2009-12 MUV 700 Big Red 700 Service Manual

A Few Words About Safety
Service Information
The Service and repair Information contained In this manual IS intended for use by qualified. professional technicians.
Attempting servICe or repairs without the proper training. 1000s, and equipment couk! cause injury 10 you or others. It could also
damage the vehICle or create an unsafe oondltlon.
This manual describes the proper methods and procedures for per10rmlng service, maintenance, and repairs. Some procedures
reqUIre the use of specialty designed tools and dedicated equipmenl. Any persoo who inleocis 10 use a replacement part, service
procedure or a 1001 that is not recommended by Honda, must determine the risks 10 their persooaJ salery and the safe operatJon of
the vehicle.
II you need to re~ce a part, use genuine Honda parts with the correct pari number or an equivalent part. We strongly recommend
that you do nol use replacement parts 01 InferIOr quality.
For Your Customer's Safety

Proper service and maintenance are essential to the customer's salety and
AWARNING
the reliability of the vehicle. Any error or oversight while servicing a vehicle Improper service or repairs can create an
can result in faulty operation, damage to the vehicle, or injury to others. unsafe condition that can cause your customer
or others to be seriously hurl or killed.
For Your Salety
Follow the procedures and precautions in thiS
Because Ihis manual is intended lor the professional service techmcian , we manual and other service materials carefully.
do nol provide warnings about many baSIC shop safety practices (e.g., Hot
parts-wear gloves) . II you have not received shop safety training or do not
feel oonfident about your knowfedge 01 safe servicing practice. we AWARNING
recommended that you do !lOt attempt to pertorm the procedures described
Failure to property Iollow Instructions and
In thiS manual. precautIOns can cause you to be seriously hurt
Some 01 the most Important general service safety precautioos are given or killed.
below. However, we cannot warn you of every conceivable hazard that can Follow the procedures and precaulJons In thts
arise in pertormtng seMCe and repair procedures. Only you can decide manual carefully.
whether or not you should perform a given task.
Important Salety Precautions

Make sure you have a clear understanding 01 all basIC Shop safety practices and that you ate wearing appropriate clothing and
uSlOg safety equipment When pertorming any Service task, be especially careful of the follOWing:
Read all of the Instructions before you begin, and make sure you have the tools, the replacement or repair 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 time you hammer, drill, grind, pry or work around
pressurized alT or liqUids, and SPrings or other stored-energy components. If there is any doubt, put on eye protection.
Use olher protectIve wear when necessary, for exampJe gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Belore you grab something lhat looks like it can hurt you. stop and put on gloves.
Protect yourself and others whene\ler you have the vehicle up in the air. Any time you liftlhe vehicle, either with a hOist or a jack,
make sure thai it is always securely supported. Use Jack stands.
Make sure the engine is off before you begIn any serVICing procedures, unless the instruction tells you 10 do otherwise.
This WIll help eliminate several potentlaJ hazards:
Carbon monoXide poisoning from engine exhaust. Be sure there IS adequate ventilation whenever you run the engine.
Burns from hoc parts or coolant. let lhe engine and exhaust system cool betare working In those areas.
Injury from mOVIng pans. If the Instruction lells you to run the engine. be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and ~drogen gases from banenes are explosive. To reduce Ihe possibility of a fire or explosion, be careful when
working around gasolme or banenes.
Use only a nonflammable solvent, not gasoline. to clean paris.
NeYer drain or store gasoline In an open container.
4 Keep all cigarenes. sparks and flames away from the banery and alilueJ.related parts.
HOW TO USE THIS MANUAL CONTENTS
Thrs 58MCe tnllflUl,l delCtlbes the WrY1C8 prooodu<es lor Ule
MUV700, GENERAL INFORMATION
FoIow !he Ma.lOt_nee ~ tSeebon 4) recommendabOnS to
_UI. that the \IehicI4I In peak operating coodibon and the TECHNICAL FEATURES
lIfI'IIS5on IlYels .,. WIIhIn tne standard. set tIy the EnYnonmenlal
PtoIectJOn Agency (EPA). CaliIc:lN'4 AIr Resources Boord (CARB)
Ind EfMroomenI ~ tEe)
PertOlnung II\ei ',rsl SCheduled malOll1011nce IS WIry mportant. II

compensates 10< the Wltbll w&ar lhat OCC\.Irs dunng me break ...... MAINTENANCE
p.,,"
SeeIions 1 1M .. apply to tn. whole vehocIe Sec::tion 3 lIusrrates LUBRICATION SYSTEM
proc:Iure, lor remO'alfinltalla1lofl ot cornpoo&nl$ thaI may De
'Bqllll\ld 10 pertorm MMce descnbed in tnelollowing sectionS
s.ctioM 5 through 24 describe parts 01 II'Ie vehlde, grouped FUEL SYSTEM (PGM-FI)
ac:cordklg to IocatlOl'l
Find the &eet.an you want on thiS page, then lurn 10 the table 01 COOLING SYSTEM
content. 00'\ the Hit' page oIllle secllOO
Most sectiol'llstar' With In 8$Sf1mb/y 04' system Illustration, sel\lice ENGINE REMOVALJINSTALLATION
ifllormatlon Ind lroubles.hootlrlg lor the section. The SI.Ibseqll6nl
pages give deta1led pl'oeedure OJ
Z CYLINDER HEADNALVE/CAMSHAFT
,t you .r. not lamMiar WIlli thiS vehICle read Tac/mlca' Features III
seetiorI2.
II you don' know 1h4t source 01 the llOUbie. go 10 sectlOI'I 26
Troubleshoolong
'"
Z
OJ
CYLINDER/PISTON
ALTERNATOR/STARTER CLUTCH
SUB-TRANSMISSION/GEARSHIFT LINKAGE
CRANKCASE/CRANKSHAFT/BALANCER
DRIVETRAIN SYSTEM
FRONT WHEELJSUSPENSION
STEERING SYSTEM
II>
'!'ou CAN be KILLED 0< SERIOUSLY iii REAR WHEELJSUSPENSION
mXWjI h! !h let! HURT IIyou cion', klIlow InsuUCllona. II>
<
:I: BRAKE SYSTEM
U
FRONT DRIVING MECHANISM
AS you read thlt manual, you woll r,nd ~ma\Jon ItIat Is preceded by REAR DRIVING MECHANISM
1tOI1iCE symbOl. The purpose of In,. message IS to help pnMHlI
damage to your Y&/lIeIe, 0I1lef property, or the 8f>Vlronmenl
BATIERY/CHARGING SYSTEM
-'
<
u IGNITION SYSTEM
ir
....
frl-' ELECTRIC STARTER
OJ
LIGHTS/METERS/SWITCHES
WIRING DIAGRAM
TROUBLESHOOTING
INDEX
SYMBOLS
The symbols used Ihroughoullhis manual show specific service procedures. If supplementary information is required pertaining to
Ihese symbols, it would be explained specifically in the texl without the use of the symbols.
....
!f;!~ Replace the parl(s) with new one(5) before assembly.
I
'D Use the recommended engine oil, unless otherwise specified.
7J Use molybdenum oil solution (mixture of the engine oil and mOlybdenum grease in a ratio of 1: 1).
u;;.. i Use multi-purpose grease (lithium based multi-purpose grease NlGI #2 or equivalent).
----
~
I, --
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent).
~ Example: Molykole BR2 plus manufactured by Dow Corning U.S.A.

Mutti-purpose M-2 manulactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI 112 or
equivalent).
Example: Molykot~ G-n Paste manufactured by Dow Corning U.S.A.
~ Honda Moty 60 (U.S.A. only)
Rocol ASP manufactured by Aocol Umited, U.K.
Aocol Paste manufactured by Sumico Lubricant, Japan
---
t1m:J
Use silicone grease.
Apply a locking agent. Use a medium strength locking agent unless otherwise specified,
.,('61ll Apply sealant.
GIl
I
Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specitied.
Use fork or suspension ftuid.

1. GENERAL INFORMATION
SERVICE RULES ......................................... '2 REAR WHEEL/SUSPENSION

SPECIFICATIONS ....................................... '-9
MODEL IDENTIFICATION .................... ...... '3
BRAKE SYSTEM SPECIFICATIONS ........ ,., 0
GENERAL SPECIFICATIONS ...................... '5
SPECIFICATIONS ..................................... ,., 0
LUBRICATION SYSTEM
SPECIFICATIONS .. .... .... .. .. .... .. .. .. .. '7
REAR DRIVING MECHANISM
FUEL SYSTEM SPECIFICATIONS .............. '7 SPECIFICATIONS ..................................... ''0
COOLING SYSTEM SPECIFICATIONS ...... ' -7 BATIERY/ CHARGING SYSTEM

SPECIFICATIONS ..................................... ''0
CYLINDER HEADIVALVE/ CAMSHAFT

SPECIFICATIONS .... .. .. .. .... .. .. .. .. .... ' -8 IGNITION SYSTEM SPECiFiCATIONS .... '',
CYLINDER/PISTON SPECIFICATIONS ...... ' -8 ELECTRIC STARTER SPECIFICATIONS .. ,."
ALTERNATOR/STARTER CLUTCH LIGHTS / METERS/ SWITCHES

SPECIFICATIONS .. .. .. ...... .. .. .. .... ...... '-8 SPECIFICATIONS ..................................... ,-"
SUB-TRANSMISSION/GEARSHIFT STANDARD TORQUE VALUES .............. 1-12

LINKAGE SPECIFICATIONS ....................... '-9
ENGINE & FRAME TORQUE VALUES .... ''2
CRANKCASE/ CRANKSHAFT/ BALANCER
SPECIFICATIONS .. .. .. .. .. .. .... .... .... ' -9 LUBRICATION & SEAL POINTS .............. 1-18
DRIVETRAIN SYSTEM CABLE & HARNESS ROUTING ............... '2'

SPECIFICATIONS .. .. .... .. .. .... .... ...... ' -9
EMISSION CONTROL SYSTEMS ............ '-46
FRONT WHEEL/SUSPENSION
SPECIFICATIONS .. .. .... .. .. ...... .. ...... ' -9 LIFT AND SUPPORT POINTS .................. 1-48
STEERING SYSTEM SPECIFICATIONS .... ' -9
1-1
GENERAL INFORMATION
SERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda 's
design specifications may cause damage to the motorcycle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with
Engl ish fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling .
5. When l ightening bolts or nut s, begin with the larger diameter or inner bolt first. Then tighten to the specified torque
diagonally in incremental steps 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 121 ).
ABBREVIATION
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbrev. t elTTl Full t elTTl
Af[ Automatic Transmission
CKP sensor Crankshaft Position sensor
Clutch PC solenoid Clutch Pressure Control solenoid
DLC Data Link Connector
I DTC -
Diagnostic Trouble Code
ECT sensor Engine Coolant Temperature sensor
EEPROM , Electrically Erasable Programmable Read Only Memory_
ELR Emergency Locking Retractor
EOT sensor Engine Oil Temperature sensor
HDS Honda Diagnostic System
. IACV Idle Air Control Valve
~;sensor Intake Air Temperature sensor
MAP sensor Manifold Absolute Pressure sensor
_~IL Malfunction Indicator Lamp
DPS Occupant Protective Structure
PCM Powertrain Control Module
(ECMfTCM ) (Engine Control ModulefTransmission Control Module)
PGM-Fl Programmed Fuel Injection
SCS connector Service Check Short connector
TP sensor Throttle Position sensor
VS sensor Vehicle Speed sensor
2WD,4WD 2 Wheel Drive, 4 Wheel Drive
1-2
GENERAL INFORMATION
MODEL IDENTIFICATION
SERIAL NUMBERS
The Vehicle Identification Number (VIN) is stamped on the right front
side of the frame the instrument panel.
The engine serial number is stamped on the right side of the rear
crankcase.
1-3
GENERAL INFORMATION
The throttle body identification number is stamped on the left side of
the throttle body. IDENTIFICIHlClN NUMBER
LABelS
The name plate is attached on the left front side of the frame behind
the instrument panel.
The color label is attached on the left front side of the frame behind the
instrument panel. When ordering color coded parts, always specify the
designated color code.
The vehicle emission control information label is attached on the front

side of the frame near the cooling fan.
1-4
GENERAL INFORMATION
GENERAL SPECIFICATIONS
- + " -0" mm (114.7 in)

Overall j 1,626 mm (64.0 in)
Overall height 1,954 mm (76.9 in)
Wheelbase 1,922 mm (75.7 in)
Front tread , ,290 mm (50.8 in)
Rea r tread 1,290 mm (50.8 in)
Seat height 863 mm (34.0 in)
Floor height 449 mm (17.7 in)
Ground clearance 262 mm (10.3 in)
Curb weight 649 kg (1,431 Ibs)
Maximum 540
space
Front suspension Double wish-bone
Front wheel travel 150 mm (5.9 i n)
Front damper Double tube
Rear suspension Double wish-bone
Rea r wheel travel 180 mm (7.1 in)
Rear damper Double tube
Front tire size 25 x 10.00-12NHS 2PR
Rear tire size 25 x 10.00-12NHS 2PR
Front rim size 12x7.5AT
Rea r rim size 12x7.5AT
Front tire brand KT953 (Dunlop)
Rear lire brand KT953 (Dunlop)
Front brake Hydraulic disc brake
Rear brake Hydraulic disc brake
Caster angle 1.70
Trail length 8.9 mm (11132 in)
Camber angle 0'
Fuel tank capacity 30 liters (7.9 US gal, 6.61mp gal)
Fuel tank reserve
Displacement
Compression ratio
Valve train
Intake valve opens at 1 mm (0.04 in) lift
Intake valve closes at 1 mm (0.04 in) lift
Exhaust valve opens at 1 mm (0.04 in) lift
Exhaust valve closes at 1 mm (0.04 in) lift
Lub rication system
Oil pump type
Cooling system
Air filtration
'i'"iicv-+~E~ngine dry weight
FUEL DELIVERY Type PGM-FI (Programmed Fuel Injection)
SYSTEM Throttle bore _ __ _ _-"--=4..0"m=m" I"' ,,
.5e.-
7 in"I_ _ __ _ _ _ _ _ _---.J
1-5
GENERAL INFORMATION
system and ,e',e,,,:

Shift clutch (lS1, 2nd and 3rd clutches) Multi-plate, wet (hydraulic clutch with electric
controlled)
Primary reduction 1.333 (64148)
Secondary reduction Forward 2.562 (41f16)
Reverse 3.153 (41/13)
Final reduction Front 3.461 (45/13)
Rear 3.461 (45/13)
Transmission ratio 1st 2,053 (39/19)
"d 1.417 (34124)
3,d 0.933 (28/30)
Reverse 2. 138 (39/19 x 25124)
Gearshift pattern Sub-transmission Reverse (A) - Neutral (N) - Drive (0)
o 3-speed automatic
R Fixed low ratio
Drive mode select pattern 2WD - 4WD (Rear differential lock) - 4WD (All
differential lock)
ELECTRICAL Ignition system Full Transistorized Ignition
Starting system Electric starter motor
Charging system Triple phase output alternator
Reg u lator/recti' ie r SeR shorted, triple phase full wave rectifica -
tion
Lighting system Battery
1-6
GENERAL INFORMATION
LUBRICATION SYSTEM SPECIFICATIONS
Unit' mm (in)
ITEM STANDARD ' SERVICE LIMIT
Engine oil capacity After draining 2.7 liters (2.9 US qt, 2.4 Im p qt)
After draining/filter 2.9 liters (3.1 US qt, 2.6 Imp qt)
change
After disassembly 4.1 liters (4.3 US qt, 3.6 Imp qtj
Recommended engine oil Pro Honda GN44-stroke oil (U.S.A. and
Canada) or an equivalent motor oil
API service classification: SG or higher
JASO T 903 standard: MA
Viscosity: SAE 10W3D, OW-30
_ ?il pressure at 5,000 rpml80C (176<>F) 785 kPa (8.0 kgf/cm', 114 psi)
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
I Body clearance 0.12 0.22 (0.005 0.009) 0.25 (0.010)
Side clearance 0.02 0.09 (0.001 0.004) 0.11 (0.004)
FUEL SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
Throttle body identification number GQ6AA
Idle speed 1,400 100 rpm
Accelerator pedal freeplay 5 10 mm (1/5 215 in)
-
ECT sensor resistance (20C/68F) 2.3 2.6 !ill
-
~
Fuel injector resistance (at 20C !6BOF) 11.1 12.30

Fuel pressure 336 350 kPa (3.43 3.57 kgflcm2, 4B.B 50.B psi)
Fuel pump flow {at 12 VI 86 cm!-{2.9 US oz, 3.0 Imp ozl minimum/10 seconds
COOLING SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS
- Coolant capacity ~~i ator and engine - 3.3 liters (3.5 US qt, 2.9 Imp qt)
Reserve ta nk 0.6 liter (0.6 US qt, 0.51mp qt) -
Radiator cap relief pressure 93 123 kPa (0.95 1.25 kgf/cm, 14 1B psi)
Thermostat Begin to open BO 84C (176 183F)
Fully open 95C (203F)
Valve lift B mm (0.3 in) minimum at 95 C (203F)
Q
Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality

ethylene glycol antifreeze containing silicate-free corrosion
inhibitors
1:1 mixtu re with distilled water I
Standard coolant concentration
1-7
GENERAL INFORMATION
CYLINDER HEADIVALVE/CAMSHAFT SPECIFICATIONS
Unit mm (in )
ITEM STANDARD SERVICE liMIT
Cylinder compression at 350 rpm 550 kPa (5.S kgf/cm , 80 psi)
Valve clearance 0.15 0.02 1O.00B 0.001)
I -;N
EX 0.33 0.02 (0.013 0.001)
I Valve, Valve stem 0.0. IN 5.475 5.490 (O.21S6 0.2161) 5.45 (0.2 15)
valve guide EX 5.455 5.470 (0.2148 0.2154) 5.43 (0.2 14)
Valve guide I.D. IN/EX 5.500 5.512 (0.2 165 0.2170) 5.53 (0.21S)
Stem-te-guide clearance IN 0.010 0.031 (0.0004 0.0015) 0.12 (0.005)
EX 0.030 0.057 (0.0012 0.0022) 0.14 (0.006)
Valve guide projection IN 14.8 15.2 (0.58 0.60)
above cylinder head EX 17.3 17.7 (0.68 0.70)
Valve seat width IN/EX 1.0 1.1 (0.039 0.043) 1.4 (0.06)
Valve spring Free length Inner 37.20 (1. 465) 36.3 (1.43)
Outer 44.20 (l.740) 43.1 (1.70)
Rocker arm I Armt.D. IN/EX 12.000 12.018 (0.4724 - 0.4731) 12.05 (0.474)
Shaft 0.0. INtEX 11.964 11.984 (0.4710 0.4718) 11.92 (0.469)
Arm-to-shaft clearance IN/EX 0.016 0.054 (0.0006 0.0021) 0.08 (0.003)
I Camshaft and Cam lobe height IN 34.6238 34.7838 (1.36314 1.36944) 34.4488 11.35625)
cam follower EX 34.9835 35.1435 (1.37730 1.38360) 34.7335 (1.36746) ,
22.46 (0.884)
Cam follower 0.0.
I ~~;~ 22.467 22.482 (0.8845 0.8851) 22.54 (0.887)
Fol lower bore 1.0. I N/~~_ +-:2.510 22.526 (0.8862 0.8868)
Follower-to-bore clear- IN/EX 0.028 0.059 (O.OOll - 0.0023) 0.07 (0.003) '----1
ance ,
~ inder head warpage 0.05 (O.002) I
CYLINDER/PISTON SPECIFICATIONS
U nl't : mm ("n)
I
ITEM STANDARD SERVICE LIMIT

Cylinder t.O. 102.000 102.015 (4.0157 4.0163) 102.05 (4.0 18)
Out-of-round 0.05 (0.002)
Taper 0.05 (0.002)
Wa rpage - 0.05 (0.002)
Piston, Piston 0.0. at 20 (0.8) from bottom 101.960 101.990 (4.0142 - 4.0153) 101.90 (4.012)
piston pin, Piston pin hole 1.[1. 23.002 23.008 (0.9056 0.9058) 23.03 {0.90~ H
piston ring Piston pin 0.0. 22.994 23.000 (0.9053 0.9055) 22.98 {a. 905)
Piston-to-piston pin clearance 0.002 0.014 (0.0001 0.0006) 0.04 (0.002)
Piston ring end Top 0.25 - 0.35 (O.OlO 0.014) 0.5 (0.02)
gap 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-to-ring Top 0.045 0.080 (0.0018 0.0031) 0.095 (0.0037)
groove clearance Second 0.025 0.060 (O.OOtO 0.0024) 0.075 (0.0030) _
Cylinder-to-piston clearance 0.010 0.055 (0.0004 0.0022) 0.19 (0.007)
Connecting rod small end 1.0. 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
1-8
GENERAL INFORMATION
SUB-TRANSMISSION/GEARSHIFT LINKAGE SPECIFICATIONS
Unit' mm (in)
ITEM STANDARD SERV ICE LIMIT
Shift for k LO. 11.000 '1.021 (0.4331 0.4339) 11.04 (0.435)
Claw thickness 4.93 5.00 (0.194 0.197) 4.5 (0. 18)
Shaft 0.0. 10.966 10.984 (0.4317 0.4324) 10.96 (0.431)
Reverse idle Gear 1.0. 13.000 13.034 (0.5118 0.5131) 13.05 (0.514)
gear Shaft 0 .0. 12.966 12.984 (0.5105 0.51121 12.93 (0.509)
Gear-ta-shaft clearance 0.10 (0.004)
CRANKCASE/CRANKSHAFT/BALANCER SPECIFICATIONS
Unit- mm (in )
J
Runout 0.05 (O.D02 ) 0. 15 (0.059)
B~;g-;;e;;: .0;26",i"""..-_ _+
nd:;-';:;;d;;,e",c;'eia",""n""e;;;-_ _ _+-iCOi05io'0'ii.6-;:5",'O,".0iiiO",2ru-,::C' --i0",.S",(O.03) ,.-----1
Big end radial clearance 0.006 0.018 (O.0002 0.0007) 0.05 (O.D02)
DRIVETRAIN SYSTEM SPECIFICATIONS

Unit- mm (in)
Oil pressure at line 785 kPa (8.0 kgf/cm', 114 psi)
5,000 rpm 1st, 2nd and 3rd clutch 785 kPa (8.0 kgf/cm ~, 114 psO
Shift clutch Initial clearance 0.7 0.9 (0.03 0.04)
(1st, 2nd and Disc thickness 1.88 2.00 (0.074 0.079) worn out lining
3rd) Plate thickness 1.95 2.05 (0.077 0.081 ) discoloration
Return spring free length 33 .8 (1.33) 31.8 (1.25)
FRONT WHEEL/SUSPENSION SPECIFICATIONS

M inimum tire tread depth 4 mm (0.2 in)
Cold tire pressure Standard 70 kPa (0.70 kgf/cm , 10.0 psi)
With cargo 70 kPa (0.70 kgf/cm , 10.0 psi )
-
STEERING SYSTEM SPECIFICATIONS

Steering wheel Rotational play o 10 mm (0 2/5 i .~I_,
() Wheel turning radius angle
Initial turni ng load 13.7 N (1.4 kgf, 3.1 Ibf)
Inward: 40~ , Outwa rd: 33 0 (reference)
Toe Toe-in: 0 10 mm (O 215 in )
REAR WHEEL/SUSPENSION SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT 1
Minimum tire tread depth 4 mm (0.2 in )
Cold tire pressure Standard 70 kPa (0.70 kgf/cm , 10.0 psi)
I With cargo ~
70 kPa (0.70 kgf/cm ,10.0 psi)
1-9
GENERAL INFORMATION
BRAKE SYSTEM SPECIFICATIONS
Unit" mm (in)
Recommended brake fluid Honda DOT 4 brake fluid
Brake disc thickness 6.8 7.2 (0.27 0.28) 6.0 (0.24)
Brake disc runout 0.30 (0.012)
Brake pedal height (from accelerator pedal) 25 40 ( 1 1-3/5)
Parking brake lever locked clicks 3 7 clicks
FRONT DRIVING MECHANISM SPECIFICATIONS

Unit' mm (in)
,--- ITEM STANDARD SERVICE LIMIT
Front final Oil capacity At draining 665 em (22.5 US OZ, 23.4 Imp oz)
drive At disassem bly 760 em (25.7 US OZ, 26.8 Imp oz)
Recommended oil Hypoid gear oil, SAE #80
-
Gear backlash 0.05 0.25 0.002 - 0.010) 0.4 (0.02)
r-~acklashdifference 0.2 (0.01)
REAR DRIVING MECHANISM SPECIFICATIONS

Unit- mm (in)
ITEM STANDARD SERVICE UMIT
Rear final Oil capacity At draining 465 em (15.7 US 02, 16.4 Imp 02)
drive At disassembly 520 em (17.6 U S OZ, 18.3 Imp ozl
Gear backlash 0.05 0.25 (0.002 0.010) 0.4 (0.02)
Backlash difference - 0.2 (0.01)
Ring gear-to-stop pin clearance 0.3 0.610.01 0.02)
BATTERY/CHARGING SYSTEM SPECIFICATIONS

ITEM SPECIFICATION S
Battery
(YTX14-BS)
Capacity
Current leakage
Vortage
(20C/68F)
Fully charged
Needs charging
12V 12 Ah
0.1 mA max .
13.0 13.2 V
Below 12.3 V
I
Charging Nor ma! 1.4 AJ5 10 h
-
I current
Capacity
Quick 6.0 All.0 h
Alternator 410 W/5,OOO rpm
I
Charging coil resistance (20"C/68" F) 0. 1 1.0n
1-10
GENERAL INFORMATION
IGNITION SYSTEM SPECIFICATIONS
ITEM
~ ____ SPEC1FICATIONS;';:;:;::;;; ; : : - -
~
spark
Spark plug
plug gap "~~""'::=-~====~-~, --"'
B"'KR 5iiE -ll
"'1.0 - 1.(NGK), K16PR-Ul1
1 mm (0.039 (DEN"S"O,,-
- 0.043 in-)- I __
Ignition coil peak voltage 100 V minimum
CKP sensor peak voltage t 0.7 V minimum
- Ignition timing t IS" Broc at idle
ELECTRIC STARTER SPECIFICATIONS

_ _ _.5.Un, it: mm (in)
ITE"'
M.--- - - STANDARD _-+~S~ER
'iV
, ICE LIMIT
Starter motor brush length,' -_ _ _ _ _ ------:lhl'22:O
.0'lIOO:.~
477j1=~~~~ 6.5 (0.26)
LIGHTS/METERS/SWITCHES SPECIFICATIONS
ITEM SPECIFICATIONS
Headlight 12V30/30Wx2
~
Brakeltaillight LEO
Neutral indicator
Reverse indicator
tt 12V -3.4W
12 V - 3.4 W
4WD indicator 12V - 3.4W
~
I Engine temperature indicator 12 V - 3.4 W
~PGM-FI indicator) +- 12V -3 .4W
Low fuel indicato r 12V -3.4W
Fuse
All differential lock indicator
Parking brake indicator
Main
Sub-fuse
+
L
12V - 3.4W
12V - 3.4W
30A x2
1SAx2, 10Ax4
1
I 1-11
GENERAL INFORMATION
STANDARD TORQUE VALUES
I
' E FASTENEi,Rc';
TVC:P
i E';;;c;-r N
cc.'C
m (kgfm. fblftl FASTENER TYP~ E ---===t~Nj:i.mii)1lk~9~fiim~,~
Ibiff.li
hl
5 mm hex bolt and nut 5 !O.5, 3.71 5 mm screw 4 (0.4, 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, 16) 6 mm flange bolt (8 mm head, small flange) 10 (1.0, 7)
10 mm hex bolt and nut 34 (3.5, 25)6 mm flange bolt (8 mm head, large flange) 12 (1.2, 9)
12 mm hex bolt and nut 54 (5.5, 40)6 mm fl ange bolt (10 mm head) and nut 12(1.2,9)
8 mm flange bolt and nut 27 (2.8, 20)
_ _ _ _ _ _"-"'
lO""m.m flange bolt and nut 39 (4.0, 29)
ENGINE & FRAME TORQUE VALUES

Torque specifications listed below are for important fasteners .
Others should be tightened to standard torque values listed above.
ENGINE
MAINTENANCE
- - -- THREAD TORQUE
ITEM a 'TV REMARKS
Spark plug 1 ,.
DIA. (mm) N'm (kgf'm, Ibf.ft)
22 (2.2, 16)
I
Vallie adjusting screw lock nut
Timing hole cap
6 17 (1.7, 12 )
10 (1 .0, 7)
Crankshaft hole cap 1 "
36 12 (1.2, 9)
Engine oil drain bolt
Engine oil filter cen ter bolt
LUBRICATION SYSTEM
1
1 12
20
2512.5, 18)
18 11.8, 13 ) .l
THREAD TORQUE
I ITEM
I a'TV
I- DIA.!mm) N 'm (kgf'm, IbUtl
REMARKS
Oil pump drillen sprocket bolt 1 12 (1.2, 9) Apply locking agent.
FUEL SYSTEM
- -- -- - - THREAD TORQUE
ITEM a 'TV REMARKS
DIA. (mm) N 'm (kgfm. Ibf.ft)
Insulator band screw (throttle body s";do;;e'l-r--,----=~
1 5 See page 6-47
Insulator band screw (engine side) 5 See page 6-47
ECT sensor 10 12 (1.2, 9)
COOLING SYSTEM
THREAD TORQUE
ITEM a 'TV REMARKS
DIA. (mm l N 'm (kgf'm, IbUtl
I Coolant bleed bolt (at thermostat caller) 6 12 (1.2, 9)
CVlINDER HEADIVAlVE/ CAMSHAFT
THREAD TORQUE
ITEM a 'TV REMARKS
DIA. (mm) Nm (kgf'm, IbUt)
Cylinder head caller cap nut
10 6516.6,48) Apply engine oil.
CYLINDER/ PISTON
~ ITEM a 'TV
THREAD
DIA. (mm)
TORQUE
N'm (kgf'm, IbUtl _
REMAR KS
~ Cylinder stud bolt
10 24 (2.4, 18) !-See page 10-7
ALTERNATOR /STARTER CLUTCH
THREAD TORQUE
ITEM a 'TV REMARKS
DIA. (mm) N'm (kgfm. Ibf.ft)
Starter clutdl bolt 6 8 3013.1.22) Apply locking agent.
I
Flywheel bolt
Alternator stator bolt
CKP sensor bolt

2
12
6
5
108 (11.0, 80)
10 (1.0, 7)
6 (0.6, 4.3) 1 Apply engine oil.
Apply locking agent.
1-12
GENERAL INFORMATION
SUBTRANSMISSION/ GEARSHIFT LINKAGE
THREAD TORQUE
ITEM O'TY REMARKS
DIA .(mm J N -m (kgfm . IbHt)
Shift drum stopper arm pivot bolt 1 6 12(1.2,9) Appl y rockin9~gent.
DRIVETRAIN SYSTEM
ITEM O'TY
THREAD TORQUE
REMARKS
DIA .( mm J Nm (kgfm. Ibfft )
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 nut 1 22 1,8 (12.0, 87) Apply engine oil.
Lock nut: replace with
a new one. Stake.
Oil feed pipe setting cap 2' 21 (2.1,15)
Oil passage sealing cap 20 18 (1.8, 13)
EDT sensor 10 12 (1.2, 9)
1-13
GENERAL INFORMATION
FRAME
FRAME/ BODY PANELS/ EXHAUST SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
OIA. lmmJ N 'm (kgfm. Ibf.ft)
Top OPS mounting nut 8 10 4915.0,36)
Front QPS mounting nut 4 10 49 (5.0, 36)
Rear OPS mounting nut 4 10 49 (5.0, 36)
Rear OPS mounting bolt 2 10 49 (5.0, 36)
Left and right rear OPS joint nut 2 10 49 (5.0, 36)
Crossbar mounting bolt 4 12 64(6.5, 47)
Seat belt anchor bolt 4 7/1 6~ 32(3.3, 24)
Seat belt retractor bolt 2 7116- 32(3.3, 24)
Seat belt buckle bolt 2 7/ 16" 32(3.3, 24)
Bed front panel screw 13 6 8 (0.8, 5.9)
Bed base panel screw 18 6 8 (0.8, 5.9)
Tailgate pivot bracket screw 2 6 810.8,5.91
Ca rgo bed release lever mudguard screw 4 6 810.8,5.91
Tailgate lock lever socket bolt 4 6 12 (1.2, 9)
Heal guard plate bolt 6 6 810.82, 5.91
Bed release lever bracket bolt (lower side; 8 6 14 (1.4, 10)
6x25mm)
Instrument panel screw (6 x 18 mm) 14 6 810.8,5.91
Instrument panel frame bolt 4 12 64 (6.5, 47)
Side panel screw (6 x 13 mm) 10 6 8 (0.8, 5.9)
Parking brake bracket socket bolt 4 8 3813.9,281
Floor cross plate socket bolt 6 8 3813.9,281
Muffler band bolt 2 8 2212.2,16)
Exhaust pipe cover band screw 5 2.5 (0.25, 1.8)
MAINTENANCE
THREAD TQ RQUE
ITEM Q'TY REMARKS
DIA. (mm) Nm (kg ' m, Ibf.ft)
"'--Front final gear case oi I filler cap 1 30 121 1.2,9)
Front final gear case oi I drain bolt 1 8 12 (1 .2,9)
Rear final gear case oil filler cap 1 30 121 1.2,9)
Rear final gear case oil drain bolt
Brake pedal height adj usting bolt lock nut ,
1 8
8
12 (1 .2,9)
22(2 .2,16)
Brake pedal height lock plate torx bolt 1 8 22(2 .2,16)
Rack guide screw 1 32 See page 4-26
Rack guide screw lock out 1 32 24(2 .4, 18)
Tie-rod end lock nut 2 14 I 31_---"_ _ _ __ _~
4414 .5, 3,,
FUEL SYSTEM
ITEM Q'TV THREAD TORQUE REMARKS

