';,l'
m") --+--'N (kf,gi'fim'\,""b,,f-'.f.t,)_'<=~=-.-_ _ --1
Cylinder stud boll
10 24 (2.4 , 18) See page 11-7
ALTERNATOR/STARTER CLUTCH
THREAD TORQUE
ITEM C 'TY REMARKS
DIA.(mm) N'm (kgf'm , IbHt)
Starter clutch boll 6 B 30{3 .1.22) +---Apply locking agent.
Flywheel boll
Allernator stator bolt
CKP sensor bolt
Alternator stator wire holder bolt
Gear selector arm pinch bolt ~~
-+-

1
+
" --
6
6
108 (11 .0 , 80)
10 (1.0 , 7 )
6 (0.6 _4.4)
10 (lil, 7)
16 (1.6. 12)
Ape!)' engine oil.
Apply locking agent.

Apply locking agent.
THREAD TORQUE
ITEM C'TY REMARKS
OIA, (mm) N-m (kgf-m , IbHt)
Shift drum stopper arm pivot bolt 1 6 12(1.2. 9) Apply locking agent.
Engine oil drain bolt 25 (2.5, 18)
,.a
1 12
Gear selector lever pivot nut 1 26 (2.7. 19) U-nut
Gear selector cable lock nut 2 26 (2.7. 19)
ENGINE REMOVAUINSTALLATION
THREAD - - TORQUE
ITEM C'TY REMARKS
DIA. (mml_ Nn:!.J kgfm , IbHt)
Engine side mounting nut (left and right) 2 10 54 (5.5, 40)
Front final gear case mounting nut 2 12 54 (5.5. 40) Lock nut: replace with
. Gear selector arm pinch boll 1 6 16 (1.6 , 12)
a new one.
-
Parking brake cable clamp boll
a 27 (2.8 , 20)
-
111
GENERAL INFORMATION
DRIVETRAIN SYSTEM
THREAD TORQUE
ITEM C'TY REMARKS
D IA. (mm~IL+--,N'.:'m"')(; ~,'::!.bfft)
kgt"f:;,m
Shift valve body cover bolt 3 6 8 (0.8, 5 g)
Primary driven gear lock nut 1 16 108(11.0,80 ) Apply engine oil.
Lock nut: replace with
a new one. Stake.
Stator shaft inner collar stopper pin 1 10 14 (1.4.10) Apply locking agent
Torque converter lock nul 1 22 118 (12.0, 87 ) Apply engine oil.
lock nut: replace with
+======-_
a new one. Stake.
Oil feed Pipe setting'c""""p' -_ _ _ __ _-+-_~24:_---'f--~21 (2.1, 15)
; Oil passage sealing cap " -_ _ _ _ _ _ _ + ,' -+_ 20 18
EOT sensor 10 12 (1.8,
(1.2, 13)
9) - -
STEERING SYSTEM _ _ __
THREAD TORQUE
ITEM Q'TY REMARKS
oiA. (mm) N'm (kgf-m, IbHl)
Sleering wheel nu~''c.=_ _ _ __ 12 49 (5.0, 36)
- ;-
Steeting shaft pinch bolt 4 8 27 (2.8, 20) Replace the bolt and
washer with new
ones.
Tie-rod bal.~,.jo~;O~'~O~UI'::::::::===:-
Rack end j~int
2
2
12
12
65 (6.6 , 48)
54 (5.5, 40)
Steering gear box mounting nut 4 10 39 (4 .0, 29) lock nut: replace with
a new one
Final clutch arm cover and base bolt 3 6 10 p.O, 7)
DRIVE SHAFT/FINAL GEAR
ITEM a'TV THREAD

OIA. (mm)
~ TORQUE
Nm (kgf-m, IbHt)
REMARKS
Front final gear case mounting nut lock nul: replace with
Front final gear case cover bolt

2
2
12
10
54 (5.5, 40)
a new one.
I
1
4 8
Differential ring gear bolt 10 8 49 (5.0, 36) ALoe bolt: replace
with a newone.
Final clutch hous,;;~og"_;'bo~'~1=~__ 3 8 25 2.5, 18)
Front pinion bearing lock nut 64 98 (10.0, 72) lock nut: replace with
a new one.
Stake.
I Final clutch shift fork boll 6 10{1.0,7) ALoe bolt: replace
with a new one.
1 10 12 (1.2, 9)
1 10 12 (1.2. 9)
3 6 10(1 .0,7f
. 9 plug I 12 21.6 (2.2,16)
, boll 1 6 20 (2.0,15)
I 1 6 10 (1.0, 7) AlOe boll: replace
with a new one.
I Differential lock clutch hDusing bolt 4 8 25 (2.5,18)
~rive mode selector lever pivot nut . 1 8 26 (2.7, 19) U-nut
Differential lock cable loek nut 2 14 15 (1.5, 11)
Rear finat gear case rna unting nut
- 3 10 44 (4.5, 32) Lock nut: replace with
a new one.
-j-
Rear final gear case coy er bolt 2 10 47 (4.8, 35) Apply locking agent.
6 _ 8 25 (2.5, 18)
Rear pinion bearing lock oul 1 72 I 98 (10.0, 72) i
Lock nut replace with
a new one.
Stake.
Rear brake disc bolt 5 6 20 (2.0, 15) ALOe bolt replace
with a newone.
Rear pinion joinllock nu I 1 16 I 108(11.0,80) Apply locking agent. ,
1-12
GENERAL INFORMATION
WHEEU SUSPENSION
THREAD TORQUE
ITEM Q'TY REMARKS
OIA. (mm) N' m (kgf'm, IbHt)
+ ~6i-=~~~~~~~"-4-
133 (13,6. 98)
137 (14.0, 101) Castle nut: tighten to
the specified torque
and further tighten
until its grooves aligns
with the cotter pin
hole.
8 8 42 (4.3, 31) ALOC bolt: replace
with a new one.
Front brake disc splash guard bolt 2 6 12 (1.2, 9) ALOC bolt replace
with a new one
Front brake caliper mounting bolt 12 108 (11 .0, 80) ALOC bolt: replace
with a new one.
Front shock absorber mounting nut 10 44 (4 .5, 32) Lock nut: replace with
t Feo"' b,ak. ho,. clamp boll

a new one.
4 6 2-c.9'")c ---+ ALOC bolt: r~.=
- ' 1'"2" ('1." pl=a,=.o-~
with a new one,
Front upper and lower a~'=
m~p
~i~
,o~t~"~u"t- 8 10 34 (3,5. 25) Lock nul: replace with
a new one,
I Front upper and tower arm ball ;oint nut 4 12 29 (3.0, 21 ) Castle nut; tighten to
the speCified torque
and further tighten
unlllits grooves aligns
With the cotter pin
hole.
~ Tie-rod ban joint nut 2 12 65 (6.6, 48)
I Rear shock absorber mounting nut 4 12 64 (6.5. 47) Lock nut: replace With
Rear upper arm pivot nut (frame side)

----~--_,---t----".---~--__,
4 10
",",__-C-ia~"~.~w
34 (3.5. 25)
~Of"~
Lock nul: replace with
______Ta~"~e~w one.
Rear lower arm pivot nut (frame side) 4 12 64 (6.5, 47) lock nut: replace with
a new one.
Rear upper and lower arm pivot nut (knuckle 4 --1---' 10"----1---- 44 (4 .5, 32) -----r-l ock nut replace with
side) a new one.
Stabili,zz.~,~a~'~m'momo;;U"~lilii"~gQbo
:iOfItC==_____ 4~--~~8;::::===::27 (2.8. 20)(_ - 1 _
Stabilizer link nut 4 10 46(4 .7, 34) Lock nul: replace with
I a new one,
BRAKE SYSTEM
i
ITEM a 'TY THREA
~ TORQUE REMARKS
OIA. (mm) N'm ( kg f' m ~,'T
b,-
f ft
"')~--'<i7"'"
Drive shaft outboard gu~a~'d;U(a~l-;:k="~U='k~I.=).-----1--4 6 11 (1 .1, 8) AlOCbolt:replace
with a new one.
-_-=-=-=-=-=-=-=-=-=~-=~13.---~_~'~0=:,
Brake hose oil bolt
Front caliper bleed valve
Rear caliper bleed valve
2 10
8
34 (3.5. _+-_ _ _
9 (0.9. 6.6):.------,_
25)
5.4 (0.6. 4.0,--)
_ _ _ _ __
__
Brake pipe joint nul 10 10 14 (1.4, 10)
Masler cylinderlbrake pedal bracket 2 8 27 (2.8, 20 ) U-nul
mounting nut
Master cylinder push rod joint
Master cylinder reservoir bolt ~
-------------f'=i==~8E=~==~17.2
1 5
(1.8 . 13)
2,5@l.. 1.B:), _-+
Front brake caliper mounting boll 4 12 108 (11 .0, 80) ALOe bolt: replace
.-...______w~ith~acc".~w~O~".~.~==
Front brake caliper slide pin bolt ---------:...:.f-..:...:.~4_2------+~--------:.8.-----t--- 23 (2.3, 17) _.
Rear brake caliper mounting bolt 8 30 (3.1, 22) - - - 'A"L' O"C'-bolt replace
with a newone.
Rear brake 2 S 32(3.3, 24 )
Rear brake ,,:I":':?~~~Slgi~~;;n::oLiC=! 1 10'----_+-_ 27 (2.8. 20,~)- - - t - - -
Parking brake cable clamp __ ..___________~__4~ 8 27 (2 .8. 20) _~_ _
1-13
GENERAL INFORMATION
LIGHTS/METERS/SWITCHES
THREAD TORQUE
ITEM
I Q'TY
OIA. (mm) , N'm (kgfm. [bOt)
REMARKS
Combination meter mounting screw
Ignilion switch nut ,,3 5
22
0.8 (0.1. 0.6
4.9 0.5, 3.6)
Parking brake switch screw 3 0.4 (0.04, 0.3)
LUBRICATION & SEAL POINTS

ENGINE
MATERIAL LOCATION REMARKS
MOlybden::"'m~O"iI';SO;;''""I'';O;;;nC--~
(a mixture of engine oil and
Camshaft cam lobes and decompres soream area
Piston pin ouler surface
,I
molybdenum disulfide Starter driven
grease in a ratio of 1:1)
Engine il ,
screw tip
" surface
~
i 1 hole
Molybdenum
grease Uilfidec--~g~~~~;~i~~~~====~-
di;s ~
surface of crankshaft See page 16-42
I
T81215
114
GENERAL INFORMATION
FRAME
~ MATERIAL LOCATION REMARKS
Multi-purpose grease Cargo bed strikers and latch pivots
Door latches Apply 1 ,g'--_ _ _ _ _ _~
----Eargo bed PiVO~ts~=.=.=======-

I Tailgate pivots
Rear seat latches
_ __ ==+===========~
Parking brak~e~'~e~,e~,~p";,
~o~t------
r-----cargo bed (OCk;~P~;,~ot~(~4~p~e~,,~o~n~t~y~p~e~O~n~'y~)= = = =:-::=---r--
Gear selector ~~ver pivot
Gear selector le~ m~p~;~,o~t'c._ _ _ _ __
,e~,~a~'~ ,
Drive mode selector lever pivot
,
j
Drive mode selector lever arm pivot
Accelerator pedal pivot shaft groove
Accelerator pedal pivot dust seal lips I
Brake pedal pivot shaft groove
Brake pedal pivot dust seal lips
Front knuckle outer d~u~'~t~,e~a~I~IIP~'=========t~F~;~"~uP:p~2q.5f-~3::g-"
Front knuckle inner dust seallips"c,~~=~_ _ _ _---,-,F~II~I~u~p~2~.5~-=-,,3~g,---_
Steering column bushing,=;~n~ne~,~a~n~d~t~o~p;,~u~rt;ac~e~_ _ _ _ _ _ _ _ __
Steering column upper and lower dUS.~t ~,e~a~I~II~p'-======~~::jJl:"';;o;","n>:===:::j
Steering rack end bushing inner surface Apply 1 g minimum
Steering rack teeth Apply 5 g minimum
Steering pinion needle bearing rotating areoa _ _ _ _ _-+--;A~p~p~"~O~2~g~m~;~n~;m~u~m
cc_---
Steering pinion ball bearing rotating area Apply 0.2 9 minimum
Steering pinion dust seal lips Apply 0.2 g minimum
Steering gear box housing (between pinion dust seal and Fill up 2 g minimum
dust cover)
-
Stee ring rack guide sliding surface (rack side) Apply 0.2 - 0.5 g
-~
Stee ring rack end joint outer surlace Apply1-2g

Fm ntfinal clutch pinion jOint oil seal lips ,
Fm nt final gear case drive shaft oil seal lips ,
Fran t final gear case cover O-ring
Diffe rentiallock arm shaft oil seal lips
Diffe rentiallock housing O-ring I
Fran t final clutch arm shaft oil seal Ups
Fron 1 final clutch arm shaft O-ring
Fran 1 final clutch arm shaft outer surface
Fran 1 final clutch housing O-ring
Fm nl final gear oil filler cap O-ring
Universal jOint bearing
Universal joint boot lips ,
Rea r final gear case pinion joint oil seal lips
Rea r final gear case drive shaft oil seal lips I
Rea r final gear pinion jOint O-ring
Rea r final gear oil filler cap O-ring
Molybdenum disulfide Fran t drive shaft splines (wheel side)
grease Rea r drive shaft splines (wheel side)
Fron t propeller shaft boot and dusl seal lips
Front propeller shaft pinion joint splines (propeller shaft Fill up 5- 8 g
side)
Front propeller shaft joint splines (output shaft side)
Front propeller shaft end (pinion joint contacting area)
~ Front final clutch pinion jOint splines Fillup5 - 8g
Rear propeller shaft O-ring
r Output shaft O-ring~(~"~o~n"~,~e~a~n,=_ _ _ _ _ _ _ _ _
Rear propeller shaft dust seal lips
+___________ ~
Rear propeller shaft pinion joinl splines Fillup5 - 8g
Universal joint splines (both sides)
Rear propeller shaft splines (gear case side)
115
GENERAL INFORMATION
ill
ill up 45 :;;~_ _ __ _-I
Fill up 60-
'"";m- ----j
Apply 0.5 9 ;;",;
(Dow Coming; Molykole
EM30L or Kluber; Noxlub
884012)
Silicone grease
Rear
Rear
Rear
DOT 4 brake fluid
Cable lubricant
T81215 or loctite LT5699

Differenliallockinner
Drive mode selector inner
Gear selector inner cable
f-S~e~al"a~nt~('"T"h-,e-e"bo-nd~----1---;W~heel
cabt~~~~~~~~~~~~=
cable
hub nul rTi'OiJiltIng threads of drive shaft

Rear final gear case cover mating surface
f Apply 5 mm
or equivalenl'L)~~_ _ _~~_
Sealant (Threebond Rack guide screw threads ' Apply 3
.,iiOi"",------i
area
Hand Grip Cement (U.SA Air
only)
Engine ,I
1-16
GENERAL INFORMATION
CABLE &HARNESS ROUTING
FRONT FINAL GEAR
FAN MOTOR WIRE CASE BREATHER HOSE
HEADLIGHT SUB HARNESS

2P (Black) CONNECTOR
BRAKE LIGHT
SWITCH WIRE
FAN MOTOR BREATHER HOSE

RIGHT FRONT
FENDER
RIGHT HEADLIGHT LEFT HEADLIGHT

REAR COVER L-_________________R_E_A~
~--------------~
1-17
GENERAL INFORMATION
FAN MOTOR WIRE RADIATOR SIPHON HOSE
FAN MOTOR
BREATHER HOSE
UPPER RADIATOR HOSE
GEAR SELECTOR CABLE

LOWER RADIATOR HOSE
PARKING
BRAKE CABLE
I II \\ \\
\\ \\ II
DRIVE MODE SELECTOR CABLE
THROTILE CABLE
DIFFERENTIAL LOCK
CABLE
FRONT FINAL GEAR

CASE BREATHER HOSE
DIFFERENTIAL LOCK
SWITCH WIRE
1-18
GENERAL INFORMATION
THROTILE CABLE 4WD SELECT DRIVE MODE SELECTOR CABLE

SW!TCHWIRE
DIFFERENTIAL LOCK
SWITCH WIRE
DIFFERENTIAL LOCK
CABLE
MAIN WIRE HARNESS
GEAR SELECTOR CABLE

BRAKE
PIPE
PAF<K"IG BRAKE CABLE
DIFFERENTIAL LOCK
SWITCH WIRE
DIFFERENTIAL
LOCK CABLE
4WD SELECT DIFFERENTIAL FRONT FINAL

DRIVE MODE SWITCH WIRE LOCK SWITCH CASE BREATHER HOSE
SELECTOR CABLE
- '-
iJ..--I~::;:;~ MAIN WIRE
HARNESS
4WO SELECT
SWITCH WIRE
DRIVE MODE
SELECTOR CABLE
DIFFERENTIAL
LOCK SWITCH
PARKING BRAKE CABLE

THROTIlE CABLE
MAIN WIRE HARNESS GEAR SELECTOR CABLE
4WD SELECT SWITCH WIRE
4WD SELECT SWITCH
1-19
GENERAL INFORMATION
Left side shown:
FRONT BRAKE HOSE
BRAKE PIPE (to RIGHT BRAKE PIPE (to FRONT

FRONT BRAKE CALIPER BRAKE CALIPERS)
~{)
--
0 0 0
61 6J
/
', ~
~
,, ~61
,
~o
; bO
<
<
~ I
BRAKE PIPE {to lEFT

FRONT BRAKE CALIPER BRAKE PIPE (to REAR
BRAKE CALIPER)
1-20
GENERAL INFORMATION
PARKING BRAKE SWITCH

IGNITION SWITCH 5P
2P I
(Black) CONNECTOR
I
FAN MOTOR 2P
MAIN WIRE
HEADLIGHT
\~~~--"","\~FIo=,..- PARKING BRJIKE SWITCH 2P (Black)
BRAKE LIGHT ~ CONNECTOR
2P (Gray) CONNECTOR
- \\
.\)
BRAKE LIGHT
SWITCH 2P (Gray)
'--~ CONNECTOR
SWITCH
COMBINATION METER SUB

