YAMAHA GRIZZLY 700 SERVICE REPAIR MANUAL

YAMAHA GRIZZLY 700 SERVICE REPAIR MANUAL

2007

485 Pages

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your ATV. Read and print pages or copy the entire manual to your hard drive.

 

 

MODELS COVERED:

YFM7FGPW

 

MANUALS COVER:

CHAPTER 1

 

GENERAL INFORMATION

VEHICLE IDENTIFICATION………………………………………………………………….1-1

VEHICLE IDENTIFICATION NUMBER……………………………………………..1-1

MODEL LABEL………………………………………………………………………………1-1

FEATURES…………………………………………………………………………………………1-2

OUTLINE OF THE FI SYSTEM………………………………………………………..1-2

FI SYSTEM……………………………………………………………………………………1-3

OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM……1-4

EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM …..1-5

INSTRUMENT FUNCTIONS……………………………………………………………1-6

IMPORTANT INFORMATION ……………………………………………………………….1-9

PREPARATION FOR REMOVAL AND DISASSEMBLY………………………1-9

REPLACEMENT PARTS…………………………………………………………………1-9

GASKETS, OIL SEALS AND O-RINGS …………………………………………….1-9

LOCK WASHERS/PLATES AND COTTER PINS……………………………..1-10

BEARINGS AND OIL SEALS…………………………………………………………1-10

CIRCLIPS……………………………………………………………………………………1-10

CHECKING THE CONNECTIONS………………………………………………….1-11

SPECIAL TOOLS ………………………………………………………………………………1-12

 

CHAPTER 2

 

SPECIFICATIONS

GENERAL SPECIFICATIONS ………………………………………………………………2-1

ENGINE SPECIFICATIONS ………………………………………………………………….2-5

CHASSIS SPECIFICATIONS………………………………………………………………2-12

ELECTRICAL SPECIFICATIONS ………………………………………………………..2-14

TIGHTENING TORQUES ……………………………………………………………………2-16

ENGINE TIGHTENING TORQUES…………………………………………………2-16

CHASSIS TIGHTENING TORQUES……………………………………………….2-19

HOW TO USE THE CONVERSION TABLE…………………………………………..2-22

GENERAL TIGHTENING TORQUE SPECIFICATIONS………………………….2-22

LUBRICATION POINTS AND LUBRICANT TYPES ………………………………2-23

ENGINE………………………………………………………………………………………2-23

COOLANT FLOW DIAGRAMS ……………………………………………………………2-25

OIL FLOW DIAGRAMS………………………………………………………………………2-26

CABLE ROUTING ……………………………………………………………………………..2-28

 

CHAPTER 3

 

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION………………………………………………………………………………….3-1