_
Fuel pump lock nut --===C::J==

1 D='A=.~l=
m m='j=--:N:;.m93(kgf'm, I~bf~.ft~''=t=======j
(9.5, 691
ENGINE REMOVALJlNSTALLATION
THREAD TORQUE
ITEM
lower engine hanger nut (left and right)
Upper engine hanger nut
Q'TY
,
2
DIA. (mml
10
10
N'm (kgfm. Ibf.ft)
54 (5.5, 40)
54 (5.5, 40)
I REMARKS
:
Upper engine hanger bolt , 2 , 8 32 (3.3, 24 ) I ,
SUB-mANSMISSION/ GEARSHIFT LINKAGE
THREAD
ITEM Q'TY
DIA. (mm)
TOR QUE
N'm (kg fm, Ibfft) REMARKS
Gear selector lever piv ot nut
Gear selector arm pinch bolt ,1 8
6
26(2 .7,201
16 (1 .6, 12)
Gear selector cable nut 2 14 26 (2 .7,20)
1-14
GENERAL INFORMATION
DRIVETRAIN SYSTEM
THREAD TORQUE
ITEM O'TV
DIA. (mml Nm (kgfm, Ibfttl I REMARKS
VS sensor bolt 1 6 100.0,7)
-
,-------------
T-E-
M-------------,--o-'TV
---r-.
THR <
EA
~D---r--~T.,O"R.,O"U"E~---,----R
-E-M
-A-R
-K-S----'
Wheel nut
________________-+__~-1-DIA.
8
(m m,..I_+---'N".m
.....
12-
~lk"igl'f.i'im",~'b"fC'.ft,..I_+--------------_I
108(11 .0,80)
Wheel hub nut 2 20 137 (14.0, 101)
Castle nut: tighten to
the specified torque
and further tighten
unti l its grooves
aligns with the cot
ter pin hole.
Brake disc bolt 8 8 42 (4.3, 31) ALOC bolt: replace
with a new one.
Brake disc splash gua rd socket bolt 6 6 11 (1.1,8) ALOe bolt: replace
with a new one.
Drive shaft outboard guard (at caliper) 4 6 11 (1 .1,8 ) ALOe bolt: replace
with a new one.
Drive shaft guard bolt (at lower arm) 4 6 11 (1.1,8) ALOC bolt: replace
with a new one.
Shock absorber mounting nut 4 10 44 (4.5, 33) Lock nut: replace
with a new one.
Brake hose clamp bolt 4 6 12 (1.2,9) ALOC bolt: replace
with a new one.
Upper and lower arm pivot nut 8 12 64 (6.5, 47) Lock nut: replace
with a new one.
Upper and lower arm ball joint nut 4 12 49 (5.0, 36) Castle nut: tighten to
and further tighten
until its grooves
aligns with the cot
I te~'JP~inho "'e~._ _ _~
L-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _L-_ _ _L-_ _ _ _-"_ _ _ _ _ _ _ _-L-"
STEERING SYSTEM
THREAD TORQUE
ITEM O'TV REMARKS
DIA. (mm) Nm (kgf'm, IbUtl
Steering wheel nut I 12 49 (5.0, 36)
Steering column mounting bolt 4 8 27 (2.8, 20) ALOe bolt: replace
with a new one
Steering shaft pinch bolt 2 8 27 (2.8, 20)
Tierod joint nut 4 12 49 (5.0, 36) Castle nut: tighten to
and further tighten
until its grooves
aligns with the cot-
ter pin hole.
Rack end joint 2 14 54 (5.5, 40)
Steering gear box mounting nut 4 10 39 (4.0, 29) Lock nut: replace
with a new one I
1-15
GENERAL INFORMATION
REAR WHEEL/ SUSPENSION
THREAD TORQUE
ITEM Q'TY REMARKS
OIA. (mm) N 'm (kgf'm, IbUt)
I Wheel nut
Wheel hub nut
8
2
12
20
lOB 11' .0, SO)
137114.0.101) Castle nut: tighten to
the specified t orque
and further tighten
until its grooves
aligns with the cot-
ter pin hole.
1
Brake disc bolt 8 8 42 (4.3, 31) ALOe bolt: replace
with a new one.
Brake disc splash guard socket bolt 6 6 11 (1.1,8) ALOe bolt replace
with a new one.
Shock absorber mounting nut
12 59 (6.0, 44) Lock nut: replace
with a new one.
Brake hose clamp bolt 2 6 12 (1.2,9) ALOe bolt: replace
with a new one.
Upper arm pivot nut
with a new one.
Lower arm pivot nut (frame side)
t2 64 (6.5, 47) lock nut: replace
with a new one.
Lower arm pivot nut (knuckle side) 2 to 44 (4.5,33) lock nut: replace
with a new one.
Stabilizer arm mounting bolt
8 27 (2.8, 20) ALOC bolt: replace
with a new one.
Stabilizer link nut
with a new one.
BRAKE SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N 'm (kgfm, Ibf.ftJ
r Brake hose oil bolt 10 34 (3.5, 25)
Caliper bleed valve to 8.5 (0.87,6.31
Brake pipe jOint nut t2 to 14 (1.4,10)
Master cylinderlbrake pedal bracket 2 8 27 (2.8, 20)
mounting nut
Master cylinder push rod joint nut 8 17.2 (1.8, 13)
Master cylinder reservoir bolt 1 5 2.5 (0.25, 1.8)
Front brake caliper mounting bolt
12 108 (11.0, BO) ALOC bolt: replace
with a new one.

Front brake caliper slide pin bolt 8 22.5 (2.3, 17)
Rear brake caliper mounting bolt to 49 (5.0, 36) ALOC bolt: replace
wi th a new one.
Rear brake caliper slide pin bolt
Rear brake caliper parking brake arm nut
2 8
to
22.5 (2.3, 17)
27.5 (2.B, 20)
Parking brake cable holder cover socket
bolt
6 11 (1. 1, B) ALOC bolt: replace
with a new one.
Parking brake cable damp bolt
8 27 (2.B, 20) ALOC bolt: replace
with a new one.
Parkin brake cable holder bolt 2 10 41 (4.2, 30)
1-16
GENERAL INFORMATION
THREAD TORQUE
ITEM o'n OIA. (mm) N'm (kgfm. Ibfft)
REMARKS
Final gear case mounting nut 2 12 54 (5.5, 40) Lock nut: replace
with a new one.
Final gear case cover bolt 2 10 46.5 (4.7, 34) Apply locking agent.
4 8 25 (2.B, 19)
Differentia l ring gear bolt 10 8 49 (5.0, 36) ALOe bolt : replace
with a new one.
Final clutch housing bolt 3 8 25 (2.6, 19)
Pinion bearing lock nut 64 9B (10.0, 72) lock nut: replace
with a new one.
Stake.
Final clutch shift fork bolt 6 10(1 .0,7) ALOe bolt: replace
with a new one.
4WD select sWitch 10 12 (1.2, 9)
Differential lock switch 1 10 12 (1.2, 9)
Final clutch arm cover and base bolt 3 6 10 (1,0,7)
Differential lock stopper spring plug 12 21.6 (2.2, 16)
Differential lock stopper arm bolt 6 20 (2.0,14)
Differentia l lock shift fork bolt 6 10 (1.0, 7) ALOe bolt: replace
with a new one.
Differential lock clutch housing bolt 4 8 25 (2.6,19)
Drive mode selector lever pivot nut 1 8 26 (2.7, 20)
Front differential lock cable nut 4 14 26 t2.7, 20)

THREAD TORQUE
ITEM O'TY
2
DIA.t mm)
12
Nm (kgfm. Ibf.ft)
-----s4 (5.5,40)
REMARKS
Lock nut: replace
I
Final gear case mounting nut
with a new one.
Final gear case cover bolt 2 10 46.5 (4.7, 34) Apply locking agent .
4 8 25 (2.6. 19)
Differential ring gear bolt 10 10 58 (5.9. 43) Left-hand threads.
Apply locking agent.
Pinion bearing lock nut 1 72 98 (10.0, 72) Lock nut: replace
with a new one.
Stake.
Differentia l lock stopper spring plug 1 12 21.6 (2.2, 16)
Differentia l lock stopper arm bolt 1 6 20 (2.0, 14) Apply locking agent.
Differentia l lock shift fork bolt 1 6 10(1.0,7) ALOe bolt: replace
with a new one.
Differential lock clutch housing bolt
Rear differential lad<. cable nut
4
4 I 8
14
25 (2.6,19)
26 (2.7, 20)
LIGHTS/ METERS/S WITCHES

THREAD TORQUE
ITEM o'n OIA .(mm) Nm (kgfm, Ibl-ft)
REMARKS
- Ignition switch nut 1 I 22 4.9 (0.50, 3.6)
Parking brake switch screw 1 3 0.4 (0.04, 0.3)
1-17
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
MATERIAL LOCATION REMARK S
,
Molybdenum oit solution I Camshaft cam lobes
(a mixture of engine oil Piston pin outer surface
and molybdenum Starter driven gear bearing
disulfide grease in a ratio Starter reduction gear teeth
of 1:1) Starter reduction gear shaft splines
Starter motor shaft splines
Engine oil Oil strainer joint pipe rubber seal
Rocker arm followe r and adjusting screw tip
Cam chain
Cam f ollower entire surface
Cylinder head cap nut threads and seating suriace
Connecting rod small end inner surface
Piston outer surface and piston pin hole
Piston r ings
Cylinder bore
St arter sprag clutch entire surface
Flywheel bolt threads and seating surface
Shift fork shaft outer surface
Shift drum guide groove
Transmission gear teeth and sl iding surfaces
Mainshaft, counters haft and output shaft journals
Primary driven gear lock nul threads and seating surface
Torque converter sprag clutch
Torque converter lock nut threads and seating surface
Oil feed pipe entire surface
Torque converter journal surface
Each bearing rotating area
Each O-ri ng
Each oil seal lips
Molybdenum disulfide Camshaft cam surface
grease Rocker arm shaft sliding surface
Valve stem sliding surface
Stator shaft inner collar bea ring sliding surface of crank- See page 14-44
shaft
Locking agent CKP sensor bolt threads
Starter clutch bolt threads
Stator shaft inner collar stopper pin threads
Shift drum stopper arm pivot bolt threads
Oil pump driven sprocket bolt threads
Cam chain tensioner pivot bolt threads
Sealant (Threebond 1215 Alternator wire grommet seating surface
or equivalent) Front crankcase cover mating surface See page 14-40
Crankcase mating surface See page 13-13
1-18
GENERAL INFORMATION
FRAME
MATERIAL LOCATION REMARKS
Multi purpose grease Cargo bed strikers
Door latch tumblers
Gear selector lever pivot
Gear selector lever arm pivot
Drive mode selector lever pivot
Drive mode selector lever arm pivot
Accelerator pedal pivot
Accelerator pedal pivot dust seal lips
Brake pedal pivot
Brake pedal pivot dust seal lips
Front knuckle outer dust seal lips Fill up 2.5 - 3 9
Front knuckle inner dust seal lips Fill up 2.5 - 3 9
Steering rack end bushing inner surface Applyl - 3g
Steering rack teeth Apply 5-10 g
Steering pinion needle bearing rotating area Apply 0.2 - 0.5 g
Steering pinion ball bearing rotating area Apply 0.2 - 0.5 9
St eering pinion dust seal lips Apply 0.2 - 0.5 g
Steering gear box housing (between pinion dust seal Fill up 2-5g
and dust cover)
Steering rack guide sliding surface (rack side) Apply 0.2 - 0.5 9
Steering rack end joint outer surface Applyl -2g
Rear knuckle outer dust seal lips Fill up 2.5 - 3 9
Rear knuckle inner dust seal lips Fill up 2.5 - 3 9
Front final clutch pinion joint oil seal lips
Front final gear case drive shaft oil seal lips
Front final gear case cover O-ring
Front differential lock arm shaft oil seal lips
Front differential lock housing O-ring
Front final clutch arm shaft oil seal lips
Front final clutch arm shaft O-ring
Front final clutch arm shaft outer surface
Front final clutch housing O-ring
Front final gear oil filler cap O-ring
Universal joint bearing
Rear final gear case propeller shaft oil seal lips
Rear final gear case drive shaft oil seal lips
Rear final gear case cover O-ring
Rear differential lock arm shaft oil seal lips
Rear differential lock housing O-ring
L""""";;;;:"";;-;~CM",,C-_+-jRear final gear oil filler cap O-ring
I Molybdenum disulfide Front shock absorber lower pivot bushing
grease Front shock absorber lower pivot dust seal li ps
Rear knuckle lower arm dust seal lip Fill up 2.5 - 3 g
Rear knuckle lower arm bushing sliding surface
Rear knuckle lower arm pivot collar sliding surface
Front drive shaft splines (wheel side)
shaft J i )
I
Front propeller shaft joint splines (propeller shaft side) Fillup5-8g
Front propeller shaft joint splines (output shaft side)
Front propeller shaft end (pinion joint contacting area)
Front final clutch pinion joint splines Fillup5-8g
Universal joint splines (both sides)
I
i
Front drive shaft inboard joint inside Fill up 60 - 80 g
Right rear drive shaft outboard joint inside Fill up 35 - 55 g
Right rear drive shaft inboard joint inside Fill up 60 - 80 g
Left rear drive shaft outboard joint inside Fill up 35 - 55 g
Left rear drive shaft inboard J,.'""'."~""______--"_FCi''',,,,,-,,8,OC-:.':''''''-_ __ _--"
1-19
GENERAL INFORMATION
MATERIAL LOCATION REMARKS
Silicone grease Rack end tie-rod boot groove Apply 0.5 0.8 9 I
(Dow Corning; Motykate
EM30l or Kluber; Noxlub
554012)
Silicone grease Master cylinder body boot groove Apply 0.19
I
Master cylinder push rod boot groove Apply 0.1 9
Master cylinder push rod end (piston side) Apply 0.1 9
Front brake caliper slide pin sliding area Apply 0.4 9
Front brake caliper piston boot Seal area: Apply 0.8 g
Inside. Fill up 2 - 3 g
Rear brake caliper slide pin sliding area
Rear brake caliper piston boot Seal area: Apply 0.2 9
Inside: Fill up 0.5 - 0.7 g
Rear brake caliper cam bearing Apply 0.5 9
Rear brake caliper cam seal grocve Apply 0.1 9
Rear brake caliper cam dust seal 9 reave Apply 0.1 9
Rear brake caliper rod ends Apply 0.15 g
Rear brake caliper cup Apply 0.1 9
DOT4 brake fluid Brake master cylinder pistons and cups
i- Brake caliper piston and piston se als
Cable lubricant Throttle inner cable
2WD/4WD selector inner cable
Sealant (Threebond 1102 Rack guide screw threads Apply 3 threads
or equivalent )
Honda bond A or Pro Air cleaner housing-to-connecting tube mating area
Honda Hand Grip Cement Air cleaner housing-to-duct tube mating area
(U.S.A. only) or equiva- Air cleaner housing-to-IAT sensor grommet mating
lent area
Air cleaner housing-to-hose gram met mating area
~lodcing agent Cooling fan motor shaft threads
1-20
GENERAL INFORMATION
CABLE & HARNESS ROUTING
FRONT HOOD
,, ,,
,, ,,
,,
,
!
-'
FRONT HOOD
\~~
FRAME
FRAME
(2 places)
~
Front ____ I
(2 places)
HEADLIGHT 3P (Black) CONNECTOR
' ,,
=
"
Right Headlig ht Left Headlight
'c===~_~J';~!~~LlGHT
RADIATOR SHROUD
. ,"-
")
=
,1\, \i'-'
/,
--~) "
1-21
GENERAL INFORMATION
N~b'i7,~;;t-- HEADLlGHT3P (Black)

CONNECTOR
GUIDE
y\\'\..~/1______
c::
0
/,
1-22
GENERAL INFORMATION
Inside of front hood:
HEADLIGHT WIRE
-----
~
,
--'
RADIATOR
RESERVE TANK ----.tIlv"'" BATTERY BOX
I'l 111./\
(
SIPHON HOSE -~;ji,d
iii L -
(
--~.r-!I P~~~1
RADIATOR
-III
FRONT FINAL GEAR CASE --'-UL--jl~-'
BREATHER HOSE I
COOLING FAN MOTOA FOOT BRAKE SWITCH

BREATHER HOSE {Pink) lL,.h, I
,I~~
Ix;
1-23
GENERAL INFORMATION
/'"
WATER HOSE
....~ "
Iii
FAN MOTOR WIRE
\ _-'.= ...'"lr
. ----,f'""";
~r'i?06L1N~AN MOTOR~'.;~~N,Y.S.;m,;.
COOLING FAN MOTOR
BREATHER HOSE (Pink) GUIDES
0' :::::;:
SIPHON HOSE
-'--"11GUIDES
II '
FRONT FINAL GEAR CASE

BREATHER HOSE
1-24
GENERAL INFORMATION
STARTER MOTOR CABLE
FUSE BOX WIRES ....""'::::;
FUSE BOX 4WQ SELECT SWITCH!

1~~ttjL- GROUND
I:?: POINT
(Main fuse, Sub-fuse, Diode) DIFFERENTIAL LOCK
SWITCH WIRE
STARTER RELAY SWITCH
r J
@
~
BATTERY
(+) CABLE DATA LINK
CONNECTOR (olC)
F
01
@
RELAY BOX
(Main relay,
Fuel cut-off relay)
l c, D ,
'"
~
RELAY BOX rake BATTERY POWERTRAINCONTROl
inhibitor relay) BATTERY H CABLE MODULE (PCM)
FAN MOTOR WIRE
~~ ~ 0-- FOOT BRAKE SWITCH WIRE
4WD SELECT SWITCHI ~
DIFFERENTIAL LOCK SWITCH ~
2P (Blue) CONNECTOR FUSE BOX 2P (Brown)
CONNECTOR

2P (G reen ) CONNECTOR
"
/II,
FAN MOTOR 2P (Brown)

CONNECTOR
1-25
GENERAL INFORMATION
BATTERY BOX
COVER
4WD SELECT SWITCHI
DIFFERENTIAL LOCK
SWITCH I
WIRE
JUNCTION
PCM 33P (Gray) OLC
CONNECTOR
~ PCM 33P (Black)
CONNECTOR PCM 5P (Black)
BATTERY
1-) CABLE CONNECTOR
, ,
=
= = /, _ \
';7 \ \
_ GROUNO _ _-""
POINT
HEADLIG HT WIRE _ -.J,---',\\',,%
BATTERY
1-) CABLE
MAIN WIRE
HARNESS :l 4WD SELECT SWITCHI
STARTER MOTOR DIFFERENTIAL LOCK
_
y CABLE SWITCH WIRE
4WD SELECT SWITCHI ~......" ---- Front

I
DIFFERENTIAL LOCK
SWITCH WIRE I
FRAME
'J
\~--71
L STARTER MOTOR
CABLE
~
1-26
GENERAL INFORMATION
Reverse side of instrument panel :
INDICATORS
--
___ LIGHTING/DIMMER
SWITCH
~----\
IGNITION SWITCH
-~"\
MAIN WIRE DRIVE MODE
HARNESS =- - SElECTOR LEVER
if-
"~~~ GEAR
REGULATOR!
RECTIFIER
DIODE
-:~~- -_.-------- -_ .. ---_.. ...- ._---_._-......_----

,
-----\~.
3P (Gray) CONNECTOR
~-m
---
3P (Black) CONNECTOR - - - .
FRONT DIFFERENTIA L ~\\\ 1- GEAR SELECTOR CABLE

U1
LOCK CABLE I \
REAR DIFFERENTIAL 2WD/4WQ SELECTOR CABLE

LOCK CABLE
1-27
GENERAL INFORMATION
Reverse side of floor panel:
REAR DIFFERENTIAL
~~::::::::::~LOCK CABLE
WIRE JUNCTIONS --..,..~:(\ " .. GEAR SELECTOR CABLE
\\ ~.~_ _ FRONT DIFFERENTIAL

LOCK CABLE
.\ ~.~_ _ _ FRONT FINAL

GEAR CASE
#'V;;;;;~~~ F~
THROTILE CABLE _
FRONT DIFFERENTIAL
- -_ _ LOCK CABLE
o a
FRONT DIFFERENTIAL
GEAR SELECTOR LOCK CABLE
o FRAME
~,
;",_ _ _ CABLE
.j
I~~-
REAR DIFFERENTIAL THROTILE
r=~~_::,:FR;:. ;BLE
LOCK CABLE
WATER
HOSE r' .~
1-29
GENERAL INFORMATION
Inside of floor panel:
REAR DIFFERENTIAL
GEAR SELECTOR FRONT DIFFERENTIAL
CABLE LOCK CABLE
2WD/4WD SELECTOR f4'-f-__ MAIN WIRE

CABLE
!-___ WATER HARNESS
HOSE
o
STARTER MOTOR
left - CABLE
CABLE
PEDAL
SelECT SWITCH!
DIFFERENTIAL LOCK
GEAR,.,.e,enR SWITCH WIRE
CABLE
REAR DIFFERENTIAL
4WDSElECT
LOCK CABLE
SWITCH
-"""To differential lock switch
2WD/4WD SELECTOR
CABLE
\
To 4WD select switch
,
:=:.=:_ CLIPS
-~-
GROMMET ------...
1-30
GENERAL INFORMATION
Inside of floor panel:
.....
......
....
~
.....::.
..
..
4WD SELECT SWITCHI .......'"
DIFFERENTIAL LOCK
SWITCH WIRE
..
"
THROTILE
, CABLE
r:::::- REAR
I-
DIFFERENTIAL
LOCK CABLE
---
MAIN WIRE
GEAR SELECTOR f~~~ HARNESS -

CABLE
, , c
-'"
......"...
---.- ... -... 0
"
".-. ".-. ".-.

i
~E ~~1i:==::::B~-\----
__
MAIN W IRE
HARNESS Clip Position: ~
Clip Position:
GEAR
SELECTOR
..
'0'
0 ... f...,
0
CABLE
REAR DIFFERENTIAL
STAR~ER MOTOR CABLE ----.....-~~~ LOCK CABLE
I=;~~t,;- STARTER MOTOR CABLE

BATTER Y H CABLE BATIERY
THROTTLE CABLE
H CABLE
WATER PIPES 0
Front ___
1-31
GENERAL INFORMATION
Front side of the engine:

(Viewed from left side)
GEAR POSITION SWITCH

3P (Black) CONNECTOR
ALTERNATORfCRANKSHAFT
CLUTCH PC/SHIFT POSITION (CKP) SENSOR 5P (Black)
SOLE NOID 2P (Black) CONNECTOR
WATER HOSE CONNECTOR
THROTIlE CABLE
STARTER MOTOR CAB ~ 4--J-,4iWlP""n/{'11

SHifT SOLENOID A
~~e-- 2P (Black) CONNECTOR
BATIERY (-) CABLE i-t-41

LOCK DIFFEREN~.~IA:L)[~b.Jll,l l"r~t _--->-\
REAR CABLE
- .
I~-a~", f,, ;o--- SHIFT VALVE BODY
~>./
~
ur _j~~~~~~:J GEAR SELECTOR
~- Left CABLE
Oil PIPES
WATER PUMP
11 "0-
;r
OI L COOLER
J~
CLIP
WATER HOSES
1-32
GENERAL INFORMATION
WATER HOSE
, I STARTER
MOTOA
CABLE
( 1fT ~ Fronl
'\
I
STARTER
MOTOR
GU IDE
BATTERY H CABLE
Upper side of the engine:
Right
t
OIL COOLER
UP . \l@ BATTERY
(-) CABLE
STARTER
MOTOR
CABLE
""
WATER HOSE
,./ THERMOSTAT
Front .........
u; ~9ht
Up .. ft:! -- Green/orange
(Q)
I
Front
If
SPARK PLUG WIRE Blacklyellow
IGNITION COil
1-33
GENERAL INFORMATION
THROTTLE CABLE
THERMOSTAT
STARTER MOTOR CABLE -

CLIP (Clamp at marking
position of thronle cable)
2P (Black) CONNECTOR PARKING BRAKE
FUEL PUMP 5P (Gray)
CONNECTOR
---:7=t::/tl~~'ft
JC'c'Y--- PAR KI NG
BRAKE
LEVER
,
~
Front
CABLE ~
MAIN WIRE HARNESS

~
TANK
1-34
GENERAL INFORMATION
ACCESSORY SOCKET
2P (Green) CONNECTOR
~\--=~ ,k-'o~
- ~\
" ,,- L
11""",...:-'
L-?.
...
,__-
"-< -
~
GROUND CABLE
(Frame-ta-Engine)
If -!
... ~
... BAND:
. Gear position switch wire
. Alternator/CKP sensor wire
IAT SENSOR
(in air cleaner
housing)
GROUND CABLE
(Frame-ta-Engine)
Eer SENSOR
OIl ;ILLER4
I GEAR POSITION
D S~'TCH
------- r \ r
\ \
EDT SENSOR
1-35
GENERAL INFORMATION
Around the throttle body:

(Viewed from right rear side)
ACCESSORY SOCKET
2P (G reen)
CONNECTOR
~" iCA ;);..1, <
GEAR POSITION
SWITCH
Around the fuel tank:
(Viewed from right side)
"-j.{ J' ~
\ \ AIR INTAKE DUCT e ~
\\~-.;>-;~~
~. ,,-:: ~~ ~ _____"
~~ ~ -J " FUEL TANK BREATHER HOSE
( 0-3mm
II ..
r
FUEL TANK
CLAMP
1-36
GENERAL INFORMATION
Around the rea r final gear case:

(Viewed from right front side)
_" '_ _ _ REARDIFFEAENTIAL

LOCK CABLE
, rl ___ "*'
.'.~----.
~
\ ..,>-
,
~ ===-
~
\'~.~ I
_ REAR DIFFE RE':;-TIAL
lfr)---,-
~ LOCK CABLE
UNDERBODY
Up
'\o
-",p/;-
_" 1\\" ~,
REAR FINAL GEAR
_ ii\..:, CASE BREATHER HOSE
-
~,-I-
\
-L-
____ Front
FRAME PIPE JOINT
;S'/
1-37
GENERAL INFORMATION
Under side of cargo bed:

(Viewed from left side)
e
\
TAILLIGHT 6P (Black)
CONNECTOR BOOT CONNECTOR
,
To taillights
J~ .
(Viewed from right front side)
CL-:..~,-----{
.~4
-fJ;<>-<-r'-i"'
,II i-' ---';no ~...j !l
~.;. ~ . ~~......... .
o
~.,.!
~)
o ~
VS SENSOR WIRE
~
1-38
GENERAL INFORMATION
~
Ii:'
~
""-- ~
LEFT TAILLIGHT
TAILLIGHT
TAIL
\>-GA~\
/' TAILLIGHT WIRE
Front
FRAME
1-39
GENERAL INFORMATION
Front brake hose routing:
MASTER CYLINDER
BRAKE HOSE
UPPER
CLAMP -~~'~~?l ARM
CLAMP
KNUCKLE
BRAKE CALIPER
(Left side)
BRAKE HOSE
1-40
GENERAL INFORMATION
Front frame bake piping :
PIPE JOINT
(Master cylinder B)
(Right Front)
BR,AKE PIPE (Right Rear)
RETAINING PLATE
o~
. . . . . . . Outside
(2 places; left and right)
1-41
GENERAL INFORMATION
Underbody bake piping:
PIPE GUIDE
MASTER CYLINDER
BRAKE PIPE (Right Rear) (Q~- BRAKE PIPE (left Rear) Front
BRAKE PIPE (left Rear)

PIPE CUPS (5 places)
1-42
GENERAL INFORMATION
Underbody bake piping :

,
,
,

BRAKE PIPE
(Right Rear)
i
BRAKE PIPE
'"~'"-~ BRAKE PIPE

( (left Rear)
o "'- Front
PIPE GUIDES
(2 places)
o
' - - ' - BRAKE PIPE
(left Rear)
\r a
~~["-'~\~~~J)1jc;:; 2.5 mm minimum
BRAKE PIPE o
a
(Right Rear)
BRAKE PIPE
( (RighI Rear)
BRAKE PIPE
,'-------'-'----
(Left Rear)
LEFT ENGINE
HANGER BRACKET
1-43
GENERAL INFORMATION
Paring brake cable routing:
lEFTPARKING
BRAKE CABLE
~-~~".-A
I >
RIGHT PARKING
, BRAKE CABLE
LEFTPARKING
l PARKING BRAKE
BRAKE CABLE LEVER
1-44
GENERAL INFORMATION
Rear brake hose and paring brake cable routing:
STOPPER
__~~~~--- STOPPER
CLAMP
PARING BRAKE CABLE

CALIPER
BRAKE CALIPER
{Left side)
~~
RETAINING PLATE
RETAINING
(2 places; left and right ) PLATE
STOPPER
CABLE HOLDER - - - - -
Flat surface
1-45
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS
The U.S. Environmental Protection Agency (EPA), the Califo rnia Ai r Resou rces Boa rd (CAR B), and Environ ment Canada
(EC) require that MUVs comply with applicable exhaust emissions standards du r ing its usefu l lif e, w hen ope rated and
maintained according to the instruction provided.
SOURCE OF EMISSIONS
The combustion process produces oxides of nitrogen (NOx), carbon monoxide (CO) and hyd rocarbons (He). Controlling
oxides of nitrogen and hydroca rbon em issions is very important because, under certai n conditions, they react to fo rm
photochemical smog when su bjected to sunlight. Carbon monoxide does not react in the same way, b ut it is toxic.
Honda Motor Co., Ltd. utilizes various system to reduce carbon monoxide, oxid es of nitrogen and hyd roca rbons.
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of the PG M -FI syst em and no adjustments shou ld be made. The
exhaust emission control system is sepa rate from the crankcase em ission control syst em.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed cra nkcase syst em to prevent discharging crankcase em issions into the atmosphere.
Blow-by gas is returned to the comb ustion cham ber through the ai r cleaner and throttle body.
CLE ANER
THROTTLE BODY
CRAN KCASE BRE ATHER 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 MUV repair
establishment or individual using parts that are ~ certified " to EPA standards.
PROHIBITED ACTIONS
The following prohibitions apply t o everyone with respect t o the engine's em ission control system.
You may not remove or disable any device or element of design that m ay affect an en gine's em ission levels. This
restriction applies before and aft er the engi ne in placed in service.
1-46
GENERAL INFORMATION
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIB ITED: State 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 ma i ntenance, 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 afthe intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other then those
specified by the manufacturer.
FUEL PERMEATION EMISSION CONTROL SYSTEM
This MUV 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 MUV 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 that significantly increase the service life of the engine, the vehicle will 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 to all Diagnostic Trouble Codes (OTC). and erase all OTCs after addressing their cause
- Use only Genuine Honda parts or equivalents
- Make sure to maintain all specifications as described in this Service Manual
1-47
GENERAL INFORMATION
LIFT AND SUPPORT POINTS
Use the following l ift and support points to support the vehicle and raise the wheels off the ground.
Block the 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 plate) or the center of the rear
end frame crosspipe IA or BI as shown, and jack up the vehicle high enough to fit the safety stands under it.
Position the safety stands under the support points Ie or DI and adjust them so the vehicle is level . Lower the vehicle onto
the stands.
Lift Points:
Front : Rear:
CROSS PIPE
CROSSPIPE
Support Points:
Rear:
'48
2. TECHNICAL FEATURES
MUV OVERViEW .. 2-2 AUTOMATIC TRANSMISSION