DATA LINK
BRAKE LIGHT
HARNESS 10P (Gray) CONNECTOR
SWITCH 2P (Gray)
CONNECTOR (OlC)
CONNECTOR
~~~~~~~~~~~~~~~~~~~~~~~
INHIBITOR
REALA'N Y ' r~cc /

BRAKE ,r---'t\--COMBINATION METER
M RELAY SUB HARNESS
I _ _ _ _-'~ HEADLIGHT
, SWITCH WIRE
HEADLIGHT ,..
RELAY
FUEL PUMP RELAY FUSE BOX
DRIVE MODE
THROTTLE SELECTOR CABLE
bI
!-- PARKING
BRAKE
CABLE
DIFFERENTIAL LOCK
PARKING
SWITCH WIRE DIFFERENTIAL LOCK
CABLE
BRAKE GEARSELECTOR
CABLE CABLE
1-21
GENERAL INFORMATION
PARKING BRAKE
PARKING BRAKE
SWITCH 2P I
PARKING BRAKE
CABLE
IGNITION
SWITCH
ACCESSORY SOCKET 2P
(Green ) CONNECTOR
COMBINATION METER
SUB HARNESS 10P
(Gray) CONNECTOR
IGNITION SWITCH SP
(BlaCk) CONNECTOR
ACCESSORY
SOCKET DRIVE MODE
SELECTOR CABLE
122
GENERAL INFORMATION
DIFFERENTIAL LOCK
SWITCH WIRE
4WD SELECT
SWITCH WIRE
MAIN WIRE
HARNESS
DRIVE MODE
___ THROTTLE
SELECTOR CABLE
\\i"---T-~~
CABLE
PARKING BRAKE CABLE
GEAR SELECTOR CABLE
STARTER RELAY SWITCH
,U
MAIN FUSE 2P (Green) CONNECTOR
POWERTRAIN CONTROL
MODULE (PCM) ~-o'-:
,
BATTERY

PCM 33P (Gray)
CONNECTOR
BATTERY H CABlE
''''R1-'. MOTOR CABLE
WIRE HARNESS
PCM SP I
CONNECTOR
1-23
GENERAL INFORMATION
FUEL FEED HOSE

MAIN WIRE HARNESS
AfT CLUTCH PC SOLENOID VALVE SUB

HARNESS 6P (Green) CONNECTOR
4P CONNECTOR
STARTER
FUEL TANK
/ '~ 8REA THER HOSE

/l I ",
1,\\/'
FUEL PUMP4P
CONNECTOR
MAIN WIRE HARNESS
BATTERY (-)eAllLE
MAIN WIRE HARNESS

THROTTLE CABLE GEAR SELECTOR CABLE
/,'c
II c -
o D
J/ 0
'I'
-, '---
~
----"
PARKING BRAKE CABLE
1-24 1
GENERAL INFORMATION
WATER HOSE (to CYLINDER)
WATER HOSE (from WATER PUMP)
WATER HOSE
(to CYLINDER)
OIL COOLER
, _______--'< AfT CLUTCH PC
SOLENOID VALVE SUB
HARNESS
WATER HOSE (from THERMOSTAT SHIFT SOLENOID

HOUSING to UPPER RADIATOR HOSE) VALVE B 2P (Brown)
CONNECTOR
SHIFT SOLENOID
VALVE A 2P (Black)
CONNECTOR
AfT CLUTCH PC
SOLENOID VALVE 2P
OI L PIPE B _-r (Black) CONNECTOR
OIL PIPE A
WATER HOSE (to OIL COOLER) WATER HOSE (from LOWER RADIATOR HOSE)
WATER HOSE (from

THERMOSTAT HOUSING)
WATER HOSE (from

LOWER RADIATOR HOSE)
WATER PUMP BLEED HOSE
1-25
GENERAL INFORMATION
UPPER RADIATOR HOSE

WATER HOSE (from THERMOSTAT HOUSING)
AlTERNATORlCKP SENSOR
SP (Black) CONNECTOR
GEAR POSITION SWITCH

3P (Black) CONNECTOR
BATIERY (-) CABLE
LOWER
RADIATOR
HOSE
WATER PIPES
WATER HOSE
\ - THROTILE
GROUND CABLE
L CABLE
~~
GROUND WIRES
"
PARKING BRAKE CABLE
GEAR SELECTOR CABLE ( MAIN WIRE HARNESS
AIT CLUTCH PC SOLENOID VALVE SUB FUEL FEED HOSE STARTER MOlOR CABLE
HARNESS6P (Green) CONNECTOR~~~~~~~sr~~~~~~~~~~~~~~~tl=

OIL COOLER
~'::J~~~~~
J ________~-C __ ~::~ ~~2=====~~t======='1~=-= BRAKE
__ PARKING
CABLE
MAIN WIRE HARNESS SA TIERY (- ) CABLE THROTIlE GEAR
CABLE SELECTOR
CABLE
1-26
GENERAL INFORMATION
THROTTLE CABLE
WATER HOSE (to UPPER
RADIATOR HOSE)
WATER HOSE
MAIN WIRE HARNESS
CRANKCASE BREATHER HOSE WATER HOSE (from

WATER HOSE
WATER PUMP)
SA TTERY (-) CABLE (to WATER PUMP)
WATER HOSE (to UPPER

RADIATOR HOSE)
THROTTLE CABLE
CRANKCASE BREATHER HOSE
WATER HOSE (to WATER PUMP)
1-27
GENERAL INFORMATION
THROTTLE CABLE
FUEL FEED HOSE
SPARK PLUG WIRE
IAT SENSOR 2P
CONNECTOR
I I COIL
CRANKCASE
BREATHER HOSE PARKING BRAKE CABLE
GEAR POSITION
SWITCH GEAR SELECTOR CABLE
EOT SENSOR 2P CONNECTOR
GEAR POSITION
SWITCH WIRE AL TERNATORfCKP
SENSOR WIRE
GROUND CABLE
1-28
GENERAL INFORMATION
IACV 4P (Black)
CONNECTOR
FUEL INJECTOR 2P
(Gray) CONNECTOR
IAT SENSOR 2P
CONNECTOR
FUEL INJECTOR 2P
(Gray ) CONNECTOR IACV 4P (Black)
CONNECTOR
Fr-_ IAT SENSOR 2P

CONNECTOR
Eel SENSOR 2P SENSOR UNIT FUEL FEED HOSE

CONNECTOR 5P CONNECTOR
129
GENERAL INFORMATION
BRAKE PIPE
BRAKE PIPE
- ~.
PARKING BRAKE CABLE

MAIN WIRE HARNESS
(10 BRAKEITAll UGHTS)
----
REAR BRAKE HOSE
vs SENSOR WIRE
VS SENSOR WIRE
REAR FINAL GEAR

CASE BREATHER HOSE
,
REAR GEAR ,
CASE BREATHER HOSE VS SENSOR 3P CONNECTOR
I
1-30
Downloaded from www.Manualslib.com manuals search engine J
GENERAL INFORMATION
2 PERSON TYPE: BRAKEfTAILLIGHT WIRE
-\
BRAKE/TAILLIGHT WIRE
Ii
MAIN WIRE HARNESS
(10 BRAKEfTAILLIGHTS)
BRAKEfT AILLIGHT
6P CONNECTOR
4 PERSON TYPE: BRAKEfTAILLIGHT WIRE
~
~
- 0
BRAKEITAILUGHT WIRE
MAIN WIRE HARNESS

(10 BRAKEfTAILLIGHTS)
,
BRAKEJTAILLIGHT
6P CONNECTOR

1-31
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
The U.S. Environmental Protection Agency (EPA). the California Air Resources Board (CARB), and Environment Canada (EC)
require that Recreational Utility Vehicles comply with applicable exhaust emissions standards during their useful life, when
operated and maintained according to the instruction provided .
SOURCE OF EMISSIONS
The combustion process produce emissions such as oxides of nitrogen (NOx), carbon monoxide (CO) and hydrocarbons (He).
Controlling oxides of nitrogen and hydrocarbon emissions is very important because, under certain conditions, they reacl to form
photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Fuel evaporation
also produces He emissions.
Honda Motor Co., Ltd. utilizes various system to reduce carbon monoxide, oxides of nitrogen and hydrocarbons.
EXHAUST EMISSION CONTROL SYSTEM

The exhaust emission control system is composed of the PGM-FI system and no adjustments should be made. The exhaust
emission control system is separate from the crankcase emission con trol system.
CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by
gas is returned to the combustion chamber through the air cleaner and throttle body.
AIR CLEANER
THROTTLE BODY
CRANI<C!\SE BREATHER HOSE
<:: I Fresh air
_ Blow-by gas
SERVICING THE HONDA

U.S.A . Only
Maintenance. replacement or repair of the emission control devices and systems may be performed by any Recreational Utility
Vehicle repair establishment or individual using parts that are "certified" to EPA standards.
PROHIBITED ACTIONS
The following prohibitions apply to everyone with respect to the engine's emission control system.
You may not remove or disable any device or element of design that may affect an engine's emission levels. This restriction applies
before and after the engine in placed in service.
132
GENERAL INFORMATION
NOISE EMISSION CONTROL SYSTEM
TAMPERING W1TH THE NOISE CONTROL SYSTEM IS PROHIBITED: Stale laws and Canadian provincial law may prohibit the
following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of
maintenance. repair or replacement. of any device or element of design incorporated Into any new vehicle for the purpose of noise
control prior to its sale or delivery to the ultimate purchaser or while it is in use: or (2) the use of the vehicle after such device or
element of design has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWING ACTS:
1. Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2 . Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Removing of disabling any emissions compliance component, or replacing any compliance component with a non-compliant
component.
FUEL PERMEATION EMISSION CONTROL SYSTEM

This Recreational Utility Vehicle complies with the Fuel Permeation Emission Control regulations of the U.S. Environmental
Protection Agency (EPA). California Air Resources Board (CARB). and Environment Canada (EC). The fuel tank, fuel hoses , and
fuel vapor charge hoses used on the Recreational Utility Vehicle incorporate fuel permeation control technologies. Tampering with
the fuel tank , fuel hoses, or fuel vapor charge hoses to reduce or defeat the effectiveness of the fuel permeation technologies is
prohibited by federal regulations.
REBUILT ENGINE
When you rebuild the engine including a major overhaul in which you replace the engine's pistons or power assemblies or make
other changes thai significantly increase the service life of Ihe engine . Ihe vehicle witl continue to comply with all emissions
regulations if you:
- Make sure you are teChnically qualified to rebuild the engine and have the proper tools
- Diagnose and respond 10 all Diagnostic Trouble Codes (OTC ). and erase all DTCs after addreSSing their cause
- Use only Genuine Honda parts or equivalents
- Make sure to maintain all specifications as described in this Service Manual
LIFT AND SUPPORT POINTS

Use the following lift and support points to support the vehicle and raise the wheels off the ground.
Block Ihe wheels that are not being lifted. When lifting the front of the vehicle, set the parking brake.
Position the floor jack under the center of the front frame crosspipe (behind the under guard) or the center of the rear end frame
crosspipe [A or B] as shown, and jack up the vehicle high enough to fit the safety stands under it.
Position the safety stands under the support points [C or OJ and adjust them so the vehicle is level. Lower the vehicle onto the
stands.
Lift Points; Front: Rear:

CROSSPIPE
Support POints:

1-33
GENERAL INFORMATION
TECHNICAL FEATURES
BOLTED FRAME CONNECTIONS
This vehicle uses two-piece main frame body, connected by bolls [1J and , - - - - - -- - - - - - - - ---,
nuts {2] during vehicle manufacture.
The front and rear frame body must not be disassembled. The frame body
should be replaced as an assembly.
Under no circumstances should Ihese fasteners be loosened or removed.
DRIVE SHAFT BOOTS WITH LOW-PROFILE BOOT

BANDS
The drive shaft boots [1J used for this vehicle are made of a puncture- , - - ,
resistant plastic malerial.
The low-profile boot bands 121 help to prevent damage to the boots from
debris and grass/plant entanglement.
For drive shaft boolslboots band service (page 18-8).
BED TILT PREVENTION SYSTEM (4 PERSON TYPE)

This model employs an independent bed tilt prevention system, which is
separate from the bed release lever located in the fronl side of cargo bed.
When the cargo bed is converted to 3 or 4 person mode, the rear seat frame
(1) loses contact with the levers [2} , allowing the hooks (3) to contact with
the striker (4) in the frame, preventing an accidental tilting of the bed.
In 2 person mode, the rear seat frame pushes down the levers in order to
disengage the hooks from the striker,
4 person mode: 2 person mode:
[2[ [2J
t
[4J
[3[
[3J
1-34
2. FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION
2-2 FRONT HOOD .......... .. .......... .............. 212
TROUBLESHOOTING ...................... 2-2 FRONT GRILLE .. .. ...... ...................... 2-12
BODY PANEL LOCATIONS

2-3 FRONT HEAT GUARD .. ...................... 2-12
FRONT SEAT .. ........................ 2-4 FRONT FENDER .. .. ...................... .... 2-13
REAR SEAT (4 PERSON TYPE ONLy) 2-6 DOOR .. ...... .. .. .. ...... .. .. .. ...... 2-13
REAR CENTER COVER INSTRUMENT PANEL ............ .............. 2-16

(4 PERSON TYPE ONLY) .. 2-7
FRONT FLOOR COVER .................... .. 2-17
MIDDLE FENDER .................................. 2-8
FRONT BUMPER ................................. 2-17
SEAT BOTTOM COVER ......................... 2-8
MAINTENANCE LID ............................. 2-18
REAR STEP (4 PERSON TYPE ONLY) ...... 2-9
CARGO BED ...................................... 2-18
MUD PROTECTOR
(2 PERSON TYPE ONLY) ........................ 2-9 SIDE NET ........................................... 2-24
REAR FOOT WELL OCCUPANT PROTECTIVE STRUCTURE

(4 PERSON TYPE ONLY) ...................... 2-10 (OPS) ................................................ 2-25
REAR SIDE COVER ............................. 2-10 SEAT BELT ........................................ 2-27
FRONT SIDE COVER ........................... 2-11 UNDER GUARD .................................. 2-29
FLOOR PANEL ................................... 2-11 EXHAUST SySTEM ................. .. .......... 2-30

2-1
FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION
GENERAL
This section covers removal and installation of the body panels, frame and exhaust system.
Always replace the gaskets after removing the exhaust system .
Always inspect the exhaust system for leaks after installation.
TOOL
Push pin pliers
07 AAC-SJAA 100 (U.S.A. only)
TROUBLESHOOTING
Excessive exhaust noise
Broken exhaust system
Exhaust gas leak
Poor performance
Deformed exhaust system
Exhaust gas leak
Clogged muffler
2-2
BODY PANEL LOCATIONS
4 person type shown:
(22)
__ -( 13)
(12)
(6)
(24)
(14) ( 19)
(17)
(4) (5)
(7) (10)
(1) FRONT SEAT (page 2-4 ) ( 14) FRONT FENDER (page 2-1 3)
(2) REAR SEAT" (page 2-6) (15) DOOR (page 2-1 3)
(3) REAR CENTER COVER" (page 2-7) ( 16) INSTRUMENT PANEL (page 2-16)
(4) MIDDLE FENDER (page 2-8) (17) FRONT FLOOR COVER (page 2-17)
(5) SEAT BOnDM COVER (page 2-B) (18) FRONT BUMPER (page 2-17)
(6) REAR STEP' (page 2-9) (19) MAINTENANCE LID (page 2-18)
(7) REAR FOOT WELL" (page 2-10) (20) CARGO BED (page 2-18)
(8) REAR SIDE COVER (page 2-10) (21 ) SIDE NET (page 2-24 )
(9) FRONT SIDE COVER (page 2-11) (22 ) OCCUPANT PROTECTIVE STRUCTURE (page 225)
(10) FLOOR PANEL (page 2-11 ) (23) SEAT BELT (page 2-27)
(1 1) FRONT HOOD (page 2- 12) (24 ) UNDER GUARD (page 2-29)
(12) FRONT GRILLE (page 2- 12) (25) MUD PROTECTOR" (page 29)
(13) FRONT HEAT GUARD (page 2-12)
": 4 person type only

" : 2 person type only

2-3
TRIM CLIP REMOVAU RETAINING PROCEDURE :
Release by pulling the cen ter pin [1] up using the push
pin pliers or a flat blade screwdriver and remove the
Remove and install
trim clip.
TOOL:
Pus h pin pliers 07AAC-$JAA100 (U.S.A. only)
CSr&fUlly align the Install the clip and lock it by pushing the center pin
cltp holes in the securely.
covers (panels) to
avoid damaging the
clip.
FRONT SEAT
SEAT CUSHION REMOVALI
INSTALLATION
Release the grommets [1] by pulling the front side of the , - - - -- - ----,13"1- - - - - - - - - ,
seat cushion [2] upward, then forward and remove it.
lnstailihe seat cushion by aligning the prongs (3] with
the frame, then press it down while aligning the
grommets with the frame bosses [4].
BACKREST REMOVAL/INSTALLATION
lift up the cargo bed .
Remove the seat cushion (page 24).
Remove the five setting bolts 111 and the backrest 121.
Installation is in the reverse order of removal.
2-4
Downloaded from www.Manualslib.com manuals search engine j
HEADREST REMOVAL/INSTALLATION
Remove the cap nuts (1] while holding the bolts [2] and
the headrest (3].
~ ..
Inslalilhe headrest in the reverse order of removal.
SEAT FRAME REMOVALI

LI31
INSTALLATION
Remove the following:
- backrest (page 2-4)
- seat bottom covers (page 2-8)
- middle fenders (page 28)
- rear side covers (page 2-10)
- upper middle OPS (page 2-25)
Release the following:
- spark plug wire (from the clamp [1)
- fuel tank breather hose (from the clip [2])
- fuel feed hose (from the clamps [3])
- water hose (from the clamps [4])
- throttle cable (from the guide [5])
Remove the front bolls [6), side nuts [7). side bolts [8]
and rear bolts [9], then remove the seat frame [10].
TORQUE :
Seat frame re ar bolt :
64 Nm (6.S kgf-m . 47 IbHt)
181

2-5
REAR SEAT (4 PERSON TYPE ONLY)
SEAT CUSHION REMOVAL/
INSTALLATION
Pull the seat belt buckle upward, then pull up Ihe rear r - - - - - -- - - - - -- -- -
seat cushion (11 and remove it. (1) 121
Inslall the seal cushion by aligning the prongs [21 with
the holes, Ihen press it down while aligning the bosses
(3] with Ihe grommets.
SEAT REMOVAUINSTALLATION
Remove Ihe rear seat cushion (page 2-6).
Disconnect Ihe upper side of seat damper (page 2-6). 131
Unlock the rear seat latch.
Remove Ihe bolts (11 and release the grooves from Ihe
frame bosses [2] by pulling the rear seat [3) forward ,
then remove Ihe rear seat.
SEAT DAMPER REMOVAU

INSTALLATION
Disconnect the seat damper
lower ball studs [21 .
111 from Ihe upper and I Lower side: Upper side:
Remove Ihe seal damper by pulling it Qui of Ihe damper
rubber [3J. 131
Installation is in Ihe reverse order of removal. ~
2-6
* 121 111
j
l
SEAT DISASSEMBLY/ASSEMBLY
Disassemble and assemble the rear seat according to
the illustration.
TORQUE :
Rea r seat b elt buckle bolt :
32 N'm (3.3 kgf'm, 24 IbOt)
PIPE GUARD SPECIAL SCREWS
~
~
@ @
~@
WIRES
~ SEAT BACK COVER

, ,- .:J
SEAT FRAME
BUCKLES
SPRING
UPPER BACKREST COVER
SCREWS
LOWER BACKREST
REAR CENTER COVER (4 PERSON

TYPE ONLY)
REMOVAL/INSTALLATION
Lift up the cargo bed.
""'-2
j2i
1 \ (1) 141
Remove the rear center cover [1] releasing the bosses ~ [3J ~
[2), tabs [3] and hooks (4] . i~
Installation is in the reverse order of removal. ~ r"'-
.~
~@
~ '"
( ;,
2-7
MIDDLE FENDER
RIGHT MIDDLE FENDER REMOVAU
INSTALLATION
4 person type only: Remove the rear center cover (page 2-7).
- right seal bottom cover (page 2-8)
- special bolt (1)
- three dips [2J
- right middle fender [3J
131
LEFT MIDDLE FENDER REMOVALI
INSTALLATION
4 p6fSOf) 'ype only: Remove the rear center cover (page 2-7).
- front seat cushion (page 2-4)
- special boll(IJ
- special screw [2)
- seven clips 13]
- left middle fender (4)
SEAT BOTTOM COVER

RIGHT SEAT BOTTOM COVER
REMOVAUINSTALLA nON
- front seat backrest (page 2-4)
- left. seal bottom cover (page 2-8)
- battery (page 21-4)
- PCM (page 4-28)
- starter relay switch (page 6-8)
Release the main fuse , harness clamp and wire band.
Remove the screw (I], five clips [2]. rubber mal (3] and
righ t seat bottom cover 14J.
TORQUE:
Right seat bottom cover mounting screw :
8 Nm (O.S kgfm , 5.9 IbHt)
2-8
LEFT SEAT BOTTOM COVER
REMOVALIINSTALLA nON
Remove the foUowing:
- front seat cushion (page 2-4)
- four screws [1]
- ten clips [2]
Remove the left seat bottom cover PI by releasing its
slots from the seat buckles [4].
TORQUE :
l eft seat bottom cover mounting screw:
B N'm (0.8 kg f' m, 5.9 IbH ! )
141
REAR STEP (4 PERSON TYPE ONLY)

REMOVAL/ INSTALLATION
- two bolts [1]
- five clips [2]
- rear step [3]
13)
MUD PROTECTOR (2 PERSON TYPE
ONLY)
REMOVALIINSTALLA TION
lift up the cargo bed.
Left side: Right side:
- clips [1J (2)
- left side: five clips
- right side: seven clips
- mud protector [2)
11)
12)
2-9
REAR FOOT WELL (4 PERSON TYPE
ONLY)
LEFT REAR FOOT WELL REMOVAU
INSTALLATION
Left side shown:
- left middle fender (page 2-8)
- rear step (page 2-9)
- twoclips[1J
- six screws [2J 131
- left rear foot well[3J
TORQUE :
Rear foot well mounting screw:
8 N'm (O.B kgf-m, 5.9 IbUt)
RIGHT REAR FOOT WELL REMOVAU

INSTALLATION
- rear step (page 2-9)
- three dips [lJ
- six screws [2J
- right rear fool well (3)
TORQUE:
Rear foot well mounting screw:
8 N' m (0.8 kgfm, 5.9 IbHt)
REAR SIDE COVER

REMOVAUINSTALLATION
Remove the following :
- seat bottom cover (page 2-8)
- two socket bolts (1]
- screw [2]
- five clips (3]
RighI side only: Temporarily remove the fuel filler cap [4).
Remove the rear side cover [5].
Inslallthe fuel filler cap.
TORQUE:
Rear side cover screw:
9 Nm (0.9 kgfm, 6.6 IbHt)
210
FRONT SIDE COVER
REMOVAUINSTALLATION
- front door (page 2-13)
- socket bolt /1 J
- two bolls [21
- five clips [31
- fron t side cover 141
TORQUE :
Front s ide cover socket bo lt:
9 N'm (0 .9 kgf'm, 6.6 Ibf-ft)
FLOOR PANEL
- fron t side covers (page 2-11)
- rear side covers (page 2-10)
- fourteen screws [1 )
- floor panel (2]
Installation IS in the reverse order of removal.
TORQUE :
Floor panel mounting screw:
8 N'm (0.8 kgf' m , 5.9 IbHt)
111
2-11
FRONT HOOD
Turn Ihe lock knobs [1] and release it by pulling the front , - - - - - - - - - - - - - - - - - - ,
hood [2J upward.
Remove the front hood by releasing Ihe hooks (3].
[3[ --~.i:>"
FRONT GRILLE
- front hood (page 2-12)
- headlight assembly (page 22-3)
Disconnect the headlight sub harness 2P (black)
connector [1J and release the wire band [21.
Remove Ihe six clips (3), four bolts [41 and front grille
[51
[4)
FRONT HEAT GUARD

[2) [1)
- three clips [1]
Remove the front heat guard [2] by releaSing the
bosses (3] and hook [4).
[4) [3[
2-12
FRONT FENDER
REMOVAUINSTALLATION
Remove the fronl grille (page 2-12).
Righfsideonly." Release the fuse box [1]. relay base [2J and headlight (21
sub harness 2P (black) connector [3].
Left side only: Release the combination meter sub harness 10P (gray)
connector [4] and headlight switch 2P (black) connector
(5(.
(1 I
LeftSid ~ (51
(41

(1 I
fronl side cover socket boll [1]
four clips {2] ~
.
- three special bolts [31
fronl fender [4]
~.
TORQUE :
Front side cover socket bolt:
9 N'm (0 .9 kgf'm, 6.6 IbHt) (21
(41
DOOR
FRONT DOOR PANEL REMOVAU
(NSTALLATION
Open the door.
Support the bottom of the fron t door panel [1]. (1 I
Remove the four socket bolts [2J and the door panel.
Close and latch the Installation is in the reverse order of removal.
door before
lightening the bolts.
TORQUE :
Front door hinge socket bolt:
30 N' m (3.1 kgf-m, 22Ibfft)
After installation, make sure the door latches securely
without requiring excessive force and opens smoothly.
If necessary, loosen the socket bolts and adjust the
door panel position. ."
(21
If the door rallies when closed, turn the door stopper {3]
rubber so that the door latches on the second click. (3~

2-13
I

REAR DOOR PANEL REMOVAU
INSTALLATION (4 PERSON TYPE
ONLY)
Open the door.
Support the bottom of the rear door pane! [1].
Remove the four socket bolts [2] and the door panel.
Close and latch the Installation is in the reverse order of removal.
door before
After installation, make sure the door latches securely
IJflhtemng the bolts. without requiring excessive force and opens smoothly
If necessary. loosen the socket bolls and adjust the
door panel position.
If the door rattles when closed, turn the door stopper
rubber [3J so that the door latches on the second click.
t-- - PI
131~
DOOR HINGE REMOVAU
INSTALLATION
Front shown: Remove the E-clip [1 ), pivot pin [21 and door hinge [3).
{21
Remove the bushing [4] from the lower side.
131
PI------ {41
DOOR HANDLE AND LATCH
REMOVAUINSTALLATION
Front shown: Remove the following:
-
-
three screws [1)
latch cover [2]
13~ 141
- two bolts [3]
- door latch plate assembly [41
121
2-14
pivot bolt [1J
- mounting bolt (2] [61 ..
tP~~-12[
- latch [3]
- lever [4] \
- spring [5] (by releasing the end off of Ihe door latch
plate [6].
I.
Hook rhe spring Installation is in the reverse order of removal.
ends onto the lever
and bracket in TORQUE:
positIOn as shown. Front door latch plate mounting bolt:
9 N'm (0.9 kgf'm , 6.6IbHt) 13[
15) 14[
REAR SEAT LATCH COVER

REMOVAL/INSTALLATION (4 PERSON
TYPE ONLY)
- bolt [1] . hook [2) and collar [3J
- three screws [4]
- rear seat latch cover (5]
14[
REAR SEAT LATCH REMOVAU

ONLY)
[5[
\
- rear seat latch cover (page 2- 15)
-
-
two latch plate mounting bolts 111
pivot bolt [2] 14) 16) ~
~
- two mounting bolts [3]
- rear seat latch [4]
- hook (51 181
-
-
lever [6]
spring [7) (by releasing the end off of the door latch
, -
plate [8])
[2[
TORQUE:
Rear door latch plate mounting bolt:
9 N' m (0.9 kgf'm , 6.6 IbHt) [7)
After installation , check the rear seat latch operation.
Loosen the mounting bolts and adjust the latch
position if necessary. 13[
2-15
INSTRUMENT PANEL
REMOVAUINSTALLATION
- front side covers (page 2-11)
- steering wheel (page 17-4)
Release and disconnect the following connectors:
- headlight switch 2P (black) connector \1 J
- combination meier 10P (gray) connector (2]
- ignition switch 5P (black) connector [3]

- drive mode selector lever knob [1]
- eight clips [2]
- four screws 13]
Release the clips [4) from the retaining bar [5] and
remove the instrument panel [6].
When installing the Installation is in the reverse order of removal.
lever knob. install
TORQUE:
with the tab (7)
facing the front. Instrument panel screw :
9 N'm (0.9 kgf'm , 6.6 IbHt)
11)
17)
[5)
/
~
2-16
FRONT FLOOR COVER
- front doors (page 2-13)
- brake pedal assembly (page 20-26)
- accelerator pedal assembly (page 7-17)
instrument panel (page 2-16)
- floor panel (page 2-11)
Disconnect the accessory socket 2P (black) connector
11 I
11 I
Take care not to Remove the seven setting bolts [1 J and the front floor
allow the from floor cover (2].
cover 10 Interfere
with the spnngs,
cable, and master
cylmder.
11 I
121
FRONT BUMPER
Remove the foUowing:
- two lower side bolts [1]
- two side bolts [2]
- four nuts [3] and bolts [4)
- front bumper [5]
121
111

217
MAINTENANCE LID
Remove the four setting bolls [1] and the maintenance , - - - - - - - - - -- - - - - - - - - - - ,
lid [2] .
(11
CARGO BED
BED DAMPER REMOVAU
INSTALLATION
lift up the cargo bed. Securely support the cargo bed
with wooden blocks or an equivalent to remove
pressure from the damper (1).
Hold the upper and lower ball studs [2]. and remove the 1
nuts (3) and damper.
Remove the supports and lower the cargo bed.
Installation is in the reverse order of removal. 1
CARGO BED REMOVAU

INSTALLATION
Release the two wire bands {1] and disconnect the , - - - - - -- - - - - - - - - - - - ,
brakeflaillight 6P connector [2].
Remove the bed damper (page 2-18).
Remove the two nuts [3] and pivot bolts [4].
While holding on to the bed frame and being careful not
to damage the brake/taillights and release lever,
remove the cargo bed [5). Set the cargo bed down on
its bed frame.
(51
I
;
141 131 (11 (31 141
2-18
BED SIDE COVER REMOVAU
INSTALLATION
4 PERSON TYPE :
- brake/taillight (page 22-4 )
- rear seat latch cover (page 2-15)
- rear door (page 2-14)
- two bolts [1]
Remove the bed side cover [2] while pulling out the
brake/taillight wire [3] from the hole.
TORQUE :
Bed side cover mounting bolt:
9 N'm (0.9 kgf' m , 6.6 IbHt)
2 PERSON TYPE :
- brake/taillight (page 22-4)
!
[2]
- three special bolts (1)
- mounting bolt [2]
Remove the bed side covef [3J while pulling oul the
brake/taillight wire (4] from the hole.
TORQUE :
Bed side cove r mounting bolt:
9 N' m (O.g kgf-m, 6.6 Ibf-ft) [3]
Bed side cover special bolt: [41
12 N'm (1.2 kgf' m, 9lbHt)
REAR STEP GUARD REMOVAL!

ONLY)
Open the rear door.
Remove the clip [1] and rear step guard [2] by releasing
its lower hooks (3) from the bed frame.
[3]

2-19
BED CENTER COVER REMOVAU
ONLY)
- nut 11]. bolt (2] and hook [3]
- four screws [4]
- bed center cover [5)
111
\
TORQUE :
Bed center cover screw:
8 N-m (0.8 kgf-m, 5.9 IbHt)
BED FRONT PANEL REMOVAU

INSTALLATION
4 PERSON TYPE:
12J
- bed center cover (page 2-20)
- twelve screws [1]
- bed front panel 12]
TORQUE:
Bed front panel screw :
8 N-m (0.8 kgf-m, 5.9 IbHt)
2 PERSON TYPE:
- bed lop cover (page 2-21)
- len screws [1 J
- four clips (2]
- bed front panel (3)
TORQUE :
Bed front panel screw:
8 N'm (0.8 kgf-m, 5.9IbHt)
111
1
2-20
1
BED TOP COVER REMOVAU
INSTALLATION
4 PERSON TYPE :
- rear seats (page 2-6)
bed center cover (page 2.20)
bed side covers (page 2-19)
two nuts [1 ]. bolts [2] and hooks [3J
two clips (4]
thirteen screws (5]
bed lOp cover [6J
Installation Is in the reverse order of removal.
TORQUE :
Bed top cover screw:
8 N'm (0.8 kgf'm, 5.9 IbHt)
151
161
121
'. .'
A
) 131 I.
11
rr .8
- -
e ~
/'
111

141
2 PERSON TYPE:
- bed side covers (page 2-19)
- four nuts [1] . bolts (2J and hooks [3J
- twenty screws [4]
- bed lop cover [5)
Installation Is in the reverse order of removal.
TORQUE :
Bed top cover screw:
8 N'm (0.8 kgf' m, 5.9 Ibf-ft)
121 , \
I
_L ClIo
.,
[31~ .\
'""" ,
0 0 .~
'i
;0::;
[51
0 0 0 '
[11~
"
0
I
"'" 0
""'
I .- -
141
2-21
BED UNDER COVER REMOVAL/
INSTALLATION
Remove the two dips 11J and bed under cover [2] by
releasing the hooks [3J from the bed frame.
jiJ
111 131
BED RELEASE LEVER REMOVAL/
INSTALLATION
- six bolts (1) and three upper holders (2J
- six collars [3]. release lever (4J and lower holders (S]
- two return springs [6)
When installing the Inslallation is in the reverse order of removal.
return springs, set
TORQUE :
them in the correct
dln!Jct/On as shown .
Bed release lever holder bolt:
14 N'm (1.4 kgf-m. 10 IbHt)
111
2-22
TAILGATE REMOVAUINSTALLATION
Remove the bed side covers (page 2-19).
Open the tailgate [1].
While holding the tailgate , remove the two socket bolts
[2]10 disconnect the support cables [3].
Remove the two washer-screws [4] and pivot brackets
[5] . then remove the tailgate from the bed frame.
Remove Ihe following:
- three tapping screws [S} and pivot pipe [71
- cap nul [8j, socket bolt [9], washer [10] and support
cable
- socket bolts [111. cable stay [12] and lock lever [13]
TORQUE :
Lock lever socket bolt: 12 N'm (1 .2 kgf'm , 9 IbNt)
Bracket washer-screw: 8 N 'm (0.8 kgf' m , 5.9 IbNt)
Pivot pipe screw: 8 N 'm (0.8 kgf'm , 5.9IbHt)
NOTE:
The tailgate must be latched on the cargo bed
securely. If it is not latched properly . loosen the lock
lever bolls and adjust the lock lever to the suitable
position.
2-23
SIDE NET
FRONT SIDE NET REMOVAU
INSTALLATION
Release the net buckle [1), snap hook [2] and Ihe strap , - - - - - - - - - - -- - - - - ,
[31
- retainer bolts [4]
- net retainers [5]
- fronl side net [6)
[31
REAR SIDE NET REMOVAU

ONLY)
Release the net buckle !1]. straps [2J and snap hook [3}. , -- - - - - - - -- - -- - - - ,
- retainer bolts 14]
- net retainers [5]
- rear side net 16]
2-24
OCCUPANT PROTECTIVE STRUCTURE
(OPS)
FRONT OPS REMOVAU
INSTALLATION
~ front side nels (page 2-24)
- eight nut caps (1]
- eight nuts (2) and bolls [3]
- buckles (4] and side net wires [5J
15)
- front OPS (6)
TORQUE:
Front QPS mounting nut:
49 N'm (5.0 kgf-m , 361bHt)
Tighten the nuts twice in an alternating sequence .
UPPER MIDDLE OPS REMOVAU

INSTALLATION
- fronl seat backrest (page 24)
- fronl OPS (page 2-25) 14)
rear side OPS (page 2-26)
- four nul caps (1)
- six nuts [2) and bolls [3)
- upper middle OPS [4)
TORQUE:
Upper middle OPS mounting nut:
49 N'm (5.0 kgf-m, 361bHt)
Tighten the nuts twice in an alternating sequence.
[2[
2-25
REAR UPPER OPS REMOVAU
ONLY)
- four nuts (1) and bolts [2] 13]
- rear upper OPS (3)
TORQU E:
Rear upper OPS m ounting nut:
49 N' m (5.0 kg f 'm , 36 IbHt)
III
REAR SIDE OPS REMOVAU
ONLY)
- rear seat belUretraclor (page 2.28)
rear side net (page 224) 151
rear upper OPS (page 2-26)
four nul caps [1]
four nuts [2], bolts (3) and side net wire [4)
rear side OPS IS]
Installation is in the reverse order of removal. 121
TORQUE:
Rear side OPS mounting nut:
49 N' m (5.0 kgf-m , 36 IbHt)
~ .~
Tighten the rear lower nuts twice in an alternating
sequence.
III 14] 131

REAR LOWER OPS REMOVAU
ONLY)
- rear side OPS (page 2-26)
- six bolts PI
- rear lower OPS 121
TORQUE :
Rear lower OPS mounting bolt:
49 N'm (5.0 kgf'm, 36 IbHt)
226
1
SEAT BELT
SEAT BELT INSTRUCTIONS
When storing the vehicle outdoors, cover the cabin
area and keep the seat belt assemblies away from
sunlight and rain .
Do not apply grease to the seat belt components. To
do so will cause dirt or sand to contamina te the
components, resulting in a loss of seat belt function.
If the seat belt gets wet, use a dry clean cloth and
allow to air dry. Never use a dryer.
If dirt or other foreign material enters the buckle,
remove it by rinsing the buckle with clean water and
allow to air dry. Make sure the buckle functions
correctly by inserting the tongue several times.
Replace the seat belt with a new assembly if any of
the following conditions occur. Do not disassemble
any part of the seat belt.
- the belt is ragged , worn or broken
- the vehicle is involved in a collision, overturns, is
submerged, etc.
FRONT SEAT BELT/RETRACTOR

Remove the fo llowing :
- anchor cover [1[
- upper anchor bolt [2J and lower anchor bolt (3J
- retractor nut [4] and front seat belt assembly [5J
NOTE:
Before installing, check that the retractor locking
mechanism functions, see below.
Assemble the wave washers and lock washers of
the anchor bolt properly if it was disassembled.
When installing the retractor, align the locating pin
[6] with the hole in the frame.
When installing the anchor bolts, make sure there no
r
twis ts or kinks in the belt.
TORQUE :
An c h or bolt: 32 N'm (3.3 kgf'm , 24 lbfft)
Retractor nut: 32 N' m (3.3 kgf' m , 24 IbHt)
[41
After installing , check the following:
- the belt does not lock when pulled slowly and it will
retract automatically when released . The seat belt is [31
designed to lock only during a sudden slop.
[61
- each anchor for free movement on the anchor bolt. If
necessary , remove the anchor bolt and check that ~-----------------~
the washers and other parts are not damaged or
improperly installed.
RETRACTOR FUNCTION CHECK
Mounted position
Before installing the retractor, check that the seal belt
can be pulled out freely within the parameters
mentioned below.
The seat bel! should not lock until the retrac tor is lilted
by 85 forward or backward or 55 left and right. Do not
attempt to disassemble the retractor.
Righ t Left
85 (-1 85
---~ -- - -
Front Rear
2-27
1
REAR SEAT BELT/RETRACTOR (4
PERSON TYPE ONLY)
Ii
131
- anchor cover [1]
- lower anchor bolt [2]
- retractor nut PI
- rear seal belt assembly 14]
141
NOT E:
Before installing, check that the retractor locking
mechanism functions (page 2-27).
Assemble Ihe washers and lock washers of Ihe
anchor bolt properly if it was disassembled.
When installing the anchor boll, make sure Ihere no
twists or kinks in the belt.
TORQUE:
Anchor bolt: 32 N'm (3.3 kgf-m , 24lbf-ftj
Retractor nut: 32 N'm (3.3 kgf' m, 24 Ibl-tt)
After installing , check the following:
,
- the belt does not lock when pulled slowly and it will
retract automatically when released. The seat belt is
designed to lock only during a sudden stop.
- each anchor for free movement on the anchor boll. If
necessary. remove the anchor bolt and check that
the washers and other parts are not damaged or
improperly installed.
121 III
FRONT BUCKLE
Remove the left seat bottom cover (page 2-8).
141
Remove the anchor bolt [1]. sea t belt buckle [2] and
131
collar [31.
NOTE :
Assemble the lock washer [4] of the buckle bolt
property if it was disassembled. [1]
TORQUE:
Front seat belt buckle bolt:
32 Nm (3.3 kgfm, 24 Ibf-ft)
REAR BUCKLE 121

For rear seat belt buckle (page 2-7).
2-28
UNDER GUARD
FRONT UNDER GUARD REMOVAU
INSTALLATION
- eleven bolts [1] and special washers [2)
- front under guard [3)
Install the front under guard with its differential oil
drain hole [4] facing the left side as shown.
131
oo~
0
0
0 ,
&
(!)crl CV
~
141
crl tV
[1 )/[2]
(!)
MIDDLE UNDER GUARD REMOVAU
INSTALLATION
- twelve boils [1J
- middle under guard [2)
Installati on is in the reverse order of removal.
(!) 121
111~ (!)
REAR UNDER GUARD REMOVAL!
INSTALLATION
- six bolts (1 J and special washers [2)
- rear under guard /3)
~31
______W"" fo\ \!i ~ \!i
[1J/[2] \.!J
2-29
EXHAUST SYSTEM
4 person type only: Remove the left rear foot weI! (page 2-10).
- left rear side cover (page 2-10)
- left middle fender (page 2-8)
seven bolts [1]
- heat guard plale [2]
Loosen the muffler band bolts [1].

- mounting nul [2], bolt [3], washers [4] and mount
rubbers [5]
- muffler (6] and gasket [7]
- two jOint nuts [8], exhaust pipe (9] and gasket (10)
- bushings [11] and mount rubber [12]
TORQUE :
Muffler band bolt:
22 N'm (2.2 kgf'm, 16 IbHt)
If the joint stud bolts [13) are loose. tighten them. Be
sure to verify the distance from the lop of the stud to
the cylinder head as shown .
Always replace the gaskets with new ones.
Tighten the joint nuts first , then tighten the mounting
nut and band bolts.
After installation, inspect the exhaust system for leaks.
f l I101 [13]
fI 171
28.0 0.5 mm
(1.10 0.02 in)
(11) (Green ) (2 places)
[11] (Black)
2-30
EXHAUST PIPE DISASSEMBLY/
ASSEMBLY
Loosen the band screws and remove the exhaust pipe , -- - -- - - -- - - - - - - ----,
cover [I].
Assembly is in the reverse order of disassembly.
TORQUE:
45 mm (1 .8 in)
Exhaust pipe cover band screw:
4 N' m (0.4 kgf' m, 3.0 Ibfh )
Position the cover bands in specified angle. 11J
Set the exhaust pipe cover in specified position.
30
/~
MUFFLER DISASSEMBLY/ASSEMBLY
NOTE :
For service of the spark arrester in the muffler, see
Maintenance section (page 3-18),
loosen the band screws and remove the muffler front
cover [11 and muffler rear cover (2].
TORQUE :
Muffler front cover band screw:
1.5 N 'm (0.2 kgf'm , 1.1 tbf-ft)
Muffler rear cover band screw :
3.2 N'm (0.3 kgf'm , 2.4 IbHt)
Position the cover bands in specified angle.
Set the exhaust pipe cover in specified position .
[2J
[1 J [.
\1.I. [t
=='='0.20 1 Top ! t Top
TOP.(g
\D$
I 1
I.
7.3 mm (O.29 in)
\ Top
2-31
MEMO
1,
1

3. MAINTENANCE
SERVICE INFORMATION
3-2 BRAKE FLUiD ........... ................. 3-14
MAINTENANCE MINDER INDICATOR 3-2 BRAKE PADS WEAR 3-15
MAINTENANCE SCHEDULE .. ......... ...... .. 3-3 BRAKE LIGHT SWiTCH .. .. 3-15
FUEL LINE ..... ..... ...... ... .. .. ...... ..... ........ 3-4 BRAKE SYSTEM ...... .. .. ....... ..... .... ....... 3-16
THROTTLE OPERATION ......... ..-............ 3-4 UNDERBODy .. .. .. 3-17
AIR CLEANER 3-5 SUSPENSION .. 3-18
AIR CLEANER HOUSING DRAIN TUBE .... 3-6 SPARK ARRESTER .. .. 3-18
SPARK PLUG ......................... 3-7 EXHAUST SySTEM .... ............. ... ....... 3-19
BATTERy
3-7 WHEELSITIRES ..... ................... ......... . 3-19
VALVE CLEARANCE .... ........... -............. 3-8 TIE-ROD AND JOINT BOOT ............. .... 3-19
ENGINE OIL .... ... .... 3-9 STEERING SySTEM

.. 3-20
COOLING SySTEM .. 3-11 SIDE NET ..... .... ..... 323
DRIVE SHAFT BOOTS ............. ........ .... 3-12 CHASSIS LUBRICATION POINTS .. 3-24
FINAL DRIVE OIL .. .. .. 3-13
3-1
MAINTENANCE
SERVICE INFORMATION
GENERAL
Place the vehicle on a level ground before starting any work.
When using the lock nut wrench, use a deflecting beam type torque wrench 20-inches long. The lock nut wrench increases the
torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut. The
specificallon given on the next page is the actual torque applied to the lock nUl, nol the reading on the torque wrench when used
with the lock nut wrench. The procedure later in the tex t gives both actual and indicated torque readings.
For gear selector cable adjustment, see Sub-transmission/Gearshift Linkage section (page 13-17).
For drive mode selector cable adjustment, see Drive ShatuFinal Gear section (page 18-65).
TOOL
Lock nul wrench
07MAA-SL00101
or 07916-SA50001 (U .S.A. only)

or 07AAA-TL2A100 (U.S.A. only)
MAINTENANCE MINDER INDICATOR

The maintenance minder indicator [1] appears when the mileage [21 or ,------------------~
operating hour [31 reaches the maintenance interval specified on the
~ 1. Initial maintenance
maintenance schedule (page 3-3).
1. Initial maintenance
- Appears at 100 miles (150 km) or 20 operating hours, whichever ~ 2. Regular maintenance interval 1
comes first.
2. Regular maintenance interval 1 ~ 3. Regular maintenance interval 2
- Appears at 600 miles (1,000 km) or 100 operating hours after the initial
II-- J
maintenance is periormed and the maintenance minder is reset.
See regular maintenance interval for 100, 300, and 500 operating 1[
hours (or corresponding mileage interval, whichever comes first) in the
maintenance schedule (page 3-3). ~ (- I <!J
3. Regular maintenance interval 2
- Appears at 600 miles (1,000 km) or 100 operating hours after the
N n . .~@
regular maintenance interval 1 is periormed and the maintenance
minder is reset.
.w, U
____ ,nn
....... M
See regular maintenance interval for 200, 400 , and 600 operating
"'"
hours (or corresponding mileage interval. whichever comes first) in the
maintenance schedule (page 3-3).
[3[
NOTE :
The initial maintenance indicator appears only once over the life of the 1 ____ 6~
'\
vehicle. The regular maintenance interval 1 and 2 indicators will appear
alternately. (4)
Reset the indicator after each scheduled maintenance is periormed. [21
To reset the indicator, press and hold the mode switch [41 and turn the L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~
ignition switch to ON. The indicator message will light up, and after 2
seconds will flash twice, the maintenance minder indicator is reset.
3-2
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the PRE-DRIVE INSPECTION in the Owner's Manual at each scheduled maintenance period.
Each item on the maintenance schedule requires some mechanical knowledge. Certain items (particularly those marked' and )
may require more technical Information and tools. Consult a dealer.
Inltlat
Service the listed Items at the indicated distance (or time, if given) Malnten Regular Maintenance Interval
anee
Frequency x 100 miles 1 I 6 12 18 24 30 36
x 100 km
Hours
1_~
20 100
20
200
30
300
40
400
50
500
60
600
1 12
Items ~~~~~~~~~~~OC~ii]i,a(le
Check engine oil 3-11) - - --iCheck oil and coolant at fuel stop
Months
Check innation and condition once a month
CheCk:,,,~e~S~~~~~~~~age 3-23)
jCheCk:i ::=::::9!~0 0 0 0 0 0 0
Check Check fluid level once a m~on~l~h:::=;::::;:=-
I I
t
II 0 0 0 0 0 0 0
Inspect valve clearance (page 3-8) -+---'0 Every 1,00Q km (600 miles) or 100 operating hours,
otherwise adjust only jf noisy
Clean spark arrester (page 3-18)
Clean air cleaner element (page 3-5), NOTE ~l[""IfE:i=t-
Check air cleaner hOUSing drain tube (page 3-S-r.-NOTE 2 Every 1,000 km (600 miles) or 100 operating hours,
whichever covers first
Check spark plug (page 3-7)
Inspect Idle speed (page 4-29) o
""'--Check fuel lines and connections (page 3-4) o o o
Check front and rear brakes (page 3-15 and 3-16). NOTE 3 o o o
Check front and rear final gear oil (page 3-13) o o o
Lubricate all hinges, latches, and pivots (page 3-24) o o
Inspect the following Items:
Suspension components (page 3-18)
Wheels (page 3-19)
Drive shaft boots (page 3-12)
Accelerator (throttle operation; page 3-4) and brake pedal o o
(page 3-16)
Brake light SWitch (page 3-15)
Exhaust system (page 3-19)
Battery terminal condition (page 3-7)
--~--------------+
Check parking brake adjustment (page 3-17)
Inspect the following items:
0_+-_-+ __+-__--,_ + o
Tie-rod ends (page 3-19)
Steering gear box and boots (page 3-20) o
Brake hoses and nnes (page 3-16)
Vehicle underbody (page 3-17), NOTE 4
Replace the following items:
Front and rear final gear oil (page 3-13)
Every 2 years (regardless of mileage)
Engine coolant (page 9-5)
Brake flUid (page 20-6)
Should be serviced by a dealer, unless the owner has the proper lools, service data. and is mechanically qualified.
In the Interest of safety. we recommend Ihese items be serviced only by a dealer
NOTES:
1. Service more frequently when operatirl9 in dusty areas. sand or snow
2. Service more frequently when operated in muddy, very wet condillons or freeZing temperatures.
3. Service more frequently when operated in muddy conditions.
4. Check the underbody whenever the under guard has been hit
3-3
MAINTENANCE
FUEL LINE
Remove Ihe right rear side cover (page 2-10).
Check the fuel line for deterioration, damage or
leakage.
Replace the fuel feed hose [lJ jf necessary.
THROTTLE OPERATION
Operate the accelerator pedal [1) and check that the
throttle cable operates smoothly with no binding or
slicking. Replace jf necessary.
Measure the accelerator pedal free play at the end of
the pedal.
PEDAL FREEPLAY: 5 - 10 mm (3/16 - 318 in)
Throttle pedal freaplay can be adjusted at either end of
Ihe throttle cable.
5-10mm
(3J16-3Jein)
Minor adjustments are made with the pedal side

adjuster.
Remove the front hood (page 2-12).
Slide the boot [1] off the adjuster 121. loosen the lock
nul [3], turn the adjuster as required and tighten the lock
nut.
Install the boot over the adjuster securely.
The adjustment at Major adjustments are made with the throttle body side
the pedal should be adjuster.
centered before
performing major
adjustment altM
throttle body.
4 person type only Remove the rear center cover (page 2-7).
Slide the boot (1) off the adjuster (2) . Loosen the lock
nut (31. tum the adjuster as required and tighten the lock
nut.
Install the boot over the adjuster securely.
Recheck the throttle operation
Install the front hood (page 2-12).
4 person type only: Install the rear center cover (page 2-7).
3-4
1
MAINTENANCE
AIR CLEANER
NOTE -
If the vehicle is used in dusty areas, sand Of snow.
more frequent inspections are required.
4 person type only: Remove the rear center cover (page 2-7),
Release the six retaining clips [1] from the air cleaner
housing cover (2] and remove the cover.
Loosen the air deaner element band screw [11 and

remove the air cleaner element assembly (2) from the
r--[1] ":'0-
I (2)
housing. t~
Remove the element band [1J and the element core

from the air cleaner element [3].
121 ;--=----=============
(2)
Wash the element in non-flammable or high flash point ~,======---------------:

solvent.
Squeeze out the solvent thoroughly, and allow the
element and filter to dry.
,
Squeeze oul
Wash

3-5
MAINTENANCE
Apply approximately 20 9 (0.7 oz) of Pro Honda Form
Filter Oil or equivalent oil to the inside of the element PRO HONDA FOAM FILTER OIL
111 111
Place the element into a plastic bag [2] and spread the
oil evenly by hand .
Install the etement core (1] into the air cleaner element ~===============::::;:::=~
[2] . aligning the locating pin with the hole.
Clean the inside of the air cleaner housing and cover.
Make sure the rubber seal in the air deaner cover is in
position and in good condition.
Install the element band onto the air cleaner element
and the element assembly over the connecting tube
flange of the housing securely.
Tighten the band screw.
Install the removed parts in the reverse order of
removal.
NOTE :
Failure to properly lighten the band screw will allow '---_ __ __ _ _ _ _ _ _ _ _ _ _ _ _--'
the air cleaner element to fall off and engine damage
could result.
AIR CLEANER HOUSING DRAIN TUBE

NOTE :
If the vehicle is used in muddy, very wet conditions
or freezing temperatures, more frequent inspections
are required.
lift up the cargo bed .
Remove the drain tube [1) from the bottom of the air
cleaner housing to empty any deposits.
Install the drain tube securely.
l ower the cargo bed .
PI
1
3-6
MAINTENANCE
SPARK PLUG
Remove the front seat cushion (page 2-4).
Release the rubber sheet from the tabs (page 3-9). 111
Clean the ama ~/ \
around tho spark Disconnect the spark plug cap [1) and clean around the
plug with spark plug base.
compressed err
Remove the spark plug [2] .
before removmg II,
and be sure thai no
debris is allowed 10
enter into the
'/
combustion
chamber BATTERY /'
~ -====-
/ 121
Check the insulator for cracks or damage, and the I

electrodes for wear, fouling or discoloration. Replace CENTER ELECTRODE
the plug if necessary.
RECOMMENDED SPARK PLUG: SIDE elECTRODE

8KR5E-11 (NGK), K16PR-U11 (DENSO)
Clean Ihe spark plug electrodes with a nylon wire type

brush or special plug cleaner.
INSULATOR
Check the gap between the center and side electrodes ~

with a wire-type feeler gauge.
SPARK PLUG GAP: 1.00 - 1.10 mm (0.039 _ 0.043 in) 1.00 - 1.10 mm
(0.039 - 0.043 In)
~J
If necessary. adjust the gap by bending the side l
electrode carefully.
Thread the spark plug in by hand to prevent cross-
threading and tighten it with a spark plug wrench.
TORQUE: 22 N'm (2.2 kgf'm , 16Ibf.ft)
Connect the spark plug cap.
Secure the rubber sheet with the tabs (page 3-9).
Install the front seat cushion (page 2-4).

Release the rubber sheet from the tabs (page 3-9).
Check the battery [1 J for loose connections or corroded
terminals [2).
~I
, ..
.0'-.
,
,
121
3-7
MAINTENANCE
VALVE CLEARANCE
NOTE:
Inspect and adjust the valve clearance while the
engine is cold (below 3so/95F).
Uft up the cargo bed .
Remove the right seal bottom cover (page 2-8).
Remove the crankshaft hole cap [1) and the liming hole
cap (21.
Remove the four bolts (1] . intake and exhaust valve

adjusting hole caps 12].
If the T man.: 's Rotate the crankshaft clockwise and align the "r mario;
passedwhenfrying (1) on the flywheel with the index mark [2] on the
/0 align /I with the crankcase cover.
IndeX mark, rotate Make sure the piston Is al TOe (Top Dead Center) on
the crankshaft only the compression stroke.
clockwise again This position can be obtained by confirming that there is
and align. This slack in both rocker arms. If there is no slack, it is
must be done /0 because the piston is moving through the exhaust
p!9venr the one- stroke to TDC. Rotate the crankshaft one full turn and
way decompressor match up the "r mark again.
system from
functlOmng and to
I
obtain the correct
valve clearance.
(1(
When checking the Check the clearance of each valve by inserting a feeler
clearance, slide the gauge (1) between the adjusting screw and valve stem.
feeler gauge from
the cen/er toward VALVE CLEARANCE:
the ou/side. IN : 0.15 0.02 mm (0.006 0.001 in)
EX: 0.32 0.02 mm (0.013 0.0011n)
,
I

3-8
MAINTENANCE
Adjust the valve clearance by loosening the lock nut [1]
and turning the adjusting screw (2) until there is a slight
drag on the feeler gauge.
Hold the adjusting screw and tighten the lock nut.
TORQUE: 17 N'm (1.7 kgf' m, 13 IbHt)
After tightening the lock nut. recheck the valve
clearance.
Coal new O-rings with oil and install them into the
groove in each valve adjusting hole cap.
Install the valve adjusting hole caps and tighten the
bolts securely.
Coat new O-rings with oil and install them into the
timing hole and crankshaft hole caps.
Inslall the timing hole and crankshaft hole caps , and
lighten them.
TORQUE:
Timing hole cap: 10 N' m (1.0 kgf' m, 7lbHt)
Crankshaft hole cap: 12 N'm (1.2 kg fm, 9lbHt)
Install the right seat bottom cover (page 2-8).
ENGINE OIL
LEVEL CHECK
NOTE '
Check the oil level after starting the engine and
allowing the oil to circulate through the engine
thoroughly. It is especially important on a dry sump
engine , due to the comparatively large volume of oil.
Do not snap Ihe throttle while idling or the oil level
reading will be inaccurate.
Place the vehicle on level ground.
Start the engine and let it idle for 3 - 5 minutes. If the air
temperature is below 1DOC (50 "F). tet the engine idle for
an additional 5 minutes (a total of 1D minutes).
Stop the engine and wail for 2 - 3 minutes .
Remove the front seat cushion (page 2-4) and release
the rubber sheet 11] from the tabs [2J.
Remove the dipstick (3) and wipe it clean.
Check the oil level by inserting the dipstick into the
engine without screwing it in.
Remove the dipstick and check the level.
The engine contains a sufficient amount of oil if the oil
level is between the upper level mark [4J and lower level
mark [5] on the dipstick.
l
3-9
MAINTENANCE
86 careful flOl to If the oil level is near or below the lower level mark.
pourthe oil In too remove the oil filler cap (1 J and add the recommended
quICkly to avoid engine oil up to the upper level mark.
overflow.
RECOMMENDED ENGINE OIL:
Pro Honda GN4 4stroke oil (U.S.A. and Canada)
or equivalent motor oil
API service classification : SG or higher
(except oils labeled as energy conserving on the
circular API service label)
JASO T 903 standard: MA
Viscosity: SAE 10W30
Reinstall the oil filler cap and dipstick.
(11
Install the rubber sheet to the two tabs.
OIL CHANGE
NOTE '
Change the oil with the engine warm 10 assure
complete and rapid draining.
Place the vehicle on level ground.
Remove the maintenance lid (page 2-18).
Remove the filter cap (release the rubber sheet from the
tabs).
Start the engine and let it idle for a few minutes.
Stop the engine.
Remove the drain bolt [1[ to drain the engine oil.
111
Remove the D -ring [11 and sealing washer [21 from the
drain bolt [3J.
Install a new sealing washer onto the drain bolt.
Coat a new D -ring with oil and instal! it into the groove
in the drain bolt.
After draining the oil completely, install the drain bolt
and tighten it.
TORQUE : 25 N' m (2 .5 kgf' m, 181bHt)
Remove the oil filler cap.

Be careful nor 10 Pour the recommended oil into the engine through the
pour the oil in /00 filler neck to the upper level mark on the dipstick (page
quickly to avoid 3-10).
overflow.
ENGINE Oil CAPACITY:
2.7 liters (2.9 US qt, 2.4 Imp qt) after draining
2.9 liters (3.1 US qt, 2.61mp qt) after draining/filter
change
4.1 liters (4.3 US qt, 3.6 Imp qt) after disassembly
Install the oil filler cap and the dipstick.
Check the oil level (page 3-9).
Make sure there are no oil leaks .
310 l
t
MAINTENANCE
OIL FILTER REPLACEMENT
Drain the engine oil (page 3-10),
Remove the fron t seat cushion (page 2-4). (21
Place a oil pan Remove the following:
- filter center boll [1 J
under the engine.
Take car(t not to - filter cover [2) ~,
lose the washer and - setting spring [3]
' ).:~:.,:;;--/ (61
spnng - washer (4]
- oil filler (5]
Remove the O-ring [6] from the oil filler cover and
cen ter bolt.
Coat new O-rings wi th engine oil and install them into
the grooves in the oil fitler cover and center bolt.
Install a new oil filter.
Reinstalilhe washer, spring . cover and center boll.
Tighten the center bolt.
TORQUE : 18 N 'm (1.8 kgf'm , 131bHt)
(1(
Fill the engine with the recommended oil (page 3-10). 14(
COOLING SYSTEM
l
RADIATOR COOLANT
13(
Check the coolant level of the reserve tank with the 11(
engine running at normal operating temperature.
~
The level should be between the "MAX" level line [1)
and "MIW level line [2) with the vehicle upright on a
level surface.
If the level is low, remove the reserve tank cap 13) and
fill the tank up to the "MAX" level line with a 1:1 mixture
of distilled waler and antifreeze (coolant preparation:
page 9-5).
RECOMMENDED ANTIFREEZE :
Pro Honda HP coolant or an equivalent high
quality ethylene glycol antifreeze containing 12(
silicate-free corrosion Inhibitors
I NOTICE I
Using coolanl with silicate corrosion inhibitors may
cause premature wear of waler pump seals or blockage
of radiator passages. Using tap water may cause
engine damage .
Check to see if there are any coolant leaks when the
coolant level decreases very rapidly.
If the reserve tank becomes completely emply, there is
a possibility of air gelling into Ihe cooling system.
Be sure to remove any air from the cooling system
(page 9-6).
3-11
MAINTENANCE
INSPECTION
- left seal bottom cover (page 2-9)
Check for any coolant leakage from the waler pump,
waler hoses and hose joints.
Check the water hoses for cracks or deterioration and
replace if necessary.
Check that all hose clamps are tight.
Remove the front grille (page 2 12).

Check the rad iator air passage for clogs or damage.
Straighten bent fins with a small, flat blade screwdriver
and remove insects, mud or other obstructions with
compressed air or low pressure water.
Replace the radiator if the air flow is restricted over
more than 20% of the radiating surface.
DRIVE SHAFT BOOTS

Check the drive shaft boots
damage.
11 J
I Front:
for culs or other 'F;;;:--r:.~~;::::;:::;:::;;;'~:\---l
For drive shaft boot replacement (page 18-8).
[11
Rear:
[11
3-12
MAINTENANCE
FINAL DRIVE OIL
FRONT FINAL GEAR CASE
lEVEL CHECK
Place the vehicle on a level surface.
Remove the oil filler cap [1] and check that the oil level
is up to the lower edge of the oil filler hole. (II
..... . - - . ,1'21
!..
Check for leaks if the oil level is low.

Pour Ihe oil through the filler hole until it reaches the
lower edge of the hote.
RECOMMENDED OIL: Hypoid gear oil, SAE #80
Coat a new D-ring [2] with grease and install it into Ihe
cap groove.
Inslallthe filler cap and lighten it.
TORQUE: 12 N'm (1.2 kgf-m, 9lbHt)
OIL CHANGE
Remove Ihe oil drain boll [3] and the filler cap to drain
the oil
When the oil is comple tely drained, installihe drain bolt
with a new sealing washer (4).
13VI41 ~
TORQUE: 12 N'm (1.2 kgf'm , 9 IbHt)
Fill the gear case with Ihe recommended oil
(page 3-13).
Oil CAPACITY:
665 em l (22.5 US OZ , 23.4 Imp oz) at drainIng
760 cm l (25.7 US OZ, 26.8 Imp oz) at disassembly
REAR FINAL GEAR CASE

LEVEL CHECK
Place the vehicle on a level surface.
Remove the oil filter cap [1] and check Ihalthe 011 level
11 I
is to the lower edge of the oil filler hole . ,
Check for leaks if the oil level is low.
Pour the oil through the filler hole until it reaches the
lower edge of Ihe hole.
RECOMMENDED OIL; Hypoid gear oil, SAE #80
Coat a new O-ring [2] with grease and install II into the
cap groove.
Install the filler cap and tighten it.
TORQUE: 12 N 'm (1.2 kgf-m , 9 IbHt)
OIL CHANGE
Place the vehicle on a level surface .
Remove the oil drain boll [3J and filler cap to drain the
oil.
When the 011 is completely drained, install the drain bolt
I3VI41 ~
with a new sealing washer [4J
TORQUE: 12 N'm (1.2 kgfm, 9 Ibf-ft)
Fi!I the gear case with the recommended oil

(page 3-13).
OIL CAPACITY:
140 eml (4.7 US OZ, 4.9 Imp oz) at draining
170 em l (5.7 US OZ, 6.0 Imp oz) at disassembly
3-13
MAINTENANCE
BRAKE FLUID
I NOTICE
Spilling fluid can damage painted. plastic O( rubber
parts. Place a rag over these parts whenever the
system is serviced,
NO TE :
Do not mix differenllypes of fluid , as they may not
be compatible with each other.
Do not allow foreign material to enter the system
when filling the reservoir.
When the fluid level is low, check the brake pads for
wear (page 3-15). A low fluid level may be due to
worn brake pads . If the brake pads are worn. the
caliper piston is pushed out, and this causes a low
reservoir level. If the brake pads are not worn and
the fluid level is low, check entire system for leaks
(page 3-16).
Check the fluid level of the reservoir.
If the level is near the ~MIN levelline [1J, add the brake
nuid as follows.
Remove the cap cover [2] and the reservoir cap 131, and
fill the reservoir with DOT 4 brake fluid from a sealed
container to the "MAX" level line [4].
Install the reservoir cap so the arrow [5] faces forward .
I
(3)
(41
Before installing the cap cover (1), tum the cap cover ,:========~~~:"""''''~~~~
inside oul. Inslalilhe cover over the reservoir cap and {II
pull it down over the cap and filler neck. ~'_ .u:' \
to
Instailihe front hood (page 2-12), 'f.I
YJ-"O .1-- ,
~"- ~ ---'
f'J;'-'>

3-14
MAINTENANCE
BRAKE PADS WEAR
NOTE:
The fronl and rear brakes have audible brake wear
indicators. When the brake pads need replacing, the
brake will screech while applying the brake.
FRONT
If you hear a continuous metallic friction sound from the
front brake wear indicators when applying the brake,
replace the front brake pads (page 20-8).
REAR
Check the rear brake pads for wear.
Replace the brake pads if the wear limit indicator mark [21
[1] on the caliper aligns with the reference mark [2] on
the caliper bracket when the brake is applied.
For rear brake pad replacement (page 20-8).
BRAKE LIGHT SWITCH

Check that the brake light comes on just prior to the
brake actually being engaged. [11
If the light fails to come on, adjust the brake light switch
(1) so thai the light comes on at the proper time.
Hold the switch body and tum the adjusting nut [2J . Do
not tum the switch body.
~,
12[
j
3-15
MAINTENANCE
BRAKE SYSTEM
HYDRAULIC BRAKE
Firmly apply Ihe brake pedal [1] and check that no air
has entered the system .
If the brake pedal feels soft or spongy when operated.
bleed the system (page 207).
Inspect the brake hoses (2] . pipes 13] and fittings for
deterioration, cracks, damage or signs of leakage.
Tighten any loose fittings.
Replace hoses, pipes and fittings as required .
BRAKE PEDAL HEIGHT

Check the brake pedal [1] for deformation or damage.
Check the brake pedal for smooth operation by
operating it several times.
Measure the brake pedal heighl from the accelerator
pedal [21.
STANDARD PEDAL HEIGHT: 2S-40mm (1-1-315In)
Adjust the pedal height as follows .
Remove the lock plate bolt (T50) [3] and lock plate [4J.
Loosen the lock nul [51 and turn Ihe adjusting bolt (T50)
[6] as required. Temporarily tigh ten the lock nut while
holding Ihe adjusting nul.
Make sure the brake pedal freeplay at the end of the
pedal is within 1 - 5 mm.
If the free play is not within standard value, loosen the
lock nut and turn the adjusting bolt until the free play is
within 1 - 5 mm .
Recheck the pedal height after adjusting the pedal
freeplay.
After adjustment procedure is completed . lighten the
Jock nut to the specified torque while holding the
adjusting boll.
TORQUE : 22 N'm (2.2 kgf'm , 161bHt)
Install the lock plale against the lock nut and tighten the
plate boll.
TORQUE : 22 N'm (2.2 kgf-m, 16 Ihl-tt)
Check for brake light operation (page 3-15).
1
1
3-16 ,
MAINTENANCE
PARKING BRAKE
Pull the parking brake lever [1] and measure the
distance the parking brake starts to take hold.
I
FREEPlAY : 40 - 60 mm (1-9116 - 23f8 in)
If the freeplay is nol as specified, adjust the parking
brake as follows.
Make sure the Adjust the parking brake lever freeplay by turning the
cutout in the adjusting nut [1].
adjusting nut is
Release the parking brake lever fully, and check thai
seated on the )omt
the brakes do nol drag when the rear wheels are
pm.
turned. Readjust if necessary.
UNDERBODY
Check the under guards [1] for cracks or damage.
Replace the under guards (page 2-29) as required.
.. -
\' ~;
[11
3-17
MAINTENANCE
SUSPENSION
Loose. worn or Check the action of the front and rear shock absorbers
damaged [1] by compressing them several times. Front
suspension parts Check the entire shock absorber assembly for signs of
Impair vehiCle leaks, damage or loose fasteners .
stability and control. Check the suspension arms [2] for damage or
defonnation.
Replace worn, loose or damaged components that
cannot be repaired .
Tighten all nuts and bolls.
12J
Rear:
SPARK ARRESTER
Remove the three bolts [1 J and the spark arrester [2J
with the gasket 13J.
Use a brush to remove carbon deposits from the screen
mesh [4), being careful nol to damage it.
The screen mesh must be free of breaks and holes.
Replace the spark arrester jf necessary.
Insta!1 the spark arrester with a new gasket and tighten
the bolts securely.
(4(
I
318
MAINTENANCE
EXHAUST SYSTEM
Start the engine and inspect the exhaust system for
leaks. Stop the engine and check for any sign of
exhaust gas leakage.
WHEELS/TIRES
INSPECTION
Tire pressure Check the tire pressure with the lire pressure gauge .
should be checked
when the tires are RECOMMENDED TIRE PRESSURE
cold. FRONT:
Up to 300 kg (661 Ibs) load :
70 kPa (0.7 kg/cm 2, 10 psi)
Up to maximum weight capacity:
70 kPa (0.7 kg/cm 2, 10 psi)
REAR :
80 kPa (0.8 kglcm2, 12 psi)
Up to maximum weight capacity :
120 kPa (1 .2 kg/cm 2, 18 psi)
Check the tires for cu ts, embedded nails, or other
damage.
Measure the tread depth at the center of the tires in al
least three locations, using a tire depth gauge .
Replace the tires when the tread depth reaches the
following limit.
MINIMUM TREAD DEPTH (Front/Rear): 4 mm (0.2 in)
Raise the wheels off the ground and check the bearings
in the hub for excessive play or abnormal noise .
Check the wheels for crack , deformation or damage.
Check the wheel nut are tightened . Torque any loose
nut.
TORQUE: Front/Rear: 133 N m (13.6 kgfm , 981bHt)
TIE-ROD AND JOINT BOOT

Raise the front wheel off the ground.
Check the tie-rod joint nuts for looseness.
Check the ball joint boots of the tie-rod [1] for tears or
other damage.
Check for any looseness of the tie-rod ball Joints [21 by
holding and attempting to move the wheel at the top
and bottom and at the front and rear.
(2J ---H"""
If any looseness is noted, inspect the following .
- tie-rod (page 17-12) and ball joint (page 17-9)
- knuckle bearing (page 19-10)
3-19
MAINTENANCE
STEERING SYSTEM
GEAR BOX BOOT AND OPERATION
l
CHECK
Raise the front wheets off the ground.
[1J
Check the gear box boots [1 J for cuts or other damage.
If the bool ls damaged, replace it (page 17-9).
Check that the steering wheel 12] moves freely from
lock to lock.
If the steering wheel moves unevenly, binds, makes a
noise, or has horizontal or vertical movement, inspect
for looseness of the steering column and gear box
fasteners, and the steering linkage joints (page 17-4).
[2J
ROTATIONAL PLAY CHECK

Set the front wheels in the straight ahead position with '-----:-[1"[- - - - - - - - - - - - '
all the wheels on the ground.
Measure how far you can turn the steering wheel (1) left
and right without moving the front wheels.
ROTATIONAL PLAY : 0 - 10 mm (0 - 215 in)
If the play exceeds the limit, adjust the rack guide

(page 321 l,
If the play is still excessive after rack guide adjustment.
inspect the steering linkage and steering gear box
(page 17-9).
1
320
1
MAINTENANCE
TURNING LOAD CHECK
NOTE:
This test should be done with original equipment
tires and wheels at the correct tire pressure.
Raise the front wheels off the ground.
11)
Set Ihe drive mode selector lever to the "2WO"
"4WD" position to free the differenliallock.
Set the front wheels in the straight ahead position.
Attach a spring scale to Ihe steering wheel [1J.
Pull the scale as shown and read it as soon as Ihe fron l
tires begin to turn.
INITIAL TURNING LOAD: 13.7 N (1.4 kgf, 3 .1Ibf)
~\
If the scale reads more than the specification, inspect
the steering linkage and steering gear box (page 17-9).
RACK GUIDE ADJUSTMENT

Remove Ihe right front wheel (page 19-6)
13)
Set the left front wheel in the straight ahead position.
Loosen the screw lock nut [1] with the special 1001 , then
loosen the rack guide screw (2).
TOOL:
Lock nut wrench [3] 07MAA-S L00101or
07916-SA50001 or
07AAA-TL2A100
(U .S.A. only)
Tighten the rack guide screw until it is stops. then

loosen it.
Tighten the rack guide screw to 4.9 N 'm (0.5 kgf.m , 3.6
IbHt), then back it off to the specified angle.
SPECIFIED RETURN ANGLE : Below 20 0 20
Refer 10 torque Tighten the lock nut using the same tool while holding 12)
wrench reading the rack guide screw stationary.
mformation on page
TORQUE: Actual : 24 N'm (2.4 kgf 'm , 181bHt)
32 'Service
Information" Indica ted : 19 N'm (1.9 kgf' m , 141bHt)
Install the right front wheel (page 19-6)

Check for unusual steering effort through the complete
turning range. \~
Check the steering wheel rotational play (page 3-20). (1)
3-21
MAINTENANCE
WHEEL ALIGNMENT
FRONT TOE INSPECTION
Place the vehicle on level ground with the front wheels
facing straight ahead.
Mark the centers of the tires with chalk to indicate the
axle center height.
Align the toe-gauge [11 with the marks on the tires as
shown.
Slowly move Ihe vehicle back until the wheels have ~========F='=O="=t=========
rotated 180" so the marks are a\ the rear of Ihe tire and i.. .. i
aligned with the gauge height. i i
Measure Ihe toe on Ihe rear part of the tires at the same i. I.
points with no load on Ihe vehicle.
TOEIN : 0 10 mm (0 2/5 in)
NOTE:
The front and rear measurements are the same for
this vehicle.
Rear
When Ihe toe is out of specification. adjust it by ~==:;;;;;;;;;;;;;;;;;~:;:::;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;~

changing the length of both tie-rods [1] equally by
loosening the lock nuts [2] and turning each tie-rod
while holding Ihe ball joint [3] .
After adjusting the tie-rods, lighten each lock nut while
holding the ball jOint.
TORQUE: 44 N'm (4.5 kgf'm, 32 IbHt)
Make sure Ihe gear box boots [4] are not twisted or
displaced.
322
MAINTENANCE
TURNING RADIUS INSPECTION
Be sure that the Raise the vehicle off the ground, set the turning radius
vehicle is level with gauges [lJ beneath the front wheels and place boards
the wheels on the (that are the same height as the radius gauge) under
radius gauges and the rear wheels, then lower the vehicle.
boards. Apply the parking brake.
Set the drive mode selector lever to the "2WO" or
"4WD" position to free the differential lock.
Turn the wheels left and right with no foot brake
applied. and measure the turning radius angle of both
wheels.
TURNING RADIUS ANGLE: Inward : 41 "
Outward : 33 (reference)
If the measurements are not to specification, even up 111
both sides of the tie-rod [2] thread length while adjusting
the toe (page 3-22).
SIDE NET
Check the side net [1] webbing for tear or damage.
Visually inspect the snap hooks (2), buckle [3) and side Front shown:
net rings (4) for wear or damage and replace the side
net assembly if necessary.
Measure the snap hook thickness.
SERVICE LIMIT: 6.0 mm (0 .24 in)
If it is less than the service limit, replace the side net

assembly.
12)

3-23
MAINTENANCE
CHASSIS LUBRICATION POINTS
lubricate the following components.
- A: rear seat latches (4 person type only)
B: cargo bed pivots
C: cargo bed strikers and latch pivot
D: tailgate pivots (page 2-23)
E: door latches
F: brake pedal pivot (page 20-26)
G: accelerator pedal pivot (page 7-17)
1
H: parking brake lever pivot (page 20-27)
I: drive mode selector lever pivots (page 18-63)
J: gear selector lever pivots (page 13-16)
Check. for smooth operation after lubrication.
B . --..
~ c
1
.--.0
Front:
,
E
.--.. Rear:
.--.. F ~._ _ G .-;;.,

,
9 ( 1
C0-
I
E .--.. .--.. J ...--.
3-24
1
Downloaded from www.Manualslib.com manuals search engine (
4. PGM-FI SYSTEM
SERVICE INFORMATION 4-2 MIL CIRCUIT INSPECTION ................... 4-25
SYMPTOM TROUBLESHOOTING 4-3 TP SENSOR/MAP SENSOR

(SENSOR UNIT) .............................. .... 4-25
COMPONENT LOCATION
4-4
ECT SENSOR .... ... .. ... ......... ................ 4-27
PGMFI SYSTEM DIAGRAM ................... 4-5
IAT SENSOR .................... ............... 4-27
PGMFI TROUBLESHOOTING
INFORMATION
4-6 VS SENSOR ...................................... 4-27
PGMFI DTC INDEX 4-9 PCM ....................... .............. ......... .... 4-28
PGM -FI DTC TROUBLESHOOTING ........ 4-10 ENGINE IDLE SPEED

4-29
4-1
PGMFI SYSTEM
SERVICE INFORMATION
GENERAL
The programmed fuel injection system is equipped with a Self-Diagnostic System (page 4-6). If the MIL blinks, follow the Self
Diagnostic Procedures to remedy the problem.
When checking the PGM-FI system, always follow the steps in the troubleshooting now chart.
The PGM-FI system has a fait-safe function to secure a minimum running capability even when there is a malfunction in the
system. When any abnormality is detected by the self-diagnosis function, running capability is secured by making use of the
numerical values of a situation preset in advance in the simulated program map. It must be remembered, however, that when
any abnormality is detected in fuel injector andlor the CKP sensor, the fail safe function stops the engine to protect it from
damage.
Prevent dirt and debris from entering the throttle bore, IACV, sensor hole, clean them using compressed air.
A faulty PGM-FI system is often related to poony connected or corroded connectors. Check those connections before
proceeding.
When disassembling the PGM-FI parts, note the location of the O-rings. Replace them with new ones upon reassembly.
Use a digital tester for PGM-FI system inspection,
TOOLS
Test probe, 2 pack SCS service connector
07ZAJ-ROJA110 070PZ-ZY30100

I

42
PGMFI SYSTEM
SYMPTOM TROUBLESHOOTING
When the vehicle has one of these symptoms, check the OTe or MIL blinking, refer to the DTe index (page 4-9) and begin Ihe
appropriate troubleshooting procedure. If there are no OTC stored in the PCM memory. do the diagnostic procedure for the
symptom, in the sequence listed below, until you find the cause.
~----~------~~~
e.~~~~S~y~m~p~t~
o~m~~~c-+-co,--,"
Diagnos i s P",o~c~e~d~u~,e~____~__~c<~~<c"A
~rs~O~c~h~e~c~k~f,"
o,
Engine cranks but won't start 1. Inspect Ihe ignition system No fuel to fuel injector
(No DTe and MIL blinking) (page 5-5). - Clogged fuel filter
2. Inspect the fuel supply system - Pinched or clogged fuel feed hose
(page 7-5). - Pinched or clogged fuel tank breather hose
- Faulty fuel pump
- Faulty fuel pump circuits
Intake air leak
Contaminated/deteriorated fuel
Engine cranks but won't start

(No fuel pump operation
sound when turning the
1 1. PCM powerlgroCu~n~d~
malfunction (page 4-28).
2. Inspect the fuel pump system
Faulty fuel injector
IACV stuck closed
ci~'C~UC.it~S----+----';O~p~e~n~c~i'~C~ui~t2in~t~h~e~p~o~w~ecr input (Redlwhite) and/
or ground (Green) wire of the PCM
Faulty main relay or related circuit
ignition switch to ON (I)) (page 7-9) . Faulty ignition switch or related circuit
Blown FI fuse (10 A)
."'~~'-__C-.-""~~~~~~o-________+-c-~B~ro~wn IGNfuse~(1~5~A~)~_________________
Engine stalls, hard to start, 1. Check the idle speed Restricted fuel feed hose
rough idling (page 4-29). Contaminated/deteriorated fuel
2. Check the IACV (page 7-23). Intake air leak
3. Inspect the fuel supply system Restricted fuel tank breather hose
(page 7~-~5L).~__~__________-r--=-~F~a~u~lt~y~ig~n~it~io~n",system
Backfiring or misfiring during Check the ignition system. Faulty ignition system
acceleration
Poor performance 1. Inspect the fuel supply system Pinched or clogged fuel feed hose
(driveability) and poor fuel (page 7-5). Faulty fuel injector
economy 2. Check the air cleaner fOf Faulty ignition system
I-======~______I-.--'c:;;ro:og"g'i'ing (page 3-5).
Idle speed is below 1. Check the idle speed IACV stuck closed
specifications or fast idle too (page 4-29). Faulty fuel supply system
low (No oTC and MIL 2. Check the IACV (page 7-23). Faulty ignition system
blinking) ____-I__'--V~alve clearance
Idle speed is above 1. Check the idle speed IACV stuck opened
specifications or fast idle too (page 4-29) Faulty ignition system
high (No oTC and MIL 2. Check the accelerator pedal Intake air leak
blinking) operation and pedal freeplay Engine top end problem
(page 3-4) Clogged air cleaner
.=----e.3~._":
Check the IACV (page 7-23L).____I-'--;v~ar~'~e~c~re~a~'a~n~c~e'.__---------------------
Mil slays on but no oTCs Troubleshoot the MIL circuit Faulty MIL circuit
set, or Mil never comes ON (page 4-25).
at all
MIL stays on at all times Check the oLC circuit (Brown/red Short circuit in the oLC related wire
(No oTC set) wire) for short circuit.
4-3
PGMFI SYSTEM
COMPONENT LOCATION
FUEL INJECTOR
MAP SENSOR!
IACV TP SENSOR
(SENSOR UNIT)
Eer SENSOR
IAT SENSOR
DLC
/ ~~
MAIN RELAY,
\ FUEL PUMP RELAY
I==-\
j
VS SENSOR
BATIERY
1,,
MAIN FUSE (40 A)
PCM
FUEL PUMP FUSE BOX
CKP SENSOR
,
I
j
I
1
4-4
1
PGM-FI SYSTEM
PGM-FI SYSTEM DIAGRAM
MAIN FUSE (40 A) IGNITION SWITCH
BATTERY
' - '-B-'1 '---0-- MAIN RELAY
BuM'~Gf IGN FUSE (ISA)

R -B-BWW--i--+--..... ,ww~
__ leo,
FI FUSE (lOA)
.------~ RIW -B- RIB!
'~'"
..
r
~~'
FUEL PUMP
CKP
" ...... RELAY
Ot
SMR 831
SENSOR
-,~ -
FlR 820 ~G
~
B23 pcp
-G- -
SE NSOR UNIT
. - ~--- - -
1 FUEL PUMP
" vec
BI. TH
INJ B33
""' -~".
FUEL
" '" INJECTOR
@~
(12 - 1)
MAP
SEN SOR [ L~ 825 PB
tON 811
"""----, BUR
@
(1-1, 1-2)
i IGN ITION
.___________ .-.J, COIL
PCM SPARK
JAT GrIB
(33-21 ..,LPLUG
SENSOR [ II "" _ " B2S TA
"" ,
@(9-19-2) - GR - lACVl"
ECT
""W
1ACV1B
lACV-2A 830
IACV26
"
C9) IACV
@(29-11
.,.
SENSOR
,
MIL
@(7", 72)
1,====== :,
SERIAl.
""
M-TXOXO 1\21
816 RR VSP
GND Gl
" SENVB
C~O~M:-;;;B~IN~A~T~IO"N;;-;M~E~T'"'ER -=
p,,, co ""' ----------'
~
813 LG (64-1 , 642)
VS SENSOR
821 POI
~
@(11-11
a10 PG2 K-liNE 811 om l {SCSSERVICE
CONNECTOR
SCS 829 ,,~
EO OLC
@( IDTC
A Engme does not stan PCM Ct C-3 A_1 AII BI 8-1\
Short temmats for reading

A-12 A22 B22
I
DTC
Bt Blacll o Orange
Sf: Brown R Red
Su: Blue V Violet
G' Green W While
Gr: Gray Y Yellow
Lg: Ught green P Pink c~ CO, A23 633
4-5
PGM-FI SYSTEM
PGM-FI TROUBLESHOOTING INFORMATION
GENERAL TROUBLESHOOTING
Interm ittent Failure
The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does not come on , check
for poor contact or loose pins at all connectors related to the circuil with Ihe trouble. If the MIL was on, but then went Qui, Ihe original
problem may be intermittent.
Opens and Shorts
Opens and "Shorts" are common electrical terms . An open is a break in a wire or at a connection . A short is an accidental
connection of a wire to ground or to another wire. In simple electronics. this usually means something will not work at all. With
PCMs this can mean something will work, but not the way it's supposed to.
If the MIL has come on
Refer to DlG READOUT (page 4-7).
If the MIL did not stay on
If the MIL did not stay on, but there is a driveabihty problem, do the SYMPTOM TROUBLESHOOTI NG (page 4-3),
SYSTEM DESCRIPTION
SELF-OIAGNOSIS SYSTEM
The PGM-FI system is equipped with the self-diagnostic system. When any abnormality occurs in the system, the PCM turns on the
Mil and stores a DTC in its erasable memory.
FAIL-SAFE FUNCTION
The PGM-Fl system is provided with a fail-safe function to secure a minimum running capability even when there is trouble in the
system. When any abnormality is detected by the self-diagnosis function, running capability is maintained by pre-programed value
in the simulated program map. When any abnormality is detected in the fuel injector, the fail-safe function stops the engine to
protect it from damage.
OTe (Diagnostic Trouble Code)
The OTC is composed of a main code and a sub code and it is displayed as a hyphenated number when retrieved from the PCM
with the MCS.
The digits In front of the hyphen are the main code, they indicate the component of function failure.
The digits behind the hyphen are the sub code, they detail the specific symptom of the component or function failure.
For example. in the case of Ihe TP sensor:
- oTC 08 - 1 = (TP sensor voltage) - (lower than the specified value)
- oTC 08 - 2 = (TP sensor voltage) - (higher than the specified value).
The MAP, ECT , TP and IAT sensor diagnosis will be made according to the voltage output of the affected sensor.
If a failure occurs , the PCM determines the Function Failure, compares the sensor voltage output to the standard value, and
then outputs the corresponding DTC to the MCS .
MIL Blink PaHern
If the MCS is nol available , DTC can be read from the PCM memory by the MIL blink pattern.
The number of MIL blinks is the equivalenlthe main code of the DTC (Ihe sub code cannot be displayed by the MIL).
The MIL will blink the current OTC . in case the PCM detects the problem at present, when the ignition switch ON or idling . The
Mil will stay ON when driving (engine speed is over 2,000 rpm).
The Mil has two types of blinks. a long blink and short blink. The long blinking lasts for 1.3 seconds. the short blinking lasts for
0.5 seconds. One long blink is the equivalent of ten short blinks. For example, when two long blinks are followed by nine short
blinks , the MIL is 29 (two long blinks = 20 blinks, plus nine short blinks).
When the PCM stores more than one OTC . the Mil will indicate them by blinking in the order from the lowest number to highest
number.

4-6
PGM-FI SYSTEM
MIL Check
When the ignition switch is turned to ON (I), the MIL will stay on for a few seconds, then go off. If the MIL does nol come on,