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

SYSTEM ……………………………………………………………………………………………3-1

GENERAL MAINTENANCE AND LUBRICATION CHART……………………….3-2

ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS …………………..3-4

ENGINE SKID PLATES…………………………………………………………………..3-4

SEAT AND SIDE PANELS………………………………………………………………3-5

FRONT CARRIER AND FRONT GUARD………………………………………….3-6

FRONT FENDERS AND FRONT GRILL……………………………………………3-8

REAR CARRIER AND REAR FENDER…………………………………………….3-9

ELECTRICAL COMPONENTS TRAY…………………………………………………..3-10

ELECTRICAL COMPONENTS TRAY 1/2………………………………………..3-10

ELECTRICAL COMPONENTS TRAY 2/2………………………………………..3-12

FOOTREST BOARDS………………………………………………………………………..3-14

AIR FILTER CASE …………………………………………………………………………….3-15

ENGINE ……………………………………………………………………………………………3-16

ADJUSTING THE VALVE CLEARANCE …………………………………………3-16

ADJUSTING THE ENGINE IDLING SPEED…………………………………….3-19

ADJUSTING THE THROTTLE LEVER FREE PLAY …………………………3-20

ADJUSTING THE SPEED LIMITER………………………………………………..3-22

CHECKING THE SPARK PLUG …………………………………………………….3-23

CHECKING THE IGNITION TIMING……………………………………………….3-24

MEASURING THE COMPRESSION PRESSURE…………………………….3-25

CHECKING THE ENGINE OIL LEVEL…………………………………………….3-28

CHANGING THE ENGINE OIL ………………………………………………………3-29

CLEANING THE AIR FILTER ELEMENT…………………………………………3-31

CHECKING THE THROTTLE BODY JOINT…………………………………….3-33

CHECKING THE FUEL HOSE……………………………………………………….3-34

CHECKING THE BREATHER HOSES ……………………………………………3-34

CHECKING THE COOLANT LEVEL……………………………………………….3-35

CHANGING THE COOLANT………………………………………………………….3-35

CHECKING THE COOLING SYSTEM…………………………………………….3-39

CHECKING THE COOLANT TEMPERATURE WARNING LIGHT………3-40

CHECKING THE V-BELT………………………………………………………………3-41

CHECKING THE EXHAUST SYSTEM…………………………………………….3-42

CLEANING THE SPARK ARRESTER …………………………………………….3-43

CHASSIS ………………………………………………………………………………………….3-44

ADJUSTING THE FRONT BRAKE …………………………………………………3-44

ADJUSTING THE REAR BRAKE……………………………………………………3-44

CHECKING THE BRAKE FLUID LEVEL………………………………………….3-46

CHECKING THE FRONT BRAKE PADS…………………………………………3-47

CHECKING THE REAR BRAKE PADS …………………………………………..3-48

CHECKING THE REAR BRAKE HOSE PROTECTORS……………………3-48

CHECKING THE BRAKE HOSES…………………………………………………..3-49

BLEEDING THE HYDRAULIC BRAKE SYSTEM ……………………………..3-49

ADJUSTING THE SELECT LEVER CONTROL CABLE AND

SHIFT ROD ………………………………………………………………………………..3-51

CHECKING THE FINAL GEAR OIL LEVEL……………………………………..3-53

CHANGING THE FINAL GEAR OIL………………………………………………..3-53

CHECKING THE DIFFERENTIAL GEAR OIL LEVEL………………………..3-55

CHANGING THE DIFFERENTIAL GEAR OIL ………………………………….3-55

CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS……….3-56

CHECKING THE STEERING SYSTEM …………………………………………..3-57

ADJUSTING THE TOE-IN……………………………………………………………..3-59

CHECKING THE FRONT AND REAR SHOCK ABSORBERS ……………3-60

ADJUSTING THE FRONT SHOCK ABSORBERS ……………………………3-61

ADJUSTING THE REAR SHOCK ABSORBERS………………………………3-62

CHECKING THE TIRES………………………………………………………………..3-62

CHECKING THE WHEELS ……………………………………………………………3-65

CHECKING AND LUBRICATING THE CABLES ………………………………3-65

LUBRICATING THE LEVERS AND PEDALS …………………………………..3-66

ELECTRICAL SYSTEM………………………………………………………………………3-67

CHECKING AND CHARGING THE BATTERY…………………………………3-67

CHECKING THE FUSES ………………………………………………………………3-73

ADJUSTING THE HEADLIGHT BEAMS………………………………………….3-76

REPLACING THE HEADLIGHT BULBS ………………………………………….3-76

 

CHAPTER 4

 