SySTEM 2-7
PGM -FI SySTEM .. 2-4
SELECTABLE 4WD AND DIFFERENTIAL
LOCK SYSTEM ......................................... 2-14
2-1
TECHNICAL FEATURES
MUV OVERVIEW
OUTLINE
MUV stands for Multipurpose off-highway Utility Vehicle.
The MUV features:
Liquid-cooled single cylinder OHV engine
PGM-FI system
Three-speed Automatic Transmission system
Tubular steal frame and occupant protective structure (OPS)
Buckel seals with retractable three-points seat belt
Tilting ca rgo bed
Selectable 4WD and differential lock systems
Front and rear independent double-wishbone suspension
OCCUPANT PROTECTEVE STRUCTURE (OPS), DOOR AND CARGO BED

The MUV body consists of a tubular steet frame, Occupant Protective Structure, cargo bed, doors, and body panels. If the
frame is damaged or deformed it cannot be repaired. This is the same as Honda ATVs.
OCCUPANT PROTECTIVE
STRUCTURE
CARGO BED
BODY PANELS
.
FRAME
2-2
TECHNICAL FEATURES
MUV STEERING SYSTEM
The MUV utilizes a rack and pinion automotive style steering system. The system consists of a steering wheel, steering col-
umn, steering gear box, and tie-rods. The steering system requires periodic maintenance (page 4-4) and rack guide adjust-
ment (page 426).
STEERING WHEEL - - - 0 - {
STEERING COLUMN
UNIVERSAL JOINTS ' \ - - - -.#J
// - . - - - STEERING SHAFT
STEERING GEAR BOX

(Rack and Pinion)
~_~ KNUCKlE
TIE-RODS
ELR (Emergency Locking Retractor) SEAT BELT

The MUV is equipped with three-point seat belts with ELR.
The three-point seat belts afe equipped with emergency locking retractors. In normal driving, the retractor lets you move
freely in your seat while it keeps some tension on the belt. During a collision or sudden stop, the retractor automatically
locks the belt to help restrain your body.
UPPER ANCHOR
on1
RETRACTOR
LOWER ANCHOR
2-3
TECHNICAL FEATURES
Normal Driving Condition Sudden Stop Vehicle leaned Condition
1
BELT _ ~'II
_ SYNCHROGEAA
LOCK LOCK LEVER

WEIGHTB RATCHET
PENDULUM
WEIGHT
PGM-FI SYSTEM
INTEGRATED SENSOR THROTTLE BODY
This model is equipped with a throttle body that integrates the following sensors and device. This throttle body has a
compact design with simplified inspection capabilities.
MAP (Manifold Absolute Pressure) sensor: detects the intake air pressure
TP (Throttle Position) sensor: detects the throttle opening position
IACV (Idle Air Control Valve): controls the engine idle speed and enhances starting
These components can be removed from the throttle body.
IACV
FUEL INJECTOR
THROTILE BODY
MAP SENSOR
TP SENSOR
2-4
TECHNICAL FEATURES
IACV (Idle Air Control Valve)
The lACV consists of a step motor and a slide valve, and controls the amount of air bypassed around the closed thronle
valve. With the ignition switch ON, the amount of idle air is determined by the PCM from information detected by various
sensors, During engine start-up or while maintaining idle (throttle valve closed), the amount of inlet air is continuously
adjusted according to various sensors' information .
This system eliminates the need for a manual idle speed adjustment and high altitude adjustment settings.
THROTILE BODY
STEP MOTOR
~kv--
SUDE VALVE
AIR BYF'AS,s
OPERATION
The PCM controls the IACV during engine idling only, so the PCM stops controlling the IACV and leaves it in the closed
position when the PCM detects the following:
Throttle valve open
Gear position switch is in gear position (except neutral)
During engine idling and warm up, from the time the ignition switch is turned ON, the PCM controls the IACV step motor
as follows:
With the ignition switch ON
When the ignition switch is turned ON, the IACV is initialized and
1fTI1~
the step motor will operate: The slide valve goes from the open
position, to the closed, and again to the open position.
Engine starting and warm up STEP MOTOR
While the throttle valve is closed, the bypass opening is optimized
by the IACV, and the correct amount of inlet air passes through
allowing proper engine starting.
After the engine has started, the PCM controls the IACV step motor
p I D
to adjust the slide valve pOSition by processing various sensors'
information. This results in a reduced amount of bypassed air com- 8 ,-
pared to the amount during engine start-up, and initiates engine
warm-up for sever a! minutes. ~i\
I~SUDE VALVE
2-5
TECHNICAL FEATURES
After warming up idling
When the PCM receives input signals that indicate the completion
of engine warm-up. it operates the step motor to move the slide
valve downward. This results in a reduced amount of bypassed air
compared to the amount during engine warm-up, which maintains
proper engine idle speed.
2-6
TECHNICAL FEATURES
AUTOMATIC TRANSMISSION SYSTEM
OUTLINE
The three-speed Automatic Transmission (AfT) system used in the MUV controls gear selection by utilizing a torque con-
verter and three hydraulic shift clutches.
To control the hydraulic clutches to shift, the system changes the supply of hydraulic pressure to each clutch (1st, 2nd, 3rd )
by activating the respective spool valves with the corresponding solenoid valves. Each solenoid valve is controlled by the
PCM, that detects the signa l from each sensor and switch.
The hydraulic oil for this system is the engine oil, which is supplied from the engine lubrication oil pump (page 5-2),
The valve body, which incorporates solenoid valves and spool valves, that is positioned on the crankcase cover to facilitate
maintenance (page 14-28)
The sub-transmission is positioned in front of the output shaft, and selecting Drive, Neutral, or Reverse can be made
mechanically by operating the selector lever located near the steering wheel.
TORQUE COIWERTE'R
PRIMARY DRIVE GEAR
MAINSHAFT
PRIMARY DRIVEN GEAR
SUB-TRANSMISSION
(COUNTERS HAFT)
'od
nlm'IIT SHAFT
3rd SHIFT CLUTCH
OlJTF'UT DRIVEN GEAR
2-7
TECHNICAL FEATURES
TORQUE CONVERTER
STRUCTURE
Pump
The pump, directly connected to the crankshaft, converts engine output (torque) into oil flow.
Turbine
Receiving the oil from the pump, the turbine transmits the t orque to the transmission by way of the primary drive gear.
Stator
The stator changes the direction of the oil flow drained from the turbine. It drains the oil toward the pump.
Stator Shaft
It transmits the stator rotation to the one-way clutch.
Stator One-way Clutch
The stator one-way clutch locks the stator at stalling and it releases (rotates) the stator at coupling (page 2-8).
Inner Collar
The inner collar, prevented from turning by the stopper pin fixed on the crankcase, stops the rotation force at stalling,
which is transmitted from the stator by way of the one-way clutch_
Engi ne Brake One-way Clutch
When engine braking is applied, the engine brake one-way clutch directly transmits the input torque from the primary
drive gear to the crankshaft. This allows the machine to slow down by engine braking.
Seal Ring and Seal Collar
The seal ring and seal coliar are provided to prevent oil leakage.
TURBINE BLADES
PUMP BLADES
--~
STATOR BLADES --Eit<+i STATOR ONE-WAY CLUTCH
Hydraulic Oil To c,ankpin and piston
i"--r---INNER COLLAR
SEAL COLLAR
CRANKSHAFT
STATOR SHAFT
STOPPER PIN
PRIMARY DRIVE GEAR
OPERATION PRINCIPLE
, . Oil Flow:
The oil in the torque convener flows in this order; from the pump, to the turbine, and then to the stator. The oil is sup-
plied from the inside of the pump, and the excess oil is drained from the turbine. The torque convener is cooled down
by the flow of fresh oil through the system .
2. Stall Range:
When the difference of rotation speed between the pump and turbine is large, the stator turns in the reverse direction
from that of the turbine by receiving the reaction force from the turbine. As this motion is locked by the one-way clutch,
the counter torque is applied to the stator. To balance the rotational direction, the turbine torque (output torque)
becomes the sum of the pump torque and the counter torque of the stator. Therefore, the output torque is amplified by
the amount of counter torque of the stator.
3. Coupling Range:
When the difference of rotation speed between the pump and turbine is small (0.8 or more), the reaction force applied
from the turbine to the stator is small and the stator turns in the same direction as that of the turbine. As the torque is
not amplified this time,the torque ratio is about 1.0 and the torque transfer efficiency to speed ratio changes in the ratio
of 1:1.
4. Engine Braking:
The input force from the primary drive gear is directly transmitted to the crankshaft by the one-way clutch, which pro-
duces the engine braking (same as the conventional ATV).
2-8
TECHNICAL FEATURES
HYDRAULIC VALVE FUNCTION
AIT Clutch Pressure Control Solenoid Valve {linea r Solenoid Valvel
The AfT clutch Pressure Control (PC) solenoid valv e controls the vehicle creep by diverting the hydraulic pressure that
flows to the entire clutch system to the linear valve.
Sh ift Solenoid V alves (A and B)
The shift solenoid valves control the shift timing by supplyin g and shutting off hydraulic pressure to activate the shift
valves.
Shift Valves (12 and 2-3)
The shift valves switch the hydraulic circuits to the three clutches.
Orifice Control Valve (2nd and 3rd)
The orifice control valves operate when clutch fluid pressure rises during shifting . It releases the pressure to reduce
shift shock.
Emergency Valve
The emergency valve is used when the hydraulic pressure is shut off by a faulty clutch PC solenoid valve (stuck;
mechanical lock ), and the vehicle is prevented from moving. Opening the bypass oil circuit manually supplies hydraulic
fluid to the system . (In thi s case, the transmission is held in 2nd range and the vehicle creeps dur ing idl i ng .)
3rd SHIFT CLUTCH
2nd SHIFT CLUTCH

3rdOAIFICE 1st SHIFT CLUTCH
CONTROL
VALVE
2nd ORI FICE SHIFT
CONTROL SOLENOID
, VALVE VALVE A
~,
2-3 SHIFT VALVE Fr:~~~
I==~
TORQUE CONVERTER 1-2 SHIFT
SHIFT
SOLENOID VALVE
VALVE B
,
Alternator
Cylinder head :=~~~ll==JLc~,~aln~k:'~h~a:ft~===~jE~
Sub-transmission OIL COOLER RELIEF ~~~~~;~;~~~~~~
VALVE
AfTCLUTCH PC
SOLENOID VALVE L _ r
OIL FILTER
OIL STRAINERS
OIL PUMP
2-9
TECHNICAL FEATURES
SHIFT CLUTCH HYDRAULIC CIRCUIT AND OPERATION
This system activates the AIT dutch PC solenoid valve and shift solenoid valves A and S, as the PCM detects the following
signals:
- throttle angle
vehicle speed
- sub-transmission gear position (0 - N - AI
- engine oil temperature
It controls the shift clutches for the driving situation according to the combination of the respective solenoid valves' opera-
tion.
Gea r in Neutral
Gear po sition
Clutch PC
Sole noid
S hift Sole noid
A B ,,, Shift Clutch
2nd I 3,d
Neu Iral -r- ON OFF OFF - -
The hydraulic passage is the same as the transmission being in the 2nd range. The AfT clutch PC solenoid valve is on
(valve closed) and the hydraulic oil that flows to all shift clutches is shut off. Therefore, all clutches arB inactive.
'od SH'HClUT'CH
2nd ORIFICE
CONTROL SHIFT
VALVE SOLENOID
VALVE A
2-3 SHIFT VALVE
TORGUE CONVERTER ' -2 SHIFT

VALVE
SHIFT
SOLENOID
VALVE B
AfT CLUTCH PC
SOLENOID VALVE
OIL PUMP
2-10
TECHNICAL FEATURES
1st gear and Re verse gea r
Gear pos iti~o~

n ---A
"lrT"'C'lut ch 1'==~
S~h~;ftt]
S~o~
' .~n~o':;d~
,.. Shift Clutch
2nd 3 r~,
1--.=>.: .=-==c.--,c
1sVReverse (idling )
! -=c:..::
s Oo'NenOid 11
_
A
ON
B
OFF +"Engaged"
1sVReverse (driving) I OFF _:t=jo~Nft=t=ofuF~F "Engage"d" + - - -
The hydraulic passage is connected to supply hydraulic oil to the 1st shift clutch, and the clutch is engaged.
Oil is supplied by way of: AJT clutch PC solenoid valve , ' 2 Shift valve 1st Shift clutch
(Oil is drained by way of:
2nd Shift clutch <::> 2-3 Shift valve -'> 1-2 Shift valve
3rd Shift clutch 2-3 Shift valve)
AI idling, the AfT clutch PC solenoid valve is on (valve closed) to eliminate vehicle creep.
At start up, the AIT clutch PC solenoid valve controls the clutch hydraulic pressure to the linear valve according to the
signal from the PCM .
AI driving, the AIT clutch PC solenoid valve is off (valve open) supplying sufficient hydraulic oil to the shift clutch.
Control of the hyd raulic passage during driving in Reverse gear is the same. However, the vehicle can be driven only in
the 1st-hold mode (no shift).
3rd SHIFT CLUTCH