troubleshoot the MIL circuit (page 4-25).
CURRENT DTC/STOREO DTC
The DTG is indicated in two ways according 10 the failure status.
In case the PCM detects the problem al present, the MIL will come on and the MIL will start to blink as its DTG. It is possible to
readout the MIL blink pattern as the current DTC.
tn case the peM does not detect any problem at present but has a problem stored in its memory. the MIL will nalright and blink.
If it is necessary to retrieve the past problem, readout the stored DTG by following the DTG readout procedure.
MCS INFORMATION
The MCS can readout the DTG, stored data. curren t dala and other peM
condition.
How t o connect the MCS
Tum the ignition switch to OFF (0).
Remove the OLC [11 from the dummy connector [21.
Connect the MCS to the OLC.
Tum the ignition switch to ON (I), and check the OTe and stored data.
NOTE :
Stored data indicates the engine conditions when the first malfunction
was detected.
DTC READOUT
When the ignition switch is tumed to ON (I), the MIL will stay on for a few
seconds , then go off.
Atter performing diagnostic troubleshooting, erase the OTC(s) (page 4-8)
and test-drive the vehicle to be sure that the problem(s) have been
removed.
If the MIL stays on or blinks, connect the MCS to the OLC (page 4-7).
Then read the DTC and follow the troubleshooting index:
- PGM FI system: page 4-9
- AfT system: page 16-13
To read the OTC with the MIL blinking. refer to the following procedure.
4-7
PGM-FI SYSTEM
Reading OTC with the MIL
Start Ihe engine and lei it idle. Read the MIL blinking Ihat is indicated as Ihe
current OTC and refer to the troubleshooting index:
- NT system: page 16-13
When retrieving the stored OTC, refer to the following procedure.
Remove the OLC from the dummy connector (page 4-7).
Short the OlC [1] using the special tool.
TOOL:
scsservice connector [2] 070PZ-ZY30 100
CONNECTION : Brown /red - Green

Turn the ignition switch 10 ON (I), read and nole the Mil blinks, and refer to
the troubleshooting index:
- AfT system: page 16-13
NOTE :
If the PCM has any OTC in its memory. the MIL will start blinking.
ERASING DTC
Erase the OTC wi th the MCS while the engine is stopped.
How to erase the OTC without MCS
1. Remove the Ole from the dummy connector (page 4-7).
2. Short the OlC (1) using the special tool.
TOOL:
SCS service connector [2J 070PZZY30100
CONNECTION : Brown/red - Green

3. Turn the ignition switch to ON (I).
4. Remove the special tool from the OlC.
5. The Mil will light for approximately 5 seconds. While the MIL lights ,
short the OLC again with the special tool. The OTC is erased if Ihe MIL
goes off and slarts blinking.
NOTE :
The OLC must be shorted while the MIL lights. If not, the MIL will not
start blinking.
Note that the OTe cannol be erased if the ignition switch is turned to
OFF (O) before the MIL starts blinking.
CIRCUIT INSPECTION
INSPECTION AT PCM CONNECTOR
Always clean around and keep any foreign material away from Ihe PCM ~-----------------,
connector before disconnecting it.
A faulty PGM-FI system is often rela ted to poorly connected or corroded
111
connections. Check those connections before proceeding.
Do not puilihe wire harness while disconnecting the PCM connectors.
In testing at PCM connector (wire harness side) terminal. always use the
;
test probe [1]. Insert the test probe into the connector terminal, then
attach the digital multimeter probe to the test probe.
1
TOOL :
Test probe, 2 pack 07ZAJROJA 110
4-8
PGM-FI SYSTEM
PGM-FI DTC INDEX
NOTE :
If the MeS is not used, perform all of the inspection on the corresponding main code (digits in front of hyphen) of the oTC .
Dre Referto
Function Failure SymptomfFail-safe function
page
1-1 t MAP sensor circuil low voltage (less than 0.195 V)
MAP sensor or its circuil malfunction
- -- Engine operates normally
Fail-safe value: 60 kPa
410
-
1-2 MAP sensor circuit high voltage (more than 3.804 V) Engine operates normally 4-11
- Loose or poor contact of the sensor unit connector Fail-safe value: 60 kPa
7-1
MAP sensor or its circuil malfunction
EeT sensor circuil low voltage (less than 0.015 V) Hard start al a low temperature 4-12
Eel sensor or its circuit malfunction Fail-safe value: 78Cf172F
Cooling fan turns on
EeT sensor circuit high voltage -(more than 4.981 V) Hard start at a low temperature

7-2 4-13
Loose or poor contact of the ECT sensor connector Fail-safe value: 78"C/172F
ECT sensor or its circuit malfunction Cooling fan turns on
TP sensor circuit low voltage (less than 0.107 V) Poor engine acceleration 4-14

8-1
Loose or poor contact of the sensor unit connector Fail-safe value: 0
TP sensor or its circuit malfunction AfT shift function and anti-creep
function does not work (2nd gear
8-2 I TP sensor circuit high voltage (more than 4.981 V)

only)
Poor engine acceleration t- 4-16
TP sensor or its circuit malfunction Fail-safe value: 0
AfT shift function and anti-creep
function does not work (2nd gear
only)
9-1 IAT sensor circuit low voltage (less than 0.015 V )
IAT sensor or its circuit malfunction
Engine operates normally
Fail-safe value: 34 .8C/94.6F
4-17
9-2 IAT sensor circuit high voltage (more than 4.981 V)

Loose or poor contact of the IAT sensor connector
Engine operates normally
Fail-safe value: 34 .8C/94 .6F
4 18
IAT sensor or its circuit malfunction

I I
11-1 VS sensor circuit malfunction Engine operates normally 4-19
Loose or poor contact of the VS sensor connector
VS sensor or its circuit malfunction
12-1 Fuel injector circuit malfunction Engine does not start 4-20
Loose or poor contact of the fuel injector connector Fuel injector, fuel pump and
+
Fuel injector or its circuit malfunction ignition shut down
29-1 IACV circuit malfunction Rough idling 4-21
Loose or poor contact of the IACV connector
332
IACV or its circuit malfunction
PCM EEPROM malfunction Engine operates normally 4-23
64- 1 Drive power circuit low voltage (less than 6.5 V) Engine does not start 4-23

Blown IGN fuse (15 A)
Main relay stuck open or its circuit malfunction
64-2 Drive power circuit high voltage (more than 8.0 V when Engine does not start 4-24
ignition switch is kOFF) Fuel injector, fuel pump and
Main relay stuck ON or its circuit malfunction ignition shut down
The MIL does not blink (DTC can be readoutJerased only by MCS).
4-9
PGMFI SYSTEM
PGM-FI OTe TROUBLESHOOTING
DTC 11 (MAP SENSOR LOW
VOLTAGE)
1. MAP Sensor System Inspection
Turn the ignition switch ON (I).
Check the MAP sensor with the Mes.
Is about 0 V indicated ?
YES - GO TO STEP 2.
NO - Intermittent failure
2. MAP Sensor Input Voltage Inspection
Turn the ignition switch to OFF (0 ).
Disconnect the sensor unil5P connector [lJ (1 I
(page 4-25).
Turn the ignition switch to ON (I).
Measure the vol tage al the wire harness side 5P
connector terminals .
Connection : Brown /white (+) - Green/red H
/5 the voltage within 4.75 - 5.25 V?
YES - GO TO STEP 4. Brown/while Green/red
NO - GO TO STE P 3.
3. MAP Sensor Input Line Inspection

Turn the ignition switch to OFF (0).
Disconnect the peM 33P (gray) connector [1] Brownlwhite (83) Brown/white
(page 4-28).
Check the wire for con tinuity between the wire
harness side 5P connector [2J and 33P (gray)
connector terminals.
~ - T
TOOL:
Test pro be, 2 pack 07ZAJ-ROJA 110
Connection : Brown/white (B3) - Brown/white

Is there conti nuity?
YES - Replace the PCM with a known good one ,
and recheck.
(11 121
NO - Open circuit in the Brown/white wire
4. MAP Sensor Output Line Short Circuit
Ins pection
Check for continui ty between the wire harness side (1 I
5P connector [1J terminal and ground.
Connection : Light green/yellow - ground
Is there continuity?
YES
NO
- Short circuit in Light green/yellow wire
- GO TO STEP 5.
h
Light green/yellow ........
j
4-10
PGM-FI SYSTEM
5. MAP Sensor Inspection
Replace the sensor unit (MAP sensor) with a known
good one (page 4-25).
Erase the Dre (page 4-6).
Turn the ignition switch to ON (I),
Check the MAP sensor with the MeS .
Is DTe 1-1 indicated?
YES - Replace the PCM with a known good one
and recheck.
NO - Faulty original sensor unit (MAP sensor)
DTC 1-2 (MAP SENSOR HIGH

VOLTAGE)
Before starting the troubleshooting, check the
sensor unit 5P connector for loose or poor contacts,
and recheck the OTG.
1. MAP Sensor System Inspection 1
Check the MAP sensor wit h the MeS.
Is about 5 V indicated?
YES - GO TO STEP 2.
NO Intermittent failure
Loose or poor contact on the sensor
unit 5P connector
2. MAP Sensor System Inspection 2
Disconnect the sensor unit5P connector [1]
(page 4-25).
Connect the wire harness side 5P connector
terminals with a jumper wire (2J .
Connection : Light green/yellow - Green/red
Check the MAP sensor with the MCS.
YES - Faulty sensor unit (MAP sensor) Green/red Light green/yellow
NO - GO TO STEP 3.
(21
3. MAP Sensor Input Voltage Inspection

Remove the jumper wire. 111
Tum the ignition switch to ON (I).
Measure the voltage between the wire harness side
5P connector [1] terminals.
Connection : Brownfwhite (+) - Greenfred H
/s the voltage within 4.75 - 5.25 V?
YES - GO TO STEP 4.
NO - Open circuit in the Green/red Wife Brown/White Green/red
4-11
PGMFI SYSTEM
4. MAP Sensor Output Line Open Circuit
Inspection
Disconnect the PCM 33P (gray) connector (1J 111 121
(page 428).
Check the wire for continuity between the wire
harness side 5P connector [2) and 33P (gray)
TOOL:
Test probe, 2 pack 07ZAJROJA110
Connection :
Ught green/yellow (825) - Light green/yellow
Ught green/yellow (825) Ught green/yellow
and recheck.
NO - Open circuit in the Light green/yellow wire
OTC 71 (ECT SENSOR LOW

VOLTAGE)
1. Eel Sensor System Inspection
Check the EeT sensor with the MeS.
YES - GO TO STEP 2.
NO - Intermittent failure.
2. EeT Sensor Inspection
Tum the ignition switch to OFF {OJ.
Disconnect the ECT sensor 2P connector
(page 427).
Check the ECT sensor with the MCS.
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. ECT Sensor Resistance Inspection
I
I
Measure the resistance between the sensor side 2P
Standard : 1.0 -1.3 kQ (40CJ104F)
Is the resistance within standard value ?

YES - Replace the PCM with a known good one.
and recheck.
,
No - Faulty ECT sensor
1
1
I
1
1
4-12
PGMFI SYSTEM
4. EeT Sensor Line Short Circuit Inspection
Disconnecllhe peM 33P (gray) connector [11
(page 4-28 ).
Check for continuity between the wire harness side
EeT sensor 2P connector [1!terminal and ground.
Connection : Black/yellow - ground
YES - Short circuit in the Black/yellow wire
NO - Replace the p eM with a known good one
and recheck.
Black/yellow
DTC 72 (ECT SENSOR HIGH

VOLTAGE)
Before starting the troubleshooting, check the Eel
sensor 2P connector fo r loose or poor con tacts, and
recheck the DTG.
1. Eel Sensor System Inspection
Check the Eel sensor with the MeS .
YES - GO TO STEP 2.
Loose or poor contact on the EeT
sensor 2P connector
2. EeT Sensor Inspection
DIsconnect the ECT sensor 2P connector 111
(page 4-27).
111
terminals with a jumper wire [21.
Connection: Black/yellow - Green/red
\~~
Tum the ignition switch to O N (I).
Check the ECT sensor with the MeS .
/5 about 0 V indicated?
, YES - Faulty ECT sensor
Black/yellow Green/red
r
I
NO - GO TO STEP 3 .
121
4-13
PGM-F[ SYSTEM
3. Eel Sensor Line Open Circuit Inspection
r[1_[i.JG_,ee_nJ_O_'~(B21
Remove the jumper wire.
Disconnect the PCM 33P (gray) connector (1) [2[
(page 4-28).
Check the wires for continuity between the Eel
sensor 2P connector [2J and PCM 33P (gray)
TOOL:
Test probe, 2 pack 07ZAJRDJA110
Connection : Black/yellow (827) - Black/yellow

Green/orange (82) - Green/red Green/red
BlackJyeliow (827)
Is there continuity? Black/yellow
YES - Replace the PCM with a known good one L _ _ _ __ _ _ _ _ _ _ __ _ __ _.J
and recheck.
NO Open circuil in the Black/yellow wire
Open circuit in the Green/orange or
Greenfred wire
DTC 8-1 (TP SENSOR LOW VOLTAGE)

Before starting the troubleshooting. check the
sensor unit 5P connector for loose or poor contacts.
and recheck the OTC .
1. TP Sensor System Inspection
Check the TP sensor with the MCS wi th the throttle
fully closed.
YES - GO TO STEP 3.
NO - GO TO STEP 2 .
2. TP Sensor Inspection
Check that the TP sensor voltage increases
continuously when the throttle is moved from fully
closed position to fully open position, using the data
list menu of the MCS.
Does the voltage increase continuously?
YES - Intermittent failure
loose or poor contact on the sensor
unit SP connector
NO - Faulty sensor unit (TP sensor)
3. TP Sensor Input Voltage Inspection
Turn the ignition switch 10 OFF (0).
Disconnect the sensor unit SP connector 11 1 [11
(page 4-25).
Turn the ignition swilch to ON (I).
SP connector terminals .
Connection : Brown/white (+) - Green/red (-)
Is the voltage within 4.75 - 5.25 V?

YES - GO TO STEP 5. Brownlwhite Green/red
I
NO - GO TO STEP 4 .
414
,
l
PGM-FI SYSTEM
4. TP Sensor Input Line Open Circuit Inspection
Disconnect the peM 33P (gray) (1) connector
Brown/white (83)
(page 4~28) .
c~Q
harness side 5P connecior [2J and 33P (gray)
connector terminals .
TOOL:
Test probe, 2 pack 07ZAJ-ROJA110
Connection : Brown/white (B3) - Brownlwhite

Is there continuity ?
YES - Replace the peM with a known good one
and recheck. 111
NO - Open circuit in the Brown/white wire
5. TP Sensor Output Line Open Circuit Ins pection
Disconnect the PCM 33P (gray) [1 J connector
(page 4-28).
harness side 5P connector (1J and 33P (gray)
connector [2J terminals.
1\ }'1
TOOL: ~
Test probe, 2 pack

I'
-I
07ZAJRDJA 110
Connection: Yellow/blue (B14) - Yellow/blue
Is there c ontinuity?
Q I
Yellow/blue (814) YelloW(lue
YES - GO TO STEP 6.
NO - Open circuli in the Yellow/b!ue wire
6. TP Sensor Output Line Short Circuit Inspection
Check the wire for continuity between the wire , - - - - - -- -------:-C----,
harness side 5P connector [1] terminal and ground. [1]
YES - Short circuit in the Yellow/blue wire
NO - GO TO STEP 7.
Yellow/blue
Replace the sensor unit (TP sensor) with a known
good one (page 4-25).
Connect the PCM 33P (gray) (1J connector
(page 4-28).
Erase the DTC (page 4-6).
Check the TP sensor with the MCS.
Is OTe 8-1 indicated?
YES - Replace the PCM wi th a known good one
and recheck.
NO - Faulty original sensor unit (TP sensor)
4-15
PGM-FI SYSTEM 1
DTC 8-2 (TP SENSOR HIGH VOLTAGE)
1. TP Sensor System Inspection
Turn the ignition switch 10 ON (I).
Check the TP sensor with the MeS.
Is about 5 V Indicated?
YES - GO TO STEP 3.
NO - GO TO STEP 2.
Check that the TP sensor vollage increases
continuously when the throttle is moved from fully
dosed position to fully open position, using the data
list menu of the MeS.
Does the voltage Increase continuously?
j
3. TP Sensor Resistance Inspection
Disconnect the sensor unit 5P connector
(page 425).
Measure the TP sensor resistance between the
sensor unit side 5P connector terminals.
Is the res /stance within 1.0 3.0 kQ c c c
YES - GO TO STEP 4.
4. TP Sensor Input Voltage Inspection

Measure the voltage at the wire harness side 5P (1 J
connector [1) terminals.
Connection: Brown/white (+) - Green/red (- )
/s the voltage within 4.75 - 5.25 V?

and recheck .
NO - Open circuit in the Green/red wire
Brown/while Green/red
416
PGM -FI SYSTEM
DTC 9-1 (IAT SENSOR LOW VOLTAGE)
1. IAT Sensor System Inspection
Check the tAT sensor with the MeS.
YES - GO TO STEP 2.
2. tAT Sensor Inspection
Disconnecllhe tAT sensor 2P connector
(page 4-27).
Check the tAT sensor with the MeS .
YES - GO TO STEP 4.
NO - GO TO STEP 3.
I
3. tAT Sensor Resistance Inspection
Measure the resistance between the IAT senso,
side connector terminals.
Standard : 2.2 - 2.1 kO (20CI68F)
Is the resistance within standard value 7
YES - Replace the PCM with a known good one,
and recheck.
NO - Faulty tAT sensor
Q
4. tAT Sensor Output line Short Circuit Inspection
Disconnect the peM 33P (gray) connector 111
(page 4-28).
IAT sensor 2P connector [11 terminal and ground .
1
Connection : Gray/blue - ground
YES - Short circui t in the Graylblue wire
NO - Replace the PCM with a known good one
and recheck.
Graylblue
Q
4-17
PGM-FI SYSTEM
DTC 9-2 (IAT SENSOR HIGH
VOLTAGE)
Before starting the troubleshooting . check the tAT
sensor 2P connector for loose or poor contacts, and
recheck the OrG .
1. tAT Sensor System Inspection
YES - GO TO STEP 2.
NO - ' Intermittent failure
Loose or poor contact on the tAT
sensor 2P connector
2. tAT Sensor Inspection
Disconnect the tAT sensor 2P connector [1]. 111
terminals with a jumper wire [2].
Connection: Gray/blue - Green/red
YES - Faulty tAT sensor Gray/blue Green/red
NO - GO TO STEP 3.
\ [21
3. tAT Sensor Open Circuit Inspection
Remove the jumper wire. 111 Green/orange (82)
Disconnect the PCM 33P (gray) connector [lJ
,----J---~
(page 4-28).
Check the wires for continuity between the IAT
sensor 2P connector 12] and PCM 33P (gray) Gray/
connector terminals. blue
TOOL:
Test probe, 2 pack 07ZAJ-ROJA 110
Connection : Gray/blue (826) - Gray/blue

Green/orange (82) - Green/red
Graylblue (826)
Is there continuity? [21
and recheck.
NO Open circui t in the Grayfblue wire
Green/red wire
j
1,

4-18
PGM-FI SYSTEM
OTe 11 -1 (VS SENSOR)
Before starting the troubleshooting, check the VS
sensor 3P connector for loose or poor contacts. and
recheck the DTG.
1. VS Sensor System Check
Erase the DlG (page 4-8).
T est-dtlve the vahide and stop the engine.
Check the VS sensor signal with the MeS.
Is the VS sensor signal indic ated normally?
NO - GO TO STEP 2.
2. VS Sensor Power Input Line Inspection
Turn the ignition sWitch to OFF (0 ).
Disconnect the VS sensor 3P connector !1 1 {11
(page 4-27).
Tu rn th e ignition switch to ON (I).
3P connector terminal and ground.
Connection: Black (+) - ground (- )
Is there battery voltage ?
YES
NO
- GO TO STEP 3.
- Open circuit in the Black wire
v Black (-t )
3. VS Sensor Ground Line Ins pec tion

3P connector [1] terminals. II I
Connection : B lack (+) - Green
Is there battery voltage?

(-I
,pd, =~
YES - GO TO STEP 4
NO - Open Clrcuil in the Green wire
Black (1- ) Green H
' - --1 V )---'

4 . VS Sensor Output Line Inspection
Measure the vol tage between the wire harness side
3P connector [1] terminals .
Connection : Pink (+1 -
Is the voltage about 5 V ?
Green H 11i
1
YES - GO TO STEP 5.
NO - Open or short circuit in the PInk wire
Pink (-t )
4-19
PGMFI SYSTEM
5. VS Sensor Inspection
Replace the VS sensor with a new one (page 4-27).
Erase Ihe oTC (page 4-8).
Test-drive Ihe vehicle and stop the engine.
Check Ihe OTG with the MeS.
Is ore 11-1 indicated?
YES - Replace the PCM wtlh a known good one
and recheck.
NO - Faulty original VS sensor
OTC 121 (FUEL INJECTOR)

Before starting Ihe troubleshooting, check the fuel
injector 2P (gray) connector for loose or poor
contacts, and recheck Ihe OTC.
1. Fuel Injector System Inspection
Turn Ihe ignition switch to OFF (0) and ON, and
chedl: the fuel injector with Ihe MeS.
Is ore 121 indicated?
NO - ' Intermittent failure
Loose or poor con tact on the fuel
injector 2P (gray) connector
YES - GO TO STEP 2.
2. Fuel Injector Resistance Inspection
Disconnect the fuel injector 2P (gray) connector
(page 7-24).
Measure the resistance between the injector side
Standard : 11 .1-12.3 a (20"C/68 D
Fj
Is the resistance within the standard values?

NO - Faulty fuel injector
YES - GO TO STEP 3.
3. Fuel Injector Input Voltage Inspection

[11
2P (gray) connector [1J terminal and ground.
Connection : Black/red (+) - ground (-)
YES - GO TO STEP 4.
.EB
NO - Open circuit in the Black/red wire
~e v
1- Black/red
j
1

4-20
PGMFI SYSTEM
4. Fuel Injector Signal Une Open Circuit Inspection
Turn the ignition switch to OFF (0). r - - - - - -- - -- -
Disconnect the PCM 33P (gray) connector 111 (1] [2[
(page 4-28).
harness side fuel injector 2P (gray) connector (2]
and PCM 33P (gray) connector terminals.
TOOL:
Test probe, 2 pack 07ZAJ-RDJA110
Connection : Green/white (B33) - Green/white

Green/white
YES - GO TO STEP 5.
NO - Open circuit in the Greenlwhite wire
5. Fuel Injector Signal Line Short Circuit Inspection
Check for continuity between the wire harness side r - - - - - - - - -
2P (gray) connector [1J terminal and ground . [11
Connection: Green/white - Ground
YES - Short circuit in the Greenlwhile wire
and recheck.
Greenlwhlte
DTC 291 (IACV)

Before starting the troubleshooting , check the IACV
4P (black) connector for loose or poor contacts, and
recheck the o TC.
1. Rechec k OTC
Start the engine and check the oTC with the MCS.
Is Dre 29-1 indicated?
loose or poor con tact on the IACV 4P
(black) connector
YES - GO TO STEP 2.
2. IACV Short Circuit Inspection
Disconnect the IACV 4P (black) connector {1! [11
(page 7-23).
Check for continuity between the wire hamess side
4P connector terminals and ground.
Brown/blue I Brown/yellow
~
Connection : Black/red - Ground
Brown - Ground
Brown/blue - Ground BlaokHed Bmw"
Brown/yellow - Ground
L
YES - Short circuit in the Black/red or Brown
wire
Short circuit in the Brown/blue or
Brown/yellow wire
NO - GO TO STEP 3.

4-21
i
PGM-FI SYSTEM
3. IACV Circuit Continuity Inspection 1
Disconnect the PCM 33P (gray) connector [ 1] Brown!
Black/red [2}
(page 4-28). [1[
yeUow
~~
Check the wires for continuity between the wire
harness side PCM 33P (gray) connector and IACV 88
4P (black) connector [2] terminals. I
~
TOOL:
..
]
Test probe, 2 pack 07ZAJ-RDJA 110
Connection : Black/red (88) - Black/red

Brown (85) - Brown
I ' 830
.~
Brown/blue (830) - Brown/blue @ i

89
Brownlyellow (89) - Brown/yellow
-@ __!.... Brown
~
Is there continuity? Brown/blue
YES - GO TO STEP 4.
NO Open circuil in the Black/red or Brown
wire
Open circuit in the Brown/blue or
Brown/yellow wire
4. IACV Resistance Inspection
Measure the resistance between the IACV side 4P , - - - - - - - - - - - - - - - - - ,
Connection: 1A - 18
2A-28
Standard : 120 - 140 0 (20C/68F) 18 lA
Is the resistance within the standard value ?
YES - GO TO STEP 5.
NO - Faulty IACV
1

28 2A
<
,
5. IACV Short Circuit Inspection j
Check for continuity between the IACV side 4P , - - - - - - - - - -- - - - - - -,
Connection : 1A - 2A j
18-28 18 lA
r-~-'
YES - Faulty fACV
1,
NO - Replace the PCM wi th a known good one
and recheck. j
~
l
i
28 2A
,
j
1
4-22
1
PGM-FI SYSTEM
DTC 33-2 (EEPROM)
1. Recheck DTC
Turn the ignition switch to OFF (0) and ON (I).
Recheck the peM EEPROM with the MeS.
and recheck.
DTC 64-1 (DRIVE POWER LOW

VOLTAGE)
Before starting the troubleshooting, check thai the
battery and IGN fuse (15 A) are in good condition.
1. Recheck OTC
Erase the DTG (page 4-8).
Recheck the DTG with the MeS.
YES - GO TO STEP 2.
2. Drive Power Input Line Inspection
Disconnect the PCM 5P (black) connector (1]. (11
5P (black) connector terminal and ground.
Connection : BlackJred (+) - Ground (-)
\
and recheck.
NO - GO TO STEP 3.
Black/red (+)
3. Main Relay Inspection

Check the main relay (page 7~ 13) .
Is the main relay normal?
YES - GO TO STEP 4.
NO - Faulty main relay
4. Main Relay Circuit Inspection
Check the main relay circuits (page 7~13).
Are the main relay circuits normal?
YES - Open circuit in the Black/red wire
NO - Faulty main relay circuit(s)
4-23
PGM-FI SYSTEM
DTe 64-2 (DRIVE POWER HIGH
VOLTAGE)
If the PCM outputs OTC 642, it maintains the main
relay ON and the Mil will stay on when the ignition
switch is turned to OFF. Therefore disconnect the
battery (-) to turn off the system, then connect it and
perform the troubleshooting.
1. Recheck oTC
Erase the OTG (page 4-8).
Recheck the OTG with the MeS.
YES - GO TO STEP 2.
2. Main Relay Inspection
Check the main relay (page 7-13).
Is the main relay normal?
YES - GO TO STEP 3.
NO - Faulty main relay
3. Main Relay Coli Ground line Short Circuit
Inspection
Oisconnecllhe PCM 33P (gray) connector
(page 4-28). [11
~
Check for continuity between the Gray wife terminal
of the main relay connector [1) and ground.
YES - Short circuit in the Gray wire
NO - GO TO STEP 4.
Q
~
Gray
~=-
-
4. Drive Power Input Voltage tnspection

Disconnect the PCM 5P (black) [1) connector
(page 4-28).
Measure the vol tage between the wire harness side
5P (black) connector terminal and ground .
Connection : Black/red (+) - Ground H
\
Is there voltage ?
YES - Short circuit to Power line in the Black/red
wire
NO - Repta ce the PCM with a known good one
and recheck. Black/red (+)

4-24 1
PGMFI SYSTEM
MIL CIRCUIT INSPECTION
Check that the MIL comes ON for a few seconds and
goes OFF when the ignition switch is turned to ON.
If the MIL and other indicators do not come on at all,
inspect the combination meier power input line
(page 22-5).
If the MIL stays ON and gear position indicator blinks
inspect the combination meter serial
communica tion line (page 22-6).
If only the MIL stays ON, check as follows:
111 Brown/red (829)
Disconnect the peM 33P (gray) connector [11
(page 4-28).
Check for continuity between the wire harness side 33P
(gray) connector terminal and ground .
Connection : Brown/red (829) - Ground
TOOL:
Test probe 07ZAJ -ROJA110
There should be no continuity.
If there is continui ty, check for short circuit in Brown/red L _ _ _ _ __
wire between the OLC and PCM .
If there is no continuity, replace the PCM with a known
good one and recheck.
TP SENSOR/MAP SENSOR (SENSOR

UNIT)
NOTE:
After replacing the sensor unit, the TP sensor reset
procedure must be performed (page 426).
4 person type only: Remove the left rear fool well (page 2-10).
Disconnect the sensor unit5P connector [11.
Remove the three torx screws [2}, sensor unit [3[ and
O-ring {4] from the throttle body.
Install a new O-ring into the groove of the throttle body.
Install the sensor unit onto the throttle body by aligning
the slot with the throttle shaft end .
Install the tOIX screws and tighten them .
TORQUE : 3.4 N-m (0 .3 kgf-m , 2_5 Ibfft)
Connect the sensor unit 5P connector.

Perform the reset procedure (page 4-26).
4 person type only: Install the left rear foot well (page 2-10).
4-25
PGM-FI SYSTEM
TP SENSOR RESET PROCEDURE
NOTE :
Make sure that the DTC is not stored in the PCM
memory. If the DTC is stored , the reset mode will not
start.
1, Remove the OLC from the dummy connector
(page 4.7).
Short the DLC [1) using the special tool.
TOOL:
SCS service connector [2) 070PZ-ZY30100
CONNECTION: Brown/red - Green
2. Disconnect the ECT sensor 2P connector [1).

Short the wire harness side connector terminals with
a jumper wire [2].
3. Turn the ignition switch to ON (I).
The MIL starts blinking (reset receiving pattern).
Within 10 seconds after turning the ignition switch to
ON (I), disconnect the jumper wire from the 2P
connector.
4. When the reset procedure is complete, the MIL
blinking changes from Reset Receiving Pattern to
Confirmation Pattern.
If more than 10 seconds elapse or the procedures

are incorrect. the MIL stays on, Repeat the reset
procedures.
~ _ _ _ _W"-'ith~i~'_'~o~'~e~'_ _ _ O 1
UI;
: 0.1 sec.' '1.2 sec: 0.3 sec~ 0.3 sec.
ON
' I t I'
, , ,
.~-----'----
,
MIL
OFF ------
,.
Reset Receiving Pattern Reset Confirmation Pattern
(Stay on: Reset procedure is not complete)
ON(I) ------ ,
I
IGNITION
SWITCH
OFF {OJ
426
PGM-FI SYSTEM
ECT SENSOR
Drain the coolant (page 9-5).
Lift up the cargo bed.
Disconnect the ECT sensor 2P connector [1].
Remove the EeT sensor [2] and D-ring [3J.
Install a new O-ring onto the EeT sensor.
Inslall the EeT sensor and tighten it.
TORQUE: 12 N 'm (1.2 kgf'm , 9lbHt)
Connect the 2P connector to the Eel sensor.

Lower t he cargo bed.
Fill the cooling system with the recommended coolant
(page 9-5),
IAT SENSOR
Lift up the cargo bed .
Disconnect the IAT sensor 2P connector [1).
Remove the IAT sensor [2] from the grommet in the air
cleaner housing.
VS SENSOR
REMOVAL/INSTALLA TION
Slide the connector cover off the VS sensor 3P
connector [1] and disconnect the connector.
Remove the boll [21. VS sensor [3] and O-ring [4] from
the rear final reduction case.
Coat a new O-ring with engine oil and install it onto the
VS sensor.
Install the VS sensor into the rear final gear case and
tighten the bolt.
TORQUE : 10 N-m (1.0 kgf-m. 7 lbHt)
Connect the VS sensor 3P connector and slide the
connector cover on the connector.
4-27
PGM-FI SYSTEM
PCM 1
POWER/GROUND LINE INSPECTION
Remove the fronl seat cushion (page 24). 1
Disconnect the PCM 33P (gray) connector [11.
,
I
1
~
i
1
1
GROUND LINE
1
1
Check for continuity between the wire harness side 33P
(gray) connector [1] terminals and ground. 11] ~
Green (810) Green (813) ~
TOOL:
Power Ground :
Connection : Green (810) - ground
1j
Green (821) - ground ~
Logic Ground : Green Q ~

Connection : Green (813) - ground (821)
There should be continuity at all times.

~ ~
If there is no continuity, check for an open circuit in the

green wires.
POWER INPUT LINE
\
33P (gray) connector (1) terminal and ground.
TOOL:
Connection: Red/white (81 ) (+) - ground H i- ~
There should be battery voltage.

!.I\
If there is no voltage , check the following;
- Redlwhi te wire for open circui t between the PCM
and the fuse box (FI fuse)
- FI fuse (10 A)
.1 (~) V (.)
Red/white (81)
Red/black or Redlwhite wire for open circuit L _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _-'

between the fuse box and ignition switch
- ignition switch
4-28
PGM-FI SYSTEM
Disconnect Ihe 5P (black) connector [1] , 33P (black)
connector [2] and 33P (gray) connector [3] from the
peM 14J.
Remove Ihe rubber band (5] and PCM.
ENGINE IDLE SPEED

IDLE SPEED INSPECTION
NOTE :
Inspect the idle speed after all other engine
maintenance items have been performed and are
within specifications.
Before checking the idle speed, inspect the following
items.
- No OTG and MIL blinking
- Spark plug condi tion (page 3-7)
- Air cleaner condition (page 3-5)
The engine must be warm for accurate idle speed
inspection.
This system eliminates the need for manual idle
speed adjustment compared to previous designs.
Use a tachometer with graduations of 50 rpm or
smaller that will accurately indicate a 50 rpm
change.
Start the engine and warm it up to coolant temperature
80 C (176 OF).
Stop the engine and connect a tachometer according to
the tachometer manufacturer's instructions.
Start the engine and let it idle. Check the idle speed.
ENGINE IDLE SPEED : 1,400 100 rpm
If the idle speed is out of the specification. check the
following:
Throttle operation and accelerator pedal freeplay
(page 3-4).
Intake air leak or engine top-end problem
(page 10-3)
Valve clearance (page 3-8)
IACVoperation (page 7-23)
4-29
MEMO

5. IGNITION SYSTEM
COMPONENT LOCATION .......... ... .. ........ 5-2 IGNITION SYSTEM INSPECTION ... .... .... .. 5-5
SYSTEM DIAGRAM .. .... ...... .. ............ 5-2 IGNITION COIL .... .............................. ... 5-7
SERVICE INFORMATION 5-3 IGNITION TIMING... ... ......... .... .. ... 5-8
TROUBLESHOOTING ...... .. .. .... ............. 5-4
51
,
IGNITION SYSTEM
COMPONENT LOCATION
IGNITION COIL MAIN RELAY
IGNITION SWITCH
BATIERY
MAIN FU';E ("0 AI
peM fUSE BOX
CKP SENSOR
SPARK PLUG
SYSTEM DIAGRAM
lrrill
peM MAIN RELAY 81: Black
G: Green
Gr: Gray
R: Red
Y: Yellow
W:While
t, ITL____________
BWY Bu: Blue
G GIB'RfW Br G,
L : =-B-UR-,---1 ~---' . ::3

f
FIFUSE(10A)
L _ _ _ _ _ _+ R1W ~ RlBI ] R --Q.../""O- BuNoI
I BUR ~G:.--cRITION::H IGN FUSE (15 A)
Bm G
G/Bu
1
R ----Q../'()-- R
IGNITION MAIN FUSE
0 11
COIL (40 A)
t
~
'-------------- BI
SPARK PLUG
CKP SENSOR BATIERY
,
5-2
Downloaded from www.Manualslib.com manuals search engine ,
IGNITION SYSTEM
SERVICE INFORMATION
GENERAL
NOTICE
The PCM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive voltage may
damage the PCM. Always tum the ignition switch to OFF before servicing.
Use spark plugs with the correct heat range. Using spark plugs with an incorrect heat range can damage the engine.
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
When sel"JiCing the ignition system , always follow the steps in the troubleshooting chart (page 5-4).
This ignition system is controlled by PCM .
The transistorized ignition system uses an electrically controlled ignition liming system . No adjustments can be made to the
ignition timing.
A faulty ignition system is often related to poor connections. Check those connections before proceeding.
Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking
speed as well as no spark at the spark plug.
CKP sensor removal/installation (page 12-5).
Ignition switch servicing (page 22-9).
Main relay inspection (page 7-13).
TOOLS
IgnitionMate peak voltage tester Peak voltage adaptor Test probe, 2 pack
MTP07-0286 (U.S.A. only) 07HGJ-0020100 07ZAJ-RDJA 11 0
(not available in U.S .A.) with

commercially available digital
mullimeter (impedance 10 MO/DCV
minimum)
5-3
IGNITION SYSTEM
TROUBLESHOOTING
Inspect the following before diagnosing the system:
- Faulty spark plug
- Loose spark plug cap or spark plug wire connection
- Water got into the spark plug cap (leaking the ignition coil secondary voltage)
"Inilial voltage" of the ignition primary coil is the battery voltage with the ignition switch turned to ON (I). (The engine is nol
cranked by the starter motaL)
No spark at spark plug
UNUSUAL CONDITION PROBABLE CAUSE (Check in numerical order)
Ignition coil No iniUal voltage with the 1. Faulty main relay and/or related circuits (page 7-13).
primary ignition switch turned to ON (I), 2. An open circuit in the Black/red wire between the ignition coil and main
voltage (Other electrical components relay.
are normaL) 3. Loose or poor connection of the primary terminal, or an open circuit in
the ignition primary coil.
4. Faulty PCM (in case when the initial voltage is normal with the PCM
gray connector disconnected).
Initial voltage is normal . but it 1. Incorrect peak voltage adaptor connections.
drops by 2 - 4 V while cranking 2. Battery is undercharged . (Voltage drops largely when the engine is
the engine. started.)
3. No voltage at the Redfwhite wire of the PCM (gray) connector, or
loose or poorly connected PCM (gray) connector.
4. Loose or poor connection, or an open circuit in the Green wire of the
PCM .
5. Loose or poor connection, or an open circuit in the Greenfblue wire
between the ignition coil and PCM.
6. A short circuit in the ignition primary coi1.
7. Faulty CKP sensor. (Measure the peak voltage.)
B. Faulty PCM (in case when above No .1 through 7 are normal).
Initial voltage is normal but 1. Incorrect peak voltage adaptor connections. (System is normal if
there is no peak voltage while measured voltage is over the specifications with reverse
cranking the engine. connections.)
2. Faulty peak voltage adaptor.
3. Faulty CKP sensor. (Measure the peak voltage.)
4. Faulty PCM (in case when above No. 1 and 3 are normal).
Initial voltage is normal but 1. The multimeter impedance is too low; below 10 MntDCV.
peak voltage is lower than the 2. Cranking speed is too slow. (Battery is undercharged .)
standard value. 3. The sampling timing of the tester and measured pulse were not
synchronized. (System is normal if measured voltage is over the
standard voltage alleast once.)
4. Faulty PCM ~in case when above NO.1 through 3 are normal).
Initial and peak voltages are 1. Faulty spark plug or leaking ignition coil secondary curren!.
normal but no spark. jumps. 2. Faulty ignition coil.
CKP sensor Low peak voltage. 1. The multi meier impedance is too low; below 10 MntDCV.
2. Cranking speed is 100 slow. (Battery is undercharged.) ~
3. The sampling liming of the tester and measured pulse were not
synchronized. (System is normal if measured voltage is over the
standard voltage at least once.) 1
4 . Faulty CKP sensor (in case when above No. 1 through 3 are normal). ~
No peak voltage. 1. Faulty peak voltage adaptor.
2. Faulty CKP sensor.
5-4
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
PEAK VOLTAGE ADAPTOR
CONNECTION
NOTE :
If there is no spark al the plug. check all connections
for loose or poor contact before measuring the peak
vol tage.
Use a commercially available digital multimeter with
an impedance of 10 MO/DCV minimum.
The display value differs depending upon the
internal impedance of the multimeter.
If the peak voltage lester (U.S.A. only) is used ,
follow the manufacturer's instructions.
Use the peak voltage tester or connect the peak voltage ,-----------------~
adaptor [1J to the digital multimeter [21 .
\r
12]
TOOLS :
IgnitionMate peak vol tage tester MTP07-0286
(U.S.A. only) or
Peak voltage adaptor 07HGJ-0020100
(Not available in
U.S.A.)
with commercia lly available digital muttimeler
v
(impedance 10 MOJOCV minimum)
111
IGNITION COIL PRIMARY PEAK
VOLTAGE
NOTE:
Check all system connections before this inspection .
Poor connected connectors can cause incorrect
readings.
Check the cylinder compreSSion and check that the
spark plug is instal led correctly in the cylinder head.
12]
4 person type only: Remove the left rear foot well (page 2-10).
Disconnect the spark plug cap {1] from the spark plug.
~I \
Connect a known-good spark plug {2] to the spark plug
cap and ground the spark plug to the cylinder head as
done in a spark test.
5-5
-------------------,
IGNITION SYSTEM
With the connector connected , connect the peak
voltage tester or adaptor probes to the ignition coil
pnmary terminal and body ground.
CONNECTION : Green/blue (+) - Body ground (-)

Check the initial voltage allhis time,
The battery voltage should be measured.
If the initial voltage cannot be measured , follow the
checks In the troubleshooting chart (page 5-4).
Shift the sub-transmission into neutral.
Crank the engine with the starter motor and read the
ignition coil pnmary peak voltage.
PEAK VOLTAGE : 100 V minimum
If the peak voltage is lower than the standard value,

fonow the checks described in the troubleshooting chart
1
(page 5-4).
CKP SENSOR PEAK VOLTAGE

NOTE :
Check that the cylinder compression is normal and
the spark plug is installed correclly in the cylinder
head.
Disconnect the PCM 33P (gray) connector (1].
NOTE
When reconnecting the PCM 33P (gray) connector,
check that there is no dirt and oil in the connector.
Connect the peak voltage tester or adaptor probes to

the wire harness side 33P (gray) connector [1]lerminal
and ground.
TOOL:
CONNECTION :
Bluelyellow (B23) (+) - Body ground H
~E!IJl~~
~ ,~~~~~~
$hif\lhe sub-transmission into neutral.
Turn the ignition switch to ON (1).
Crank the engine with the starter motor and read the
CKP sensor peak voltage. - _____ Blue/yellow
(B23) C+)
PEAK VOLTAGE: 0.7 V mi nimum
If the voltage measured at the PCM connector is

abnormal, measure the peak voltage at the alternator
connector.
5-6
IGNITION SYSTEM
Remove the alternator/CKP sensor 5P (black)
connector [1) from the stay and disconnect it.
Connect the peak voltage tester or adaptor probes to
the CKP sensor side terminal and ground.
CONNECTION : Blue/yellow (+) - Body ground (-)
In the same manner as at the PCM connector, measure
the peak voltage and compare it to the voltage
measured at the PCM connector.
If the peak voltage measured at the PCM connector
is abnormal and the one measured at the alternator
connector is normal, the Blue/yellow wire has an
open or short circuit. or loose connection.
If both peak voltages are abnormal. follow the
checks described in Ihe troubleshooting chart
(page 5-4).
If Ihe CKP sensor is faulty, replace the alternator/CKP
sensor assembly (page 12-7).
IGNITION COIL
4 person type only: Remove the left rear foot well (page 2-10).
Disconnect the spark plug cap [1) from the plug.
Release the sparK plug wire [2) from the clamp (3)
Disconneclthe primary wire connectors (1).

Remove the two bolts [2) and ignition coil {3].
5-7
IGNITION SYSTEM
IGNITION TIMING
Start the engine and warm it up to operating
temperature .
Stop the engine and remove the liming hole cap {11
from the rear crankcase cover.

Connect a timing light [11.
Start the engine, let it idle and check the ignition timing.
The ignition timing is correct if the "F" mark [1) on the ~------------[2-)--="---
flywheel is visible from the timing hole [2] in the rear
crankcase cover at idle.
Increase the engine speed and make sure the "F" mark
begins to move.
Coat a new O-ring with oil and instal! it onto the timing
hole cap.
Instalithe timing hole cap and lighten it.
TORQUE: 10 Nm (1 .0 kgf-m, 7 lbHt)

[1 )
5-8
6. ELECTRIC STARTER
COMPONENT LOCATION ....................... 6-2
SYSTEM DIAGRAM .......................... 6-2

STARTER MOTOR ........ ............ ............. 6-4
STARTER RELAY SWITCH ..................... 6-8

SERVICE INFORMATION
6-3 DIODE ................................................. 6-9
TROUBLESHOOTING ............................ 6-3 BRAKE INHIBITOR RELAy ................... 6-10
6-1
ELECTRIC STARTER
COMPONENT LOCATION
8T ARTER MOTOR GEAR POSITION SWITCH
IGNITION SWITCH
BOX
MAIN
MAIN RELAY
STARTER SWITCH
SYSTEM DIAGRAM
St: Black W: White
STARTER RELAY SWITCH BATTERY G: Green Bu: Blue
, . . . _ BI
Gr: Gray Bf: Brown
~-
I ~
BI~BII
@ e
R: Red
Y: Veliow
Lg: Light green
I
STARTER
MOTOR M IGNITION ,
I"R:Jl
SWITCH
LgiR VIR 1
R -<J../"O- R
MAIN FUSE
peM DIODE (40 A)
1
]
GiSU
W/BI -S- Y/R VIR ----0....,..;-0 BUR

t BRAKE INHIBITOR
START FUSE
( 10 A)
PIGN FUSE RiBI
Lg
I Bu~BI I Br~ RELAY
~,~SX ~
~ (15 A)
G GI
WtBI G-::::L 1
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4-+-' I
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BRAKE LIGHT
BoiW SWITCH
GEAR POSITION
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SWITCH ' - - - - - - - - - - -- - - - - -- -- BulBI -<00- GfY -<)""--0-- BI/Bu
6-2
Downloaded from www.Manualslib.com manuals search engine 1
ELECTRIC STARTER
SERVICE INFORMATION
GENERAL
I NOTICE
If the current is kept flowing through the starter motor to /um it while the engine is not cranking over, the starter motor may be
damaged
Always tum the ignition switch OFF before servicing the starter motor. The motor could suddenly start. causing serious inJury.
The starter motor can be serviced with the engine in the frame
When checking the starter system. always follow the sleps In the troubleshooting (page 6-3).
A weak battery may be unable to turn the starter motor quickly enough. or supply adequate ignition current
Starter clutch servicing (page 12-5).
Ignition switch servicing (page 22-9),
Brake light switch inspection (page 22-15).
Gear position switch inspection (page 16-21).
Gear position switch replacement (page 16-54).
TROUBLESHOOTING
NOTE :
The starter motor should operate when the transmission is in neutral or when the transmission is in drive and the foot brake IS
applied .
Unusual condition Probable cause (C he!=k in numerical order)

Starter molar Starter motor does not turn 1. Loose or poor contact on related connectors and terminals
2. Blown fuse
3. Weak battery
4. Loose connection, open or short Circuit in starter motor
cable
5 Faulty starter relay switch
6 Faulty starter motor
7. Faulty gear position switch
8 Faulty brake inhibitor relay
9. Faulty brake light switch
IO.Faulty ignition switch
11 .Faultydiode
12.0pen cirCUit in starter relay switch ground circuit
13.0pen circuit in starter relay switch power circuit
14.Loose contact or open circuit in related"-",w~;,~e~s_ _
Starter motor turns slowly 1. Low battery voltage
2. Poorly connected battery terminal cable
~
3. Poorly connected starter motor cable
4. Faulty starter motor
5. Poorly connected battery ground cable 4
Starter motor turns, but engine does 1. Starter motor is running backwards
not tum - Case assembled improperly
- Terminals connected improperly
2. Faulty starter clutch
3. Damaged or faulty starter idle gear and/or reduction gear
Starter relay switch Clicks, but 1. Crankshaft does not tum due to engine problems
engine does not tum over
6-3
1
ELECTRIC STARTER
STARTER MOTOR
REMOVAUINSTALLATION
,
Remove the fronl seat cushion (page 2-4).
Disconnect the negative (-) cable from the battery
(page 21-4).
<
Slide the rubber cap [1] off and remove the terminal nul
[2] . then disconnect the cable from the terminal. j
Remove the two mounting bolts [3J . hose guide [4J and
starter motor 15}.
1
1
j
14J
j
ISJ
Remove the O-ring [11 from the starter motor [2}.
Apply engine oil to a new O-ring.
I
1
j
DISASSEMBLY
Disassemble the starter motor according to the illustration.
Record the location and

number of shims.
SHIMS'
I
I
;
\~~
ARMATURE

CASE BOLTS
\
SHIMS'
INSULATED SHIM
BRUSH HOLDER
\
INSULATED
BRUSH
\
\ LOCK WASHER
O-RING
WASHER ~~ SEAL RING
NUT~ -
INSULATOR
INSULATOR
WASHERS
MOTOR CASE
6-4
ELECTRIC STARTER
INSPECTION
Check the oil seal [1] and needle bearing [2) in the fronl ~-----------------,
cover for deterioration, wear or damage.

Check the bushing [3] in the rear cover for wear or
damage.
12}
Check the commutator bars [1] of the armature for ~=================~

discoloration.
NOTE :
Do nol use emery or sand paper on the commutator.
Check for continuity between pairs of commutator bars

11 }.
;::C=
O
=N
=T='N=U
==
'T=
Y'=--------====~I
There should be continuity.
Check for continuity between each commutator bar [1]

NO CONTINUITY:
and the armature shaft [2).
6-5
ELECTRIC STARTER
Check for continuity between the insulated brush [1]
CONTINUITY:
and cable terminal [2).
121
Check for continuity between the insulated brush [1J
and motor case [2 }.
Measure the brush length.
SERVICE LIMIT: 6.5 mm (0.26 in)
ASSEMBLY
Install the following:
- insulator [1]
-
-
insulated brush (2]
cable terminal [3) 1
- new O-ring [4]
- insulator washers [5} 121
- washer [6]
- nut {71
161 111
6-6
ELECTRIC STARTER
Install the brush holder [I]. aligning the holder tab with
Ihe case groove, and the holder grooves with the
insulated brush wires.
Align
Push and hold the brushes inside the brush holder, and
install the armature [1] through the motor case and
brush holder.
When installing the armature into the motor case, hold
the armature tightly to keep the magnet of the case
trom pulling the armature against it.
NOTICE
The coil may be damaged if the magnet pulls the
armature against the case.
Install the same number of shims [1] in the same

location as noted during removal.
Install a new seal ring [2J onto Ihe molor case.
Apply a thin coa t of grease to the armature shaft end.
Install the rear cover [3). aligning its groove with the
brush holder tab.
Install the shims

properly as noted
Install the shims [1) and insulated washer [2] onto the
armature shaft.
~!~~~~~~~=:==:===~~~~
during removal. Install a new seal ring (3) onto the motor case.
Apply grease to the oil seal lip and needle bearing in the
fronl cover [4).
Install the lock washer [5) onto the front cover.
Install the front cover.
15)
6-7
ELECTRIC STARTER
Install and lighten the starter motor case bolls (1].

Remove the front seal cushion (page 2-4).
Disconnect the negative H cable from the battery
(page 21-4).
Disconnect the starter relay switch 2P (green)
connector [1].
Pull off the terminal covers (2).
Remove the terminal nuts [3J and washers (4]. then
disconnect the relay cables.
Remove the starter relay switch [5).
OPERATION INSPECTION
Tum the ignition switch to START (II).
The coil is normal jf the starter relay switch (1 J clicks.
If you don" hear the switch click, inspect the relay
switch circuits (page 6-9),
6-8
ELECTRIC STARTER
CIRCUIT INSPECTION
Remove the front seat cushion (page 2-4)
Oisconnect the starter relay switch 2P (green)
connector [1}.
GROUND LINE
Check for continuity between the White/black wire
terminal of the wire harness side connector and ground.
If there is continuity when the transmission is in neutral
and brake pedal is depressed with the ignition switch
turned to ON (I). the ground circUli IS normal.
POWER INPUT LINE
Measure the voltage between the Yellow/red wire
terminal (+) of the wire harness side connector and
ground (-).
If the battery voltage appears only when the ignition
switch is turned to START (II), the power input circui t is
normal.
FUNCTION INSPECTION
Disconnect the negative (-) cable from the battery
(page 21-4).
Disconnect the starter relay sWi tch 2P (green)
connector.
Remove the battery (+) cable and starter motor cable
from the starter relay.
Connect the fully charged 12 V battery positive (+)
\
terminal to the Yellow/red wire termmal and negative (- ) Q
terminal to the Whitefblack wire terminal of the starter
relay switch side connector.
There should be continuity between the cable terminals (.) H
while the battery is connected , and no continUity when
the battery is disconnected .
DIODE
INSPECTION
r
111
Remove the fuse/relay box cover [1].
Open the fuse box cover [21. 121
/'
6-9
ELECTRIC STARTER
Remove the diode [1) from the fuse box.
Check for continuity between the diode terminals.

When there is continuity. a small resistance value will
register.
If there is continuity in one direction, the diode is
normal.
,------,
BRAKE INHIBITOR RELAY

Remove the fuse/relay box cover (page 6-9).
Tum the ignition sWitch to OFF (0).
Remove the brake inhibitor relay (11 from the connector.
RELAY INSPECTION
Remove the brake inhibitor relay (page 6-10).
Check for conllnuily between the No. 1 and No. 2
terminals.
Connect the fully charged 12 V battery (+) terminal to
the relay NO.4 terminal and the (-) terminal 10 the NO. 3
terminal.
There should be continuity when the battery is
disconnected , and no continuity when the battery is
connected.
No. 2 No. 4
610
ELECTRIC STARTER
CIRCUIT INSPECTION
NOTE :
Before this inspection, check that the brake lights
operate properly and the starter relay switch is
normal.
1. Relay Ground Line Inspection
Remove the brake inhibitor relay (page 6-10).
Check for continuity between the Green wire 111
terminal of the brake inhibitor relay connector (1)
and ground .
YES - GO TO STEP 2.
NO - Open circuit in the Green wire between the
relay connector and ground terminal.
2. Relay Coil Power Input Line Inspection

Turn the ignition SWitch to ON (t).
Measure the vol tage between the Black/red wire
terminal (+) of the brake inhibitor relay connector [1] 111
and ground (-).
YES - GO TO STEP 3.
NO - Open circui t in the Black/red wire between
the junction connector and brake inhibitor
relay connector.
Black/red
3. Relay Coil Power Ground Line Inspection

1'~
Disconnect the PCM 33P (black) connector
(page 4-28).
Check for continui ty between the Brown!white wire
terminals of the brake inhibitor relay connector [1]
and PCM 33P (black) connector [2].

YES - GO TO STEP 4. 7
Brown! A~Brownl
@
NO - Open circuit in the Brown/white wire white white)
between the PCM 33P (black) connector
and brake inhibitor relay connector.
6-11
ELECTRIC STARTER
1
4. Starter Relay Switch Line Inspection
Measure the voltage between the White/black wire
terminal (+) of the brake inhibitor relay connector While/black
and ground (- ).
There should be battery vollage when the ignition 111
switch is turned to START (II).
YES - The brake inhibitor relay circuits are
normal.
NO - Open circuit in the White/black wire
between the junction connector and brake
inhibitor relay connector.
1
~
1
1
l
1
1
6-12 1
7. FUEL SYSTEM
SYSTEM COMPONENTS .. .............. ........ 7-2 AIR CLEANER HOUSING ........ .... ..... ... 716
SERVICE INFORMATION .. .. 7-4 INTAKE AIR DUCT .... ..... .... .. ........... ... 7-17
FUEL LINE INSPECTION .... ..... .............. 7-5 ACCELERATOR PEDAL .. .. 717
FUEL PUMP 7-9 THROTTLE BODy 7-19
MAIN RELAY/FUEL PUMP RELAy 713 IACV .. 7-23
FUEL TANK 7-15 FUEL INJECTOR .. .. .. 7-24
7-1
FUEL SYSTEM
SYSTEM COMPONENTS
"-".-. ..
~ --= ..-..
~-
.//.(/~f-~ )
,
'1'1______
,
A
-- \ '
\
cd-
~
~
7-2
FUEL SYSTEM
r n,
7-3
FUEL SYSTEM
SERVICE INFORMATION
GENERAL
Before disconnecting the fuel feed hose, relieve pressure from the system (page 75).
Bending or twisting Ihe control cable will impair smooth operation and could cause the cable to stick or bend , resulting in loss of
vehicle control.
Work In a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a
fire or explosion.
Do not snap the throttle valve from full open to full dose after the throtl1e cable has been removed. 1\ may cause incorrect idle
operation .
Seal the cylinder head intake port with tape or a clean cloth to keep dirt and debris from entering Ihe intake port after the throttle
body has been removed.
Do not damage the throttle body. II may cause incorrect throtlle valve operation.
Prevent dirt and debris from entering the throttle bore, IACV, sensor hole and fuel feed hose , clean them using compressed air.
The throttle body is factory preset. Do not disassemble in a way other than shown in this manual.
Do not loosen or tighten the white painted bolts, nuts and screws of the throWe body. Loosening or tightening them can cause
throttle body malfunction.
TOOLS
Fuel pressure gauge Pressure gauge manifold Hose attachment. 9 mm/9mm
07406"()040004 07ZAJS5A0111 07ZAJSSA0120
or 07406..Q04000C (U.S.A . only) Not available in U.S A . Not available in U.S.A .

or 074()6...{)04000B (U.S.A . only)
Adaptor, male Adaptor, female Pressure manifold hose
07AAJS6MA200 (U.SA only) 07AAJS6MMOO (U.S.A . only) 07AMJ-HW3A100 (U.SA only)
Fuel connector remover

070MFHP50200

7-4
FUEL SYSTEM
FUEL LINE INSPECTION
FUEL PRESSURE RELIEVING
1. Remove the right rear side cover (page 2-10).
2. Turn the ignition switch to OFF (0).
3 Disconnect the fuel pump 4P connector Pl.
4. Start the engine, and let it idle until it slalls.
5 Turn the ignition switch to OFF (0).
QUICK CONNECT FITTING REMOVAL

NOTE :
Before disconnecting fuel feed hose, relieve the
pressure from the system (page 7-5).
Do not bend or twist fuel feed hose.
Fuel injector side: 1. Remove the left middle fender (page 2-8) .
2. Clean the quick connect fitting if necessary. and
place a shop lowel over the Quick connect filling.
3. Pull and release the connector damper (1) from the , - - -
retainer [2]. Fuel injector side:
[2[
Fuel pump side:
[1]
/ I c
I [2]
7-5
FUEL SYSTEM
4. Hold the connector [1) with one hand and squeeze
the retainer tabs (2] with the other hand to release (1{
the locking pawls [3].
[2)
If using the speciatlool:
Set the special \00110 Ihe retainer labs and push and
release the locking pawls .
TOOL
[4J Fuel connector remover 070MFHP50200
(3)
pun the connector off. then remove the retainer and
connector damper from the pipe end.
NOTE:
Absorb Ihe remaining fuel in the fuel feed hose from
flowing out with a shop toweL
Be careful not to damage the hose or olher parts.
Use Ihe specified special tool only.
If the connector does not move, keep Ihe retainer
tabs pressed down, and alternately pull and push
the connector until it comes off easily.
(4)
5. To prevent damage and keep foreign matter oul,

cover Ihe disconnected connector and pipe end with
;::==================
the plastic bags [1]. J
(1)
j
~
QUICK CONNECT FITTING
INSTALLATION
1
NOTE :
Always replace the retainer and connector damper
1
of the quick connect fi tting when the fuel feed hose is ~
disconnected ,
~
,~
Use the same manufacturer's retainer as the
removed one.
Do not bend or kink the fuel feed hose.
i
,
1. Insert a new retainer [11 into the connector [21.
(2)
~
NOTE :
Align the retainer locking pawls with the connector
grooves.
(1) ~ j
1
1,
,
Align
~
i
~
1
7-6 ~
FUEL SYSTEM
l
2. Set a new connector damper [1] to the joint as
shown. Fuel injector side: 131
Then press the quick connect fitting (2) onto the pipe Align
until both locking pawls !31lock with a "CLICK" .
NOTE :
For fuel injector side, align the retainer groove with
121
Ihe connector damper tabs.
If it is hard to connect, put a small amount of engine
oil on the joint.
[31
Fuel pump side:
e l11 121
3. Make sure the connection is secure and Ihal Ihe

locking pawls [1) are firmly locked into place; check
~====~~~==========~
[21
visually and by pulling Ihe connector [2] .
4. Make sure the connector damper [3] is positioned
correclly (between the pipe [4] and retainer tabs [5)).
5. Instalilhe left middle fender (page 2-8).
Fuel injector side:
[31
6. Increase the fuel pressure (page 7.7),
111
151 141
FUEL PRESSURE INCREASING
1. Connect the fuel pump 4P connector (11 .
Do not staft the 2. Turn the ignition switch to ON (I ).
engine. The fuel pump will run for about 2 seconds, and fuel
pressure will rise.
3. Repeat step 2 several times, and check thai there is
no leakage in the fuel supply system.
4. Instalilhe right rear side cover (page 2- 10).
7-7
FUEL SYSTEM
FUEL PRESSURE TEST
Relieve the fuel pressure (page 7-5).
Disconnect the quick connect fitting from the fuel pump
(page 7-5).
Release the fuel feed hose [1) from the hose clamp [2].
Attach the special tools between the fuel pump and fuel
feed hose.
14]
Except U.S.A. TOOLS :
Fuel pressure gauge (3) 07406-0040004
Pressure gauge man if old (4) 07ZAJ-S5A0111
Hose attachment, 9 mml9 mm 07ZAJS5A0120
151
U.S.A. TOOLS:
Fuel pressure gauge, 100 psi 07406-004000C or
07406-0040006
Pressu re manifold hose 07 AMJ-HW3A 100
Adaptor, male 07AAJS6MA200
Adaptor, female 07AAJS6MA400
Connect the fuel pump 4P connector 11}.
Start the engine and let It idle.
Read the fuel pressure.
Standard : 331 - 367 kPa (3.4 - 3.7 kgflcm'.
48 - S3 psi)
If the fuel pressure is higher than specified pressure.

replace the fuel pump (faulty fuel pump or fuel pressure
regulator).
If the fuel pressure is lower than speCified pressure,
inspect the following:
- fuel flow (page 7-8)
- pinched or clogged fuel feed hose
- fuel pump (page 7-9)
Disconnect the fuel pump 4P connector, start the
engine and let it idle until it stalls to relieve the fuel
pressure.
Wrap a shop lowel Remove the special tools from the fuel feed hose and
Bround the fuel pump.
attachment 10 soak
Connect the quick connect fitting to the fuel pump
up any spilled fuel.
(page 7-6).
FUEL FLOW INSPECTION

II]
Disconnect the quick connect fitting from the fuel pump 1
(page 7-5).
Remove the fuel pump relay (page 7-13). Brown ~ . -+__,
Connect the Black/red and Brown wire terminals of the
fuel pump relay connector [1J using a jumper wire 12J.
1,
Black/red
1
I
12]
j
J
,
7-8
FUEL SYSTEM
Attach the special 100110 the fuel pump [1J.
12] 11]
Except U.S.A. TOOL:
Hose aHachment, 9 mm/9 mm 07ZAJ-S5A0120
[2]
U.S.A . TOOLS:
Pressure manifold hose 07AMJ HW3A100
Adaptor, female 07AAJ S6MA400
Place the end of the special 1001 into an approved
gasoline container (3].
Turn the ignition switch to ON (I) for 10 seconds and
tUfn it to OFF (0).
Measure the amount of fuel flow.
Amount of fuel flow :
356 em' (12.0 US OZ, 12.5 Imp oz) minimuml
10 seconds at 12 V
If the fuel flow is less than specified volume , Inspect the
following :
- fuel pump (page 7+9)
- pinched or dogged fuel feed hose
Connecllhe quick connect fitting to the fuel pump
(page 76).
Remove the jumper wire from the relay connector and
install the fuel pump relay (page 7-13).
FUEL PUMP
INSPECTION
Remove the right rear side cover (page 2- 10),
Turn the ignition switch ON (I ) and confirm thai the fuel
pump operates for a few seconds.
If the fuel pump does not operate, inspect as follows :
Disconnect the fuel pump 4P connector [IJ .
Turn the ignition switch to ON (1) and measure the

voltage between the wire harness side 4P connector (I]
terminals.
Connection : Brown (+) - Green (-I

There should be battery voltage for a few seconds after
the igOllion switch turned to ON (I).
If there is battery voltage, replace the fuel pump
assembly.
If there is no voltage, check the following:
- open circuit in the Brown wire between the fuel
v e
pump and fuel pump relay
- open circuit in the Green wire between the fuel
pump and ground terminal
- fuel pump relay and its circuits (page 7-13)
7-9
FUEL SYSTEM
REMOVAL 1
Disconnect the quick connect fitting (1] from the fuel
pump (page 7-5).
Remove the right seat bottom cover (page 2-8).
Disconnect the fuel lank breather hose [2].
Remove the fuel pump rubber [3].
Remove the locking ring [1] by rotating it

counterclockwise using the special tool.
TOOL :
Fuel pump lock ring wrench SPX OTe #6599
[2J commercially
availa ble in the U.S.A.
Be careful not to Remove the locking ring and fuel pump assembly [3}
bend the floa/ arm. from the fuel lank.
Remove the O-ring [1].
DISASSEMBL YIASSEMBL Y
Disconnect the fuel level sensor connector 11J and fuel
pump connector [21 .
Release the wires from the hooks [31.
710
FUEL SYSTEM
Release the hose jOint [1] and disconnect it.
[3[
Release the hooks [21 and remove fuel pump body [3)
from the reservoir [4J .
[l[ _ _- '-.J [4[
Release the hooks [1 J and remove the pump retainer ;:::===============:;;:::;

[2[.
When installing the retainer, align the tabs [3] of the
retainer and pump body.
Release the hooks (1) and pull out the fuel fil ter ;:::===:::;;;;;:========::::[3~[=~
assembly [2) from the fuel pump body [3). /
[l[
[2[
Disconnect the connector [1] and remove the fuel filter ~=============:;;~::;:;;;~
assembly [2) from the fuel pump body [3]. S., ,
Remove the O-ring (41 and spacer [51 .
Apply small amount of engine oil to a new O-ring.
[ 5[---~
[2[
[l[
7-11
FUEL SYSTEM
Release the hooks 111 and remove the relainer (2].
,

131
Remove the pressure regulator 131 from the pump body. I
Remove the O-rings (4] and spacer [5] from the
pressure regulator. 1
removal.

Apply small amount of engine oil 10 new O-rings.
I
{21 131 {51
INSTALLATION
Clean the O-ring seating area of the fuel tank, and
be sure that no foreign materials are allowed.
Always replace the 0rin9 with a new one.
Install a new O-ring [1) onto the fuel tank.
8& careful not to Instailihe fuel pump assembly [I] into the fuel tank by
damage or pinch
the O-ring.
aligning its lab with the index mark on the fuel tank.
1
1
~
Inslall a new locking ring 11J and tighten it by rotating it

clockwise using the special tool until the grooves of the
locking ring [2] align wi th the marks of the fuel tank.
TOOL:
Fuel pump lock ring wrench SPX OTC #6599
[3J commercially
available in the U.S.A.
removal.
7-12
FUEL SYSTEM
MAIN RELAY/FUEL PUMP RELAY
REMOVALIINSTALLATION
Remove the relay/fuse box cover (page 6-9).
Remove the main relay [1] and fuel pump relay [2] from
the connectors.
RELAY INSPECTION
Remove the main relay and fuel pump relay
(page 7-13).
No.2 No.
Check for continuity between the No. 1 and No. 2
~1
terminals.
Connect the fully charged 12-V battery (+ ) terminal to
the relay No. 41erminal and the (-) lerminallo the NO .3
terminal.
There should be continui ty when the battery is
connected, and no continui ty when the battery is
~
disconnected.
MAIN RELAY CIRCUIT INSPECTION

1. Power Input Line Inspection
NO.3 NO. 4
J
Remove the main relay (page 7-13).
Measure the voltage between the Bluefwhite wire
terminals (+) of the main relay connector [1[ and
111
ground (-).
Blue/white (+)
YES
NO
- GO TO STEP 2.
Open circuit in the Blue/white wire V~e--t---( V
l
between the relay connector and fuse
box.
Blown IGN fuse (15 A).
Open circuit in the Red wire between
the fuse box and junction connector.
\--L--L-..J
Bluefwhite (+)
7-13
l
FUEL SYSTEM
,
2. Relay Coil Ground Line Inspection
Check for continuity between the Gray wire terminal
of the main rel ay connector [1J and ground. [11
YES - The main relay circuits are normal.
NO Open circuit in the Gray wire between
Ihe relay connector and PCM
Faulty power/ground line of the PCM ~
(page 4-28)
Faulty PCM I
Gray
1
FUEL PUMP RELAY CIRCUIT
INSPECTION
Remove the fuel pump relay (page 7-13).
Measure the voltage between the Black/red wire 111
terminals (+) of the fuel pump relay connector [1) 4
and ground (-).
Is there battery vo ltage ? ~
YES
NO
- GO TO STEP 2 .
- ' Open circuit in the Black/red wire
V 1
between the main relay and fuel pump
\
relay connectors
Faulty main relay or its circui ts
Black/red (+) 1
2. Relay Coli Ground Line Inspection
Turn Ihe ignition switch to OFF (0).
Check for continuity between the Violet wire
terminal of the fuel pump relay connector {1] and [11
ground .
Is there continuity for about 2 seconds?
YES - The fuel pump relay circuits are normal.
NO _. Open circuit in the Violet wire between
the relay connector and PCM
Faulty power/ground line of the PCM
(page 4-28)
Faulty PCM
j
Violet
714
FUEL SYSTEM
FUEL TANK
REMOVAUINSTALLATION
Disconnect the quick connect fitting from the fuel tank
(page 7-5).
- right seat bottom cover (page 2-8)
- right reaf side cover (page 210)
Release the fuel tank breather hose [1] from the clips
121
Release the fuel feed hose (3) from the clamp ]4J
Remove the two washer-bolts [5J, bolt [6) and collar (7).
Remove the fuel tank [8] with the tank band [91 Oul of
the frame to the right side.
When tightening the Installation is in the reverse order of removal.
washerboIls, allfJn
Connect the quick connect filting (page 7-6).
each rel811ler lab
with the hole In the [2} [4}
lank base plate.
[9}
[1 }
-\
[8}
7-15
1
FUEL SYSTEM
AIR CLEANER HOUSING
4 person type only: Remove the rear fool wells (page 2-10).
Disconnect the IAT sensor 2P connector [1).
Apply soapy water Disconnect the crankcase breather hose [2J from the air
to Ihe hose to aid in cleaner housing [3] and release it from the guides [4] in
removal. connecting lube and housing.
Release the fuel feed hose [5J from the clamp [6).
Loosen the air cleaner connecting tube band screw 171
and intake air ducl band screw [8}.
Remove the washer-screw {9] and two bolls [10].
Release Ihe connecting tubes off of the throttle body
and intake air duct, and remove the air cleaner housing.
Set Ihe duel so ils Installation is in the reverse order of removal.
stoppers are fully TORQUE :
seated on (he
connecting tube, Air cleaner housing mounting washer-screw:
8 N'm (0.8 kgf' m, 5.9 IbHtj
161 141
[31
[81
,
1
1
j
[51
1
~
1
j
[21
[101
7-16
FUEL SYSTEM
INTAKE AIR DUCT
Remove the bed release lever (page 2-22).
Release the fuel feed hose [1] from the guide [21.
Loosen the connecting tube band screw (3J.
Remove the special bolt [4] and intake air duct [5].
Remove the clip (6) and air duct cap [71_
111
[61
[7]
13]
141 [2[ [5]
ACCELERATOR PEDAL
REMOVAL/INSTALLA nON
Release the cable retainer (Yellow) [1) by pulling it to
the right side to disconnect the inner cable (2] from the
accelerator pedal [3]. [1 [
Remove the bolt [4]10 disconnect the outer cable from

the bracket.
Remove the two bolts [5J and accelerator pedal
assembly.
Installation IS in the reverse order of removal.
[2]
[51
[3]
7-17
I
l
FUEL SYSTEM
OISASSEMBLY
Unhook the spring end 111 off of the accelerator pedal
1
[2) and remove the following:
,
- cotter pin [31 and washer (4)
- pivot shaft [5]
- accelerator pedal
- return spring [6]
- collar [7)
- dust seals (8]
k----17J
12J
ASSEMBLY
Coal the lips of new dust seals [1) with grease.
Install the dust seals into the accelerator pedal [2J with
the fiat sIde facing out untillhey are fully seated.
718
FUEL SYSTEM
Inslall Ihe collar (1] and spring [2] onlo the accelerator
pedal (3) in the direction as shown.
Apply grease to the groove in the pivot shaft (4].
Inslallthe pedal Into the bracket [5] so the lower spring
end [6) is rest on the bracket by inserting the pivot shaft
from the right side. and align the flat surfaces of the
shaft and bracket.
Hook the upper spring end (7) onto the pedal
Install the washer [8J and a new cotter pin (9).
THROTTLE BODY
REMOVAL
NOTE
If the TP sensor/MAP sensor (sensor unit) is
removed from the throttle body, the TP sensor reset
procedure must be performed after installing the
throttle body (page 4-26).
Disconnect the quick connect fitting from the fuel
injector (page 7-5).
Remove the air cleaner housing (page 7-16).
Disconnect the following:
- fuel injector 2P (gray) connector 11]
- IACV 4P (black) connector [2]
- sensor unit 5P connector PJ
7-19
FUEL SYSTEM
Remove the washer screw [1] and thro ttle drum cover j
,~
[1 [
[2] by releasing the locating tab 131 from the throttle
body slot.
~-J
~ \

~
[2[
[31
Loosen the throttle cable adjuster lock nut [11. remove ~!;;;iiO~:1iiiiiiilir,;c.iiP;;;ji~;;::i,~;;ti~ 1
the adjuster [2] from the throttle body and disconnect
the cable end (3) from the throllle drum (4].
Loosen the insulator band screw [11 and remove the

j
throttle body [21 from the insulator.
1
Loosen the insulator band screw [1] and remove the

insulator [2J from the cylinder head. 1
7-20
FUEL SYSTEM
l
NOTE :
Do not loosen or tighten the white painted screws [1) , - - - - - - - - -- ---
and nut [2] .
IACV removal/installation (page 7-23)
Fuel injector removallinslallation (page 7-24)
TP sensor/MAP sensor (sensor unit) replacement
(page 4-25)
[11
INSTALLAnON
Align the hole of the insulator band [1] with the boss of r-I'~-;a;:;IJ'IIT---::--i"liJ;7-!iI!Ji
the insulator [2J .
Install the insulator onto the cylinder head by aligning
the groove with the lug.
Align the hole of the insulator band [1] with the boss of
the insulator [2).
Install the throttle body (3) into the insulator by aligning
the lug with the groove .
Tighten both insulator band screws so that the distance

between the band tabs is as shown.
12 1 mm
(0.47 0.04 in)
7-21
FUEL SYSTEM
Connect the throttle cable end [1] to the throttle drum
[2[.
Install the throttle cable adjuster [3J into the throttle
body and temporarily tighten the lock nut [4].
Adjust the accelerator pedal freeplay (page 3-4).
Inslall the throttle drum cover [1] by aligning Ihe locating ~-----------------
tab {2] with the slot in the throttle body.

Install and tighten the washer screw (3].
""l'
\I \
) ~.
I , '.
i?/r [2[ [l[
Connect the following:

- fuel injector 2P (gray) connector {1J
- IACV 4P (black) connector {2]
- sensor unit 5P connector [3]
Connect the quick connect fitting to the fuel injector
(page 7-6).
Install the air cleaner housing (page 7-16).
7-22
FUEL SYSTEM
IACV
INSPECTION
NOTE:
The IACV is installed on the throttle body and is
operated by the stepping moior. When the ignition
switch is turned to ON (I), the IACV operates for a
few seconds.
Remove the left middle fender (page 2-8),
Turn the ignition switch to ON (J) and check the IACV.
If the step motor operating sound is heard. the IACV is
normal.
If the IACV does not sound with no MIL blinking, inspect
as follows:
Remove the IACV (page 7-23),
If the idling is unstable, check the condition of the D-
ring.
Temporarily connect the IACV 4P (black) connector [1].
Turn the ignition switch to ON {Il while holding the slide
valve [2] as shown.
The slide valve should move back and forth.
Install the IACV (page 7-23).
REMOVAL
Remove the left middle fender (page 2-8).
Clean the throttle body to prevent dirt and debris rrom
entering the IACV passage.
Disconnect the IACV 4P (black) connector [1].
Remove the two torx screws (2]. retainer plate PI and
IACV{4].
INSTALLATION
Install a new O-ring (1) onto the IACV {2].
Turn the slide valve [31 clockwise until lightly seated on
the IACV body.
Install the IACV into the throttle body by aligning the
valve slit with the guide pin in the throttle body.
7-23
FUEL SYSTEM
Install the retainer plate [1] by aligning the groove with
the valve boss.
Install and tighten the two torx screws [2].
TORQUE : 2.1 N'm (0.2 kgf-m, 1.5IbHt)
Connect the IACV 4P (black) connector [3].
Install the left middle fender (page 2-8).
FUEL INJECTOR
Disconnect the quick connect filting from the fuel
injector (page 7-5).
Clean around the fuel injector base with compressed air
before removing the fuel injector, and be sure that no
debris is allowed to enter into the combustion chamber.
Disconnect the fuel injector 2P (gray) connector [1] and
IACV 4P (black) connector [2].
Remove the two mounting bolts [3] and the fuel injector
assembly 14] from the throttle body.
st'D
- injector joint ]1]
- joint rubber ]2]
- a-ring [3]
- fuel injector [4] [5)
- seal ring [5]
Apply engine oil to new seal ring and a-ring and install
them onto the fuel injector.
Install a new joint rubber. [1 )
[4[
Install the injector joint [1] onto the fuel injector [2] with ~=================~
the stopper [3] facing the connector as shown, being
careful not to damage the O-ring.
[3)
[1)
7-24
FUEL SYSTEM
Install the fuel injector assembly [1J into the throttle
body being careful not to damage the seat ring.
Install the fuel injector joint mounting bolts [2J and
tighten them.
TORQUE: 5.1 N'm (0.5 kgf' m, 3.8 IbHt)
Connect the fuel injector 2P (gray) connector (3) and
IACV 4P (black) connector [4J.
Connect the quick connect fitting to the fuel injector
(page 7-6),
7-25
1
MEMO

8. LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM 8-2 OIL PRESSURE CHECK 8-4
SERVICE INFORMATION
8-3 OIL PUMP .. ...................... ................ .. 8-4
TROUBLESHOOTING ........ ........ .. ..... 8-3 OIL COOLER .................. .................. 8-10
8-1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
ROCKER ARMS
CYLINDER HEO'D <OOl/ER
CAMSHAFT
CRANKSHAFT
TORQUE CONVERTER , -------------
,
FLYWHEEU I
STARTER
,
<
I REVERSE IDLE
: GEAR
MAINSHAFT
SHIFTVAlVE
BODY
RELIEF VALVE
COUNTERSHAFT
OIL PUMP
2ndl 3rd SHIFT CLUTCH
OIL TANK
~.~~~'--J
OIL STRAINER SCREEN
8-2
LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
A CAUTION
Used engine oil may cause skin cancer jf repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as
possible after handling used oil.
- --
This section covers service of the oil pump and oil cooler.
The service procedures in this section can be performed with the engine installed in the frame.
When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
If any portion of the oil pump is worn beyond the specified seNice limits, replace the oil pump as an assembly.
After oil pump, oil cooler andlor oil hoses have been installed, check for oil leaks.
For oil level check, oil change and filter replacement. see Maintenance section (page 3-9).
TOOL
Oil pressure gauge set
07406-0020005
--=-
(, -'-"'\-."",.,
~ - -.- . ~ If
-.... ~
...:v ~::-~j"'>'",-
- ~
~> ,.. <1':J;r...c '
.,,~_=--
C'y
or 07ZMJ-HN2A 100
and 07AMJ-HNBA100 (U.SA only)
TROUBLESHOOTING
Oil level too low - high oil consumption
Oil consumption
External oil leak
Worn piston rings or incorrect piston ring installation
Worn cylinder
Worn valve guides or stem seals
Low oil pressure
Oil level low
Oil pressure relief valve wear
Clogged oil strainer or filter
Faulty oil pump
Internal oil leak
Incorrect 011 being used
No oil press ure
Ollievel too low
011 pressure relief valve stuck open
Clogged oil strainer or filter
Broken oil pump drive chain or sprocket
Damaged oil pump
Internal 011 leak
High oil pressure
Oil pressure relief valve stuck closed
Clogged oil gallery or orifice
Incorrect oil being used
Oil contamination
Oil or filter not changed often enough
Worn piston rings or incorrect piston ring installation
Worn valve guides or slem seals
Oil emulsification
Blown cylinder head gasket
Leaky coolant passage
Water entry
8-3
LUBRICATION SYSTEM
OIL PRESSURE CHECK
Fa/lure to warm the Check the oil level and add the recommended oil if
engine will cause necessary (page 3-9).
very high 011 Also, warm the engine to normal operating temperature
ptessure readings. and check for eXlemalleaks.
External leaks win
Remove the oil gallery sealing bolt (1] and washer (2]
cause low oil on the left side of the front crankcase cover.
pressure readings.
NOTE
Clean around the sealing bolt with compressed air
before removing the bolt. and be sure that no dirt
enters the oil gallery.
Connect the oil pressure gauge [1] and adaptor to the

oil gallery hole.
TOOL;
Pressure gauge set 0740S"'()020005
U.S.A. TOOLS :
Oil pressure gauge 0-160 psi 01ZMJHN2A100 and
Adaptor, banjo 8 x 1.25 mm 07AMJHN8A100
Start the engine and check the oil pressure.

OIL PRESSURE (80CI176"F):
785 kPa (8.0 kgfl em!, 114 psi) at 5,000 rpm
Slop the engine and remove the oil pressure gauge and
adaptor.
Install the sealing bolt {1] with a new sealing washer 121
and lighten the bolt securely.
Start the engine and make sure there are no oil leaks.
removal
OIL PUMP
REMOVAL
Remove the torque converter (page 16-40).
If the oil pump will be disassembled, loosen the two
assembly bolts [1].
- three mounting bolls [2]
- oil pump 13] (from the crankcase and release the
drive chain [4])
84 j
LUBRICATION SYSTEM
- three a-rings (1]
- strainer joint pipe 12]
- rubber seal (3]
- two boJts [1]

- oil return pipe (2]
- O-(lng [3]
INSTALLATION
Coat a new a-ring (1] with engine oil and install it onto r--.--
the 011 relurn pipe [2J.
Install the pipe onto the crankcase and lighten Ihe two
bolts (3J securely.
Coal a new a-ring [1] and a new rubber seal (2) with
engine 011. and Inslall them onto the strainer joint pipe
[3].
Install the joint pipe onto the strainer pipe (4] in the
crankcase.
8-5
LUBRICATION SYSTEM
Coat new O-rings [11 with engine oil and install them
onto the joint pipes on the oil pump [2J .

Place the driven sprocket [31 on the oil pump onto the
oil pump drive chain [4J. and install the pump onto the
crankcase by aligning the joint pipes with the jOint holes
,
properly.
1
1
Install the three mounting boits (1) and tighten them. If

the pump was disassembled, lighten all the bolts [1]1[2]
in a crisscross pattern in several steps.
Install the torque converter (page 16-42).
OISASSEMBL Y
Disassemble the oil pump according to the illustration.
DRIVEN SPROCKET
RELIEF VALVE
.,p~/~ t7T BOLT
C-RING
INNER ROTORS PUMP BOOYA
PUMP BOOYD
PUMP BODY B
ASSEMBl Y BOLTS PUMP BODY C

OUTER ROTORS
8-6
LUBRICATION SYSTEM
INSPECTION
Remove the O-ring [11 from the relief valve {2].
Check the operation of the valve by pushing on the
piston [3].
Temporarily assemble each inner rotor, outer rotor and

drive pin on the pump shaft, and install them into each
L 121
~==-------=::;:::;;;;;;;;;;;;:~
pump body individually.
Measure the rotor lip clearance.
Measure the body clearance.
Remove the oil pump shaft and drive pin.

Measure the side clearance.
8-7
LUBRICATION SYSTEM
ASSEMBLY
Coat all inner parts with clean engine oil.
Inslall the outer rotor [1J and inner rotor 12] into the
pump body A (3]. 131
Insert the drive pin [4] into the pump shaft (5].
Install the pump shaft through the inner rotor and pump
body A. aligning the drive pin with Ihe rotor grooves.