ENGINE

ENGINE REMOVAL …………………………………………………………………………….4-1

AIR DUCTS, MUFFLER AND EXHAUST PIPE ………………………………….4-1

SELECT LEVER UNIT ……………………………………………………………………4-3

LEADS, CABLES AND HOSES ……………………………………………………….4-4

ENGINE MOUNTING BOLTS ………………………………………………………….4-6

INSTALLING THE ENGINE……………………………………………………………..4-8

INSTALLING THE SELECT LEVER UNIT …………………………………………4-9

CYLINDER HEAD………………………………………………………………………………4-10

REMOVING THE CYLINDER HEAD……………………………………………….4-12

CHECKING THE CAMSHAFT SPROCKET……………………………………..4-13

CHECKING THE TAPPET COVERS ………………………………………………4-13

CHECKING THE TIMING CHAIN TENSIONER………………………………..4-13

CHECKING THE CYLINDER HEAD ……………………………………………….4-14

INSTALLING THE CYLINDER HEAD ……………………………………………..4-15

ROCKER ARMS AND CAMSHAFT……………………………………………………..4-18

REMOVING THE ROCKER ARMS AND CAMSHAFT……………………….4-20

CHECKING THE CAMSHAFT………………………………………………………..4-20

CHECKING THE DECOMPRESSION SYSTEM……………………………….4-21

CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ……..4-21

INSTALLING THE CAMSHAFT AND ROCKER ARMS ……………………..4-22

VALVES AND VALVE SPRINGS…………………………………………………………4-25

REMOVING THE VALVES AND VALVE SPRINGS ………………………….4-26

CHECKING THE VALVES AND VALVE SPRINGS…………………………..4-27

INSTALLING THE VALVES AND VALVE SPRINGS…………………………4-31

CYLINDER AND PISTON……………………………………………………………………4-34

REMOVING THE PISTON …………………………………………………………….4-35

CHECKING THE CYLINDER AND PISTON …………………………………….4-35

CHECKING THE PISTON RINGS…………………………………………………..4-37

CHECKING THE PISTON PIN ……………………………………………………….4-38

INSTALLING THE PISTON AND CYLINDER …………………………………..4-39

AC MAGNETO…………………………………………………………………………………..4-42

REMOVING THE AC MAGNETO ROTOR……………………………………….4-45

CHECKING THE STATOR COIL AND CRANKSHAFT POSITION

SENSOR ……………………………………………………………………………………4-46

CHECKING THE STARTER CLUTCH…………………………………………….4-46

CHECKING THE TORQUE LIMITER………………………………………………4-47

INSTALLING THE AC MAGNETO ROTOR ……………………………………..4-47

BALANCER GEARS AND OIL PUMP GEARS ……………………………………..4-49

REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP

DRIVEN GEAR……………………………………………………………………………4-51

CHECKING THE OIL PUMP DRIVE ……………………………………………….4-51

CHECKING THE BALANCER DRIVE……………………………………………..4-51

INSTALLING THE BALANCER DRIVE GEAR, BALANCER DRIVEN

GEAR, AND OIL PUMP DRIVEN GEAR…………………………………………4-52

PRIMARY AND SECONDARY SHEAVES…………………………………………….4-53

PRIMARY SHEAVE………………………………………………………………………4-55

SECONDARY SHEAVE ………………………………………………………………..4-56

REMOVING THE PRIMARY AND SECONDARY SHEAVES……………..4-57

DISASSEMBLING THE SECONDARY SHEAVE………………………………4-57

CHECKING THE PRIMARY SHEAVE …………………………………………….4-58

CHECKING THE SECONDARY SHEAVE……………………………………….4-58

ASSEMBLING THE PRIMARY SHEAVE…………………………………………4-59

ASSEMBLING THE SECONDARY SHEAVE……………………………………4-60

INSTALLING THE PRIMARY AND SECONDARY SHEAVES…………….4-62

CLUTCH …………………………………………………………………………………………..4-63