'od
3rd ORIFICE
CONTROL
VALVE
2nd ORIFICE
CONTROL SHIFT
VALVE SOLENOID
VALVE A
23 SHIFT VALVE
TORQUE CONVERTER ' 2SHIFT

VALVE
SHIFT
~~~~~~~~\"-------I-EMERGENCY
U] VALVE
SOLENOID
VALVE B
II AfT CLUTCH PC
SOLENOID VALVE L_r
OIL PUMP
I 2-11
I
TECHNICAL FEATURES
Driving in 2nd range
Gear position AIT Clutch Shift Solenoid Shift Clutch

PC Solenoid A 8 , ht 2nd 3'"
2nd gear OFF OFF OFF - ~ Enga ged -
The hydraulic passage is connected to supply hydraulic oil to the 2nd sh ift clutch.
Oil is supplied by way of: AfT clutch PC solenoid valve <:> ' 2 Shift valve q 2-3 Shift valve q 2nd Shift dutch
1st Shift clutch Q '-2 Shift valve ~ 2nd Orifice cont rol valve
3rd Shift cl utch q 2-3 Shift valve)
When shifting from 1st to 2nd pOSition, the draining volume of the 1st clutch hydraulic oil is controlled by the ordinary
orifice and the 2nd orifice control valve to reduce shift shock.
When the PCM detects system failure (fail-safe model, the hydraulic passage is the same as above. (Therefore, the
vehicle ca n be ridden only in the 2nd-hold mode and creeping can occur at idle)
2nd
2nd ORIFICE
CONTROL SHIFT
VALVE SOLENOID
VALVE A
23 SHIFT VALVE
TORQUE CONVERTER ' 2 SHIFT

VALVE
SHIFT
~::~~~~~~~---- ~EMERGENCY
I.<
__
VALVE
SOLENOID
VALVE B
AIT CLUTCH PC
SOLENOID VALVE
OIL PUMP
2-12
TECHNICAL FEATURES
Driving in 3rd range
Gear position '""CA'lnT~C"I~u;;tc~hO--- _--=~S:h~;ft~S~O~'e~n~O~;d~== Shift C lu tch:----~

PC Solenoid A B 1st 2nd
~rd gear I OFF ~
OFF ON "Engaged"
The hydraulic passage is con nected to supply hydraulic oil to the 3rd shih clutch.
Oil is supplied by way of: AfT clutch PC solenoid valve 1-2 Shift valve '-. 2-3 Shih valve 9 3rd Shift dutch
1st Shift dutch "", 1-2 Shift valve '-'.' 2nd Orifice control valve
2nd Shift clu tch 2-3 Shih valve q 3rd Orifice control valve)
When shifting from 2nd to 3rd position, the draining volume of the 2nd clu tch hydraulic oil is contra lied by the ordinary
orifice and the 3rd o rifice control valve to reduce shift shock.
CLU TCH
,,, SHIFT ClmCH

3rd ORIFICE
CONTROL
VALVE
2nd QRIFICE
CONTROL SHIFT
VALVE SOLENOID
VALVE A
~~;5~_~-~~2;r~;;:J
23
""'l'-'1'L - SHIFT VALVE

TORQUE CONVERTER 1-2 SHIFT
A VALVE
SHIFT ~~~~
SOLENOID
VALVE B
r "I--~~-~"=----"U
:t:l
AfT CLUTCH PC
SOLENOID VALVE
OIL PUMP
2-13
TECHNICAL FEATURES
SELECTABLE 4WD AND DIFFERENTIAL LOCK SYSTEM
The MUV's drivetrain system can be selected for 2WD/4WD and differential lock according to trail conditions. The clutch for
the selectable 4WO is located between the propeller shaft and front final gear case. The clutches for the differential lock are
installed in both front and rear final gear cases. These clutches are mechanical-select systems that are controlled by the
selector lever via the control cables.
DRIVE MODE SELECTOR LEVER

____ (3 mode)
CABLES

Wheel Whettl
REAR DIFFERENTIAL
FRONT DIFFERENTIAL
'
. - - - - LOCK CLUTCH
LOCK CLUTCH ______
U
f77
Fron! O;flerefllial
DRIVE _ _~~~I
SHAFTS.~ _ _,--_---.. 2WD/4WD
Engine
'---------'
PROPELLER SHAFT
v Rea. Differential
_~____ DRtVE
SHAFTS
FINAL CLUTCH Wheel
DRIVE MODE SELECTOR LEVER:
r---4WD - Rear diHerentiallock

2WD _ _.:..\ , J,
J___ 4WD - All differential lock
2WD/ 4WD FINAL CLUTCH OPERATION
When the operator selects 4WD with the selector lever, the sh ift fork slides the clutch sleeve to engage the pinion joint with
the pinion gear. If the spline between the pinion joint and the pinion gear does not engage, the system has a lost motion
mechanism to engage the pinion joint
DRIVE MODE
SElECTOR LEVER
FIOri! Rear
2WD/4WD Final Clutch Mechanism:

--_/ To rear dilla,emiallock _ ---'
To lrom differerltiallock_ - _ _- '
CLUTCH SLEEVE
~-PINION JOINT
CLUTCH ARM SHAFT
2-14
TECHNICAL FEATURES
2WDto 4WO
Pushing the selector lever to 4WD (Rear Diff Lock)
pulls the clutch arm shaft and toads the clutch lock
spring . In lost motion state. the clutch sleeve stays on
the pinion gear. When the spline is engaged, the Lost motion state:
clutch sleeve slides onto the pinion joint. engaging
4WD by the tension of the clutch lock spring. LOCK SPRING
=~~i--- SLEEVE
4WD position
-----Cf;=;15 t
2WD position
4WDto 2WD
Pulling the selector lever to 2WD returns the clutch
arm shaft. In lost motion state, the clutch arm shaft SELECTOR
stays in the 4WO position with the clutch sleeve. LEVER
When the spline is engaged , the clutch sleeve returns ():==I[O)
from the pinion joint. for 2WD mode, by the tensi on
of the relurn spring. lost motion state:
,:!;!i~- SLEEVE
4WD position
~~
2WD position
2-15
I
TECHNICAL FEATURES
DIFFERENTIAL LOCK CLUTCH OPERATION
With normal differential function, if one drive wheel loses traction the differential will stop power to the other wheel. When
locking the differential, both drive shafts are locked together so power is equally distributed to both wheels.
Differential Actuation: Differential lock :
When the operator selects ditferentiallock with the selector lever, the shift fork slides the clutch sleeve to engage the differ-
ential gear housing in the final gear case with the half shaft (connected to the right drive shaft) directly. If the spline
between the gear housing and the half shaft does not engage, the system has a lost motion mechanism to engage the dif-
ferential housing.
SELECTOR LEVER
Oitferentiallock Clutch Mechanism:

(Rear final gear case shown)
SHIFT
HALF SHAFT
To front differentialloc"-
To 2WDI4WD final clutch _ _ _ _ _ _~
HOUSING
LOCK ARM SHAFT
PINION GEAR
RING
2-16
TECHNICAL FEATURES
Normal Operation to Differential lock
Setting the selector lever to differential lock pulls the
lock arm shaft to secure it wi th the stopper spring Lost motion state:
and loads the fork sp ring. In lost motion state, the
STOPPER
clutch sleeve stays on the differential housing. When
SPRING
the spline is engaged, the clutch sleeve sl ides onto SLEEVE
the half shaft, engaging d ifferential lock by the ten-
sion of the fork spring.
FORK
BALL
SPRING
lock
Free
Differential lock to Normal Operation
-
Setting the selector lever to lock free returns the lock
arm shaft to secure it with the stopper spring and Lost motion state:
loads the fork spring. In lost motion state, the shift
fork stays in the differential lock position with the
SELECTOR SLEEVE
clutch sleeve. When the spline is engaged, the clutch
sleeve retu rns from the half shaft. LEVER
2-17
MEMO
3. FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION "",, 3-2 FLOOR CROSS PLATE """""""""",,",,,,. 3-13
TROUBLESHOOTING " .. "." ... ".". " .. "."." ... 3-2 INSTR UMENT PANEL """ """ """ "" """" 3-13
BODY PANEL LOCATIONS "-""""""""",,. 3-3 FOOTREST PANEL """ """"""""""""",, 3-14
SEAT " "" "" .". " ... " .. " ".".' ". "._. ".".,," """"" 3-4 FRONT HOOD """"""""""""""""""""". 3-14
SEAT CENTER COVER """".,"""""""""". 3-5 FRONT GRILLE """"""""""""""""""",,. 3-15
SEAT UNDER COVER """ """"" "" """""". 3-6 FRONT BUMPER """"""""""""""""""" 3-16
ENGINE FRONT COVER """ " " " " "" """ "". 3-6 MAINTENANCE LID """"""""""""",,",,. 3-16
PARKING BRAKE LEVER BRACKET """"" 3-7 CARGO BED "",, "" """""" " " " "" """"" "" 3-16
CENTER FRAME COVER """." " "" .. ,,""",,. 3-7 SIDE NET """"""""""""""""""""""""" 3-21
CROSSBAR ". " .. . ". ". " ..." " .. "" ".". "".".,,"" 3-8 OCCUPANT PROTECTIVE STRUCTURE
(OPS) ""."." ..... " ........................... "." ........ 3-21
DOOR,, " ... ". " .. " ... " " .. "" ".".,," ". "." "." "" .. 3-9
SEAT BELT .................. " ........ " ........ " .. " .. .. 3-22
SIDE PANEL "" """" "" """" """ """""" "" 3-11
FUEL TANK PLATE/ COVER """""""" .. " 3-24
M UDG UARD """"" "" "" """"" """" "",, ". 3-12
EXHAUST SYSTEM .... " .. " .......... " ...... " ... 3-25
FLOOR PAN EL " " "" """ "" "" "" """ " " """ 3-12
3-1
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.
TORQUE VALUES
Top CPS mounting nut 49 Nm (5.0 kgf.m, 36 Ibl tt)
Front DPS mounting nut 49 N'm (5.0 kgfm, 36 Ibftt)
Rear OPS mounting nut 49 N'm (5.0 kgfm, 36 Ibftt)
Rear OPS mounting bolt 49 N'm (5.0 kgfm, 36 Ibftt)
left and right rear DPS joint nut 49 N'm (5.0 kgfm, 36 Ibftt)
Crossbar mounting bolt 64 N'm (6.5 kgfm, 47 Ibftt)
Seat belt anchor bolt 32 N'm (3.3 kgfm, 24 Ibf.ft)
Seat belt retractor bolt 32 Nm (3.3 kgfm, 24 Ibf-ft)
Seal bell buckle bol l 32 Nm (3.3 kgfm, 24 Ibftt)
Bed front panel screw 8 N'm (0.8 kgfm, 5.9 Ibftt)
Bed base panel screw 8 Nm (0.8 kgfm, 5.9 Ibftt)
Tailgate pivot bracket screw 8 Nm (0.8 kgfm , 5.9 Ibftt)
Cargo bed release lever mudguard screw 8 Nm (0.8 kgfm, 5.S Ibftt)
Tailgate lod: lever socket bolt 12 Nm (1.2 kgfm , Slbfft)
Heat guard plale bolt 8 Nm (0.8 kgfm, 5.S Ibftt)
Bed release lever bracket bolt (lower side; 6 x 25 mm) 14 Nm (1.4 kgl-m , 10 Ibl-ft)
Instrument panel screw (6 x 18 mm) 8 N'm (0.8 kg fm, 5.9 lbfft)
Instrument panel frame bolt 64 Nm (6.5 kgfm, 47 Ibfh)
Side panel screw (6 x 13 mml 8 N'm (0.8 kg f-m , 5.9 Ibf-ft)
Parking brake bracket socket bolt 38 N'm (3.9 kgfm, 28 Ibfft)
Floor cross plate socket bolt 38 Nm (3.9 kgfm, 28 Ibfh)
Muffler band bolt 22 Nm (2.2 kgf'm, 1S lbfft)
Exhaust pipe cover band screw 2.5 N'm (0.25 kgf.m, 1.8 Ibfft)
TOOLS
~pinpliers
I 07AAC-SJAA100 (U.S.A. only)
TROUBLESHOOTING
Excessive exhaust noise
Broken exhaust system
Exhaust gas leak
Poor perform ance
Deformed exhaust system
Exhaust gas leak
Clogged muffler
32
BODY PANEL LOCATIONS
(15)
(21 )
(16)
(1) SEAT (page 34) (13) INSTRUMENT PANEL (page 3-14)

(2) SEAT CENTER COVER (page 3-5) ( 14) FOOTREST PANEL (page 3- 14)
(3) SEAT UNDER COVEA (page 3-6) (15) FRONT HOOD (page 3-14)
(4) ENGINE FRONT COVER (page 3-6) (16) FRONT GRILLE (page 3-15)
(5) PARKING BRAKE LEVER BRACKET (page 3-7) (17) FRONT BUMPER (page 3-16)
(6) CENTER FRAME COVER (page 3-7) (1S) MAINTENANCE LID (page 3-16)
m CROSSBAR (page 3-8) (19) CARGO BED (page 3-16)
(8) DOOA (page 3-9) (20) SIDE NET (page 3-21)
(9) SIDE PANEL (page 3-'1) (21) OCCUPANT PROTECTIVE STRUCTURE (page 3-21 )
(10) MUDGUARD (page 3-12) (22) SEAT BELT (page 3-22)
(11) FLOOR PANEL (page 3-12) (23) FUEL TANK PLATE/COVER (page 3-24)
(12) FLOOR CROSS PLATE (page 3-13)
TRIM CUP REMOVAL AND RETAINING PROCEDURE: ,--- - - - - - - - - - - ------,
Release by pulling the center pin up using the push Remove and i nstall
pin pliers or a flat blade screwdriver and remove the
trim clip.
TOOL:
Push pin pliers 07AAC-SJAA100 (U.S.A. only) t
~LOCk
~~
Carefully align the Install the clip and lock it by pushing the center pin CENTER PIN
clIp holes in the securely. Relea?
covers (panels) to
avoId damagmg the
clip
3-3
SEAT
SEAT CUSHION
Unlock by pulling the release lever up and remove SEAT CUSHION
the seat cushion. PRONGS
Install the seat cushion by aligning the prongs onto
the frame pipe, then press down to lock it.
SEAT FRAME
Remove the seat cushion (page 3-4),
Remove the following.
- three bolts
- mounting rubbers and collars
- seat frame
The collars have the Installation is in the reverse order of removal.
identification
marks: FR: from / FLANGE SOL T5
RR rear
BOLT
RUBBERS AND COLLARS ="""~~~g<~~
\ \
3-4
HEADREST
Remove the three socket bolts while holding the, HEADREST
reverse side bolts and the headrest.
Install the headrest in the reverse order of removal.
BACKREST
Remove the two setting boils and the backrest.
BACKREST
Install the back rest by setting the upper or lowe r
prongs onto the frame pipe. Carefully align the bolt
holes and install the bolts, and tighten them.
PRONGS
(Upper Position) (lower Position)
SEAT CENTER COVER

Remove the driver and passenger seal cush-
ions (page 3-4),
Raise the parking brake lever.
6 x 20 mm 6 x 18 mm
Remove the six setting screws
(two 6 x 20 mm, four 6 x 18 mm). SCREWS SCREWS
Move the seat beh buckles as ide and remove

the center cover out ofthe brake lever.
Installation is in the reverse order of removal. !
3-5
SEAT UNDER COVER
Remove the following:
- seat frame (page 3-4)
- seat center cover (page 3-5) SCREWS
(6 x 18 mm)
Remove the six setting screws and the seal under
I
cover. UNDER COVER
Installation is in the reverse order of removal.
ENGINE FRONT COVER

Remove the seat under covers (page 3-6).
BOLTS
Remove the following;
- three bolts and sub-frame (to get the space for
front cover removal )
- five setting screw s
- engine front cover
SUB-FRAME
FRONT COVER
,
1'3
SCREWS
mm
,
..
3-6
PARKING BRAKE LEVER BRACKET
Remove the engine front cover (page 3-6).
j
SOCKET
Secure the vehicle from rolling. release the BOLTS
parki ng brake, and remove and/or
disconnect the following: NUT SPRING
- throttle cable (from the cable clip)
- two hose dips (from reverse side of the
bracket) CONNECTOR
- brake switch wire clip
- brake switch 2P (black) connector 11
- adjusting nut and joint pin (to disconnect
the brake rod)
- rod sp ring
four socket bolts
- brake lever bracket
Installation is in the reverse order of
removal.
TORQUE:
Socket bolt: 38 N'm (3.9 kgfm , 28 Ibf.ft)
After installation, adjust the pa rking brake
lever (page 4-21),
HOSE CLIPS
CENTER FRAME COVER

Unlock the cargo bed by pull i ng up on the
release lever and then raise t he bed.
Remove the following fasteners:
- five trim clips
- four setting screws
(two 6 x 18 mm )
(two 6 x 20 mm)
Release the center frame cover from the seat
II I
6 x 20 mm
under cover carefully.
Disconnect the accessory socket 2P (g reen)
connector to remove t he frame cover.
Align the matmg Installation is in the reverse order of removal.
area of the frame
cover and sear
under cover
properly
FRAME COVER
3-7
CROSSBAR
Remove the following :
- seat center cover (page 3-5)
- center frame cover (page 3-7)
Remove the adjusting nut and joint pin to discon-
nect the parking brake rod. Remove the rod spring.
Remove the following from the crossbar:
- two bolts and brake cable holder
- throttle cable clip
- ignition coil wire and throttle body wire (untie
the wire band and release the ignition coil wire
from the wire clip)
- accessory socket 2P (g reen) connector
Remove the four 10-mm nuts and bolts.
Remove the four 12-mm bolts and the crossbar.
TORQUE :
12 mm bolt : 64 N-m (6.5 kgfm , 47 IbUt)
10 mm nut: 49 N -m (5.0 kgfm, 36 Ibf.tt)
After installation, adjust the parking brake lever
(page 421).
ADJUSTING
NUT 12 mm BOLT
10mm NUT
AND BOLT
WIRES BAND
CUP
3-8
DOOR
DOOR PANEL
Open the door.
Support the bottom of the door panel.
Remove the fou r cap nuts and socket bolts,
and the door panel.
CIOSB8nd lalell the Installation is in the reverse order of removal .
door before
tlghfemng the nuts TORQUE: 26 N'm 12.7 kg'm, 19lbfft J
After installation, make sure the door latches
securely without requiring excessive force
and opens smoothlv. If necessary, loosen the
cap nuts and adjust the door panel position.
NUTS
\
BOLTS
DOOR HINGE
Remove the door panel (page 3-9).
4
BOLTS AND
Remove the following: WASHER S
- two socket boils and washers
- door hinge
' HINGE , ,I
: .J~t
- two socket bo lts
- hinge bracket
TORQUE: 26 N m 12.7 kgfm . 19 Ibf.ft )
BOL~~
~
DOOR HANDLE AND LATCH

- four screws (6 x 13 mm)
- latch cover
- two bolts
- latch assembly
,
, 1 I~
~,' LATCH
............... ASSEMBLY
SCREWS
l 3-9
FRAME / BODY PANELS/ EXHAUST SYSTEM
- two bolts
- latch
Release the spring end off of the bracket.
- lock pin
- locating pin
- collar
- spring
- handle
- collar
- rod
I
Hook the Spflng Installation is in the reverse order of rem oval.
ends ontO the
h8ndle and bracket l eft side shown:
COLLAR
In poSition 8S
shown LOCK PIN LATCH
BOLTS
LOCATING PIN \
$
o
COLLAR ---... _~
o ,.y/
ROO--
BRACKET
LOCK PIN SPRING
Short
1 long
(Rig ht side spring position)
3-10
SIDE PANEL
Remove th e following:
~ center frame cover (page 3-7)
- door panel (page 3-9)
Remove the following fasteners:
- right side panel; seven t r im clips
left side panel; six trim clips
- ten setting screws
(five 6 x 13 mm; side face)
(three 6 x 20 mm; floor side)
(two 6 x 18 mm; seat side)
Remove the fuel fill cap (right side only).
Release the side panel from the seat under cover
carefully to remove it, then install the fuel fill cap
(right side only).
A/(gn the matmg Installation is in the reverse order of removal.
area of the Side
TORQUE:
panel and seal
undercover 6 X 13 mm screw: 8 N -m (0.8 kgf -m , 5.9 Ibf-ft )
properly
6 x 18 mm SCREWS
TRIM
SIDE PA'''L
~'> _ _ -- v x 20 mm SCREWS
-..!!!.)- - - 6 x '3 mm SCREWS
3-11
FRAME/BODY PANELS/ EXHAUST SYSTEM
MUDGUARD
Unlock the cargo bed by pulling up on the release
TRIM CUPS
lever and then raise the bed.
Remove the seven trim clips and the rear mud-
guard.
MUD GU.ARC
FLOOR PANEL
- driver and passenger seat cushions (page 3-4)
- side panels (page 3-1 1)
Remove the 23 setting screws (four 6 x 18 mm seat
side, nineteen 6 x 18 mm floor bottom).
Release the floor panel from the seat under and cen-
ter covers carefully to remove it.
A/(gn the mating Installation is in the reverse order of removal.
area of the floor
panel and sear
under/center covers
properly.
~----------'FLOORPANE'~L~========~qrj
""""--'1 I
3-12
FLOOR CROSS PLATE
Remove t he floor panel (page 3-12 ).
SOCKET BO LTS
Remove the six socket bolts and the cross plate. ,,
Installation is in the reverse order of remova l.
TORQUE: 38 N' m 13.9 kgfm , 28 Ibftt) -.
CROSS PLATE
INSTRUMENT PANEL
- door pa nels (p age 3-9)
- steeri ng wheel (page 16-5)
BANDS
Release t he retaining straps and open the front
hood .
Remove the wire bands from the indicato r cover
and disconnect the following connectors:
- lighting/dimmer switch 4P (green )
- indicator lOP (black)
- indicator 6P (black)
- ignition switch 5P (black)
Remove the drive mode selector lever knob.
Remove the 18 setting screws (four 6 x 13 mm
upper side, fourteen 6 x 18 mm lower side) and the
instrument panel.
Whan Ins/allmg rne Installation is in t he reverse order of removal.
lever knob, Install
TORQUE:
with the tab facmg
the front side 6 x 18 mm screw: 8 Nm (0.8 kgfm , 5.9 Ibfft)
6 x 13 mm SCREWS 6 x 13 mm SCREWS
6x18mm
SCREWS
KNOB - - - . . . . ( \ .......TAB
'\
6x 18 mm
SCREWS
~Front
\
~J.l
3-13
FRAME/BODY PANELS/ EXHAUST SYSTEM
FOOTREST PANEL
- door hinges (page 39) FOOTREST PANEL
- brake pedal assembly (page 18-27)
- accelerator pedal assembly (page 6-42)
instrument panel (page 3-13)
- floor panel (page 3-'2)
=~
Take care not to Remove the three setting bolt s and the footrest o
~~ THR~TTLE
allow the footrest panel.
panel to tnteriere Installation is in the reverse order of removal.
wIth the springs, CABLE
cable, and master
cylmder
SPRINGS! MASTER CYLINDER
SCREWS _______
(6 x 18 mm)
FRONT HOOD
REMOVALIINSTAlLA TION
Release the retaining straps and open the front
hood. STRAP
Remove the wire band from the frame and discon-

nect the headlight 3P (black) connector.
While supporting the front hood secu rely, remove
the following from the hood pivot s, then remove the
hood.
- two lock pins
- two joint pins
"" ,Y )
- four bushings
Be sure 10 sellhe Installation is in the reverse order of removal.
prOllgs behind Ihe
msrrumenr panel
FR(lNT HOOD
when closmg the
hood
LOCK I
BUSHI NGS
~=9I
3-14
DISASSEMBLY/ASSEMBLY
Remove the front hood (page 3-14).
- headlight wire (release from the wire bands)
- seven bolts (6 x 14 mm; long step)
- four nuts and bolts (6 x 14 mm; short step)
- hood frame
- headlights (page 24-4)
Assembly is in the reverse order of disassembly.
FRONT GRILLE
Release the retaining straps and open the
TRIM CLIPS
front hood.
Remove the six trim clips.
Close the hood and remove the front grille.
Installation is in the reverse order of remo val.
I
~
GRILLE
3-15
FRONT BUMPER
Remove the six bolts and front bumper.
10 mm WASHER-BOLTS
6 mm BOLTS
MAINTENANCE LID
Remove the four setting bolts and the maintenance LID
lid.
~
BOLTS
CARGO BED
BED DAMPER
lever and then raise the bed. Securely support the
cargo bed with wooden blocks or an equivalent to
remove pressure from the damper.
Unscrew the upper and lower ball studs, and
remove the damper.
Remove the supports and lower the cargo bed.
3-16
REMOVALIINSTALLATION
Remove the wire band from the bed frame
and disconnect the brake/taillight 6P (black)
connector.
Remove the bed damper (page 3-16).
Remove the two mounting nuts and bolts.
While holding on to the bed frame and being
careful not to damage the brake/taillights and
release lever, remove the cargo bed. Set the
cargo bed down on its bed frame.
Make sure rhe Installation is in the reverse order of removal.
rubber mounts on
the chassis frame
are In poSition and
in good condItIOn
)
CARGO BED
DISASSEMBLY/ASSEMBLY
BED SIDE PA NEL
- trim clip
~
- four bolts and collars
...
- bed side panel
Installation is in the reverse order of remova l .
TRIM CUP
..
(
,'
(
o
BOLTSAND~
COLLARS
3-17
BED BASE PANEL
- bed side panels (page 3-17)
- brakeltaillights (page 24-5)
Release the gate lock lever to open the tailgate.
- four nuts, bolts and tie-down hooks
- 18 setting screws
- six trim clips
- bed base panel
TORQUE: Screw: 8 N 'm (0.8 kgf-m , 5.9 IbUt)
TRIM CUPS
BOLTS-
_ _ . ..
\
f?::=V" ===o.=;;;~;=7
. _.~.e==~.~;;=i
~ .c= _)
-:/;
~. Qn I
HOOKS~
, ,0, o o ,0'
NUTS-- .. i!I
~,
"
\

@)
" 1i-- (6x18mm)
SCREWS
~,--~-"-;;-f~-~'~'~'-~~-----;&
,C , BASE PANEL ,
BED FRONT PANel

Remove the bed base panel (page 3-18),
SCREWS
Remove the 13 setting screws and the bed (6x1Bmm)
f'~
front panel.
'-'
TORQUE: 8 N-m (0.8 kgf-m, 5.9 Ibf.ft)
BED FRONT PANEL
318
TAILGATE
Remove the bed side panels (page 317).
Release the tailgate lock lever to open the tailgate.
While holding the tailgate, remove the two socket
bolts to disconnect the support cables.
Remove the two washer-screws and pivot brackets,
then remove the tailgate from the bed frame.
- three tapping screws and p ivot pipe
- cap nut, socket bolt, washe r and support cables
- socket bolts, cable stay and lock lever
Inst allation is in the reverse order of removal.
TORQUE:
Lock lever socket bolt: 12 N'm (1.2 kgfm , 9Ibf.ft)
Bracket washer-screw: 8 N'm (0.8 kgfm , 5. 9 Ibf.ft)
NOTE :
The tailgate must be latched on the cargo bed
securely. If it is not latched properly, loosen the
lock lever bolts and adjust the lock leve r to the
suitable position.
BOLTS
(6 x 19 mm)
TAILGATE
\ SUPPORT CABLES
';>E~~'O . BRACKETS
.~
WASHER-SCR EWS
)
I
BOLTS
(6x 16 mm )
WASHER TAPPING
NUT SCREWS STAY
y;:=L==~~~/
BOLT
LEVER
3-19
RELEASE LEVER
Remove the six bolts and heat guard plate.
Release each return spring end off of the setting
hole in the bed frame.
- four bracket bolts (from the bottom of the outer
brackets)
- four bracket nuts and bolts (from side face of the
inner brackets; nuts-inside/bolts-outside)
- release lever assembly (from the cargo bed
frame)
Remove the fo llowing from the release lever:
- outer brackets (separate them)
- retu rn springs
- nuts, bolts and inner brackets (sepa rate them)
When ins/ailing the Installation is in the reverse order o f removal.
return springs, set
them In the correa
TORQUE:
direc/ion as shown 6 X25 mm bracket bolt: 14 N'm 11 .4 kgfm, 10 Ibfft )
Heat guard plate bolt : 8 N' m (0.8 kgfm . 5.9 Ibfft)
INNER
BRACKET
NUTS
HOLE
6 x 25 mm
BOLTS PLATE
(6x 12 mm)
BRACKET
3-20
SIDE NET
Release the net buckle and the strap.
- retainer bolts
- net retainers
- net
BOLTS
Strap T ightening Procedure:
OCCUPANT PROTECTIVE STRUCTURE

(OPS)
TOPOPS
- side nets (page 3-21)
- eight nut caps TOP
- eight nuts and bolts
- top OPS
TOROUE: 49 N'm (5.0 kgfm. 36 Ibfft)
3-21
FRONT OPS
Remove the top OPS (page 321).
FRONT OPS
- two nuts and bolts
r
- frOnl OPS ,
Installation is in the reverse order of removal. I\
TORQUE: 49 N m (5.0 kgfm. 36 Ibf.ftl BOLTS
(10 x 50 mm)
i
{Jl,1
NUTS
REAR OPS
Remove the top OPS (page 3-21).
10x20mm
Unlock the cargo bed bv pulling up on the REAR OPS
release lever and then raise the bed.
- two joint nuts and bolts
- mounting bolt (front side)
- two mounting nut and bolts (rear side)
- rear QPS
Installation is in the reverse order of removal. 10x50mm
BOLTS
TORQUE: 49 N 'm (5.0 kgfm , 36 Ibf.ft)
lOx 20 mm BOLT -~"i
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 componen ts.
To do so wilt cause dirt or sand to contaminate
the component s, 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 fu nc-
tions correctly by inserting the tag several times.
Replace the seat belt with a new assembly if any
of the following conditions occur. Do not disas-
semble any part of the seat belt.
- the belt is ragged, worn or broken
- the vehicle is involved in a col lision, overturns,
is submerged, etc.
3-22
BELT/RETRACTOR
Unlock the cargo bed by pull ing up on the release
ANCHOR BOLT
Remove t he following:
- anchor cover (by slid ing it down)
- upper and lower anthor bolt (16 mm head)
- retractor bolt (washer-bolt)
1=:;"",=1 SEAT B~E~
L T~o=
- seat belt assembly
Route the belt Installation is in the reverse order of removal.
behmd the OPS as COVER
shown. NOTE:
Sefore installing, check that the retractor locking
mechanism functions, see below.
Assemble the washers of the anchor bolt prop-
erly if it was disassembled.
When installing the retractor, align the locating
pin with the hole in the frame.
When installing the anchor bolts, make sure
there no twists or kinks in the belt.
I
TORQUE: 32 N m (3.3 kgfm , 24 Ibf.ft)
After installing, check the following:
- the belt does not lock when pulled slowly and it RETRACZ
will retra ct automatically when released . The I
seat belt is designed to lock only during a sudden ANCHOR BOLT
stop.
- each anchor for free movement on the anchor Upper Anchor;
A~)~.
bolt. If necessary. remove the anchor bolt and
check that the washers and other pans are not 'i1.
damaged or imprope rly installed . LOCK / / j ,,\Q (]
WASHER ""'-
WAVE WASHER PLASTIC WASHER
Lower Anchor:
LOCK ~~ ..
WAS HER '"'" / : ;
"'-... ,~"-
WAVE WASHER
f'~ PLASTIC WASHERS
RETRACTOR FUNCTION CHECK

Before installing the retractor, ch eck that the seat Mounted position
belt can be pulled out freely within the parameters
mentioned below.
The sea t belt should not lock until the retractor is
tilted by 85 forward or backward or 55 left and
right. Do not attempt to disassemble the retractor.
55<0>""
Right . Left
85 (-1 B5
---~--
Front Rear
3-23
BUCKLE
Remove the center frame cover (page 3-7).
Remove the washer-bolt and seat belt buckle.
NOTE:
Assemble the washers and stopper plate of the
buckle bolt properly if it was disassembled.
TORQUE : 32 N'm (3.3 kgfm, 24 Iblftl
STOPPER PLATE
e-
~ I ?~
lOCK/
' \ v COl BUCKLE
WASHE R
WASHER
FUEL TANK PLATE/COVER

Remove the fuel tank (page 6-40).
- two trim clips and four bolts
- fuel tank plate
- three trim clips and setting screw
- fuel tank cover
TANK COVER
TRIM CUPS
SCREW
(6x 13 mm)
BOLTS
(10 x 20 mm)
TANK PLATE
3-24
EXHAUST SYSTEM
REMOVAL
- parking brake lever bracket (page 3-7)
- left side panel (page3-1')
- spark arrester (page 4-23)
When the exhaust system will be separated, loosen
the muffler band bolts.
- two joint nuts
- two mounting nuts and bolts
- exhaust pipe/muffler assembly
- gasket
Separate the exhaust pipe and muffler and remove
the gasket.
MOUNTING BOlT5
~j ARRESTER
MOUNTING NUTS
"'~ ./
.
'
1- ~~__ MUFFlER
JOINT NUTS - - - - -"
~,- _ _ _ BAND BOLTS
EXHAUST PIPE ~GASKET
3-25
EXHAUST PIPE DISASSEMBLY/
ASSEMBLY
NOTE :
For service of the spark arrester in the muffler,
see Maintenance section (page 4-23).
TO RQUE:
Ba nd screw; 2.5 Nm (O.25 kgfm, 1.8 IbHt)
FRONT EXHAUST PIPE COVER
63"
47 mm (1.9 in)
SIDE EXHAUST PIPE COVER
FRONT EXHAUST PIPE COVER c'@)
3-27
MEMO
4. MAINTENANCE
SERVICE INFORMATION 4-2 BRAKE FLUID .... 4-18
MAINTENANCE SCHEDULE ...... .... .... ........ 4-4 BRAKE PADS WEAR ........ ........................ 4-19
FUEL LINE 4-5 FOOT BRAKE SWITCH ............................. 4-19
THROTTLE OPERATION 4-5 BRAKE SYSTEM 4-20
AIR CLEANER 4-6 UNDERBODY 4-22
AIR CLEANER HOUSING DRAIN TUBE 4-8 SUSPENSION ... .................. ....... ...... ..... .. .. 4-23
SPARK PLUG 4-8 SPARK ARRESTER ................................... 4-23
BA TTERY ............ ....................................... .. 4-9 EXHAUST SYSTEM ................................. 4-24
VALVE CLEARANCE 4-10 WHEELS/TIRES ............ ......... .... ............... 4-24
ENGINE OIL 4-12 TIE- ROD AND JOINT BOOT 4-25
COOLING SySTEM 4-15 STEERING SYSTEM ................. ....... ......... 4-25
DRIVE SHAFT BOOTS .............................. 4-16 CHASSIS LUBRICATION POINTS ........... 4-29
DIFFERENTIAL OIL .................... ............... 4-16
4-1
I
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 th e torque wrench reading will be less than the torque actually applied to the
lock nut. The specification given on the next page is the actual torque applied to the lock nut, nol the reading on the
torque wrench when used with the lock nut wrench. The procedure later in the text gives both actual and indicated
torque readings.
For gear selector cable adjustment, see Sub-transmission/Gearshift linkage section (page 12-16),
For drive mode selector cable adjustment, see Front Driving Mechanism section (page 19-44).
SPECIFICATIONS
~:;:;;;;:;:::;;g
IT!E!!
MC:-- _~====+-: SPECIFICATIONS
Accelerato
Spark plug'""',-=
pedal freeplay - 10'm=m::-T('~1<5~2"15"';o~I"
5 ~,:~~~~~~~~~~~~~~~==~
BKR5E-l l (NGK), K16PR-U11 (DEN SO)
Spark plug gap 1.0 1.1 mm (0.039 0.043 in)
Valve clearance IN 0.15 0.02 mm (0.006 0.001 in)_ _ _ __ _ __
EX 0.330.02mm(0.013O.OOl in)
Recommended engine oil -'--='------"-iPro Honda GN4 4-stroke 011 (U.S.A. and Canada) or an
equivalent motor oil
Viscosity: SAE 10W-30, OW-30 I
, ~
Engine oil capacity After draining 2.7 liters (2.9 US qt. 2.4 Imp qt)
After draininglfilter change 2.9 liter (3.1 US qt. 2.6 Imp qt) <
I After disassembly
Recommended diffe rentialoil
4.1 liter (4.3 U S qt, 3.61mp qt)
Hypoid gear oil, SAE #80
-
Front differential At draining f-- S65 cm' 122.5 US OZ, 23.4 Imp ozl
oil capacity At disassembly 760 cm] 125.7 US oz, 26.8 Imp oz)
Rear differe~o~t~;a"r-
oil capacity
Recommended brak e fluid
At draining
At disassembly
465 cm] 115.7 US oz, 16.41mp oz)
520 cm (17.6 US oz, 18.3 Imp oz)
Honda DOT 4 brake fluid
0
Brake pedal height ( from accelerator pedal) 25-40 mm (1 1-3/5 in)
Parking brake lever locked clicks 3 7 clicks
~
Cold tire pressure (F rontJRear) h Standard - r---70 kPa (0.70 kgf/cm' , 10.0 psi)
With cargo 70 kPa (0.70 kgf/cm2, 10.0 psi)
Tire size r--~ront- 25 x 10.00-12NHS 2PR
Rear 25 x 10.00-12NHS 2PR
Tire brand Front KT953 (Dunlop)
Rear KT953 (Dunlop)
Minimum .,.:==, dep,h I 4mm(0.2 in)
; I 0- 10 mm (0-215 in)
Wheel
sao:'~oad 13.7 N (1.4 kgf, 3.1Ibf)
Inward : 40, Outward: 33 0 (reference)
Toe , Toe-i n: 0 10 mm (0 215 in) 0
4-2
MAINTENANCE
TORQUE VALUES
Spark plug 22 N-m (2.2 kgf.m, 16Ibf.ft)
Valve adjusting screw lode: nut 17 Nm (1.7 kgfm, 12 Ibf-h)
Timing hole cap 10 N-m (1.0 kgf-m, 7Ibfft)
Crankshaft hole cap 12 N-m (1.2 kgf.m, 9Ibfft)
Engine oil drain bolt 25 Nm (2.5 kgf-m, 18Ibf.ft)
Engine oil filter center bolt 18 N-m (1.8 kgf-m, 13 IbUt)
Front final gear case oil filler cap 12 N-m (1_2 kgf-m, 9Ibf-ft)
Front final gear case oil drain bolt 12 N-m (1.2 kgf-m , 9 Ibf-ft)
Rear final gear case oil filler cap 12 Nm (1.2 kgf-m , 9 Ibfft)
Rear final gear case oil drain bolt 12 Nm (1.2 kgf-m, 9 Ibf-ft)
Front differential lock cable nut 26 Nm (2.7 kgf-m, 20 Ibfft)
Rear differential lock cable nut 26 N-m (2.7 kgfm, 20 Ibfft)
Final clutch arm cover bolt 10 N-m (1.0 kgfm, 7 Ibfft)
Gear selector cable nut 26 N-m (2.7 kgfm, 20 Ibfft)
Brake pedal height adjusting boh lock nut 22 Nm (2_2 kgfm, 16Ibfft)
Brake pedal height lock plate torx bolt 22 N-m (2.2 kgfm, 16 Ibf-ft)
Wheel nut 108 Nm (11.0 kgfm, 80 Ibf-ft)
Rack guide screw See page 4-26
Rack guide screw lock nut 24 N-m (2.4 kgfm, 18 Ibf-ft)
Tie-rod end lock nut 44 Nm (4.5 kgfm, 33 Ibfft)
TOOL
I Lock not w<ench

07MAA-SL00100
or 07916SA50QOl (U.S.A only)
4-3
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the PREDRIVE 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 H) may require more technical information and tools. Consult an authorized Honda dealer.
Service the listed items at the indicated distance or t~me ~nl.tial

Regular Maintenance Interval
whichever comes first na~ce
r--~~~~~~~____ ,"' Ix '00 HO~" 200 ::=

Item':::~~~~~~~~~~'~
~1I.e, (paoe '~iiiiii~~3
F IChedt engine alII ,.ge 4'2) and,
I ,
C- ~heok b<ake fluid page .~ '8)
I (page 4,'5)
-
I M~
and oondillon onoe a month
Chedt fluid level once a month
1=I'~"e, engine all and fllte< 0 I 0 0 C U
Inspect valve clearance (page 4-10) 0 I::very , ,000 Km~~~~ ~Iles) o~ ~~~S'y' ~ hours
"IClean c (page .23)
f- ~:II~ I d<aln tub~' ,NOTE 2

Every 1,000 km (600 miles) or 100 operating
hours, whichever covers first
, Cheok ;i;,~ :~~;d '~2::~8;
n o
he, '.ont and "a"""",,,- page, '9 and . 20), NOTE
he, '<ont and .ea. dlHew I loll 0 _
I , all I I , and pi 'ots Ipage 4291 ,
Ithe, I I,:,
Item"
I" components (page 4-23)
Wheels (page 4-24)
Drive shaft boots (page 4-16)
o o
Accelerator (throttle operation; page 4-5) and brake
pedals (page 4-21 )
Foot brake switch (page 4- 19)
Exhaust system (page 4-24) 1
f--t-Jl:'.'!'~~te~.~m~l~nal condition:(:p:a;g;e;4~'9~)~21j====~~~;f=:::'1;~~~~9~;9~~~~=~
, Rotate lI.e, (page .24) ~;;~.~u;:: :-"uu,~"e,)
n I
[- ,Chedt I
Ithe II I
., Tie-rod ends (page 4-25)
Steering gear box and boots (page 4-25)
o
Brake hoses and lines (page 4-20)
I :"t,,;~~1:~ unde.body (page 4.22), NOTE 1
I" the following items:
Front and rear differential oil (page 4-16)
, ::,,~i .. , coolant (page 7-5)
Every 2 years (regardless of mileage)
, "<ake fluid (pag~ t8.6)
* Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is
mechanically qualified.
** In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
NOTES:
1. Service more frequently when operating in dusty areas, sand or snow.
2. Service more frequently when operated in muddy, very wet conditions or freezing temperatures.
3. Service more frequently when operated in muddy conditions.
4. Check the underbody whenever the under guard has been hit.
4-4
MAINTENANCE
FUEL LINE
Remove the following:.
- passenger seat under cover (page 3-6)
Check the fuel line for deterioration, damage or
leakage.
Replace the fuel feed hose jf necessary.
THROTTLE OPERATION
Operate the accelerator pedal and check that the
throttle cable operates smoothly with no binding or
sticking. Replace jf necessary.
Measure the accelerator pedal freeplay at the end of
the pedal.
PEDAL FREEPLAY: 5 - 10 mm (1/5 - 215 in )
Throttle pedal freeplay can be adjusted at either end
of the throttle cable.
Minor adjustments are made with the pedal side

adjuster,
hood .
Slide the boot off the adjuster. Loosen the lock nut,
turn the adjuster as required and tighten the lock
nut.
Install the boot over the adjuster securely.
Major adjustments are made with the throttle body

side adjuster.
Slide the boot off the adjuster. Loosen the lock nut,
turn the adjuster as required and tighten the lock
nut.
Install the boot over the adjuster securely.
Recheck the throttle operation
Close the front hood and secure it with the straps.
Install the cen t er frame cover (page 3-7).
4-5
MAINTENANCE
AIR CLEANER
NOTE:
If the vehicle is used in dusty areas, sand or
snow, more frequent inspections are required.
Release the four retaining clips and two lid springs
from the air cleaner housing cover and remove the
air cleaner cover.
Loosen the air cleaner element band screw and

remove the air cleaner element assembly from the
housing.
Remove the element band and the element core

from the air cleaner element.
CORE
Wash the element in non flammable or high flash

point solvent.
Squeeze out the solvent thoroughly, and allow the
element and filter to dry.
..\t:I
Squeeze out
Wash
4-6
MAINTENANCE
Apply approximately 20 9 (0.7 oz) of Pro Honda
Form Filter Oil or equivalent oil from the inside of PRO HONDA FOAM FIL TEA OIL
the element.
Place the element into a plastic bag and spread the
oil evenly by hand.
PLASTIC BAG
Install the element core into the air cleaner element,

aligning the locating pin with the hole.
ELEMENT
Clean the inside of the air cleaner housing and

cover.
Make sure the rubber seal in the air cleaner cover is
in position and in good condition.
Install the element band onto the air cleaner ele-
ment and the element assembly over the connect-
ing tube flange of the housing securely.
Tighten the band screw.
NOTE :
Failure to properly tighten the band screw will
allow the ai r cleaner element to fall off and
engine damage could result .
Install the air cleaner cover while aligning the

stepped area with the element as shown.
Secure the air cleaner housing cover with the retain-
ing clips and lid springs.
lower the ca rgo bed.
4-7
MAINTENANCE
AIR CLEANER HOUSING DRAIN TUBE
NOTE '
If the vehicle is used in muddy, very wet condi-
tions or freezing temperatures, more frequent
inspections are required.
Remove the drain tube from the bottom of the air
cleaner housing to empty any deposits.
Install the drain tube securely.
lower the cargo bed.
SPARK PLUG
Remove the seat center cover (page 3-5).
Clean with Disconnect the spark plug cap and clean around the
compressed air spark plug base.
before removmg
Remove the spark plug.
the plug, and be
sure that no debns
Is allowed to enter
Info the combustion
chamber
Check the insulator for cracks or damage, and the

electrodes for wear, fouling or discoloration.
Replace the plug if necessary. CENTER ELECTRODE
RECOMMEN DED SPARK PLUG :

BKR5E 11 (NGK ). K16PR U11 (DENSO )
Clean the spark plug electrodes with a nylon wire

type brush or special plug deaner.
4-8
MAINTENANCE
Check the gap between the center and side elec-
trodes with a wire-type feeler gauge .
SPARK PLUG GAP: 1.0 - 1.1 mm (0.039 - 0.043 in) 1.0-1.1 mm

~
If necessary, adjust the gap by bending the side
(0.039-0.043 in)
~ ~
electrode carefully.
Thread the spa rk plug in by hand to prevent cross-
;""
threading and tighten it with a spark plug w rench .
U H
Connect t he spark p lug cap.
Install the seat center cover (page 3-5). I
BATTERY
Release the retaining straps and open the front , - - - - - - - - - - - - - - - - - - - ,
hood.
Release t he cover lab and remove the box cover
f rom the tab of t he battery box.
Check the battery for loose connections or corroded
terminals.
"
(+) TERMINAL
~~
4-9
MAINTENANCE
VALVE CLEARANCE
NOTE-
Inspect and adjust the valve clearance while the
engine is cold (below 35J95" F) .
Check the engine idle speed after the valve clear-
ance inspection (page 6-55),
lever and then raise the bed .
- mudguard (page 3-12)
- driver seat under cover (page 3-6)
Remove the crankshaft hole cap and the timing hole
cap.
Remove the four bolts, intake and exhaust valve

adjusting hole caps.
If the Tmarkrs Rotate the crankshaft clockwise and align the "T"
passed when trymg mark on the flywheel with the index mark on the
INDEX
to align If with the crankcase cover. MARK
index mark. rotare Make sure the piston is at TDC (Top Dead Center) on
the cranksnaft only the compression stroke.
clockwise again and This position can be obtained by confirming that
align. ThIS mus r be there is slack in both rocker arms. If there is no
done ro prevem Ihe slack, it is because the piston is moving through the
one-way exhaust stroke to TDC. Rotate the crankshaft one full
decompressor turn and match up the "T" mark again.
sysrem from
f unC/lonrng and /0
ob /arn t he correc r
valve clearance. "T" MARK
Wh en checking rhe Check the clearance of each valve by insening a

clearance, slIde rhe feeler gauge between the adjusting screw and valve
feeJer gauge from stem.
the cenrer toward
rhe outside VALVE CLEARANCE:
IN: 0.15 0.02 mm !0.006 0.001 in)
EX: 0.33 0.02 mm !0.013 0.001 in)
4-10
MAINTENANCE
Adjust the valve clearance by loosening the lock nut
and turning the adjusting screw 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 kgfm, 12Ibf.ft)
After tightening the lock nut, recheck the valve
clearance.
Coat new O-rings with oil and install them into the
groove in each valve adjusting hole cap.
Install the valve adjusting hole caps and lighten the
bolts securely.
Coat new O-rings with oil and i nstall them into the
timing hole and crankshaft hole caps.
Install the timing hole and c rankshaft hole caps, and
tighten them.
TORQUE:
Timing hole cap: 10 N' m 11.0 kgfm, 7 rbftt)
Crankshaft hole cap: 12 N'm (1 .2 kgfm, 9 IbUt)
Install the following:
- seat under cover (page 3-6)
Lower the cargo bed.
4-11
MAINTENANCE
ENGINE OIL
LEVEL CHECK
NOTE:
Check the oil level after starting the engine and
allowing the oil to circulate th rough the engine
thoroughly. It is especially important on a dry
sump engine, due to the comparatively large vol-
ume of oil.
Do not snap the th rottle while idling or the oil
level reading will be inaccurate.
Place the vehicle on level ground.
Start the engine and let it idle fo r 3 - 5 minutes. If
e
the air temperature is below 10 0 (50F), let the
engine idle for an additional 5 minutes (a total of 10
minutes).
Stop the engine and wait for 2 - 3 minutes.
Remove the driver seat cushion (page 3-4) and
release the rubber sheet from the tabs.
Remove the dipstick and wipe it clean.
Check the oil level by inserting t he dipstick into the
engine without screwi ng it in.
The engine contains a sufficient amount of oil if the
oil level is between the upper and lower level marks
on the dipstick.
If the oil level is near or below the lower level mark,

remove the oil fille r cap and add the recommended
engine oil u p to the u pper level mark.
RECOMMENDED ENGINE Oil:

Pro Honda GN4 4stroke oil !U.S.A . and Canada)
or equivalent motor oil
Viscosity: SAE 10W-30, OW-30
4-12
MAINTENANCE
NOTE -
Other viscosities shown in the chart may be used
when the average temperature in your driving OIL VISCOSITIES
area is within the indicated range.
Reinstall the oil filler cap and dipstick.
I
.
Install the rubber sheet to the two tabs.
Install the seat cushion (page 3-4),
1
'11'1
.,. iii
.,0 ,
,
,16
" . .. ..
,I I
" " io"
I
'"
,,c
lZO' F
OIL CHANGE
NOTE:
Change the oil with the engine warm to assure
complete and rapid draining.
Place the vehicle on level ground.
- maintenance l id (page 3-16)
- driver seat cushion (page 3-4)
Start the engine and let it idle for a few minutes.
Stop the engine.
Remove the drain bolt and the filler cap (release the
ru bber sheet from the tabs) to drain the engine oil.
DRAINBOLT ~
SHEET
Remove the O-ri ng and sealing washer from the

d rain bolt. DRAIN BOLT
Install a new sealing washer onto the drain bolt.
Coat a new O-ring with oil and install it into the
groove in the d rain bolt.
After draining the oit completely, install the drain
bolt and tighten it.
TORQUE: 25 Nm (2.5 kgfm , 18 Ibf.ft)
4-13
MAINTENANCE
Pour the recommended oil into the engine through
the filler neck to the upper level ma rk on the dipstick
(page 4- 12).
ENGINE Oil CAPACITY:

2.7 liters 12.9 US qt, 2.4 Imp qt) after draining
2.9 lit ers (3.1 US qt, 2.6 Imp qtJ afte r drainingl
fitter change
4.1 liters (4.3 US qt, 3.6 Imp qt) afte r disassembly
Install the oil filler cap and the dipstick.
Check the oil level (page 4-12).
Make sure there are no oil leaks.
OIL FILTER REPLACEMENT

Drain the engine oil (page 4-13).
Remove the engine front cover (page 3-6). CENTER BOLT
Place a oil pan Remove the following :
under the engme - filter center bolt COVER
Ta*e care not to - filter cover
lose the washer - setting spring
and spnng - washer
- oil filter
Remove the O-r ings from the oil filter cover and
center bolt.
Coat new O-rings with engine oil and install them
into the grooves in the oil fil t er cover and cen ter (View from underbody)
bolt.
Install a new oil filter.
Reinstall the washer, spring, cover and cen t er bolt. g~
Tighten the center bolt. " ' - - 7 ORINGS
TORQUE: 18 Nm 11.8 kgfm , 13Ibf.ft)
Fill the engine with the recommended oi l (page 4-
13).
Install the engine front cover (page 3-6).
4-14
MAINTENANCE
COOLING SYSTEM
RADIATOR COOLANT
Release the retaining straps and open the front ,.
hood.
Check the coolant level of the reserve tank with the
engine running at normal operating temperature.
The level should be between the "MAX" and HMIN"
level lines with the vehicle upright on a level sur-
face.
If t he level is low, remove the reserve tank cap and
fill the tank up to the "MAX" level line with a 1;1
mixture of distilled water and antifreeze (coolant
preparation: page 7-5).
RECOMMENDED ANTIFREEZE:
Pro Honda HP coolant or an equivalent high qual -
ity ethylene glvcol antifreeze containing silicate
free corrosion inhibitors
NOTICE
Using coolant with silicate corrosion inhibitors may
cause premature wear of water pump seals or
blockage of radiator passages. Using tap warer 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 empty, there
is a possibility of air getting into the cooling system.
Be sure to remove any air from the cooling system
(page 7-6).
INSPECTION
- engine front cover (page 3-6)
hood.
Check for any coolant leakage f rom the water pump,
water 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 3- 15).

Check the radiator air passage for dogs or damage.
Straighten bent fins with a small, flat blade screw-
driver and remove insects, mud or other obstruc-
tions with compressed air or low pressure water.
Replace the radiator if the air flow is restricted over
more than 20% of the radiating surface.
4-15
MAINTENANCE
DRIVE SHAFT BOOTS
Check the drive shaft boots for cuts or other dam- r - - - - - - - -- - - - - - - ----,
age.
If the boot is damaged, replace it.
- front drive shaft (page 19-7)
- rear drive shaft (pa ge 20-7)
Rear:
DIFFERENTIAL OIL
FRONT FINAL GEAR CASE
LEVEL CHECK
Place the vehicle on a level surface.
Remove the oil fi l ler cap and check that the oil level
is up to the lower edge of the oil filler hole.
Check for leaks if the oi l level is low.
Pour the oil th rough the filler hole until it reaches
the lower edge of the hole.
RECOMMENDED OIL: Hypoid gear oil, SAE #80
Coat a new O-ring with grease and install it into the
cap groove.
Install the filler cap and tighten it.
TORQUE: 12 N'm (1.2 kgf-m. 9Ibf.ft)
4-16
MAINTENANCE
OIL CHANGE
Remove the oil drain bolt and the filler cap to drain
the oil.
When the oil is completely drained, install the drain
bolt with a new sealing washer.
TORQUE: 12 Nm (1.2 kgfm. 9 IbUt)
Fill the gear case with the recommended oil (page 4-
16).
Oil CAPACITY:
665 em' (22.5 US oZ, 23.4 Imp oz) at draining
760 em] (25.7 US OZ, 26.8 Imp oz) at disassembly
REAR FINAL GEAR CASE

LEVEL CHECK
Place the vehicle on a Jevel surface.
Remove the oi l filler cap and check that the oil level
is to the lower edge of the oil tiller hole.
Check for leaks if the oi l level is low.
Pour the oil through t he filler hole until it reaches
the lower edge of the hole.
RECOMMENDED Oil: Hypoid gear oil, SAE #80
cap groove.
Install the filler cap and tighten it.
TORQUE: 12 N'm (1.2 kgfm, 9 Ibfft)
OIL CHANGE
Remove the oil drain bolt and filler cap to drain the
oil.
When the oil is completely drained. install the drain
J>
bolt with a new sealing washer. L
TORQUE : 12 N'm (1.2 kgfm, 9Ibfft)
Fill the gear case with the recommended oil (page 4 -
l
17).
Oil CAPACITY:
o
465 em l (15.7 US OZ, 16.4 Imp oz) at draining v~~~y n
520 em' (17.6 US OZ, 18.3 Imp oz) at disassembly
!11 SEALING WASH~R
4-17
MAINTENANCE
BRAKE FLUID
I NOTICE
Spilling fluid can damage painted, plastic or rub-
ber parts. Place a rag over these parts whenever
the system is serviced.
NOTE:
Do not mix different types 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 4-19). 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 4-20).
Release the retaining straps and open the front OOVER
hood .
Check the fluid level of the reservoir.
If the level is near the ~M I N ~ level line, remove the
cap cover and the reservoir cap, and fill the reser-
voir with DOT 4 brake fluid from a sealed container
to the "MAX" level tine.
Install the reservoir cap so the arrow faces forward.
CAP
"MAX" LEVEL
LINE
Before installing the cap cover, turn the cap cover ~=========~~~~~~~~~~
inside out. Install the cover over the reservoir cap
and pull it down over the cap and fitter neck.
4-18
MAINTENANCE
BRAKE PADS WEAR
NOTE
The front and rear brakes have audible brake
wear indicators. When the brake pads need
replacing . the brake will screech while applying
the brake.
Remove the wheels.
- front (page 15-6)
- rear (page 17-5) Front:
Check the brake pad for wear.
INNEAPAO~
Replace the brake pads if the wear limit groove of
either pad is worn Qut. ~~\B
Brake pad replacement (page 18-8)
~~~
LIMIT GROOVE
,
Rear:
UMITGROOVE
FOOT BRAKE SWITCH