[51 "D
Apply locking agent to Ihe sprocket boll [1J threads.
Install the driven sprocket [2] onto the pump shaft,
aligning the flats . Install the sprocket bolt and tighten it.
TORQUE: 12 N'm (1 .2 kgf-m , 9lbHt)
I CS
Coat a new O-ring {1] with engine oil and install it into
the relief valve [2] groove.
:===================
[21
Inslall the relief valve [1] into the pump body B [2J .
Inslall the oil pump body B onto Ihe pump body A [3] . [11
8-8
LUBRICATION SYSTEM
Insert the drive pin 11J into the pump shaft.
Install the inner rotor [2J onto the pump shaft, aligning ['[
its grooves with Ihe drive pin.
Install the outer rotor [3J into oil pump body C [4].
Install the pump body C onto the pump body B (5].
[3] ~
Install the dowel pins PI through the pump bodies C, B

and A.
Insert the drive pin [2J into the pump shaft.
Install Ihe inner rotor [3] onto Ihe pump shaft, aligning
its grooves with the drive pin.
Install the Quter rotor (4] into the oil pump body D (5).
Install the pump body D onto the pump body C.
--"711 --"711 ]']

[3] Iii iI
Make sure thai there is no clearance at the mating ~=================~
surfaces of the pump bodies.
Instalilhe two assembly bolts (1].
8-9
LUBRICATION SYSTEM
OIL COOLER
REMOVAL
Drain the engine oil (page 3- 10).
Drain the coolant (page 9-6).
Remove the bolt [11 and wire slay [21.
Remove the joint bolts [1) from each oil pipe ends.
Disconnect the oil pipes 121 from the engine and oil
cooler, and remove them out of the frame.
Remove the O-rings [3] from the oil pipes .
Loosen the band screws [lJ and disconnect the water

hoses [2] from the oil cooler [3].
,,- =
Remove the two mounting bolts [4] and the oil cooler.
INSTALLATION
Install the oil cooler with the two bolts and tighten them
securely.
Connect the wa ter hoses to the oil cooler and tighten
the band screws.
Coal new O-rings (1) with engine oil and install them ,--;:-c==---------~-_;:c_=::;;:"
into the grooves of oil pipe A [2] and oil pipe B [31.
810
LUBRICATION SYSTEM
Install the oil pipe A [1) and oil pipe B [2] into the oil
cooler and connect them into the engine in shown
direction.
Install the four joint bolts [3) and tighten them securely.
Install the wire stay [1) while aligning its edge with the
oil cooler lug as shown , then install and tighten the bolt
[2] securely.
Fill the engine with the recommended oil (page 3-10).
Fill and bleed the cooling system (page 9-5).
Check the engine oil level (page 3-9) .
DISASSEMBLY/ASSEMBLY
- five bolts [1j
- cooler cover [2]
@
/
- D-ring [1)
Replace the O-ring with a new one .
8-11
LUBRICATION SYSTEM 1
- four bolls (1]
- oil cooler core [2)
1
j
1
1
j
- two joint coltars [1]

j
- two O-rings {2] I
Assembly is in the reverse order of disassembly .
Clean the cooler housing. cover and core fins with
compressed air thoroughly.
Replace the joint O-rings with new ones and coal
them with engine oil. 1
j
111 i
~
1
1
j
8-12
9. COOLING SYSTEM
SYSTEM FLOW PATTERN 9-2 THERMOSTAT .... ...... .. .. .... .. .... .... 9-7
SERVICE INFORMATION ........ .. .. ...... .. 9-3 WATER PUMp ...................................... 9-8
TROUBLESHOOTING ...... .. ........ ...... ...... 9-3 COOLING FAN/SHROUD ...................... 9-10
SYSTEM TESTING ............................... .. 9-4 RADIATOR .... ... .. .......... ...................... 9-12
COOLANT REPLACEMENT ........ .. ......... 9-5 RADIATOR RESERVE TANK ................ 9-13
9-1
COOLING SYSTEM
SYSTEM FLOW PATTERN
RADIATOR
RES"RVETANK
THERMOSTAT
1
1;
all CUl)LO"
WATe" PUMP
1
9-2
i,
COOLING SYSTEM
SERVICE INFORMATION
GENERAL
AWARNING
Removing the radiator cap while the engine is hoi can allow the coolant to spray out. seriously scalding you .
Always let the engine and radialor cool down before removing the radiator cap .
NOTICE
Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passage.
Using lap water may cause engine damage.
Add coolant to the system at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
All cooling system service can be done with the engine installed in the frame.
Avoid spilling coolant on painted surfaces.
After servicing the system , check for leaks with a cooling system tester.
For cooling fan motor inspection (page 22-12 ).
TROUBLESHOOTING
Engine temperature too high
Thermostat stuck closed
Faulty radiator cap
Insufficient coolant
Passage blocked in radiator, hoses or water jacket
Air in system
Faulty cooling fan motor
Faulty water pump
Coolant leaks
Faulty water pump mechanical seal
Deteriorated O-rings
Faulty radiator cap
Damaged or deteriorated cylinder head gasket
Loose hose connection or clamp
Damaged or deteriorated hoses
9-3
COOLING SYSTEM
SYSTEM TESTING
COOLANT (HYDROMETER TEST)
Remove the front hood (page 2-12),
The engme must be Remove the radiator cap [1).
cool before
removing the
radiator cap.
Test the coolan t gravity using a hydrometer [11.
STANDARD COOLANT CONCENTRATION:

1: 1 mixture of distilled water and antifreeze
look for contamination and replace the coolant if
necessary.
1
~
j
1
j
9-4
1
COOLING SYSTEM
RADIATOR CAP/SYSTEM PRESSURE
INSPECTION
Remove the radiator cap [1] (page 9-4 ).
We t the sealing surfaces of the cap. then insta ll the cap [1J
onto tester [2].
TOOLS:
Cooling system pressure tester SVTS4AH
Cooling system adaptor OTCJ33984A
Pressurize the radiator cap using the tester.

Replace the radia tor cap if it does not hold pressure, or
if relief pressure is 100 high or too low. It must hold the
specified pressure for alleast 6 seconds.
RADIATOR CAP RELIEF PRESSURE: {21
93 - 123 kPa (0 .95 - 1.25 kgf/cm 2, 14 - 18 psi)
Connect the pressure lester [1J and check the radiator,

engine and hoses for leaks.
I NOTICE
Excessive pressure can damage the cooling system
components. Do not exceed 123 kPa (1.25 kgflcm'.
18 psi).
Repair or replace components if the system will not hold
the specified pressure for at least 6 seconds.
Remove the tester and install the radiator cap.
COOLANT REPLACEMENT
PREPARATION
NOTICE
Using coolant with silicate corrosion inhibitors may
cause premature wear of water pump seals or blockage
of radiator passages. Using tap waler may cause
engine damage.
NOTE'
The effectiveness of coolant decreases with the
accumulation of rust or if there is a change in the
mixing proportion during usage. There fore, for best
performance change the coolant regularly as ANTIFREEZE
specified in the maintenance schedule. SOLUTION
Mix only distilled. Jaw mineral water with the

recommended antifreeze. (ETHYLENE
GLYCOL BASE LOW MINERAL
RECOMMENDED ANTIFREEZE: SOLUTION) OR DISTILLED
Pro Honda HP Coolant or an equiva lent high WATER
quality ethylene glycol antifreeze containing
silicate-free corrosion inhibitors
RECOMMENDED MIXTURE :
LJl'"----.. COOLANT
1:1 (distilled water and recommended antifreeze)
9-5
COOLING SYSTEM
REPLACEMENT/AIR BLEEDING
NOTE:
When filling the system with a coolant, place Ihe
vehicle on a flat, level surface.
~ front hood (page 2-12)
- middle under guard (page 2-29) v
The engine must be Pull up the reserve tank [1 J and release its groove from
cool before Ihe tab [2].
seNicing rhe Remove Ihe reserve tank cap [3] and empty the reserve
cooling system. tank and rinse Ihe inside of Ihe tank wi th water.
Install the reserve tank by setting its groove onto Ihe
lab.
Drain the coolant from Ihe system into a pan by ~iiiiiiiiij;iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii.;;;;;;~;;;;~

removing the drain bolt [1J and sealing washer {2J.
Install the bolt with a new sealing washer and tighten it
securely.
Remove the water pipe mounting bolts [1]. Ihen slide

the water pipe [2] and release it from Ihe frame.
Loosen Ihe band screws [3) and disconnect the water
hoses [4) from the pipe ends.
Drain the coolant from the water pipes into a pan.
Connect the water hoses to the pipe ends and tigh ten
the band screws. 1
Set the water pipe onto the frame, then install and j
tighten the bolts. ,
1
j
9-6
1
COOLING SYSTEM
Remove the bleed bolt [1] and sealing washer [2J from
the thermostat cover, and loosely install the bolt with a 111
new sealing washer.
Place Ihe shop towels around the bleed bolt.
Fill the system with Ihe recommended coolant up to the
filler neck (31. Tighten Ihe bleed bolt as soon as coolant
starts to run oul in a steady stream without bubbles.
TORQUE : 12 N' m (1.2 kgf-m, 9 lbH t )
1. Shift the transmission into neutral and set the

parking brake. Start the engine and let it idle for 2 -
3 minutes.
2. Snap the throttle 3 - 4 times to bleed air from the
system.
3. SlOp the engine and add coolant up 10 the filler neck
4. Inslallthe radiator cap.
Fill the reserve tank to the MAX hne (II and install the
tank cap [2].
Install the following :
- middle under guard (page 2-29)
THERMOSTAT
REMOVAUINSTALLA TION
Drain the coolant from the system (page 9-6).
121
- two bolls [1)
- thermostat cover [2]
111
9-7
COOLING SYSTEM
- thermostat 11]
Make sure the rubber seal [2J on the thermostat Is in
good condi tion.
Apply coolant to the rubber seal and install the
thermostat into the housing, aligning the bleed hole with
the lug.
removal.
Fill and bleed the cooling system (page 95).
INSPECTION
I
Visually inspect the thermostat [1] for damage .
[21
Replace the thermostat if the valve stays open at room
temperature .
/
,.
[1J
Do not let the Heat a container of water with an electric heating
thermostat or
thermometer (2J
element for 5 minutes.
Suspend the thermostat in heated water to check its
/
"",/""2 ,
~
louch the pan, or operation.
you will get a false
THERMOSTAT BEGIN TO OPEN :
reading .
80 - 84C (176 _ 183F) '\
VALVE LIFT:
J)
8 mm (0.3 in) minimum at 95C (203F)
Replace the thermostat if the valve opens at a
- -<::./
temperature other than those specified. ---- "-
WATER PUMP
MECHANICAL SEAL INSPECTION
1
Check the bleed hose [1] aftha water pump for signs of r l- - - -
coolanlleakage.
NOTE
A small amount of coolant weeping from the bleed
hose is normal.
Make sure that there are no continuous coolant
leakage from the bleed hose while operating the
engine.
Replace the water pump as an assembly if necessary.
REMOVAL
Drain the coolant from the system (page 9-6).
L 111
Loosen the band screws (lJ and disconnect the water

hoses (21 from the water pump.
1
9-8 j
I
COOLING SYSTEM
Loosen the three cover bolts (1] .
- two mounting bolts [2]
- water pump assembly [3J
three cover boilS [1J and sealing washer (2J

- pump cover [3J ISJ
- O-rings [4J
- bleed hose [5J
- hose guide [6]
INSTALLATION
Install the hose guide [1] onto the bleed hose [2J and r-:-~ ..
the hose onto the pump body [3J.
Coal a new O-ring (4) with engine oil and install it on the
stepped section of the pump body.
Install the water pump while turning the impeller to
engage the pump shafts.
Align the mounting bolt holes in the pump body and c.,,___~
crankcase cover, and be sure the water pump is fully r
seated.
Install a new O-ring [5] into the pump body groove
properly.
99
COOLING SYSTEM
Taka cant not to let Install the pump cover with the two mounting bolts (1)
the O-nng come off and temporarily lighten them until the cover is sealed.
the body groove
Install the three cover bolts [2J with a new sealing
washer [3] (in poSition as shown ; triangular mark) and
the hose guide [4] (aligning the groove with the
stopper). Tighten all the bolts in a crisscross pattern in
several sleps.
Connect the water hoses [1] and lighten the band

screws [2].
COOLING FAN/SHROUD
REMOVAUINSTALLATION
Remove the front grille (page 2-12).
Pull up the reserve lank (lJ and release its groove 12)
from the tab.
12J
Release the two wire clips 111 to free the fan motor wire.
Release the fan motor 2P connector [2] from the frame
and disconnect it.
,
J
9-10 1

COOLING SYSTEM
Release Ihe siphon hose 111 from the guide [2] .
Remove the two radiator mounting bolts (3) and pull the
radiator [4] forward .
Remove the two fan shroud mounting bolts [1].

Pull the cooling fan/shroud assembly [2] upward and
release the bosses [3] from the grommets of the frame.
Release the hooks [4J of the shroud from Ihe radialor
and remove the cooling fan/shroud assembly, being
careful nol to damage the radiator fins.
TORQUE:
Radiator mounting bolt:
8.4 N' m (0.9 kgf'm, 6.2 IbH t)
OISASSEMBL Y/ASSEMBL Y
Release the breather hose (1] from the four hose guides
121
Release the wire band [3] from the fan shroud .
9-11
l
COOLING SYSTEM 1
- nut [1]
- cooling fan [2]
When installing the cooling fan , align the nat
surfaces of the fan and shaft.
Apply locking agentto the mounting nut threads.
- bolts 111
- fan motor [21
Assembly is in the reverse order of disassembly.
TORQUE :
Fan motor mounting bolt:
5.2 N' m (0.5 kgf'm, 3.8 IbHtj
Cooling fan mounting nut:
2.7 N'm (0.3 kgf'm, 2.0 IbHt)
RADIATOR
REMOVAUINSTALLATION
NOTE:
Take care not to damage the radiator fins while
servicing the radiator.
Drain the coolant from the system (page 96).
Remove the front grille (page 2-12).
Loosen the band screw [11 and disconnect the lower
radiator hose [2] from the hose joint.
Disconnect the siphon hose [1] from the radiator.

Loosen the band screw [2] and disconnect the upper
radiator hose [3] from the hose jOint.
9-12
I
~
COOLING SYSTEM
Remove the two radiator mounting bolts [1).
Release the radiator [1) from the hooks (2) of the shroud
and remove the radiator, being careful not to damage
the fins.
TORQUE :
Radiator mounting bolt:
8.4 N'm (0.9 kgf' m , 6.2 IbHt)
RADIATOR RESERVE TANK

REMOVALIINSTALLA nON
Pull up the reserve tank [1) and release its groove from
the tab 12].
Remove the reserve tank cap [3} and empty the reserve [41
lank.
Inslall Ihe reserve lank by setting its groove onto Ihe
tab.
Fill Ihe reserve tank with the recommended coolant to
the MAX line [4J and install the tank cap.
Instalilhe fronl hood (page 2-12).
9-13
MEMO
1
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1

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10. CYLINDER HEADNALVEICAMSHAFT
SYSTEM COMPONENTS 102 VALVE GUIDE REPLACEMENT1011
SERVICE INFORMATION
103 VALVE SEAT INSPECTIONI
REFACING

.. 1011
TROUBLESHOOTING ...... ... ........ ......... 10-4
CAMSHAFT
1013
CYLINDER COMPRESSION 10-5
CYLINDER HEAD ASSEMBLY
1016
CYLINDER HEAD COVER REMOVAU
DISASSEMBLY 105 CYLINDER HEAD INSTALLATION 1017
CYLINDER HEAD REMOVAL ......... ... .. .. 108 CYLINDER HEAD COVER ASSEMBLYI
INSTALLATION .. ..... ... .... ... 1018
CYLINDER HEAD DiSASSEMBLy 10-9
CAM CHAIN TENSIONER LIFTER 1021
CYLINDER HEAD INSPECTION
10-9
101
CYLINDER HEADNALVE/CAMSHAFT
SYSTEM COMPONENTS
65 N'm (6.6 kgf 'm, 481bHt)
1
22 Nm (2.2 kgf-m. 16Ibf-ft)
1

4
1,
\
,
,
12 N'm (1.2 kgf'm, 9lbHt)
i
J
1
I
I
~

J,
l

1
10-2 ,
CYLINDER HEADIVALVEICAMSHAFT
SERVICE INFORMATION
GENERAL
This section covers service of the rocker arms, cylinder head, valves and camshaft. These services can be done wi th the engine
installed in Ihe frame.
When disassembling , mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection.
Rocker arm, valve and camshaft lubricating oil is fed through oil passages in the cylinder head and head cover. Clean the oil
passages before assembling cylinder head and head cover.
Be careful not to damage Ihe mating surfaces when removing the cylinder head cover and cylinder head.
TOOLS
Valve spring compressor Valve guide driver, 5.5 mm Valve guide reamer, 5.5 mm
07757-0010000 07742-0010100 07984-2000001
or 07984-2000000 (U.S.A. only)

Valve seat culler. 35 mm (45 IN/EX)
0
Flat culler, 38.5 mm (32 IN) Flat culler, 35 mm (32 EX)
0
07780-0010400 07780-0012400 07780-0012300
C~
or equivalent commercially available in or equivalent commercially available in or equivalent commercially available in
U.S.A. U.S.A. U.S.A.
Interior cutler, 34 mm (60 INfEX) Cutter holder, 5.5 mm Tensioner holder 8
07780-0014700 07781-0010101 070MG-0010100
or equivalent commerCially available in or equivalent commercially available in or 07AMG-001A100 (U .S.A. only)

U.S.A. U.S.A. or 07AMG-MFJA100 (U .S.A. only)
103
l
j
TROUBLESHOOTING
Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-
end noise with a sounding rod or stethoscope.
If the performance is poor at low speeds, check for a whil e smoke in the crankcase breather hose. If the hose is smoky , check
for seized piston ring (page 11-3).
Compression too low, hard starting or poor performance at low speed
Valves:
- Incorrect valve adjustment
- Burned or bent valve
- Incorrect valve timing
- Broken valve spring
- Uneven valve sealing
- Valve stuck open
Cyllnder head:
- leaking or damaged cylinder head gasket
- l oose spark plug
- Warped or cracked cylinder head
Cylinder/piston problem (page 11-3)
Compression too high, overheating or knocking
Excessive carbon build-up on piston head or combustion chamber
Worn or damaged decompressor system
Excessi ve smoke
Worn valve stem or valve guide
Damaged stem seal
Excessiv e noise
Incorrect valve clearance
Sticking valve or broken valve spring
Excessively worn valve seat
Worn or damaged camshaft
Worn rocker arm and/or shaft
Worn rocker arm follower or valve slem end
Worn or damaged push rod andlor cam follower
Worn cam chain
Worn or damaged cam chain tensioner
Worn cam sprocket tee th
Rough idle
Low cylinder compression
1
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10-4 j
CYLINDER COMPRESSION
Remove the left seal bottom cover (page 2-9)
Warm up the engine to normal operating temperature.
Stop the engine, disconnect the spark plug cap and
remove the spark plug (page 3-7).
Install the compression gauge (11 into the spark plug
hole.
TOOLS :
Compression tester EEPV303A
Adaptor MT26J200
(U.S.A. only)
Shift the sub-transmission into neutral and sel the
parking brake.
Open the throttle all the way and crank the engine with
the starter motor until the gauge reading stops rising.
The maximum reading is usually reached within 4 - 7
seconds.
COMPRESSION PRESSURE :
549 kPa (5.6 kgf/cm 2, 80 psi) at 350 rpm
Check that there is no leakage at the gauge connection.

Low compression can be caused by:
- blown cylinder head gasket
- improper valve adjustment
- valve leakage
- worn piston ring or cylinder
High compression can be caused by:
- carbon deposits in combustion chamber or on piston
head
CYLINDER HEAD COVER REMOVAL!

DISASSEMBLY
REMOVAL
Disconnect the spark plug cap (page 3-7).
Remove the seat bottom covers (page 2-8).
Remove the bolts (1J and crossbar [2].
[2J
10-5
Set the piston position to Top Dead Center on the
compression stroke (page 3-8).
- seven bolts [1J and three washers [2]
- four cap nuts (3] and washers [4)
- cylinder head cover (5)
Mark 1M push rods - push rods [1]

so they can be - gasket [21
placed back in their - dowel pins [3)
original locations.
- cam followers [11
DISASSEMBLY
Remove the two bolts [1] and sealing washers [2\.
Push the rocker arm shaft [3] wi th the small screwdriver
through the bolt hole until the O-ring on the shaft is I"Il'-....,
~...
removed out of the head cover.
106
CYLINDER HEADNALVEfCAMSHAFT
Mark all the parts Remove the following:
so they can be
- rocker arm shafts
placed back in their
- rocker arms [1]
originalloca/ions.
- wave washers [21
111
INSPECTION
ROCKER ARM /SHAFT
Check the rocker arms and shafts for wear or damage.
If the rocker arm follower is worn or damaged , check
the push rod and oil passages.
Measure each rocker arm shaft 0.0.
SERVICE LIMIT : 11 .92 mm (0.469 in )
Measure each rocker arm I.D.
SERVICE LIMIT : 12.05 mm (0.474 in )
SUbtract each rocker ann shaft 0.0. from the
corresponding rocker arm 1.0. to obtain the rocker arm-
to-shaft clearance.
SERVICE LIMIT : 0.08 mm (0.003 in)
PUSH ROD
Check the push rods for wear or damage.
If the push rod is worn or damaged, check the cam
,
follower and camshaft.
CAM FOLLOWER
Check the cam follower and follower bore in the cylinder , - - - - - -- - - - - - -- - - - ,
head for scoring, scratches or damage.
Measure each follower 0.0.
SERVICE LIMIT : 22.46 mm (0.884 in )
10-7
Measure each follower bore 1.0.
SERVICE LIMIT: 22.54 mm (O.S87 in)

Subtract each follower 0.0. from the corresponding
bore 1.0. to obtain the follower-Io-bore clearance.
<

CYLINDER HEAD REMOVAL

- spark plug (page 3-7)
ECT sensor (page 4-27)
throttle body (page 7-19)
exhaust system (page 2-30)
cylinder head cover (page 105)
thermostat (page 9-7)
Loosen the band screw !1 1 and disconnect the water
,
hose [2] from the cylinder head.
Do nottap the - five bolts [1]

cylinder head 100 - cylinder head [2)
hard and do not
damage the matmg
surface with a
screwdnver.

1
- gasket 111
i
- dowel pins [2] 1

1
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10-8
CYLINDER HEAD DISASSEMBLY
To prevent loss ofRemove the valve spring cotters [1] using the valve ~-
tension. do not spring compressor [2).
compress the valve
springs more than TOOL :
necessary. Valve s pring compressor 07757-0010000
Mark all the parts Remove the following:

so they can be
- spring retainer [1]
placed back In thalf
- inner and outer valve springs 121
angina/locations
- valve [31
- slem seal [4]
- spnng seat (5J
(41
CYLINDER HEAD INSPECTION

CYLINDER HEAD
Be careful not 10 Remove the carbon deposits from the combustion
damage the gasket chamber [lJ. being careful not to damage the gasket
surface. surface.
Check the spark plug hole and valve areas for cracks.
Check the cylinder head for warpage with a straight

edge and feeler gauge.
~=~~~~~~~~~~~~
10-9
VALVE SPRING
Measure the valve spring free length.
SERVICE LIMITS: tnner: 36.3 mm (1 .4310)

Outer: 43.1 mm (1 .70 In)
VALVENALVE GUIDE
Check that the valve moves smoothly in the guide.
Check the valve for bending. burning or abnormal wear.
Measure each valve slem 0 .0 . and record it.
SERVICE LIMITS : IN : 5.45 mm (0.215 in)
EX : 5.43 mm (0.214 In)
Ream the valve guide to remove any carbon build-up

before measuring the guide .
Insert the reamer [1] from the combustion chamber side
of the cylinder head and always rotate the reamer
clockwise.
TOOLS:
Valve guide reamer, 5.5 rnm 079842000001 or
079842000000
(U .S.A. only)
Measure each valve guide 1.0. and record it.
Subtract each valve stem 0 .0 . from the corresponding

guide 1.0. to obtain the stem-to-guide clearance.
SERVICE LIMITS: IN: 0.12 mm (0.005 in)
EX ; 0.14 mm (0.006 In)
Inspect and roface

the valve seals
If the stem-to-guide clearance exceeds the service limit .
determine if a new guide with standard dimensions 1
j
whenever the valve would bring the clearance within tolerance.
guides are replaced If so, replace any guides as necessary and ream to fit.
(page 10-11). If the stem-to-guide clearance exceeds the service limit
with a new guide, also replace the valve.
1
10-10
VALVE GUIDE REPLACEMENT
Mark new valve guides at the specified height indicated
below, using a marker. Chill the new valve guides in a [1 [
freezer for about an hour.
Be sure to wear Heat the cylinder head to 130C - 140C (266"F -
heavy gloves to 284F) with a hot plate or oven. Do not heat the cylinder
avoid bums when head beyond 150C (302F). Use temperatu re indicator
handling the heated sticks, available from welding supply stores. to be sure
cylinder head. the cylinder head is heated 10 the proper temperature.
Using a torch /0
Support the cylinder head and drive the valve guides
heat the cylinder
out of the cylinder head from the combustion chamber
head may cause
side using the special tool.
warpage
TOOL :
Valve guide driver, 5 .5 mm (1J 07742-0010100
While the cylinder head is still heated. remove the new

valve guides [l J from the freezer and drive them into the
cylinder head from the rocker arm side until the
exposed height is at the specified value (al the mark).
[1[ ~
TOOL:
Valve guide driver, 5.5 mm [2) 07742-0010100
VALVE GUIDE PROJECTION :

IN: 14.8 -15.2 mm (0.58 - 0.60 in)
EX: 17.3 -17.7 mm (0.68 - 0.70 in)
let the cylinder head cool to room temperature.
Take care not fa tilt Ream the new valve guides.

or lean the reamer Insert the reamer [1) from the combustion chamber side
in the guide while of the head and always rotate the reamer clockwise.
reaming
Use curling oil on
TOOL:
the reamer dunng Valve guide reamer, 5.5 mm 079842000001 or
this operation. 07984-2000000
(U.S.A. only)
Clean the cylinder head thoroughly to remove any

metal particles after reaming and reface the valve seat
(page 10-11).
VALVE SEAT INSPECTION/REFACING

INSPECTION
Clean all intake and exhaust valves thoroughly to r-------------~
remove carbon deposits.
Apply a light coat of Prussian Blue to each valve seat.
Tap the valve against the valve seat several times
without rotating the valve using a hand-lapping tool [1].
to check for proper valve seat contact.
10-11
1
The valVe cannot Remove the valve and inspect the valve seat face.
be ground. "the The valve seat contact should be within the specified
valve face is burned width and even all around the circumference.
01' badlyworn Of if it
rontacts the seat
STANDARD ; 1.00 - 1.10 mm (0.039 - 0 .043 in)
unevenly. rep/ace SERVICE LIMIT: 1.4 mm (0.06 in)
the valve. If the valve seat width is not with in specification, raface
the valve seat.
Inspect the valve face for:
Damaged face: SEAT WIDTH
- Replace the valve and rerace the valve seat.
Uneven seal width :
- Replace the valve and reface the valve seat.
Contact area (too high or too low) J
- Reface the valve seat.
VALVE SEAT REFACING

Follow the refacing Valve seal cultersJgrinders or equivalent valve seat
manufacturer's refacing equipment are recommended to correct worn
operating valve seals ,
0 '
Instructions.
If the contact area is too high on the valve, the seat
must be lowered using a 32 flat cutter. 45'
o
If the contact area is 100 Iowan the valve, the seat must
be raised using a 60 interior cutter.
Refinish Ihe seat to specifications, using a 45 finish SO'
Reface the seat with

cutle,
Use a 45" cu tter 10 remove any roughness or
I '3"
a 45 cutter irregularities from the seat
whenever a valve
TOOLS :
guide is replaced.
Seat cutter, 35 mm (IN/EX) 07780-0010400 L _ __ _ _ _ _ _ _ _ _ _ _ _ _---'
Cutter holder, 5.5 mm 07781-0010101
or equivalent commercially available In U.S.A.
Use a 32 culter 10 remove the top 1/4 of the existing
valve seat material.
TOOLS :
1
Flat cutter, 38.5 mm (IN) 07780-0012400
1
Flat cutter, 35 mm (EX) 07780-0012300
or equivalent commercially available in U.S.A.
Use a 60 cutter to remove the bottom 114 of the old
I
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seat.
TOOLS :
Interior cutter, 34 mm (IN/EX) 07780-0014700
or equivalent commercia lly available in U.S.A.
Using a 45 seat cutter, cut the seat to the proper width.
Make sure that all pitting and irregularities are removed.
Refinish if necessary. i
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10-12 ,
Downloaded from www.Manualslib.com manuals search engine ,
Excessive lapping After cutting the seat, apply lapping compound and
pressure may engine oil to the valve face, and lap the valve using light
deform or damage pressure.
the seal. Change the angle of lapping tool [1) frequently to
Do not allow prevent uneven seat wear.
lapping compound
After lapping, wash any residual compound off the
10 enter the guides.
cylinder head and valve. Recheck the seal contact after
lapping.
CAMSHAFT
REMOVAL
Remove the cylinder head (page 10-8).
Remove the lifter plug [1] and washer (2] from the cam
chain tensioner lifter.
Install the special tool so its blade is into the tensioner
lifter and the labs are just above the slots in the lifter
(there should be space between the bottom of tool and
lifter body).
Then turn the tool clockwise until it stops turning and
engage the tabs with the slots (the lifter shaft is fully
secured with the special tool).
TOOL:
Tensioner holder B [3) 070MG-0010100 or
07 AMG-001 A 100 or
(U.S.A. only)
07AMG-MFJA100
(U.S.A. only)
Remove the four camshaft holder bolts [1].
Suspend the cam Raise the holder plate [2) so the dowel pins fitted in Ihe
chain with a pieceD' camshaft holders are removed off the cylinder.
Wire 10 prevent il Release the cam chain [3] from the cam sprocket to
'rom falling into Ihe remove the camshaft assembly [4] and holder plate.
cranKcase,
Remove Ihe camshaft holder B [1) from the camshaft

assembly.
Do not forcibly Remove Ihe dowel pins {2J.
remove the dowel
pins from the
camshaft holders,
[21
10-13
INSPECTION
Check the sprocket teeth for wear or damage.
Turn the camshaft holder to check each bearing.
Replace the camshaft assembly if the bearing does not
turn smoothly and quietly.
Check the cam surfaces for scoring, scratches or
evidence of insufficienllubricalion.
Measure each cam lobe height.
SERVICE LIMITS: IN : 34.4488 mm (1 .3 5625 in)
EX: 34.7335 mm (1.36746 in)
Check the decompressor cam (1] operation.

Press on the decompressor cam as shown.
As you press on one side, the decompressor cam
should lock above the base of the exhaust cam lobe.
As you press on other side, the decompressor cam lobe
should extend below the base of the exhaust cam lobe.
I1J
INSTALLATION
Carefully rotate the -r
Turn the crankshaft clockwise and align the mark [11 , - - - -- - - - - - - - - - - -- ,
crankshaft while on the flywheel with the index mark [21 in the crankcase
holding the cam cover.
chain to avoid Retract the tensioner lifter shaft and secure it with the
jamming the cam tensioner holder (page 10-13).
chain against the
timing sprocket of
the crankshaft.
I1J 12J
Install the dowel pins [1J if they are removed.

Install the camshaft holder B [2] onto the camshaft
assembly.
11J
10-14
Before ins/ailing the Lubricate the camshaft bearings and cam chain with
camshaft. be sure engine oil.
the cylinder boll Install the camshaft holder plale [1] onto the camshaft
(under the cam holders, aligning the holes with the dowel pins,
shaft) is tightened
Place the camshaft assembly [2] onto the cylinder and
securely
instalilhe cam chain [3] over the sprocket while aligning
(page 11-9).
the timing marks (index lines) [4J on Ihe sprocket with
the cylinder lop surface and holder plale edge.
Locate the dowel pins into the holes in Ihe cylinder
securely.
Be sure the timing marks lines up with Ihe cylinder top
surface and holder plate edge
Install the four holder bolts (1} and tighten them.

Apply molybdenum oil solution to the cam lobes and
decompressor cam area.
Make sure the Remove the tensioner holder, and instalilhe cam chain
timing marl< on the tensioner lifter plug [1] with a new sealing washer [21
sprocket aligns with and tighten it.
the cylinder surface
Install the cylinder head (page 10~ 17).
when the -r mark
is aligned with the
index marl<
10-15
CYLINDER HEAD ASSEMBLY
conERS
SPRING RETAINER
OUTER VALVE SPRING
INNER VALVE SPRING
.....
~..., STEM SEAL
SPRING SEAT
VALVE GUIDE
~
INTAKE VALVE
Blow through the oil passage (stud bolt hole) in the , - - - - - - - - - --

cylinder head with compressed air.
Install the valve spring seals [1) and new slem seals (2).
[4[
Lubricate the valve stem sliding surlace with
molybdenum disulfide grease.
Insert the valve !31 into the guide while turning it slowly
to avoid damaging the stem seal.
Install the inner and outer valve springs [4] wi th the
tightly wound coils facing the combustion chamber. l
1
Install the spring retainer [5).
~
1
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Combustion chamber side
10-16
Grease the cotters Install the valve cotters [1 J using the valve spring
to ease installarion. compressor 12].
To prevent loss of
tension. do not TOOL:
compress Ihe valve Valve spring compressor 07757-0010000
springs more than
necessary.
Support Ihe cylinder Place a suitable tool [1] onto the valve stem [2].
head so Ihe valve
Tap the 1001 gently to seat the cotters [3J firmly using a
heads will not
hammer.
contact anything
that cause damage.
[31
[2[
CYLINDER HEAD INSTALLATION

Clean the mating surface of the cylinder and head.
Install the dowel pins [1] and a new gasket (2).
Inslallthe cylinder head [1] on the cylinder.

Tighten tile cylinder Inslallthe five bolts [21 and temporarily tighten them.
head bolrs after
installing Ihe
cylinder head cover,
10-17
CYLINDER HEADNALVEfCAMSHAFT
Connect the water hose [1] to Ihe cylinder head and
lighten the band screw [2] .
Instal! the following:
- cylinder head cover (page 10-19)
thermostat (page 9-7)
Eel sensor (page 4-27)
spark plug (page 3-7)
CYLINDER HEAD COVER ASSEMBLYI

INSTALLATION
ASSEMBLY
INTAKE ROCKER ARM ~
,
I
----, EXHAUST ROCKER ARM

~
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ROCKER ARM SHAFTS j
I
1
:11 SEALING WASHERS
~
"
~
~@l ~" J."
..... 1
O-RINGS ~
~
~
SETIING BOLTS
Coat new O-rings [1] with engine oil and install them.
Apply molybdenum disulfide grease to Ihe rocker arm
1
1
shaft [21 sliding surface.
,
~
-,
1
$" I
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1018 ~
Install the rocker arms [1]. wave washers [2] (setting
bolt side) and arm shafts [3J.
.
[3[
Align the bolt holes in the head cover and rocker arm
shaft [1] by turning the shaft.
Install the setting bolts [2] wi th new sealing washers [3]
and lighten the bolts securely .
INSTALLATION
Turn the crankshaft and align the "r mark [1] with the
index mark (2). then check the cam lobes through the
cam follower holes.
If the cam lobes face up. rolate the crankshaft one full
turn and match up the "r mark again so the cam lobes
face down.
[1 [ [2[
Coat the cam followers [1] with engine oil and install
them into the cylinder head.
10-19
r-.. .""~==-:---~~----
Inslalithe dowel pins [1] and a new gasket 12].
Install the push rods {3] in the cam followers and rest
them on Ihe gasket cutout as shown.
Apply engine oil to the rocker arm followers and ~==~~;::~:~

adjusting screw tips .
Installing the head Install the cylinder head cover [1J while holding the It?~!P:r
coverincorrectly will rocker arms in order to align the rocker arm followers
result in severe with the push rod ends.
engine damage. Do Be sure to seat Ihe rocker arm followers to the push
fIfJ/ Ughten the head rods properly by turning the crankshaft slowly.
cover fasteners
when the rocker
ann are not aligned
with the push rod
end.
Apply engine oil to Ihe cap nul threads and sealing :-;~:::;;:;;;;
surfaces and install the following fasteners.
- four washers [1] and cap nuls [2]
- three new washers [3] and seven bolts [4]
Tighten the nuts and bolts (including the cylinder and
cylinder head bollS) in a crisscross pattern in several
steps.
TORQUE: Cap nut: 65 N'm (6.6 kgf.m , 48 lbHt)
Check the valve clearance (page 3-8).
Install the crossbar [11 and tighten the bolts (2].

Inslalilhe seal bottom covers (page 2-8).
Connecllhe spark plug cap (page 3-7).
~,
[1 [ ,I,
,
1020 ,
CAM CHAIN TENSIONER LIFTER
Remove the front seal cushion (page 2-4).
Remove the cam chain tensioner lifter plug [1] and
sealing washer [2].
Turn the cam chain tensioner lifter shaft fully in

(clockwise) and secure it using the special tool.
TOOL :
Tensio ner holder B [1] 070MG-0010100 or
07AMG001A100 o r
(U.S.A . only)
07AMG-MFJA 100
(U.S.A. o nly)
Remove the cam chain tensioner lifter mounting bolts

121
Remove the cam chain lensioner lifter [3J and gasket
[4]. ,'Or .
Install a new gasket [1] on the cam chain lensioner lifter ~;~;;;~;~;;;:;:;:;:::::.~:;~::::::~
[2) and install them to the cylinder.
Instan and tighten the cam chain lensioner lifter :;;:~;;;;;;!!:;::::::;;=::=::!==~

mounting bolts [1J.
Remove the lensioner holder.
Install and tighten the cam chain lensioner lifter plug [2)
with a new sealing washer [3).
Inslalithe front seal cushion (page 2-4),
10-21
CYLINDER HEADNALVEICAMSHAFT
INSPECTION
Check the cam chain lensioner lifter (1) operation:
- The cam chain tensioner lifter shaft should not go
into the cam chain lensioner lifter body when it is
pushed.
- When it is turned clockwise with the tensioner holder
or a screwdriver [21. the cam chain tensioner lifter
shaft should be pulled into the cam chain tensioner
lifter body. The cam chain tensioner lifter shaft
should spring out of the cam chain tensioner lifter
body as soon as the tensioner holder is released.
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10-22
11. CYLINDER/PISTON
SYSTEM COMPONENTS
11-2 CYLINDER/PISTON REMOVAL11-4
SERVICE INFORMATION
11-3 CYLINDER/PISTON INSPECTION ... ..... .. 11 -5
TROUBLESHOOTING ....... ................. .. 11-3 CYLINDER/PISTON INSTALLATION 11-8
III
11-1
1
CYLINDER/PISTON
SYSTEM COMPONENTS
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11-2
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CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
The cylinder and piston can be serviced wi th the engine installed in the frame.
Take care nollo damage the cylinder wall and piston .
Be careful nollo damage the mating surfaces when removing the cylinder.
Rocker arm and valve lubricating oil is fed through the oil passage in the cylinder. Clean the oil passage before installing the
cylinder.
When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
Leaking cylinder head gasket
Worn, stuck or broken piston ring
Worn or damaged cylinder and piston
Compression too high, overheating or knocking
Excessive carbon built-up on piston head or combustion chamber
Excessive smoke
Worn cylinder, piston or piston rings
Improper installation of piston rings
Scored or scratched piston or cylinder wall
Abnormal noise
Worn piston pin or piston pin bore
Worn connecting rod small end
Worn cylinder, piston or piston rings
11-3
CYLINDER/PISTON
CYLINDER/PISTON REMOVAL
CYLINDER REMOVAL
- camshaft (page 10-13)
- cam chain tensioner lifter (page 10-21)
- bolt [1] and water pipe [2]
- Oring (3]
- crankcase breather hose [1J
Do not tap the - four bolts [1) and cylinder [2]

cylinder too hard
and do flO( damage
the mating surface
with a screwdriver.
,1
- gasket [1)
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- dowel pins [2]
11-4
CYLINDER/PISTON
PISTON REMOVAL
Place a clean shop towel over the crankcase to prevent n~"':"':"-1T:ii1"'=iiiiio;;;;.Jrl
the piston pin clip (1J from falling into the crankcase,
Remove the piston pin clips with pliers.
Push the piston pin [2] out of the piston and connecting
rod , and remove the piston PI.
00 not damage the Spread each piston ring and remove it by lifting up at a
piston ring by point opposite the gap.
spreading the end
too far.
Never use a wire Clean carbon deposits from the piston ring grooves with
brush; it will scratch a ring that will be discarded.
the groove.
CYLINDER/PISTON INSPECTION
CYLINDER
Inspect the cylinder bore for scratch or wear.
Measure the cylinder 1.0. at three levels in an X and Y
axis. Take the maximum reading to determine the
cylinder wear.
Calculate the cylinder-ta-piston clearance.
Measurement of the piston 0.0 . (page 11-7)
11-5
CYLINDER/PISTON
Calculate the cylinder taper and oul-of-round at three
levels in an X and Y axis. Take the maximum reading to
determine the taper and out-of-round.
SERVICE LIMITS : Taper: 0.05 mm (0.002 in)

Out of round: 0.05 mm (0 .002 In)
MIDDLE ,
-- --
BOTTOM 1' ..... --1-- . . ,
, .... -_ !1 .__ ... '
Check the lop of the cylinder for warpage with a straight ~=====-----=::----:========::,
edge and feeler gauge across the stud holes.
PISTON/PISTON RING
Inspect the piston rings for smooth movement by ~-------
rotating the them. The rings should be able to move in
their grooves withou t catching.
Push the ring unlil the outer surface of the piston ring is
nearly flush with the piston and measure the ring-Ie-ring
groove clearance
SERVICE LIMITS : Top : 0.095 mm (0.0037 In)
Second : 0.075 mm (0.0030 in)
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Insert the piston ring (lJ into the bottom of the cylinder ~=~:"'''';~~~=~====.;",;;;;;;;;;;;;;;;
squarely using the piston crown.
Measure the ring end gap.
SERVICE LIMITS : Top: 0.5 mm (0.02 in)
Second : 0.7 mm (0.03 in)
011 (side rail) : 0.9 mm (0.04 in)
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11-6
Downloaded from www.Manualslib.com manuals search engine J
CYLINDER/PISTON
Measure the piston 0.0. at a point 20 mm (0.8 in) from
the bottom and 90 to the piston pin hole.
SERVICE LIMIT: 101 .90 mm (4.012 i n)
Compare this measurement against the maximum

cylinder 1.0. measurement and calculate the cylinder-
to-piston clearance (page 11-5).
20 mm
(O.S in )
Measure the piston pin hole 1.0. Take the maximum r--==========--~
reading to determine the 1.0 .

Measure the piston pin 0.0. at three points.
SERVICE LIMIT: 22.9S mm (0 .905 in)
Calculate the piston-to-piston pin clearance.

CONNECTING ROD
Measure the connecting rod small end 1.0.
SERVICE LIMIT : 23.06 mm (0.90S in)

Calculate the connecting rod-Io-plston pin clearance.
SERVICE LIMIT: O.OS mm (0.003 In)
CYLINDER STUD BOLT

REPLACEMENT
Thread two nuts onto the stud and tighten them
together, and use a wrench on them to turn the stud bolt
out
23S.5 :i: O.S mm
Install a new stud bolt in the direction as shown. (9.39:i: 0 .003 in)
- Front crankcase: 90033-HNS-OOOO
(atl four)
(Yellow mark on boll head)
- Rear crankcase: 90032-HNB-OOOO (No mark)
TORQUE : 24 N 'm (2.4 kgf'm , 18Ibfft)
Be sure to verify the stud height from the crankcase

surface.
o ,
Adjust the height if necessary.
U
---=----
11-7
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CYLINDERJPISTON
CYLINDER/PISTON INSTALLATION
PISTON RING INSTALLATION
Be careful nor to Carefully Install the piston rings into the piston ring ,---------=-
11)
-------,
damage the piston grooves with the markings [1] facing up.
and rings.
NOTE :
Do not confuse the top ring (21 and second ring [3J . [2)
To install the oil ring [4J, install the spacer [5] first,
--+ (
then install the side rails [6].
Stagger the piston ring end gaps 120 apart from each
other. --+[
[3)
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Stagger the side rail end gaps as shown.
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20 mm ar more
[5)
PISTON INSTALLATION
Place a dean shop towel over the crankcase to prevent
the piston pin dip (1] from falling into the crankcase.
Apply molybdenum oil solution to the piston pin {2] outer ..,-:=:...;.,
surface.
Apply engine oil to the piston pin hole and connecting
rod inner surface.
Install the piston (3] with the "IN" mark [4] toward the
intake side and insert the piston pin through the piston
and connecting rod.
Inslal new piston pin clips.
NOTE:
Make sure the piston pin clips are seated securely.
Do not align the clip end gap [1] wilh the piston
cutout [2].
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11-8 <
CYLINDERIPISTON
CYLINDER INSTALLATION
Clean the gasket surface of the crankcase thoroughly.
being careful not to damage them, and being careful not
to allow gasket material into the crankcase.
Blow through the oil passage (stud bolt hole) in the
cylinder with compressed air.
Install the dowel pins [1] and a new gasket [2].
Be careful not to Apply engine oil to the cylinder wall , piston outer
damage the piston surface and piston rings.
rings and cylmder
wall_
Route the cam chain [1J through the cylinder [2] and
install the cylinder over the piston while compressing
the piston rings with your fingers.
Align the cam chain guide bosses [3] with the grooves
[4] in the cylinder properly to seat the cylinder on the
crankcase.
Tighten the three Make sure that the cylinder [1] touches the crankcase
outside bolts again evenly. Install the four bolts [2] and tighten them
after installing the securely.
cylinder head
cover.
Connect the crankcase breather hose 11] to the jOint of

the cylinder.
11-9
CYLINDERIPISTON
Coat a new O-ring {1] with coolant and install it on the
water pipe 12]. Ihen connect it to the cylinder.
Install and lighlen the bolt 13].
Instalilhe following:
- camshaft (page 10-14)
- cam chain tensioner lifter (page 10-21 )
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11-10
12. ALTERNATORISTARTER CLUTCH
SYSTEM COMPONENTS
12-2 ALTERNATOR STATOR/STARTER
REDUCTION GEARS ........................... 125
SERVICE INFORMATION12-3
FL YWHEELISTARTER CLUTCH 12-10
TROUBLESHOOTING .... .... ..... ............. 12-4
121
AL TERNATORISTARTER CLUTCH
SYSTEM COMPONENTS
16 N'm (1.6 kgf'm, 12 tbf-ft )
~ .~
108 N'm (11.0 kgf'm, 80 IbHt)
12-2
SERVICE INFORMATION
GENERAL
This section covers service of the alternator/stator, starter reduction gears and flywheel/starter clutch.
Alternator/stator and starter reduction gears can be serviced with the engine installed in the frame.
Flywheel/starter dutch service requires lifting up the engine in the frame (page 13-5).
Crankshaft lubricating oil is fed through the oil passage in the alternator cover. Clean the oil passage before installing the
alternator cover.
Be careful not to damage Ihe mating surfaces of the alternator and crankcase covers when servicing.
For rear crankcase cover removal/installation (page 13~5) ,
For alternator stator inspection. see Battery/Charging System section (page 21-6),
For starter motor service, see Electric Starter section (page 6-4).
TOOLS
Flywheel holder Rotor puller Remover weight
07725~004000 1 07733-0020001 07741-0010201
or 07933-3950000 (U.S.A. only) or 07936-371020A or 07936-3710200

(U.S.A. only)
Bearing remover shaft, 10 mm Bearing remover head , 10 mm Remover handle
07936-GE00100 07936-GE00200 07936~3710100
or 07936-GEOAOOO (U .S.A. only) or 07936-GEOAOOO (U.S .A. only)

Driver Attachment, 24 x 26 mm Pilot, 10 mm
07749-0010000 07746-0010700 07746-0040100
12-3
Torque limiter attachment B Torque limiter attachment 0
07YMJ-MCF0200 070MJ-HN80100
nol available in U.S.A. nol available in U.S.A.
TROUBLESHOOTING
Starter motor turns , but engine does not turn
Faulty starter dutch
Damaged reduction gears or torque limiter
.
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12-4
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ALTERNATOR STATOR/STARTER
REDUCTION GEARS
AL TERNA TOR COVER REMOVAL
4 person type only: Remove the rear foot wells (page 2-10).
Remove the heat guard plate (page 2-30)
Drain the engine oil (page 3-9).
Disconnect the alternalor/CKP sensor SP (black)
connector [1J and release the wires from the clip [2].
Disconnect the EDT sensor 2P connector [1] and

release the wire band [2J from the cable holder.
Shift the sUb-transmission into neutral.

Remove the two bolts (1J and cable holder [2].
Remove the pinch bolt [1) and release the gear selector
arm [2J from the gearshift spindle.
12-5
The cover (stator) ;s - ten bolts (1], four sealing washers (2) and clip stay
magnetically [3J
attracted to the - alternator cover [4]
flywheel. be careful
dunng removal.
- dowel pins [1]

- gasket [2]
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- starter torque limiter 111
- reduction gear (2)
- gear shaft [3]
INSPECTION
Check the bearings [11 in the alternator and rear
crankcase covers.
Turn the inner race of each bearing with your finger.
The bearing should turn smoothly and quietly.
Also check that the outer race of the bearing fits lightly
in the covers.
Torque limiter bearings replacement (page 12-8)
12-6
ALTERNATORlSTARTER CLUTCH
Check the teeth of the reduction gears [1] and torque
limiter {2] for abnormal wear or damage.
[2]
Hold the torque limiter 11 J in a vise with the special tool.

Rep/ace the torque Check the slip torque with the special tool and a torque
limiter as an wrench.
assembly.
TOOLS :
Torque limiter attachment B 07YMJMCF0200 (not
[2] available in U.S.A.)
Torque limiter attachment D 070MJ HN80100 (not
[3] available in U.S.A.)
STANDARD SLIP TORQUE :

53 - 84 N' m (5.4 - 8.6 kgf'm, 39 - 62 IbHt)
STATORlCKP SENSOR REMOVAL!

[NSTALLAT[ON
Remove the CKP sensor mounting bolts [1] and release , - - - - -
the CKP sensor [2].
Remove the boll [3) and wire holder [4]. then release
the wire grommet ISJ off the alternator cover.
Remove the fou r bolts [6] and alternator stalorlCKP
sensor assembly [7] .
[7]
Install the siatorfCKP sensor assembly {1] onto the

alternator cover.
Apply sealant (Threebond T81215 or equivalent) to the
wire grommet seating surface and install the grommet
[2] into the cover groove securely.
Install and tigh ten the four alternator stator bolts [3110
the specified torque.
TORQUE: 10 N'm (1 .0 kgf'm , 7 Ibfft)
Apply locking agenllo the CKP sensor bolt [4] threads,
then install and tighten them to the specified torque.
TORQUE : 6 N'm (0.6 kgf' m, 4.4 Ibf.ft) [2]
Instal! the wire holder [5] .

.,(!.!I! I
Apply locking agent to the wire holder bolt [6] threads,
then install and tighten them to the specified torque.
TORQUE : 10 N'm (1 .0 kgf'm , 7lbHt)
12-7
BEARING REPLACEMENT
Remove the torque limiter bearings in the alternator
cover and rear crankcase covers, using the special
tools [1}.
TOOLS:
Bearing remover head, 10 mm 07936-GE00200
Remover shaft, 10 mm 07936-GE00100
Remover weight 07741-0010201
U.S.A. only too ls:

Bearing remover, 10 mm 07936GEOAOOO
Remover handle 079363710100
Remover weight 07936371020A or
07936-3710200
Drive new Torque limiter bearings in with the mar1<s

facing up.
TOOLS :
Driver [1] 07749-0010000
Attachment, 24 x 26 mm [2J 07746-0010700
Pilot, 10 mm [3] 07746-0040100
ALTERNATOR COVER INSTALLATION

NOTE:
Route the wires and cables properly (page 1-17).
Blow through the oil passage in the alternator cover
with compressed air.
Clean the cover mating surfaces.
Apply molybdenum oil solution to the gear teeth and
splines.
Install the reduction gear shaft [1J into the crankcase
and the reduction gear 12] onto the gear shaft.
Install the torque limiter [3].
Install the two dowel pins [1] and a new gasket [2].
12-8
The cover (stator) is Carefully install the alternator cover (1J.
magnellcally
Inslall the len bolts 12) with four new sealing washers [3]
attracted 10 the
and the clip stay [4], and tighten them in a crisscross
flywheel. be careful
pattern in several steps.
not 10 gel anything
caugh/between NOTE'
these parts when The location for the bolt With sealing washer is
Installing indicated with triangle marks on the cover.
Inslall the gear selector arm [1J by aligning the slit with
the index hne of the spindle.
Install the pinch bolt [2J and tighten it to the specified
torque .
TORQUE: 16 N'm (1 .6 kgf'm , 12 IbHt)
Install the cable holder 11] with the two bolts [2).
Installlhe wire band 111 into the cable holder.

Connect the EDT sensor 2P connector (2].
12-9
ALTERNATORISTARTER CLUTCH
Connect the altemator{CKP sensor 5P (black)
connector [1) and secure the alternaiorlCKP sensor and
gear position switch wires with the clip [2].
Install the heat guard plate (page 2-30).
"person type ooly: Inslall the rear fool wells (page 2-10),
Fililhe engine with the recommended oil (page 3-9).
FLYWHEELISTARTER CLUTCH
REMOVAL
Remove the rear crankcase cover (page 13-5),
Hold the flywheel [1 ) wi th the special 1001 and remove
the bolt (2] and washer [3].
TOOL:
Flywheel holder 14] 07725-0040001 J
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Remove the flywheel (1) and starter driven gear using

the special 1001.
TOOL:
Rotor puller (2] 07733'{)020001 or
079333950000
(U.S.A. only) ,

Remove the needle bearing (1), thrust washer [21. and

the wOOdruff key (3).
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12-10
STARTER CLUTCH DISASSEMBLY/
INSPECTION
Make sure that the starter driven gear [1] turns clockwise '----cll~J----------------,
smoothly and does not turn counterclockwise.
Remove the driven gear while turning it clockwise.
Hold the flywheel (1) with the special tool and remove ~==="=~:':::====':::~~----~
the starter clutch bolts [2].
TOOL :
Flywheel holder [3] 07725-0040001
Remove the starter clutch assembly from the flywheel.
Remove the sprag clu tch [1] from the clu tch outer [2}.
Check the clutch outer and sprag clutch for abnormal [2J
wear or damage.
Check the starter driven gear [1] teeth and needle

bearing [2] for wear or damage. [1]
Measure driven gear boss 0.0.
SERVICE LIMIT: 51 .61 mm (2.032 in)
12-11
STARTER CLUTCH ASSEMBLY
lubricate the sprag clutch (lJ with engine oil and install , - - - -
it into the dutch outer 12] with the flanged side facing
the flywheel side.
~================~
Apply locking agent to the starter clutch bolt 111 threads.
Install Ihe flywheel [2J onto the clutch outer and the
clutch bolts.
.cu J
Hold Ihe flywheel wilh the special 1001 and lighten the
bolts.
TOOL:
Flywheel holder [3) 07725-0040001
TORQUE : 30 N'm (3.1 kgf' m , 22 IbHt)
Install the starter driven gear [1] while turning it

clockwise .
~=============""'=~
INSTALLATION
lubricate the needle bearing 111 with molybdenum oil
solution . Install Ihe washer 12] and bearing onto Ihe
crankshaft.
Inslall the woodruff key (31 into the key groove.
Clean any oil from the tapered portion of the crankshaft
and f1ywheellhoroughly.
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12-12 I
Downloaded from www.Manualslib.com manuals search engine l
Install the f1ywheeUstarter driven gear by aligning the
key-way [1J with the key on the crankshaft
Apply engine oil to the flywheel bolt [11 threads and

seating surface, then instal! the washer [21 and bolt.
Hold the flywheel [31 using the special tool and tighten
the bott.
TOOL:
Flywheel holder [4] 07725..(1040001
TORQUE: 108 N' m (11 .0 kgfm, 80 IbHt)

Instatlthe rear crankcase cover (page 13-7).
1213
MEMO
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13. SUB-TRANSMISSION/GEARSHIFT LINKAGE
SYSTEM COMPONENTS " .......... ....... .. 13-2 SUB-TRANSMISSION ..... ... ..... .... ......... 13-9
SERVICE INFORMATION
13-3 GEAR SELECTOR LEVER LiNKAGE 1316
TROUBLESHOOTING ....... ... ..... ..... ...... 13-4 GEAR SELECTOR CABLE
ADJUSTMENT 13-17
REAR CRANKCASE COVER ... . .......... .. 13-5

131
SUBTRANSMISSION/GEARSHIFT LINKAGE
SYSTEM COMPONENTS
12 N'm (1.2 kgf-m, 9lbHt)
1
1
1
1
1
1
1
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12 N'm (1.2 kgf-m, 9lbHt) 25 N'm (2.5 kgf-m, 181bHt)
13-2
SUBTRANSMISSION /GEARSHIFT LINKAGE
SERVICE INFORMATION
GENERAL
This section covers service of Ihe sub-transmission and gearshift linkage (forward-reverse). These services require lifting up the
engine in the frame (page 13-5).
Sub-transmission lubricating oil is fed through the oil passage in the rear crankcase cover. Clean the oil passage before
installing the crankcase cover.
Be careful nol to damage the crankcase and cover mating surfaces when servicing.
For automatic transmission service, see Drivetrain System section (page 16-3).
TOOLS
Remover weight Attachmen t, 37 x 40 mm Pilot, 17 mm
07741-0010201 07746-0010200 07746-0040400
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or 07936-371020A or 07936-3710200
(U.S.A. only)
Pilot, 25 mm Driver Attachment, 42 x 47 mm
07746-0040600 07749-0010000 07746-0010300
Remover handle Bearing remover, 17 mm

07936-3710100 07936-3710300
13-3
TROUBLESHOOTING
NOTE :
Be sure the MIL is not blinking (No drivetrain DTG) before checking the fol(owing (page 16-13).
Excessive s hift s hoc k or abnormal noise when shifting sub-transmission (D-N-R)
1. Sh ift condition check
Check gear selector lever free play between the Neutral-Drive and Neutral-Reverse.
Is the freeplay the same for each gear?
NO - Faulty gearshift linkage (page 13-4).
YES - GO TO STEP 2.
2. Vehicle c reep check
Start the engine.
Shift the sub-transmission in Drive position with the brake applied.
Wait several seconds. Release the brake and check the vehicle condition .
Does the vehicle creep?
YES - Perform the inspection "Vehicle creeps when idling- (page 16-5) while applying the brake as same
manner as above.
NO - Adjust the selector cable (page 13-17).
Hard to s hift
Bent shift fork claw
Bent shift fork shaft
Damaged shift drum guide groove
Damaged shift fork guide pin
Damaged gearshift spindle and drum tee th
Damaged selector lever linkage
Improperly adjusted selector cable
Improperly installed gearshift spindle and drum
Trans mission jumps out of gear
Worn gear and shifter dogs
Worn gear shifter groove
Bent shift fork shaft
Broken shift drum stopper arm
Weak or broken stopper arm spring
Damaged shift drum cen ter plate
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13-4
SUB-TRANSMISSION /GEARSHIFT LINKAGE
REAR CRANKCASE COVER
REMOVAL
- exhaust pipe (page 2-30)
air cleaner housing (page 7-16)
front propeller shaft (page 18-14)
rear propeller shaft (page 18-45)
EOT sensor (page 16-55)
gear position switch (page 16-54)
starter motor (page 6-4 )
alternator cover (page 12-5)
starter reduction gears (page 12-5)
bolt (1] and ground cable [2]
- two bolts [1], oil filler pipe [2J and O-ring [3]
Place a jack or an adjustable support under the engine.

Remove the engine side mounting nuts [lJ and bolts [2].
HOld the engine Slightly lift the engine upward until there is enough
securely and lake clearance for rear crankcase cover removal.
care not to damage
the frame and
engine.

121L--/
- two 8 mm bolts [1]
- oil drain bolt [2] , sealing washer (3] and O-ring (4)
- eleven 6 mm bolls [5]
- rear crankcase cover 16)
PI [2J/13]/14]
13-5
- two dowel pins [1]
- oil joint collar [2] and O-rings [3]
- gasket [4]
[1)
- gearshift spindle oil seal [1)

- output shaft oil seal [2J
BEARING REPLACEMENT 1
For rear crankcase bearings replacement (page 149).
OUTPUT SHAFT BEARING
Drive out the output shaft bearing [1] from the
crankcase cover.
,----------,,------C----,
1
l
Drive a new output shaft bearing [1) in with its marked

side facing up until it is fully seated.
~iii::'~::~.~"Ii~==~~~
~
TOOLS :
Driver (2} 07749-0010000
Attachment, 42 x 47 mm (3} 07746-0010300
Pilot, 25 mm (4] 07746-0040600
13-6
COUNTERSHAFT BEARING
Remove the countershaft bearing [1] using the special
tools.
TOOLS :
Bearing remover, 17 mm [2) 079363710300
Remover handle [3] 079363710100
Remov er weight (4) 07741 0010201 or
07936371020A
(U.S.A . only) or
079363710200
(U.S.A. only)
Drive a new counlershaft beanng [1 J in with its sealed

side facing down unlil it is fully seated .
TOOLS :
Driver [2] 07749"{)010000
Attachment, 37 x 40 mm 13] 07746-0010200
Pilot, 17 mm (4J 0774S'()040400
INSTALLATION
Blow through the oil passage m the rear crankcase
cover with compressed air.
Clean the crankcase and cover malmg surfaces.
Apply engine oil to the lips of a new gearshift spindle oil
seal [11 and grease to the lips of an output shaft oil seal
{21 . and install them into the crankcase cover until they
are fully seated.
Coat new O-rings [1] with engine oil and install them
into the JOint collar [2] grooves Install the oil joint collar
Into the crankcase.
13-7
Install the two dowel pins (1] and a new gasket (2] .
Make sure that the reverse idle shaft washer [3] and
gearshift spindle washer [4] are installed, and thai the
shift drum position is neutral as shown (switch pin
groove [5] is in vertical position).
Install a new sealing washer [11 onto the drain bolt [21.
Coal a new O-ring [3J with engine oil and install it into
the drain bolt groove.
Install the rear crankcase cover [4] with the following
fasteners:
- eleven 6 mm bolts [5)
- two 8 mm bolts [6)
- oil drain bolt
Tighten the bolts in a crisscross pattern in severa!
steps.
TORQUE: Drain bolt: 25 N-m (2.5 kgf'm, 18 IbHt)
l ower the engine and maneuver it into place.

HoIdtMengme Insert the engine side mounllng bolts (1J from the front
secure/yandtake side.
care not to damage Install the engine side mounling nuts [2] and tighten
the frame and them.
engine.
TORQUE : 54 N' m (5.5 kgf' m, 40 IbUt)
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Coat a new O-ring [1] with engine oil and install it onto
the oil filler pipe [2]. t
I
Install the filler pipe with the two bolts {3].
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13-8
Install the ground cable [1J and tighten the boll 12J by
aligning the terminal edge with the case rib as shown.
InslaUthe following:
- starter reduction gears (page 12-8)
- alternator cover (page 12-8)
- starter molor (page 6-4)
- gear position switch (page 16-54)
- EOT sensor (page 16-55)
- rear propeller shaft (page 18-61)
- front propeller shaft (page 18-42)
- air cleaner housing (page 7-16)
- exhaust Pipe (page 2-30)
SUB-TRANSMISSION
DISASSEMBLY
- rear crankcase cover (page 13-5)
- washer [1]
- idle gear [2J
- washer (3J
- gear shaft (4)
- two needle bearings (5J
- shift fork shaft [11

- shift fork 121
- countershaft assembly 131
- output shaft [1J

- output driven gear [2]
13-9
SUBTRANSMISSIONIGEARSHIFT LINKAGE
Remove the oil seal [1] from the front crankcase cover.
Remove the shift drum [1] while lifting the stopper arm
(2] with a screwdriver.

- washer [1]
gearshift spindle [2J
pivot bolt [3]
stopper arm [4)
washer [5]
return spring [6]
,

!
1
!
t
I
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j
1
13-10 1
Remove the lock washer on the shaft end with a screwdriver and disassemble the countershaft according to the
illustration
SHAFT GUIDE
GEAR SHIFTER
WASHER REVERSE GEAR
SHAFT GUIDE
BEARING (20 x 24 x 17)
COUNTERSHAFT
WASHER
INSPECTION
COUNTERSHAFT
Check the gear dogs and splines in the shaft guides (1]
for abnormal wear or damage .
Check the teeth and splines of the drive gear [2) and
reverse gear 13) for abnormal wear or damage.
Check the gear shifter (4) for smooth operation.
Check the gear shifter groove, dogs and splines for
abnormal wear or damage.
Check the countershaft (5) and needle bearings (6] for
12J I'J
OUTPUT SHAFT
Check the teeth and splines of output driven gear [1) for
abnormal wear Of damage.
Check the ou tput shaft [2) for abnormal wear or
damage .
12J
13-11
REVERSE IDLE GEAR
Check the gear [1] teeth for abnormal wear or damage.
Check the gear shaft [2) for abnormal wear or damage.
Check the needle bearings [3) for abnormal wear or
damage.
121
131
SHIFT FORK AND SHAFT
Check shift fork guide pin for abnormal wear or , - - - - -- -- - - - -- - - - - - ,
damage.
Measure each shift fork claw thickness.
Measure the shift fort< 1.0.

Measure the shift fork shaft 0.0.

SHIFT DRUM
Replace the shift Check the guide groove [I] for abnormal wear or , - - - - - - - - - - - -- - - - - - ,
drum as an damage. PI
8ssembly.
Check the drum center plale [2] and shifter gear [3) for
111
GEARSHIFT SPINDLE
Check the shifter gear and splines for abnormal wear or , - - - - -- -- - - - - - - - - - - ,
damage.
13-12
INSTALLATION
Apply engine oil to the reverse gear needle bearing
(20 x 24 x 17) [1] and countershaft [2] sliding surface ,
Install Ihe washer [3] and needle bearing onto the
countershaft.
Apply engine oil to the teeth of the reverse gear [1].

Instalilhe shaft guide [2). reverse gear and lock washer
[3) onto the counlershaft [4] .
121
Apply engine oil to the needle bearings.

Install the gear shifter [1] . washer [2], needle bearing
(20 x 24 x 13) [3] and needle bearing (20 x 24 x 17) [4] --""711
onto the countershaft (5]. iii
15)
Apply engine oil 10 Ihe teeth of the drive gear [1).
Install the shaft guide [2], drive gear and washer [3]
onto the countershafl [4] .
[2[
13-13
Apply locking agent to the pivot bolt [1] threads.
Install the spring (2] , washer [3) (between the crankcase
and arm) and stopper arm [4) wi th the bolt as shown
and tighten the bolt.
TORQUE : 12 N' m (1.2 kgf' m, 9lbHt)
Install the snap ring [1] inlo the spindle groove with the
chamfered edge facing the crankcase cover side
!~~~~~~~~~;;:~:~!!~!
Install the shifter gear [2J with the index line (3J facing
the snap ring, aligning the wide groove wi th the wide
tooth.
Install the gearshift spindle (4J and rest It onto the
stopper (5J on the crankcase.
Install the washer [6] onto the spindle.
Apply engine oil to the shift drum (1] guide groove

lift the stopper arm [2J and install the shift drum so the
index line [3J on the spindle shifter gear is aligned
between the punch marks [4].
Turn the shift drum clockwise and set It in neutral
position so its groove poSition is vertical.
j
I
j
Apply grease to the lips of a new oil seal [11. and Install
it into the front crankcase cover until fully seated. I
I
I
I
1314
--"'71
Apply engine oil to the output driven gear (1]leelh and
set the it into the crankcase.
Insert the output shaft [2] through the driven gear and .
install it into the crankcase.
Install the countershaft assembly [1] by engaging the

splines.
Apply engine oil to the fork shaft [1) outer surface.

Before inslallat/OT1, InslaUthe shift fork [2} into the gear shifter groove and
be sure thai/he drum guide groove with the mark SIde facing out.
switch pin groove Insert the fork shaft through the fork and Install it into
{3J in the shift drum the crankcase.
;s vertICal as shown
'D I'I
Apply molybdenum oil solution to the reverse idle gear ~~~1ii.'iRiii~~:;;

shaft [lJ whole surface.
Apply engine oil to the gear teeth and needle beanngs
121
Inslallthe following:
- gear shaft
- washer [3)
- two needle bearings
- idle gear [4]
- washer [5]
Install the rear crankcase cover (page 137).
13-15
GEAR SELECTOR LEVER LINKAGE
DISASSEMBLY
Remove the gear selector lever grip [1).
Loosen the cable nuts (page 13-17),

161
- cotter pin (1] and washer (2]
- gear selector cable [3) 171 191
- collar (4J
Loosen the lever pivot nut IS] .
151
Be careful nollO While holding the lever (6) securely, remove the arm
damage the threads pivot bolt (washer-bolt) [7] and the selector lever 12]
in the frame. assembly.
141 (11
- pivot nut and boll [8]
- selector lever 131
- spring [9J
ASSEMBLY
Apply grease to the groove of the pivot boll [lJ.
Sel the spring [2) onto the selector lever (3] and insert . - - . 11] 131
the pivot bolt into the arm [4] and lever.
Inslallthe pivot nul lS]. (41
j
121
Apply grease to the sliding surface of the arm pivot bolt
(washer-bott) [6].
Install the selector lever assembly and the bolt while
~ (6]
j
holding the lever. (51
Tighten the arm pivot bolt (washer-bolt).
Tighten the lever pivot nul.
191 1
TORQUE : 26 Nm (2.7 kgfm , 19Ibfft)
(101 tI 1
J
181
- collar [7)
- gear selector cable [8)
- washer [91
- new cotler pin [101
1
13-16
- gear selector lever grip [I]
Adjust the gear selector lever cable (page 13-17).
GEAR SELECTOR CABLE

ADJUSTMENT
Set the gear selector lever [1] to the neutral (N)
position.
Completely loosen the upper and lower cable nuts [1) ~--------
on the selector cable [2]. [21
~l ,! lllnC bF
Tum the ignition Operate the selector arm (I] on the rear side of the
switch 10 ON (lJ and engine by hand and shift the sub-transmission into
check thaI the neutral (the selector arm will be vertical).
neutral indicator
comes on at this
lime.
13-17
Do flOl move the Without applying force to move Ihe cables, gradually
1
selector lever from screw Ihe cable nuts 111 together by hand until they
the nell/ral positIOn. touch the cable holder [2).
Tighten the cable nut while holding the other nut.
TORQUE: 26 N'm (2.7 kgf'm, 191bHt)
(1(
(2(
Make sure the gear selector lever [11 freeplay is as ~=================~

indicated when in the neutral (N) position.
After adjustment, check Ihat the selector lever operates
properly. (1(
More than
2 mm (0. 1 in)
j
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1
,,,
1
13-18
14. CRANKCASE/CRANKSHAFT/BALANCER
SYSTEM COMPONENTS .. .... .. .. 14-2 CRANKSHAFT .. .. ................................ 14-6
SERVICE INFORMATION
_14-3 CRANKCASE BEARING
REPLACEMENT ....... .. ..... ... .. ............... 14-9
TROUBLESHOOTING ................ -.. ....... 14-4
CRANKCASE ASSEMBLY
14-11
CRANKCASE SEPARATION .... .... ......... 14-5
14-1
SYSTEM COMPONENTS
,/J
,/J
~ ~
IS'~~",l~~
_ -""'x: ~
14-2
SERVICE INFORMATION
GENERAL
The crankcase halves must be separated to service the crankshaft and AfT (mainshaft and 2nd/3rd shift clutch [countershaftj).
To service these parts, the engine must be removed from the frame (page 15-3).
For AfT service, see Drivetrain System section (page 16-3).
Be careful not to damage the crankcase mating surfaces when servicing.
TOOLS
Remover weight Remover handle Bearing remover, 17 mm
07741-0010201 07936-3710100 07936-3710300
~/
)
or 07936-371020A or 07936-3710200
(U.S.A. only)
Bearing remover, 20 mm Attachmen t, 37 x 40 mm Attachment. 42 x 47 mm
07936-3710600 07746-0010200 07746-0010300
Attachment, 52 x 55 mm Attachment, 62 x 68 mm Driver

07746-0010400 07746-0010500 07749-0010000
Pilot, 17 mm Pilot, 20 mm Pilot, 28 mm

07746-0040400 07746-0040500 07746-0041100
14-3
Pilot, 35 mm Pilot, 40 mm Attachment, 20 mm 1.0.
07746-0040800 07746-0040900 07746-0020400
Attachment, 78 x 90 mm Ball joint remover/installer Assembly coltar

Q7GAD-SD40101 07WMF-HN00100 07965-VM00100 (U.S.A. only)
Assembly collar spacer Threaded adaptor Assembly shaft

j
07AMF-HM8A100 (U .S.A. only) 07965-VM00300 07965-VM00200 I
j
i
I
I
or 07931KF00200 (U.S.A. only) or 07931-ME401 DB and

07931-HB3020A (U.s.A. Only)
TROUBLESHOOTING
Excessive engine noise
Worn or damaged connecting rod bearing
Worn crankshaft main journal bearing
Worn connecting rod smaU end
Worn balancer bearing
Worn, seized or chipped transmission gear
Worn transmission bearings
Abnonnal vibration
Improper balancer timing
14-4
CRANKCASE SEPARATION
- engine (page 15-4)
cylinder and piston (page 11-4)
sub-transmission/gearshift linkage (page 13-9)
flywheel/starter clutch (page 12-10)
torque converter (page 16-40)
1s1 shift clutch (page 16-44)
oil pump (page 8-4)
cam chain [1]
cam chain guide [2]
oil pump drive chain (3]
pivot boll [41
cam chain tensioner (5] and coliar [61
The crankcase - nine rear crankcase bolts [1]

bolts are loosened
in a crisscross
pattem in several
sleps.
- five front crankcase bolts [1J

Place the crankcase assembly with the rear crankcase
I
FRONT
down.
Do nor pry /he Remove the front crankcase while tapping it at several
crankcase apaft locations with a soft hammer.
With a screwdriver.
- crank shaft bearing inner race [1]
- two dowel pins [21
- oil joint collar [3] and O-rings [4)
[1 [
14-5
Remove the oil lank strainer (1) and oil pan strainer 12).
Clean each strainer screen thoroughly.
Install the oil tank Inslallthe strainers properly as shown.
strainer with the thin
edge facing the
crankcase.
CRANKSHAFT
REMOVAL
Separate the crankcase (page 14-5).
- oil strainers (page 14-6)
- mainshaft 111 and countershaft (2]
Refer \0 Drivetrain System section for mainshaft and
countershaft (page 16-44).
Ij
Becarefu/nolto Remove the crankshaft [1] and balancer (2] from the
damage the rear crankcase using a hydraulic press. Be sure to hold
crankcase matIng the crankshaft and balancer while pressing them out of
surface and the crankcase.
crankshaft
assembly.
Remove crankshaft bearing [1 ) using a commercially

available bearing puller (2) with a suitable protector [3]. j
NOTE
I
Always replace the rear crankshaft bearing with a
new one whenever the crankshaft is removed.
I
I
I
I
(3J
1
14-6
INSPECTION
Set the crankshaft in a sland or V-blocks and measure
the runout using a dial indicator.
r---
I
SERVI CE LIMIT: 0.15 mm (0.006 in)
Measure the side clearance between the connecting

rod big end and crank weight with a feeler gauge .
Measure the radial clearance al the connecting rod big

end in an X and Y directions.
SERVICE LIMIT: 0.05 rnm (O.002 In)
Check the balancer gear for wear or damage.
147
CRANKSHAFT AND BALANCER
INSTALLATION
Apply engine oil to a new rear crankshaft bearing 111.
Drive the crankshaft bearing into the rear crankcase
with the marking side facing up.
TOOLS :
Driver (2J 07749-()010000
Attachment, 78 x 90 mm (3) 07GAO-SD40101
Pilot, 40 mm [4] 07146..()040900
Other bearing replacement in the crankcase halves
(page 14-9)
Engage the crankshaft and balancer by aligning the

index lines on the sides of the balancer drive gear Ii)
and driven gear [2] as shown. and install them together
into the rear crankcase.
Assemble the special tools onto the crankshaft.
Be careful nOI /0 let Draw the crankshaft. into the bearing inner race by
the connecting rod turning the assembly shaft while holding the shaft nut.
press against the
TOOLS:
crankcase marlflg
surface whils Ball joint remover/installer [1] 07WMFHN00100
drawing. AHachment, 20 mm 1.0 . [2] 07746-0020400
Assembly shaft [3] 07965VM00200
Threaded adaptor [4] 07965VM00300
U.S.A. only TOOLS :
Puller shaft 07931ME4010B
Special nut 07931HB3020A
Threaded adaptor 07931KF00200
Assembly collar 07965VM00100
Assembly collar spacer 07AMFHM8A100
After installing the crankshaft in. make sure the index
line (1] on the crank weight is aligned between the index
lines [2] on the balancer driven gear.
148
Install the mainshaft [1] and counlershaft [2J assembly
as a set into the rear crankcase.
install the 011 strainers (page 14-6).
Assemble the crankcase halves (page 14-11).
CRANKCASE BEARING
REPLACEMENT
REAR CRANKCASE
Remove the balancer [1 J, mainshaft [2J and shift drum r - - - - - - - - - - - - - -__-~
[3J bearings with the specialloois
TOOLS;
Balancer and Shift Drum Bearings;
Beari ng remover, 17 mm [4J 07936-3710300
Remover handle 07936-3710100
Remover weight (5] 07741-0010201 or
07936-371020A or
07936-3710200
(U .S.A. only)
Mainsh aft Bearing:

Beari ng remover, 20 mm 07936-3710600
Remover ha ndle 07936-3710100
Remover weight 07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
Drive the countershaft (6) and output shaft [7J bearings
oul of the rear crankcase.
14-9
Apply engme oil 10 new bearings (1].
~
Orive the bearings in with the marks facing up,
TOOLS : [2[
Balancer and Shift Drum Bearing ~
Driver (2J 07149-0010000 [1[
Attachment, 37 J( 40 mm P] 07146-0010200
,
Pilot, 17 mm [4] 07746-0040400 ,
Themamshaft Malnshaft Bearing
oeanng Is insta/Ied Driver 07749-0010000
with the sealad side Attachment, 42 x 47 mm 07746-0010300
facing down. Pilot, 20 mm 07746-0040500
Counlershaft Bearing
Driver 07749'{)O10000
Attachment, 52 x S5 mm 07746-0010400
Pilot, 28 mm 07746'()041100
Output Shaft Bearing

Driver 07749-0010000
Attachment, 62 x 68 mm 07746-0010500
Pilot, 28 mm 07746-0041100
FRONT CRANKCASE
Remove the balancer [1] and countefShaft (21 bearings
with the spedallools.
TOOLS :
Balancer Bearing :
Bea ring remover, 17 mm [3] 079363710300
Remover weight (4} 077410010201 or
07936371020A or
079363710200
(U.S.A. only)
I
Countel'$haft Bearing :
Bearing remover, 20 mm 079363710600
07936371020A or
079363710200
(U.S.A . only)
Remove the oil feed pipe oil seal [5).
Drive the mainshaft [61 and crankshaft [7] bearings out
of the front crankcase.
Apply engine oil to the lips of a new feed pipe oil seat
Install the oil seal with the flat side facing the crankcase
until it is fully seated.
1
14-10
Apply engine oil to new bearings [1).
Drive the bearings in with the marks facing up.
TOOLS:
Balancer Bearing
Driver [2] 07749-0010000
AttaChment, 37 x 40 mm [3] 07746-0010200
Pilot, 17 mm (4) 07746-0040400
Mainshaft Bearing
Driver 07749-0010000
Attachment, 62 x 68 mm 07746-0010500
Pilot, 35 mm 07746-0040800
The countershaft Countershaft Bearing

bearing is installed Driver 07749-0010000
with the sealed side Attachment, 42 x 47 mm 07746"()010300
facing down. Pilot, 20 mm 07746-0040500
Crankshaft Bearing
Driver 07749-0010000
Attachment, 78 x 90 mm 07GAD-SD40101
CRANKCASE ASSEMBLY
Before installing the front crankcase cover, make sure
the gear side surfaces (Cl and Ml gears [1]) of the
countershaft [21 and mainshaft [3] are flush .
Clean the fron t and rear crankcase mating surfaces ....- --

thoroughly, being careful not to damage them.
Blow through the oil passages in the crankcases wi th
compressed air. "".........,.j
into the joint collar grooves. Install the oil joint coUar [2J
into the crankcase.
14-11
CRANKCASEfCRANKSHAFT/BALANCER
Instalilhe two dowel pins Il}.
Install the bearing inner race [2] onto the crankshaft
with the flange side facing in.
Apply liquid sealant (Threebond T61215 or equivalent)

to the mating surface of the front crankcase.
Make SU/ll the InsleUthe front crankcase [1] ovef the rear crankcase,
mating surfaces aligning the oil strainer pipe [2] with the pipe hole.
evenly fouch, thaI
Install the five front crankcase bolls [3].
there is no
clearance between Check thai the mainshaft (4] and crankshaft 151 turn
the cases. smoothly and quietly.
Install the nine rear crankcase bolts [1].

Tighten all the crankcase bolls in a crisscross pattern in
several sleps.
14-12
Apply locking agent to the threads of the lensioner pivot
bolt (1).
Install the cam chain tensioner 12J and pivot collar (3)
with the flange side of the collar facing the crankcase,
and tighten the bott.
Install the oil pump drive chain [1] and cam chain [2]
onto the crankshaft.
~~~~~~~~~~~;:~~~~1111
Instal! the cam chain guide [3J by aligning its end wllh
the groove in the crankcase .
- oil pump (page 8-5)
- 1st shift clutch (page 16-53)
- torque converter (page 16-42)
- flywheel fstarter clutch (page 12-12)
- sub-transmissionfgearshift Imkage (page 13-13)
- cylinder and piston (page 11 -8)
- engine (page 15-8)
14-13
MEMO
l
1
1
1
I
I
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1
,1
15. ENGINE REMOVAUINSTALLATION
SYSTEM COMPONENTS .......... 152 ENGINE REMOVAL ............................. 15-4
SERVICE INFORMATION ........ .. ............ 15-3 ENGINE INSTALLATION .. ........ .. ... ....... 15-8
15-1
SYSTEM COMPONENTS
27 Nm (2.8 kgfm. 20 IbHI)
-",..---~-
J
j
j
I
1
1
j
i
16 .6 kgfm,
121bUt)
54 Nm (5.5 kgf'm, 40 IbHt )
15-2
ENGINE REMOVAUINSTAllATION
SERVICE INFORMATION
GENERAL
When removing/installing the engine. tape the frame around the engine and final gear case , and cover the body panels
beforehand for frame and plastic components protection.
The following components require engine removal for service:
- mainshaft and 2nd/3rd shift clu tch (counlershaft) (page 16-44)
- crankshaft/balancer (page 14-6)
15-3
ENGINE REMOVAL
Drain Ihe engine oil (page 3-10).
Drain Ihe coolant (page 9-6).
- front bumper (page 2-17)
oil cooler (page 8-10)
cargo bed (page 2-18)
rear brake caliper mounting bolts (page 20-20)
seat frame (page 2-5)
fuel lank (page 7-15)
Remove the bolts (1] and oil filler [2] from the frame.
Disconnect the spark plug cap (1]. Eel sensor 2P