REMOVING THE CLUTCH ……………………………………………………………4-65

CHECKING THE CLUTCH…………………………………………………………….4-66

INSTALLING THE CLUTCH…………………………………………………………..4-67

CRANKCASE ……………………………………………………………………………………4-68

TIMING CHAIN AND OIL FILTER …………………………………………………..4-68

CRANKCASE ………………………………………………………………………………4-70

CRANKCASE BEARINGS……………………………………………………………..4-71

SEPARATING THE CRANKCASE………………………………………………….4-72

CHECKING THE TIMING CHAIN AND GUIDE…………………………………4-72

CHECKING THE RELIEF VALVE …………………………………………………..4-72

CHECKING THE BEARINGS…………………………………………………………4-73

CHECKING THE CRANKCASE……………………………………………………..4-73

ASSEMBLING THE CRANKCASE………………………………………………….4-73

INSTALLING THE SHIFT LEVER …………………………………………………..4-74

CRANKSHAFT AND OIL PUMP………………………………………………………….4-75

OIL PUMP …………………………………………………………………………………..4-76

REMOVING THE CRANKSHAFT …………………………………………………..4-77

CHECKING THE OIL PUMP ………………………………………………………….4-77

CHECKING THE OIL STRAINER …………………………………………………..4-78

CHECKING THE CRANKSHAFT……………………………………………………4-78

ASSEMBLING THE OIL PUMP………………………………………………………4-79

INSTALLING THE CRANKSHAFT………………………………………………….4-79

TRANSMISSION………………………………………………………………………………..4-81

DRIVE AXLE ……………………………………………………………………………….4-83

REMOVING THE TRANSMISSION ………………………………………………..4-85

CHECKING THE SHIFT FORKS…………………………………………………….4-85

CHECKING THE SHIFT DRUM ……………………………………………………..4-86

CHECKING THE TRANSMISSION…………………………………………………4-86

CHECKING THE SECONDARY SHAFT………………………………………….4-87

CHECKING THE STOPPER LEVER AND STOPPER WHEEL…………..4-87

ASSEMBLING THE SHIFT FORK ASSEMBLY ………………………………..4-87

INSTALLING THE TRANSMISSION……………………………………………….4-88

MIDDLE GEAR………………………………………………………………………………….4-89

MIDDLE DRIVE SHAFT ………………………………………………………………..4-89

MIDDLE DRIVEN SHAFT………………………………………………………………4-90

REMOVING THE MIDDLE DRIVE SHAFT ………………………………………4-92

REMOVING THE MIDDLE DRIVEN SHAFT…………………………………….4-93

CHECKING THE PINION GEARS ………………………………………………….4-95

SELECTING MIDDLE DRIVE AND DRIVEN GEAR SHIMS……………….4-96

INSTALLING THE BEARING AND OIL SEALS ………………………………..4-99

INSTALLING THE MIDDLE DRIVEN SHAFT …………………………………4-100

INSTALLING THE MIDDLE DRIVE SHAFT……………………………………4-102

MEASURING THE MIDDLE GEAR BACKLASH……………………………..4-102

 

CHAPTER 5

 

COOLING SYSTEM

RADIATOR …………………………………………………………………………………………5-1

CHECKING THE RADIATOR…………………………………………………………..5-3

INSTALLING THE RADIATOR…………………………………………………………5-4

THERMOSTAT ……………………………………………………………………………………5-5

CHECKING THE THERMOSTAT……………………………………………………..5-6

INSTALLING THE THERMOSTAT……………………………………………………5-6

WATER PUMP…………………………………………………………………………………….5-7

DISASSEMBLING THE WATER PUMP…………………………………………….5-9

CHECKING THE WATER PUMP……………………………………………………..5-9

ASSEMBLING THE WATER PUMP………………………………………………..5-10

 

CHAPTER 6

 

FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEM………………………………………………………………….6-1