Check that the brake light comes on just prior to the
brake actually being engaged.
If the light fails to come on, adjust the switch so that
the light comes on at the proper time.
Hold the switch body and turn the adjusting nut. Do
not turn the switch body.
4-19
MAINTENANCE
BRAKE SYSTEM
HYDRAULIC BRAKE
Firmly apply the brake pedal and check that no ai r
has entered the system.
If the brake pedal feels soft or spongy when oper-
ated, bleed the system.
Bleeding procedure (page 18-7)
hood.
Inspect the brake hoses, pipes and fittings for deteri
oration, cracks, damage or signs of leakage.
Tighten any loose fittings.
Replace hoses, pipes and fittings as req uired.
4-20
MAINTENANCE
BRAKE PEDAL HEIGHT
Check the brake pedal for deformation or damage .
Check the brake pedal for smooth operation by
operating it several times.
Measure the brake pedal height from the accelera -
tor pedal.
STANDARD PEDAL HEIGHT: 25 - 40 mm (1 - 1-3/5 i n )
Adjust the pedal height as follows.

Remove the lock plate bolt (T50) and lock plate.
loosen the lock nut and turn the adjusting bolt (T50 )
as required. Temporarily tighten the lock nut while
holding the adjusting nut.
The pedal freep/ay Make sure the brake pedal freeplay at the end of the
IS from the pedal is within 1 - 5 Mm .
looseness at rhe If the freeplay is not within standard value, loosen
pedal Pivot WI/houl the lock nut and turn the adjusting bolt until the
preSSing the master freeplay is within 1 - 5 mm.
cylmder lad Recheck the pedal height after adjusting the pedal
freeplay.
After adjustment procedure is completed, tighten
the lock nut to the specified torque while holding
the adjusting bolt.
TORQUE : 22 N m 12.2 kgfm , 1S lbf.ft)
Install the lock plate agai nst the lock nut and tighten
the plate bolt.
TORQUE : 22 N m (2.2 kgf.m , 1Slbfft )
Check for brake l ight operation (page 4-19).
PARKING BRAKE
Pull the parking brake lever and check the freeplay
at the lever end.
LEVER FREEPLAY: S5 - 85 mm 12.S - 3.3 in )

If the parking brake lever freeplay is out of specifica-
tion, adjust the parking brake as follows.
4-21
MAINTENANCE
( '\1
Raise the rear wheels off the ground (page 1-48) eUSTINGN~T
Put the gear selector lever to the N (neutra l) position
and the drive mode selector lever to the 2WD posi- ~~
tion.
Release the parking brake lever fully.
Press the brake pedal several times.
loosen the brake adjusting nut.
Make sure the parking brake arm on each rear brake
caliper contacts the stopper pin.
The brake arm will contact the pin when the adjust-
ing nut is loosened.
Pull the parking brake lever 1 click (65 - 85 mm).
Make sure the Tighten the adjusting nut until the brakes drag
cutout in the slightly when the rear wheels are turned.
adjusting nUl IS
Release the parking brake lever fully, and check that
seated on the jOint
the brakes do not drag when the rear wheels are
pm.
turned. Readjust if necessary.
Make sure the parking brake lever freeplay within
the specification (page 4-21).
STOPPER PIN
Install the seat center cove r (page 3-5).
UNDERBODY
Check the under guard plates for cracks or damage.
Repair the u nderb ody plate as required.
4-22
MAINTENANCE
SUSPENSION
Loos8, worn or Check the action of the front and rear shock absorb- ~------------------~
damaged ers by compressing them several times. Front
SHOCK ABSORBERS
suspension parts Check the entire shock absorber assembly for signs
impair vehicle of leaks, damage or loose fasteners.
srabiliryand control. Check the suspension arms for damage or deforma-
t:l,
tion.
Replace damaged components that cannot be
repaired .
Tighten all nuts and bolts.
SUSPENSION ARMS
Rear:
SHOCK ABSORBERS ~~~~
SUSPENSION ARMS
SPARK ARRESTER
Remove the three bolts and the spark arrester with
the gasket.
U S8 a b rush to remove ca rbon deposits from th e ~l11l11l11l111oiiliiiiii"'l11l11l11l11l11l11l11l11l11l11l11~

screen mesh, being ca reful not to damage it.
The screen mesh must be free of breaks and holes.
Replace the spark arrester if necessary .
4-23
MAINTENANCE
Install the spark arrester with a new gasket and
tighten the bolts securely.
Lower the cargo bed.
EXHAUST SYSTEM
Start the eng ine and inspect the exhaust system fo r
leaks. Stop the engine and check for any sign of
exhaust gas leakage.
WHEELS/TIRES
INSPECTION
Tirepressure Check the lire pressure with the tire pressure gauge.
should be checked
when the fifes are RECOMMENDED TIRE PRESSURE (Fro nt/ Rea r):
cold Sta ndard : 70 kPa (0.70 kg / cm 2 , 10.0 ps i)
With cargo : 10 kPa (0.70 kg /cm 2 , 10.0 ps i)
Check the tires for cuts, embedded nails, or other
damage.
Measure the tread depth at the center of the tires.
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 bear-
ings in the hub for excessive play or abnormal
noise.
Check the wheels for crack, defo rmation or damage.
Check the wheel nut are tightened. Torque any
loose nut.
TORQUE: Fro nt/ Rear: 108 N m (11.0 kgfm , 80 Ibf.ft)
TIRE ROTATION
Rotate the tires according to the maintenance , - - - - - - - - - - -- - -- - - - ,
schedule to help increase tire life and distribute
wear more evenly. Move the tires to the positions
shown in the figure.
><
Wheet removal/installation
- Front wheet (page 15-6) [:=J I [:=J
- Rear wheel (page 17-5)
'mnt +-
[:=J [:=J
4-24
MAINTENANCE
TIE-ROD AND JOINT BOOT
Raise the front wheel off the ground (page ' -48),
Check the tie-rod joint nuts for looseness.
Check the ball joint boots of the tie-rod for tears or
other damage.
Check for any looseness of the tie-rod ball joints by
holding and attempting to move t he wheel at the
top and bottom and at the front and rear.
If any looseness is noted, inspect the following.
JOINT
- tie-rod (page 16-14) and ball joint (page 16-8)
- knuckle bearing (page 15-10)
STEERING SYSTEM
GEAR BOX BOOT AND OPERATION
CHECK
Raise the front wheels off the ground (page 1-48),
BOOT
Check the gear box boots for cuts or other damage.
If the boot is damaged, replace it (page 16-9),
Check that the steering wheel 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 16-5),
4-25
MAINTENANCE
ROTATIONAL PLAY CHECK
Set the front wheels in the straight ahead position
with all the wheels on the ground.
Measure how far you can turn the steering wheel
left and right without moving the front wheels.
ROTATIONAL PLAY: 0 - 10 m m (0 - 2/5 in)
If the play exceeds the limit, adjust the rack guide
(page 4-26 ).
If the play is still excessive after rack guide adjust-
ment, inspect the steering linkage and steering gear
box (page 16-2).
TURNING LOAD CHECK

NOTE:
This test should be done with original equipment
tires and wheets at the correct tire pressure.
Raise the front wheels off the ground (page 1-48).
Set the drive mode selector lever to the 2WD posi-
tion to free the differentia! lock.
Set the front wheels in the straight ahead position.
Attach a spring scale to the steering wheel.
Pull the scale as shown and read it as soon as the
front tires begin to turn.
INITIAL TURNING LOAD: 13.7 N (1.4 kgf, 3. 1 Ibf)
If the scale reads more than the specification,

inspect the steering linkage and steering gear box
(page 16-2).
RACK GUIDE ADJUSTMENT

Remove the left front wheel (page 15-6).
Set the right front wheel in the straight ahead posi-
tion.
Loosen the screw lock nut with the special tool , then
loosen the rack guide screw.
TOO L:
Lock nut w rench 07MAA-SL00100
o
Wrench, 40m m 07916-S A50001
~
(U.S.A. only )
Tighten the rack guide screw until it is stops, then LOCKNUT

toosen it. WRENCH
Tighten the rack guide screw to 4.9 N'm (0.50 kgfm, ~
3.6 Ibf-ft). then back it off to the specified angle.
SPECIFIED RETURN A NGLE: Below 20~ 20"
Refer 10 torque Tighten the lock nut using the same tool while hold-
wrench reading ing the rack guide screw stationary.
informatIOn on pagB
4-2 Service
TORGUE: Actual: 25 Nm 12.5 kgf-m , 18 IbUt)
Ind icated: 19 N-m (1.9 kgfm. 14 IbUt)
Informa/lon. RACK GUIDE --\t\
Install the front wheel (page 156) SCREW
Check for unusual steering effort through the com-
plete turning range. LOCK NUT
Check the sleering wheel rotational play (page 4- L _ _ _ _ _ _ _ _ _ _ _ _--'-'-'-_-'-_-'
26).
4-26
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 gauge with the marks on the tires as
shown.
TOE-GAUGE
Slowly move the vehicle back until the wheels have

turned 1aOo so the marks are at the rear of the tire
:..
Front
and aligned with the gauge height. ..;
Measure the toe on the rear part of the tires at the
same points with no load on the vehicle.
TOE-IN : 0 10 mm (0 215 in)
NOTE:
The front and rear measurements are the same
for this vehicle.
I Rear
.. I
When the toe is out of specification, adjust it by .ii~-~i!!i!~~I---------'

changing the length of the tie-rods equally by loos-
ening the lock nuts and turning each tie-rod while
holding the ball joint.
After adjusting the tie-rods, tighten each lock nut
while holding the ball joint.
TORQUE: 44 Nm (4.5 kgfm, 32 IbUt )
Make su re the gear box boots are not twisted or dis-
placed.
4-27
MAINTENANCE
TURNING RADIUS INSPECTION
Raise the vehicle off the ground (page 1-48) .
Be sure that theSet the turning radius gauges beneath the front
wheels and place boards (that are the same height
vehicle IS level With
the wheels on the as the rad ius gauge) under th e rear wheels, then
radiUS gauges and lower the vehicle.
boards
Apply the parking brake.
tion 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: 40"
TURNING RADIUS GAUGE
Outward: 33" (reference)
If the m easu rements are not to specification, even
up both sid es of the tie-rod thread length whi le
adjusting the toe (page 4-27).
4-28
MAINTENANCE
CHASSIS LUBRICATION POINTS
Lubricate the following components.
- A: front hood pivots
- B: cargo bed pivots
- C: cargo bed strikers
- 0: tailgate pivots (page 3-19)
- E: door ratches
- F: brake pedal pivot (page 18-28)
- G: accelerator pedal pivot (page 6-43)
H: parking brake lever pivot (page 3-5)
I: drive mode selector lever pivots (page 19-43)
J: gear selector lever pivots (page 12-16)
Check for smooth operation after lubrication.
---..
o
_...m;;. E
4-29
MEMO
5. LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM .. .. 5-2 OIL PRESSURE CHECK ....... ..... .................. 5-5
SERVICE INFORMATION .......................... . 5-3 OIL PUMP ................................................... 5-6
TROUBLESHOOTING ................................. 5-4 OIL COOLER .. .. 5-13
5-1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
ROCKER ARMS
CYLINDER HEAD COVER
CAMSHAFT
CRANKSHAFT
TORQUE COIWERTE'R , ----------- - _.
FLYWHEEU
STARTER
CLUTCH
I
BODY
REUEFVALVE
OIL
2nd13rd SHIFT CLUTCH
OIL COOLER
OIL STRAINER SCREEN
5-2
LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL
A. CAUTION
Used engine oil may cause skin cancer if repeat edly 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 procedu res 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 service 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 filler replacement, see Maintenance section (page 4 12).
SPECIFICATIONS
Unit mm (in)
ITEM STANDARD I SERVICE LIMIT
I Engine oil capacity After draining 2.7 liters (2.9 US qt, 2.4 Imp qt)
After draining/filter I 2.9 liters (3.1 US qt, 2.6 Imp qt)
~~.nad"",
change
-After disassembly 4.1 liters (4.3 US qt, 3.6 Imp qt)
Recommended engine oil Pro Honda GN4 4-stroke oil (U.S.A. and
.n equ,v.'ent moto, 0,1
API service classification: SG o r higher
pump rotor
TORQUE VALUE
Oil pump driven sprocket bolt 12 N'm (1.2 kgfm , 9Ibf.ft ) Apply locking agent to the threads.
TOOL
Oil pressure gauge set

07406-0020005
or 07ZMJ-HN2A 100 and 07AMJ-

HN8A 100 (U.S.A. Only)
5-3
LUBRICATION SYSTEM
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
Oil pump worn or damaged
low oil pressure
Oil level low
Oil pressure relief valve wear
Clogged oil strainer or filter
Faulty oil pump
Internal oil leak
Incorrect oil being used
No oil pressure
Oil level too low
Oil pressure relief valve stuck open
Broken oil pump drive chain
Broken oil pump drive or driven sprocket
Damaged oil pump
Internal oil teak
High oil pressure
Oil pressure relief valve stuck closed
Clogged oil gallery or orifice
Incorrect oil being used
Oil contamination
Oil or filter nol changed often enough
Worn piston rings or incorrect piston ring installation
Worn valve guides or stem seals
Oil emulsification
Blown cylinder head gasket
Leaky coolant passage
Water entry
5-4
LUBRICATION SYSTEM
OIL PRESSURE CHECK
Fa/lure fO warm the Check the oil level and add the recommended oil if
engme will cause necessary (page 4-12).
very high 011 Also, warm the engine to normal operating temper-
pressure reaomgs ature and check for external leaks.
EKfernalleaks will
Remove the oil gallery sealing bolt and washer on
cause low oil
the left side of the front crankc ase cover.
pressure readmgs
NOTE :
Clean around the sealing bolt with compressed
air before removing the bolt. and be sure that no
dirt enters the oit gallery.
Connect the oil pressure gauge and adapter to the

oil gallery hole. Oil PRESSURE GAUGE
TOOLS:
Pressure gauge set 074060020005
U,S.A. TOOLS:
Oil pressure 9auge 0-160 psi 07ZMJHN2Al00 and
Adapter, banjo 8 x 1.25 mm 07AMJHN8Al00
Start the engine and check the oi l pressure.
Oil PRESSURE (80~C / 176 F) :
785 kPa (8.0 kgflcm ~, 114 psi) at 5,000 rpm
Stop the engine and remove the oi l pressure gauge
and adapter.
Install the sealing bolt with a new sealing washer

and tighten the bolt securely.
Start the engine and make sure there are no oi l
leaks.
Install the rubber sheet to the two tabs.

Install the seat cu shion (page 3-4).
55
LUBRICATION SYSTEM
OIL PUMP
REMOVAL
Remove the torque converter (page 1442).
If the oil pump will be disassembled, loosen the two
assembly bolts.
three mounting bolts
oit pump (from the crankcase and release the
driver chain)
- three O-rings
- strainer joint pipe
- rubber seal
- two bolts
- oil return pipe
- O-ring
DISASSEMBLY
- two bolts
5-6
LUBRICATION SYSTEM
Milrk tile rotors S{) - pump body 0
they can be - outer rotor
reinstalled In che" - inner rotor BODY 0
Oflgmal/oC(i1Ions - drive pin DOWEL PINS
- two dowel pins OUTER ROTOR
- pump body C
- outer rotor
- inner rotor BODye
- drive pin
nil'" ROTOR
INNER RO"roR
- pump body B
- pressure relief valve
RELIEF VALVE
- bolt
- driven sprocket
5-7
LUBRICATION SYSTEM
- pump shaft
- drive pin
- outer rotor
- inner rotor
Clean all the disassembled parts thoroughly.
INSPECTION
Remove the O-ring from the relief valve.
Check the operation of the valve by pushing on the
piston .
Temporarily assemble each inner rotor, outer rotor

and drive pin on the pump shaft, and install them
into each pump body individually.
Measure the rotor tip clearance.
SERVICE LIMIT: 0.20 m m (0.008 in )
Measure the body clearance.
SERVICE LIMIT: 0.25 mm (0.010 in)
5-8
LUBRICATION SYSTEM
Remove the oil pump shaft and drive pin .
Measure the side clearance .
ASSEMBLY
DR IVEN SPROCKET
DR IVE PINS
RELIEF VALVE I?Y

o .
e)
a -RING
!Qi"~,
~ ';/'v<..
INNER ROTORS
$J ,~~ , PUMP BODY A
~'P~:;\
DOWEl PINS
'~ \
PUMP BODY D
~.
~
\ PUMP BODY B
OUTER ROTORS
PUMP BODye
Coat all parts with clean engine oi l.

Install the outer and inner rotors into the pump
body A. BODY
Insert the drive pin into the pump shaft.
Install the pump shaft th rough the inner ro t or and
pump body A, aligning the drive pin with the rotor
grooves.
OUTER ROTOR SHAFT
5-9
LUBRICATION SYSTEM
Apply locking agent to the sprocket bolt threads.
Install the driven sprocket onto the pump shaft,
aligning the flats. Install the sprocket bolt and
tighten it.
TORQUE: 12 N'm (1 .2 kgfm , 9Ibftt)
Coat a new O-ring with engine oil and install it into

the relief valve groove.
Install the relief valve into the pump body B.

Install the oil pump body B onto the pump body A.
RELIEF VALVE
Insert the drive pin into the pump shaft.

Install the inner rotor onto the pump shaft, aligning
its grooves with the drive pin. SODye
Install the outer rotor into oil pump body C.
Install the pump body C onto the pump body B.
DurER AOTOR
INNER ROlrOR
5-10
LUBRICATION SYSTEM
Install the dowel pins through the pump bodies C, B
and A.
Insert the drive pin int o the pump shaft BODYO
Install the inner rotor onto the pump shaft. aligning
its grooves with the drive pin.
Install the outer rotor into the oil pump body O.
Install the pump body 0 onto the pump body C.
INNER ROTOR
Make sure that there is no clearance at the mating

surfaces of the pump bodies.
Install the two assembly bolts.
INSTALLATION
Coat a new O-ri ng with engine oit and install it onlo
the oil return pipe.
Install the pipe onto the crankcase and tighten the
two bolts securely.
Coat a new O-ring and a new rubber seal with

engine oil, and install them onto the strainer joint
pipe.
Install the joint pipe onto the strainer pipe in the
crankcase .
5-11
LUBRICATION SYSTEM
onto the joint pipes on the oil pump.
Place the driven sprocket on the oil pump onto the
oil drive chain, and install the pump onto the crank-
case by aligning the joint pipes with the joint holes
properly.
Install the three mounting bolts and tighten all the

bolts in a crisscross pattern in several steps.
Install the torque converter (page 14-44),
5-12
LUBRICATION SYSTEM
OIL COOLER
REMOVAL
Drain the engine oil (page 4-13).
Drain the coolant (page 7-6).
- floor panel (page 3-12)
Release the hose clip and wire band from the stay.
Remove the two joint bolts from each oit pipe ends.
Disconnect the oil pipes from the engine and oil
cooler, and remove them out of the frame.
Remove the O-rings from the oil pipe.
Disconnect the water hoses from the oil coole r.

Remove the two mounting bolts and the oil cooler.
DISASSEMBLY
- five bolts
D-RING
- cooler cover
BOLTS
- O-ring
5-13
LUBRICATION SYSTEM
- four bolts
- oil cooler core
- two joint collars

- two O-rings
ASSEMBLY
Clean the ccoler housing, cover and core fins with
compressed air thoroughly.
onto the joint collars.
Install the collars into the cooler housing.
Install the cooler core with the four bolts and tighten
them securely.
5-14
LUBRICATION SYSTEM
Install a new O-ring into the housing groove.
COVEA
Install the cooler cover with the five bolts and
tighten them securely.
INSTALLATION
Install the oil cooler with the two bolts and tighten
them securely.
Connect the water hoses to the oil cooler.
Coat new D-rings with engine oil and install them

into the grooves in each pipe ends. QRINGS ~ "7111
.... II
Install the pipe A Install the oil pipes into the oil cooler and connect
(flange lug) 10 the them into the engine.
front side
5-15
LUBRICATION SYSTEM
Install the four joint bolts and lighten them securely,
BOLTS
Install the hose clip and wire band into the stay.
Fill the engine with recommended oil (page 4-14).
Fill and bleed the cooling system (page 75).
Check the engine oil level (page 412)
engine front cover (page 3-6)
- floor panel (page 3-121
BOLTS
5-16
6. FUEL SYSTEM (PGM-FI)
SYSTEM COMPONENTS ........................... 62 MAIN RELAY / FUEL PUMP RELAy .......... 638
SERVICE INFORMATION ...... .. ........ ........... 64 FUEL TANK .. ............................................ 640
SYMPTOM TROUBLESHOOTING ............. 66 AIR CLEANER HOUSING ............ ...... .... ... 641
PGM FI SYSTEM COMPONENT INTAKE AIR DUCT .. .. ............................ 642

LOCATION ...... .. .. .... .... .. .. .... .... .... ........ 67
ACCELERATOR PEDAL .. .......................... 642
PGM FI SYSTEM DIAGRAM ...................... 68
THROTTLE BODy ...................... .. .... ........ 645
PGM FI CONNECTOR LOCATION ............. 69
IACV .. ............ ............................................ 648
PGM FI TROUBLESHOOTING
INFORMATION .. ................................ .... 6 11 FUEL INJECTOR ....................................... 649
PGMFI DTC INDEX .................................. 6 14 TP SENSOR/ MAP SENSOR

(SENSOR UNIT) .......... .. .......................... 651
DTC TROUBLESHOOTING ....................... 6 15
ECT SENSOR ............................................ 653
MIL CIRCUIT INSPECTION ............. .... ...... 630
VS SENSOR ..................................... .... ..... 653
FUEL LINE INSPECTION .......................... 631
PCM ........ ................................................... 654
FUEL PUMp ...... .. .. .. .......... .... .. ...... .. 636
ENGINE IDLE SPEED ...... .... .. ................ 655
6-1
FUEL SYSTEM (PGMFI)
SYSTEM COMPONENTS
6-2
FUEL SYSTEM (PGM-FI)
\. .
\
\
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\
6-3
SERVICE INFORMATION
GENERAL
This FUEL SYSTEM section covers service of the electrical and mechanical system of the PGM-Fl system, fuel supply
system and air cleaner.
Before disconnecting the fuel feed hose, relieve pressure from the system (page 6 31 I,
Bending or twisting the control cable wi l l 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 close aher the throttle cable has been removed. It may cause incor-
rect idle operation.
Seal the cylinder head intake port with tape or a clean cloth to keep dirt and debris from entering the intake port after
the throttle body has been removed.
Do not damage the throttle body. It may cause incorrect throttle valve operation .
Prevent dirt and debris from entering the throttle bore, IACV, sensor hole and fuel feed hose, clean them using com~
pressed air.
The throttle body is factory pre-set. Do nOI disassemble in a way other than shown in this manual.
Do not loosen or tighten the white painted bolts, nuts and screws of the throttte body. Loosening or tightening them can
cause throttle body malfunction.
A faulty PGMFI system is often related to poorly 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.
SPECIFICATIONS
- -' ,Ti
TE"M'- - - -
~,~,~"yiY:~,nc:
TORQUE VALUES
Insulator band screw (throttle body side) See page 6-47
Insulator band screw (cylinder head side) See page 6-47
ECT sensor 12 N'm (1.2 kgfm, 9 Ibfh)
Fuel pump lock nut 93 Nm (9.5 kgfm, 69 Ibfh)
6-4
TOOLS
Fuel pressure gauge Pressure gauge manifold Pressure gauge hose attachment A
07406-0040004 07ZAJ-S5A0111 07ZAJS5A0120
or 07406-0040008 (U.S.A. only) Not available in U.S.A. Not available in U.S.A.
Pressure gauge hose attachment B Hose attachment B joint Pressure manifold hose
07ZAJ-SSA0130 07ZAJ-S5A0150 07AMJ-HW3Al00 (U.S.A. only)
Not available in U.S.A. Not available in U.S.A.
Adaptor, male Adaptor, female SCS connector

07AAJ-S6MA200 (U.S.A only ) 07AAJ-SSMA400 (U.S.A. only ) 070PZZY30100
HOS pocket tester Test probe, 2 pack Fuel sender wrench

TDS 35570'1201 (U.S.A. Only) 07ZAJRDJAll0 07AAA-SOXA100
6-5
SYMPTOM TROUBLESHOOTING
When the vehicle has one of these symptoms, check the OTC or MIL blinking, refer to the DTe index (page 6-14) and begin
the appropriate troubleshooting procedure. If there are no OTC/Mll blinking stored in the PCM memory, do the diagnostic
procedure for the symptom, in the sequence listed below, until you find the cause.
Symptom Diagnosis rocedure Also check for
Engine cranks but won't 1. Inspect the ignition system No fuel to fuel injector "--- - -----1
start ~page 22-5). - Clogged fuel filter
(No OTC and Mil blinking) 2. Inspect the fuel supply system - Pinched or clogged fuel feed hose
(page 631). - Pinched or clogged fuel tank breather
hose
- Faulty fuel pump
- Faulty fuel pump circuits
Intake air leak
Contaminated/deteriorated fuel
Faulty fuel injector
IACV stuck closed
Engine cranks but won't 1. PCM power/ground ci rcuits Open ci rcu it in the power input (BlaclUgreen)
start malfunction ~page 6-54). andlor ground ~Green) wire of the PCM
(No fuel pump operation 2. Inspect the fuel pump system Faulty main relay or related circuit
sound when turning the (page 636) . Faulty ignition switcn or related circui t
ignition switch to ON (I)) Blown FI fuse (10 A)
Blown IGN fuse (10 A)
Engine stalls. hard to start, 1. Check the idle speed ~page 6 Restricted fuel feed hose
rough idling 55). Contaminated/deteriorated fuel
2. Check the IACV (page 6-48). Intake air leak
3. Inspect the fuel supply system Restricted fuel tank breather hose
(page 6-31). Faulty ignition system
Backfiring or misfiring dur- Check the ignition system. Faulty ignition system
ing acceleration
Poor performance 1. Inspect the fuel supply system Pindled or dogged fuel feed hose
(driveability) and pOor fuel (page 6-31). Fau lty injector
economy 2. Check the air cleaner for clog- Fau lty ignition system
ging (page 4-6).
Idle speed is below specifi- 1. Check the idle speed (p age 6 IACV stuck dosed
cations or fast idle too low 55). Faulty fuel supply syst em
(No OlC and MIL blinking) 2. Check the IACV (page 6-48). Faulty ignition syst em
Valve clearance
-
Idle speed is above specifi- 1. Check the idle speed (page 6- IACV stuck opened
cations or fast idle too high 55) Fau lty ignition system
(No DTC and MIL blinking) 2. Check the accelerat or pedal Intake air leak
operation and pedal freeplay Engine top end problem
(page 45). Clogged air cleaner
3. Check the IACV (page 648). Valve clearance
MIL stays on but no OTCs Troubleshoot the MIL circuit Faulty Mil circuit
set, or MIL never comes (page 6-30).
ON at all
MIL stays on at all times Check the DlC circuit (Brown/red Short circuit in the OLC related wire
(No OTC set) wire) for short circuit.
6-6
FUEL SYSTEM (PGM -FI)
PGM-FI SYSTEM COMPONENT LOCATION
MAP SENSOR!
TP SENSOR IGNITION SWITCH
FUEL INJECTOR
ECT SENSOR
IAT SENSOR
MAIN RELAY,
FUEL PUMP RELAY
VS SENSOF
FUEL CKP SENSOF
GEAR pn<:tT;()N
FUSE BOX
6-7
PGMFI SYSTEM DIAGRAM