connector (2) and ignition coil primary wire connectors
[3j.
Remove the clips [4] and ignition coillray [5J.
Disconnect the EDT sensor 2P connector [1) and

release the wire band [2] from the cable holder [3].
Remove Ihe two bolts [4] and cable holder,
1j
j
Remove the pinch bolt [1) and release the gear selector 1
arm [2] from the gearshift spindle.
j
,
j
,
15-4
Remove the bolt {1] and ground cable [2[.
Disconnect the alternatorfCKP sensor 5P (black) ::;~;:;;;;;;;;;;;;;;;;;;;":==;;:~:~~~

connector (1[ and gear position switch 3P (black)
connector [2[.
Remove the bolt [3] and parking brake cable clamp [4).
Release the three harness clips 11] from the frame.

Secure the main wire harness [2) to the right side of the
vehicle with a string to prevent interference when
removing the engine.
Loosen the front final gear case front mounting nut [1J .
- front final gear case upper mounting nut(2J and bolt
131
- two front final gear case mounting bracket bolts (4J
15-5
ENGINE REMOVAL/INSTALLATION
Pull the fronl final gear case forward for maximum
clearance between the propeller shaft joint (1J and
engine, then disconnect the fronl propeller shaft (2]
from the output shaft.
Remove the boot bands [3] from the propeller shaft boot
(4) and pull it off from the pinion joint 15].
Pull the fronl propeller shaft rearward to force the
stopper ring (6) past the groove in the pinion joint to
disconnect it from the front final gear case.
Remove the propeller shaft out of the frame.
Remove the stopper ring from the propeller shaft.
Remove the O-ring [7] from the output shaft.

- four side engine hanger nuts [1] and bolts [2)
- two rear engine hanger nuts [3] and bolts [4]
1
I
15-6
Make sure the engine wires and cables are not
interfered with the frame components.
Hold the engme Slightly 11ft the engine upward, then slide it forward to
securely and take disconnect the universal joint [1) from the output shaft
care not to damage [2] and rear propeller shaft 13].
rhe frame and
Remove the O-rings [4] from the output shaft and rear
engine.
propeller shaft.
I NOTICE I
00 not hold or strike the solenoid valves on the shift
valve body during engine romoval. Holding the solenoid
valve or 8Kcessive shock may damage the solenoid
valve.
Remove the engine out of the frame from the upper
side.
Remove the six nuls [1) and three engine mounting
rubbers [2) from the frame.
Remove the engine side mounting nuts [1) and bolts [2]. ~=::;;;::==::;;;;;;;;;;;;;;;;~;:;
Remove the engine under frame [3] and mounting
collars [4].
['VI'I 13)
Check the mounting rubbers [1] for detenoration. wear ~==

or damage.
15-7
ENGINE INSTALLATION
NOTE:
Route the wires, cables and hoses properly
(page 1-17).
Set the mounting collars 111 and engine under frame (2]
in position. 111
Insert the bolts [3J from the front side.
Install the engine side mounting nuts 14]. but do nol
tighten them fully.
//
[3[ [2[
Install the three engine mounting rubbers (1] and six

nuts [2]. but do not lighten them fully.
I
j
Apply molybdenum disulfide grease to new O-rings (1)
and install them into the grooves of the output shaft [2)
and rear propeller shaft [3].
Apply molybdenum disulfide grease to the splines in the
universal joint [4]. then install it to the rear propeller I
shaft.
lift up the engine and maneuver it into place. j
j
Hold the engine With the engine slightly lifted above the mounting
securely and lake position, move the engine forward and connect the
care not /0 damage output shaft into the universal joint.
the frame and
Lower the engine and place the engine under frame [5)
engine.
over the mounting rubbers. j
I NOTICE I I
Do not hold or strike the solenoid valves on the shift
valve body during engine installation. Holding the
solenoid valve or excessive shock may damage the
solenoid valve.
J
158
Insert the four side engine hanger bolts [lJ from the
front side and instalilhe nuts [2].
Insert the two rear engine hanger bolts 13J from the left
side and install the nuts (4).
After installing all the mounting fasteners and seat
them, tighten the engine side mounting nuts ,
TORQUE : 54 N'm (5.5 kgf' m, 40 IbHt)
Tighten the engine hanger nuts and mounting rubber
nuts,
Install a new stopper ring [1) into the groove in the

propeller shaft [2].
Apply molybdenum disulfide grease to the seal lip of the
front side boot [3J.
Make sure the seal lip is not turned outside in.
Apply molybdenum disulfide grease to the fronl end of
the propeller shaft.
121
15-9
ENG)NE REMOVAU[NSTALLAT[ON
Apply 5 - 8 g of molybdenum disulfide grease to the
pinion ;oint (1) splines.
Place the boot band (2) over the front propeller shaft [3]
temporarily.
Install the propeller shaft into the pinion joint, aligning
the splines until the stopper ring [4J seats in the groove.
Make sure the stopper ring is seated properly by pulling
the propeller shaft lightly.
Install the boot [5J over the pinion jOint and propeller
shaft grooves securely and the boot band into the boot
groove.
Coat a new O-ring [6) with molybdenum disulfide
grease and install it into the output shaft groove.
Apply molybdenum disulfide grease to the propeller
shaft joint [71 splines.
Move the fron t final gear case forward for maximum
clearance between the shaft joint and output shaft.
Engage the shaft jOint over the output shaft and move
the front final gear case rearward.
The mountmg bolt Align the upper mounting boll holes in the front final ~r~;;;;
is Installad from the gear case and frame, then install the front final gear
/eft side. case upper mounting bolt [1) and a new mounting nut
[2).
Install the two front final gear case mounting bracket
bolts [3) and tighten them.
Tighten the final gear case mounting nuts.
TORQUE : 12 mm nut: 54 N' m (5.5 kgfm. 40 IbHt)
Position the main wire harness (1) as shown, then ~K;~~~;:;:.r;;~~;;I;"~ j

install the three harness clips [2) into the frame.
ij
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J
1510
Connect the afiemator/CKP sensor 5P (black)
connector 111 and gear position sWitch 3P (black)
connector 12].
Install the parking brake cable clamp (3] by aligning its
tab with the frame groove, then install and lighten the
bolt (4] .
TORQUE : 27 N-m (2.8 kgf' m, 20 tbHt)
Install the ground cable [1J and lighten the bolt (2) by
aligning the terminal edge with the case rib as shown.
Inslalithe gear selector arm [1J by aligning the slit with

the index line of the spindle.
=::~iiiiiiiiiiii~~~ir.=;;~~
Install the pinch bolt 121 and tighten it to the specified
torque.
TORQUE : 16 N'm (1.6 kgf-m , 121bHt)
Instalilhe cable holder [1] with the two bolts (2).

Install the wire band (31 into the cable holder.
Connect the EOT sensor 2P connector (4J
15-11
Install the ignition coil tray [1) and secure it with two
clips [2) .
Connect the spark plug cap [3]. ECl sensor 2P
connector [4) and ignition coil primary wire connectors
151
Install the oil filler [1) and tighten the bolts (2).
- fuel tank (page 7~1S)
seat frame (page 2-S)
rear brake caliper mounting bolts (page 20-2S)
cargo bed (page 2-18)
all cooler (page 8-10)
front bumper (page 2-17)
Check the gear selector lever for smooth operation and
adjust the selector cable if necessary (page 13-17).
Fill and bleed the cooling system (page 9-S).
Check the engine oil Jevel (page 3-9).
I
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15-12
16. DRIVETRAIN SYSTEM
SYSTEM COMPONENTS .. 16-2 DRIVETRAIN DTC

TROUBLESHOOTING ....................... 16-14
SERVICE INFORMATION .. 16-3
SHIFT VALVE BODY .. 16-25
SYMPTOM TROUBLESHOOTING .......... 16-5
FRONT CRANKCASE COVER 16-34
COMPONENT LOCATlON 16-10
TORQUE CONVERTER 16-40
DRIVETRAIN SYSTEM OIAGRAM 16-11
SHIFT CLUTCH/MAINSHAFT/
DRIVETRAIN TROUBLESHOOTING COUNTERS HAFT 16-44
INFORMATION 16-12
GEAR POSITION SWITCH 1654
DRIVETRAIN DTC INDEX 16-13
EOT SENSOR .. .. ........... .... ...... ....... "16-55 l1li
16-1
DRIVETRAIN SYSTEM
SYSTEM COMPONENTS
14N m(1.4 101bHt)
118 N'm (12,0 kgf.m. 871bHt)
I
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108 N'm (11.0 kgf.m , 80 Ibfft) / /
21 N'm (2.1 kgf.m , 15 Ibfft)
8 N'm (0.8 kgf'm, 5.9Ibfft)
16-2
DRIVETRAIN SYSTEM
SERVICE INFORMATION
GENERAL
This "Drivetrain System" section covers service of the Automatic Transmission (AfT) system and drive mode (2WD. 4WD , 4WD
with the differential locked) selector.
A faulty drivetrain system is often related to poorly connected or corroded connectors. Check Ihose connections before
proceeding.
Read "Drivetrain Troubleshooting Information~ carefully, and inspect and troubleshoot the drivetrain system according to the
oTC. Observe each step of the procedures one by one. Note the DTG and probable faulty part before starting diagnosis and
troubleshooting.
The PCM may be damaged if dropped. Also, if a connector is disconnected when current is flowing, the excessive voltage may
damage the PCM. Always turn off the ignition switch before servicing.
The engine must be removed from the frame when servicing the torque converter and 1st shift clutch. To service the mainshaft
and 2nd/3rd shift clutch (countershaft), the crankcase halves must be separated (page 14-5).
The engine oil is used for AIT oil. lubrication system service (oil pump and oil cooler) (page B-2).
AIT and lubricating all is fed through the oil passage in the front crankcase cover. Clean the oil passages before installing the
crankcase cover.
Be careful not to damage the crankcase and cover mating surfaces when servicing.
Replace the torque converter as an assembly if it is faulty.
Front final clutch and differential lock clu tch service (page 1B-19).
Drive mode selector lever service (page 1B-63).
Sub-transmission (Forward-Neutral-Reverse) service (page 13-3).
For Drivetrain System Troubleshooting
The drivetrain system is controlled by the PCM . Therefore some detection items that are shared in the PGM-FI and drivetrain
systems, and they may affect the operation of both systems
Before starting any troubleshooting, check the follOWing Items and refer to the appropriate troubleshooting .
1. Mil blinks or OTG for the PGM-FI system and AIT system (page 4-7).
2. Symptom troubleshooting of the AIT system (page 16-5).
TOOLS
Pressure gauge set Remover weight Attachment, 42 x 47 mm
07406-0020005 07741-0010201 07746-0010300
or 07ZMJ-HN2A 100 and or 07936-371020A or 07936-3710200

07AMJ-HNBA100 (U.S.A. only) (U.S.A . only)
Pilot, 17 mm Pilot, 25 mm Driver
07746-0040400 07746-0040600 07749-0010000
.h
163
DRIVETRAIN SYSTEM
Puller, 35){ 1.0 mm Remover handle Bearing remover, 17 mm
Q7933HA80000 07936-3710100 07936-3710300
::l ..
or 07933-H83000A (U.S.A . only)
Compressor bolt assembly Clutch compressor attachment SCS service connector
07GAEPG40200 07LAEPX4Q100 (2 required) 070PZ-ZY301QO
or 07GAE-PG4020A (U.S.A. only) or 07LAE-PX4A 100 (U.S.A. only)

Test probe, 2 pack
07ZAJ-ROJA 11 0
16-4
DRIVETRAIN SYSTEM
SYMPTOM TROUBLESHOOTING
GEN ERAL INFORMATION
When t he vehicle has any AfT system trouble, check
the DI G or MIL blinking, refer to the OTC index (page
16-13) and begin the appropriate troubleshooting
procedure. If there are no DTC or MIL blinking, do the
diagnostic procedure for the symptom, and check the oil
pressure and diagnose according to the hydraulic circuit
troubleshooting chart (page 16-9).
Symptom Diagnosis p rocedure Also check f or

I-vVe~h";~cl~e~d~o~e~,~o~o~t'~t~a;;rt-+--=- Check the Aff clu tch PC solen~o~;d~v~a~lv~e~o~p"e~,~at";o~oo---===='-""---I
(page 16-5).
Check the line oil pressure and 1st clutch oil pressure
(page 16-7),
Check the 1st shift clutch system (page 16-44).
~
E xcesslve slartmg Check the line oil pressure and 1sl clu tch oil pressure
shock (page 16-7).
Check the 1st shift clutch system (page 16-44 .
Vehicle creeps (vehicle;;---+--c~C'"'he~c~k~t~h~at~t~h~e~e~m~e~,~ge~o~c~y~v~a~Iv~e~;~,~o~ofta~c~t~;v~e=----l
does not stop) when (page 16-25).
idling Check the 1st clutch oil pressure (page 16-7).
D'";vC;;o~g~p"o~wC;e~'~f~al""'~O~".---+---c:-iC~h~e~c::;k~th~e::-;'AfT~dOiC'tiOich PC solenoid valve operation
when starting (page 16-5).
Engine oil level
(insufficient engine Check the 1st clutch oil pressure (page 16-7).
(page 3-9)
f--Cb:;,;a;ke~)'cc===~_--1__ Check the 1st shift clutch system (page 16-44).
Engine stalls when Check the engine idle speed (page 4-29).
starting Check the 1st clutch oil pressure (page 16-7).
NT does not shift Check the TP sensor installation condition
(page 4-25).
Check the VS sensor installation condi tion
(page 4-27).
Check the shift solenoid valve operation (page 16-6).
Check the clutch oil pressures (page 16-7).
Check the 1sV2nd shift clutch system (page 16-44).
Excessive shift shock, Check the clutch oil pressures (page 16-7).
engine rpm rises or Check the lsV2nd shift clutch system (page 16-44).
driving power falls off
AlT CLUTCH PC SOLENOID VALVE

OPERATION INSPECTION
Turn the ignition switch to ON (I) and check for a click"
sound from the NT clutch PC solenoid valve [11.
If the "click" sound is heard, the AfT clu tch PC solenoid
valve is normal.
165
DRIVETRAIN SYSTEM
If the "click" sound is not heard, remove the valve body
cover (page 16-25).
Turn the ignition switch to OFF (0) and disconnect the
NT clutch PC solenoid valve 2P (black) connector [1].
Connect a 12 V battery [1J to the solenoid valve

connector [21 terminals as shown.
The AfT clutch PC solenoid valve should operate
(sound) when the battery is connected.
,
j
121 (11
SHIFT SOLENOID VALVE OPERATION

INSPECTION
Remove the valve body cover (page 16-25).
Disconnect the shift solenoid valve A 2P (black)
connector (1] and shift solenoid valve B 2P (brown)
connector [2J. l
i
Connect a 12 V battery [1] to the terminals of each ~1III~o;,o""I11I11I11I11I11I11I11I11I11I11I111~;;o.~

solenoid valve connector [2) as shown.
The shift solenoid valve should operate (sound) when
the battery is connected.
(21
(1 I
16-6
DRIVETRAIN SYSTEM
OIL PRESSURE CHECK
NOTE :
If Ihe oil pressure is abnormal. inspect and clean the
parts according to the hydraulic circuit
troubleshooting chart (page 16-9).
Failure to warm Ihe engine will cause very high oil
pressure readings and oil leaks will cause low oil
pressure readings.
Check the oil level and add Ihe recommended engine
oil if necessary (page 3-9),
Warm the engine to normal operating temperature and
check for external oil leaks.
LINE OIL PRESSURE
Clean around the sealing bolt [IJ With compressed air.
Be sure thai no dif1 Remove Ihe sealing bolt and washer [2] from the right
Is aI/owed 10 enter side of the shift valve body.
the 0;1 gallery.
Connecllhe oil pressure gauge II] and adaptor to the ~~~~~~~~~~~~=~~~~~~

sealing bolt hole (hole threads : M8 x 1.25).
Except U.S.A. TOOL:

Pressure gauge set 07406-0020005
U.S.A. TOOLS :
Oil pressure gauge 0-160 psi 07ZMJHN2A 100 and
Adaptor, banjo 8 x 1.25 mm 07 AMJHN8A 100
(U.S.A. only)
Shift the sub-transmission into neutral (set the gear
selector lever in the center position).
Start the engine and measure the oil pressure.
LINE OIL PRESSURE (80C/176F):
785 kPa (8.0 kgflcm 2 , 114 psi) at 5,000 rpm
._-
Stop the engine.
Remove the pressure gauge and adaptor.
Install the sealing bolt with a new sealing washer, and
tighten it.
Instalilhe left seat bottom cover (page 2-9).
16-7
DRIVETRAIN SYSTEM
SHIFT CLUTCH OIL PRESSURE
Remove the left rear side cover (page 2-10).
Be careful no/touch Support the vehicle using a hoist or equivalent and
the rotating wheels raise all the wheels off the ground.
during inspection.
Clean around the sealing bolts [11 with compressed air.
Be sure that no dirt Remove the sealing bolts and washers (21 from the
is allowed /0 enter bottom of the shift valve body.
the oil gallery.
Connect the oil pressure gauges [11 and adaptors to

each sealing bolt hole (hole threads: MB x 1.25).
~=~~~::!~::!===::!~~;~;..I~
[lJ
Except U.S.A. TOOL :
Pressure gauge set 07406-0020005
U.S.A. TOOLS:
Oil pressure gauge 0-160 psi 07ZMJ -HN2A100 and
Adaptor, banjo 8 x 1.25 mm 07AMJ-HN8A100
1
(U.S.A. only)
Start the engine and shift the sub-transmission into
Drive (set the gear selector lever in the rear position).
Raise the engine speed and measure each shift dutch
oil pressure.
SHIFT CLUTCH OIL PRESSURE (60C/17S"F) :
785 kPa (6.0 kgf/cm2, 114 psi) at 5,000 rpm
Stop the engine.
Remove the pressure gauges and adaptors.
Install the sealing bolts with new sealing washers and
tighten Ihem.
Inslall the left rear side cover (page 2-10).
16-8
DRIVETRAIN SYSTEM
HYDRAULIC CIRCUIT
TROUBLESHOOTING CHART
PRESSURE CHECK SECTION MEASUREMENT RESULT (_: Abnormal I Blank: Normal )
Line oil pressure
1sl clutch oil pressure
Referto
2nd clutch oil pressure
page
3rd clutch oil pressure

AfT clutch PC solenoid valve
0
Emergency valve 0
1-2 shift valve 0 0
2-3 shift valve
Shift solenoid valve A
"- 0 -r--~- f-o
+-
0
16-25
Shift solenoid valve 8 0 0
2nd orifice control valve
" 3rd orifice control valve

D- Shift valve body
- o 0 0 0
,; Orifice control valve body

~ 0 0 0 0
151 shift clutch 0
~
2nd shift clu tch 16-44
- - 0
0
~ 3rd shift clutch

D
:Feed pipe A
- -1- 16-34 I
0 ,
Feed pipe B 0 0 0
' Feed pipe C 0 0 0
I Torque converter _ 16~Q...'
,
0
Oil pump 0 8-4
Oil pipe selling collar 0 0 0 0 16-34
Oitfilter
Oil strainer 1--- I- 0
3-11
14-5
Oil level
-- I-?
0 3-9
16-9
DRIVETRAIN SYSTEM
COMPONENT LOCATION
SHIFT SOLENOID VALVE B
TP SENSOR
(SENSOR UNIT) SHIFT SOLENOID VALVE A
I I SWITCH
SRI'KE LIGHT SWITCH
VS SENSOR
peM FUSE BOX
EOT SENSOR
AfT CLUTCH PC SOLENOID VALVE
1610
DRIVETRAIN SYSTEM
DRIVETRAIN SYSTEM DIAGRAM
BATTERY MAIN FUSE (40A) IGN FUSE (15 A) MAIN RELAY
:;-iii! ~'~' I '~'"" t'""~'"'

l L~_ _8--' L ':~: L ~
1
SlIIW Gr
FI FUSE (lOA) LIGHT FUSE (15A)
G
""~~" ~" ~" J
BRAKE LIGHT SWITCH
RfW
" MAIN! STOPLIIMPSW .0.14 ,uI~ _ G!Y ~B"Br
@(31-1 I
G, _ _ _ _ _ _ _ _ _...J
~
" 'M' '"
TP SENSOR
G
I "'O BrlW ",C
(SENSOR UNIT) '(/By 814 TH
@(8-1,8-2) " 'G
G"
B2a TO MIL
tE1
~---- O
M-TXDXD A21 BwR - SERtAl IGN RIW

EOT
SENSOR GND G1
@(44-1 , 44-2) C-LO~M~B~I~N~A~T~IO~N~M~E~T"'ER -=-
_ _ _ _ _ _ _ _---.J
PCM
'" ""
,~
@(32. 1,33.2)
-'13 GPO
SFT SOL A
" SHIFT SOLENOID
VALVE A
SFT SOL A LO A26 @(15-1 , 15-2)
.0.11 GPN
r1J
19 --+- GlBu
,--"",,~---- G, 1<.25 GP R
SFT$OL B A29 "G SHIFT SOLENOID
VALVE B
-.L G @(16-1, 16-2)
LIN P AS
LIN M .0.9
' ' ----n
BulR-----ttr
A1T CLUTCH PC
SOLENOID VALVE
@(4-1, 4-2.4-3)
, - - --
~---- G
- G 813 LG
811 PGl
RR VSP
SENVB l '"'" :, =====:;l
G..=--
....- - - - G 810 PG2 '-r==::r--' VS SENSOR
[ @(11-1)
PCM C-l C-3

A 1 -
All -
B 1 -
@(
OJ'
IOTC A-12
~
\ A22 B12 822
BI: Black 0: Orange 6=d, . ~!DDODD~~ ~DODOOD~~

Br: Brown P: Pink
cr9
f:DDDDOODD~~ .~~DDDDODD~~
Bu: Blue R' Red 000000000 000000000
G: Green V: Violet
Gr: Gray W: White
Lb: Light blue Y; Yellow -I
19: Light green
C~ C-5 A-33 B-23 B-33
16-11
DRIVETRAIN SYSTEM
DRIVETRAIN TROUBLESHOOTING INFORMATION
Refer to PGM-FI TROUBLESHOOTING INFORMATION" in PGM-FI system section except following infonnalion (page 4-6).
SELF-DIAGNOSIS SYSTEM
The PCM (Powertrain Control Module) integrates the ECM (Engine Control Module) and the reM (Transmission Control Module).
Therefore some detection items are shared by the PGM-FI and drivetrain systems and they may affecllhe system operation of both
systems.
The drivetrain system is equipped with the self-diagnoslic system. When any abnormality occurs in the NT system , the PCM turns
on the MIL and stores a DTG in its erasable memory.
FAIL-SAFE FUNCTION
The drivetrain system is provided with a fail-safe function to secure a minimum running capability even when there is trouble in the
system.
When the PCM detects a problem in the AfT system, the PCM stops the automatic shift function and anti-<:reep function, and
defaults the transmission into 2nd gear. Also, the MIL blinks to indicate the DTC.
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16-12
DRIVETRAIN SYSTEM
DRIVETRAIN DTC INDEX
-M
When the AIT system does not operate property but no problem code IS Indicated and retrieyable. refer to the symptom
troubleshooting (page 16-5).
If the MCS is nol used, perform atl of the inspection on the corresponding main code (digits in front of hyphen ) of the OTC.
Ref er j
I
I DTC Function Fail ure Symptom/Fail-safe Function ==---j---it~o,page
4-1 AfT clutch PC solenoid valve low input +----c-Aff""~s::;h"ift function and anti-creep function 16-14
Loose or poor contact of the NT clutch PC does not work (2nd gear only)
solenoid valve related connector
AfT clutch PC solenoid valve or its circuit
malfunction
4-' --+--AffM clutch PC solenoid valve High mput --~----C"A!T shift function and anti-creep funChon 16-15
AfT clutch PC solenoid valve or its circuit does nol work (2nd gear only)
malfunction
4-3 AfT clutch PC solenoid valve drive circuit AfT shift function and anti-creep function 16-14
AfT clu tch PC solenoid valve or its circuil does not work (2nd gear only)
malfunction
8-1 TP sensor cir~C~u";t'l~O~w~,~o'"lt~a9~e'"(le
~S~S than O.1077'V,,)-t-c-p~o~o~,~eo=gine acceleration - - --+1 4-'4
" Loose or poor contact of the TP sensor Fail-safe value: O
connector AfT shift function and anti-creep function
" TP sensor or its Circuit malfunction does not work (2nd gear only)
-'-B_~,.-------f---,TP sensor circuit High voltage (more than 4.981 V) Poor engine acceleration 416
" TP sensor or its circuit malfunction Fail-safe value: OG
NT shift function and anti-creep function
does not work (2nd gear only)
11-1 VS sensor no Signal AfT shift function and~a~"t";-o~,"~e~p~fu~"~ct::;;~O~
" -!1- 4-19
" Loose or poor contact of the VS sensor does not work (2nd gear only)
connector
f-~~--t- " VS sensor or its circuit malfunction
15-1 Shift solenoid valve A (short) NT shift function and anti-creep function 16-16
L ",.,----h" Shift solenoid valve A or its circuit malfunction does not work (2nd gear only)
,. 15-2 Shift solenoid valve A (open) AfT shift function and anti-creep function 16-17
~~~_----1~~ " Shift solenoid valve A Of its circuit malfunction does not work (2nd gear only)
16-1 Shift solenoid valve B (short) AfT shift function and anti-creep function 16-18
~~~_ _~~ . c:Shift solenoid valve B Of its circuit malfunction does not work (2nd gear only)
16-2 Shift solenoid valve B (open) NT shift function and anti-creep funclion 16-19
---._ _ _.'""S~h~ift,-"solenoid valve B or its circuit malfunction does not work (2nd gear only)
31-1 System voltage Low (less than 9 .3 V) NT shift function and~a~"t~;-o~,"~e~p~fu~"~c::;ti~O~"-----'1-- 16-20
---._ _ _.'-="P~CO"M: power input circuit malfunction does not work (2nd gear only)
32-1 Fail-safe relay circuit ---+-~AfT shift function and anti-creep function --t-"~6~_'''''-----~
__ ---+" .""F.;ail-safe relay circuit malfunction does not work (2nd gear .O~"~IY~)_ _ _ _-j----.oc",_~
33-2" PCM EEPROM malfunction - 423
41-1 Gear position switch circuit AfT shift function and anti-creep function 16-21
" Gear position switch circuil malfunction (S~h~o~rt~)'---,_-=-dioe~s~not work (2nd gear only)
44-1.---------+"EO~T~S~e~"~s~or circuit low voltage (less than 0.07 V) NT shift function and anti-creep function 16-23
" EOT sensor or its circuit malfunction does not work (2nd gear only)
Cooling fan turns on
44-2 ~EOT sensor circuit high voltage (more than 4,c.B~5'V'")-=-----c----'iAff-;:cs~h3ift function and anti-creep function 16-24
Loose or poor contact of the EOT sensor does not work (2nd gear only)
connector Cooling fan turns on
'----_ _ _ _~_ EOT sensor or its circuit malfunction
" The MIL does not blink (OTC can be readout/erased only by MCS).
16-13
DRIVETRAIN SYSTEM
DRIVETRAIN DTC
TROUBLESHOOTING
NOTE-
Perform inspection with the ignition switch turned to
OFF (0 ) unless otherwise specified.
After troubleshooting , erase the DIG (page 4-8) and
test-drive the vehicle to be sure that the system is
normal.
DTC 4-1 (AfT CLUTCH PC SOLENOID

VALVE LOW INPUT). DTC 4-3 (AfT
CLUTCH PC SOLENOID VALVE DRIVE
CIRCUIT)
Before starting the troubleshooting, check the AfT
clutch PC solenoid valve 2P (black) connector for
loose or poor contacts, and recheck the DIG.
1. Recheck DIG
Tes t-drive the vehicle and slop the engine.
Recheck the current DI G with the MeS.
Is Dre 4-1 or 4-3 indicated?
YES - GO TO STEP 2.
2. AIT Clutch PC Solenoid Valve Inspection
Disconnect the NT clutch PC solenoid valve 2P (1)
(black) connector (page 16-25),
Measure the resistance between the solenoid valve
side 2P connector !1]lerminals.
Standard : 5.1 - 5.7 a (20"C/6S"F)
Is the resis tance within standard value ?
YES - GO TO STEP 3.
NO - Faulty AfT clutch PC solenoid valve.
I
3. AfT Clutch PC Solenoid Valve Circuit Inspection
Measure the voltage between the wire harness side 11)
2P (black) connector (1] terminals.
Connection : Yellow/red (+) - Blue/red H
Blue/red (-) Yellow/red (+)
Is the voltage about 11 V?
YES - GO TO STEP 5.
NO - GO TO STEP 4.
'-----{ V }---'
1614
DRIVETRAIN SYSTEM
4. A1T Clutc h PC Solenoid Valve line Open Circuit
Inspection
Turn the Ignition switch to OFF (0).
Disconnect the peM 33P (black) connector (1J Yellow/red (AS)
(page 428). [21
Check Yellow/red and Blue/red wires for conllnurty
between the 33P (black) connector and 2P (black)
connector [2) terminals.
TOOL :
Test probe. 2 pack 07ZAJRDJA110
YES - GO TO STEP 5.
NO Open circuil in the Yellow/red wire.
Open cirCUit In the Blue/red wire. I
Blue/red (A9)

~
89',e/,'"
Yellow/red
5. Fai lure Reproduction

Connect the NT clutch PC solenoid valve 2P (black)
connector and peM 33P (black) connector.
Erase the DIG (page 4-6).
Test-drive the vehicle and slop the engine.
Recheck the OTG with the MeS .
Is DTC 41 or 43 indicated ?
YES - Replace the peM with a known gOOd one
and recheck.
DTC 4-2 (AfT CLUTCH PC SOLENOID

VALVE HIGH INPUT)
1. Recheck OTC
Test-drive the vehicle and stop the engine.
Recheck the current DTG With the MeS.
Is DTC 4-2 indicated?
YES - GO TO STEP 2
2. AfT Cl ut ch PC Solenoid Valve Inspection
Disconnect the NT clutch PC solenoid valve 2P
[11
(black) connector (page 16-25)
side 2P (black) connector [1) terminals.
Standard : 5.1 - 5.7 n (20CI68F)
Is the resistance within standard value ?
YES - GO TO STEP 3.
NO - Faulty AIT clutch PC solenoid valve.
16-15
DRIVETRAIN SYSTEM
3. AIT Clutch PC Solenoid Valve Line Short Circuit
Inspection
Disconnect the peM 33P (black) connector
(page 4-28). 1'1
Check the for continuity between the wire harness
~~
side 2P (black) connector 111 terminal and ground .
Connection: Blue/red - Ground Blue/red Yellowl ,ed
Yellow/red - Ground
YES - ' Short circuit in the Yellow/red wire .
Short circuil in the Blue/red wire.
NO - GO TO STEP 4 .
4. Failure Reproduction
Connect the AfT clutch PC solenoid valve 2P (black)
Test-drive the vehicle and slop the engine .
Recheck the oTC with the MeS.
and recheck.
DTC 151 (SHIFT SOLENOID VALVE

A SHORT)
1. Recheck oTC
Recheck the curren t DTe with the MeS.
YES - GO TO STEP 2.
2. Shift Solenoid Valve A Inspection
Disconnect the shift solenoid valve A 2P (black) 1'1
'\
connector (page 16-25).
side 2P connector [1 J terminals.
Is the resistance within 14.6 - 16.2.n
(20C/68Fj?
YES - GO TO STEP 3.
NO - Faulty shift solenoid valve A .
'------{ Q )---'
1616
DRIVETRAIN SYSTEM
3. Shift Solenoid Valve A Line Shott Circuit
Inspection
Disconnect the peM 33P (black) and 33P (gray) r----------------~
connectors (page 4-28).
2P (black) connector [1] terminals and ground.
Connection: Yellow/black - Ground Yellow/black Green/white
Green/white - Ground
YES - ' ShOll circuit in the Yellow/black wire.
Short circuit in the Green/while wire.
NO - GO TO STEP 4.
Connect the shift solenoid valve A 2P (black). peM
33P (black) and 33P (gray) connectors.
Erase the DTC (page 4-8),
Recheck the DTG with the MeS
Is DTC 151 indicated?
and recheck.
DTC 15-2 (SHIFT SOLENOID VALVE

A - OPEN)
Before starting the troubleshooting, check the shift
solenoid valve A 2P (black) connector for loose or
poor contacts, and recheck Ihe OTG.
1. Recheck DTC
Recheck the current DTG with the MeS.
YES - GO TO STEP 2.
2. Shift Solenoid Valve A Inspection
Disconnect Ihe shift solenoid valve A 2P (black) PI
connector (page 16-25),
side 2P connector [1J terminals.
Is the resistance within 14.6 - 16.2 n
(20"C/68F)?
YES - GO TO STEP 3.
NO - Faulty shift solenoid valve A.
16-17
DR[VETRA[N SYSTEM
3. Shift Solenoid Valve A Line Open Circuit
Inspection
Connect the shift solenoid valve A 2P (black) r - - -- - - - - - - -- - - - - --
connector.
Disconnect the peM 33P (black) connector (1] and
33P (gray) connector \2] (page 4-28),
Measure the resistance between the wire harness
side peM 33P connector terminals.
TOOL:
Connection:
Yellow/black (B7) - Green/white (A2G)
(20 CI6S0Fj ?
[2[
YES - GO TO STEP 4.
NO - ' Open circuit in the Yellow/black wire .
Open circuit in the Greenlwhile wire.
Connect the shift solenoid valve A 2P (black), peM
33P (black) and 33P (gray) connectors.
Erase the OTC (page 4-8).
Recheck the o TC with the MCS.
Is DTC 15-2 Indicated?
and recheck.
DTC 16-1 (SH[FT SOLENO[D VALVE

B - SHORT)
1. Recheck OTe
Test..orive the vehicle and stop the engine.
Recheck the current DTC with the MeS.
Is OTC 161 indicated?
YES - GO TO STEP 2.
NO - Intermittent failure .
2. Shift Solenoid Valve B Inspection
Disconnect the shift solenoid valve B 2P (brown) [1 [
\.
side 2P connector 11]lerminals.
Is the resis tance within 14.6 - 16.2 n J l
(20Cl68F) ?
YES - GO TO STEP 3. 11 I
NO - Faulty shift solenoid valve B.
Q j
j
j
1618 1
DRIVETRAIN SYSTEM
3. Shift Solenoid Valve B Une Short Circuit
Ins pection
Disconnect the peM 33P (black) connector
(page 4-28). 11 I
Check for continuity between the w ire harness side
2P (brown) connector [1) terminal and ground.
Connection : Yellow{green - Ground
YES - Short circuit in the Yellow/green wire.
l
NO - GO TO STEP 4.
j
Yellow/green
Connect the shift solenoid valve B 2P (brown)
Erase the DIC (page 4-8).
Recheck the DIG with the MeS .
and recheck.
DTe 162 (SHIFT SOLENOID VALVE

B OPEN)
Before starting the troubleshooting , check the shift
solenoid valve B 2P (brown) connector for loose or
poor contacts , and recheck the DTC.
1. Recheck OTC
Recheck the current DTC with the MCS .
YES - GO TO STEP 2.
2. Shift Solenoid Valve B Inspection
Disconnect the shift solenoid valve B 2P (brown ) PI
connector (page 1625).
\~~
side 2P connector (lJ terminals.
(20"Cl68F) ?
YES - GO TO STEP 3.
NO - Faulty shift solenoid valve B.
'----{ Q )---'
16-19
DRIVETRAIN SYSTEM
3. Shift Solenoid Valve B Input line Open Ci rcu it
Inspection
Disconnect Ihe PCM 33P (black) connector (1]
(page 4-28),
[11 [21
Check the Yellow/green wire for continuity between
the 33P (black) connector and 2P (brown) connector
121
TOOL:
Test p robe, 2 pack 07ZAJRDJA110
Is there conti nui ty? Yellowfgreen (A29)
YES - GO TO STEP 4. Yellowf
NO - Open circuit in the Yellow/green wire. @ green
4. Shift Solenoid Valve 8 Ground Line Open Circuit

Inspection
Check for continuity between Ihe wire harness side ,-----------------~
2P (brown) connector [1) terminal and ground . 111

YES - GO TO STEP 5.
NO - Open circuit in the Green wire.
Q
Green
Connect the shift solenoid valve B 2P (brown)
Erase Ihe oTC (page 4-8).
Recheck the OTC with the MCS .
Is OTC 16 2 indicated ?
and rechecl<.
DTC 31-1 (SYSTEM VOLTAGE LOW)

Before starting the troubleshooting, check that the
battery is in good condition and recheck the OTC.
1. PCM Sy stem Vo ltage Inspection
Recheck the battery voltage in the Data List menu of
MeS .
Is the voltage less than 9.3 V?
YES - GO TO STEP 2.
1620
DRIVETRAIN SYSTEM
2. PCM Power Input Line Inspection
Disconnect the PCM 33P (gray) connector [1] 111
(page 4-28). Red/WhHe~
33P (gray) connector terminal and ground.
TOOL:
Test probe, 2 pack 07ZAJRDJA110 +~
Connection: Redfwhite (81) (+) - Ground (-)

YES - GO TO STEP 3.
NO - ' Open circuit in the Red/white wire .
Blown FI fuse .
Connect the PCM 33P (gray) connector.
Erase the DlG (page 4-8 ).
Recheck the DTC with the MeS.
Is DTC 3 1-1 indicated?
and recheck.
DTC 32-1 (FAIL SAFE RELAY CIRCUIT)

1. Recheck DTe
Recheck the OTG with the MGS.
Is DrC 32-1 indicated?
and recheck.
DTC 41 -1 (GEAR POSITION SWITCH

CIRCUIT)
Before starting the troubleshooting . check Ihe gear
position switch 3P (black) connector for loose or
poor contacts. and recheck the OTC ,
1. Recheck DTC
Recheck the current OTC with the MeS.
Is DrC 41 -1 indicated?
YES - GO TO STEP 2.
16-21
DRIVETRAIN SYSTEM
2. Gear Position Switch Inspection at peM
Connector
Turn the ignition switch to OFF (0) .
Disconnect the peM 33P (black) connector (11 11] Gray (A25) Light blue/white (A13 )
(page 4-28).
Check for continui ty between the wire harness side
33P (black) connector terminals and ground .
There should be continuity in each gear position ,
and no continuity in the olher position .
ear pas t on
rive
onnec or termma
19 t ue Ite
.=Q
Green/blue
(A17 )
eutra reen ue
everse cay
TOOL:
Test probe , 2 pack 07ZAJRDJA110
Are the test results normal?
YES - GO TO STEP 4 .
NO - GO TO STEP 3.
3. Gear Position Switch Inspection at Switch
Connector
Disconnect the gear position switch 3P (black) , - - - - - - - - - - - - - -- - -,
connector [11 (page 16-54).
Check for continuity between Ihe switch side 3P 11]
connector terminals and ground . light blue/white Gcay light green
There should be continuity in each gear position ,
and no continuity in the other position .
ear POSI Ion onnector ermma
rive Igt ue Ie
eutra Ig t green
everse cay
Are the test results normal? ]
YES - Open or short circuit in the light bluel
white wire.
Open or short circuit in the Green/blue
wire.
Open or short circuit in the Gray wire .
1
NO - Faulty gear position switch. j
Connect the PCM 33P (black) connector and gear
pOSition switch 3P (black) connector.
Recheck the DTC with the MCS.
Is Dre 41-1 indicated?
YES - Replace the PCM wi th a known good one
and recheck.
NO - Intermittent failure .
1622
DRIVETRAIN SYSTEM
DTe 44-1 (EOT SENSOR LOW
VOLTAGE)
1. EOT Sensor System Inspection
Check the EDT sensor with the MeS.
YES - GO TO STEP 2.
2. EOT Sensor Inspection
Disconnect the EDT sensor 2P connector
(page 16-55).
Check Ihe EDT sensor with the MeS.
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. EaT Sensor Resistance Inspection
Measure the resistance between the sensor side 2P III
connector [1] terminals.
Standard : 2.5 - 2.8 kO (20CI68F)
Is the resistance within standard value?
and recheck.
NO - Faulty EDT sensor.
4. EOT Sensor Line Short Circuit Inspection

Disconnect the PCM 33P (gray) connector
(page 4-28). [11
2P connector [1[ terminal and ground.
Connection : Orange - Ground
YES - Short circuit in the Orange wire.
and recheck.
Orange
1623
DRIVETRAIN SYSTEM
DTe 44-2 (EOT SENSOR HIGH
VOLTAGE)
Before starting the troubleshooting , check the EOT
sensor 2P connector for loose or poor contacts, and
recheck the OTC.
1. EOT Sensor System Inspection
Check the EOT sensor with the MCS .
Is about 5 V IndIcated?
YES - GO TO STEP 2.
NO Intermittent failure.
loose or poor contact on the EOT
sensor 2P connector.
2. EOT Sensor Inspection
Turn the ignition switch to OFF (OJ.
Disconnect the EOT sensor 2P connector [1) (11
(page 16-55).
tenninals with a jumper wire 12).
Connection: Orange - Green/red
Check the EaT sensor with the MCS .
Orange Green/red
YES - Faulty EOT sensor.
NO - GO TO STEP 3.
(2(
3. EOT Sensor Une Open Circuit Inspection j
Tum the ignition SWitch to OFF (0).

Remove the jumper wire. (1J Greenforange (82) (2J
\ ~
Disconnect the PCM 33P (gray) connector (1) 1
(page 4-28).
Check for conlinuity between the wire harness side j
EOT sensor 2P connector (2) and PCM 33P (gray)
TOOL:
I I I I
Test probe, 2 pack 07ZAJROJA110
Connection : Orange (B28) - Orange

Greenlorange (B2) - Greenl red
Is there contInuity?
Orange (828)
1 Q
Orange
Green/red
YES - Replace the PCM with a known good one,

and recheck.
NO Open circuit in the Orange wire.
Green/red wire.
16-24
DRIVETRAIN SYSTEM
SHIFT VALVE BODY
I NOTICE I
Do not drop or strike the solenoid valves when
servicing. Excessive shock may damage the solenoid
valve.
EMERGENCY VALVE FUNCTION
NOTE'
The emergency valve is used when the hydraulic
pressure is shut off by the faulty AJT clutch PC
solenoid valve (stuck; mechanical lock). and the
vehicle is hindered from running. Open the bypass
oil circuit manually to supply hydraulic pressure. (In
this case, the transmission will be fixed in the 2nd
range and the vehicle creeps during idling.)
The stopper bolt (1] that operates the emergency
valve Is secured with the lock plate [2]. When trouble
occurs, remove the plate screw [31 and lock plate,
and then turn the stopper boll all the way in to
activate the emergency valve.
REMOVAL
- left seat bottom cover (page 2-9)
left rear side cover (page 2-10)
wire clip [1]
two 6 x 18 mm bolts [2J and washers
6 x 14 mm bolt [3J and collar
valve body cover 14J
Disconnect the fOllowing :

Clean around the
valve body with
12] 11]
- shift solenoid valve A 2P (black) connector [1)
compressed air to
- shift solenoid valve B 2P (brown) connector [2J
remove dust, dIn
- AIT clutch PC solenoid valve 2P (black) connector
and foreign
material.
131
16-25
DRIVETRAIN SYSTEM
If the valve body will Remove the following
be disassembled,
- six bolts [1] (small head)
loosen the six
- shift valve body assembly [2J
solenoid valve bolts
and four sealing
bolts (large head).
Place a shop lowel
under the valve
body.
- gasket [1]
- four oil jOint collars (2]
- O-rings [3]
DISASSEMBL Y/INSPECTION
NOTE :
Keep dust and dirt away from all the parts .
Take care nol to damage the mating surfaces of the
valve bodies.
The emergency SOLENOID AND EMERGENCY VALVES
valve is built In the
AfT clutch PC
solenoid valve. - two bolts [1] and valve body cover stay [2 J
- shift solenoid valves A [31 and B 14]
- four bolts and AfT clutch PC solenoid valve
assembly [5)
- rubber seal {61
1
[5[ [6[
Use a hand-
operated air pump
Connect a pressure pump to the input port (filter side) of
the shift solenoid valve.
;::=================::;
only. Do not use a
Connect a 12 V battery [1\ to the terminals of each shift
high pressure air

I
solenoid valve connector [21 as shown and check for air
source.
flow conditions.
[2) [1 [
1626
DRIVETRAIN SYSTEM
Air should not flow (the pressure should be maintained)
while the battery is connected, and should flow out of
the output ports that goes to the shift valve when the
battery is disconnected.
OUTLET PORTS
INLET PORT
Connect the 12 V battery [1] positive terminal to the AfT

clutch PC solenoid valve connector [2[ terminals and
check the spool valve through the oil passages for
operation.
EB 8
121 111
The valve should move away from the solenoid side ~=================~
when the battery is connected , and should be returned
by spring force when the battery is disconnected.
SPOOL VALVE
Remove the following from the AfT clutch PC solenoid ~==================~

valve assembly:
- screw (1] and lock plate [2]
- valve stopper bolt PI 121
- emergency valve [4J
- valve spring [5J
Blow through all the Wash atl the removed parts with a high flash point or
oil passages non-flammable solvent and blow dry them with
thoroughly compressed air to clean completely.
(including sa/enoid
Check the emergency valve and valve bore for scoring,
valves).
scratch or abnormal wear.
[31

1627
DRIVETRAIN SYSTEM
ORIFICE CONTROL AND SHIFT VALVES
- four bolts [1]
- orifice control valve body [2]
1
1
- separator plate (1]
- shift valve body [2] 1
l
1
j
i
!
- separator plate [2]
i
j
j
1
111
- four sealing bolts 111 and washers 12)
I
[1 VI']
16-28
DRIVETRAIN SYSTEM
Remove the following from the orifice control valve
body: 131 121
- spring seats [1]
- valve springs [2]
- orifice control valves (2nd [3J and 3rd [4])
~111 141
Remove the following from the shift valve body:
- spring seals [1]
- valve springs [2J
- shift valves (1-2 (3J and 2-3 [4))
Blow through all theWash all the parts with a high flash pOint or non-
oil passages flammable solvent and blow dry them with compressed
thoroughly. air to clean completely.
Check the orifice control valves, shift valves and valve
bores for scoring. scratch or abnormal wear.
~111 141
1629
DRIVETRAIN SYSTEM
ASSEMBLY
NOTE :
Before assembly, clean all the parts with compressed air. Make sure thai there is no dust or lint on any
parts.
---.::. VALVE S\PRING ~ ~~ ~

iii EMERGENCY VALVE U AIT CLUTCH PC
~
~:J\C\ _ _ - - SOLENOID VALVE
"~
STOPPER BOLT ____
/
p\
--~~
Q,~@
..,...
Q, J ~ RUBBER SEAL
@ y
"" /It
iii lll!I~ ,
1
~
SCREW LOCK PLATE .. ~! .@)6jl
SOLENOID VALVE BODY SHIFT SOLENOID VALVE B

1
SEPARATOR PLATE
DOWEL PINS ~ ...
"- <
~-"~_ SHIFT SOLENOID
' 0 '~ \ VALVE A
"..0._ fj,y>9,'"
SHIFT VALVE BODY L.1~,--\,,->
~- '::-:~~~'-G I
\ ,
/ I t SHIFT VALVE 12-3) "-:-- ~ ;<'>1 1

- ill ....--.... ~ SHIFT VALVE (1-2)
VALVE BODY 1
SPRING SEAT .. fh ~ ..... '" ~ SEPARATOR PLATE COVER STAY
<:J \ "~ "" ~

.# -
VALVE SPRING
ORIFICE CONTROL
"!
SPRING SEAT -----4 VALVE (2nd)
. , : SEALING WASHERS
:lI--"7!I : O-RINGS
SHIFT AND ORIFICE CONTROL VALVES

Apply engine oil to the shift valves.
Install the spring Insert the shift valves (1-2 [1J and 2-3 (2]) and springs
seats with the slit [3J into the shift valve body and secure them with the
spring seats {41.
facing away from
the orifice control 1
valve body
(page 16-30).
141 131 121 "!