CIRCUIT DIAGRAM ……………………………………………………………………….6-3

ECU SELF-DIAGNOSTIC FUNCTION………………………………………………6-5

SELF-DIAGNOSTIC FUNCTION TABLE…………………………………………..6-6

TROUBLESHOOTING CHART………………………………………………………..6-7

DIAGNOSTIC MODE ……………………………………………………………………..6-8

TROUBLESHOOTING DETAILS ……………………………………………………6-12

CHECKING THE INTAKE AIR PRESSURE SENSOR ………………………6-26

CHECKING THE INTAKE AIR TEMPERATURE SENSOR………………..6-26

FUEL TANK………………………………………………………………………………………6-28

REMOVING THE FUEL TANK……………………………………………………….6-30

REMOVING THE FUEL PUMP ………………………………………………………6-30

CHECKING THE FUEL PUMP BODY……………………………………………..6-31

CHECKING THE ROLLOVER VALVE …………………………………………….6-31

INSTALLING THE FUEL PUMP……………………………………………………..6-31

INSTALLING THE FUEL HOSE……………………………………………………..6-32

THROTTLE BODY……………………………………………………………………………..6-33

REMOVING THE THROTTLE BODY ASSEMBLY ……………………………6-36

CHECKING THE FUEL INJECTOR ………………………………………………..6-36

CHECKING THE THROTTLE BODY ………………………………………………6-36

INSTALLING THE THROTTLE BODY ASSEMBLY…………………………..6-37

CHECKING THE FUEL PUMP AND PRESSURE REGULATOR

OPERATION ………………………………………………………………………………6-38

CHECKING AND ADJUSTING THE THROTTLE POSITION

SENSOR ……………………………………………………………………………………6-39

 

CHAPTER 7

 

DRIVE TRAIN

TROUBLESHOOTING………………………………………………………………………….7-1

CHECKING NOISES………………………………………………………………………7-1

TROUBLESHOOTING CHART………………………………………………………..7-3

FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR……..7-4

REMOVING THE DIFFERENTIAL GEAR ASSEMBLY………………………7-10

CHECKING THE FRONT CONSTANT VELOCITY JOINTS……………….7-10

CHECKING THE DIFFERENTIAL GEARS ………………………………………7-11

CHECKING THE DIFFERENTIAL GEAR MOTOR ……………………………7-11

ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS …………..7-12

ASSEMBLING THE DIFFERENTIAL GEARS…………………………………..7-13

MEASURING THE DIFFERENTIAL GEAR LASH …………………………….7-14

ADJUSTING THE DIFFERENTIAL GEAR LASH………………………………7-15

CHECKING THE DIFFERENTIAL GEAR OPERATION …………………….7-16

REAR CONSTANT VELOCITY JOINTS AND FINAL DRIVE GEAR ………..7-17

ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS……………..7-24

DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY…….7-25

POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR …7-25

ADJUSTING THE FINAL DRIVE PINION GEAR BACKLASH…………….7-25

ADJUSTING THE FINAL DRIVEN PINION GEAR BACKLASH ………….7-27

MEASURING THE FINAL DRIVEN PINION GEAR THRUST

WASHER CLEARANCE……………………………………………………………….7-29

MEASURING THE WHEEL GEAR THRUST CLEARANCE……………….7-30

CHECKING THE REAR DRIVE SHAFT…………………………………………..7-31

CHECKING THE FINAL DRIVE ASSEMBLY……………………………………7-31

MEASUREMENT THE FINAL GEAR LASH……………………………………..7-32

ADJUSTING THE FINAL GEAR LASH ……………………………………………7-33

ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY………….7-34

ASSEMBLING THE FINAL GEAR CASE…………………………………………7-35

 

CHAPTER 8

 