IGNITION SWITCH FAN FUSE (1SA)
BArrERY
'1 MAIN FUSE (30A)
R ~ R--+-- R~
rRIBI~ BI~ B"
IGNFUSEil0Al
RM'
W;R ~V
MAIN RELAY
R RIY ~ WIR WIR ~ BIIY
FI FUSE (10 Al
G'''~ 'W
~'~ ~ ~
I
" ~ 'W
FUel PUMP
RELAY
CKP BUG al MAIN SMR B9
SENSOR
O ~t===''' '
FlR 821 Gr/O
" G
'" pe,
~
'U GIW B12 PCM
SENSOR UNIT FUEL PUMP -=-

r-----------,
I
[EtE~'~"G~E~ ","
TP
SENSOR ',",
Bl vee
814 TH '"' '" G"' ---~ ' w
FUEL
@ 181 G/8) G/BI 82 SG
INJECTOR
@( 121 ~
MAP ,,'" IGN 811 "" - -- --, 'W
SENSOR
+--+ "'" "".
@l l l
"'" IGNITION
COI L
PCM SPARK
IAT
SENSOR ,-itr---i-<,,,..,-j '" ,. -!-PLUG
@(91
1ACY-1A H2O
1.f.CII.18 Bl2
Gm, IAClJ.M B3D
IACV.28 531
ECT MIL
SENSOR
@(71 WARN 819 I-W""---- --f;,.-1i- ""
f'VB Col BIIY - - - - -- - - - - - '
r - -- -- G 813 LG OLC
+-- - - -- -0
+-- - - - --0
Bnro,
8\0 PG2
II(-UN 817
"" . ~~{b
..r- SCS CONNECTOR
PCM C-l C-3

- A 11- -
B 1 811
@ ( ): MIL Blink A 12 ,,22 B12 8-22
BI: Black 0 : Orange 6=cb ~!?ODODO~~ ~!?OOOOD~~

Br: Brown R: Red 000000000 000000000
Bu: Blue
G: Green
Gr: Gray
V: Violel
W: While
Y: Yellow
?9 000000000 000000000
19: light green

C-5 A-3J B-23
68
PGM-FI CONNECTOR LOCATION
The parts listed below the connector must be removed to disconnect the connector.
OLC PCM 5P BU'CKCONNECTQA

PCM 33P BLACK CONNECTOR
PCM 33P GRAY CONNECTOR
PCM connectorsJDLC
- banery box cover (page 21 -6)
A LTERNATOR 5P BLACK CONNECTOR
Alternator 5P black connect or

- engine front cover (page 3-6 )
6-9
INJECTOR 2P GRAY CONNECTOR
-'
tAT SENSOR 2P BLACK CONNECTOR
EeT SEN SOR 2P CONNECTOR SENSOR UN IT 5P BLACK CONNECTOR
Injector 2P gray connector

EeT sensor 2P connector
- raise the cargo bed
Sensor unit 5P black connector
tAT sensor 2P black connector
- raise the cargo bed
IACV 4P BLACK CONNECTOR
IACV 4P black connector

6-10
PGM-FI TROUBLESHOOTING INFORMATION
GENERAL TROUBLESHOOTING
Interm ittent Failure
The term "i ntermittent 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 circuit wi th the trouble. If the MIL was on, but then went
out, the or iginal problem may be intermittent.
Opens and Shorts
"Opens and "Shorts are com mon electrical terms. An open is a break in a wire or at a con nection. 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 al 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 DTe READ OUT (page 6-12).
If the MIL did not stay on
If the MIL did not stay on, but there is a dr iveability problem, do the SYMPTOM TROUBLESHOOTING (page 6-6).
SYSTEM DESCRIPTION
SELF DIAGNOSIS 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 OTC in its erasable memory.
FAIL-SAFE FUNCTION
The PGM-FI 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 selfdiagnosis function, running capability is maintained by pre-
programed value in the simulated program map. When any abno rmality is detected in the fuel injector and crankshaft posi-
tion (CKP) sensor, the fail -safe function stops the engine to protect it from damage.
DTC (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 HOS pocket tes ter.
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 the 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 deter mines the Function Failure, compa res the sensor voltage output to the standard value,
and then ou tputs the corresponding OTC t o the HOS Pocket Tester.
For example:
- If the output voltage line (A) on the MAP sensor is opened, the PCM/ECM detects the output voltage is about 5 V, then
the OTC 1-2 (MAP sensor circuit high voltage) will be displayed.
- If the input voltage line (B) on the TP sensor is opened, the PCM/ECM detects the output voltage is 0 V, then the OTC
8-1 (TP sensor circuit low voltage) will be displayed.
5V
MAP SENSOR 5V TPSENSOR 5V
r-~?-- (BI--<?--'
OUTPUT VOLTAGE
>-=--9- (AI- -9--+-
OUTPUT VOLTAGE
- <?-- -+---t-
5V
->- _~ V
EeT SENSOR IATSENSOR
OU TPUT VOLTAGE OU TPUT VOLTAGE
* .,1 * .,1
6-11
Mil Blink Pattern
If the HDS pocket tester is not available, DTe can be read from the
peM memory by the MIL blink panern.
The number of MIL blinks is the equivalent the main code of the
Ole (the sub code cannot be displayed by the Mil).
M\
The MIL will blink the current OTe, in case the peM 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
tong blinking lasts for 1.3 seconds, the short blinking lasts for 0.5
seconds. One long blink is the equivalent of len short blinks. For
example, when two long blinks are followed by five short blinks, the
(-
;' 00
(:
/
/
08 0 @
0..
-\ -~,
~-
,,
,
\
Mil is 25 (two long blinks = 20 blinks, plus five short blinks). ,,',
I
When the PCM stores more than one oTC, the MIL will indicate -
them by blinking i n the order from the lowest number to highest
number.
MIL Chec:k
When the ignition swi tch is turned to ON (I). the MIL will stay on for a few seconds, then go off. If the MIL does not come
on, troubleshoot the MIL circuit ~page &30) .
CU RRENT DTC/ STORED DTC
The OTC is indicated in two ways accord ing to the failure status.
In case the PCM detects the problem at present, the MIL will come on and the MIL will start to blink as its oTC. It is pos-
sible to readout the MIL blink pauern as the current OTC.
In case the PCM does not detect any problem at present but has a problem stored in its memory, the MIL will not l ig ht
and blink. If it is necessary to retrieve the past problem, readout the stored OTC by following the OTC readout proce-
dure.
HDS POCKET TESTER INFORMATION

The HOS can readout the OTC, stored data, current data and other PCM condition.
How t o connect the HDS Pocket Tester
Turn the ignition switch to OFF (0).
Remove the banery box cover (page 21-6).
Remove the dummy connector from the OLC.
Connect the HOS pocket tester to the OLC.
Turn the ignition switch to ON (I), and check the OTC and stored data.
NOTE:
Stored data i ndicates the engi ne conditions when the first malfunc
tion was detected .
PCM reset
The HOS can reset the PCM data including the OTC, stored data and
some learning memory.
DTC READOUT
When the ignition switch is turned to ON (I), the MIL will stay on for
a few seconds. then go off.
Aher performing diagnostic troubleshooting, erase the OTC(s)
(page 613) and test-drive the vehicle to be sure that the problem(s)
M\
have been removed.
'/
"
- \
If the MIL stays on or blinks, co nnect the HOS Pocket Tester to the OLC
(page 6-12).
Then read the OTC and follow the troubleshooting index :
/
/
I
0r 8 0 @ e ,
,;
- PGM FI system: page 6-14
0
- A/Tsystem page 1416 8) 0 !
I
To read the OTC with the MIL blinking, refer to the following proce-
dure.
6-12
Reading OTC with the MIL
Start the engine and let it idle. Read the MIL blinking that is indicated
as the current DTC and refer to the troubleshooting index:
- PGM FI system: page 614
- AfT system page 14-16
When retrieving the stored DTG, refer to the follow ing procedure.
Remove the dummy connector (page 6- 12).
Short the DLe terminals using the special tool.
TOOL:
SCS connector 070PZ-ZV30100
CONNECTION : Brown/ red - Green
Turn the ignition switch to ON (I), read and note the MIL blinks, and
refer to the troubleshooting index:
- PGM Ft system: page 6- 14
- AfT system page 14-16
NOTE :
If the PCM has any DTC in its memory, the MIL will start blinking.
ERASING OTC
Connect the HDS Pocket Tester to the OLe (page 6-12).
Erase the DTC with the HOS while the engine is stopped.
To erase the OTC without HOS. refer to the following procedure.
How to erase the OTC with SCS connector
, . Remove the dummy connector (page 6-12).
2. Short the OLC terminals using the special tool.
TOOL:
SCS connector 070PZZV30100
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 terminals again with the special tool. The OTC is
erased if the Mil goes off and starts blinking.
NOTE :
The OLC must be shorted while the MIL lights. If not, the MIL wilt
not start blinking.
Note that the OTC cannot be erased if the ignition switch is turned to OFF (0) before the Mil starts blinking.
CIRCUIT INSPECTION
INSPECTION AT PCM CONNECTOR
Always clean around and keep any foreign material away from the , - - -- - - - - - - - - -- - - --,
PCM connector before disconnecting it. TEST PROBE
A faulty PGMFI system is often related to poorly connected or cor-
roded connections. Check those connections before proceeding.
Do not pull the wire harness while disconnecting the PCM connec-
tors.
In testing at PCM connector (wire harness side) terminal, always
use the test probe. Insert the test probe into the connector terminal.
then attach the digital multimeter probe to the test probe.
TOOL:
Test probe, 2 pack 07ZAJ ROJA110
6-13
PGM-FI DTC INDEX
Function Failure Symptom/ Fail-safe fun ction Refer to
I
Loose or poor
MAP sensor
'.0""" connector
EeT sensor or its circuit malfunction value:

or poor

TP sensor or its circuit Fa il-safe value: 0
AfT shift function and anti-creep
function does not work (2nd gear
I
Loose or poor contact TP sensor connector Fail-safe value: 0

TP sensor or its circuit malfu nction AfT shift function and anti-creep
fu,,,tllon does not work (2nd gear
sensor i I
IAT sensor or i
4.93 V) I
IAT sensor connector I

of the fuel injector connecto r pump and
malfunction
I
Loose or poor contact of the IACV connector
lACY or its ci rcuit malfunction
, I
Blown fuse (10 A)
Main stuck or its circuit malfunct ion
i power
ignition swit ch is "
Main its circuit
6-14
DTC TROUBLESHOOTING
DTC 1-1 (MAP SENSOR LOW
VOLTAGE)
1, MAP Sensor Syst em Inspection
Turn the ignition switch ON (I).
Check the MAP sensor with the HDS pocket
tester.
Is about a 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 unit 5P black connector.
Turn the ignition switch to ON (I) . SENSOR UNIT 5P BLACK CONNECTOR
Measure the voltage at the wire harness side 5P (Terminal side of the wire harness)
connector terminals.
Connection: Brown I green (+) - Green/ black H
Is the voltage within 4.75 - 5.25V?
YES - GO TO STEP 4.
Brown/green Green/black
NO - GO TO STEP 3.
3. MAP Sensor Input line Inspection

Turn the ignition switch to OFF (0 ).
Disconnect the PCM 33P gray connector.
Check the Brown/green wire for continuity BmWn/g,.~~owrog,een
between the wire harness side 5P black connec-
tor and 33P gray connector terminals.
TOOL:
Test probe. 2 pack 07ZAJ -RDJA 110
- -
Connection: Brown/green (83) - Brow n / green - SENSOR UNIT

Is there continuity? PCM 33P GRAY CONNECTOR 5P BLACK
CONNECTOR
YES - Replace the PCM with a known good
one, and recheck.
(Terminal side of the wire harness)
NO - Open circuit in the Brown/green w i re.
4. MAP Sensor Output Line Short Circuit Inspec-
tion
Check for continuity between the wire harness , - - - - -- - - - -- -- - -- - - -,
side 5P black connector terminal and ground.
SENSOR UNIT 5P BLACK CONNECTOR
Connection : light green/ yellow - ground (Terminal side of the wire harness)
Is there continuity?
7c~
YES - Shan circuit in Light green/ yellow wire.
NO - GO TO STEP 5.
light green/yellow '-.:::
6-15
5. MAP Sensor Inspection
Replace the sensor unit (MAP sensor) with a
known good one (page 6-51).
Erase the DIe (page 6 12).
Turn the ignition switch to ON (I).
tester.
Is DTe 7-1 indicated?
one and recheck.
NO - Faulty original sensor unit (MAP sen-
sor),
DTC 1-2 (MAP SENSOR HIGH

VOLTAGE)
Before starting the troubleshooting, check the
sensor unit 5P black connector for loose or poor
contacts, and recheck the Ole.
1. MAP Sensor System Inspection 1
Check the MAP sensor wi th the HDS pockel
tester.
Is about 5 V indicated?
YES - GO TO STEP 2.
NO _ . Intermittent failure .
l oose or poor contact on the sensor
unit SP black connector.
2. MAP Sensor System Inspection 2
Turn the ignition switch 10 OFF (0).
Disconnect the sensor unit 5P bl ack connector.
Connect the wire harness side 5P black connec- SENSOR UNIT 5P BLACK CONN ECTOR
tor terminals with a jumper wire. (Terminal side of the wire harness)
Connection: Light green/ yeUow - Green/ black
Turn Ihe ignition switch 10 ON (I).
tester.
YES - Faulty sensor unit (MAP sensor). Green/black light greenlyeUow
NO - GO TO STEP 3.
JUMPER WIRE
3. MAP Sensor Input Voltage Inspection

Turn the ignition swilch to OFF (0).
Remove the jumper wire.
Turn the ignition switch to ON (I). SENSOR UNIT 5P BLACK CONNECTOR
(Terminal side of the wi re harness)
Measure the vollage between the wire harness
side 5P connector terminals.
Connection: Brown/g reen (+) - Green / black H
Is the voltage within 4.75 - 5.2SV?
YES - GO TO STEP 4.
NO - Open circuit in the Green/black wire. Green/black
6-16
FUEL SYSTEM IPGM-FI)
4. MAP Sensor Output Line Open Circuit Inspec-
tion
Tu rn the ignition switch to OFF (0).
Disconnect the PCM 33P gray connect or.
Check the light green/yellow wife for continuity SENSOR UNIT
peM 33P GRAY CONNECTOR
5P BLACK
CONNECTOR
TOOL:
Test probe, 2 pack 07ZAJ ROJA 110 )
Connection; ..~ /' Q /
Ught green/ yellow fB2S1 - light green/ yellow
Is there continuity? light green/yellow (825) light gre!n,yeliOW
YES - Replace the peM with a known good
one and recheck. (Terminal side of the wire harness)
NO - Open circu it in the Light green/ yellow

wire.
DTC 7-' IECT SENSOR LOW

VOLTAGE)
1. Eer Sensor System Inspection
Check the Eer sensor with the HOS pocket
tester.
YES - GO TO STEP 2.
NO - Interminent failure.
2. ECT Sensor Inspection
Disconnect the ECT sensor 2P connector.
Check the ECT sensor w ith the HOS pocket
tester.
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. ECT Sensor Resistance Inspection
Measure the resistance between the sensor side ECT SENSOR 2P CONNECTOR
2P connector terminals. (Terminal side of the sensor)
Standard: 2.3 - 2.6 kn (20 C C/ 68 FJ
Is the resistance within standard value?
one, and recheck .
No - Faulty ECT sensor.
6-17
4. ECT Sensor Line Short Circuit Inspection
Check for continuity between the wire harness Eel SENSOR 2P CONNECTOR
side EeT sensor 2P connector terminal and (Terminal side of the wire harness)
ground.
Connection: Black/ blue - ground
YES - Short circuit in the Black/blue wire.
NO - Replace the PCM with a known good
one and recheck.
Black/blue
OTC 7-2 (ECT SENSOR HIGH

VOLTAGE)
Eel sensor 2P connector for loose or poor con-
tacts, and recheck the DTe.
1. Eel Sensor System Inspection
Check the EeT sensor with the HDS pocket
tester.
YES - GO TO STEP 2.
ND _ . Intermittent failure.
Loose or poor contact on the ECT
sensor 2P connector.
2. EeT Sensor Inspectio n
Disconnect the ECT sensor 2P connect or. ECl SENSOR 2P CONNECTOR
Connect the wi re harness side 2P connector ter (Terminal side of the wire harness)
minals with a jumper wire.
Connection: Black/ blue - Green/ black
Check the ECT sensor with the HDS pocket T" J~
tester.
Is about 0 V indicated7
Black/blue Green/black
YES - Faulty ECT sensor.
NO - GO TO STEP 3.
JUM3R WIRE
6-18
3. Eel Sensor Line Open Circuit Inspection
Turn the ignition switch to OFF (0). Eel SENSOR
Remove the jumper wire. Greenlblack (82)
2P CONNECTOR
Check the Black/blue and Greenlblack wires for PCM 33P GRAY \
continuity between the EeT sensor 2P connector CONNECTOR --\
and PCM 33P gray connector terminals.
TOOL:
Test probe, 2 pack 07ZAJ-ROJA110
Connection : Black/ blue (827) - Black/ blue

Green/ black (82) - Green/ black
Is there continuity? Black/blue (827 )
Black/blue
YES - Replace the PCM with a known good (Terminal side of the wire harness)
one and recheck. L _ _-'--_ _ _ _ _ __ _ _ _ _- '_ _.J
NO _ . Open ci rcuit in the Black/blue wire .
Open ci rcu it in the Green/black wi re.
DTe 8-1 (TP SENSOR LOW VOLTAGE)

sensor unit 5P black connector for loose or poor
contacts, and recheck the OTC.
1. TP Sensor System Inspection
Turn t he ignition switch to ON (I).
Check the TP sensor with the HOS pocket tester
with 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 con
tinuously when the throttle is moved to fully
closed position t o fully open position, using the
data list menu of the HOS pocket tester.
Does the voltage increase continuously?
YES - . Intermittent failure .
Loose or poor contact on the sensor
unit 5P black connector .
NO - Faulty TP sensor.
3. TP Sensor Input Voltage Inspection
Turn the ignit ion switch to OFF (0).
SENSOR UNIT 5P BLACK CONNECTOR
Turn the ignit ion switch to ON (I).
Measure the voltage between the wire harness (Terminal side of the wire harness)
side 5P connector terminals.
Connection: Brown/ green 1+) - Green / black H
Is the VO/t89ft within 4.75 - 5.25 V?
YES - GO TO STEP 5.
NO - GO TO STEP 4. Green/black
6-19
4. TP Sensor Input Une Open Circuit Inspection
Brown/green (83) Brown/green
Check the Brown/green wire for continuity
~'IJJ'[.
TOOL:
Test probe, 2 pack 07ZAJ RDJA1'O
Connection: Brown/green (83) - Brown/green

SENSOR UNIT
Is there continuity? PCM 33PGRAY 5P BLACK
CONNECTOR CONNECTOR
one and recheck.
NO - Open circuit in the Brown/green wire.
5. TP Sensor Output line Open Circuit Inspection
Check the Yellow/gray wire for con tinuity
tor and 33P gray connect or terminals. PCM 33P GRAY
CONNECTOR SENSOR UNIT
TOOL:
5P BLACK
Test probe. 2 pack 07ZAJ-ROJA110
CONNECTOR
Q~
Connection: Yellow / gray (B14) - Yellow/ gray .J.
YES - GO TO STEP 6.
NO - Open circuit in the Yellow/gray wire.
yeliOW/9tISl.) Yellow/gray
6. TP Sensor Output Une Short Circuit Inspection

Check the Yellow/gray wire for continuity , - - - - - -- - - - - - - - - - - -
between the wire harness side 5P black connec- SENSOR UNIT 5P BLACK CONNECTOR
tor terminal and ground. (Terminal side of the wire harness)
YES - Short circuit in the Yellow/gray wire.
NO - GO TO STEP 7.
Yellow/gray
Replace the sensor unit (TP sensor) with a
known good one (page 6-51).
Reset the PCM (page 6-12).
Turn the ig nition switch to ON (I).
Check the TP sensor with the HDS pocket tester.
fs DTe 8-1 indicated?
one and recheck
NO - Faulty original sensor unit (Tp sensor).
6-20
DTC 8-2 (TP SENSOR HIGH VOLTAGE)
1. TP Sensor System Inspection
Turn the ign ition swit ch to ON (I).
Check the TP sensor with the HDS pocket tester.
YES - GO TO STEP 3.
NO - GO TO STEP 2.
Check that the TP sensor voltage increases con-
tinuou sly w h en the throttle is moved to fully
closed position to fully open position, using the
data list menu of the HDS pocket tester.
Does tha voltage increase continuously?
YES - Intermittent failure.
NO - Fau lty TP senso r.
3. TP Sensor Resistance Inspection
Disconnect the sensor unit 5P black connector. SENSOR UNIT 5P CONNECTOR
Measure the TP sensor resistance between the (Terminal side of the sensor)
sensor unit side 5P connector terminals.
Is the resistance within 1.0 - 3.0 lin
o o o
YES - GO TO STEP 4.
NO - FauilY TP sensor
4. TP Sensor Input Voltage Inspection

Measure the vollage al Ihe wire harness side 5P
connector term inals. SENSOR UN IT 5P BLACK CONNECTOR
(Ter mi na l side of the wire harness)
Connection : Brown/green (+) - Green/ black H
Is the voltage within 4. 75 - 5.25 V7
YES - Replace the PCM wilh a known good
one and recheck
NO - Open circuit in Ihe Green/red w ire.
Brown/green V Green/blac*
() e
621
FUEL SYSTEM (PGMFI)
OTC 9' (lAT SENSOR LOW VOLTAGE)
1. IAT Sensor System Inspection
Check the IAT sensor with the HDS pocket tester.
YES - GO TO STEP 2.
ND - Intermittent failure.
2. IAT Sensor Inspection
Disconnect the IAT sensor 2P black connector.
Check the IAT sensor with the HOS pocket tester.
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. IAT Sensor Resist ance Inspection
Turn the ignition switch OFF (0 ).
Measure the resistance between the IAT sensor tAT SENSOR 2P CONNECTOR
side connector terminals. !Terminal side o f the sensor)
Standard : 2.2 - 2.7 kO (20"C/68~ F)
one, and recheck.
NO - Faulty IAT sensor.
Q
4. IAT Sensor Output line Short Circuit Inspection
Check for continuity between the wire harness tAT SENSOR 2P BLACK CONNECTOR
side IAT sensor 2P connector term inal and !Terminal side of the wire harness)
ground.
Connection: Gray/ blue - ground
YES - Shan circuit in the Gray/blue wire.
NO - Replace the PCM wi th a known good
one and recheck.
Gra y/blue
Q
6-22
DTC 9-2 (lAT SENSOR HIGH VOLTAGE)
IAT sensor 2P black connector for loose or poor
contacts, and recheck the DTe.
1. IAT Sensor System Inspection
Check the IAT sensor with the HDS pocket tester.
Is /Jb out 5 V indicated?
YES - GO TO STEP 2.
NO _ . Intermittent failure.
loose or poor contact on the IAT
sensor 2P black connector.
2. IAT Sensor Inspection
Turn the ignition switch to OFF ~O) .
Disconnect the IAT sensor 2P black connect or. IAT SENSOR 2P CONNECTOR
Con nect the wire harness side 2P connector ter- (Terminal side of t he wire harness)
Connection : Gray/ blue - Green / black
Turn the ignition switch to ON (I),
Check the IAT sensor with the HOS pocket tester.
YES - Faulty IAT sensor Gray/blue Green/black
NO - GO TO STEP 3.
\
JUMPER W IRE
3. IAT Sen sor Open Circuit Inspection

Green/blade (82)
Remove the jumper wire.
Disconnect the PCM 33P gray connector. PCM 33P GRAY ~
Check the Gray/blue and Green/black wires for CONNECTOR
continuity between the IAT sensor 2P connector
and PCM 33P gray connector terminals. Green/
black
TOOL:
Test probe, 2 pack 07ZAJROJA110
Connection : Gray/ blue (826) - Gray/ blue

Green/ black (82) - Green/ black
Gray/blue (826) IAT SENSOR
Is there continuity? 2P CONNECTOR
YES - Replace the PCM with a known good (Terminal side of the wire harness )
one and recheck. L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _-'
NO _ . Open circuit in the Gray/blue wire .

Open circuit in the Green/black wire.
6-23
DTC 11-1 (VS SENSOR)
Before starting the troubleshooting, check the VS
sensor 3P black connector for loose or poor con-
tacts, and recheck the OTe.
1. VS Sensor System Check
Erase the ore (page 6-13).
Test-drive the veh icle and st op the engine.
Check the VS sensor signal wi th the HOS pocket
tester.
Is the VS sensor signal indicated normally?
YES - Intermittent failure.
NO - GO TO STEP 2.
2. VS Sensor Power Input line Inspection
Discon nect the VS sensor 3P black connector. VS SENSOR 3P BLACK CO NNECTOR
Turn the ignition switch to ON (I). (Terminal side of the wi re harness)
Measure the vol tage between the wi re harness
Connection: Black (+) - ground H
Is there battery voltage?
YES - GO TO STEP 3.
Black (+)
NO - Open circuit in the Black wire.
3. VS Sensor Ground Line Inspection

Measure the voltage between the wire harness
side 3P black connector terminals. VS SENSOR 3P BLACK CONNECTOR
Connection: Black 1+1- Green I-J
YES - GO TO STEP 4.
NO - Open ci rcui t in the Green wire.
Black (+) Green H
4. VS Sensor Output Line Inspection

side 3P black connector terminals. VS SENSOR 3P BLACK CONNECTOR
Connection: Pink 1+) - Green H
Is the voltsge sbout 5 V?
YES - GO TO STEP 5.
NO - Open or short circui t in the Pink wire.
6-24
5. VS Sensor In spection
Replace the VS sensor with a new one (page 6
53).
Erase the DTe (page 6-13),
Test-drive the vehicle and slop the engine.
Check the DTe with the HOS pocket tester.
Is Dre 111 indicated?
one and recheck.
NO - faulty original VS sensor.
DTC 12-1 (FUEL INJECTOR)

fuel injector 2P gray connector for loose or poor
contacts, and recheck the DTe.
1. Fuel Injector System Inspection
Erase the OTC (page 6-13).
Turn the ignition switch to OFF (0) and ON, and
check the fuel injector with the HOS pocket
tester.
Is Dre 72-1 indicated?
NO _ . Intermittent failure .
Loose or poor contact on the fuel
injector 2P gray connector.
YES - GO TO STEP 2.
2. Fuel Injector Resistance Inspection
Disconnect the fuel injector 2P gray connector. INJECTOR 2P CONNECTOR
Measure the resistance between the injector (Terminal side of the inj ector)
Standard: 11.1 - 12.3 n (20"C/6S-FI
Is the resistance within the standard values?
NO - Faulty fuel injector.
YES - GO TO STEP 3.
Q )----'
3. Fuel Injector Input Voltage Inspection
Turn the ignition switch to ON (I) .
Measure the vol t age between the wire harness INJECTOR 2P GRAY CONNECTOR
side 2P gray connector terminal and ground. (Terminal side of the wire harness)
Connection : Black/ yellow 1+1- g roond (-)
YES - GO TO STEP 4.
NO - Open circui t in the Black/yellow wire.
Black/yellow
6-25
4. Fuel Injector Signal Line Open Cin:uit Inspection
Disconnect the peM 33P gray connector.
Check the Green/brown wire for continuity INJECTOR
between the wire harness side injector 2P gray 2P GRAY
connector and PCM 33P gray connector termi- CONNECTOR
nals.
TOOL:
-=-
Test probe, 2 pack 07ZAJ-RDJA 110 I N
"
" tn"
Connection: Green/ brown (B33) - Green/ brown /
Is there continuity'?
YES - GO TO STEP 5.
Greenl~wn (B33) Green~rown
NO - Open circuit in the Green/brown wire.
5. Fuel Injector Signal line Short Circuit Inspection
Check for continuity between the wire harness , - - - - - - - - - - - - - - - - - ,
side 2P gray connector terminal and ground. INJECTOA 2P GRAY CONNECTOR
(Terminal side of the w ire harness)
Connection: Green / brown - Ground
YES - Short circuit in the Green/brown wire.
NO - Replace the peM with a known good
one and re check.
Q
Green/brown
DTC 29-' (lACV)

Before starting the troubleshooting. check the
IACV 4P black connector for loose or poor con-
tacts, and recheck the OTC.
, . Recheck DTC
Start the engine and check the OTC with the HOS
pocket tester.
NO _. Interm ittent failure.
loose or poor contact on the IACV 4P
black connector.
YES - GO TO STEP 2.
2. IACV Short Circuit Inspection
Disconnect the IACV 4P black connector. IACV 4P BLACK CONNECTOR
Check for continuity between the wire harness (Terminal side of the wi re harness)
side 4P connector terminals and ground. Brown/blue Brownlyellow
Connection: Black/gray - Ground
Brown/orange - Ground
Brown/ blue - Ground
Brown/ yellow - Ground L-"-Brownl
orange
YES - . Short circuit in the Black/gray or
Brown/orange wire .
Short ci rcuit in the Brownlblue or
Brown/yellow wire.
NO - GO TO STEP 3.
6-26
FUEL SYSTEM (PGMFI)
3. IACV Circuit Continuity Inspection
Disconnect the peM 33P gr ay connector.
peM 33P GRAY Black! IACV 4P
Check the IACV wi res for continuity between the
CONNECTOR gray CONNECTOR
wire harness side peM J3P gray connector and
I.
IACV 4P black connector terminals. B20 , ----{Sl}-- -\- , Brawn/yellow
TOOL:
B31
Test probe. 2 pack 07ZAJRDJA110
Connection: Black/ gray (820) - Black/ gray [3-.- ;}

~~'I-..J
Brown/orange (B32) - Brown!
orange
Brown/blue (B30)- Brown/ blue
Brown/ yellow (B31)- Brown /yellow Brown!
B32 B30 Brownlblue orange
Is there continuity? (Terminal side of the wire harness)
YES - GO TO STEP 4.
NO - . Open circuit in the Black/gray or
Brown/orange wire .
Open circuit in the Brown/blue or
Brawnlyellow wire.
4. IACV Resistance Inspection
Measure the resistance between the IACV side
4P connector terminals. tACV 4P CONNECTOR
(Ter minal side of the IACV)
Connection: 1A - 1B
2A -2B
Standard: 120 - 140 n (20C/ 68F) 18 lA
Is the resistance within the standard values?