16-30
DRIVETRAIN SYSTEM
Apply engine oil to the orifice control valves.
Install the spring Insert the orifice control valves (2nd (11 and 3rd (21) and
58als with the slit springs [3] into the shift valve body and secure them
faclfIg away from with the spring sea ts [4] .
the shiff valve body
(page 16-30).
Install the four sealing bolts PI into the solenoid valve

body (2) with new seating washers [3].
Install the foUowing :

L
~[=::---==::-
1 1 131 e~
- two dowel pins (1]
- separator plate (2]
- shift valve body 131
111
- separator plate [1]
- orifice control valve body [2]
111
16-31
DRIVETRAIN SYSTEM
Install the four bolts 111 and tighten them securely.
SOLENOID AND EMERGENCY VALVES

Apply engine oil to the emergency valve (1] .
Inslall the spring [21 and emergency valve into the AfT
clutch PC solenoid valve body [31 with the concave end
of the valve facing in .
the stopper bolt (2] groove.
~========~~;::;:;==""""""""~
Install the valve stopper bolt and lurn it in until the
groove edge is aligned with the valve body surface.
Secure the stopper bolt with the lock plate (31 as shown
and lighten the screw [4).
Coat a new rubber seal [11 with engine oil and install il ~=========~"""~:"""""""""",,,:,,~
into the groove In the AfT clutch PC solenoid valve body
121.
Install the AfT clutch PC solenoid valve assembly and
four bolts [3) onto the solenoid valve body, and tighten
the bolts.
1632
DRIVETRAIN SYSTEM
into the grooves in each shift solenoid valve. 13] 121
Do not interchange Install shift solenoid valves A [2) and B [3] into the
valves A and B. solenoid valve body.
Install the valve body cover slay [1J and two bolls (21.
and tighten the bolts.
INSTALLATION
Clean the mating surtaces of the valve body assembly
and fron t crankcase cover, being careful not to damage
them.
Coat new O-rings 11] with engine oil and install them
into the grooves in the oil joint collars [21.
Install the four joint collars and a new gasket (3] .
Install the shift valve body assembly [1) with the six
bolts [2] and tighten bolts securely.
16-33
DRIVETRAIN SYSTEM
Connect the following:
121
-
- shift solenoid valve A 2P (black) connector (1)
- shift solenoid valve B 2P (brown) connector [2] I,
- AIT clutch PC solenoid valve 2P (black) connector
PI
Inslall the valve body cover 11] with the three bolts [2J.
I-J~~
~=======--===11::1=====~
two washers (3]. coliar [4 ], and lighten bolls. [2V[3]
TORQUE; 8 N'm (0.8 kgf'm, 5.9 tbHt)

Install the wire clip [4J Into the body cover.
Check the transmission oit pressure if necessary
(page 16-7).
Inslalithe following:
- left rear side cover (page 210)
- left seal bottom cover (page 2-9)
[41
FRONT CRANKCASE COVER

REMOVAL j
- exhaust system (page 2-30)
j
- oil cooler (page 8-10)
- water pump (page 9-8)
- shift valve body coverfconnectors (page 16-25)
Loosen the pipe setting cap (1).
- fourteen bolts [2[
- front crankcase cover [3[
- two oil joint pipes [1] and O-rings [2]

- oil orifice [3] and O-rings [4]
- two dowel pins [51
16-34 1
Downloaded from www.Manualslib.com manuals search engine i
DRIVETRAIN SYSTEM
- pipe setting cap [1) and O-ring [2)
- oil feed pipe C [3)
- pipe setting collar [1) (by pushing it from the inside

with a suitable rod) and O-rings [21
- oil feed pipe B [31 and O-ring (4)
- output shaft oil seal [5)
- oil filter (page 3-11)

- shift valve body (page 16-25)
- dipstick {1]
- sealing bolts [2) and washers [3]
- oil passage sealing cap (4) and O-ring [5}
- three bolts [61, oil pipe joint [71 and O-ring 18]
Wash the crankcase cover with solvent and blow
through all the passages with compressed air to clean
them thoroughly.
111 I'VI3]
16-35
DRIVETRAIN SYSTEM
INSPECTION
Check feed pipes fo r abnormal wear or damage.
NOTE:
The operating (engine) oil of each shift clutch is
supplied through the following :
- feed pipe A [1] for the 151 shi ft clutch
- feed pipe B [2] for the 2nd shift clutch
- feed pipe C [3] for the 3rd shift clutch
{31
121
Check the crankshaft seal collar [1] behind the bearing ;;;;:::;;;;;::==:;;;;:::=::::;;;;;;;;;;;;;;;;;;;;;;;;;;;
for abnormal wear or damage .
NOTE :
The crankshaft seal collar is for the engine oil
supplied to the torque converter and crankpin
Replacement (page 16-36).
BEARING REPLACEMENT
Remove the crankshaft bearing (1] using the special .--.::-----=::;;;;;,-;;,------------,
lools.
TOOLS :
Bearing remover, 17 mm [2] 07936-3710300
,
Remover weight [3J 07741-0010201 or
07936-371020A or 1
07936-3710200
(U .S.A. only) l
Drive the output shaft bearing [4} out of the crankcase 1
cover.
16-36 I
Downloaded from www.Manualslib.com manuals search engine ~

DRIVETRAIN SYSTEM
Remove the snap ring [1], washer [2], and the seal
collar [3].
Coat a new O-ring [4] with engine oil and install it into
Ihe groove in Ihe collar.
Be careful not to Inslali l he collar until it is seated.
damage the inner Install the washer and the snap ring into the cover
surface of the col/ar. groove properly.
Drive new bearings in with the marked side facing up.
TOOLS:
Crankshaft bearing (1) :
Driver (2J 07749-0010000
Attachment, 42 x 47 mm [3] 07746-0010300
Pilot, 17 mm (4) 077460040400
Output shaft bearing [5) :
Driver 077490010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 25 mm 077460040600
INSTALLATION
Clean the crankcase and cover mating surfaces.
Coat a new O-ring [1] with engine oil and install il into
the oil pipe jOint (2) groove.
Install the oil pipe joint and three bolts [31 and tighten
the bolts.
Coat a new O-ring [4] with engine oil and install it into
the oil passage sealing cap [5] groove.
Install the sealing cap and tighten it.
TORQUE : 18 N'm (1.8 kgf' m, 13lbfft)
Instalilhe following:
- sealing bolts 11] with new washers [2]
- dip stick (3]
- oil filter (page 3-11)
131
16-37
DRIVETRAIN SYSTEM
Apply grease to the lips of a new oil seal [1] , and install
it into the crankcase cover until it is fully seated.
Coat new O-rings [1] wi th engine oil and install them

onto the joint pipes [2).
Install the joint pipes into the oil pump.
j
Apply liquid sealant (Threebond T81 215 or equivalent)

to the mating surface of the fronl crankcase cover as
shown.
Blow the oil orifice with compressed air to clean the

passage.
Coal new O-rings [1] with engine oil and inslall them
into the orifice (2) grooves.
Install the oil orifice with the small end facing oui.
16-38
DRIVETRAIN SYSTEM
Install the two dowel pins [1J.
Make sure fhe Install the front crankcase cover [1].

mating surfaces Install the fourteen bolts [2] and tighten them in a
touch evenly. There crisscross pattern in several steps.
Should be no
clearance between
the cover and
crankcase.
Coat a new O-ring [1] with engine oil and install it onto
the flange of the feed pipe B [2].
Apply engine oil to the outer surface of pipe 8.
Align the nange tabs Carefully insert the feed pipe B while turning it slowly to
with the grooves in avoid damaging the oil seal in the crankcase.
the cover.
into the setting collar [21 grooves.
Install the setting collar until it is seated.
16-39
DRIVETRAIN SYSTEM
Apply engine oil to the outer surface of feed pipe C [1 J.
Align the flange labs Insert feed pipe C while turning it slowly to avoid
with Ihe grooves in damaging the O-ring in the setting collar.
the collar.
the oil feed pipe setting cap [3] groove.
Inslall the selling cap and tighten it.
TORQUE : 21 N' m (2.1 kgfm, 151bHt)
Inslali lhe following:

- shift valve body (page 16-33)
- water pump (page 9-9)
- oil cooler (page 8-10)
- exhaust system (page 2-30)
TORQUE CONVERTER
REMOVAL
Remove the front crankcase cover (page 16-34).
Be careful not to Unstake the lock nul [1].
damage the Loosen the lock nul while holding the converter boss
crankshaft threads. with an open end wrench (width across flats: 32 mm).
Remove the lock nut and washer {2J.
<
j
j
1
Remove the torque converter assembly [1 J using the ;;;::::;:=;
special tools.
TOOL:
Puller, 35)( 1.0 mm [2J 07933-HA80000 or
07933-HB3000A
(U .S.A . only)

- stator shaft 11] (while tuming it counterclockwise)
- needle bearings [2J
16-40
DRIVETRAIN SYSTEM
- needle bearing {1]
- washers {2]
- thrust needle bearing [3J
- Inner collar [4]
- needle bearing [5]
INSPECTION
NOTE :
Replace the torque converter as an assembly (from
converter to inner collar).
Check the primary drive gear [1] teeth for abnormal
wear or damage.
Hold the torque converter and turn the drive gear to
check the one-way clutch in the torque converter.
The gear should turn counterclockwise smoothly and
should not turn clockwise.
111
Check the needle bearings for abnormal wear or
damage.
Check the sprag clutch [1] in the stator shaft [2] for
abnormal wear, damage or irregular movement.
Check the sprag clutch contacting surface of the inner
collar [3] for abnormal wear or damage.
12)
Check the seal ring [1J on the stator shaft for
deterioration, wear or damage.
11 )
16-41
DRIVETRAIN SYSTEM
Assemble the stator shaft and inner collar.
Hold the inner collar and turn the stator shaft.
The shaft should tum counterclockwise smoothly and
should not tum clockwise.
lj
,
TORQUE CONVERTER INSTALLATION
j
Lubricate the bearings, gear teeth and sprag clutch . j
INNER COLLAR
TORQUE CONVERTER
Apply molybdenum disulfide grease to the inner collar

needle bearing {1] and thrust needle bearing [2] .
Install the needle bearing into Ihe inner collar [3].
Instan Ihe inner collar onto Ihe crankShaft by aligning
the cutout with the stopper pin .
Install the thrust needle bearing onto the inner coliar
with the needle roller side facing in.
Install the washers [4].
16-42
DRIVETRAIN SYSTEM
Apply engme oil to the two needle bearings (1] and
install them Into the stator shaft from both sides.
Apply engine oil to the needle bearing 12] and install it
onlo the stator shaft.
121 'D
Install the stator shaft (1] onlo the crankshaft (2] and the
inner coliar [3) while turning it counterclockwise.
Install the torque converter [1] by aligning the splines

carefully, and engaging the primary drive and driven
gear teeth [2].
Inslallthe washer [3).
Apply engine oil to the threads of a new lock nut (1].

Install the lock nut and tighten it while holding the
converter boss with an open end wrench (width across
flats: 32 mm ).
TORQUE : 118 N'm (12.0 kgf' m, 87IbHt)
Be careful not to Slake the lock nut into the crankshaft groove.
damage/he
Install the front crankcase cover (page 16-37)
crankshaft threads.
16-43
DRIVETRAIN SYSTEM
SHIFT CLUTCH/MAINSHAFTI
COUNTERSHAFT
1st SHIFT CLUTCH REMOVAL
Remove the torque converter (page 16-40).
8& careful not ro Unstake the lock nut [11 .
matns::ft~~Y,;a~:' loosen the lock nut while holding the driven gear boss
with an open end wrench (width across flats: 29 mm).
- lock nut
- washer [2]
- 181 shift dutch assembly [3]
- washer!l]
- M1 gear guide 12J
- O-rings [3]
Remove the primary driven gear [1] by prying it.

Remove the O-rings from the primary driven gear.
I
MAINSHAFT DISASSEMBLY
Remove the mainshaft (page 14-6).
l
- M1 gear 11]
needle bearing (2]
washer (3]
M3 gear 14]
snap rings [5]
M2 gear[6]
16-44
DRIVETRAIN SYSTEM
COUNTERSHAFT DISASSEMBLY
Remove the countershaft (page 146).
- end washer [1)
C1 gear {2J
thrust washer (3]
C2 gear (4)
bearing
lock washer
131 11)
- end washer [1)
(3{
- C3 gear [2] , (4{
- bearing
- thrust washer [3]
- 2nd/ 3rd shift clutch assembly [4)
- O-rings
12)
SHIFT CLUTCH DISASSEMBLY
NOTE:
The following procedures are for the 1s1 clutch . The ,----------:-c:---.,_~____,
procedures for the 2nd and 3rd clutches are the

same as for the 1st clutch .
- stopper nng [1)
- end plate (2)
- three clutch discs [1] and plates [2]

- wave spring [3]
16-45
DRIVETRAIN SYSTEM
If either support Instalithe special tools onto the shift clu tch.
block {1} end is sel
over an area of the TOOLS :
retainer which is Clutch compressor attachment 07LAEPX40100 or
unsupported by the (21 07LAEPX4A100
return spring. the (U.S .A. only)
Support area
retainer may be (2 required)
damaged. Compressor bolt assembly (3) 07GAEPG40200 or
07GAE-PG4020A
(U .S.A. only)
NOTE:
Be sure the special 1001 is adjusted to have full
contact the stepped areas with the spring retainer
[4[.
To prevent loss of Compress the return spring [11 by lightening the nut.
spring tension, do Remove the snap ring [21 from the boss.
not compress more
Loosen the nut and remove the special toots, snap ring,
than necessary.
spring retainer 13] and re turn spring.
Wrap a shop towel around the clutch drum.

Apply air pressure to the oil hole while closing the other
holes with your finger to remove the clutch piston. I-_~~,,:;~
Remove the O-rings from the piston.
Clean aU the parts of the shift clutch in solvent
thoroughly and blow dry them with compressed air.
[NSPECT[ON
MAINSHAFTfCOUNTERSHAFT
The M1 gear Check each gear tooth and needle bearing for r"""C::-C::--~
N=E=
E=D-
L=E =8=E=
A=R='N
~GC:--~M~'--c=c:--",
bearing has one abnormal wear or damage.
roller missing from
Check the oil holes in the mainshaft and countershaft
88Ch cage by
for Clogs. I
I
deSIl}n.
M3GEAR MAINSHAFT I
j
,,
16-46
DRIVETRAIN SYSTEM
CLUTCH DRUM AND PISTON
Check the clutch drum [1) for nicks, indentations or , - - - - - - --CCC- - - - -::-:--
abnormal wear made by the clu tch plates.
Check the oil holes in the drum boss and check valve
121 in the piston (3] for clogs.
CLUTCH DISC AND PLATE

Rep/ace the clutch Check the linings of the clutch discs [1] for wear (disc , - - - - - - - -- -- - -
discs and plates as groove disappearance).
a sel. Check the clutch plates 121 for discoloration.
CLUTCH RETURN SPRING

Measure the spring free length,
16-47
DRIVETRAIN SYSTEM
SHIFT CLUTCH ASSEMBLY
1st S HIFT CLUTCH
--"'7J CLUTCH DISCS (3 pes) CLUTCH PLATES (3 pes)
END PLATE \
STOPPER RING ~"".<:~q:~\ \ I

PRIMARY DRIVEN GEAR
~~
WAVE SPRING
SPRING RETAINER
O-RINGS et,
CLUTCH PISTON
SNAP RING RETURN SPRING
2n dJ3rd SHIFT C LUTC H
CLUTCH PISTON
et,
O-RINGS
CLUTCH DRUM
6?"<
CLUTCH PLATES (3 pes) ~
, CLUTCH DISCS (3 pes) SPRING RETAINER ,-
END PLATE
WAVE SPRING
RETURN SPRING
SNAP RING
STOPPER RING
16-48
DRIVETRAIN SYSTEM
NOTE
The followmg procedures are for the 1SI dutch. The
procedures for the 2nd and 3rd clutches are the
same as for the 1st clutch.
Clean the inner surface of the clutch drum [11
thoroughly and blow through the oil holes in the drum
boss and check valve in the piston [21 .
Apply engine oil 10 new O-rings [3] and install them into
the piston grooves.
Place the clutch piston into the clutch drum with the flat
side facing in.
13J g ' l
Becarefufnotto Install the piston 111 while turning it to ensure proper ~============;::===;:::=~
pinch the ()..rings seating .
with too much
force.
Place the return spring 11). spring retainer [2] and snap
ring [3] mto the clutch drum.
Instalilhe special tools (4J while adJustmg their position
carefully (page 16-46).
To prevent loss of Compress the return spring by tightening the nut.
spnng tension. do
not compress more
than necessary.
131 [1[ 12J

AJign the end gap Install the snap ring I1j into the groove in the drum boss
with the groove (3 properly.
pJaces) in the
Loosen the nut and remove the special tools .
spring retainer.
11J
16-49
DRIVETRAIN SYSTEM
Install the wave spring (1) into the piston groove.
Coat the clutch discs (2) with engine oil.
Install the three clutch plates [3) and discs alternately,
starting with the plate .
13]
Inslallthe end plate (1] with the stepped side facing out.
Install the stopper ring (2J into the drum grooves
properly.
Check the clutch initial clearance (page 16-50),
11]
CLUTCH INITIAL CLEARANCE CHECK

Set a dial indicator on the end plate111 with the plale
lowered.
Lift the end plate up against the stopper ring and read
the clearance, and record it.
Perform this inspection althe three points in 120 apart.
STANDARD : 0.7 - 0.9 mm (0.03 - 0.04 in)
If the clearance is nol within the standard value, select

the replacement end plate as follows:
Remove the stopper ring and end plale.

Measure the flange thickness of the end plate at several
points and record it.
Calculate Ihe new plate thickness using the equation
below. Choose a new plate as close 10 this dimension
as possible.
A= (B - O.8) +C
A : New plate thickness
B: Recorded clearance
C: Old plale thickness
16-50
DRIVETRAIN SYSTEM
If/he calculated Select the end plate 111 from the lable below.
dimension is over
j
the Ih/Ckest plale
thickness, replace
tile Clutch discs and " I Thicli:ness
2.:' mm
Mark
1
~Ickness
4:.3 mm
piates as a set.
r--~' mm
2 2~ mm
I
: -=t=:f'2
D mm 3 2.9mm
2.4mm
;t. :I mm 3.5 mm
mm
r--~ mm , 11 2.15mm-
7 2.7 mm 12 mm
r -11 1.9 mm 13 ~~7 5 m m
mm I
~z:-O 3-:-0Smm
I
':::::!2 1.
15 3.3S mm
-
i _ __ _ _ _ 111
3.6S mm
Inslall the end plate into the drum.
Inslall the stopper ring 12J into the drum grooves
property.
COUNTERS HAFT ASSEMBLY
---., C2 GEAR LOCK WASHER ~ J
THRUST WASHER j; \9~ I
~ ~:\\~
> BEARIN~ ~\2~j
' C,GEAR
\ ""';:\) \J g
ENDWA~ .~ c :)
END WASHER
' O-RINGS
~ ~~ , NEEDLE
",r~~' . "-
ii'~-.~ j'V '"
I '~~ 1-1 ) C'GEAR ,
".~ NEEDLE BEARI NG ~

/ ~ THRUST WASHER
2nd/3rd SHIFT CLUTCH
Blow through the oil passages in the counlershaft with ,~~~~~~~~~~~~
compressed air.
Coat new Orings [1] with engine oil and install them
into the shaft grooves as shown .
Install the countershaft into the 2nd/3rd shift clutch [21
by aligning the splines.
12)
1651
DRIVETRAIN SYSTEM
Apply engine oil to the teeth of C3 gear [1J and needle
bearing (2J and install the following:
- thrust washer [3J
- needle bearing
- C3 gear
- end washer [4J
' D Ill
Inslall the lock washer [1] by aligninglhe four grooves
with the tabs on the clutch drum boss.
~================
Apply engine 011 to the teeth of C2 gear [1J and needle

bearing [2J and inslalithe following:
;::================
- needle bearing
- C2 gear
!
- thrust washer (3)
Apply engine oil 10 the teeth of Cl gear [1J and install

the following:
;::===============:::::
- C1 gear
- end washer [21
Install the countershaft assembly (page 14-9).
1652
Downloaded from www.Manualslib.com manuals search engine I
DRIVETRAIN SYSTEM
MAINS HAFT ASSEMBLY
Blow through the oil passages in the mainshaft with
compressed air.
Install the snap ringApply engine oil to the gear teeth and install the
with the chamfered following:
(rolled) edge facing - M2 gear (1]
the gear. - snap rings (2] (so thai its end gap aligns with the
groove in the splines)
- M3 gear (3J (with the ribs [4) facing oul)
Make sure the snap rings are fully seated in the shaft
grooves.
[2J 14J
The M1 gear Apply engine oil to the gear teeth and needle bearing .
bean"ng has one and install the following:
roller missing from
- thrust washer [1]
each cage by
- needle bearing [2)
design.
- M1 gear (3]
Install the mainshafl assembly (page 14-9).
I1J [2J
1sl SHIFT CLUTCH INSTALLATION
Blow through the oil holes in the primary driven gear [1]
boss with compressed air.
Coal new O-rings (2) with engine oil and install them
into the grooves in the driven gear boss .
Install the driven gear into the 1st shift clutch (3) until it
is fully seated .
Apply engine oil to the gear teeth and install the M1

gear guide [1] and washer [2] onto the mainshaft.
Coat new O-rings [3J with engine oil and install them
into the mainshafl grooves.
16-53
DRIVETRAIN SYSTEM
Line up the tabs of the three clutch discs in the shift
clu tch.
Align the disc tabs Carefutly instatl the 1sl shift clutch assembly [1] onto
with the gear guide the mainshaft and onto the M1 gear guide until it is fully
teeth. sealed (the whole of the shaft threads (2] are exposed).
Apply engine oil to the threads of a new lock nut [1].

Install the washer [2] and lock nut.
Tighten the lock nut while holding the driven gear boss
with an open end wrench (width across flats: 29 mm).
TORQUE: 108 N' m (11 .0 kgf-m , 80 IbHt)
Be careful not to Stake the lock nut into the mainshaft groove.
damage the
Instatl the torque converter (page 16-42).
mainshaft threads.

REMOVALIINSTALLATION
Remove the heat guard plale (page 2-30).
Disconnect the gear position switch 3P (black)
connector [1].
Release the gear position switch wire from the clamp

111
Remove the two bolts [2] and the gear position switch
[31 and O-ring [4] from the rear crankcase cover.
1654
DRIVETRAIN SYSTEM
Coat a new a-ring (1J with engine oil and install it onto
the gear position switch [2J.
Be sure the sub- Position the switch pin [3] with its long end facing down.
transmiSSIOn is in Install the gear position switch by aligning the switch pin
neutral. with the slot [4J in the crankcase cover being careful not
to damage the switch pin.
Install the two bolts and tighten them.
Route the gear position switch wire properly
(page 1-17).
Connect the gear position switch 3P (black) connector.

Install the heat guard plate (page 2-30).
EOT SENSOR
Drain the engine oil (page 3-10).
Disconnect the 2P connector (1] from the EaT sensor
[21
Remove the EOT sensor and sealing washer [3).
Install the EDT sensor with a new sealing washer and
tighten it.
TORQUE: 12 Nm (1 .2 kgfm, 9 IbHt)
Connect the 2P connector to the EDT sensor.
1655
MEMO

17. STEERING SYSTEM
SYSTEM COMPONENTS .... .... .. .... .. 172 STEERING COLUMN AND SHAFT ......... 17-4
SERVICE INFORMATION 173 TIEROD BALL JOINT .............. .. .... ...... 177
TROUBLESHOOTING .............. ............ 173 STEERING GEAR BOX

179
STEERING WHEEL
17-4
17-1
STEERING SYSTEM
SYSTEM COMPONENTS
49 N'm (5.0 kgf'm, 361bHt)
27 N'm (2.8 kgf-m, 20 IbHt)
27 N'm (2.8 kgf-m, 20 IbHt)
o
39 N'm (4.0 kgfm, 29
\
65 N'm (6.6 kgf-m. 481bHt)
17-2
STEERING SYSTEM
SERVICE INFORMATION
GENERAL
A jack or other support is required to support the vehicle (page 1-33).
Use Honda Genuine replacement bolts and nuts for all joint and mounting points.
Adjust toe whenever the knuckle or steering gear box components are replaced or removed (page 3-22).
For knuckle and wheel hub service, see Wheel/Suspension section (page 19-2).
TOOLS
'-B
= ""
IJ"'
o~i""I~,e~m~o
~v~e",~,2
~8"'
m"mo-----~"D~'i~
ve~,~,"
2"2 "m~m"'I."D'.--------'-'B",::::
se cotlar
07MAC-SL00201 07746-0020100 07GAJ-PG20120
07MAC-SL00202 (U .S.A . only)

lock washer clinch pilot Lock nut wrench
07NAZ-SR30100 07MAA-SL00101
l
or 07916-SAS0001 (U.S.A only)
or a commercially available punch or 07AAA-Tl2A 100 (U.S.A only)
(U .S.A. only)
TROUBLESHOOTING
Hard steering
Insufficient tire pressure
Faulty front tire
Incorrect rack guide adjustment
Worn or damaged steering column bearing
Damaged steering shaft
Worn or damaged steering gear box components
Damaged suspension components (page 19-4)
Steers to one side or does not track straight
Unequal tire pressure
Damaged tie-rod, steering gear box or column components
Incorrect wheel alignment (page 3-22)
Faulty suspension or wheel components (page 19-4)
Steering wheel wobbles
Loose steering wheel
Worn steering shaft splines
Noise o r vibration when turning the steering wheel
Incorrect rack guide adjustment
Worn or damaged steering column bearing
Loose steering shaft joint fasteners
Loose tie-rod joint fasteners
Damaged \ie-rod ball joint
Damaged or deteriorated mounting bushings
Loose steering gear box mounting fasteners
Worn or damaged steering gear box components
173
STEERING SYSTEM
STEERING WHEEL
MarX tile steering Remove the following:
wheel and shaft
- center cover 11] (by releasing Ihe three hooks from
before removing to
Ihe steering wheel)
identify its original
- nut 12l
position.
- steering wheel [3]
- dust seal/collar 14]
TORQUE:
Steering wheel nut:
49 N'm (5.0 kgf' m , 361bHt)
Apply grease to the dust sealfcollar lips.
Check Ihe condition of dust seal/collar and replace if
necessary.
STEERING COLUMN AND SHAFT

REMOVAL
- steering wheel (page 17-4).
- left front fender (page 2-13)
Raise Ihe front wheels off the ground.
Remove the upper pinch bolt 11] and lock washer (2).
Remove Ihe lower pinch bolt {3] and lock washer [4].
Lower Ihe steering shaft 15J and disconnect it from the
column shaft [6J, then remove it from the steering pinion
[71.
17-4
STEERING SYSTEM
Remove the dust seal [1}, snap ring [2] and washer [3] ,
Remove the column shaft [1] and washer [2] .
INSPECTION
Check the steering column bushings [1} for wear or r,,:,,,...~-::'i!
damage.
If the they are damaged, also check the column shaft.
Check the column shaft [1) for deformation or other , - - - - - - - - - - - - - - - - - ,

damage.
Check the shaft splines for wear or damage.
If the they are damaged . check the steering shaft
splines .
[1J
17-5
STEERING SYSTEM
Check that the universal joints [I] move smoothly
without binding or noise. [2]
Check the steering shaft [2) for deformation or other
damage.
Check the shaft splines for wear or damage.
If the they are damaged , check the column shaft and
pinion splines.
111
INSTALLATION
Apply grease to the top and inner surfaces of steering
column bushings [I].
Instalilhe washer (2] and column shaft (3].
Install the washer [I) and snap ring [2] into the column
shaft groove.
Apply grease to the lips of a new dust seal 13] and
install it.
j
j
17-6
STEERING SYSTEM
Becarefu/nolto Install the steering shaft 11) onlo the sleenng pinion (2]
damage the shaft with the slepped side facing up while aligning the bott
splines. hole in the universal joint with the flat surface in the
steering pinion properly.
Install a new pinch bolt (3) with a new lock washer [4],
but do not lighten it yet.
Pull up and connect the steering shaft so the flat

surface in the column shaft (1) is aligned w ith the bolt
hole in the universal joint [2}.
Install a new pinch bolt [31 with a new lock washer [4]10
be sure the shafts are aligned properly
Tighten the upper and lower pinch bolts to the specified
torque while supporting the shaft to ensure thai the
bolts are centered vertically in the slols.
TORQUE : 27 Nm (2.8 kgf-m , 20 Ibf-ft)

- left front fender (page 2-13)
- steering wheel (page 17-4)
Check that the steering wheel rotates smoothly from
lock-to-lock, without binding , and that from center to
I
lock-left and lock-nght is an equal number of turns.
TIEROD BALL JOINT

REMOVAL
Remove the front wheel (page 19-6). [1[
Loosen the tie-rod end lock nut [1] while holding the ball
joint [2] .
Loosen the ball Joint nut [3]. but do not remove it yet.
[3[
17-7
STEERING SYSTEM
Release the ball joint 11] using the special too
according to the following instructions.
TOOL:
Ball Joint remover, 28 mm [2J 07MACSL00201 or
07MAC-5L00202
(U .S.A . only)
Apply grease to the ball taint remover at the point ;:~~~~11[============~

shown.
This will ease installation of the tool and prevent Apply grease here
damage to the pressure bolt [ 1J threads.
Insert the jaws carefully, making sure that you do nol
damage the ball ;oint boot.
,,,
If necessary. apply Adjust the jaw spacing by turning the pressure botl.
penetrallng type
lubncanl lO loosen
lhe baN joint.
To prevent the tool from dropping. lie the strap (1J on a ~======-===========:;
neighboring solid part such as the upper arm, frame
pipe. etc. before operation.
NOTE:
Do not tie the strap on the brake hose, brake pipe,
rubber boot, and other parts that can be damaged
easily.
,
4
Once the tool is in place, turn the adjusting bolt [1) as ~=================~
necessary to make the jaws parallel. 4
Then hand-tighten the pressure bolt 12J and recheck the
jaws to make sure they are still paralleL
Tighten the pressure bolt with a wrench unlil the ball 1
joint stud pops loose. I
Remove the ball joint nut and disconnect the tie-rod
from the knuckle.
JI
Remove the ball Joint from the tie-rod.

1
(11 I
,
,
I
I
17-8 1
STEERING SYSTEM
INSPECTION
Inspect the ball joint boot [11 for tears or other damage
and the ball joint [2] for looseness by moving the ball
jOint stud [31.
They should move freely and smoothly without binding.
,,
121
INSTALLATION
Tighteningoflhis Instailihe ball joint [1] onto the tje~rod [2] and screw it
against the lock nut [31 so that the thread length is 5 - 7 5 - 7mm
nul to the specified
torque is performed mm (0.2 - 0.3 in) for initial reference.
111 (0.2 - 0.3 in) 121
l
when adjusting the Temporarily tighten the lock nut while holding the ball
wheel alignment. joint.
131
Connect the ball jOint [11 to the knuckle with the joint nut ~================-~
121
Tighten the joint nut to the specified torque .
TORQUE: 65 N' m (6.6 kgf'm, 48 IbHt)
Install the front wheel (page 19-6)
Adjust the wheel alignment (page 3-22)
121
STEERING GEAR BOX
REMOVAL
Remove /he lie-rod Disconnect the tie-rods (page 17-7).
ball joints if the gear
box will be
disassembled. - cover bolt {1]
- clutch arm cover {2] (by releasing the two labs (3])
- base bolts [4]
- cover base (5)
- holder bracket [6]
17-9
STEERING SYSTEM
Remove the pinch bolt [1J and lock washer [2J on the
lower side of the steering shaft.
,1
Be careful nof to Support the steering gear box securely and remove the
damage the lie-rod four mounting nuts [1] and bolts (2), then disconnect the
boots and shaft steering shaft.
splines. Remove the gear box assembly [3] oul of the frame to
the right while moving the clutch arm cover base [41 1
rearward. 1
OISASSEMBLY
Cut off the boot band [1] in the position as shown and ,-----------.-.-----~--,
remove it.
Remove Ihe boot clip [21 and the tie-rod boot [3).
Loosen the rack end joint [1] of the tie-rod while holding :========::::;;;========~
Ihe steering rack [2J to remove the tie-rod.
Remove Ihe lock washer [3J. ~
I
17-10
STEERING SYSTEM
Loosen the lock nut 11] using the special tool:
TOOL:
lock nut wrench [2] 07MAA-Sl00101or
07916-SA50001or
07AAA-Tl2A100
(U.S.A. only)
- lock nut
- rack guide screw [3]
- cone washer [4]
- pressure spring [5]
- rack guide [61 [2]
~o
[3] " - [1]
- dust cover [11
- dust seal [2]
- snap ring [11
17-11
STEERING SYSTEM
Hold the steering pinion in a vise with soft jaws or shop
towels. [
Take cam not to Drive the gear box housing 111 on contact with a
wooden block at the point as shown (arrows) evenly to l
1
damage the
housing. remove the steering pinion/bearing assembly.
Replace the pinion
Do not reuse the pinion andlor bearing.
and bearing as an
assembly.
ae careful nolto Remove Ihe steering rack [2] from the gear box
1
damage the sliding housing.
surface and teeth of
the raCK.
Remove the snap ring [1J and end bushing [2J.

Clean the disassembled parts with a high flash point or
non-flammable solvent and dry them with compressed
air.
INSPECTION
Check the rack [1J teeth for wear, chipping or damage.
Check the gear box housing (2] for damage.
[1]
Check the tie-rod PI for distortion or damage.

Check that the rack end joint (universal joint) (2] moves
smoothly without binding or noise.
[2]
1
17-12
STEERING SYSTEM
ASSEMBLY
NOTE:
Keep dust and dirt out of the gear box housing.
DUST COVER
~DUSTSEAL $I ~
~ (0.2 9 minimum)
~SNAPRING
PRESSURE SPRING
~ ~ (0.2 9 minimum)
STEERING PINION/BEARING
~
CONE WASHER (0.2 - 0.5 g)
",Illl GEAR BOX HOUSING
RACK GUIDE SCREW

~ (1 9 minimum)
RACK END BUSHING
LOCK NUT
SNAP RING
$I
LOCK WASHER - -_ , .. ~ (5 9 minimum)
STEERING RACK
_.s;;;;,.
(1 - 2 g)
54 N'm (5.5 kgf-m. 40 IbHt) "' ....... /> BOOT
BOOT CLIP
(0.5 9 minimum)
TIE-ROD
~~
fI BOOT BAND
Apply 1 9 minimum of grease to the inner surface of the r-------------------,

end bushing [1] and install it into the gear box housing.
Install the snap ring {2l into the housing groove.
17-13
STEERING SYSTEM
Apply 5 9 minimum of grease to the teeth of the steering
rack [1J evenly.
Be careful not 10 Insert the rack into the gear box housing [2] slowly in
damage the the direction as shown .
bushing by the rack
end edge.
Apply 0.2 9 minimum of grease to Ihe needle bearing ~==========;;;::;;;;::::::::~

[1] in the gear box housing and Ihe bal! bearing [2] on
the steering pinion.
Make sure Ihe rack teeth [3J can be seen through the
j
pinion hole and insert a new pinionfbearing assembly
[4] into the housing.
Press the bearing in until it is fully seated , using Ihe
special tool.
j
TOOL:
Driver, 22 mrn 1.0. [5] 077460020100 j
j
Make sure the snap Install the snap ring [1] into the groove in the housing
ring is finnly seated with Ihe chamfered side faCing down .
in the groove.
17-14
STEERING SYSTEM
Wrap vinyl tape around the pinion splines and groove ,
n/
and coat it wilh grease 10 avoid damaging the dust seal 21
lip.
Inl
Apply 0.2 g minimum of grease to a new dust seal [1]
lips. Install the dust sea) with the flat side facing up until
it is fully seated.
TOOLS :
Driver, 22 mm 1.0 . [2] 07746-0020100 {3{
Base collar (3) 07GAJPG20120
Remove the tape.
Pack 2 g minimum of grease in between the dust seal

and dust cover [1] (shadowed area). {21
Be sure the dust Install the dust cover and fit it into the pinion groove [2]. PI
cover does not
contact fhe gear box
housing {3].
131
Apply 0.2 - 0.5 g of grease to the sliding surface (rack

side) of the rack guide [1[.
Apply sealant (Threebond TB1102 or equivalent) to the
3 threads of the rack guide screw [2J .
Instali l he following:
rack guide
- cone washer [3] (with the concave side facing out)
- pressure spring [4J
- rack guide screw
- lock nut [5J
Perform the rack guide adjustment (page 3-21).
Check the rack and pinion for smooth movement.
17-15
STEERING SYSTEM
....
Instal! a new lock washer [11 onlo the steering rack (2].
aligning the tabs with the grooves , then install the be- ~ 111
''''' 13].
Hold the rack and tighten the rack end joint [4] of Ihe lie-
rod to the specified torque.
TORQUE : 54 N' m (5.5 kgf-m, 40 IbHt)
12] Align 13]
Use 8 V-block/o Clinch the lock washer [11 onlo the rack end joint
hold the rack end. notches in four places, using Ihe special tool and a
hydraulic press.
I NOTICE I
If the special tool is tilted or is misaligned from the
center of the lock washer, it will cause the tool to pop
Qut. Set the components in a hydraulic press properly
and hold the special tool and gear box securely.
TOOL:
Lock washer clinch pilot [2) 07NAZSR30100 or a
commercially
available punch
(U .S.A. only)
Inslall the other side tie-rod in the same procedure as
above.
Clean off any grease or contamination from the boot
groove in the housing end. 13]
Apply 1 - 2 g of grease to the outer surface of the rack
end joint {1j .
Apply 0.5 g minimum of silicone grease (Dow Corning Clean
Molykote EM30l or Kluber Noxlub SS4012) to the boot
groove [2J in the lie-rod.
Do nol gat groase Install the lie-rod boot {3] and fit it in the boot grooves in
on the lierod the housing and tie-rod.
threads.
Install the boot clip [4}.
11]
.-61 12 ] ,..u;;;,.
17-16
STEERING SYSTEM
Install a new boot band [11 by setting the labs [2] into
the holes with the pinch point facing rearward.
{11
Pinch the ear portion of the boot band [1J with a pincher
until the pinched area clearance is 2.0 - 4.5 mm (0 .08 -
;: :=================::;
{2]
0.18 in) as shown to secure tie-rod boot.
I
TOOL :
Pincher (21 Oetiker 1098 or equivalent
commercially available in the
U.S.A.
Install the other side boot in the same procedure as
above .
Slide the rack right and left to be certain that the boots
are not deformed or twisted.
Pinched Area
-~~-
2.0 - 4.5 mm
(O.08-0.18in)
INSTALLATION
Be careful not to Place the gear box assembly 111 into the frame from the
damage /he fie-rod right side .
boots and shaff
Hold the gear box securely and connect the steering
splines. pinion to the steering shaft carefully. Align the bolt holes
and install the four bolts [2\ from the front side.
Install four new nuts (31. Be sure to touch each side of
the housing onto the frame and tighten all the fasteners
to the specified torque.
TORQUE : 39 Nm (4.0 kgf-m , 29 IbHt)
17-17
I
j
STEERING SYSTEM
Install a new pinch bolt [1] with a new lock washer [21
and tighten it to the specified torque while supporting
the shaft to ensure that the bolt is centered vertically in
the slot.
,
<
i
Inslall the holder bracket PI and cover base (2) with the
1
two bolls [3], and tighten them to the specified torque .
TORQUE : 10 N'm (1.0 kgf-m , 1 Ibfft)

Instalilhe clutch arm cover [4] by aligning the slits with
the tabs [5] and tighten the boll [6] to the specified
torque.
TORQUE: 10 N'm (1 .0 kgf'm , 7lbHt)
Connect the tie-rods (page 17-9).
17-18
18. DRIVE SHAFT/FINAL GEAR
SYSTEM COMPONENTS .. 182 FRONT FINAL GEAR ASSEMBLY 1839
SERVICE INFORMATION18-4 FRONT FINAL DRIVE INSTALLATION 18-42
TROUBLESHOOTING ... ...... .... ............ 187 REAR FINAL DRIVE REMOVAL .......... 18-45
DRIVE SHAFT ..... .... ......................... 188 REAR FINAL DRIVE DlSASSEMBLYI
INSPECTION .... .. .... .. .. .... ... ... ... ... ..... 18-49
FRONT FINAL DRIVE REMOVAL 1814
REAR FINAL DRIVE GEAR CASE
FRONT PROPELLER SHAFT
1817 BEARING REPLACEMENT 1855
FRONT FINAL CLUTCH 1819 REAR FINAL DRIVE ASSEMBLY 1857
DIFFERENTIAL LOCK CLUTCH 1825 REAR FINAL DRIVE INSTALLATION 1861
FRONT FINAL GEAR DISASSEMBLYI DRIVE MODE SELECTOR LEVER

INSPECTION...................... 1830 LINKAGE

1863
FRONT FINAL GEAR CASE BEARING DRIVE MODE SELECTOR CABLE

REPLACEMENT ..... .. ............. .......... . 1836 ADJUSTMENT 1865
18-1
SYSTEM COMPONENTS
FRONT
54 N'm (5.5 kgf'm, 40 IbHt)
10 N'm (1.0 kgfm, 7lbHt)
10 N 'm (1.0 kgf 'm,

7lbHt)
\
1I \.
54 N'm (5.5 kgfm, 40 Ibf-ft)
18-2
REAR
44 N'm (4 .5 kgf.m, 32 Ibf-ft)
I~
I
18-3
SERVICE INFORMATION
GENERAL
Perform the gear contact pattern and backlash inspection whenever you replace the bearings , gears, differential or gear case.
The extension lines from Ihe gear engagement surfaces should intersect at one point.
Protect the gear case with a shop lowel or soft jaws while holding it in vise. Do not clamp it 100 l ighl as it could damage Ihe gear
case.
When usinglhe lock nut wrench (including Holding Tool). use a deflecting beam type torque wrench 20 inches long. The lock nut
wrench increases the torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to Ihe
lock nut The specification given is the actual torque applied to the lock nut, not Ihe reading on the torque wrench. Do not
overtighten the lock nut. The specification later in the text gives both actual and indicated.
Replace the ring and pinion gears as a set.
Do not confuse the left and right drive shaft shafts .
Protect the gear case with a shop towel or soft jaws while holding it in vise. Do not clamp it too tight as it could damage the gear
case.
TOOLS
Bearing clip compressor, 25 mm Threaded adaptor lock nut w rench
070ME-HN80100 070MF-HP50100 07716-0020203
or 070ME-HN8A100 (U.S.A. only) or 070MF-HP5A100 (U.S.A . only)

Remover weight Attachment, 42 x 47 mm Attachment, 52 x 55 mm
07741 -0010201 07746-0010300 07746-00 10400
<=> <=>
or 07936-371020A or 07936-3710200 or 07 JAD-PH80101

(U.S.A . only)
Attachmen t, 62 x 68 mm Attachment, 72 x 75 mm Attachment. 22 x 24 mm
07746-0010500 07746-0010600 07746-0010800
<=> <=>
18-4
lock nut wrench, 30 x 64 mm Puller shaft Remover head, 12 mm
Q7916MB00002 07931-ME40000 07936-1660 11 0
or 07931-ME4010B
and 07931HB3020A (U.S.A. only)
Remover shaft, 12 mm Remover shaft, 15mm Remover head, 15mm
07936-1660120 07936-KC 101 00 07936-KC10200
or 07936-166010A (U.SA only) or 07936-KC10S00 (U.S.A. only) or 0793&.KC10S00 (U.S.A . only)

Driver Oil seal driver Puller shaft and nut
07949-3710001 07965-KE80200 Q7965-VMOO200
".
(no\ available in U.SA) or 07931-ME4010B

and 07931-HB3020A (U.S.A. only)
Pinion puller base Oil seal driver attachment Driver attachment
07HMC-MM80110 07JAO-PH80101 07LAD-PW50S00
(J
or 07HMC-MM8011A (U.SA only)
18-6
Pilot, 32 mm Pinion holder Holding 1001
Q7MAD-PR90200 07SMB-HM702QO Snap-on YA6010A or equivalent
TROUBLESHOOTING
Consistent noise during cruising
Oil level too low
Foreign mailer contaminating gear oil
Worn or damaged bearing
Worn or damaged ring gear and pinion gear
Worn or damaged drive shaft, propeller shaft or universal joint
Deformed ring gear or gear case
Improper tooth contact between ring gear and pinion gear
Gear noises while running
Oil level too low
Foreign matter con taminating gear oil
Chipped or damaged gears
Improper tooth contact between ring gear and pinion gear
Gear noise while coasting
Chipped or damaged gears
Abnormal noises when turning
Worn or damaged ring gear bearing
Damaged differential componen ts (side gear. pinion or shaft )
Worn or damaged gear case housing
Abnormal noises at start or during acceleration
Excessive backlash between ring gear and pinion gear
Worn differential splines
Loose fasteners
Oil leak
Oil level too high
Clogged breather
Damaged seals
Loose case cover bolt
Overheating
Oil level too low
Insufficient backlash between ring gear and pinion gear
18-7
DRIVE SHAFT/FINAL GEAR 1
DRIVE SHAFT
FRONT DRIVE SHAFT REMOVAL 1
Remove the knuckle (page 19-10).
To prevent damage Hold the inboard jOint [11 of the drive shaft and tug firmly
to the gear case oil to force the stopper ring on the inboard joint end past
s9a/. hold the the groove while prying with a screwdriver. 1
inboard joint 1
honzonlal until/he
drive shaff IS dear
o( the gear case.
Remove the stopper ring [1] from the inboard joint.

I
REAR DRIVE SHAFT REMOVAL

Remove the knuckle (page 19-21).
To prevent damage Hold the inboard joint (1] of the drive shaft and tug firmly
/0 the gearc8se oil to force the stopper ring on the inboard joint end past
seal, hold the the groove while prying with a screwdriver.
Inboard JOint
horizontal un/!! the
drive shaft Is clear
of the gear case
Remove the stopper ring [11 from the inboard joint.

1
,.
18-8
DISASSEMBL YIINSPECTION
NOTE
The following procedure is common to front and rear
drive shaft. [2J (Outboard)
Do nol confuse the left and right drive shaft parts.
Do not confuse the front and rear drive shaft parts.
Check the boots [1] for cu ts or other damage.
Check the drive shaft joints [2) for excessive play or
noise by moving the joints in a circular direction.
If the outboard joint seems to be worn or damaged, the
drive shaft must be replaced .
NOTE
To replace the outboard boot, first remove the
inboard boot as described In the following steps.
Then remove the bands and outboard boot from the
(2] (Inboard)
inboard end of the shaft.
The outboard joint cannot be disassembled.
Rep/ace the band Cut off and remove the boot bands [11 from the inboard , - - - - - - - -- - -- - - - - - - ,
with new ones boot [2] .
whenever removing
them
111
- stopper nng (1J
- inboard joint 12]
121
- snap ring [1]

- bearing (2)
- inboard boot (3]
111
121
18-9
Replace Ihese Check the following for wear or damage:
componenrs as an - bearing cage [1]
assembly. - race [2] 141
- steel balls [3]
- inboard joint [4]
131
RepJace the band Cut off and remove the boot bands (1) from the
with new ones outboard boot [2].
whenever removing
Remove the outboard boot.
them.
~===============~ '" 121
III
ASSEMBLY
NOTE
The following procedure is common to front and rear drive shaft.
!ld! INBOARD INB'DAFID BOOT

__ jiIII BOOT BANO
BEARING
~ iNBOARD JOINT INBOARD SHAFT

(Front80 - 100g) BOOT BAND
(Rear: 60 - 80 g)
STOPPER RING
~
OUlrBO,'"O JOINT (45 - 65 91
OUTBOARD SHAFT DRIVE SHAFT
BOOT BAND ~ ""!',llJ.y-
OUTBOARD BOOT
OUTBOARD BOOT BAND :II
18-10
Each boot [1J has following identification number [2J. Do
not interchange them. [1)
FRONT DRlVE SHAFT BOOT:

INBOARD BOOT: 519-75
OUTBOARD BOOT : 9871 L
REAR DRIVE SHAFT BOOT:
INBOARD BOOT : 67275L
OUTBOARD BOOT : 9871 L
121
Note the installation direction of the boot bands [11.
Forward rotation direction
Each band has following identification number [21. Do
not interchange them.
[1[
FRONT DRIVE SHAFT BAND :

INBOARD SHAFT BOOT BAND: 25
INBOARD BOOT BAND: 68
OUTBOARD SHAFT BOOT BAND : 24
OUTBOARD BOOT BAND : 69
REAR DRIVE SHAFT BAND :
INBOARD SHAFT BOOT BAND : 25
INBOARD BOOT BAND : 72.5
OUTBOARD SHAFT BOOT BAND : 24
OUTBOARD BOOT BAND: 69
c: - 0:>
Pack Ihe outboard joint with the specified grease.

[11
SPECIFIED GREASE :
Front/rear: NKG708
AMOUNT:
Front/rear: 45 - 65 g
- outboard boot 11]
- new shaft boot bands [2]
- inboard boot [3]
Do not tighten the bands at this time.
Install the bearing [11 with the small 0 .0. facing the ~==~------------==~
drive shaft.
Install the snap ring [2] with the chamfered side facing
the bearing.
[1[
18-11
The shaft O.D. of Pack the inboard Joint 111 with the specified grease.
the left inboard jomt
is larger than the SPECIFIED GREASE:
right Inboard joint. Front: NKG708
Do not interchange Rear: NKG509
them. AMOUNT:
Front: 80 - 100 9
Rear: 60 - 80 9
Install the inboard Joint over the bearing.
Install the stopper ring [21 into the groove in the inboard
joint properly,
Install the boot over the inboard joint securely.
[11
Adjust the length of the drive shaft to the figure given ~=====~~~~~~'======~ 1
below. j
FRONT DRIVE SHAFT LENGTH: J
Left: 730 mm (28 .7 in)
Right: 632 mm (24.9 in)
REAR DRIVE SHAFT LENGTH :
Left/Right: 706 mm (27.8 in)
Nola the installation Install a new outboard boot band [lJ onto the outboard ~=======:;;;;;;;;::=======~
direction of the 000\[2].
band (page 18-11). lock the shaft boot band [3) and outboard boot band
with commercially available pliers.
TOOL:
Pliers [4) Oetiker 14100134 or equivalent
commercially available in the
U.S.A.
1
111 111
~======::::;;;;;:;;;::=='=====;
B
Install a new Inboard boot band [1] onto the inboard
b001 [2].
Lock the shaft boot band (3) and inboard boot band with

pliers.
Lock
[31
111 [1[
1812
FRONT DRIVE SHAFT INSTALLATION
Install a new stopper ring 111 into the groove in the
inboard joint splines.
The left dnVe shaft Install the drive shaft by holding the inboard joint (1)
is longer than the until the stopper ring seats in the groove of the
right drive shaft. Do differential .
not interchange
Make sure that the stopper ring is seated properly by
them.
pulling on the inboard joint lightly.
Be careful not to
damage /he oil seal Install the knuckle (page 19-13).
in the gear case.
REAR DRIVE SHAFT INSTALLATION

Install a new stopper ring [1] into the groove in the
inboard jOint splines.
Be careful not /0 Install the drive shaft by holding the inboard joint [1]
damage the oil seal until the stopper ring seats in the groove of the ring
in the gear case. gear.
Make sure that the stopper ring is seated properly by
Install the knuckle (page 19-22).
18-13
FRONT FINAL DRIVE REMOVAL
Drain the front final drive oil (page 3-13).
- front wheels (page 19-6)
- left drive shaft (page 18-8)
Remove the following from the gear case:
- 4wD select switch connector (1]
- differential lock switch connector p]

- breather hose [2]
j
!
- cotter pin [1] and washer [2]

- differential lock cable (loosen the cable nul [3J and
remove from the cable holder (4] and lock arm [5])
1
1
- coverboll[1J
- clutch arm cover (21 (releasing from the two tabs (3))
18-14
- adjusting nut [1)
- cable retaining plate [2]
- selector cable (3) (remove from the cable holder (4) ( 3 1 - -.....''"''
and joint pin [51)
- cable spring [6]
- jOint pin {61
- base bolts [1 ]
- arm cover base [2)
- holder bracket 13]
Loosen the two bracket bolts (10 mm) [1] and remove
the lower mounting nut [2] and bolt (12 mm) [3].
Remove the bracket bolls and mounting bracket [4].
Ilii~;~; !~~:-~:::~II!I~
Support the gear case [5J with wooden blocks and
remove the upper mounting nut [6) and bolt (12 mm) [7).
18-15
I
Move the gear case assembly forward for maximum
clearance between the propeller shaft joint (1J and
engine.
Pull the propeller shaft joint to disconnect it from the 1
output shaft [2] of the engine. l
Remove the boot bands [3] and release the propeller
shaft boot (4) off the pinion joint (5) of the gear case.
j
Pull the propeller shaft [6] to force the stopper ring [71
past the groove in the pinion joint to disconnect it. c..._- ~
Remove the propeller shaft out of the frame.
Remove the stopper ring from the propeller shaft.
Remove the O-ring [8) from the output shaft.
j
1
Separate the right drive shaft [1] from the gear case as
you remove it.
Remove the gear case assembly (2) out of the frame.
OPERATION CHECK
Turn the pinion jOint [1] while the clutch arm (2] is set to
the upper side (4WD position), and check that the gear
turns smoothly and quietly wi thout binding.
If the gear does not turn smoothly or quietly, the pinion
141 111
\ .)~
,~e
/'f . (
gear, ring gear, bearing and/or clutch components may
be damaged or faulty. They must be checked after
disassembly; replace them if necessary.
Operate the 2WD/4WD change-over mechanism while -'\
'/ fl.~y
~ ') ~
turning the pinion joint. check for smooth engagement!
disengagement.
I ~OCk ~ I "I:-'
Check the differential lock change-over mechanism
while turning the pinion joint; both differential shafts [3J
in the gear case should turn each other when the
differential lock arm 14J is in the lock position, and the
right shaft should not turn when the lock arm is in the 131 121
unlock (lock free) position.
18-16
FRONT PROPELLER SHAFT
DISASSEMBLY/INSPECTION
Remove the outer boot band [1] and the shaft boot [2] , - - - - - - - - - - - - - - ----,
from the propeller shaft joint [3) to remove the shaft
joint.

- joint spring [1 J
- innerboolbands{2}
14J
- dust seal [3)
12J
- shaft boots [4]
11J
Check the propeller shaft for deformation Of damage.
Check the splines [5] of the propeller shaft and jOint for
wear or damage.
If they are damaged, check the splines of the output
shaft and pinion joint.
Check the boots and dust seal for cuts, deterioration or [2[
damage.
Check the seal lip in each boot for damage.
[5[
ASSEMBLY
~ ~
SEAL LIP SEAL LIP
I
il
PROPELLER SPLINES PROPELLER

SHAFT
~ SHAFT JOINT
(5- 8 9 )
18-17
Place the inner boot bands on the propeller shaft.
\
Do not allow the Apply molybdenum disulfide grease to the seal lips of 131
sea/lip 10 tum front side boot and dust seal [1].
outside in. Install the dust seal and boots [2] onto the shaft
grooves, being careful not to damage the seal lip.
Install the inner boot bands into the each boot groove.
Install the joint spring [3] Into the propeller shaft
securely.
121
111 ~
Apply 5 - 8 9 of molybdenum disulfide grease to the ~=================~

propeller shaft joint splines.
Sel the shaft joint [1] onto the propeller shaft while
compressing the spring, then install the boot [2] over
~ 15 - 891
the shaft joint groove and the outer boot band (3) into
the boot groove to secure it.
18-18
FRONT FINAL CLUTCH
The housing IS Remove the following:
[4)
under spring
- 4WD selecl switch (1 ] and sealing washer (2] [3)
pressure: hold Ihe
three bolts [3]
housing when
final clutch housing [41 (by releasing the shift fork (5]
loosening Ihe bolt.
from the sleeve)
clutch sleeve [6]
O-ring [7J
dowel pins [BJ
Check the splines of the pinion joint, clutch sleeve and .....--~
pinion gear shaft for wear or damage .
Check the needle bearing in the pinion gear shaft for
wear or damage.
Release the clutch spring end [1] from the stopper plate
[2J by pulling the arm shaft.
Remove the fork bott [11.

Pry the clutch arm tab to release it from the collar [2] [1)
and slide the shaft [3J outward.
18-19
- clu tch spring [1]
stopper plate [2)
shift fork [3]
clutch arm shaft [41
lock spring (5]
coliar [6]
O-ring [7] j
oil seal [8]
Check the shift fork claws 11] for wear or damage.

Check the arm shaft (2) and stopper plate [3) for 151 12}
deformation or damage.
~-
Check the clutch spring (4] and lock spring [5) for
fatigue or damage.
PINION JOINT BALL BEARING

A>t:t
14} 13} 11}
1
I
REPLACEMENT
Remove the snap ring [1] and drive the pinion joint [2]
out of the bearing.
Remove the oil seal [1J and the snap ring [2J.
Drive the bearing [3J oul of the housing.
18-20
Drive a new bearing 11) into the housing .
TOOLS :
Driver [2] 07749-0010000
Attachment, 52 x 55 mm [3] 07146-0010400 121
Pilot, 32 mm (4] 07MADPR90200
g 111-
Install the snap ring [1] into the housing groove securely ,--===~~~~~=~~~~-===~
with the chamfered edge facing the bearing.
Pack the seal lips of a new oil seal [2] with grease.
Instali l he oil seal so it is flush with the housing end.
Be careful not 10
damage/he oil seal
Hold the bearing inner race and press the pinion joint
(1) into the bearing unt il it is fully seated.
~~~~~~~cf~~~~~....- -.::i
lips.
TOOLS :
.,
Fork seal driver body [2] 07747-0010100
Driver attachment, 07747'()010501
33 mm 1.0. [3]
Oriver attachment 07HMDMR70100
Install the snap ring [1] into the pinion joint [2] groove
securely With the chamfered edge faCing the bearing .
18-21
ASSEMBLY
SNAP RING
g BEARING (32 Ie 58 Ie 13)
CLUTCH SPRING SNAP RING
e,1
l-~ ~n
( 1?) >: 1
PINION JOINT
~
.
t;f
.;0 all SEAL
....>', --.
"",., all SEAL ~ .-6..
f
7 T~.---
.cJC~, <r---- .....
.-6..
'.r~-- CLUTCH ARM
LOCK '\. SHAFT
SPRING COLLAR D-RING
e!I~
Coat a new a-ring [11 with grease and install II into the , - - - - -
arm shaft groove.
Apply grease 10 the arm shaft outer surface (collar, fork
and housing contacting area).
121
Install the collar [2) and the loel< spring [3) in shown
direction, and set the spring end into the hole [4] in the
collar.
Apply grease to the lips of a new oil seal [1] and install it
into the clutch housing until it is fully seated.
L
;::======---=========::; I
I
Take care not /0 let Install the arm shaft assembly [2]. being careful not to
the /ocJ( spnng damage the oil seal.
come off the collar
during assembly.
121
18-22
Install the shift fork (1) and align the groove with the lock
spring [2] end.
While holding the Install the stopper plate [1J by aligning the flat surfaces
shift fork, push the so the plate is attached onto the fork lug [21.
arm shaft to slide il
inward and instali Install the clutch spring [3] with the bent end [4) toward
the shift fork.
the shaft end into
the pivot hole in the
housing.
Tum the arm shaft [1] clockwise by holding the collar [21
with a open end wrench and align the arm tab with the
;"'''''======:'' ' '=.........IIIIIIII="===~
collar groove, then tap the shaft to fit them securely.
Align the bolt hole in the fork with the groove in the shaft
and install a new fork bolt [3].
Tighten the fork bolt.
TORQUE: 10 N'm (1 .0 kgf'm, 7 IbHt)
Align
[1 [
18-23
Turn the arm shaft and set the clutch spring [1 ) ends
onlo the housing groove [2) and the reverse side of the
stopper plate 131 as shown.
Check the arm shaft for smooth operation.
Inslall the clutch sleeve PI with the large 0.0. side ~=:::=::""'~~~=======~===~
facing the inside.
Coat a new D-ring (2) wi th grease and install it into the
case groove.
Install the two dowel pins [3].
Aligning the fork claws [1] with the sleeve groove (2), ~~~~~~~~~~~=======~
install the final clutch housing [3] white turning the
clutch arm [41. then secure it with the bolts [5).
Tighten the three bolts.
TORQUE : 25 N'm (2 .5 kgf-m, 18 IbUt)
Install the 4WD select switch [6] with a new sealing
washer [7] and tighten it.
TORQUE : 12 N'm (1.2 kgf'm , 9lbHt) 111
Check the final clutch operation (page 18-16).
151
18-24
DIFFERENTIAL LOCK CLUTCH
- differential lock switch [1] and sealing washer [2]
- stopper spring plug [3J and sealing washer [4]
- stopper spring [5}
- steel ball [6]
- four bolts [7) and cable holder [8]
18)
differenliallock clutch housing [1] (by releasing the ~=========:-=====~

shift fork [2] from the sleeve )
- differential half shaft [3)
- lock sleeve [41
- Oring [5]
Check the splines of the lock sleeve and half shaft for
wear or damage .
Check the sleel ball and stopper spring for wear or
damage .
[3)
18-25
Remove the oil seal {1].
~
I
Remove the fork boll [1J .

Slide the shift fork [2] to release its spring pin [3J from
the spring ends.
Release the fork spring [4] from the spring pin [5] on the
stopper arm (6].

- arm boll11J and washer [2J [1V[21
stopper arm [3J
fork spring (4] [71
shift fork [5J
lock arm shaft (6]
oil seal (7]
161---'
Check the shift fork claws [11 for wear or damage,

Check the arm shaft [21 and stopper arm (3) for [21
deformation or damage.
Check the spring (4) for fatigue or damage.
l
i
I
141
18-26
HALF SHAFT BEARING
REPLACEMENT
Drive Ihe bearing out of the housing.
Drive a new bearing [1] into the housing with the
marking facing up.
TOOLS :
121
Driver [2] 07749-0010000
Attachment, 62 x 68 mm [3] 07746-0010500
Pilot, 35 mm [4J 07746-0040800
Sfl III- _ 13V[4]
ASSEMBLY
7 0liEAL ~ .s;;;v.. DIF FERENTIAL LOCK

ARM SHAFT
(:;r
....41)" --6iii..
OIL SEAL
f,/ d
FORK SPRING _ _ __
IA
(fl~~
~
~_ _
BEARING (6007)
- - SHIFT FORK
S"
STOPPER ARM ---~~~lf _ - - - 1 0 N'm (1.0 kgf'm, 7
WASHER ~--- 20 N-m (2.0 kgf'm, 15Ibfft)

Apply grease to the lips of a new oil seal (1) and install it
into the clutch housing until it is fully sealed. [3J
Install the lock arm shaft {21, being careful not to
damage the oil seal, then installhe shift fork [3] with the
bolt hole facing up.
(21
Install the fork spring [1J and stopper arm [2J and set the ~===============::::;
shaft end into the pivot hole in the housing so the spring (3]
end rest onto the spring pin on the stopper arm as 14)
shown . III
Align the bolt holes with the shaft arm facing down, then
install the stopper arm bolt {3] with the washer {4] and
tighten it. 121
TORQUE: 20 N 'm (2.0 kg"m , 151bHt)
18-27
Hook the fork side spring end [1] onto the underside of
the spring pin (2) on the stopper arm, using a
screwdriver.
Slide the shift fork [1J and set its spring pin (2] between ~===~~~===;;;;;;~;;;;;;;;;::;;;;;~
the spring ends [31.
Align the bolt hole in the fork with the groove in the shaft ~===~~,jllII:;:III"'~~~:::III~~~~~
and install a new fork bolt [1].
Tighten the fork bolt.
TORQUE : 10 N'm (1 .0 kgf'm, 7lbHt)
Install a new oil seal [1] so that it is flush with the ~====~==::::;~=========
housing end, being careful not to damage the lip.
TOOLS :
Driver [2) 07749-OQ10000
Oil seal driver attachment [3] 07 JADPH801 01
Pack the seal lips of the oil seal with grease.
_ _ -[3]
....
~ [1]"
18-28
Install the lock sleeve 11] and half shaft (2] in the
direction as shown . 1$1 ..u;;.. J2J
Coat a new O-ring (3] with grease and install it into the 13J
case groove.
Inslall the two dowel pins [4). 11 J
Install the differenliallock dutch housing [1) by aligning , - - -

the lork claws [2] with the sleeve groove [3).
Install the four bolts [4] with the cable holder {5] and
tigh ten them.
TORQUE : 25 N' m (2.5 kgf' m , 181bHt)
ISJ
1829
Install the steel ball [ 1] and stopper spring [2] .
InslaUthe spring plug [3J with a new sealing washer [4]
and lighten it.
TORQUE: 21.6 N'm (2.2 kgf'm, 16 1bHt)
Install the differenl iallock switch [5] with a new sealing
washer (6) and tigh ten it.
TORQUE: 12 N'm (1 .2 kgf'm, 9lbHt)
Check the differential lock clutch operation
(page 18-16).
111 161
151
FRONT FINAL GEAR OISASSEMBLVI

INSPECTION
- final clutch housing (page 18-19)
- differential lock clutch housing (page 18-25)
BACKLASH INSPECTION
Set the final gear case into a jig or vise with soft jaws.
Cover fhe clutch Hold the pinion gear with the special tools.
housing mating
surface WIth
TOOLS:
protective tape or Pinion puller base (1J 07HMCMM80110
en equiYalent to Puller shaft and nut [2] 07965VM00200
prevent damaging Threaded adaptor [3J 070MFHP50100
if. U.S.A. TOOLS :
Pinion puller base 07HMCMM8011A
Special nut 07931HB3020A
Threaded adaptor 070MFHP5A100
1
j

,
~
18-30 1
Set a horizontal type dial indicator on the ring gear
through the filler hole .
Turn the ring gear back and forth using the Jock nut
wrench to read backlash.
TOOL :
Lock nut wrench [1] 07716"()020203
STANDARD : 0.05 - 0.25 mm (0.002 - 0.010 in)

Remove the dial indicator. Turn the ring gear 120 and
0
measure backlash. Repeat this procedure once more.

Compare the difference of the three measurements.
If the difference in measurements exceeds the service
limit, it indicates thai the bearing is not installed
squarely, or the case is deformed.
Inspect the bearings and case.
If the backlash is excessive, replace the ring gear left i ------;::;!:;:;---------l
side shim [1] with a thinner one.
If the backlash is too small, replace the ring gear left
side shim with a thicker one.
The backlash is changed by about 0.06 mm (0.002 in)
12]
when the thickness of the shim is changed by 0.10 mrn
(0.004 in).
11]
NOTE :
Fifteen different left shims (from A to 0) and
seventeen different right shims (from A to 0) are
available in thickness increments of 0.06 mm (0 .002
in) .
RING GEAR SHIMS :

Right s ide:
A : (thinnest): 0.64 mm (0.025 In)
G: (standard): 1.00 mm (0.039 in)
0 : (thic ke st ): 1.48 mm (0.058 In)
Left s ide :
A : (thinnest): 0.64 mm (0.025 in)
G: (standard): 1.00 mm (0.039 in)
Q: (thic kest): 1.60 mm (0.063 in)
Change the right side shim [21 as follows : If the left shim
was replaced with a 0 .10 mm (0 .004 in ) thicker shim,
replace the right shim with one thai is 0.10 mm (0 .004
in ) thinner.
DIFFERENTIAL REMOVAL
Loosen the six cover bolts [1] in a crisscross pattern in
11]
several steps and remove them.
Pry the case cover (2) at the points (3) as shown and
remove it.
18-31
Remove the O-ring [1].

Remove Ihe differential assembly (2] and shims [3]. [1 )
(2)
BEARING INSPECTION
Tum the inner race of each bearing [1] in the gear case , --
and cover with your finger. The bearings should turn
smoothly and quietly. Also check thai the bearing outer
race fils tightly in the case or cover.
For differential bearing replacement (page 18-36).
GEAR TOOTH CONTACT PATTERN

CHECK
KBep dust and dirt Apply thin coat of Prussian Blue to Ihe pinion gear teeth , -- - - - - - - - - - - - - - - - ,
out of the case and for a tooth contact pattern check.
cover.
Inslall the ring gear shims !1 J onto the differential
assembly 12].
Inslalilhe differential assembly into Ihe gear case.
[11 Shim)
(2)
18-32
II is important to InslaU the case cover (1 1and l ighten the bolts in several
[21
fum the pinion gear sleps until the cover evenly touches the gear case.
while tightening the Then, while rotating the pinion gear, tighten t he bolts to [31
bolts. If the nng the specified torque in a crisscross pattern in several
gear shim IS too steps.
thick, the gears will
lock after only light TORQUE :
tightening. 10 mm bolt [2J : 47 N' m (4.8 kgf' m , 351bHt)
8 mm bolt (3): 25 N'm (2.5 kgf'm, 181bHt)

NORMAl:
Rotate the ring gear several times in bolh directions of HEEl~
rotation .
TOE
Check the gear tooth contact pattern through the oil
filler hole. I
j FACE __ __ FACE
The pattern is indicated by the Prussian Blue applied to
the pinion.
Contact is normal if the Prussian Blue is transferred to
1 9~ 1
th e approximate cen ter of each tooth , but slightly to the FLANK FLANK
heel side and to the flank side. Coast side
If the patterns are not correct, remove and change the
pinion shim with one of an alternate thickness.
Replace the pinion shim [1]with a thicker one if the

contact pattern is too high, toward Ihe face.
~T=O=O=H='G=H='==~==========~
J;~ [11
FACE FACE
Drive side
Ie? ~l
Coast side
Replace Ihe pinion shim [11 wilh a Ihinner one if Ihe ~T:':O':O=L=O=W='=============~
contact pattern is 100 low, toward the flank.
The pattern will shift about 0.5 - 1.0 mm (0.02 - 0.04 in)
when the thickness of the shim is changed by 0.12 mm
(O.005 in).
NOTE :
Fifteen different thickness shims (from A to 0) are
available in thickness increments of 0.06 mm
(0.002 in).
Ic:? ~ I
PINION GEAR SHIMS:
A : (thinnest) : 1.64 mm (0.065 in)
G: (standard) : 2.00 mm (0.079 in) Drive side Coast side
FLANK
0 : (thickest): 2.48 mm (0.086 in)
For pinion shim replacement (page 1835).
18-33
DIFFERENTIAL INSPECTION
Replace the Turn the differential gears in the housing and check that , - - -- - - - - - - - - - - - -
differential as an the gears turns smoothly and quietly with out binding.
assembly.
Check each gear for wear or damage.
RING GEAR REMOVAL

Remove the ten bolts 111 and the ring gear [2).
[21
PINION GEAR REMOVAL

Be careful that Unstake the bearing lock nul [1 J with a drill or grinder.
metal particles do
not enter the
bearing and the
threads of the case
are not damaged.
Remove the lock nut and discard it.
TOOL:
Lock nut wren ch, 07916-MB00002
30 x 64 mm [1J
18-34
Cover the clutch Install the special tools onto the pinion gear shaft and
housing mating gear case , Using a heat gun, heat the case.
surface with
aluminum shims or TOOLS : _ _ [21
an equivalent to Pinion puller base [1] 07HMCMMS0110
prevent damaging Puller shaft and nut (2) 07965VM00200
il. Threaded adaptor (3] 070MFHP50100
U.S.A. TOOLS:
Pinion puller base 07HMCMM8011A
Special nut 07931HBJ020A 131
Threaded adaptor 070MFHP5A100
Pull the pinion assembly out from the gear case.
PINION BALL BEARING AND SHIM

REPLACEMENT
Take care notlo Press the pinion gear [1J oul of the bearing.
contact the support
Remove the pinion shim [2).
blocks agamst/he
gear/eeth. Replace the pinion joint needle bearing in the shaft end
if necessary (page 18-36).
Install the shim 111 and a new bearing [2J onto the pinion ~-----------------,
gear [3].
NOTE :
When the gear set, differential bearing, differential
and/or gear case has been replaced, use a 2.00 mm
(0.079 in) thick shim for initial reference .
Press the pinion gear [1J into the bearing until it is fully :========::::;;;;;;~=======~
seated by supporting the bearing inner race.
TOOL:
Attachment, 30 mm 1.0. [2] 07746-0030300
18-35
PINION JOINT NEEDLE BEARING
REPLACEMENT 1
Remove the pinion ball bearing (page 18-35).

11]
Be sure /0 wear Heat the pinion gear (1] to about 80~C (176F) and
heavy gloves /0 remove the needle bearing (2), using the special tools.
avoid bums when
handling the heated
TOOLS :
gear. Remover head, 12 mm 079361660110
Using a lorch to Remover shaft, 12 mm 079361660120 or
heal the gear may 07936166010A
cause warpage. (U .S.A. only)
07936371020A
(U.S.A. only) or
079363710200
(U .S.A . only) [2]
Press a new bearing Ii] into the pinion gear with the ~------
marking facing up so that it is flush with the shaft end.
TOOLS :
Driver [2] 07749.(1010000
Attac hment, 22 x 24 mm [3] 07746-0010800
Pilot, 12 mm [41 07746-0040200 ]3]1]4]
Install the pinion ball bearing (page 18-35).
-'" ]']---
S"
FRONT FINAL GEAR CASE BEARING

REPLACEMENT
DIFFERENTIAL BEARING
Remove the oil seal [1J from the gear case.
Drive the bearings [2) out of the case and cover.
18-36
Drive new bearings (1) into the gear case [2) and cover.
TOOLS :
Case Side:
Driver (3) 07749-0010000
Atta chment, 62 x 68 mm [4] 07746-0010500
Pilot, 40 mm [5] 07746-0040900
Cover Side:
Driver 07749-0010000
Attachment, 72 x 75 mm 07746-0010600
Install a new oil seal [1) so that it is flush with the gear ;;;~=~~~~~"':
case , being careful not to damage the lip.
TOOLS :
Driver (2] 07749-0010000
Oil seal driver attachment [3J 07JADPH80101
Pack the seal lips of the dust seal with grease .
PINION NEEDLE BEARING

Rota te the stopper ring [1] untit its end appears in the
access hole [2] .
Strike gently near the end of the ring with a punch to
bend the end upward.
Grasp the end of the ring with needle-nosed pliers and
pull the stopper ring out through the access hole.
Be sure /0 wear Heat the gear case to about aoc (176F) and remove
heavy gloves 10 the needle bearing [3), using the special tools .
avoid bums when
TOOLS :
handling Ihe heated
gear case. Remo ..... er head. 15 mm 07936-KC10200
Using a loreh to Remo ..... er s haft, 15 mm 07936-KC10100 or
heat Ihe gear case Bearing remo ..... er. 15 mm 07936-KC10500
may cause (U .S.A. only)
warpage Remover weight 07741-tl010201or
07936-371020A
(U .S.A . only) o r
07936-37 10200
(U .S.A. only)
Remove the bearing cage and bearings from the inside

of the pinion bearing to allow the special tool to grip the
bearing .

1837
Install a new stopper ring [1J into the groove in a new
bearing (2] .
Make sure the Install the bearing into the compressor [3J until the
stopper nng slays in stopper ring is Hush with the end of the tool.
the groove.
TOOL:
Bearing clip compressor, 070MEHN80100 or
25mm 070MEHN8A 100
(U.S.A. only)
121
131
111
Place the driver (1), attachment [21 and pilot (3J on the ~=======:;;;;;;========~
top of the bearing (4J and tape the driver to the
compressor 15[.
TOOLS :
Drtver 079493710001
Attachment, 22 x 24 mm 07746-0010800
Pilot, 15 mm 07746-0040300
Place the bearing and tool assembly into a freezer for at
least 30 minutes.
Using a heat gun, heatlhe gear case to aoc (176"F).
Remove the bearing and tool assembly from the freezer
and drive the bearing into the gear case using the
special tools.
Only strike the driver once. If you strike it more than
once, the stopper ring [6[ may slip out of the groove. If
this happens, remove the ring and bearing , and Install a
new ring.
Make sure that the stopper ring is securely set in the
groove of the gear case.
18-38
FRONT FINAL GEAR ASSEMBLY
DIFFERE NTIAL lOCK SWITCH

SPRING PLUG 12 N'm (1.2 9lbHt)
~
47 N 'm (4.8 kgf 'm, 351bHt)
DIFFERENTIAL LOCK 4WD SELECT
C LUTCH HOUSI NG SWITCH
SEALING 12 N 'm (1.2
FINAL CLUTCH
WASHER - --.l!" D-RING HOUSI NG kgf-m, 91b ttl
STOPPER HALF
SPRI NG
STEEL BALL
~~~~~~~= GEAR CASE COVER
LOCK
J----O-RING SLEEVE
PI NS SEALING
WASHER
25 N m (2.5 kgf'm, ~~~~," -_ _ CLUTCH
SLEEVE PINION BEARING (6206)
181bHt) , IV. RIGHT RING GEAR SHIM
DIFFERENTIAL ~ PINION JOINT NEEDLE LOCK NUT"

BEARING (6009) BEARING (12 x 18 x 12)
PINION NEEDLE f!!