CHASSIS

FRONT AND REAR WHEELS ………………………………………………………………8-1

FRONT WHEELS…………………………………………………………………………..8-1

REAR WHEELS …………………………………………………………………………….8-3

CHECKING THE WHEELS ……………………………………………………………..8-5

CHECKING THE WHEEL HUBS………………………………………………………8-5

CHECKING THE BRAKE DISCS ……………………………………………………..8-6

INSTALLING THE BRAKE DISCS ……………………………………………………8-6

INSTALLING THE WHEEL HUBS…………………………………………………….8-6

INSTALLING THE WHEELS ……………………………………………………………8-7

FRONT AND REAR BRAKES……………………………………………………………….8-8

FRONT BRAKE PADS ……………………………………………………………………8-8

REAR BRAKE PADS………………………………………………………………………8-9

REPLACING THE FRONT AND REAR BRAKE PADS………………………8-10

FRONT BRAKE MASTER CYLINDER…………………………………………….8-12

REAR BRAKE MASTER CYLINDER ………………………………………………8-15

CHECKING THE MASTER CYLINDERS…………………………………………8-18

ASSEMBLING THE FRONT AND REAR BRAKE MASTER

CYLINDERS ……………………………………………………………………………….8-18

INSTALLING THE FRONT BRAKE MASTER CYLINDER………………….8-19

INSTALLING THE REAR BRAKE MASTER CYLINDER……………………8-21

FRONT BRAKE CALIPERS …………………………………………………………..8-23

REAR BRAKE CALIPERS……………………………………………………………..8-25

DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS……….8-27

CHECKING THE FRONT AND REAR BRAKE CALIPERS ………………..8-27

ASSEMBLING THE FRONT AND REAR BRAKE CALIPERS…………….8-28

INSTALLING THE FRONT AND REAR BRAKE CALIPERS ………………8-29

STEERING SYSTEM………………………………………………………………………….8-31

HANDLEBAR……………………………………………………………………………….8-31

REMOVING THE HANDLEBAR GRIPS…………………………………………..8-33

CHECKING THE HANDLEBAR ……………………………………………………..8-33

INSTALLING THE HANDLEBAR ……………………………………………………8-33

INSTALLING THE HANDLEBAR GRIPS …………………………………………8-34

INSTALLING THE REAR BRAKE MASTER CYLINDER……………………8-34

INSTALLING THE FRONT BRAKE MASTER CYLINDER………………….8-35

INSTALLING THE THROTTLE LEVER ASSEMBLY …………………………8-35

STEERING STEM ………………………………………………………………………..8-36

CHECKING THE STEERING STEM……………………………………………….8-38

INSTALLING THE STEERING STEM……………………………………………..8-38

INSTALLING THE PITMAN ARM……………………………………………………8-40

TIE-RODS AND STEERING KNUCKLES………………………………………..8-41

REMOVING THE STEERING KNUCKLES………………………………………8-43

CHECKING THE TIE-RODS ………………………………………………………….8-43

CHECKING THE STEERING KNUCKLES……………………………………….8-43

INSTALLING THE TIE-RODS ………………………………………………………..8-46

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES………….8-47

REMOVING THE FRONT ARMS……………………………………………………8-49

CHECKING THE FRONT ARMS…………………………………………………….8-49

CHECKING THE FRONT SHOCK ABSORBERS……………………………..8-51

INSTALLING THE FRONT ARMS AND FRONT SHOCK

ABSORBERS ……………………………………………………………………………..8-51

REAR KNUCKLES AND STABILIZER…………………………………………………8-52

CHECKING THE REAR KNUCKLES………………………………………………8-54

CHECKING THE STABILIZER……………………………………………………….8-54

REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES ……………..8-55

CHECKING THE REAR ARMS………………………………………………………8-57

CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES…………….8-57

INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER

ASSEMBLIES……………………………………………………………………………..8-58

 

CHAPTER 9

 