YES - GO TO STEP 5.
NO - Faulty IACV.
2B 2A
5. IACV Short Circuit Inspection

Check for continuity between the IACV side 4P
tACV 4P CONNECTOR
Connection : 1A - 2A
1B (Terminal side of the IACV ) lA
1B - 2B
YES - Faulty IACV.
one and recheck.
2B 2A
6-27
DTC 33 -2 (EEPROM)
1. Recheck o TC
Erase the OTC (page 613).
Turn the ignition switch to OFF (0) and ON (I).
Recheck the PCM EEPROM with the HDS pocket
tester.
Is OTC 33-2 indica ted?
one and recheck.
DTC 64-' (DRIVE POWER LOW

VOLTAGE)
Before starting the troubleshooting, check that
the battery and IGN fuse (10 A) are in good con-
dition.
1. Recheck oTC
Turn the ignition switch to OFF (0) and ON (I).
Recheck the OTe with the HOS pocket lester.
Is ore 64 1 indica ted ?
YES - GO TO STEP 2.
2. Drive Power Input line Inspection
Disconnect the PCM 5P black connector. PCM 5P BLACK CONNECTOR
Turn the ignition switch to ON (I). (Terminal side of the wire harness)
Connect ion: Black/yellow (+ ) - Ground H
Is th ere battery vol tage?
\
one and recheck.
NO - GO TO STEP 3.
Black/yetlow (+)
3. M ain Relay Inspection

Check the main relay (page 638) .
Is th e m Jlin r elay normJlI?
YES - GO TO STEP 4.
NO - Faulty m ain relay.
4. M ai n Relay Circuit Inspection
Check the main relay ci rcu its (page 6-39).
Are th e main r elay circuits norm al?
YES - Open circuit in the Blacklyellow wire.
NO - Faulty main relay circuit(s).
6-28
DTC 64-2 (DRIVE POWER HIGH
VOLTAGE)
If the peM outputs DTe 64-2, it maintains the
main relay ON and the MIL will stav on when the
ignition switch is turned to OFF. Therefore dis-
connect the battery H to turn off the system ,
then connect it and perform the troubleshooting.
, . Recheck OTe
Erase the DTe (page 6-13 ).
Turn the ignition switch to OFF (0 ) and ON (I).
Recheck the DTC with the HOS pocket tester.
Is DTC 64-2 indicat8d7
YES - GO TO STEP 2.
2. M ain Relay Inspection
Check the main relay (page 6-38).
Is the main relay normal?
YES - GO TO STEP 3.
NO - Faulty main relay.
3. Main Relay Coil Ground line Short Circuit
Inspection
Disconnect the peM 33P gray con nector.
Check for continuity between the Violet wire ter- MAIN RELAY CONNECTOR
minal of the main relay (relay box) connector (Terminal side of the relay box)
and ground.
15 there continuity?
YES - Short circuit in the Violet wire.
NO - GO TO STEP 4.
Q
~=-
Violet
4. Drive Power Input Voltage Inspection

Turn the ignition switch to OFF (0) .
Disconnect the PCM 5P black and 33P gray con- PCM 5P BLACK CONNECTOR
nectors. (Terminal side of the wire harness)
Connection : Black/ vellow (+) - Ground H
15 there no voltage?
\
one and recheck.
NO - Short circu it to Power line in the Black!
yeUowwire. Black/yellow (+)
6-29
MIL CIRCUIT INSPECTION
If the engine can be started but the MIL does not
come on when the ignition switch is turned to ON
(I), check as follows: M\
( 0e~
( )
@l 0
II 00 J
1, Indicator Power Input Line Inspection
Check that the neutral indicator, reverse indica-
tor and 4WD indicator function properly.
Do they operate properly?
YES - GO TO STEP 2.
NO - Open circuit in the Black/yellow wire
between the junction connector and
indicator lOP connector.
2. MIL line Open Circuit Inspection
Turn the ignition switch to OFF {OJ.
Disconnect the PCM 33P gray connector. PCM 33P GRAY CONNECTOR
Ground the White/blue wire (619) terminal of the (Terminal side of the wire harness)
wire harness side connector with a jumper wire.
TOOL:
mlfilr~~
Test probe, 2 pack 07ZAJ-RDJA 110
Turn the ignition switch to ON (1) and check the
MIL.
~
Does the MIL come on?
one and recheck.
White/blue (819)
NO - GO TO STEP 3.
3. Indicator Bulb Inspection

Disconnect the indicator lOP connector. INDICATOR lOP CONNECTOR
Check for continuity between the indicator side (Terminal side of the indicator harness)
CONNECTION: Black/yellow - White fb lue
YES - Open circuit in the White/blue wire
between the PCM and indicator lOP
connector.
NO _. Faulty MIL bulb. Black/yellow White/blue
Faulty indicator wire harness.
6-30
FUEL LINE INSPECTION
FUEL PRESSURE RELIEVING
1. Remove the passenger seat under cover (page 3-
61.
2. Turn the ignition switch to OFF (0).
3. Disconnect the fuel pump 5P connector.
4. Start the engine, and let it idle unti l it stalls.
5. Turn the ignition switch to OFF (0).
QUICK CONNECT FITTING REMOVAL

NOTE
Before disconnecting fuel feed hose, relieve pres-
sure from the system (page 6-31).
Do not bent or twist fuel feed hose.
INJECTOR SIDE
1. Remove the center frame cover (page 3-7).
2. Clean the quick connect fitti ng if necessary, and
place a shop towel over the quick connect fitting.
3. Remove the wire band from the clamp and
remove the screw and the hose clamp from the
throttle body and feed hose.
4. Hold the connector with one hand, squeeze the

retainer tabs with the other hand to release the
~1II1II1II~~~~~III~III~:g~~IIIIII~
RETAINER TABS
locking pawls from t he connector and pull the
connector off t he fuel pipe. CONNECTOR
~\
Prevent the remaining fuel in the fuel feed hose
from flowing out with a shop towel.
Be careful not to damage the feed hose, connec-
tor and fuel pipe.
Do not use lools.
If the connector does not move, keep the retainer
tabs pressed down, and alternately pull and push
the connector until it releases.
5. Remove the retainer and joint rubber from the
fuel pipe. LOCKING PAWLS
6. To prevent damage and keep foreign matter Qut,

cover the connector and fuel pipe with plastic
bags.
6-31
FUEL TANK SIDE
1. Release the fuel feed hose from the clips on the
fuel tank and air duct
2. Clean the Quick connect fitting if necessary, and
place a shop towel Oller the quick connect fitting.
CUPS
3, Pull the rubber cOlier off the joint pipe as shown.

RUBBER COVER
I~
~~
JOINT PIPE
4. Hold the connector with one hand, squeeze the

retainer tabs with the other hand to release the I;::==Zc~~~~==========l
locking pawls from the connector and pull the
connector off the fuel pipe. RETAINER ~
Prevent the remaining fuel in the fuel feed hose
from flowing out with a shop towel.
Be careful not to damage the feed hose, connec-
tor and fuel pipe.
Do not use tools.
If the connect or does not move, keep the retainer
tabs pressed down, and alternately pull and push
the connector until it releases. LOC,""'" PAWLS
5. Remove the retainer and rubber cover from the RUBBER COVER
RETAINER TABS
fuel pipe.
6. To prevent damage and keep foreign matter out,
cover the connector and fuel pipe with plastic
bags.
6-32
FUEL SYSTEM (PGMFI)
QUICK CONNECT FiniNG
INSTALLATION
NOTE
Always replace the retainer and joint rubber of
the quick connect fitting when the fuel feed hose
is disconnected.
Use the same manufacture's retainer as the
removed one.
Do not bent or kink the fuel feed hose.
INJECTOR SIDE
1. Insert a new retainer into the connector.
CONNECTOR
sit RETAINER
2. Install a new joint rubber onto the fuel pipe.

If it is hard /0 3. Install the con nector on the fuel pipe straight and
connect the fittmg, align the retainer grooves with the joint rubber CONNECTOR
\~
put 8 small amoum tabs as shown.
of engme 011 on the Then press the connector onto the fuel pipe until
fuel pipe end. both locking pawls click.
"' (
~ JOINT
S RUBBER
LOCKING PAWLS
4. Make sure that the quick connect fitling is con-

nected securely and the locking pawls afe locked
firmly by pulling the connector.
5. Install the hose clamp onto the feed hose and
throttle body by aligning the hole with the boss,
and tighten the screw.
6-33
6. Connect the fuel pump 5P connector.
Do not Slarr the 7. Turn the ignition switch to ON (I).
engme. The fue l pump will run fo r about 2 seconds, and
fuel pressure will rise.
Turn the ignition switch to OFF !O).
8. Repeat step 7 two or three times, and check that
there is no leakage in the fuel supply system.
9. Install the following :
- passenger seat under cover (page 3 6)
FUEL TANK SIDE

1. Insert a new retainer into the connector.
111 RETAINER
CONNECTOR
2. Install a new rubber cover onto the fuel pipe as
shown. CONNECTOR
If it is hard tD 3. Install the connector on the fuel pipe straight and

connect the fmmg, press the connector onto the fuel pipe until both RUBBER
pur a smallamounr locking pawls click. COVER
of engme oil on rhe
fuelppeend
LOCKING PAWLS
PIPE
4. Make sure that the quick connect fiing is con- ~=================~

nected securely and the locking pawls are locked ~ QUICK CONNECT FITTING
firmly by pulling the connector. ~~/ '
5. Secure the fuel feed hose with the hose clips.
CUPS
6-34
6. Connect the fuel pump 5P connector.
Do nor start the 7. Turn the ignition switch to ON 0).
engme The fuel pump will run for about 2 seconds, and
fuel pressure will rise.
B. Repeat step 6 two or three times, and check that
there is no leakage in the fuel supply system.
9. Install the passenger seat under cover (page 3-6).
FUEL PRESSURE TEST

Relieve the fuel pressure (page 6-31).
GAUGE
Disconnect the quick connect fitting from the fuel
injector (page 6-31).
MANIFOLD \ ATTACHMENT, 6 mml9 mm
Attach the special tools between the injector and
fuel feed hose. (-..
EJecept U.S.A . TOOLS:
Fuel pressure gauge 07406-0040004
Pressure gauge manifold 07ZAJ-S5A0111
Hose attachment, 9 mm / 9 mm 07ZAJ-S5A0120
Hose attachment, 6 mm / 9 mm 07ZAJ -S5A0130
Attachment joint, 6 mm/ 9 mm 07ZAJ-S5A0150
U.S.A. TOOLS:
Fuel pressure gauge, 100 psi 07406-0040008
Pressure manifold hose 07AMJ-HW3A 100
Adapter, male 07AAJ-S6MA200
Adapter, female 07AAJ -S6MA400
ATTACHMENT. S mm/S mm
JOINT, 6 mm/9 mm
Connect the fuel pump 5P connector.

Start the engine and let it idle.
Read the fuel pressure.
Standard: 336 - 350 kPa (3.43 - 3.57 kgf/c m ~,
49 - 51 psi)
If the fuel pressure is higher than specified pressure,
replace the fuel pump assembly (faulty fuel pump or
fuel pressure regulator).
If the fuel pressure is lower than specified pressure,
inspect the following;
- fuel flow (page 6-36)
- pinched or clogged fuel feed hose
- fuel pump (page 6-36)
Disconnect the fuel pump 5P connector, start the
engine and let it idle until it stalls to relieve the fuel
pressure.
Wrap a shop rowel Remove the special tools from the fuel injector and
around the fuel feed hose.
atracilmem to soak
Connect the quick connect fitting to the fuel injector
up any spilled fuel
(page 6-33).
6-35
FUEL FLOW INSPECTION
Relieve the fuel pressure (page 631).
FUEL PUMP RELAY CONNECTOR
(Terminal side of the relay box)
Remove the fuel pump relay (page 6-38) Brown
---l
Connect the Black/yellow and Brown wi re terminals
-
of the fuel pump relay (relay box) connector using a
jumper wire.
Blacklyellow -
1\
JUMPER WIRE
Place the end of the fuel feed hose into an approved

gasoline container.
Turn the ignition switch to ON (I) for 10 seconds and
turn it to OFF (0).
Measure the amount of fuel flow.
Amount of fuel flow:
86 em' (2.9 US OZ, 3.0 Imp ozl minimum / lO sec
onds at 12 V
If the fuel flow is less than specified volume, inspect
the fo l lowing:
- fuel pump (page 6-36)
- pinched or clogged fuel feed hose
(page 633).
Remove the jumper wire from the relay box
connector and install the following:
- fuel pump relay GASOLINE CONTAINER
- relay box cover
- battery box cover (page 21-6)
FUEL PUMP
INSPECTION
Remove the passenger seat under cover (page 3-6).
Turn the ignition switch ON (I) and confirm that the
fuel pump operates for a few seconds.
If the fuel pump does not operate, inspect as fol-
lows:
Disconnect the fuel pump 5P connector.
6-36
Turn the ignition switch to ON (I) and measure the
voltage between the wire harness side 5P connector FUEL PUMP 5P CONNECTOR
terminals. (Terminal side of the wire harness)
Connection : Brown (+1- Gree n H

There should be battery voltage for a few seconds
aher the ignition switch turned to ON (I),
If there is battery voltage, replace the fuel pump
assembly.
If there is no voltage, check the following :
- open circu it in the Brown wire between the fuel
pump and fuel pump relay
- open circuit in the Green wire between the fuel Brown (+) Green H
pump and ground terminal L _ _ _ _ _ _ _ _ _ _ __ __ _ _ _.J
- fuel pump relay and its circuits (page 6-381
REMOVAL
Remove the fuel tank (page 6-40).
FUEL SENDER WRENCH
loosen the fuel pump lock nut using the special
1001.
TOOLS:
Fu el sender wrench 07XAA001010A
Be careful 001/0 Remove the lock nut and fuel pump assembly from
bend the float arm the fuel tank.
Remove the base gasket.
LOCK NUT
\
INSTALLATION
Install a new gasket onto the fuel tank.
FUEL PUMP
Install the fuel pump assembly into the fuel tank by
I
Be careful not to
damageorpmch aligning the index marks.
the base gasket
:If
~~
6-37
Install the fuel pump lock nut and tighten il using FUEL SENDER WRENCH
the specialloo!.
TOOLS:
Fuel sender wrench 07XAA001010A
TORQUE: 93 N' m t9.5kgfm , 69 IbUt)

Install the fuel tank (page 6-40),
LOCK NUT
MAIN RELAY/FUEL PUMP RELAY

REMOVALIINSTALLA TION
Remove the battery box cover (page 21-6).
Remove the relay box cover.
Remove the main relay and fuel pump relay from

the relay box.
RELAY INSPECTION
Remove the main relay and fuel pump relay (page , - - - - -- - - - - -- - - -- - - ,
6-38).
No.2 No. 1
Check for continuity between the NO.1 and No. 2
terminals.
Connect the fully charged 12-V battery (+) terminal
to the relay NO.4 terminal and the H terminal to the
No.3 terminal.
There should be continuity when the battery is con
nected, and no continuity when the battery is dis-
connected.
No.3 No.4
6-38
MAIN RELAY CIRCUIT INSPECTION
1. Power Input line Ins pection
Remove the main relay (page 6-38),
Turn the ignition switch to ON (I), MAIN RELAY CONNECTOR
Measure the voltage between the White/red wire (Terminal side of the relay box)
terminals (+l of the main relay (relay box) con-
nector and ground H. White/red (+)
YES
NO
- GO TO STEP 2.
_ . Open circuit in the White/red wire
between the relay box and fuse box.
v .-+---{ v
Blown IGN fuse (10 A).
Open circuit in the Red/yellow or Red
wire between the fuse box and bat-
\-'-----L.----'
tery. WhiteJred (+)
2. Relay Coil Ground line Inspection

Check for continuity between the Violet wire ler- , - -- - - - - - - - - - - - - - --,
minal of the main relay (relay box) connector MAIN RELAY CONNECTOR
and ground. (Terminal side of the relay box)
YES - The main relay circuits are normal.
NO - . Open circuit in the Violet wire
between the relay box and PCM.
Faulty power/ground line of the PCM
Q
(page 6-54)
Faulty PCM.
FUEL PUMP RELAY CIRCUIT -==-
INSPECTION Violet
1. Power Input line Inspection

Remove the fuel pump relay (page 6-38).
Turn the ignition switch to ON (I). FUEL PUMP RELAY CONNECTOR
Measure the voltage between the Black/yellow (Terminal side of the relay box)
wire terminals (+) of the fuel pump relay (relay
box) connector and ground (-). Black/yel low (+)
YES - GO TO STEP 2.
NO _ . Open circuit in the Black/yellow wire
between the main relay and fuel
pump relay connectors.
Faulty main relay or its circuits.
Blacklyellow (+)

Check for continuity between the Gray/orange FUEL PUMP RELAY CONNECTOR
wire terminal of the fuel pump relay (relay box) (Terminal side of the relay box)
connector and ground.
Is there continuity for about 2 seconds?
YES
NO
- The fuel pump relay circuits are normal.
- . Open circuit in the Gray/orange wire
Q
between the relay box and PCM.
Faulty power/ground line of the PCM
(page 6-54)
~'=-
Faulty PCM.
Gray/orange
6-39
FUEL SYSTEM (PGM-FII
FUEL TANK
Relieve the fuel pressure (page 631).
injector (page 631).
- right side panel (page 3-1 1)
- right rear wheel (page 17-5)
Release the breather hose from the clips.
Remove the four washer-bolts and tank retainers.
Remove the fuel tank out of the frame to the rear
side.
When tlghrenmg Installation is in the reverse order of removal.
the boll, align eecll
Connect the quick connect fitting (page 6-33),
retamer lab with
the /lole In the tani<
base plate properly
FUEL TANK
t TABS
6-40
AIR CLEANER HOUSING
REMOVALIINSTALLA nON
- passenger seat under cover (page 3-6)
Unlock the cargo bed by pulling on the release lever
and raise the bed.
Oisconnect the IAT sensor 2P (black) connector.
Apply soapy waler Disconnect the crankcase breather hose from the air
/0 the hose /0 sid In cleaner housing and remove it from the connecting
removal tube.
Remove the two duct mounting bolts and trim clip
to loosen the intake air duct.
Loosen the connecting tube band screws.
Remove the three housing mounting bolts.
Release the connecting tubes off of the throttle body
and air ducl, and remove the air cleaner housing .
Sel/he duel so Its Installation is in the reverse order of removal.

stoppers are fully
seBted on the CONNECTOR
Ji
connectrngrube
BANDS
i r--BOLTS
~
AIR CLEANER HOUSING
~ BOLT~~
"
n
", II
0
~
,
~
6-41
INTAKE AIR DUCT
Remove the air cleaner housing {page 6-41 J,
Release the fuel feed hose clip on the fuel tank.
Remove the hose clips from the air duct.
Remove the duct cap by releasing it from the two
tabs.
Remove the intake air duct.
When Iflsraliing the Installation is in the reverse order of removal.

duct cap. align the
index lines.

-.
CLIPS
\ CAP
ACCELERATOR PEDAL
REMOVAL/INSTALLATION
Release the cable retainer (Yellow) by pulling it to , - - - - - - -- - - - - - - - - - - ,
the right side to disconnect the inner cable from the BOLT
pedal.
Remove the bolt to disconnect the outer cable from
the bracket.
Remove the two bolt and accelerator pedal assem-
bly.
8 '\
PEDAL
642
FUEL SYSTEM (PGM-FII
DISASSEMBLY
Unhook the spring end off of the pedal and remove
the following:
- coner pin and washer
- pivot shaft
- accelerator pedal
return spring
- collar
- dust seals
PIVOT SHAFT
),
COLLAR
ASSEMBLY
Coat the lips of new dust seals with grease.
Install the dust seals into the brake pedal with the
flat side facing until they are fully seated.
6-43
Install the collar and spring onto the accelerator
pedal in the direction as shown. BRACKET
Apply grease to the groove in the pivot shaft.

Install the pedal into the bracket so the lower spring
end 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 onto the pedal.
Install the washer and new cotter pin.
PEDAL
6-44
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 install-
ing the throttle body (page 6-52),
Relieve the fuel pressure (page 6-31).
Remove the air cleaner housing (page 6-41).
Disconnect the following:
- injector 2P gray connector
- IACV 4P black connector
- sensor unit 5P black connector
Remove the wire clip from the hose guide bracket.
Remove the screw/washer and throttle drum cover.
Loosen the throttle cable adjuster lock nut, remove

the adjuster from the throttle body and disconnect
the cable end from the throttle drum.
loosen the insulator band screw and remove the
throttle body from the insulator.
6-45
Loosen the insulator band screw and remove the
insulator from the cylinde r head.
NOTE:
Do not loosen or tighten the white painted
screws and nut.
IACV removal/installation (page 6-48)
Fuel injector replacement (page 6-49)
TP sensor/MAP sensor (sensor unit) replacement
(page 6-51)
WHITE PAIINT'D SCREWS
lACY INJECTOR
TP SENSOR/MAP SENSOR
INSTALLATION
Align the pin of the insulator band with the insulator r - - - - - - - - -
BA- N-D- S
-C
- R-' W
------.
groove.
Install the insulator onto the cylinder head by align-
ing the groove with the lug.
INSULATOR GROOVE LUG
6-46
Tighten the insulator band screw so that the dis-
tance between the band tabs is as shown .
5.5 1 mm
(0.22 0.04 in)
Align the end of the insulator band with the stopper ~;;;;;_u.;:::=,:::;=,:::;;:;===========~
of the insulator.
Install the throttle body into the insulator by align-
ing the lug with the groove.
Tighten the insulator band screw so that the dis-
tance between the band tabs is as shown.
Connect the throttle cable end to the throttle drum.

Install the throttle cable adjuster into the throttle
body and temporarily tighten the lock nut.
Adjust the accelerator pedal freeplay (page 4-5).
Install the throttle drum cover by aligning the locat-

SCREW/WA$HER
ing tab with the slot in the throttle body.
Install and tighten the screw. ~
LOCATING TAB
THROTILE DRUM COVER
6-47
Connect the following :
- injector 2P gray connector
- IACV 4P black connector
- sensor unit 5P black connector
(page 6-33).
Install the air clea ner housing (page 6-41).
IACV
INSPECTION
NOTE:
The IACV is installed on the throttle body and is
operated by the step motor. When the ignition
switch is turned ON (I), the IACV operates for a
few seconds.
Remove the center frame cover (page 3- n
TheJACVoperaflOfl Turn the ignition switch to ON (I) and check the
can be chedr.ed IACV.
visually by If the step motor operating (beep) sound is heard,
remOVIng fila IACV the IACV is normal.
wah /he connector
connected
REMOVAL
Remove the center frame cover (page 3-7) ,
Clean the throttle body to prevent dirt and debris
from entering the IACV passage.
Disconnect the IACV 4P black connector.
Remove the two torx screws, retainer plate and
IACV.
6-48
INSTALLATION
Instat! a new O-ring onto the IACV .
Turn the slide valve 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.
Install the retainer plate with the two tone screws by

aligning the groove with the valve boss.
Connect the IACV 4P black connector.
Install the center frame cover (page 3-7).
FUEL INJECTOR
REPLACEMENT
Relieve the fuel pressure (page 6-31 1,
injector (page 6-31),
Clean around the fuel injector base with com-
pressed air before removing the fuel injector, and
be sure that no debris is allowed t o enter into the
combustion chamber.
Disconnect the fuel injector 2P gray connect o r.
Remove the two mounting bolts and the fue l injec~
tor assembly from the throttle body.
6-49
Remove the injector jOint and seal ring from the
injector.
Install a new seal ring onlo a new injector.

Apply engine oil to the seal ring and Qring on the
injector.
Install the injector joint onto the injector being care-
ful not to damage the a r ing.
Install the fuel injector assembly into the throttle

body being careful not to damage the seal ring.
Install the injector mounting bolts and tighten them.
Connect the fu el injector 2P gray connector.
(page 633).
6-50
TP SENSOR/MAP SENSOR (SENSOR
UNIT)
REPLACEMENT
NOTE:
After replacing the sensor unit the TP sensor
reset procedure must be performed (page 6-52)'
Remove the three torx screws and the sensor unit
from the throttle body,
Install a new D-ring into the groove of the throttle

body.
Install the a new sensor unit onto the throttle body
by aligning the slot with the throttle shaft end.
Install the torx screws and tighten them.

Connect the sensor unit 5P black connector.
Perform the reset procedure (page 6-52),
6-51
TP SENSOR RESET PROCEDURE
NOTE :
Make sure that the DTC is not stored in the peM
memory. If the DTe is stored, the reset mode will
not start.
,. Remove the dummy connector from the OLe
{page6-12l,
Short the OLe terminals using the special tool.
TOOL:
SCS connector 070PZZY30100
CON NECTION: Brown/ red - Green
2. Disconnect the Eel sensor 2P black connector.

Short the wire harness side connector terminals
(Terminal side of
with a jumper wire.
the wire harness)
3. Turn the ignition switch to ON (I).
The MIL stars blinking (reset receiving pattern).
Within 10 seconds after turning the ignition
switch to ON (I), disconnect the jumper wi re 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.
Gj) 0 Within 10 sec.

U - '- - - -- Ul ;
: 0.1 sec. 1,2 sec. I 0.3 sec. , . I 0.3 sec.
ON _ _ _ _ _ ..J ___ _ "I~I'~'- - " " ;---'---'
MIL
='----'==-==-=~~.
OFF
- - - --- !
,' =
Reset Receiving Pattern Reset Confirmation Pattern
(Stay on: Reset procedure is not complete)
IGNITION
SWITCH
ON (I)
OFF (0)
------ I
6-52
ECT SENSOR
REPLACEMENT
Unlock the cargo bed by pulling on the release lever
and raise the bed.
Disconnect the 2P black connector from the EeT
sensor.
Remove the ECT sensor and O-ring .
Install a new O-r ing onto the Eel sensor.

Install the EeT sensor and tighten it.
TORQUE: 12 N 'm (1,2 kgfm , 9 Ibf.ft)
Connect the 2P black connector to the EeT sensor.
lower the cargo bed.
Fill the cooling system with the recommended cool-
ant (page 75).
VS SENSOR
Slide the connector cover off the VS sensor 3P black
connector and disconnect the connector.
Remove the bolt and VS sensor from the rear differ-
ential case.
Coat a new O' ring with engine oi l and install it onto

the VS sensor.
Install the VS sensor into the rear differential case
and tighten the bolt.
Connect the VS sensor 3P black connector and slide
the connector cover on the connector.
6-53
PCM
POWER/GROUND LINE INSPECTION
Oisconnect the PCM 33P g ray connector.
POWER GROUND LINE

Check for continuity between the wire harness side r ---p-C-M-3
- 3-P- G-R-"-Y- C
-O- N-N-E-C-T-O-R- - - - - ,
33P connector terminals and ground.
TOOL: Green (810)
Test probe, 2 pack 01ZAJ-ROJA110
Power Ground:
Connection: Green (810) - ground
Green (822) - ground
Logic Ground: ~nIB131
Connection: Green (813) - ground
Q
There should be continuity at all times. Gree~ (B~ -.l
If there is no continuity, check for an open circuit in
the green wires.
POWER INPUT UNE
Turn the ignition switch to ON Ul.
Measure the voltage between the wire harness side (Terminal side of the wire harness)
33P connector terminal and ground.
1 r-1 1
TOOL:
Test probe, 2 pack 07ZAJ-RDJA110
Connection : Black/ red (B 1) 1+) - ground H

There should be battery voltage.
If there is no voltage, check the following;
- Black/green wire for open circuit between the
PCM and the fuse box IFI fuse)
- FI fuse (10 Al
H 1 V (+) Black/red (Bl )
- Red/white wire for open circui t between the fuse L _ _ _ _ _ _ _ _ _ _ _ __ _ __ _..J

box and ignition switch
- ignition switch
6-54
REMOVAl/INSTALLATION
Remove the battery box cover (page 21 -6).
Turn the ignition switch to OFF {OJ.
Disconnect the 5P black connector, 33P black con-
nector and 33P gray connect or from the PCM, and
remove the PCM from the battery box.
Install the PCM in the reverse order of removal.
ENGINE IDLE SPEED

IDLE SPEED INSPECTION
NOTE
Inspect the idle speed after all other engine main-
tenance items have been perfor med and are
within specifications.
Before checking the idle speed, inspect the fol-
lowing items.
- No DTe and MIL blinking
- Spark plug condition (page 4-8)
- Air cleaner condition (page 4-6)
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
smal ler that will accurately indicate a 50 rpm
change.
Start the engine and warm it up to coolant tempera-
ture 80 C (176 OF).
Stop the engine and connect a tachometer accord-
ing 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

fo l lowing:
Throttle operation and accelerator pedal freeptay
(page 4-5).
Intake air leak or engine top-end problem (page
9-31
Valve clearance (page 4-10)
IACV operation (page 6-48)
6-55
MEMO
7. COOLING SYSTEM
SYSTEM FLOW PATTERN ",,,,,,,, 7-2 THERMOSTAT ". "" ". ". "" ". """"" " .. ".". ". 7-7
SERVICE INFORMATION " " """""""""",,7-3 WATER PUMP " " " """" " """""" """ """"" 7-9
TROUBLESHOOTI NG ." """ ". "" """".".".". 7-3 COOLING FAN " """"""" """""" """" " "" 7-11
SYSTEM TESTING" ". " " . ". " .,, " " . " . " "." " " 7-4 RADIATOR,, " " "" " " ." " .. ". ". " ..." " . " .. ". " . 7-13
COOLANT REPLACEMENT """""""""""" 7-5 RADIATOR RESERVE TANK " " " """" "" " 7-14
7-1
COOLING SYSTEM
SYSTEM FLOW PATTERN
RADIATOR
t-'I-RES~RVE TANK
THERMOSTAT
WATER PUMP
7-2
COOLING SYSTEM
SERVICE INFORMATION
GENERAL
AWARNING
Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you.
Always let the engine and radiator cool down before removing the radiator cap.
NOTICE
Using coolam with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator
passage. Using tap water may cause engine damage.
Add coolant to the system at the reserve tank. Do not remo.... e 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 tesler.
For engine temperature indicator and cooling fan motor inspection, see lights/Meters/Switches section (page 24-9).
SPECIFICATIONS
ITEM
-C=oOo"laCnCtCcCaCpcaccc;ty~-----' Radiator and engine
Reserve tank
Radiator cap relief press~u",~.~~_ _ _~~_ __
I SPECIACATIONS
3.3 liters (3.5 US qt, 2.9 Imp qt)
0.6 liter (0.6 US qt, 0.51mp qt)
93 - 123 kPa (0.95 - 1.25 kgf/cm""), 14 ~-..:';8fP"'S,,;)_ _ __
Thermostat Begin to open 80 84"C (176 - 183F)
~I open 95C (203F)
Valve lift 8 mm (0.3 in) minimum at 95C (203F)
Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality
ethylene glycol antifreeze containing silicate-f ree corrosion
Standard coolant concentration

"!I@<~==========_ .=====t==;n=h=;=b=;t=O='S====~rn,
_ 1:1 mixture with distilled water
TORQUE VALUE
Coolant bleed bolt (at thermostat cover) 12 Nm (1.2 kgfm, 9Ibfft)
TROUBLESHOOTING
Engine t emperature too h igh
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 mechani cal seal
Deteriorated O-r ings
Faulty radiator cap
Damaged or deteriorated cylinder head gasket
Loose hose connection or clamp
Damaged or deteriorated hoses
7-3
COOLING SYSTEM
SYSTEM TESTING
COOLANT (HYDROMETER TEST)
hood.
The engme must be Remove the radiator cap.
cool before
removmg rhe
radlBtor cap
Test the coolant gravity using a hydrometer.
STANDARD COOLANT CONCENTRATION:

1:1 mixtu re of disti lled water a nd a ntifreeze
look for con tamination and replace the coolant if
necessary.
7-4
COOLING SYSTEM
RADIATOR CAP/SYSTEM PRESSURE
INSPECTION
Remove the radiator cap !page 7-4),
Wet the sealing surfaces of the cap, then install the RADIATOR CAP
cap onto tester.
TOOLS:
Cooling system pressure tester SVTS4AH
Cooling system adaptor OTCJ33984A
Pressurize the radiator cap using the tester.
Replace the radiator cap jf it does nOI hold pressure,
or if relief pressure is too high or too low. It must
hold the specified pressure for at least 6 seconds.
TESTER
RADIATOR CAP RELIEF PRESSURE:
93 - 123 kPa (0.95 - 1.25 kgf/c:m', 14 - 18 psi)
Pressure test the radiator, engine and hoses, and

check for leaks.
I NOTICE I TESTER
Excessive pressure can damage the cooling system
components. Do not exceed 123 kPa (1.25 kgflCnT,
18 psi).
Repair or replace components jf the system will not
hold the specified pressure for at least 6 seconds.
Remove the tester and install the radiator cap.
Close the front hood and secure it with the st rap s.
COOLANT REPLACEMENT
PREPARATION
I NOTICE I
Using coolant with silicate corrosion inhibitors may
cause premature wear of water pump seals or
blockage of radiator passages. Using tap water may
cause engine damage.
0<27
NOTE
The effectiveness of coolant decreases with the
accumulation of rust or if there is a change in the
mixing proportion during usage. Therefore, for
best performance change the coolant regularly ANTIFREEZE
as specified in the maintenance schedule. '--SOL_U
TIO-----'N ' \ I
Mix only distilled, low mineral water with the rec-
ommended antifreeze. (ETHYLENE
GLYCOL BASE LOW MINERAL
RECOMMENDED ANTIFREEZE: SOLUTION ) OR DISTILLED
Pro Honda HP Coolant or an equivalent high WATER
quality ethylene glycol antifreeze co ntaining
silicate-free corrosion inhibitors
COOLANT
RECOMMENDED MIXTURE:
1:1 (distilled weter end recommended antifreeze)
7-5
COOLING SYSTEM
REPLACEMENT/AIR BLEEDING
NOTE :
When filling the system with a coolant, place the
vehicle on a flat, level surface.
Remove the seat center cover (page 3-5) .
hood.
The engme must be Drain the coolant from the system by removing the
cool before drain bolts and sealing washers on the water pipes
(8mrNing rhe above the underbody, and the radiator cap.
cool,ng system
Reinstall each drain bolt with a new sealing washer
securely.
Remove the reserve tank cap, and the mounting bolt
and reserve tank. Empty the reserve tank and rinse DRAIN BOLTS AND WASHERS
the inside of the tank with water. \ '-/ J ~
Install the reserve tank with the bolt by inserting the ~ S
boss and rib into the frame.
Remove the bleed bolt and seal ing washer from the
thermostat cover, and loosely install the bolt with a
new sealing washer.
Place the shop towels around the bleed bolt.
Fill the system with the recommended coolant up to
the filler neck. Tighten the bleed bolt as soon as
coolant starts to run out in a steady stream without
bubbles.
TORQUE: 12 N 'm (1.2 Icgfm , 9Ibf.ft)
1. Shift the sub-transmission into neutral. 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. Stop the engine and add coolant up to the filler
neck.
4. Install the radiator cap.
7-6
COOLING SYSTEM
Fill the reserve tank to the MAX line and install the ,.
tank cap.
Install the seat center cover (page 3-5).
THERMOSTAT
REMOVAL
Drai n the coolan t from t he system (page 7-6).
Remove the driver seat under cover (page 3-6).
- two bolts
- thermostat cover
- thermostat
INSPECTION
Visually inspect the thermostat for damage.
Replace the thermostat if the valve Slays open al THERMOMETER
room temperature.
Do not let the Heat a container of water with an electric heating
thermostat or element for 5 minutes.
thermometer (ouell Suspend the thermostat in heated water to check its
the pan, Of you will operation.
gel 8 false reading
THERMOSTAT BEGIN TO OPEN:
80 - 84~ C (176 - 183 ~F)
VALVE LIFT:
8 mm (0.3 in ) m inimum at 95 C ( 203 ~ F I
Replace the thermostat if the valve opens at a tem-

peratu re other than those specified.
7-7
COOLING SYSTEM
INSTALLATION
Make sure the rubber seal on the thermostat is in
good condition.
Apply coolant to the rubber seal and install the ther-
mostat into the housing, aligning the bleed hole
with the lug.
Install the thermostat and tighten the two bolts

securely.
Fill and bleed the cooling system !page 7-5),
Install the seat under cover (page 3-6),
7-8
COOLING SYSTEM
WATER PUMP
MECHANICAL SEAL INSPECTION
Check for signs of seal leakage.
A small amount of weeping from the bleed hose
(connected to the water pump) located in the under-
body is normal.
WATER
PUMP
REMOVAL
- floor panel (page 3-12)
Drain the coolant from the system (page 7-6).
Release the hose clip from the stay on the oil cooler.
Remove the bolt securing the water pi pes.
Take care nor to Disconnect the front water hose from the water
damage the water pump and remove it from the waler pipe while hold-
hose ing the pipe securely to get the clearance for pump
removal.
Disconnect the upper water hoses from the water
pump.
PUMP
loosen the three cover bolts.