....
~ 49 N 'm (5.0 kgrm, 36 BEARING (15 x 25 x 16)
DIFFERENTIAL
PINION
SHIM
PINION
GEAR
DIFFERENTIAL
RI NG !"
"'.
BEARING (6008)
slip : Q-rings, sealing washers and bearings

GEAR CASE
OIL SEAL
~ : arings and oil seals 'Actual: 98 N 'm (10.0 kgf 'm , 72lbf ft )
Indicated: 89 N 'm (9.1 kgfm. 66lbfft)
PINION GEAR INSTALLATION

Drive the pinion gear assembly [IJ into the gear case .
TOOLS :
Driver [2] 07749-0010000
Attachment, 42 x 47 mm (3) 07746'{)010300 or
011 seal driver attachment 07 JADPH801 01
Fork seal driver body (4) 07747-0010100 or
Fork seal driver, 37 mm 07947-3710101
_ _ 131
141 J
18-39
Install a new lock nut 111 and tighten it.
TOOL:
Lock nut wrench, 07916MB00002 121
30 x 64 mm (21
Refer /0 the Service TORQUE : Actual : 98 N' m (10.0 kgf'm , 721bHt)
....
Infonnetion for Indicated : 89 N'm (9.1 kgf'm, 66 tbHt)
torque wrench !~ {11-
reading information
(page 18-4).
&! careful not to Slake the lock nut into the case groove.
damage the threads
orrha case.
RING GEAR INSTALLATION

Clean the mating surfaces of the ring gear [1] and , - - - - - - - - - - - - - - - - - ,
differential housing [2] thoroughly and install the ring
gear, aligning the bolt holes in the gear and housing.
Install new ring gear bolts [31 and lighten them in a 121
crisscross pattern in several steps.
TORQUE: 49 N' m (5.0 kgf'm , 36 IbHI)
18-40
FINAL GEAR CASE ASSEMBLY
NOTE :
When the gear set. bearing, differential andlor gear
case has been replaced , check the tooth contact
pattern (page 18-32) and check the gear backlash
(page 18-30).
Keep dust and din Clean the mating surface of the gear case and cover,
out of the case and being careful not to damage them.
cover.
Blow compressed air through the breather hole in the
case cover.
Install the proper ring gear shims [1) onto the differential ~::::'111111111111111~~~~~~111111111111=~
assembly. [1J
Inslall the differential assembly (1) into Ihe gear case ___
{2{. ll'iW ~~
Coat a new O-ring [3} with grease and install it into the [3] {11
case cover groove.
Install the case cover (4] over the gear case.
141 121
18-41
It is important 10 Apply locking agent to the threads of the two 10-mm
tum the pinion gear bolts.
while tightening the Install the six bolts and tighten them in several sleps 12]
bolts. If the ring until the cover evenly touches the case. Then, while
gear shim is /00 rotating the pinion gear, tighten the bolts to the
thick, the gears will specified torque in a crisscross pattern in several steps.
lock after only light
TORQUE:
tightening.
10 mm bolt [1] : 47 N'm (4.8 kgf-m, 351bHt)
8 mm bolt [2]: 25 N'm (2.5 kg f-m , 18 lbHtl
Make sure that the gear assembly rotates smoothly
withou t binding.
final clutch housing (page 18-24)
- differentiallockclulch housing (page 18-29)
j
FRONT FINAL DRIVE INSTALLATION
Place the gear case assembly [1) into the frame.
Install the right drive shaft [2] into the gear case 1
(page 18-13). I
j
j
Install a new stopper ring (1) into the groove in the , - - - - - -- - - - - - - - - - -,

Apply mOlybdenum disulfide grease to the seal lip (3) of
the front side boot (4).
....!:!" [3] ~
11]
Make sure the seal lip is not turned outside in .

Apply molybdenum disulfide grease to the front end of
11
~
the propeller shaft.
. I
..
~
[2]
14]
18-42
DR[VE SHAFT/FINAL GEAR
Apply 5 - 8 g of molybdenum disulfide grease to the
pinion joint splines.
Install the propeller shaft into the pinion joint [1],
aligning the splines until the stopper ring seats in the
groove.
Make sure the stopper ring is seated properly by pulling
the propeller shaft lightly.
Install the boot [2] over the pinion JOint groove securely
and the boot bands /3] into the boot grooves.
Coat a new O-ring [4] with molybdenum disulfide
grease and inslailit into the output shaft groove.
Apply molybdenum disulfide grease to the propeller
shaft joint splines.
Move the gear case assembly forward for maximum
clearance between the shaft joint [5] and output shaft
[6[
Engage the shaft joint over the output shaft and move
the gear case assembly rearward.
The mounfing bolts Install the mounting bracket [1] onto the gear case [2]
are installed from with the lower mounting bolt (12 mm) (3J and a new
the left Side mounting nut (41.
Align the upper mounting bolt holes in the gear case
and frame, then install the mounting bolt (12 mm) [5)
and a new mounting nut [61.
Inslailthe two bracket bolls (10 mm) 17],
Tighten Ihe bracket bolts.
Tighten the gear case mounting nuts.
TORQUE : 12 mm nut: 54 N' m (5.5 kgf'm, 40 IbUt)
18-43
Install the holder bracket [1] and cover base (21 wilh the
two bolts [3], and tighten them .
TORQUE : 10 N' m (1.0 kgf' m, 7 lbHt)
Sellhe drive mode selector lever 10 the 2WD position.

tnstali lhe spring [11 onlo Ihe selector cable ]2],
Insert the cable into the cable holder [3] and connect it
to the clu tch arm with the joint pin [4] and adjusting nul
[51.
Set the groove in the cable grommet [6J onto the cover
base end proper1y.
Install the retaining plate [71 onto the cable with the
concave facing the cable holder to secure the cable.
Operate the differenliallQck arm to the upper side to set :;;==;;;;;;;;=~;:;;;;;;;;;;;;;;;;;;; 1

it to the lock free position.
Connect the differential lock cable to the lock arm 11]
and install it into the cable holder [2] by aligning the flat
surfaces.
Install the washer [3] and a new cotter pin [4] .
Make sura that the Screw the cable nuts [5] together gradually (to move
dnWJ mode selector both nuts to the cable holder side) by your hands so
lever is 2WD that the cable is not forced until they are touched to the
position and the cable holder.
differential lock ann Tighten the cable nut while holding the other nut.
is Jock free (upper)
position
Connect the breather hose [1] and the differential Jock

switch connector (2].
18-44
Connect the 4WD select switch connector [1).
- left drive shaft (page 18-13)
- front wheels (page 19-6)
Fill the gear case with the recommended oil
(page 3-13).
Adjust the selector cable (page 18-65).
REAR FINAL DRIVE REMOVAL

Drain the rear final drive oil (page 3-13).
- right rear drive shaft (page 18-8)
- right lower arm (page 19-23)
- rear brake caliper mounting bolts (page 20-20)
- breather hose [1]
- VS sensor 3P connector [2]
Remove the boot bands [1[ and release the propeller ~iii;;
shaft boot [2) off the pinion joint [3) of the gear case.
18-45
Support the gear case with wooden blocks to relieve
stress for ease of bolt removal , and remove the gear
case mounting nuts [1] and bolls [2}.
Release the gear case assembly from Ihe mounting
points by pulling it rearward and disconnect Ihe
propeller shaft [3).
"'''''/t
Hold Ihe inboard joint [1] of Ihe left rear drive shaft and
tug firmly to force the stopper ring [2J on the inboard
joint end past the groove while prying with a
screwdriver.
Move the drive shaft aside and remove the rear final
gear case [3].
Disconnect the universal joint [1) from the output shaft ---~
[2J and remove the Oring [3] .
18-46
Remove the universal jOint (1) and O-ring (2) from the
propeller shaft {3].
121
111
Remove the following from the propeller shaft 111.

(5( (41
- spring [2]
- dust seal [3]
- boot (4]
- boot bands [5]
(3(
INSPECTION
PROPELLER SHAFT
Check the splines (1J of the propeller shaft for wear or
damage. (1 I
If they are damaged, check the pinion and universal
joint splines also.
UNIVERSAL JOINT
Check the boot for cuts or other damage.
Check that the joint moves smoothly without binding or
noise.
18-47
OPERATION CHECK
Turn the pinion joint [1] and check that the gear turns , - - -- - - - - - - - - - - - - - ,
smoothly and quietly without binding.
If the gears do not turn smoothly or quietly, the gears
and/or bearing may be damaged or faulty.
They must be checked after disassembly; replace them
if necessary.
UNIVERSAL JOINT DISASSEMBLYI

ASSEMBLY
Bend up the lock tabs [1] and raise the band ends {211o , - - - - - - - - - - - - - - - , : : - - - - ,
loosen the boot bands.
Remove the joint boot [3].
Apply grease to the joint bearing and boollips.
Inslall the boot and set it onto the universal joint
properly.
Install new boot bands 111 so the band ends are facing ~=================~
opposite the forward direction. Viewed from the rear side:
Bend down each band end [2) and secure it with the
lock labs [31. Tap the lock tabs with a plastic hammer.
Forward directi~
11..._- 13]
12]
e ll]
18-48
REAR FINAL DRIVE DISASSEMBLYI
INSPECTION
BACKLASH INSPECTION
Remove the rear brake disc (page 18-50).
Install the special toot into the pinion joint, and set the
final drive assembly and tool in a vise.
TOOL:
Pinion holder (1) 07SMB-HM70200
Install the drive shaft 121 into the final drive assembly
and hold it.
Set a horizontal type dial indicator on the ring gear [11

through the filler hole.
Turn the ring gear back and forth with the drive shaft to
read backlash .
STANDARD : 0.05 - 0.25 mrn (0.002 - 0.010 in)
SERVICE LIM IT : 0.4 mm (0.02 in)
Remove the dial indicator. Turn the ring gear 120 and
measure backlash.
Repeat this procedure once more.
Compare the difference of the three measurements.
SERVICE LIMIT: 0.2 rnm (0.01 In)
If the difference in measurements exceeds the service

limit, it indicates that the bearing is not installed (21
squarely, or the case is deformed.
Inspect the bearings and case.
If the backlash is excessive, replace the ring gear right
shim (1] with a thinner one.
If the backlash is too small. replace the ring gear right
shim with a thicker one.
Backlash is changed by about 0.06 mm (0,002 in) when
thickness of the shim is changed by 0. 12 mm (0.005 in).
NOTE
Nine dlHerent shims (from A to J) are avaitable in 111
thickness increments of 0.06 mm (0.002 in) ,
Ring gear shims:

A: 1.82 mm (0.072 In) F: 2.12 mm (0.083 in)
B: 1.88 mm (0.074 in) G: 2.18 mm (0.086 in)
C : 1.94 mm (0.076 In) H: 2.24 mm (0.088 in)
D: 2.00 mm (0.079 In) t: 2.30 mm (0.091 in)
E : 2.06 mm (0.081 in)
Change the left shim (21 thickness in an opposite
amount of what the right shim was changed; if the right
shim was replaced with a 0 ,12 mm (0.005 in) thicker
one, replace the left shim with a 0 .12 mm (0.005 in)
thinner one
18-49
FINAL GEAR CASE DISASSEMBLY
Remove the bolts (1] and rear brake disc (2] .
Loosen the cover bolts 11] in a crisscross pattern in ~===============:::;

several sleps and remove them.
Pry the case cover [1] altha prying points 12J using a ~===========I='I====:::;
screwdriver and remove the case cover.
Remove the ring gear (1] and shims 121.
18-50
BEARING INSPECTION
Turn the inner race of each bearing [1] in the gear case
and case cover with your finger. The bearings should
turn smoothly and quietly. Also check that the bearing
outer race fits tightly in the case and cover.
For ring gear bearing replacement (page 18-55).
GEAR TOOTH CONTACT PATTERN

CHECK
KfffJp dust and dirt Clean the mating surfaces of the gear case and cover.
oul of Ihe case and
Apply thin coat of Pruss ian Blue to the pinion gear teeth
colier. for a tooth contact pattern check.
Install the ring gear shims (1J onto the ring gear [21 .
Inslallthe ring gear wi th the shims into the gear case.
ILeftShimJ
Align the boll holes and install the case cover [1].
/I is Important 10 tum Install the cover bolls and tighten them in several steps
the pin/Ofl while until the cover evenly touches the gear case.
lighlenmg the bolts Then. while rotating the pinion gear, tighten the bolts to
If the ring gear the specified torque in a crisscross pattern in several
shims is /00 IhlCk, steps.
the gears will lock
TORQUE :
after only light
tightening
10 mm bolt [2]: 47 N'm (4.8 kgf'm , 35 Ibfft)
8 mm bolt [3] : 25 N 'm (2.5 kgf'm , 18 Ibfft)
131
18-51
NORMAl:
Rolate the ring gear several times in both directions of
rotation.
Check the gear tooth contact pattern through the oil HEEL ~
filler hole. 'N-\
The pattern is indicated by the Prussian Blue applied to TOE
the pinion. ' -;;==;;;J:i-L:;:=~~Br~~, ---_ FACE
Contact is normal if the Prussian Blue is transferred to If.
the approximate center of each tooth, but slighlly to the
heel side and to the flank side.
I?' ~ ~
FACE -
FLANK FLANK
If the pattern are not correct, remove and change the
Drive Coast
pinion shim with one of an alternate thicknes s. side side
Replace the pinion shim [1 J with a thicker one if the ~T:O=H

O ='G:H:'=============~
contact pattern is too high, toward the fa ce.
[1)
FACE I FACE
~~I
Drive side Coast side
Replace the pinion shim [1J with a thinner one if the ~T:O:O:L:O=W='=============~
contact pattern is too low, toward the flank.
The pattern will shift about 0.5 - 1.0 mm (0.02 - 0.04 in)
when the thickness of the shim is changed by 0.12 mm
(0.005 in).
Pinion gear s hims :
A: 1.32 mm (0.052 in) F: 1.62 mm (0.064 In)
B: 1.38 mm (0.054 in) G: 1.68 mm (0.066 In)
IV'[":ll
C: 1.44 mm (0.057 In)
I 11)
0 : 1.50 mm (0.059 in)
E: 1.56 mm (0.061 in)
FLANK FLANK
For pinion shim replacement (page 18-54). Drive side Coast side
PINION GEAR REMOVAL

I
Install the special tool into the pinion joint [1), and set , - -- -- - - - - - - - - - - - - - - ,
the final drive assembly and tool in a vise. 1
TOOL:
Pi nion holder (2) 07SMB-HM70200
Take care nol fa loosen the pinion joint nut [3), and remove the joint nut
drop the final drive and pinion jOint.
assembly from the
Vise.
18-52
Remove the oil seals [1] and Oring [21.
Be carofullhal Unstake the pinion bearing lock nut [1) with a drill or ~=~~~IIiI::;:~~~~~~~,,",~~~
meral particles do grinder.
nor enter the
bearing and rhe
threads of the case
are not damaged
Remove the lock nut using the special tool.
TOOL:
Holding tool 111 Snap-on YA6010A or equivalent
Install the special tools onto the pinion gear shaft and
gear case.
TOOLS :
Pinion puller base 111 07HMCMM80110 or
07HMCMM8011A
(U.S.A . only)
Puller shaft [2] 07931ME40000 or
07931ME4010B and
07931HB3020A
(U.S.A. only)
Puilihe pinion gear assembly out from the gear case.
18-53
PINION GEAR BEARING/SHIM
REPLACEMENT
Pull the pinion bearing [1 ) from the shaft with a , - - - - -- -_ , - - - -- -----,
commercially available bearing puller [2].
Remove the pinion shim 13].
,
,
13J
Inslalithe shim (1] and a new bearing [2) onlo the pinion ~===============~
gear (3).
NOTE: (11
When the gear set, ring gear bearing, andlor gear
case has been replaced, use a 1.50 mm (0.059 in)
thick shim for initial reference.
j
Press the pinion gear (1] in the bearing until it is seated
by supporting the bearing inner race with the special
tool.
TOOL:
Attachment, 25 mm 1.0. [2) 07746-0030200
1854
REAR FINAL DRIVE GEAR CASE
BEARING REPLACEMENT
RING GEAR BEARING
Remove the oil seals (1 ) from the case and cover.
Drive the bearings 121 oul of the case and colier.
Drive each new bearing [1) using the special lools.
TOOLS :
Case cover:
Driver (2J 07749'()010000
Attachment, 62 x 68 mm [3) 07745'()010500
Pilot, 30 mm [4] 07746.(1040700
Gear case: 13VI4j
Driver 07749.0010000
Attachment, 62 x 68 mm 07746.Q010500
Pilot, 30 mm 07746-0040700
Apply grease to new oil seal [1J lips. ~iiiiliil.-;:

Install each oil seal with the metal side facing oul until it
is fully seated .
TOOLS :
Driver, 40 mm 1.0. [2] 07746-0030100
Attachment, 35 mm 1.0. [3J 07746..o03040Q
18-55
PINION NEEDLE BEARING
Remove the stopper ring [1] by rotating it until the end
of the stopper ring appears in the access hole [21.
Strike gently near the end of the ring with a punch to
bend the end upward.
Grasp the end of the ring with needle-nosed pliers and
pull the stopper ring out through the access hole.
Be sure 10 wear Heat the gear case to aOQc (176F) and remove the
heavy gloves /0 needle bearing [3] by using the special tool.
evold bums when
TOOLS :
handling the heated
gear case. Using 8 Remover head, 15 mm
07936KC10200
torch to heat the Remover shaft, 15 mm 07936KC10100 or
gear case may Bearing remover, 15 mm 07936KC10500
cause warpage. (U.S.A. only)
Remover weight 07741-(1010201 or
07936371020A
(U.S.A. only) or
079363710200
(U.S.A. only)
Remove the bearing cage and bearings from the inside
of the pinion bearing to allow the special 1001 to grip the
bearing.
Install a new stopper ring 11] into the groove in a new
bearing 12].
Inslall the bearing into the special tool until the stopper
ring is flush with the end of the tool.
TOOL:
Bea ring c lip compress or, 070MEHN80100 or
25 mm (3] 070MEHN8A100
(U.S.A. only)
Freeze the pinion bearing with the tool on ice or in a

freezer.
Heat the gear case 10 80C (176F).
(31
....
121 ~
Tape the clip

compressor (1J 10
Drive the pinion bearing (2] into the gear case using the
special tools as follows. I:=====~~=jii:====~~=l
the driver fOf
beanng installation . TOOLS:
Driver [3J 079493710001
Attachment, 22 x 24 mrn [4) 07746~010800
Pilot, 15 mm [5] 07746'()040300
Only strike Ihe driver once. If you strike it more than
once, the stopper ring 161 may slip out of the groove.
If this happens, remove the ring and bearing, and install
a new one again.
Make sure that the stopper ring is securely set in the
groove of the gear case.
18-56
REAR FINAL DRIVE ASSEMBLY
RIGHT RING GEAR ......
~
BEARING ~
s., ~ OIL SEAL

GEAR CASE
RING GEAR
SHIM
!II STOPPER RING
~ PINION NEEDLE 25 N'm (2.5 kgf 'm,

~ \ 181bHt)
./
IIIWII BEARING
PINION GEAR ~
SHIM ~0~~(f:,~;;; ,
~
STOP
PIN ----c,f l
PINION /. ~
BEARING
PINION JOINT - --,e,.. SHIM

OIL SEAL
LOCK NUT" ~
..... GEAR CASE COVER
111 '--"
INNER OIL SEAL ~ ~
47 N 'm (4.8 kgf-m .
"1m
........ ..
35 Ib,.ft)
20 N ' m (2.0
OUTER OIL SEAL ~ ~
kgf-m. 1Slbfft)
""iii' .. "Actual: 98 N 'm (IO.O kgf-m, 72lbHt)
BRAKE OISC Indicated: 89 N'm (g.t kgfm. 66lbHt)
PINION JOINT LOCK NUT ~

108N'm(11 .0kgf-m. 80IbHt) ,
18-57
PINION GEAR INSTALLATION
Keep the dOller Drive Ihe pinion gear assembly (1] into the gear case.
centered with the
beanng outer niee
TOOL:
during In$/8118tlOO.
011 seal driver [21 07965-KE80200 (not
available In U.S.A.)
[11
U.S.A. only :
Be sure to wear Freeze the pinion gear and bearing.
heavy gloves /0 Heat Ihe gear case to aoc
(176 F).
avoid bums when Drop the cold pinion assembly into Ihe warm gear case.
handting the healed
gear case. Using a
torch /0 heal/he
gear case may
cause warpage
Install a new lock nul [IJ and l ighten it using Ihe special '--------------:::;;;;;~
1001. I
TOOL:
Holding tool 12] $nap-on YA6010A or equiva lent
Refer to torque TORQUE:

wrench reading Actual : 98 N'm (10.0 kgfm. 721bHt)
informallOTl OIl Indicated : 89 N'm (9.1 kgf' m, 661bHt)
-Service
InfonnallOfl " (page
18-4).
Be careful not /0 Slake the lock nut [lllnlo Ihe case groove.
damage /he threads
aftho case,
1858
Coal a new O-ring [11 with grease and inslall il onto Ihe
pinion gear shaft. ~~
Apply grease 10 the lips of new oil seals. ........ [2]
Inslall the inner oil seal [21 inlo the gear case unlil it Is 10.0 - 10.5mm
10.0 - 10.5 mm (0.39 - 0.41 in) from the top surface of (0.39 - 0.41 in )
gear case.
TOOLS: 14)
Driver [3] 07749.(1010000
Driver attachment [4] 07LAD-PW50500
Inslalilhe ouler oil seal11J mto Ihe gear case until il is

flush wilh Ihe gear case outer surface, using the same
tool.
TOOLS :
Driver (2) 07749.(1010000
Driver attachment [3] 07LAD-PW50500
13)
Clean the threads of the pinion gear shaft thoroughly.

Install the pinion joint [1) onto the pinion gear shaft,
being careful nol to damage the oil seal lips.
Apply locking agent to Ihe threads of the pinion joint nut
12] and screw it in by hand as far as it goes.
Hold the pinion joint with the special tool and tIghten the
joint nut
TOOL:
Pinion holder (31 07SMB-HM70200
TORQUE : 108 N' m (11.0 kgf'm , 80 IbHt)
RING GEAR CLEARANCE

INSPECTION
Inslall the ring gear [IJ with Ihe shIm [2J into the case
cover 13J.
Measure the clearance between Ihe ring gear and stop
pin 14J with a feeler gauge.
CLEARANCE : 0.3 - 0.6 mm (0 .01 - 0.02 in)
18-59
Remove the ring gear.
8& sure to wear tf the clearance is not within specification, heat the case
heavy gloves 10 cover to approximately 80C (176F) and remove the
avoid bums when stop pin [1) by lapping the cover.
handUng the healed
Install a stop pin shim [2] to obtain the correct
case cover. Using a clearance.
torch to heal/he
case cover may STOP PIN SHIMS:
cause warpage. A : 0.10 mm (0.004 In)
8 : 0.15 mm (0.006 In)
Drive the stop pin into the case cover.
FINAL GEAR CASE ASSEMBLY

NOTE:
When the gear set. bearing, and/or gear case has
been replaced , check the tooth contact pattern
check (page 1851).
Check the gear backlash (page 18-49).
Keep dust and dirt Clean the mating surface of the gear case and cover,
out of the case and being careful not to damage them.
cover.
Blow compressed air through the breather holes in the
gear case and cover.
Install the proper ring gear shims (1} onto the ring gear
[2J and install them into the gear case.
18-60
Apply sealant to the case cover [1] mating surtace.
Install the case cover onto the gear case.
Apply locking agent to the threads of the two 10-mm
bolts [2].
It is important to tum Install the cover bolts [3] and tighten them in several
the pinion while steps until the cover evenly touches the case. Then ,
tightening the bolts. while rotating the pinion gear, lighten the bolls to the
If the nng gear shim specified torque in a crisscross pattern in several steps.
is /00 thick. the
gears wi/llock after TORQUE :
only light lightening. 10 mm bolt [2] : 47 N'm (4.8 kgf-m, 351bHt)
8 mm bolt [3] : 25 N 'm (2.5 kgf-m , 18 IbHt)
Check thai the gear assembly turns smoothly without
binding.
Install t he rear brake disc [1].
Install and tighten new brake disc bolts (2]
TORQUE : 20 N' m (2.0 kgf' m , 151bHt)
....!3tJ>." 121
REAR FINAL DRIVE INSTALLATION

Inslall a new dust seal [1] onto the seal groove in the ~-----------------~
propeller shaft [2] in the direction as shown .
Apply molybdenum disulfide grease to the dust seal
lips.
Install the following to the propeller shaft. 151
- boot bands (3]
- boot [41
- spring [5]
111 f1~
Coat a new O-ring [1] with molybdenum disulfide ~==:=:==============;
grease and install it into the groove in the propeller
shaft [2].
Apply molybdenum disulfide grease to the splines of the
both sides in the universal jOint [3J.
Install the universal joint to the propeller shaft until it is
fully seated.
1861
Coat a new O-ring 111 with molybdenum disulfide
grease and install it into the groove in the output shaft
121
Install the universal joint 131 onto the output shaft unlil it
is fully sealed.
Install a new stopper ring [11 into the groove in the

inboard joint splines of the left rear drive shaft.
Place the gear case assembly [11 into the frame.

Be careful not to Install the left rear drive shaft by holding the inboard
damage the 011S6a/ joint [21 until the stopper ring seals in the groove of the
m the gear case. differential.
Make sure thai the stopper ring is seated properly by
Apply 5 - 8 9 of molybdenum disulfide grease to the

pinion toint splines.
Apply molybdenum disulfide grease 10 the splines of the
Connect the propeller shaft, aligning the splines
properly while compressing the joint spring (2J .
18-62
Align the bolt holes and install the mounting bolts [1]
from the right side.
Install new mounting nuts [2J and tighten them .
TORQUE: 44 Nm (4.5 kgf' m, 32 IbHt)
Install the propeller shaft boot [1] onto the pinion joint
[2] of the gear case.
Install the boot bands [3] into the grooves of the boot.

- breather hose [1]
- VS sensor 3P connector [2]
- rear brake caliper mounting bolts (page 20-25)
- right lower arm (page 19-25)
- right rear drive shaft (page 18-13)
Fill the gear case with the recommended oil
(page 3-13).
DRIVE MODE SELECTOR LEVER

LINKAGE
REMOVAL
Sellhe drive mode selector lever to the 2WD position.
- selector lever grip [1] (by pulling up on the grip)
18-63
- cable joint nul [1]
- differential lock cable [2J (1(
- lever pivot nul [31 and bolt [4]
- selector lever [5J
- lever spring [6)
(2]
- arm pivot boll [1]

(2]
- lever arm [21 (from the frame)
- drive mode selector cable [3) (from the arm)
(1
INSTALLATION
Apply grease to Ihe sliding surface of Ihe selector lever
arm pivot bolt [1].
Connect lever arm [2] to Ihe drive mode selector cable
[3] and instalilhe lever arm onto the frame with the pivot (3]
bolt (washer-bolt).
Tighten the pivot boll.
(1]
Apply grease to the groove in the selector lever pivot

bolt (1].
~==========.========~
_ !jjjVp
Install the lever spring (2] onto Ihe selector lever [3) in
the direction as shown.
Instal! the selector lever through the lever gale and onto
the lever arm by setting the lower spring end into the
arm groove as shown. Hold the lever pivot securely to
(2]
align the bolt holes, then install the pivot bolt (socket
bolt).
Install the pivot nut [4J and tighten it. (5]
TORQUE: 26 N'm (2.7 kgf.m, 19 IbHt)

Connect the differential lock cable [5] to the selector
lever from the lower side. Install the jOint nut [6J and ' -_ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _-.l
tighten it.
18-64
Install the lever grip [11 with the tab [2] facmg forward.
Check the selector lever for smooth operation
Perform the cable adjustment if necessary
(page 18-65).
Insta!1 the front hood (page 2-12).
DRIVE MODE SELECTOR CABLE

ADJUSTMENT
- right front wheel (page 19-6)
Set the drive mode selector lever 11] to the 2WD
position.
Remove the bolt 11] and the clutch arm cover 12] by
releasing it from the two labs 13].
loosen the adjusting nul [11 on the drive mode selector ,-----
cable [2J thoroughly until the cable is not forced (to get
the clearance between the jOint pin [3] and upper side
of the arm slot [4]).
131
PI
18-65
Donotloosenthe loosen the lever side cable nuts [1 ) (both lower and
gear case skIe upper) on the differential lock cable [2].
cable nuts,
Tum the ignition Operate the differential lock ann [1] by your hand and
switch to ON (I) and sel it to the lock free position (upper side).
check thai the
differentia/lock
indica/or does not
rome on.
Do not move the

selector lever from
Screw the cable nuls 111 on the differential lock cable
together gradually (to move both nuts to the cable
r==================::;
the 2WD position. holder [2] side) by your hands so that the cable is not
forced until they are touched to the cable holder.
Tighten the cable nul while holding the other nut.
TORQUE: 15 N'm (1 .5 kgf'm, 111bHt)
[2[
18-66
Make sure the selector lever [1] freeplay lengthwise in
the gate [2) at the 2WD and the 4WD position in Ihe
direction as shown .
[11 More Ihan
Make sure the freeplay crosswise at the 4WD and the 2mm (O. 1 in)
4WO-Oiff lock position in the direction as shown.
4WD
More than
2 mm (0.1 In)
More than
More than 2 mm (0.1 in)
2 mm (0.1 in)
4WDDiff
4WD Lock
ii II
"
Set the drive mode selector lever to Ihe 2WD position . ~=================~
Be sure the clutch arm poSition is between the 2WD 131
marks (1] . (Touches
Tum Ihe adjusting nut [2J on the drive mode selector the slol)
cable clockwise until the joint pin [31 just touches the
clutch arm slot (4J with the nut ends (5] contacting the 1I41urn
joint pin (cutout is not seated). Then further turn it , I
clockwise 1/4 of a turn to seat the cutout in Ihe nut onto
the joint pin .
7
"
Make sure that the clearance between the joint pin and
arm slot is 0,25 - 2 mm (0.01 - 0.39 in). [51
0.25 - 2 mm
After adjustment. check the selector lever for smooth (0.01 - 0.39 In)
operation. [41 [21
Install the arm cover [I} by aligning the slits with the ~;;;;r.;;';:;;;"_ii;;;;;;;;"iiii;;;
tabs 12} and tighten the bolt [3] .
TORQUE : 10 Nm (1 .0 kgf'm, 7 lbHt)

- front wheel (page 196)
- front hood (page 212)
18-67
MEMO

19. WHEEUSUSPENSION
SYSTEM COMPONENTS .. .... 19-2 FRONT SUSPENSION ARM 19-15
SERVICE INFORMATION 19-4 FRONT SHOCK ABSORBER 19-20
TROUBLESHOOTING ........... ............... 19-5 REAR WHEEL HUB/KNUCKLE 19-21
WHEELS ... ...... ..... .... ...... .... .. ... ..... ... .. 19-6 REAR SUSPENSION ARM 19-23
TIRES ....... ......................................... 19-6 REAR SHOCK ABSORBER .............. 19-27
FRONT WHEEL HUB/KNUCKLE ..... .... 19-10
19-1
WHEEL/SUSPENSION
SYSTEM COMPONENTS j
FRONT:
,32IbHt) j
~,
34 N'm (3.5 kgf 'm, 251bHt)
44 N'm (4 . 5 ""m., 321bHI)
12 N'm ( 1.2 kg"m, 9lbHt)
11 Nm(1 .1 kgf'm,
8Ibft!)
_~_- ___.-JU-12 N'm (1.2 kgf'm, 9Ibf-ft)
- 65 N'm (6.6 kgf'm, 48 IbUt)
29 N'm (3.0 kgf 'm, 21 Ibfft)
108 N'm (11 .0 kgf'm, 80 Ibfott)
137 N'm (14.0 kgf'm,

101 Ibf"ft)
133 N'm (13.6 kg"m, 981bHt)
19-2
WHEEUSUSPENSION
REAR:
64 N'm (6,5 kgf 'm, 47 IbHt)
34 N' m (3.5 kgfm. 25Ibf'H) \ 34 N'm (3.S kgl'm, 251bHt)
64 N'm (6 .5 kgf-m , 47 IbHt) 64 N-m (6.5 kgf 'm , 471bHt)
46 N'm (4.7 kgfm, 34lbf-ft)
27 N'm (2 .8 kgf-m. 20 IbHt)
137 N'm ( 14.0 kgf-m, 101 Ibfft)
44 N -m (4 .5kgf-m,
321bHt)
~
l 46 N'm (4.7 kgf 'm, 34 Ibf'H)
,~ ~ 133 N'm (13.6 kgf-m , 981bHt)
/
~
64 N'm (6.5 kgfm, 47 1bf tt)
44 N'm (4.S kgfm. 32 Ibf-ft)
193
WHEEUSUSPENSION
SERVICE INFORMATION
GENERAL
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contamina ted disc with a
high quality brake degreasing agent.
A jack or other suppon is required to support the vehicle (page 133).
Do not twist or bend the brake hose and pipe when serving.
Use Honda Genuine replacement bolts and nuts for all suspension pivots and mounting points.
Adjust toe whenever the knuckle or steering gear box components are replaced or removed (page 322).
For brake system service, see Brake System section (page 204).
For steering system service, see Steering System section (page 173).
TOOLS
Attachment, 62 x 68 mm Attachment, 72 )( 75 mm Driver
077460010500 07746-0010600 07749-0010000
Attachment, 28 x 30'Cm
""'m: - - - - - - \ -"F"o"',.-seal driver Oil seal driver attachment
07946-1870100 07947-3710101 07947-6340201
or07AMD-Hl1A100 (U.S.A. only)

ATV Bead Buster Attachment, 62 )( 64 mm Ball joint remover, 28 mm
KlS379024 (U.S.A. only) 07947-6340400 07MAC-Sl00201
or 07AMD-Hl1A100 (U.S.A. only) 07MAC-Sl00202 (U.S.A. only)
19-4
WHEEl/SUSPENSION
Fork seal driver attachment Inner bearing driver attachment Attachment, 52 )( 55 mm
Q7947KA40200 07HMD-MR70100 07746-0010400
~rk seal driver Ball jOint base

07947-4630100 07965-5800300
or 07JAF-S H20200
TROUBLESHOOTING
Wheel wobbling
Benl rim
Worn or damaged knuckle bearing
Faulty tire
Loose wheel hub nut
Loose suspension fasteners
Soft suspension
Weak shock absorber spnng
Oil leakage from damper unit
Stiff suspension
Damaged shock absorber damper
Faulty shock absorber pivot bushings
Improperly installed suspension arms
Faulty suspension arm bushings
Suspension noise
Faulty shock absorber
Loose suspension fasten ers
Worn suspension pivot bushings
Damaged suspension components
Steers to one side or does not track stra ight
Unequal tire pressure
Damaged suspension arm or frame
Worn or damaged knuckle bearing
Weak shock absorber
Incorrect wheel alignment (page 3-22)
Faulty steering system components (page 173)
19-5
WHEEUSUSPENSION
WHEELS
REMOVAL
loosen the wheel nuts (lJ.
Raise the wheels off the ground.
Remove the nuts and wheel.
INSTALLATION
Clean the mating surfaces of Ihe wheel and hub
thoroughly.
Install the wheel and the nuts with the tapered side
facing inward, and lighten them.
TORQUE : 133 N'm (13.6 kgf'm, 98 Ibfft)
TIRES
REMOVAL
NOTE:
This service requires the ATV Bead Busler
(KLS379024).
Remove and inslall the tire from the rim side
opposite Ihe valve stem.
Remove the core from Ihe valve slem.
Use a pneumatic tire changer or equivalent to remove
the tife from the rim. If a tire changer is not available,
rim protectors and tire irons may be used.
Adjust the bottom rim supports PI to the proper rim
size. Align the flat side of the support with the 111
corresponding rim size indicator.
US90nlywarerasa Lube the bead area of the tire with wa ter, pressing
lubncanr when down on the tire sidewalVbead area in several places to
remoVing 01' allow the water to run into and around the bead .
mounting tires.
Soap or soma
mountmg IlIbrlcanrs
maylealla a
sJippery 00
residue whK:h can
calise the tIrO to
shift on the nm and
lose tire pressure
during drilling.
Place the wheel assembly over the center shaft [1J and
use the correct size cone [2] to keep the wheel centered
during operation.
11~ 13J
tnstall the bottom hold down nut [3]. bearing side down.
and finger tighten it so the wheel can rotate freely
during operation.
""
196
WHEEUSUSPENSION
Install the breaker arm assembly (1J over the center
shaft and adjust the upper rim supports 121 to fit the
outside rim diameter.
Install the lop hold down nul [3) and tighten it finger
light.
Failure 10 back out Pull the leverage bar [11 down so the breaker shoe [2] is ~=================::;
the breakershoe just below the rim lip. Turn the crank [3] to fully push the
two turns will cause breaker shoe between the tire bead and rim. Once the 11)
the shoe 10 scratch shoe contacts the rim, back the crank out two turns to
Ihe bead lock, allow Ihe shoe to clear the rim's bead lock.
which may cause
the fire to /eak.
131
121
~=============::-===::;I
1
Push down on the leverage bar [1) to push the tire bead
over the bead lock. Use only short strokes on the
1
handle . While the shoe [21 is still engaged , turn the _ ------1 1
wheel as far as it will go between strokes as you break
the bead around the rim.
Remove the breaker arm assembly and Hip the wheel
over. Install the breaker arm assembly, adjust the shoe
properly and break the other bead by following the
above procedures.
Remove the lire from the rim using a lire changing
machine or tire irons and rim protectors.
19-7
WHEEUSUSPENSION
TIRE REPAIR
NOTE:
Use the manufacturer's instructions for the lire repair
kit you are using . If your kit does not have
instructions. use the procedures described below.
Check the tire for puncturing objects.
Chalk mark the punctured area and remove the
puncturing objects.
Inspect and measure the injury.
Tire repairs for injuries larger than 15 mm (5/8 in)
should be a section repair.
Section repairs should be done by a professional lire
repair shop.
If the injury is smaller than 15 mm (5/8 in). proceed with
the repair as described here.
Install a rubber plug into the injury as follows:

Apply a cement to a plug inserting needle and work the
needle into the injury to clean and lubricate it.
Do this three times.
Do not let the cement dry.
Insert and center a rubber plug through the eye of the
inserting needle.
Apply cement to rubber plug.
Push the inserting needle with plug into the injury until
the plug is slightly above the tire.
Be careful not to Twist the needle and remove it from the tire; the plug
push the plug all the will slay in the tire.
way into the tire fo
prevent from fa/ling
inside.
Trim the plug 6 mm (114 in) above the tire surface.

Repeat the above procedure if the puncture is large.
Do not use more than two plugs per injury.
Allow the repair to dry. Drying time will vary with air
temperature . Refer to the tire repair kit manufacturer's
recommendations.
Inflate the tire and test the seal by dabbing a small
amount of cement around the plug. Escaping air will
cause a bubble in the cement. If there is leakage,
remove the lire (page 19-6) and apply a cold patch to
the inside of the tire.
19-8
WHEEL/SUSPENSION
If a plug has been inserted, trim it even with the inner
lire surface.
Temporarily place a rubber patch that is at least twice
the size of the puncture over the injury. Make a mark
around the patch, slightly larger than the patch itself.
Rough the area marked inside the tire with a tire buffer
or a wire brush. Clean the rubber dust from the buffed
area.
Apply cement over the area marked and allow it to dry

untillacky.
Do not touch the cement with dirty or greasy hands.
Remove the lining from the palch and center over the
injury.
Press the patch against the injury using a special roller.
ASSEMBLY
Instalilhe lire onto the rim, noting the proper direction of , - - -- - - - - - - - -- - - - - - -,
rotation , where the rim shoulder width is the narrowest,
to simplify installation.
Clean the rim bead seat and flanges.
Use only waler as a Apply clean water to the rim flanges, bead seat and
lubricant when base. \
removing or
Install the valve core in the valve stem.
mounting tires.
Install the tire with the arrow mark facing in the normal
Soap or some
rotating direction .
mounting lubricants
Inflate the lire to seal the tire bead .
may leave a
slippery residue Deflate the tire . Wait 1 hour and inflate the tire to the
which can cause the specified pressure.
tire to shift on the
rim and lose air
RECOMMENDED TIRE PRESSURE
pressure dunng FRONT:
dnving. Up to 300 kg (661 Ibs) load:
70 kPa (0.7 kg/cm2, 10 psi)
70 kPa (0.7 kg/cm ~, 10 psi)
REAR:
80 kPa (0.8 kg/cm 2, 12 psi)
120 kPa (1.2 kg /cm 2, 18 psi)
Check for air leaks and install the valve cap.
19-9
WHEEUSUSPENSION
FRONT WHEEL HUB/KNUCKLE j
REMOVAL
- front wheel (page 19-6)
- outboard guard (page 20-8)
- boll 11] and brake hose clamp {2]
- bolt 131 and splash guard [4]
Support the caliper - two mounting bolts \11 and brake caliper [2]
so thaI il does nol
hang from the
brake hoS6 Do 001
twist or bend the
brake hosa.
- cotter pin [11

- hub nut [21
- wheel hub (3]
131
1910
WHEEUSUSPENSION
Remove the cotter pins (1) from the ball joint studs of
the upper and lower arms.
Loosen the ball joint nuts (2] , but do not remove them
yet.
121
To prevent the knuckle from falling, support it with a
strap [1J.
Release the three ball joints, using the special toot
according to the following instructions.
TOOL:
Ball joint remover, 28 mm (2J 07MACSL00201 or
07MAC-5L00202
(U.S.A . only)
Apply grease to the ball jOint remover at the point

Apply here
shown .
This will ease installation of the tool and prevent
damage to the pressure bolt (1) threads.
Insert the jaws carefully, making sure that you do not
damage the ball joint boot.
Adjust the Jaw spacing by turning the pressure bolt. ,
If necessary, apply
penetrating type
lubricant to loosen
the ball joint.
-
1911
WHEEUSUSPENSION
To prevenl lhe tool from dropping. tie the strap (11 on a
neighboring solid part such as the frame pipe. shock
absorber, etc. before operation.
NOTE :
Do not tie the strap on the brake hose , brake pipe.
rubber boot, and other parts that can be damaged
easily.
Once the tool is in place, tum the adjusting bolt [1J as ~=================~
necessary to make the jaws parallel.
Then hand-tighten the pressure bolt [2] and recheck the
jaws to make sure they are stili parallel.
Tighten the pressure bolt with a wrench until the ball
joint stud pops loose .
Remove the ball joint nuts and the knuckle.
PJ
INSPECTION
Remove the dust seals (11 from the knuckle [21.
Turn the inner race of the bearing PI in the knuckle with
your finger. The bearings should turn smoothly and
quietly. Also check that the bearing outer race fils tightly
knuckle.
Inspect the knuckle for damage or cracks.
131 J1 J
BRAKE DISC REPLACEMENT
Remove the four bolts 111 and brake disc [21 from the
wheel hub. 12J
Do not get grease Install a new brake disc with the stamp mark facing the
on the brake disc or
stopping power win
bemduced.
hub.
Install new disc bolts and tighten them.
TORQUE: 42 Nm (4.3 kgfm , 31 IbHt ) ""
1912
WHEEL/SUSPENSION
BEARING REPLACEMENT
Remove the snap ring [1].
Press the bearing [2) out of the knuckle using a suitable
collar.
Carefully press a new bearing in the knuckle with the
marking side facing up until it is fully seated .
TOOLS :
Driver [3] 07749-0010000
A"achment, 62 x 64 mm [4) 07947-6340400 or
07AMD-H L1A100
(U.S.A. only)
Inslall the snap ring into the knuckle groove with the
chamfered side facing in.
INSTALLATION
Install the inner seal Coat the lips of new inner dust seal (1) and Quter dust r-------~
first, then install /he seal [2] with grease and install each dust seal until it is
outer seal. flush with the knuckle, being careful nollo damage the
lip.
TOOLS :
Driver (3] 07749-0010000
Oil seal driver aHachment (4) 07947-6340201 or
07AMO-Hl1A100
(U.S.A. only)
Pack the lip cavities of the each dust seal with 2 .5 - 3 g
of grease.
19-13
WHEEUSUSPENSION
Rout& the brake Install the knuckle (1 J onlo the drive shaft, and lower
hose properly and upper arms wi th the washers [2) and ball joint nuts
(page 117,. (3].
Tighten each ball jOint nut to the specified torque and
further lighten until its grooves align with the colter pin
hole.
J
TORQUE: 29 N' m (3.0 kgf'm , 21 IbHt)
Install new cotter pins (4].
Connect the tie-rod (1] to the knuckle with the ball joint
nut 12].
~==~~~~~~~~=======~
Tigh ten the joint nut to the specified torque.
TORQUE : 65 N' m (6.6 kgf'm, 48 IbHt)
(21
Apply molybdenum disulfide grease to the drive shaft

[1] splines.
Apply 5 mm (0.2 in ) bead of sealant (Threebond TB
1215 or l octile l T5699 or equivalent) to the innermost
threads of the drive shaft (hub nut mounting area).
Install the wheel hub [1 ) to the knuckle and drive shaft.

Install the hub nul [2) and tighten it to the specified
torque and further tighten until its grooves align with the
I ~
....
cotler pin hole.
TORQUE: 137 Nm (14.0 kgf'm, 101 IbHt)
Install a new cotler pin [3].
111
1914
WHEEUSUSPENSION
Install the brake caliper [1J with new mounting bolts [21
and tighten them.
TORQUE: 108 N' m (11 .0 kgf-m , 80 IbHt)
Install the splash guard [1J with a new bolt [2] and :=~IIIIIIIIIIIIIIIIII~:""'=====:--===:
tighten it to the specified torque.
TORQU E: 12 N' m (1 .2 kg f' m, 9 lbHt)

Install the hose clamp [3] with a new clamp bolt [4] and
tighten it to the specified torque.
TORQU E: 12 N' m (1.2 kgf'm , 9lbHt)
- front wheel (page 19-6)
FRONT SUSPENSION ARM

REMOVAL
- front wneel (page 19-6)
Remove the two bolls [1) and brake hose clamps [2}.
Remove the cotter pins PI from the ball joint studs.

Loosen the ball joint nuts [2]. but do not remove them
yet.
19-15
WHEEUSUSPENSION
Loosen the lower and upper arm pivot nuts [1J.
Remove the shock absorber lower mounting nut [2] and
bolt 13).
To prevent the wheel hub/knuckle assembly from
j
falling, hang it with a strap 111.
Release the ball joints, using the special tool according
to the instructions (page 19-11).
TOOL:
Ball joint remover, 28 mm [2] 07MAC-5L00201 or
07MAC-5L00202
(U.S.A. only)
Remove the ball joint nuts (3] . washers (4] and the
wheel hub/knuckle assembly from the arms and drive
shaft, and support it securely.

- pivot nuts [1J, bolts [2] and lower arm [3)
- pivot nuts [4J, bolts [5J and upper arm [6J
19-16
WHEEUSUSPENSION
INSPECTION
Check the upper arm (1] and lower arm (2) for bend ,
crack or other damage.
Check the pivot bushings [3J for wear or damage.
Forballjornr Inspect the ball JOinl boots [4) for lears or other damage
replacement by moving the ball jOint stud .
(page 19-17) II should move freely and smoothly.
[31
BALL JOINT REPLACEMENT
UPPER ARM
Remove the snap ring [1 J from the ball joint [2J.
[11
SUpport the upper arm with the special tool and press ~::::::::;;:;;;;;;;:=::;;;;;;;;;;;;;;:==:::;:===:
the ban Joint [1) oul of the upper arm.
TOOLS:
Attachment, 28 x 30 mm [2J 079461870100
Fork seal driver attachment 07947KA40200
[31
19-17
WHEEUSUSPENSION
Support the upper arm using a special tool as shown.
Press the bal! joint (1) into the upper arm until it is fuUy
seated using special tools.
TOOLS :
Inner driver attachment [2J 07HMD-MR70100
Fork seal driver (3) 07947-3710101
Attachment, 62 x 68 mm [4J 07746-0010500
I NOTICE I
If you feel strong resistance when lowering the press,
stop. Reset the inner driver attachment so the ball jOint
head can go into the hollow of the attachment end try
again.
Install the snap ring [1) With the chamfered edge facing
in.
LOWER ARM
Remove the bool from the ball joint [1}.
Support the lower arm with the special tool and press
the ball joint out of the lower arm.
TOOLS :
Attachment, 52 x 55 mm [2] 07146-0010400
Inner driver attachment [3] 07HMD-MR70100
Ball joint base (4) 07965-5800300 or
07 JAF.sH20200
Support the lower arm with the special tool as shown.

Press the ball joint (1) into the lower arm until it is fully
seated using special tools.
TOOLS :
Attachment, 52 x 55 mm (2) 07746-0010400
Inner drtver attachment (3] 07HMDMR70100
Fork seal drlver (4] 07947-4630100
I NOTICE I
If you feel strong resistance when lowering the press,
stop. Reset the fork seal driver attachment so the ball
joint head can go into the hollow of the seal driver and
try again.
1918
WHEEUSUSPENSION
INSTALLATION
Route the brake Install upper arm [1] and lower arm {2] into the frame
hose property with the pivot bolls [3] and new nuts [4] , and loosely
(page 1-1 7). lighten them .
Insett all/he bolts
from the fronl side.
Install the wheel hub/knuckle assembly onto the drive

shaft and arms, and install the ball joint nuts [lJ and
washers [21 .
Tighten each nut to the specified torque and further
tighten until its grooves align with the cotter pin hole.
TORQUE: 29 N 'm (3.0 kgf'm , 21 IbHt)
Install new cotter pins Pl.
Adjust the suspension arm angle with a jack supporting

the lower arm so that the distance between the centers
of the shock absorber mounting bolt holes is 440 - 448
mm (17.3 -17.6 in).
After adjusting the angle. lighten all the upper and lower
arm pivot fasteners to the specified torque.
440 -448 mm
TORQUE (Upper and lower):
(t7.3-17 .6 in )
34 Nm (3.5 kgfm, 251bHt)
Tighten
Support
1919
WHEEUSUSPENSION
Insertlheboltfrom Install the shock absorber lower mount with the bolt [1 1
the front side. and a new nut [2] . and lighten it to the specified torque.
TORQUE : 44 N'm (4.5 kgf-m, 321bHt)

Inslalilhe hose clamps [3] with new clamp bolts [4) and
lighten them,
TORQUE : 12 N'm (1.2 kgf-m , 9lbHt)
Install the outboard guard (page 20-8)
Install the front wheel (page 19-6).
FRONT SHOCK ABSORBER

REMOVAUINSTALLATION
Raise the front wheels off the ground.
Support the lower arm ,
Remove the mounting nuts Pl. bolts [2] and shock
absorber [3].
Insert the bolfs from Inslalilhe shock absorber with the mounting bolts and
the front side. new nuls, and lighten them.
TORQUE : 44 N'm (4.5 kgf-m, 32Ibf-ft)
INSPECTION
Check the bushings [1) for wear or damage,
Check the damper unit [2] for leaks or other damage.
Replace the shock absorber assembly if necessary.
19-20
WHEEUSUSPENSION
REAR WHEEL HUB/KNUCKLE
REMOVAL
- rear wheel (page 19-6)
- rear shock absorber (page 19-27)
- cotter pin [11
- hub nut 12]
- wheel hub (3)
131
- lower arm pivot nul 111 and boll [2]
- upper arm pivot nut [3] and bolt [4J
- knuckle [5] (from the drive shaft)
INSPECTION
Check the pivot bushings (1] for wear or damage.
Inspect the knuckle [2] for damage or cracks.
Turn the inner race of the bearing [3] in the knuckle with
your finger. The bearing should tum smoothly and
quietly. Also check that the bearing outer race fits tightly
in the knuckle.
19-21
WHEEUSUSPENSION
BEARING REPLACEMENT
Remove the snap ring {1J .
Press the bearing [2] out of the knuckle using a suitable
collar.
Carefully press a new bearing in the knuckle with the
marking side facing up until it is fully sealed.
TOOLS:
Driver [3J 07749-0010000
Atta c hment , 72 x 75 mm [41 07746-0010600
Install the snap ring into the knuckle groove with the
chamfered edge facing in.
INSTALLATION
Apply molybdenum disulfide grease to the drive shaft
splines.
Install the knuckle (1) to the upper and lower arms with
its ~UP mark (2] facing up as shown.
/nserrtheOOlls from Install the pivot bolts 13] and new nuls (4] . then tighten
the rearside. them to the specified torque.
Apply 5 mm (0.2 in) bead of sealant (Threebond TB
1215 or loclile LT5699 or equivalent) to the innermost
threads of the drive shaft (hub nut mounting area).
Install the wheel hub (11 to the knuckle and drive shaft.
Inslall the hub nut {2] and tighten it to the specified
torque, then further lighten until its grooves align with
the coller pin hole.
TORQUE : 137 N'm (14.0 kgf' m , 1011bHt)
Install a new cotter pin {3J.
12J {11
1922
WHEEUSUSPENSION
REAR SUSPENSION ARM
REMOVAL
Support the wheel hub/knuckle assembly securely.
LOWER ARM
- lower arm pivot nut (1] and bolt [2] (knuckle side)
- lower arm pivot nuts [3] and bolls [4] (frame side)
- lower arm [5}
UPPER ARM
- upper arm pivot nut [1] and bolt (2) (knuckle side)
- upper arm pivot nuts PI and bolts [4] (frame side)
- upper arm (5]
STABILIZER ARM AND LINK

- link nuts [1 ) (while holding the stud bolt end)
- stabilizer links [2]
19-23
WHEEUSUSPENSION
- four nuts (11 and bolls [2J
- holders (3J
- stabilizer arm [41
- stabilizer bushings [5J
INSPECTION
Check the upper arm (1] and lower arm [2] for bend,
crack or other damage,
Check the pivot bushings [31 for wear or damage.
For pivot bushing inspection of the knuckle side, see
Rear Wheel Hub/Knuckle (page 19-21 ).
131
Check the stabilizer bushings (11 for wear or damage ,
Check the stabilizer arm [21 for distortion or damage.
Inspect the ball joint boots 131 of the stabilizer link [4) for
lears or other damage by moving the ball joint stud .
19-24
WHEEUSUSPENSION
INSTALLATION
NOTE :
The upper and lower arm pivot fastener lightening is
performed after adjusting the suspension arm angle
(page 19-26),
STABILIZER ARM AND LINK
Install the stabilizer bushings [1[ and holders [2) onto
the stabilizer arm [3).
Install the stabilizer arm onto the frame with bolts [4J
and nuts (5]. Tighten the four bolts while holding the
nuts alternately.
TORQUE : 27 N'm (2.8 kgf-m , 20 IbHt)
The stabilizer links [1 ] have the identification mark:

Left link: L mark [2]
Righi link: R mark (3]
Install the stabilizer Install the stabilizer links with new link nuts [4) and
links with the lighten them while holding the stud bolt end.
identification mark
131
facing up. TORQUE: 46 N-m (4.7 kgf'm , 341bHt)
19-25
WHEEUSUSPENSION
UPPER ARM
Insert the frame Inslall the upper arm [IJ into the frame with the pivot rc="
side PIvot bolts frOm bolts [2J and new nuts (3J.
the inSide of the
,~ .
Insert the knuckle Connect the upper arm to the knuckle with the pivot bolt
side pivot bolt from [4J and a new nut [5] .
the fronl side.
Tighten the fasteners with both the upper and lower
arms installed (page 19-26).
lOWER ARM
Insert the frame Install the lower arm [1 J into the frame with the pivot r;:::::;:;-
side pivot bolts from bolts {2] and new nuts [3].
the inside of the
.~.
Insen the knuckle Connect lower arm to the knuckle with the pivot bolt [4]
Side pivot boll from and a new nut [5),
the front Side
Tighten the fasteners with both the upper and lower
arms installed (page 19-26).
(11
1
SUSPENSION ARM FASTENER TIGHTENING
Adjust the suspension arm angle with a jack supporting , -- - -- -
the lower arm so that the distance between the centers ~
of the shock absorber mounting bolt holes is 409 - 417
mm (16.1-16.4 in).
409-417 mm
After adjusting the angle. lighten all the upper and lower (16.1 _ 16.4 in)
arm fasteners to the specified torque.
TORQUE :
Upper arm pivot nut (frame s ide):
34 N' m (3.5 kgf' m , 25 lbf-ft)
Lower ann pivot nut (f rame side):
64 N' m (6.5 kgf' m, 47 Ibf-ft)
Upper and lower pivot nuts (knuckle side):
t Tighten
J
44 N' m (4.5 kgf'm, 32 lbf-ft)
Support
- rearwheet (page 19-6)
1926
WHEEL/SUSPENSION
REAR SHOCK ABSORBER
Remove the rear wheel (page 19-6).
Remove the link nuts [11 while holding the stud bolt 121
end, and then disconnect the stabilizer link (3J from the
lower arm.
Remove the mounting nuts [1 J and bolts (2] .