ELECTRICAL

ELECTRICAL COMPONENTS………………………………………………………………9-1

CHECKING SWITCH CONTINUITY……………………………………………………….9-4

CHECKING THE SWITCHES………………………………………………………………..9-5

CHECKING THE BULBS AND BULB SOCKETS ……………………………………9-7

TYPES OF BULBS…………………………………………………………………………9-7

CHECKING THE CONDITION OF THE BULBS …………………………………9-8

CHECKING THE CONDITION OF THE BULB SOCKETS …………………..9-9

IGNITION SYSTEM ……………………………………………………………………………9-10

CIRCUIT DIAGRAM ……………………………………………………………………..9-10

TROUBLESHOOTING ………………………………………………………………….9-11

ELECTRIC STARTING SYSTEM…………………………………………………………9-16

CIRCUIT DIAGRAM ……………………………………………………………………..9-16

STARTING CIRCUIT OPERATION…………………………………………………9-17

TROUBLESHOOTING ………………………………………………………………….9-18

STARTER MOTOR…………………………………………………………………………….9-22

CHECKING THE STARTER MOTOR ……………………………………………..9-24

ASSEMBLING THE STARTER MOTOR………………………………………….9-26

CHARGING SYSTEM…………………………………………………………………………9-27

CIRCUIT DIAGRAM ……………………………………………………………………..9-27

TROUBLESHOOTING ………………………………………………………………….9-28

LIGHTING SYSTEM …………………………………………………………………………..9-30

CIRCUIT DIAGRAM ……………………………………………………………………..9-30

TROUBLESHOOTING ………………………………………………………………….9-31

CHECKING THE LIGHTING SYSTEM…………………………………………….9-32

SIGNALING SYSTEM ………………………………………………………………………..9-34

CIRCUIT DIAGRAM ……………………………………………………………………..9-34

TROUBLESHOOTING ………………………………………………………………….9-36

CHECKING THE SIGNALING SYSTEM………………………………………….9-37

COOLING SYSTEM……………………………………………………………………………9-45

CIRCUIT DIAGRAM ……………………………………………………………………..9-45

TROUBLESHOOTING ………………………………………………………………….9-46

FUEL PUMP SYSTEM………………………………………………………………………..9-50

CIRCUIT DIAGRAM ……………………………………………………………………..9-50

TROUBLESHOOTING ………………………………………………………………….9-51

2WD/4WD SELECTING SYSTEM………………………………………………………..9-53

CIRCUIT DIAGRAM ……………………………………………………………………..9-53

TROUBLESHOOTING ………………………………………………………………….9-54

EPS (ELECTRIC POWER STEERING) SYSTEM…………………………………..9-58

CIRCUIT DIAGRAM ……………………………………………………………………..9-58

EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION…………………9-59

EPS WARNING LIGHT DURING NORMAL OPERATION………………….9-60

DIAGNOSTIC MODE ……………………………………………………………………9-61

SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)………………….9-64

TROUBLESHOOTING DETAILS (EPS SYSTEM)…………………………….9-65

CHECKING THE EPS MOTOR………………………………………………………9-69

CHECKING THE EPS TORQUE SENSOR………………………………………9-69

 

CHAPTER 10

 

TROUBLESHOOTING

STARTING FAILURE/HARD STARTING ……………………………………………..10-1

FUEL SYSTEM…………………………………………………………………………….10-1

ELECTRICAL SYSTEM…………………………………………………………………10-1

COMPRESSION SYSTEM…………………………………………………………….10-2

POOR IDLE SPEED PERFORMANCE…………………………………………………10-2

POOR IDLE SPEED PERFORMANCE……………………………………………10-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE…………………………..10-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE …………………….10-2

FAULTY DRIVE TRAIN………………………………………………………………………10-3

FAULTY GEAR SHIFTING………………………………………………………………….10-4

HARD SHIFTING………………………………………………………………………….10-4

SHIFT LEVER DOES NOT MOVE………………………………………………….10-4

JUMPS OUT OF GEAR…………………………………………………………………10-4

FAULTY CLUTCH PERFORMANCE……………………………………………………10-4

ENGINE OPERATES BUT VEHICLE WILL NOT MOVE……………………10-4

CLUTCH SLIPPING ……………………………………………………………………..10-4

POOR STARTING PERFORMANCE………………………………………………10-4

POOR SPEED PERFORMANCE……………………………………………………10-5

OVERHEATING…………………………………………………………………………………10-5

OVERHEATING …………………………………………………………………………..10-5

OVERCOOLING………………………………………………………………………………..10-5

COOLING SYSTEM ……………………………………………………………………..10-5

FAULTY BRAKE ……………………………………………………………………………….10-5

POOR BRAKING EFFECT…………………………………………………………….10-5

SHOCK ABSORBER MALFUNCTION …………………………………………………10-6

MALFUNCTION……………………………………………………………………………10-6

UNSTABLE HANDLING……………………………………………………………………..10-6

UNSTABLE HANDLING………………………………………………………………..10-6

LIGHTING SYSTEM …………………………………………………………………………..10-6

HEADLIGHT DOES NOT COME ON………………………………………………10-6

BULB BURNT OUT ………………………………………………………………………10-6

 

 

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 

Language: English 
Format: PDF – Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.) 

Windows/Mac/Tablet/Phone Friendly