Push down the lower arm and remove the rear shock
absorber [3J .
Install the shock absorber in pOSition while pushing
down the lower arm.
Insert the bolts from Install Ihe mounting bolts and new nuts, and tighten
the front side. them.
TORQUE: 64 N' m (6.5 kgf'm, 47 Ibl-tt)
Instailihe stabilizer link [1] with a new link nut [2J and
tighten it while holding the stud bolt [3] end.
TORQUE : 46 N'm (4.7 kgf' m , 341bHt)

Instalilhe rear wheel (page 19-6).
INSPECTION
Check the pivot bushings (11 for wear or damage .
Check Ihe damper unit [2] for leaks or other damage.
Replace the shock absorber assembly if necessary.
19-27
MEMO
I
l
I

20. BRAKE SYSTEM
SYSTEM COMPONENTS " .... ............. ... 20 -2 MASTER CYLINDER ... ... .... ... ........... .. . 20-1 2
SERVICE INFORMATION ...... ...... .. .... 20-4 FRONT BRAKE CALIPER .................... 20 -16
TROUBLESHOOTING .. ........................ 20-5 REAR BRAKE CALIPER .................. .... 20-20
BRAKE FLUID REPLACEMENT/AIR BRAKE PEDAL ................ .. ................ 20-26

BLEEDING ......................................... 20-6
PARKING BRAKE LEVER ...... ...... ...... 20-27
BRAKE PAD/DISC .................. .. .... .. ..... 20-8
20-1
BRAKE SYSTEM
SYSTEM COMPONENTS
14 N'm (1.4 kgf-m, 10 Ibfft )
27 N 'm (2.8 kgf'm, 20 Ibfft)
~
108 N 'm (11 .0 kgf -m, 80 IbHt)
11 N'm ( 1.1 kgf-m, 81bHtJ
I
/ I
~ , I
I
I
~,"Y ~,~@
34 N 'm (3.5 kgfm, 25Ibfft)
20-2
BRAKE SYSTEM
30 Nm (3.1 kgf-m, 22Ibf-ft)
34 N 'm (3.5 kgf-m, 25Ibf-ft)
32 Nm (3.3 kgf-m. 24 Ibfft)
27 N-m (2.8 kgf-m, 20 IbHt)
==
==
20-3
BRAKE SYSTEM
SERVICE INFORMATION
GENERAL
ACAUTION
Frequent inhalation of brake pad dust, regardless of male rial composition could be hazardous to your health.
Avoid breathing dust particles.
Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
NOTICE I
Spilled brake fluid will severely damage the plastic parts and painted surfaces. It is 81so harmful to some rubber parts. Be careful
whenever you remove the reservoir cap.
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads, and clean a contaminated disc with a
high quality brake degreasing agent.
Never allow contaminates (dirt, water, etc.) to get into an open reservoir.
Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid as
they may not be compatible.
Always check brake operation before driving the vehicle.
TOOLS
Lock nut wrench= - - - - - - - - - - , Snap ring pliers
07716-0020100 07914-SA50001
or 07914-3230001
20-4
BRAKE SYSTEM
TROUBLESHOOTING
Brake pedal soft or spongy
Air in hydraulic system
Leaking hydraulic system
Contaminated brake pad/disc
Worn caliper piston seal
Worn master cylinder piston cups
Worn brake pad/disc
Contaminated caliper
Contaminated master cylinder
Caliper not sliding properly
Low brake fluid level
Clogged fluid passage
Warped/deformed brake disc
Stickinglworn caliper piston
Sticking/wom master cylinder piston
Incorrect pedal height adjustment (page 3-16)
Brake pedal hard
Clogged/restricted brake system
Stickinglwom caliper piston
Sl ickinglWorn master cylinder piston
Bent brake pedal
Brake drags
Contaminated brake pad/disc
Badly worn brake pad/disc
Warpedfdeformed brake disc
Cloggedl restricted fluid passage
Sticking caliper piston
Incorrect parking brake adjustment (page 3-17)
20-5
BRAKE SYSTEM
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
BRAKE FLU[D DRA[N[NG
Remove the front hood (page 2-12). 1
Release the parking brake lever. I
Remove the cap cover (1) oul of the reservoir tank. I
Remove the reservoir
counterclockwise.
cap [2) by turning it
I
Remove the bolts (1] and outboard guard [21.
Remove the bleed valve cap (1) . ~=i~~;]~~

Connect the bleed hose [2) to the caliper bleed valve ~
[3[.
Loosen the bleed valve and pump the brake pedal unlil
no more fluid flows out of the bleed valve.
Perform above procedure for each caliper bleed valve.
20-6
BRAKE SYSTEM
BRAKE FLUID FILLING/BLEEDING
Release Ihe parking brake lever.
Close each caliper bleed valve [1).
Fill Ihe reservoir with DOT 4 brake fluid from a sealed
container.
Follow the Connect a commercially available brake bleeder (2J to
manufacturer's the bleed valve.
operating
Operate the brake bleeder and loosen the bleed valve.
instructions.
ChecJ< the fluid level If an automatic refill system is not used , add fluid when
often while bleeding Ihe fluid level in the reservoir is low.
the brake 10 prevent
aJr from being
pumped into the
system.
If air enters the Perform the bleeding procedure until the system is
bleeder from comple tely flushed/bled .
around the bleed
valve threads, seal Tighten the bleed valve.
the threads with TORQUE :
teflon tape. Front : 9 N'm (O.9 kgf-m. 6.6 IbHt)
Rear: 5.4 N'm (0.6 kgf' m, 4.0 IbHt)
Inslallihe valve cap.
Perform the above procedure al each remaining bleed
valve.
After bleeding air, operate the brake pedal. If it still feels
spongy, bleed the system again.
If the brake bleeder is nol available, perform the

following procedure:
Pump up the system pressure with the brake pedal until
the pedal resistance is felt.
Connect a bleed hose [1] to the caliper bleed valve (2]
and bleed the system as follows :
Do nol release the 1. Depress the brake pedal all the way and loosen the
brake pedal until/he bleed valve 1/4 of a turn . Wait several seconds and
bleed valve nas then close the bleed valve.
been Closed.
2. Release the brake pedal Slowly and wait several
seconds after it reaches the end of ItS travel.
3. Repeat the steps 1 and 2 until there are no air
bubbles in the bleed hose.
Tighten the bleed valve.
TORQUE :
Front: 9 N' m (0.9 kgf'm, 6.6 IbUt)
Rear: 5.4 N'm (0.6 kgf'm, 4.0 Ibf-ft)
Install the valve cap
Perform the above procedure at each remaining bleed
valve.
After bleeding air, operate the brake pedal. " it still feels
spongy. bleed the system again.
207
BRAKE SYSTEM
Install the outboard guard (1] and new bolts 12J. then
tighten them.
TORQUE : 11 Nm (1 .1 kgf'm, 8lbHtj
Fill the reservoir to the MAX line (1] with DOT 4 brake , - - - -- --
fluid from a sealed container.
Install the reservoir cap (2] so the arrow [31 is facing
forward.
Tum the cap cover 11] inside out and install it over the ;::=======~'::'~~IIIIIIIIIIII~~~
reservoir cap securely.
PI
BRAKE PAD/DISC
FRONT BRAKE PAD REPLACEMENT
Remove the front wheel (page 19-6).
Remove the bolts 11] and outboard guard [2] .
Remove the lower slide pin bolt [3).
20-8
BRAKE SYSTEM
Pivot the caliper body [11 up and remove the brake pads
[2) from the caliper bracket.
Always rep/aaJ the Install new pads onlo the caliper brackel properly so the
brake pads in pairS wear indicator 13J on the inner pad is facing the lower
to ensure even diSC side.
pressure.
lower the caliper body, install the lower slide pin bolt 11J
and tighlen it.
TORQUE : 23 N'm (2,3 kgfm . 17 IbHt)

Install the outboard guard [21 and new bolts [31, then
tighten them.
TORQUE : 11 N'm (1 .1 kgfm . 8lbHt)
Operate the brake pedal to seat the caliper piston
against the pad.
Install the front wheel (page 19-6).
REAR BRAKE PAD REPLACEMENT

Remove the right rear wheel (page 19-6).
Remove the slide pin bolts 11J.
Remove the caliper body 12] from the caliper bracket.
Remove the brake pads [1 J from the caliper bracket.

Always rep/ace the Install new pad onto the caliper bracket properly so thai
brake pads in pairs the pin (2] on the pad is facing the piston.
to ensure even diSC
pressure.
20-9
BRAKE SYSTEM
Rota te the caliper piston (1] clockwise using the special
tool or equivalent to retract it and align the piston
groove (2) with the index mar1< (3] on the caliper body.
TOOL:
Lock nut wrench 07716-0020100
Install the caliper body (1) over the pads and caliper
bracket, aligning the groove in the piston with the pin on
the pad .
Instal! the slide pin bolts [21 and tighten them.
TORQUE : 32 N' m (3.3 kgf'm, 24 1bHt)
Install the right rear wheel (page 19-6).
Operate the brake pedal to seal the caliper piston
against the pad.
BRAKE DISC INSPECTION

Remove the brake pad (page 208).
Visually inspect the brake disc for damage or crack.
Measure the brake disc thickness at several points.
SERVICE LIMIT :
Front : 10.0 mm (0.39 In)
Rear: 6.0 rnm (0.24 In)
Replace the brake disc jf the smallest measurement is

less than service limit.
20-10
BRAKE SYSTEM
Check the brake disc for runout.

Check the knuckle bearing for excessive play, if the
runout exceeds the service limit.
Replace the brake disc if the bearing Is normal.
Brake disc repl acement:
- front (page 1910)
- rear (page 18-50)
20-11
BRAKE SYSTEM
MASTER CYLINDER
Drain the brake fluid (page 20-6).
Remove the clip (1J and joint pin [2] to disconnect the
push rod (31.
When removmg the Loosen the joint nuts [4] to disconnect the brake pipes
jomt nut. covar the 151
ends of the brake
Remove the two mounting nuts [6J. bolts [7J and master
pipes to prevent
cylinder [61 from the frame .
brake fluKJ lea kage .
Insert the bolts from Install the master cylinder with the mounting bolls and
the pedal side. the nut. aligning the push rod slit with the brake pedal.
Be careful not to Connect the brake pipes to the master cylinder with the
cross-thread the joint nuts.
joint nuts. Tighten the mounting nuts. then tighten the jOint nuts.
TORQUE :
Mounting nut 27 N'm (2.8 kgf' m , 20 IbHt)
Brake p ipe joint nut: 14 N'm (1.4 kgf'm , 10 Ibf-ft)
Connecllhe push rod 10 the pedal wilh the joint pin and
secure il with the clip.
Check the brake pedal height (page 3-16).
Fill and bleed the hydraulic system (page 20-7).
17]
111
121
131
20-12
BRAKE SYSTEM
OISASSEMBL Y
~ boll [1]
- reservoir [2]
- oil seals (31
121
- boot [1] (from Ihe master cylinder body)
- push rod [2] (from the boot)
-
-
-
snap ring 11]
secondary piston assembly [21
primary piston assembly [3]
Clean the reservoir, master cylinder and pistons in
131 I121
clean brake fluid.
INSPECTION
Check the piston cups [4) and boot for wear,
deterioration or damage.
Check the piston springs [51 for damage.
Check the master cylinder and piston for scoring,
scratches or damage. 151
20-13
BRAKE SYSTEM
ASSEMBLY
BOLT
2.5 N' m (0.3 kgf-m , 1.8 IbH!)
RESERVOIR ~
(0.1 g)
SNAP RING
PUSH ROD
~
(0.1 g)
SECONDARY PISTON A
ASSEMBLY
I
Coat the primary piston [1 J. secondary piston (21 and
cups (3J with clean DOT 4 brake fluid.
Do not allow the Install the primary and secondary piston assemblies
t I
pIston cup lips to into the master cylinder.
tum inside oul.
Be certa'n the Sfl8p Install the snap ring (1J into the groove in the master ~;;;;;;;;=============:~
nng IS firmly sealed cylinder with the chamfered edge facing in.
in the groove.
[1[
20-14
BRAKE SYSTEM
If Ihe rod joint [1J of push rod [2J is reinstalled, lighten
Ihe joint to the specified torque.
TORQUE: 17.2 N'm (1 .8 kgf' m , 13 1bHt)
Apply 0.1 9 of silicone grease 10 the boot groove In the

push rod [1]. Install the boot [2] into the boot groov8.
;:===============:---:;
Apply 0.1 9 of silicone grease to the boot groove in the
master cylinder body and to the push rod end.
Install Ihe push rod/boot assembly into the piston and
boot groove in the master cylinder.
Install new oil seals [1] onto the reservoir [2J.

InSlali the reservoir into the master cylinder and secure
it with the bolt 131.
TORQUE : 2.5 N'm (0.3 kgf'm, 1.8Ibfft)
20-15
BRAKE SYSTEM
FRONT BRAKE CALIPER
REMOVAL
Remove the front wheel (page 19-6).
Disconnect the brake hose III by removing the oil boll
[2] and sealing washers [3].
If the brake caliper will be disassembled, loosen the two

slide pin bolts [1].
Remove the two mounting bolts 121 and brake caliper
(31
DISASSEMBLY
Remove the two slide pin bolts [1] and separate the , - - - - - - - - - - - - - -- ----,
caliper bracket [2) from the caliper body.
Remove the brake pads [3}.
121
Release the boot [1] rib from the pin groove and remove
the pin A [21 and pin B [3]. Remove the boots from the
;::===============::;
caliper bracket.
Remove the pad retainers 14].
131
20-16
BRAKE SYSTEM
Place a shop towel over the piston.
Do not use high Position the caliper body with the piston down and
pressure air or bnngapply small squirts of air pressure to the fluid inlet to
the Mule too close remove the piston.
/0 the inlet.
Remove the piston boot [1].
Be careful nolto Push the piston seal [11 in and lift it out.
damage the pis/on
Clean the boot and seal grooves, caliper cylinder, and
sliding surface.
piston with clean brake fluid .
INSPECTION
Check the caliper cylinder and piston for scoring,
scratches or damage.
2017
BRAKE SYSTEM
ASSEMBLY
PIN BOLTS
SLIDE
23 N'm (2.3 kgf'm, 17lbHt) ~ PIN B SliDEPINA ~
(0.4 9
minimum)
CALIPER BODY BOOT
f1I~ CALIPER BRACKET
:III PISTON SEAL

PAD RETAINERS
.....
~ PISTON BOOT
CALIPER PISTON a
~ (O. 6 - 1 .591
Coal a new piston seal [1J with clean brake fluid and , - - - - -- -- - - - - - - - - - ,
..
install it into the seal groove in the caliper cylinder.
Pack the inner and outer edge of a new piston boot [2J
with 0.6 - 1.5 g of silicone grease.
Install the inside boot rib of piston boot into the boot
groove in the caliper cylinder properly.
Coat the caliper piston [3J with clean brake fluid and
place it into the caliper body with the groove side
toward the brake pad. Cover the piston with the boot
carefully, then push the piston and set the outside boot
rib into the boot groove in the piston to seat the piston.
20-18
BRAKE SYSTEM
Install the pad retainers [1] onto the bracket.
III 121 ~
Apply silicone grease to new pin boots [2] and Install
~ ~~
them into the grooves in the bracket.
Apply 0.4 9 minimum of silicone grease to the sliding
area of each slide pin.
~---I,j
Do not Interchange Install slide pin A (3] (flat surface) and pin 8 [4) (round
the pm A endB surface) into the caliper bracket to be sure each boot rib
)
is seated to the boot groove in the pin .
~ I'J ~I
I~============-=====;
Install the brake pads [1) onto the caliper bracket [2) so
the wear indicator [3] on the inner pad is facing the [IJ
lower side.
Inslall the bracket on to the caliper body with the slide 131
pin bolts [4J.
121 1'1
INSTALLATION
Install the brake caliper (I] onto the knuckle With new ...- --
mounting bolls (2), and lighten them
TORQUE : 108 N'm (11 .0 kgf'm, 80 IbHt)

If the caliper was disassembled . tighten the slide pin
bolts {3) while holding the slide pin .
TORQUE : 23 N' m (2.3 kgf' m, 17 IbUt)
Set the hose joJnt Connect the brake hose {11 to the brake caliper With the
Into the stopper oil boll{2) and new sealing washers Pl. and tighten it.
groove {4}
TORQUE : 34 N 'm (3.5 kgf'm , 25 IbHt)
Instalilhe front wheel (page 19-6),
20-19
BRAKE SYSTEM
REAR BRAKE CALIPER
REMOVAL
Remove the right rear wheel (page 19-6).
Remove the adjusting nut (1] and disconnect the
parking brake cable [2] from the brake arm [3).
Remove the cable from the caliper body (4].
Remove the joint pin [5].
Disconnect the brake hose [1) from the caliper body by

removing the oil bolt [2J and sealing washers (3).
If the brake caliper [1] will be disassembled , loosen the

slide pin bolt [2] .
Remove the two mounting bolts [3] and the brake
caliper from the final gear case.
DISASSEMBLY
Remove the slide pin bolt [1] and pivot the caliper body ~----------------
121
I1J
20-20
BRAKE SYSTEM
Remove the brake pads [1J and pad spring [21.
[21
Separate the caliper body [1 J from the caliper bracket ~=================~
[21.
Remove the boots [3] and coilar [4J from the caliper
bracket.
Remove the caliper piston (11 by turning it ~===~;:;;;;;;;;;;;;;;~========;

counterclockwise.
Remove the piston boot [2].
Be careful not 10 Push the piston seal [1J in and 11ft II out
damage the pIs/on
sliding surface
2021
BRAKE SYSTEM
Remove the snap ring [1] using the special 1001.
TOOL :
Sna p ring pliers [2] 07914-5A50001 or
079143230001
Remove the following.

- spring guide (1]
adjusting spring B (2)
spacer [3]
bearing A [4J
adjusting bolt [5J
cup (6)
sleeve piston [7]
rod (8]
D-ring (9)
(71
lSI
(31 PI
- tetum spring [1]
- parking brake arm nut [2]
- spring washer [3]
- brake arm (4)
- brake cam {5]
- dust cover [6]
Clean the disassembled parts in clean brake fluid .
INSPECTION
Check the caliper cylinder and piston for scoring or
other damage.
2022
BRAKE SYSTEM
ASSEMBLY
CALIPER BRACKET BOOTS ...,,~ -=::::., (OA 9

~ ~ mlnlmum)
COLLAR
~
O-RING
SLIDE PIN BOLT
. 32 N'm (3.3 kgf-m,
SLIDE PIN BOLT 241bHt)
~ ~
32 N'm (3.3 kgf-rn. 24 IbHt)
SLEEVE , /
.-'iiSiII OUST C~ ,' PISTON ~ ~, RETAIN~

(0.19)
.-'iiSiII BRAKE CAM -

(0.1 g) BRAKE
~.
n
...
'tj
i
./
~R('~~~ ~ SPRING GUIDE PISTON SEAL
I ~~
liIIii....
ARM
RETURN
- - '--eo"~;Q""~
-.. ~
CUP
~ .-'iiSiII
CALIPER PISTON a
7 .-'i Si11 ~rf
SPRING ~ (0.1 g)
WASHER
(0.4 9
minimum)
~ .-'iiSiII
ADJUSTING SPRING B
ARM NUT
27 N'm (2.8 kgf'm, 20 IbHI) SNAP RING
PISTON BOOT (Seal area: 0.2 g.
fill upO.S-O.7g)
Apply 0.1 9 of silicone grease to the dust cover [II lips

and install it into the caliper body .
Apply 0.1 9 of silicone grease to the brake cam [2]
groove and install it into the caliper body with the
groeve facing the caliper cylinder.
Instalilhe brake arm 13], spring washer [4] and parking
brake arm nut [5).
Tighten the parking brake arm nul.
TORQUE: 27 N 'm {2.8 kgf.m, 20 IbHtj
Install the return spring [6J as shown.
Coat a new O-ring (1J wi th silicone grease and install it

into the sleeve piston (2) groove.
~===============:""
j ..
[1) ~.-'iiSiII
......~
Coat a new cup [3) with 0.1 g of silicone grease and
install it onto the adjusting bolt [4).
Install the adjusting bolt into the sleeve piston.
Coat the rod [5] ends with 0.15 g of silicone grease and
install it into the sleeve piston.
Install the piston assembly in the caliper cylinder by
aligning the pins of the piston with the holes in the ~
r:::::::.,
[51
1 r/ / h cf~
!.,
[3] .... jjiIII ~
[61
tfa. _,)8 J
~,
.-'iiSiII
caliper. I 'if@,~
Apply 0.5 g of silicone grease to the sliding surface of (2) [4] 171 ~
bearing A [61.
Install bearing A. spacer [71. adjusting spring B [8] and
spring guide [9] onto the adjusting bolt. [9]
20-23
BRAKE SYSTEM
Inslall the snap ring (1] using Ihe special tool
TOOL
Snap ring pliers [2] 07914-SA50001 or
079143230001
Coat a new piston seal [1) with clean brake fluid and ~IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII'===========~
install it into the seal groove in the caliper.
Coat the caliper piston [2) with clean brake fluid .
Apply 0.2 9 of silicone grease to the seal area, and 0.5 -
0.7 g to the inside of a new piston boot [3]. 13J ~
Install the piston boot onto the caliper piston .
Install the piston boot into the groove in the caliper.
Install the caliper piston into the caliper cylinder and
~
onto the adjusting bolt by turning it clockwise.
Install the piston boot into Ihe groove in the caliper
piston.
121 1
Apply 0.4 g minimum of silicone grease to the sliding ~===============!
==~==~
area of new boots [1) and install them into the caliper ~ .......
bracket.
Inslalilhe collar (2) into the caliper bracket. ~
Coal Ihe slide pin [3) of the caliper body with 0.4 9
minimum of silicone grease and install it into the caliper
bracket.
Install the pad spring [1) in the caliper body as shown.

Inslalilhe brake pads [2] onto Ihe caliper bracket.
Align the piston groove with the index mati<
(page 20-9).
2024
BRAKE SYSTEM
Pivot the caliper body [1) over the pads and bracket.
Temporarily install the slide pin bolt (2).
121
INSTALLATION
Install the brake caliper [1] wilh new mounting bolts [2]
and tighten them.
TORQUE : 30 Nm (3.1 kgf' m, 22 IbHt)

If the brake caliper was disassembled, tighten the slide
pin bolt 131.
TORQUE : 32 N' m (3.3 kgf' m, 24 IbHt)
Connect the brake hose [1) to the brake caliper with the
oil bolt [2) and new sealing washers [3J, and tighten the
oil bolt.
TORQUE : 34 N'm (3.S kgf' m , 25 IbHt)
Install the pa~ing brake cable 111 into the caliper body
(2) and connect It to the brake arm [3] with the joint pin
141-
Install the adjuSling nut [51.
Adjust the par1<ing brake lever freeplay (page 3-17).
Install the right rear wheel (page 19-6).
20-25
BRAKE SYSTEM
BRAKE PEDAL
REMOVAL
Unhook the return spring 11J and switch spring [21 from
the brake pedal [3].
Remove the clip [4] and joint pin 15] to disconnect the
push rod 16].
Do not fr:Kce the Remove the two nuts [71. two upper bolts (8J, two lower
master cylInder bolts (9], and the brake pedal assembly.
after removing the
brake pedal INSTALLATION
assembly or the Install the brake pedal assembly with the four bolls and
brake pipes will be two nuts, aligning the pedal arm with the push rod slit.
deformed. Tighten the fasteners alternately.
TORQUE: 27 Nm (2.8 kgf'm, 20 IbHt)
Connecllhe push rod to the pedal with the jOint pin and
secure it with the clip.
Hook the relum spring and switch spring.
Check the brake pedal height (page 3-16),
DISASSEMBLY
- cotter pin [1 J and washer [2J
- pivot shaft [3J
- brake pedal [4]
- dust seals [5J
131
20-26
BRAKE SYSTEM
ASSEMBLY
Coat the lips of new dust seals [1J with grease.
Install the dust seals into the brake pedal (2] with the flat
side facing oul until they are fully sealed.
Apply grease to the groove in the pivot shaft [3J.
Install the brake pedal into the bracket [4] by inserting
the pivot shaft from the left side, and align the flat
surfaces of the shaft and bracket. ....
~~
[1 )
Install the washer (5) and a new cotter pin [6].
[4[
PARKING BRAKE LEVER

REMOVAUINSTALLATION
Remove the left front fender (page 2-13).
Release the parking brake. [4J
Disconnect the parking brake switch 2P (black)
connector [1J.
Remove the nuts (2], bolts [3] and parking brake lever
[4] from the frame.
Remove the lever boot [5].
Remove the cotter pin [6], washers [7] and joint pin [8],
then disconnect the parking brake cable [9J from the
lever.
Route the switch Installation is in the reverse order of removal.
7~~;ro::~~r Inspect the parking brake lever freeplay (page 3-17).
[5)
[3)

2027
MEMO

21. BAITERY/CHARGING SYSTEM
COMPONENT LOCATION .. .. .. ............. 212 BATIERY .... .. .. .. .. .. ...... .. .... .. 21-4
SYSTEM DIAGRAM ............................. 212 CHARGING SYSTEM INSPECTION ........ 215
SERVICE INFORMATION ......... .... ......... 213 ALTERNATOR CHARGING COIL .. .. .... .. . 216
TROUBLESHOOTING ...................... .. .. 21-4 REGULATORJRECTIFIER .......... .. ........ 21 6
21-1
BATIERY/CHARGING SYSTEM
COMPONENT LOCATION
BATTERY
MAIN
REGULATOR/RECTIFIER
ALTERNATOR
SYSTEM DIAGRAM
G: Green
R:Red
MAIN FUSE (40 A) Y; Yellow
81: Black
,-- R ---o...ro- R - - - ,
y y y
y Y Y R G R
I I I I I
r'---L-- -'-L] .,
o e
ALTERNATOR
REGULATOR/RECTIFIER BATTERY
21-2
BATTERY/CHARGING SYSTEM
SERVICE INFORMATION
GENERAL
"WARNING
The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when
charging.
The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing
and a face shield.
- If electrolyte gets on your skin. flush with water.
- If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
Electrolyte is poisonous.
- If swallowed , drink large quantities of water or milk and call your local Poison Control Center or a physician immediately. I
NOTICE
Always tum OFF the ignition switch before disconnecting any electrical component.
Some electrical components may be damaged if tenninals or connectors are connected or disconnected while the ignition switch
is ON and current is present.
For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space,
For a battery remaining in a stored vehicle, disconnect the negative battery cable from the battery,
The maintenance free battery must be replaced when it reaches the end of its service life,
The battery can be damaged if overcharged or undercharged, or if lett to discharge for long period, These same conditions
contribute to shortening the "life span" of the battery. Even under normal use, the performance of Ihe battery deteriorates after
2-3 years.
Battery voltage may recover after battery charging. bul under heavy load. the battery voltage wiJJ drop quickly and eventually die
out. For this reason, Ihe charging system is often suspected as the problem. Battery overcharge often results from problems in
the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage
does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte leve)
goes down quickly.
Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is
frequently under heavy load. such as having the headlight and taillight on for long periods of time without driving the vehicle.
The battery will self-discharge when the vehicle is not in use. For this reason, charge the battery every two weeks to prevent
sulfation from occurring.
Filling a new battery wilh electrolyte will produce some voltage, but in order to achieve its maximum performance. always charge
the battery. Also, the battery life is lengthened when il is initially charged.
When Checking the Charging system, always follow the steps in the troubleshooting (page 21-4).
Alternator removaVinstaliation (page 12-5).
BATIERY CHARGING
Tum power ON/OFF at the charger, nol at Ihe battery terminal.
For battery charging, do not exceed the charging current and time speCified on the battery, Using excessive current or extending
the charging time may damage the battery,
Quick charging should only be done in an emergency; slow charging is preferred.
BATIERY TESTING
Refer to the instructions in the Operation Manual for the recommended battery tester for details about battery lesting . The
recommended battery tester puts a "load" on the battery so that the actual battery condition can be measured.
RECOMMENDED BATIERY TESTER: Micro 404XL (U.S.A, only), BM-210 or equivalent
TOOLS
Motorcycle battery analyzer Christie battery charger
Micro 404XL (U.S.A. only) MC1012/2T or Tecmate PRO 4
(U.S.A. only)
or BM-210

I 21-3
TROUBLESHOOTING
2. higher than specified value

switch
Sh"ri,,,, ,v;re harness
3. Faulty alternator charging coil
4. Faulty regulator/rectifier
5. circuil or
BATTERY
REMOVAUINSTALLATION
Remove the front seal cushion (page 24).
With the ignition switch turned to OFF (0). disconnect
the negative H cable [1) first, then disconnect the
positive (+) cable [2] by removing each terminal bolt [3].
Remove the battery holder band {4] .
Remove the battery [51.
Connect the Installation is in the reverse order of removal.
positive (+) cable
first and then the
negative (-) cab/e.
VOLTAGE INSPECTION
Measure the battery voltage using a commercially
available digital mullimeter.
VOLTAGE (20C/68F): FuUy charged : 13.0 - 13.2 V
Under c harged: Below 12.3 V
BATTERY TESTING
Remove the battery (page 21-4).
Refer to the instructions that are appropriate to the
battery testing equipment available to you.
TOOL:
Battery tester Micro 404Xl (U.S.A. only),
BM210 or equivalent
BATIERY CHARGING (U.S.A. only)

Remove the battery (page 21-4).
Refer to the instructions that are appropriate to the
battery charging equipment available to you.
TOOL:
Christie battery charger MC1012/2T or
Tecmate Pro 4
(U.S.A. only)
21-4
BATTERY/CHARGING SYSTEM
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION
With the ignition switch turned to OFF (0). disconnect
the negative H cable [1J from the battery.
Connect the ammeter (+) probe [2] to the negative (-)
cable and the ammeter (-) probe [3]10 the battery (-)
terminal (4].
With Ihe ignition switch turned to OFF (0), check for
current leakage.
NOTE :
When measuring current using a lesler, set it to a
high range, and then bring the range down to an
appropriate level. Current flow higher than the range
selected may blow Ihe fuse in the tester.
While measuring current, do not turn the ignition
switch to ON (I). A sudden surge of current may
blow the fuse in the lester.
SPECIFIED CURRENT LEAKAGE : 0.1 rnA maximum
If current leakage exceeds the specified value, a

shorted circuit is likely.
Locate the short by disconnecting connections one by
one and measuring the curren!.
CHARGING VOLTAGE INSPECTION

Be sure the battery is in good condition before
performing this test.
Warm up the engine to normal operating temperature,
Connect the multimeter between the battery positive (+)
and negative (-) terminals.
NOTE :
To prevent a short, make absolutely certain which
are the positive (+) and negative (-) terminals or
cables.
Do not disconnect the battery or any cable in the
charging system without first switching off the
ignition switch. Failure to follow this precaution can
damage the tesier or electrical components.
With the headlights on , measure the voltage on the
multimeier when the engine runs at 5,000 rpm.
STANDARD: Measured BV < Measured CV < 15.5 V
BV = Battery voltage (page 21-4)
=
CV Charging voltage

21-5
ALTERNATOR CHARGING COIL
INSPECTION
Remove the alternator/CKP sensor 5P (black)
connector 11] from the stay and disconnect it.
Check the oonnector for loose contacts or corroded
terminals.
Measure the resistance between the Yellow wire
tenTIinals of the alternator side connector.
STANDARD : 0.1 -1.0 n (20 ~C/68 F)
Check for continuity between each Yellow wire terminal

of the alternator side connector and ground.
Replace the alternator stator if resistance is out of
specification , or if any wire has continuity to ground.
Alternator stator replacement (page 12-5).
REGULATOR/RECTIFIER
WIRE HARNESS INSPECTION
Disconnect the regulator/rectifier 3P (black) connector
[1] and 3P (gray) connector [21.
Check the connectors for loose contacts or corroded
terminals.
Check the following at the wire harness side
connectors.
Battery Une:
Measure the voltage between the Red wire terminal
and ground.
There should be battery voltage at all times.
Ground Une:
Check the continuity between the Green wire
terminal and ground .
Charging Coil Une:
Measure the resistance between the Yellow wire
terminals.
STANDARD : 0.1 - 1.0 0 (20C/68F)
Check for continuity between each Yellow wire

terminal and ground.
REMOVAUINSTALLATION
Disconnect the regula tor/rectifier 3P (black) connector
(1) and 3P (gray) connector {2) .
Remove the two bolts (3) and regulator/rectifier [4).
216
22. LIGHTS/METERS/SWITCHES
COMPONENT LOCATION 22-2 HEADLIGHT SWiTCH 22-10
SERVICE INFORMATION 22-2 HEADLIGHT RELAY 22-10
HEADLIGHT ... ........ ........ ... .... .. 22-3 COOLING FAN MOTOR 22-12
BRAKEITAILLlGHT 22-4 FUEL METERIFUEL LEVEL SENSOR 22-14
COMBINATION METER 22-4 BRAKE LIGHT SWITCH 22-15
ACCESSORY SOCKET ...................... .. 22-8 PARKING BRAKE SWITCH 22-16
IGNITION SWITCH ............................... 22-9
22-1
COMPONENT LOCATION
COMBINATION METER
HEADLIGHT RELAY
HEADIL IGHl SWITCH
~=:::==:::;:ry~~~\e~~~iib'7~~'---- IGNITION SWITCH
FUEL LEVEL SENSOR

LIGHT SWITCH
ACCESSORY SOCKET
SERVICE INFORMATION
GENERAL
I NOTICE
Note the following when rep/acing the halogen headlight bulb.
- Wear clean gloves while replacing the bulb. Do not put fingerprints on the headlight bulb, as they may create hot spots on the
bulb and cause it to fail.
- If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure.
A halogen headlight bulb becomes very hot while the headlight is on , and remains hot for a while after it is turned off. Be sure 10
let it cool down before servicing.
All plastic connectors have locking tabs that must be released before disconnecting , and must be aligned when reconnecting.
To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually be
made without removing the part from the vehicle. Simply disconnect the connectors and connect a continuity tester to the
terminals or connections.
TOOL
Test probe, 2 pack
Q7ZAJRDJA11Q
22-2
HEADLIGHT
BULB REMOVAL/INSTALLATION
Remove the headlight cover cap [1] .
Disconnecllhe headlight 2P connector (21.
Remove the headlight bulb (3] by turning it clockwise for
the len headlight and counterclockwise for the right
headlight.
I NOTICE I
Avoid touching a halogen headlight bulb. Fingerprints
can create hot spots that cause 8 bulb to fai/.
Align the bulb tabs Installation is in the reverse order of removal.
with the headlll}hl 121
grooves properly.
131
- headlight bulb (page 22-3)
- four tapping screws (1]
- boll 121
- wire band [3]
- headlight assembly [4J
- adjusting screw (1]

- washer (2]
- nut [3J
- spring [4]
- headlight unit [5] from the cover [6] by releasing the
bosses 71 from the holes
161
223
Install the headlight unit in the reverse order of removal.
After installing the headlight, align the index marl< on
Ihe headlight with the lop of the tab on the cover by
turning Ihe adjusting screw [lJ .
BRAKEITAILLIGHT
Remove the screws [1] and brake/taillight unit [2].
Disconnect the 3P connector [3] from the brake/taillight.
Remove Ihe well nuts [41.
COMBINATION METER
REMOVAUINSTALLATION
Remove Ihe left front fender (page 2-13).
Release the harness clamp [1] .
Remove the four screws [21 and combination melerfrear
cover assembly (3).
Remove the three screws 11] and combination meter [2]

from the meter rear cover [3).
131
22-4
pun back the connector boot 111 and disconnect the
combination meter 16P connector [21.
Installation is in the reverse order of removaL
TORQUE :
Combination meter mounting screw :
0.8 N'm (0.1 kgf'm , 0.6 IbUt)
DIGITAL CLOCK ADJUSTMENT

Turn the ignition switch to ON.
Push the mode switch {1] until the display enters the
clock mode.
Press and hold the mode switch. The clock will start
blinking.
Press and hold the mode switch until the desired time
appears.
To end the adjustment. push the mode switch, or turn
the ignition switch to OFF.
(1 J
POWER/GROUND LINE INSPECTION

Disconnect the combination meter sub harness 1QP
(gray) connector (1J.
Check the power and ground lines at the wire harness
side connector.
POWER INPUT LINE

Measure the voltage between the Black/red wire
terminal (+) and ground (-). Black/red
There should be battery voltage with the ignition switch
turned to ON (1).
If there is no voltage. check the following:
- Black/red wire between the combination meter and
main relay for an open circui t
- main relay and its circuit (page 7-13)
22-5
GROUND LINE
Check for continuity between the Green wire terminal
and ground . Green
If there is no continuity, check for an open circuil in the
~~"
Green wire.
SERIAL COMMUNICATION LINE

Gear position indicator continuously blinks " ", all
segments of coolant temperature gauge blink, and
MIL remains ON .
1. PCM Power Input Check
Check thai the engine can be started normally,
Does the engine s tart?
YES - GO TO STEP 2.
NO - Check the PCM power/ground line
(page 428).
2. Connector Check
Check the combination meter sub harness 10P
(gray) connector and PCM 33P connectors for loose
contacts or corroded terminals.
Are the connectors in good condition?
YES - GO TO STEP 3.
NO - loose or poor contacts at the combination
meter sub harness 10P (gray) connector or
PCM 33P connector.
3. Combination Meter Serial Line Short Circuit
InspectIon
Turn the ignition switch to OFF.
Disconnect the PCM 33P (black) connector and
combination meter 1OP (gray) connector.
Check. for continuity between the wire harness side
lOP (gray) connector terminal and ground .
Connec tion : Blue/red ground
YES - Short circuit in the Blue/red wire.
NO - GO TO STEP 4.
Blue/red
22-6
4. Combination Meter Serial Line Open Circuit
Inspection
Check the Blue/red wire for conllnuity between the , -- - - - -- - - -- - - - - - - ,
.
wire harness side 33P (black) connector and 10P Blue/red
(gray) connector terminals .
TOOL: /
Test probe, 2 pack 07ZAJ-ROJA 110
,
Is there co ntinuity?
YES - GO TO STEP 5.
NO - Open circuit in the Blue/red wire.
Blue/red (A21)
-@
5. PCM Circuit Inspection
Connect the PCM 33P (black) connector.
Green
Turn the ignition switch to ON and wait 5 seconds or I
more. Measure resistance at the combina tion meter
sub harness lOP (gray) connector terminal.
Connection: Blue/red - Green
Is the resistance 0.1 - 100 kO?

YES - Replace the combination meIer with a Bluelred
known good one, and recheck.
NO - Replace the PCM with a known good one,
and recheck.
SPEEDOMETER
Speedometer does not operate
1. Combination Meter Power/Ground Line
Inspection
Check the odometerllrip meter and meter indicators
functions.
Do they (unction properly?
YES - GO TO STEP 2.
NO - Check the combina tion meter power/
ground lines (page 22-5).
2. Drivetrain System DTC Inspection
Check the drivetrain system DIC (page 16-12).
YES - Perform the DTC 11-1 troubleshooting
(page 4-19).
NO - GO TO STEP 3.
22-7
3. Speedometer Line Open Circuit Inspection
Disconnect the combination meter sub harness lOP
(gray) connector (page 22-5),
Disconnect the VS sensor 3P connector [I ) (located
on the rear final drive gear case).
Check the Pink wire for continuity between the
combination meter sub harness tOP (gray)
connector and VS sensor 3P connector terminals.
YES - Replace the combination meter
(page 22-4).
NO Open circuil in the Pink wire .
loose or poorly connected related
connectors.
Pink
Pink
-@
ACCESSORY SOCKET
INSPECTION
Disconnecllhe accessory socket 2P (green) connector
11 J.
Measure the voltage between the Whitelblack (+) and
Green (-) wire terminals of the wire harness side 2P
(green ) connector.
There should be battery voltage with the ignition switch
turned to ON (I).
If there is no voltage, check for blown ACC fuse (10 A)
and an open drcuit in the wire harness.
Remove the accessory socket cap [1].

Check for continuity between the White/black wire
terminal of the socket side 2P (green) connector and
bottom center terminal 121 of the socket, and between
the Green wire terminal and side wall terminal [3].
If there is no continuity, check the sub harness for open
circuit.
If the sub harness is OK, replace the accessory socket.
22-8
[2J
Disconnect the 2P (black) connector [1J from the
accessory socket.
Remove the accessory socket nut [2] .
(1/
11J
Remove the accessory socket (1J from the instrument
panel.
tnstali l he accessory socket by aligning the lug with the
groove in the instrument panel.
removal.
IGNITION SWITCH
INSPECTION
Disconnect the ignition switch 5P (black) connector [1].
Check for continuity between the connector terminals in
each switch position according to the continuity chart
(page 23-2).
Disconnect the ignilion switch 5P (black) connector
(page 22-9).
Remove the ignition switch nut [1) and ignilion switch [2]
from the instrument panel.
Install the ignition switch into the instrument panel by
aligning the fla t surfaces.
Inslallthe ignition switch nut and tighten it.
TORQUE : 4.9 Nm (0.5 kgfm , 3.6 IbHt )
Connect the ignition switch 5P (black) connector.

Install the front hood (page 2.12).
229
HEADLIGHT SWITCH
INSPECTION
Disconnect the headlight switch 2P (black) connector
[11
Check for continuity between the switch side connector
terminals.
The switch is normal jf there is continuity only when the
switch is turned to ON (I).
Disconnect the headlight switch 2P (black) connector
(page 22-10).
Release the hooks 111 and remove the headlight switch
(2) from the instrument panel.
HEADLIGHT RELAY
Remove the relaylf1lse box cover (page 6-9).
Tum the ignilion switch to OFF (0).
Remove the headlight relay [11 from the connector.
2210
RELAY INSPECTION
Remove the headlight relay (page 22-10).
Check for con tinuity between the No. 1 and No. 2 No.2 No.1
terminals.
Connect the fully charged 12-V battery (+) terminal to
the relay No. 41erminal and the (-) lerminallo the No. 3
terminal.
There should be con tinuity when the battery is
connected, and no continuity when the battery is
disconnected.
No. 3 No. 4
HEADLIGHT RELAY CIRCUIT

INSPECTION
Remove the headlight relay (page 22-10).
Turn the ignition switch to ON (I). 111
Measure the voltage between the Brown wire
terminal (+) of the headlight relay connector [11 and Brown (+)
ground (-).
YES
NO
- GO TO STEP 2.
- ' Open circuil in the Brown wire between
~~~ffi'V l
the relay connector and fuse box
Blown LIGHT fuse (15 A)
Open circuit in the Redlblack wire
between the fuse box and ignition
switch
2. Relay Coli Ci rc u it Inspection

Turn the ignition switch and headlight switch to ON .
Measure the voltage between the Whitelblack (+) 111
and Green (-) terminals of the headlight relay
connector [1].
Is th ere ba ttery voltage?
W",elblaok \-+--+-- ,0( Green (-)
YES - The headlight relay circuits are normal.

NO Open circuit In the White/black wire
between the headlight switch and relay
connector
ffi e
Open circuit in the Green wire between
the relay connector and ground
Faulty headlight switch
Open circuit in the Brown wire between
the headlight switch and fuse box L _ _ _ _ _ _ __ _ __ _ _ _ _ _ _--'
22-11
COOLING FAN MOTOR
SYSTEM INSPECTION
Cooling fan motor does not start
1. Fuse Inspection
Remove the fuse/relay box cover (page 6-9).
Check the FAN fuse (15 Al.
Is the fuse blown ?
YES - Replace the FAN fuse.
NO - GO TO STEP 2.
2. PGMFI System OTe Inspection
Check the PGMFI system DTC (page 4-7).
Is DTe 71 and/or 72 Indicated?
YES - Perform the DTC 7-1 troubleshooting
(page 4-12),
Perform the DTC 7-2 troubleshooting
(page 4-13),
NO - GO TO STEP 3.
3. Ground Line Inspection
Remove the front seat cushion (page 2-4),
Disconnect the PCM 5P (black) connector (1] .
Check for continuity between the Green wire , - - - - - - - - - - - - - - - - - - - ,

terminal of the wire harness side 5P (black)
connector and ground.
YES - GO TO STEP 4 .
NO - Open circuit in the Green wire.
1
Green
2212
4. Cooling Fan Motor Operation Inspection
Connect the Greenlblack and Green wire terminals
of t he wire harness side SP (black) connector with
the jumper wire [1]. Green/black
Turn the ignilion switch to ON (I) and check the
cooling fan.
Does the cooling fan start?
YES - Replace the PCM wIth a known good one,
and recheck.
NO - GO TO STEP 5.
Green
111
5. Cooling Fan Motor Ground Line Inspection
Disconnect the cooling fan 2P connector.
With the jumper wire connected to the PCM 5P

(black) connector, check for continuity between the
Green/black wife terminal of the wire harness side
2P connector and ground,
YES - GO TO STEP 6.
NO - Open circuit in the Greenlblack wire.
Green/black
6. Cool ing Fan Motor Power Input Line Inspection

Measure the voltage between the Blue wire terminal
(+) of the wire harness side 2P connector and
ground (-).
Is there battery voltage ?
YES - Replace the cooling fa n motor with a new
one (page 9-10).
NO - Open circuit in the Blue wire between the
cooling fan and fuse box.
22-13
FUELMETE~FUELLEVELSENSOR
I
FUEL METER INSPECTION
If the fuel meier 111 indicates the blinking pattern as r I-'-J - - - - -- - - - -- - -- - - - ,
shown when the ignition switch is turned to ON, perform '-
the following inspection . "'"
I
I
Disconnect the combination meter sub harness lOP
(gray) connector (page 22-4).
Disconnect the fuel pump 4P connector (page 7-5),
Check for continuity between the combination meter
10P (gray) connector 12] and fuel pump 4P connector
[3] of the wire harness side.
CONNECTION: White/blue - White/b lue
Light blue - Ught b lue
If there is no continuity, check for open circuit in Whilel 12J
blue or Light blue wire and loose contact of the wire ~ Whitel
harness connectors. blue
Check for continuity between the combination meier
sub harness lOP (gray) connector and ground 13J

CONNECTION: White/blue - Ground
@
If there is con tinuity, check for short drcui! in Whilelblue Light blue
wire.
If the wires are OK, check the fuel level sensor
(page 22-14).
If the fuel level sensor is OK, replace the combination
meter.
Whitelblue , - - - {
12J
FUEL LEVEL SENSOR INSPECTION
1\1)
Remove the fuet pump (page 7.10).
Measure the resistance between the connector
terminals [1] at the float upper (full) and lower (empty)
positions.
(20 C/B8 FI
FLOAT FULL EMPTY
POSITION
RESISTANCE 85.3 - 101 .3 0 628.5 - 752.5 0
Replace the fuel level sensor (page 22-15) if it is out of
specification.
FULL
EMPTY
22-14
FUEL LEVEL SENSOR REMOVAU
INSTALLATION
Remove the fuel pump (page 7-10).
Disconnect the fuel level sensor connector [1].
Release the wires from the hooks (2).
Unhook and remove the fuel level sensor [1] by sliding it

upward.
Install the fuel level sensor by aligning its slot with
the pump tab and slide it down until it is fully locked.
BRAKE LIGHT SWITCH

Disconnect the brake light switch 2P (gray) connector
and [11 release the wire from the two wire clips [2].
Unhook the brake light switch spring [3] and brake
pedal return spring [4] from the brake pedal and brake
light switch [5].
Remove the brake light switch from the stay of the
frame.
Route the brake Installation is in the reverse order of removal.
light sWitch wire
After installing the brake light switch, adjust it
properly
(page 3-15).
(page 1-17).
[4[
13[ lSI /
2215
INSPECTION
Check the foot brake pedal height and adjust it if ,--- - - - - - - - - - - - - -- - - ,
necessary (page 3-16).
Remove the fronl hood (page 2-12).
Disconnect the brake light switch 2P (gray) connector
{1] and check for continuity between the switch side
There should be continuity wilh the brake pedal
depressed and no continuity wilh the pedal released .
(1(

INSPECTION
Remove Ihe left fron t fender (page 2-13),
connector [1].
Check for continuity between the switch side connector
terminals.
There should be continuity when Ihe parking brake is
applied , and no continuity when the parking brake is
released .
REMOVAUINSTALLATION
Puilihe parking brake lever fully and remove the screw
[1] and parking brake switch [2].
Instalilhe parKing brake switch by aligning the pin and
hole, and tighten the screw.
TORQUE : 0.4 N'm (0.04 kgf'm , 0.3 Ibf-ft)
Route the parking brake switch wire properly and

connect the 2P (black) connector.
Install the left front fender (page 2-13).
2216
23. WIRING DIAGRAM
WIRING DIAGRAM .... ............ ............ 23-2
231
1
MEMO
,
I
j

INDEX
ACCELERATOR PEDAL ............. .. 7-17 DRIVETRAIN DTC TROUBLESHOOTING ............. 16-14
ACCESSORY SOCKET ..... . ................... 22-8 DRIVETRAIN SYSTEM DIAGRAM ....................... 16-11
AIR CLEANER .. .. ............ . 3-5 DRIVETRAIN TROUBLESHOOTING
AIR CLEANER HOUSING ... .... .... 7-16 INFORMATION .. 16-12
AIR CLEANER HOUSING DRAIN TUBE ............. 3-6 ECT SENSOR ...... 4-27
ALTERNATOR CHARGING COIL .. 21-6 EMISSION CONTROL SYSTEMS 1-32
ALTERNATOR 5T AlOR/STARTER REDUCTION ENGINE IDLE SPEED .............. ' 4-29
GEARS ............................. ........... 12-5 ENGINE INSTALLATION ........................... 15-8
BATIERY ENGINE OIL ................... ................ 3-9
BATIERY/CHARGING SYSTEM 21-4 ENGINE REMOVAL ........... 15-4
MAINTENANCE ........... 3-7 EOT SENSOR .......... .............. . .. 16-55
BODY PANEL LOCATIONS ............................... "' 2-3 EXHAUST SYSTEM
BRAKE FLUID ' ......................... 3-14 FRAME/BODY PANELS/EXHAUST SYSTEM ....... 2-30
BRAKE FLUID REPLACEMENT/AIR BLEEDING ...... 20-6 MAINTENANCE .... ...... .......................... 3-19
BRAKE INHIBITOR RELAY 6-10 FINAL DRIVE OIL 3-13
BRAKE LIGHT SWITCH FLOOR PANEL ...... ... ............. . .... 2-11
LIGHTS/METERS/SWITCHES 22-15 FLYWHEEUSTARTERCLUTCH ................ "'12-10
MAINTENANCE .......... . . 3-15 FRONT BRAKE CALIPER ......... ..... 20-16
BRAKE PAD/DISC ............................. 20-8 FRONT BUMPER . .. ...... ....... 2-17
BRAKE PADS WEAR ................. 3- 15 FRONT CRANKCASE COVER ............................ 16-34
BRAKE PEDAL ..... ......... . ...... 20-26 FRONT FENDER ' ........... . ...... 2-13
BRAKE SYSTEM 3-16 FRONT FINAL CLUTCH .............. 18-19
BRAKEfTA1LLlGHT ............. 22-4 FRONT FINAL DRIVE INSTALLATION .. 18-42
CABLE & HARNESS ROUTING 1-17 FRONT FINAL DRIVE REMOVAL .... . .. 18-14
CAM CHAIN TENSIONER LIFTER ............. 10-21 FRONT FINAL GEAR ASSEMBLy .. 18-39
CAMSHAFT .............. . ..................... 10-13 FRONT FINAL GEAR CASE BEARING
CARGO BED ..................................... '2-18 REPLACEMENT . .. ......... .. .... .. ........ ,8-36
CHARGING SYSTEM INSPECTION 21-5 FRONT FINAL GEAR DISASSEMBLY/
CHASSIS LUBRICATION POINTS ............ 3-24 INSPECTION .. ........................ . .. 18-30
COMBINATION METER .... . ....... ........... 22-4 FRONT FLOOR COVER 2 -17
COMPONENT LOCATION FRONT GRILLE ............. 2-12
BATTERY/CHARGING SYSTEM ......... . .. 21-2 FRONT HEAT GUARD 2-12
DRIVETRAIN SYSTEM " ...... ...... 16-10 FRONT HOOD ........... 2-12
ELECTRIC STARTER ..... . .......... 6-2 FRONT PROPELLER SHAFT ............. 18-17
IGNITION SYSTEM ...... ........... "'5-2 FRONT SEAT ............................................... 2-4
LIGHTS/METERS/SWITCHES .. . 22-2 FRONT SHOCK ABSORBER ................ ,9-20
PGM-FI SYSTEM .. .. 4-4 FRONT SIDE COVER ...................... 2-11
COOLANT REPLACEMENT ........ ... 9-5 FRONT SUSPENSION ARM . . ................... 19-15
COOLING FAN MOTOR ..... ............ . 22-12 FRONT WHEEL HUB/KNUCKLE ... 19-10
COOLING FAN/SHROUD ................ . .............. '9-10 FUEL INJECTOR ... .......... .. 7-24
COOLING SYSTEM ................... 3-11 FUEL LINE ......... ~
COOLING SYSTEM FLOW PATTERN "'9-2 FUEL LINE INSPECTION .............. 7-5
COOLING SYSTEM TESTING ................... 9-4 FUEL METER/FUEL LEVEL SENSOR' 22-14
CRANKCASE ASSEMBLY ... ....... 14-11 FUEL PUMp "'7-9
CRANKCASE BEARING REPLACEMENT ... . .. 14-9 FUEL TANK ....................... 7-15
CRANKCASE SEPARATION ........................... 14-5 GEAR POSITION SWITCH ................ 16-54
CRANKSHAFT ....... ............. ........... 14-6 GEAR SELECTOR CABLE ADJUSTMENT ,3-17
CYLINDER COMPRESSION ............. ,0-5 GEAR SELECTOR LEVER LINKAGE ................... 1316
CYLINDER HEAD ASSEMBLY .. 10-16 HEADLIGHT ... ...... ....... ... ....... ..... . .. 22-3
CYLINDER HEAD COVER ASSEMBLYI HEADLIGHT RELAy 22-10
INSTALLATION .... .. ............. .. .. .. ... .... ....... "10-18 HEADLIGHT SWITCH 22-10
CYLINDER HEAD COVER REMOVAU IACV' ................. .. .. . ..... ... .. 7-23
DISASSEMBLY ................... . ... 10-5 IAT SENSOR ............. 4-27
CYLINDER HEAD DISASSEMBLY '" 10 -9 IGNITION COIL "'5-7
CYLINDER HEAD INSPECTION .. ..... 10-9 IGNITION SWITCH . 22-9
CYLINDER HEAD INSTALLATION .... "10-17 IGNITION SYSTEM INSPECTION .... 5-5
CYLINDER HEAD REMOVAL ....... 10-8 _m~n~~ N
CYLINDER/PISTON INSPECTION ......... ........... 11-5 INSTRUMENT PANEL ........ 2-16
CYLINDER1PISTON INSTALLATION ' 11-8 INTAKE AIR DUCT ........... "'7-17
CYLINDER/PISTON REMOVAL .... 11-4 LIFT AND SUPPORT POINTS ................... 1-33
DIFFERENTIAL LOCK CLUTCH .. .. ... .... ....... .. 18-25 LUBRICATION & SEAL POINTS ............ 1-14
DIODE ... ..... ........ ..................... 6-9 LUBRICATION SYSTEM DIAGRAM 8-2
DOOR .............. ........ 2- 13 MAIN RELAY/FUEL PUMP RELAy 7-13
DRIVE MODE SELECTOR CABLE MAINTENANCE LID 2-18
ADJUSTMENT ................... 18-65 MAINTENANCE MINDER INDICATOR "'3-2
DRIVE MODE SELECTOR LEVER LINKAGE .. 18-63 MAINTENANCE SCHEDULE 3-3
DRIVE SHAFT ........... . .................. 18-8 MASTER CYLINDER ..... 20-12
DRIVE SHAFT BOOTS ..... . ....... ... 3-12 MIDDLE FENDER .................. 2-8
DRIVETRAIN DTC INDEX ,6-13 MIL CIRCUIT INSPECTION ............... 4-25

INDEX
MODEL IDENTIFICATION .... 1-2 SPECIFICATIONS ...................... . ... ........ . 1-4
MUD PROTECTOR (2 PERSON TYPE ONLY) ........... 2~9 STARTER MOTOR ...................... . ........... . 6-4
OCCUPANT PROTECTIVE STRUCTURE (OPS) 2-25 STARTER RELAY SWITCH .......... . 68
OIL COOLER ........... . .... ... ...... .. 8-10 STEERING COLUMN AND SHAFT 17-4
OIL PRESSURE CHECK .............. 8-4 STEERING GEAR BOX .. .... . 179
OIL PUMP ...................... 8-4 STEERING SySTEM 320
PARKING BRAKE LEVER '20-27 STEERING WHEEL .......... . 17-4
PARKING BRAKE SWITCH .. .. .. .... 2216 SUBTRANSMISSION ................. . 13-9
PCM ...................... ................................. 4-28 SUSPENSION ........................... . 3-18
PGMFI Drc INDEX ................................. 4-9 SYMPTOM TROUBLESHOOTING
PGM-fl OTC TROUBLESHOOTING .. 4-10 DRIVETRAIN SYSTEM .. .. ... ... ... ..... .. .. 165
PGM-FI SYSTEM DIAGRAM 4-5 PGMFI SySTEM ... 43
PGM-FI TROUBLESHOOTING INFORMATION ... .. ... .. 4-6 SYSTEM COMPONENTS
RADIATOR ......... .. .. ... .. 9-12 ALTERNATOR/STARTER CLUTCH 122
RADIATOR RESERVE TANK .. ... ............... 9-13 BRAKE SYSTEM 20-2
REAR BRAKE CALIPER .... ............................... 20-20 CRANKCASE/CRANKSHAFT/BALANCER ........ 14-2
REAR CENTER COVER (4 PERSON TYPE ONLY) 2-7 CYLINDER HEADNALVE/CAMSHAFT 102
REAR CRANKCASE COVER ...................... 13-5 CYLINDER/PISTON ... .... ..... ......... 112
REAR FINAL DRIVE ASSEMBLY .......... . 18-57 DRIVE SHAFT/FINAL GEAR 182
REAR FINAL DRIVE DISASSEMBLY! DRIVETRAIN SYSTEM .. .. .. .. ... . ... .. .. .... . 162
INSPECTION ........... 18-49 ENGINE REMOVAUINSTALLATION .. ... ..... .. ... ... 152
REAR FINAL DRIVE GEAR CASE BEARING FUEL SYSTEM ..................................... 72
REPLACEMENT 18-55 STEERING SySTEM ...... ..... .. .. ' 172
REAR FINAL DRIVE INSTALLATION 18-61 SUBTRANSMISSION/GEARSHIFT LINKAGE 132
REAR FINAL DRIVE REMOVAL ... 18-45 WHEEUSUSPENSION .. . 192
REAR FOOT WELL (4 PERSON TYPE ONLY) 2-10 SYSTEM DIAGRAM
REAR SEAT (4 PERSON TYPE ONLY) .. . . .. 2-6 BATIERYfCHARGING SYSTEM ............... '21-2
REAR SHOCK ABSORBER ...... ................ 19-27 ELECTRIC STARTER ..... .. .... 6-2
REAR SIDE COVER ... .. . ...... ............... 2-10 IGNITION SYSTEM ... .. 52
REAR STEP (4 PERSON TYPE ONLY) ........ 2-9 TECHNICAL FEATURES 134
REAR SUSPENSION ARM ........... .... . 19-23 THERMOSTAT ................ 9-7
REAR WHEEL HUB/KNUCKLE ... ........... 19-21 THROTILE B O D y 7- 19
REGULATOR/RECTIFIER ..... .... .. 21-6 THROTILE OPERATION 3-4
SEAT BELT ................ ........... . 2-27 TIEROD AND JOINT BOOT 3- 19
SEAT BOTIOM COVER ......... ....... 28 TIE-ROD BALL JOINT .................. .. .. .. .. .. .. ... .. . 177
SERVICE INFORMATION TIRES .. .. .. .. ....... .. .. .. .. .. ... . 196
ALTERNATOR/STARTER CLUTCH .......... 123 TORQUE CONVERTER 16-40
BATIERY/CHARGING SYSTEM 213 TORQUE VALUES ... .. ... ... .... .... . 19
BRAKE SYSTEM ... ... .. .... ... 20-4 TP SENSOR/MAP SENSOR (SENSOR UNIT) ....... 425
COOLING SYSTEM .... ... .... . ........... 9-3 TROUBLESHOOTING
CRANKCASE/CRANKSHAFT/BALANCER .......... 14-3 ALTERNATOR/STARTER CLUTCH ...... 12-4
CYLINDER HEADNALVE/CAMSHAFT ............... 103 BATIERY/CHARGING SYSTEM 21-4
CYLINDER/PISTON ............ .... .. . 113 BRAKE SYSTEM ........ .... . 205
DRIVE SHAFT/FINAL GEAR .............. 18-4 COOLING SYSTEM .... .......... 9-3
DRIVETRAIN SYSTEM .. 163 CRANKCASE/CRANKSHAFT/BALANCER 14-4
ELECTRIC STARTER ... . .. 63 CYLINDER HEADNALVE/CAMSHAFT 10-4
ENGINE REMOVAUINSTALLATION ...... 15-3 CYLINDER/PISTON 113
FRAME/BODY PANELS/EXHAUST SySTEM22 DRIVE SHAFT/FINAL GEAR ...................... 187
FUEL SySTEM 7-4 elECTRIC STARTER ... .... .... .. .. .... .... . ... 63
IGNITION SYSTEM .... ............. . 53 FRAME/BODY PANELS/EXHAUST SySTEM 22
LIGHTS/METERS/SWITCHES .. 222 IGNITION SYSTEM ....... ....... ........... . 5-4
LUBRICATION SYSTEM .... .. ........... 83 LUBRICATION SYSTEM ................. .............. ..... 8-3
MAINTENANCE ... 32 STEERING SYSTEM 173
PGMFI SYSTEM ............................................ 4-2 SUB-TRANSMISSION/GEARSHIFT LINKAGE 13-4
STEERING SYSTEM 173 WHEEUSUSPENSION .. .. .. .. ... .. 195
SUBTRANSMISSION/GEARSHIFT LINKAGE ..... 133 UNDER GUARD 229
WHEEUSUSPENSION .............................. ...... 19-4 UNDERBODy 3-17
SERVICE RULES .. . . .. ..... .... . ... 12 VALVE CLEARANCE ...... .... .... . 38
SHIFT CLUTCH/MAINSHAFT/COUNTERSHAFT 16-44 VALVE GUIDE REPLACEMENT 1011
SHIFT VALVE BODY 1625 VALVE SEAT INSPECTION/REFACING 1011
SIDE NET VS SENSOR ...... .. .. .. .. ... .. . .. 427
FRAME/BODY PANELS/EXHAUST SYSTEM . 224 WATER PUMp 98
MAINTENANCE 323 WHEELS ............. 19-6
SPARK ARRESTER ............................... 318 WHEElSITIRES .................... . .............. 319
SPARK PLUG 37 WIRING DIAGRAM .. 232

2014 SXS 700M2 M4 Service Manaul

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com manuals search engine

For You r Customer's Safety

For Your Safety

Important Safety Precautions

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You CAN be HURT if you don't follow instructions.

Instructions - how to service this vehicle correctly and safely.

Date of Issue: August. 2013

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I Replace the par1(s) with new ona(s) before assembly.

Use the recommend engine oil, unless otherwise specified.

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use silicone grease.

Use fork or suspension fluid.

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SERVICE RULES . ............ 12 CABLE & HARNESS ROUTING ............. 1-17

MODEL IDENTIFICATION 1 2 EMISSION CONTROL SySTEMS 1-32

SPECIFICATIONS"""""""""" " """""" 1-4 LIFT AND SUPPORT POINTS

LUBRICATION & SEAL POINTS ............ 114

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ELECTRICAL Ignition system Fun Transistorized Ignition

PGMFI SYSTEM SPECIFICATIONS

IGNITION SYSTEM SPECIFICATIONS

ELECTRIC STARTER SPECIFICATIONS

FUEL SYSTEM SPECIFICATIONS

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COOLING SYSTEM SPECIFICATIONS

CYLINDER HEADNALVE/CAMSHAFT SPECIFICATIONS

Valve IN 161) 5,45 1,2'

"' , - 30,1430 \ "ou00 - '

ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

SUB-TRANSMISSION/GEARSHIFT LINKAGE SPECIFICATIONS

DRIVETRAIN SYSTEM SPECIFICATIONS

STEERING SYSTEM SPECIFICATIONS

FASTENER TYPE N' m (kgf-m, Ib"f.~ ) _ _,

ENGINE & FRAME TORQUE VALUES

= :;::=~==~;98 (0(0.9.B. 65.9) ;

ITEM a 'TY THREAD TORQUE REMARKS

CYLINDER HEADfVALVE /CAMSHAFT

ITEM C'TY THREAD TORQUE REMARKS

Apply locking agent.

ITEM a'TV THREAD

Front final gear case cover bolt

t Feo"' b,ak. ho,. clamp boll

Rear upper arm pivot nut (frame side)

LUBRICATION & SEAL POINTS

----Eargo bed PiVO~ts~=.=.=======-

Stee ring rack end joint outer surlace Apply1-2g

DOT 4 brake fluid

T81215 or loctite LT5699

hub nul rTi'OiJiltIng threads of drive shaft

HEADLIGHT SUB HARNESS

FAN MOTOR BREATHER HOSE

RIGHT HEADLIGHT LEFT HEADLIGHT

HEADLIGHT SUB HARNESS

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HARNESS6P (Green) CONNECTOR~sr~~~~~~~~~tl=