Remove the followi ng:
- two mounting bolts
- water pump assembly
7-9
COOLING SYSTEM
- three cover bolts and sealing washer
- pump cover PUMP BODY
- a-rings
~\
- bleed hose
- hose guide
a-RING
BOL T5 AND WASHER
INSTALLATION
Install the hose guide onto the bleed hose and the
hose onto the pump body.
Coat a new O-ring 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 crankcase cover, and be sure the water pump is
fully seated.
Install a new D-ring into the pump body groove
properly.
Take cafe nor to let Install the pump cover with the two mounting bolts
tile O-nng come off and temporarily tighten them until the cover is
the body groove seated.
Install the three cover bolts with a new sealing
washer (in position as shown; t r iangular mark) and
the hose guide (al igning the groove with the stop-
per). Tighten all the bolts in a crisscross pattern in
several steps.
7-10
COOLING SYSTEM
Connect the upper water hoses.
Ta/(e care nor to Install fronl water hose onto the waler pipe and con-
damage fhe water nect it to the water pump while holding the pipe
hose securely.
Install the bolt to secure the water pipes.
Install the hose clip into the st ay on the oi l cooler.
Fill and bleed the cooling system (page 7-5) ,
engine front cover (page 36)
- floor panel (page 3- 12)
PUMP
COOLING FAN
REMOVAL/INSTALLA TION
Remove the banery box cover (page 21-6),
Release the two w ire clips to free the fan motor
wire.
Remove the fan mOlor 2P (brown) connector from
the battery box and disconnect it.
Remove the four battery box mounting bolts to get

the clearance for fan motor removal.
7-11
COOLING SYSTEM
Release the breather hoses from the hose guides of
the fan shroud and disconnect them from the frame
pipe.
Remove the two mounting bolts and coltars.

Be careful not to Release the two mounting bosses of the shroud bot-
damage the radla/or tom from the frame and remove the cool ing fan
fins assembly so the battery box is not interfered .
Route the hoses Installation is in the reverse order of removal.
and wires properly
(psgB 1-21).
OISASSEMBLY I ASSEMBLY
- nut
- cooling fan
7-12
COOLING SYSTEM
- collar ,..
cap COLLAR
- three washer-screws
- fan motor (by aligning the hose joint with the slot
in the shroud)
WASHER-
SCREWS ....
Assembly is in the reverse order of disassembly.

NOTE "
When installing the cooling fan, align the flat sur-
faces of the fan and shaft.
Apply locking agent to the motor shaft threads.
RADIATOR
NOTE :
Take care not to damage the radiator fins while
servicing the radiator.
Drain the coolant from the system (page 7-6).
Remove the fan motor (page 7-11).
- siphon hose (disconnect from the radiator)
- headlight 3P connector (from the radiator
shroud)
7-13
COOLING SYSTEM
- water hoses (disconnect from the radiator)
Toprevem the - six bolts and sub-frame (remove with the radia -
fad,a tor from fallmg tor grille and shroud)
down, hold Ihe - radialor (release mounting bosses on the radia -
radiator casing tor bottom from the frame)
securely
Route the he8dl~hr Installation is in the reverse order of removal.

wire property (page
Install the fan motor (page 7-11).
1-211-
Fill and bleed the cooling system (page 7-5).
RADIATOR RESERVE TANK

Aelease the retaining straps and open the front
hood.
Remove the reserve tank cap.
Remove the mounting bolt. Release the boss and rib
from the frame to remove the reserv e tank and
drain the coolant.
INSTALLATION
Inslallthe reserve lank with the boll by inserting the
boss and rib into the frame. Tighten the bolt .
Fill the reserve tank with the recommended coolant
to the MAX tine and install the tank cap.
7-14
8. ENGINE REMOVAL/INSTALLATION
SYSTEM COMPONENTS ........................... 82 ENGINE REMOVAL .................................... 84
SERVICE INFORMATION .......... .. ............... 83 ENGINE INSTALLATION ............ ................ 89
8-1
ENGINE REMOVALlINSTAlLATION
SYSTEM COMPONENTS
32 N-m (3.3 , 241bf.ft )
16 Nm (1.6 . 12Ibfft)
8-2
ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION
GENERAL
When removing/installing the engine, tape the frame around the engine and fina l gear case, and cover the body panels
beforehand for frame and plastic components protection .
The following components require engine removal for service:
- mainshah and 2nd/3rd shift clutch (countershaft) (page 1447)
- crankshaft/balancer (page 13-2)
SPCIFICATIONS
I Engine dry weight

Engine oil capacity
ITEM
~ fter draining
[ SPECIFICATIONS
60. t kg (132.5Ibs)
2.7 liters (2.9 US qt, 2.4 Imp qt) _ __ _
After draining/filter 2.9 liters (3.1 US qt, 2.6 Imp qt)
Ih r-*an ge --1
After disassembly -----+ 4.1 titers (4.3 US qt, 3.6 Imp qt)
I Coolant capacity (ra diator and engine) ! 3.3 liters (3.5 ~2.9 Irnpqt)
TORQUE VALUES
lower engine hanger nut (left and right) 54 N'm (5.5 kgfm, 40 Ibf.ft)
Upper engine hanger nut 54 Nm (5.5 kgfm, 40 Ibfh)
Upper engine hanger bolt 32 Nm (3.3 kgfm, 24 Ibfh)
Front final gear case mounting nut (12 mm) 54 N'm (5.5 kgfm, 40 Ibfh) Lock nut: replace with a new one.
Rear final gear case mounting nut (12 mm) 54 Nm (5.5 kgfm, 40 Ibfh) Lock nut: replace with a new one.
Gear selector arm pinch bolt 16 Nm (1.6 kgfm, 12Ibf.ft)
EOT sensor 12 N'm (1.2 kgf.m, 9Ibf-ft)
8-3
ENGINE REMOVAL
Drain the engine oil (page 4-13),
Drain the differential oi l from the rear final gear case
(page 4-17).
- front bumper (page 3-16)
- oil cooler (page 5-13)
- exhaust system (page 3-25)
- ca rgo bed (page 3-17)
- throttle body (page 645)
Disconnect the negative H cable from the battery
(page 21-6).
Remove the following from the engine:
EeT sensor 2P (black) connector
- spark plug cap
- wire band (from the cable holder)

- EOT sensor 2P (black) connect or
- EDT sensor and sealing washer
- oil fille r hose (from the oil pipe)

- two bolts and cable holder
- pinch bolt and gear selector am
- bolt and ground cable
8-4
- solenoid valve 6P (green) connector
- gear position switch 3P (black) connector
- allernalor/CKP sensor 5P (black) connector
- wire band (release to free the gear position
switch and alternalor/CKP sensor wires)
- mOlor cable clip (release to free the cable)

- rubber cap (release from the terminal st opper)
CLIP
- nut and starter motor cable
- water hose (from the cylinder head)
8-5
Take care not to - water pipe bolt
damage the water - water hose (disconnect from the water pump,
hose. then remove from the water pipe while holding
the pipe securely)
Secure the water pipe to the right side of the frame
pipe with a string to prevent interference when
removing the engine.
Remove the rear propeller shaft as follows.

- rear final gear case breather hose
- wire band (from the cable holder)
- VS sensor 3P (black) connector
- differential lock cable (from the two cable clips)
Remove the two bolts and damper stay.

Support the gear case with wooden blocks to relieve
stress for ease of bolt removal, and remove the gear
case mounting nuts and bolts.
Move the gear case assembly rearward fully. Pull
the universal joint out of the output shaft of the
engine while compressing the shaft spring on the
propeller shaft end firmly, then remove the propel-
ler shaft assembly from the gear case.
Remove the Oring.
~ BOLTS
C::5: STAY
~NUTS
"'--SPRING
PROPELLER SHAFT
8-6
Disconnect the front propeller shaft from the engine
as follows.
- 4WD select switch connector
- differential lock switch connector

- breather hose
loosen the two bracket bolts PO mm) and remove

the lower mounting nut and bolt (12 mm).
Remove the bracket bolts and mounting bracket.
Support the gear case with wooden blocks and
remove the upper mounting nut and boll (12 mm).
BRACKET
8-7
Move the gear case assembly forward for maximum
clearance between the propeller shaft joint and
engine.
Pull the shaft jOint out of the output shaft of the
engine.
Remove the O ring .
Remove the following from the engine upper

mount:
- two engine hanger bolts (engine side)
- engine hanger nut and bolt (frame side)
- hanger bracket
- mounting rubbers
Set suitable wooden blocks between the engine and

underbody to support the engine.
Becarefulnotto Remove the following from each engine lower
damage the brakemount:
engine hanger nut and bolt
pipeS of the left
-
engme mounting - two hanger bracket bolts
area - hanger bracket
- mounting rubbers
Make sure the engine wires and cables is not inler-
fered with the frame components.
Hold the engme Lift the engine and place it on the floor. Remove the
securely and take engine out of the frame from the left side.
care not to damage
(left side shown)
the frame and NOTICE
engine
Do not hold or strike the solenoid valves on the shift
valve body during engine removal. Holding the
solenoid valve or excessive shock may damage the
solenoid valve.
Remove the engine mounting bushings and dust
seals.
8-8
Check the mounting rubbers, bushings and dust
seals for deter ioration, wea r or damage,
BUSHING
ENGINE INSTALLATION
NOTE
Route the wires, cables and hoses proper ly (page
1-21 ).
Install the lower mounting bushings into the engine
lower mounts.
Install the dust seals with the lip side facing out.
BUSHING
Hold rhe engme Temporarily place the engine on the floor from the
securely and be left side, then place the engine into the frame and
careful nollO support it in position with suitable wooded blocks.
damage Ihe frame
end engine NOTICE
Do not hold or s/rike the solenoid valves on the shih
valve body during engine removal. Holding the
solenoid valve or excessive shock may damage the
solenoid valvB.
Install the mounting rubbers onto the lower mount-
ing bushing with the large I.D. side facing in.
Install the hange r bracket and bolts, and the hanger
Take care not 10 let Front
the mountingbolt (from the front side ) while aligning the boll
rubbers come off holes carefully.
the bushmg durmg
Loosely install the hanger nut.
mSlallatlO(l,
Install the other side mounting fasteners in the
same manner as above.
Front _
(Left side shown )
8-9
Install the mounting rubbers onto the upper mount-
ing bushing in the hanger bracket with the large 1.0.
side facing in.
Install the hanger bracket with the 10-mm hanger
bolt (from the front side) and nut.
Install the two 8-mm hanger bolts.
After installing all the mounting fasteners and seat
them, tighten the fasteners in ord er as follows:
- left and right lower engine hanger nuts
TORQUE: 54 N'm 15.5 kgfm. 40 Ibf.ft)
- left and r ight lower hanger bracket bolts
TORQUE: 26 N'm 12.1 kgf.m, 20 Ibf.ft)
- frame side upper engine hanger bolt
TORQUE: 54 N-m (5.5 kgf-m, 40 Ibf.ft)
- engine side upper engine hanger bolts
TORQUE: 32 N'm (3.2 kgfm, 24 Ibf.ft)

Coat a new O-ring with molybdenum disulfide
grease and install it i nto the output shaft groove.
Apply molybdenum disulfide grease to the propeller
shaft joint splines.
clearance between the shaft joi nt and output shaft.
Engage the shaft joint over the output shaft and
move the gear case assembly rearward.
The mountmg bolts Align the upper mounting bolt holes in the gear
are ins railed from case and frame, then install the mounting bolt (12
the leff side mm ) and a new mounting nut.
Install the mounting bracket with the two bolts (10
mm).
Install the upper mounting bolt (12 mm) and a new
mounting nut.
Tighten the all the gear case mounting fasteners.
TORQUE: 12 mm: 54 Nm (5.5 kgfm, 40 Ibf.ft)
BRACKET BOLTS
8-10
Connect the breather hose.
Connect the differential lock switch connector.
Connect the 4WO select switch connector.
8-11
Take care not to Install front water hose onto the water pipe and can -
damag e the warer nect it to the water pump while holding the pipe
hose securely.
Install the bolt to secure the water pipes.
Connect the water hose to the cylinder head.
Connect the ground cable to the engine with the r - - - -- - - - - - - - - - - - - - ,

CLIP
Connect the starter motor cable with the nut and
tighten it. Install the rubber cap.
Secure the moto r cable with the dip.
8-13
Connect the alternator/CKP sensor SP (black) and
gear position swit ch 3P (black) connectors, and 3P CONNECTOR
secure their wires with the wire band on the frame. ;,-;:;:
Connect the solenoid valve 6P (green) connector. 6P CONNECTOR ; ';:< 5P CONNECTOR
Connect the grou nd cable to the engine with the

.iiiiiiiii.~~!iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii.
Install the gear selector arm by aligning the slit with
the index line of the spindle. Install the pinch bolt
and tighten il.
TORQUE: 16 N-m (1 .6 kgfm , 12 Ibfftl
Secure the selector cable onto the engine with the
two cable holder bolts and tighten them.
Connect the oil filler hose.
8-14
Install the EOT sensor with a new sealing washer
and tighten it.
TORQUE : 12 N'm 11.2 kgf-m , 9 Ibf.ft )

Connect the 2P (black) connector and install t he wire
band onto the cable holder.
Connect the ECT sensor 2P (black ) connector.

Connect t he spark plu g cap.
Check the gear selector lever for smooth operation
and adjust the selector cable jf necessary (page 12-
16).
- throttle body (page 6-46)
- oil cooter (page 5-15)
- cargo bed (page 3-17)
Connect the battery negative H cable (page 21-6).
Fill the rear final gear case with the recommended
oi l (page 4 17).
Fi ll the engine wi th the recommended oil (page 4-
13).
Fill and bleed the cooling system (page 7-5).
Check the engine oil level (page 4-12).
8-15
MEMO
9. CYLINDER HEAD/VALVE/CAMSHAFT
SYSTEM COMPONENTS ........................... 9-2 CYLINDER HEAD INSPECTION ............... 9-10
SERVICE INFORMATION ............ .............. 9-3 VALVE GUIDE REPLACEMENT .............. 9-12
TROUBLESHOOTING ................................. 9-5 VALVE SEAT INSPECTION!

REFACING ...... .... .. .. ...... .. ........ .. .... .. 9-13
CYLINDER COMPRESSiON ........................ 9-6
CAMSHAFT .... .... .. .. .. .. .. .. .. .. ...... .. 9-16
CYLINDER HEAD COVER REMOVAL!
DISASSEMBLY .......................................... 9-6 CYLINDER HEAD ASSEMBLy ................ 9-19
CYLINDER HEAD REMOVAL .................... 9-9 CYLINDER HEAD INSTALLATION .......... 9-20
CYLINDER HEAD DISASSEMBLY ............ 9-10 CYLINDER HEAD COVER ASSEMBLY!

INSTALLATION ........................................ 9-2 1
9-1
CYLINDER HEADIV ALVE/CAMSHAFT
SYSTEM COMPONENTS
22 N 'm (2.2 kgfm. 16Ibfft)
/~~
12 Nm (1.2 kgf.m. 9Ibf.ft)
32 Nm (3.3 kgf.m, 24 Ibfft )
9-2
CYLINDER HEADIVALVE/CAMSHAFT
SERVICE INFORMATION
GENERAL
This section covers service of the rocker arms, cylinder head, valves and camshaft. These services can be done with the
engine installed in the frame.
When disassembling, mark and store t he d isassembled parts to ensure that they are reinstalled in their original loca-
tions.
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 th rough oil passages in the cylinder head and head cover. Clean
the oi l passages before assembling cylinder head and head cover.
Be careful not to damage the mating surfaces when removing the cylinder head caver and cylinde r head.
SPECIFICATIONS
Uo;" mm On:
I ITEM I 'L1MIl
;
~~05 k:~{510'g{ifi BO,;,';) -
Valve I IN
EX '.33 0.02 {0.013 .001) -
Valve, Valve stem 0.0. IN _ 5.475 - 5.490 !p.2156 - 0.2161) 5.45 ).215)
valve guide ;.455 - 5.47 ~ 154) ).2141
I
Valve guide I.D--:-
, IIEX
;~~g ~ 'l: c if,-~) )
anee EX 0.030-0.~ )
I I
,-~-,;;;~-
above , 3- 17.71.
I ) w;dlh 'lEX 1-1.110.039 1.410.06)
Valve ,p,;n9 F, ee le091h Inne, 37.20 1.465) 36311.43)
Rocker arm 1.0.- .OOO-~ . ;~~~Z~~.-) -

A'm
Shaft C.D. "" .964 - 110.4710- . 11.92 l.469)
0.08- 1003)
c.mTobeh~;~
IN/EX
0~_054
~1746)
tiiiid
cam follower Ex" I- )
Cam I , 0.0. IN/EX 2.467 - '.482 ; -, . :0:
I ,1.0. IN/EX 22. 510 - 22.526 2- 22.54 l.88:
I "lea/- IN/EX 0.028 1-' 0.07 111.003)
anee
Cylinder head warpage
TORQUE VALUE
Cylinder head cover cap nut 65 N m (6.6 kgfm, 48 [bUt) Apply engine oil to the threads and seati ng surface.
Upper engine hanger nut 54 Nm (5.5 kgfm, 40 [bUt)
Upper engine hanger bracket bolt 32 N-m (3.3 kgf.m, 24 IbHt)
Spark plug 22 Nm (2.2 kgf-m, 16Ibfft)
Eel sensor 12 Nm (1.2 kgf-m, 9 Ibf.ft)
9-3
TOOLS
Valve spring compressor Valve guide driver, 5.5 mm Valve guide reamer, 5.5 mm
077570010000 07742-0010100 07984-2000001
or 07984-2000000 (U.S.A. only )
Valve seat cutter, 35 mm (45 0 IN/EX) Flat cutter, 38.5 mm (32 0 IN) Flat cuner, 35 rnm (32 0 EX)
077800010400 07780-0012400 07780-0012300
or equivalent commercially or equivalent commercially or equivalent commercially

available in U.S.A. available in U.S.A. avai lable in U.S.A.
Interior cutter, 34 mm (60 0 INIEX ) Cutter holder, 5.5 mm Tensioner holder B

07780'()014700 07781 0010101 070MGOQ10100
or equivalent commercially or equivalent commercially or 07AMG-001A 100 (U.S.A. only)

avai lable in U.S.A. available in U.S.A. or 07AMG-MFJA100 (U.S.A. only)
9-4
TROUBLESHOOTING
Engine top-end problems usually affect engine performance . These can be diagnosed by a compression test, or by trac-
ing top-end noise with a sounding rod or stethoscope.
If the performance is poor at low speeds, check for a white smoke in the crankcase breather hose. If t he hose is smoky,
check for seized piston ring (page 10-2),
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 seating
- Valve stuck open
Cylinder head:
- Leaking or damaged cylinder head gasket
- Loose spark plug
- Wa rped or cracked cylinder head
Cylinder/piston problem (page 10-3)
Compression too high, overheating o r knocking
Excessive carbon build-up on piston head or combustion chambe r
Worn or damaged decompressor system
Excessive smoke
Worn valve stem or valve guide
Damaged stem seal
Cylinder/piston problem (page 10-3)
Excessive noise
Incorrect valve clearance
Sticking valve or broken valve spring
ExceSSively worn valve seat
Worn or damaged camshaft
Worn rocker arm and/o r shaft
Worn rocker arm fo l lower or valve stem end
Worn or damaged push rod andlor cam follower
Worn cam chain
Worn or damaged cam chain tensioner
Worn cam sprocket teeth
Cylinder/piston problem (pa ge 10-3)
Rough idle
Low cylinder compression
9-5
CYLINDER COMPRESSION
Warm up the engine to normal operating tempera-
ture.
Stop the engine, disconnect the spark plug cap and
remove the spark plug (page 4-8).
Install the compression gauge into the spark plug
hole.
TOOLS :
Compression tester EEPV303A
Adaptor MT26J200
(U.S.A. only)
Shift the transmission in neutra1.

Open the throttle all the way and crank the engine
with the starter motor untit the gauge reading stops
rising. The maximum reading is usually reached
within 4 - 7 seconds.
COMPRESSION PRESSURE:
550 kPa (5.6 kgflcm~. 80 psi) at 350 rpm (min"' )
Check that there is no leakage at the gauge connec-
tion.
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
If you plan to remove the cylinder head remove the
following .
- throttle body (page 6-45)
- ex haust system (page 3-25)
- crossbar (page 3-8)
- upper engine hanger bracket bolts
- upper engine hanger nut and bolt
- hanger bracket and mounting rubbers
9-6
Set the piston position to Top Dead Center on the
compression stroke (page 4-10). 1..:.:.::';:;: AND WASHERS _ _,;,H;,;EoA;D COVER

- spark plug cap
- seven bolts and three washers
- four cap nuts and washers
- cvlinder head cover
Marl< the push rods - puSh rods

so they C<ln be gasket
placed back In rhell - dowel pins
onglna/locatlons
- cam followers
DISASSEMBLY
Remove the two bolts and sealing washers.
Push the rocker arm shaft with the small screw-
driver through the bolt hole until the O-ring on the
shaft is removed out of the head cover.
ROCKER ARM SHAFTS
9-7
Mark all the parts Remove the following :
so they can be WAVE WASHERS
- rocker arm shafts
placed back In rhelr
- rocker arms
Oflgma/loc8l!ons
- wave washers
ROCKER
INSPECTION
ROCKER ARM / SHAFT
Check the rocker arms and shafts for wear or dam-
age.
If the rocker arm follower is worn or damaged,
check the push rod and oil passages.
Measure each rocker arm shaft 0.0.
Measure each rocker arm 1.0.

Subtract each rocker arm shaft 0.0. from the corre-

sponding rocker arm 1.0. to obtain the rocker arrn-
to-shaft clearance.
PUSH ROO
Check the push rods for wea r or damage.
If the push rod is worn or damaged, check the cam
follower and camshaft .
CAM FOLLOWER
Check the cam fo llower and follower bore in the cyl-
inder head fo r scoring, scratches o r damage.
Measure each follower 0 .0.
9-8
Measure each follower bore 1.0 .
SERVICE UMIT: 22.54 mm (0.887 in )
Subtract each follower 0 .0 . from the corresponding

bore 1.0. to obtain the follower-tobore clearance.
SERVICE UMIT: 0.07 mm (0.003 in)
CYLINDER HEAD REMOVAL

- cylinder head cover (page 9-6)
- thermostat (page 77)
Disconnect the ECT sensor 2P (black) connector.

- ECT sensor and O-ring
- bypass hose (from the cylinder head )
Do nor strike the - spark plug

cylInder head too - five bolts
hard and do not - cylinder head
damage the matmg
surface WIth a
screwdriver.
9-9
- gasket
- dowel pins
CYLINDER HEAD DISASSEMBLY

To prevent lOSS of Remove the valve spring colters using the valve
tenSIOn, do no/ spring compressor .
compress the valve
sptmgs more than TOOL:
necessary Valve spring compressor 07757-0010000
SPRIING COMPRESSOR
Mark all rhe parIS Remove the following:

so they can be - spring retainer
placed back In tflelr
- inner and outer valve springs VALVE SPRINGS
ongma/locatlons
l
- valve
- stem seal
- spring seat
~ VALVE
\ SPRING SEAT
STEM SEAL
CYLINDER HEAD INSPECTION

CYLINDER HEAD
Be carefulnOllO Remove the carbon deposits from the combustion
damBg8 the gasket chamber, being careful not to damage the gasket
surface surface.
Check the spark plug hole and valve areas for
cracks.
9-10
Check the cylinder head for warpage with a straight
edge and feeler gauge.
SERVICE LIMIT: 0.05 mm (0.002 in )
VALVE SPRING
Measure the valve spring free length.
SERVICE LIMITS : Inner: 36.3 mm (1 .43 in)

Outer : 43.1 mm (1.70 in )
VALVEIVALVE GUIDE
Check that the valve moves smoothly in the guide.
Check the valve for bending, burning or abnormal
wear.
Measure each valve stem 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 from the combustion chamber
side of the cylinder head and always rotate the
reamer clockwise.
TOOLS:
Valve guide reamer, 5.5 mm 07984-2000001 or
079842000000
(U.S.A. only)
9-11
CYLINDER HEADIVALVEI CAMSHAFT
Measure each valve guide J.D. and record it.
Subtract each valve stem 0.0. from the correspond-

ing guide 1.0. to obtain the stem-la-guide clearance.
SERVICE LIMITS: IN : 0.12 mrn (0.005 in)
EX : 0.14 mm (0.006 in)
Inspect and refacs If the stem-Ieguide clearance exceeds the service

the valve sears limit, determine if a new guide with standard
whenever the valve dimensions would bring the clearance within toler-
guodes are replaced anea.
(page 9-13J If so, replace any guides as necessary and ream to
fit.
If the stem-Ie-guide clearance exceeds the service
limit with a new guide, also replace the valve.
VALVE GUIDE REPLACEMENT

Mark new valve guides at the specified height indi- ..- -...
VALVE GUIDE DRIVER
cated below, using a marker. Chill the new valve
guides in a freezer for about an hour.
8e sure to wear Heat the cylinder head to 130"C-140C (275F-
heavy gloves to 290 a F) with a hOI plate or oven. Do not heat the cyl-
aVOid burns when inder head beyond 150C (300"F). Use temperature
handling the heated indicator sticks, available from welding supply
cylinder head stores, to be sure the cylinder head is heated to the
Using a torch fO proper temperature.
hear the cylmder
Support the cylinder head and drive the valve
head may cause
guides out of the cylinder head from the combus-
warpage
tion chamber side using the special tool.
TOOL:
Valve guide driver, 5.5 mm 071420010100
While the cylinder head is still heated, remove the
VALVE GU IDE DRIVER
new valve guides from the freezer and drive them
into the cylinder head from the rocker arm side until
the exposed height is at the specified value (at the
mark).
TOOL:
Valve guide dri\ler, 5.5 mm 07142-0010100
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 coot to room temperature.
Take care nor ro rilt Ream the new valve guides.

or lean the reamer Insert the reamer from the combustion chamber
In the (jfJ/de while side of the head and always rotate the reamer clock-
reamIng wise.
Use cutting 011 on
rhe reamsr dUring
TOOL:
thiS operation. Valve guide reamer, 5.5 mm 079842000001 or
07984-2000000
(U.S.A. only)
Clean the cylinder head thoroughly to remove any
metal particles after reaming and reface the valve
seat (page 9- 14).
9-12
VALVE SEAT INSPECTION/REFACING
INSPECTION
Clean all intake and exhaust valves thoroughly to
remove carbon deposits. HAND-LAPPING TOOL
Apply a light coat of Prussian Blue to each valve
seat.
Tap the valve against the valve seat several times
without rotating the valve, to check for proper valve
seat contact.
Tile valve cannor be Remove the valve and inspect the valve seat face.
ground. If the valve Th e valve seat contact should be within the speci-
face IS burned or fied width and even all around the circumference.
badly worn or If II
contacts the seat STANDARD: 1.0 - 1.1 mm (0.039 - 0.043 i n)
unevenly, replace SERVICE LIMIT: 1.4 mm (0.06 in)
the valve
If the valve seat width is not within specification,
refaee the valve seat,
SEAT WIDTH
Inspect the valve face for:

Damaged face:
- Replace the valve and reface the valve seat.
Uneven seat width:
- Replace the valve and reface the valve seat.
DAMAGED FACE UNEVEN SEAT WIDTH
Contacl area !too high or too low)

- Reface the valve seat.
TOO LOW TOO HIGH
9-13
REFACING
NOTE :
Follow the retaeer manufacturer'S operating
instructions .
Be ca reful not to grind the seat more than neces
say.
II ~ 45
~ ,
60
If the contact area is 100 h ig h on the valve, the seat

CONTACT TOO HIGH
must be lowered using a 32 flat cutter.
If the contact area is too Iowan the valve, the seat '7 .::f:SEATWIDTH
must be raised using a 600 interior cutter.
1 . ...:0.. 32"
CONTACT TOO LOW

~ ~ LDSEATWIDTH
1 -------' ~ 60
Using a 45 seat cutter, remove any roughness or
irregularities from the seat.
TOOLS : ROUGHNESS
Seat cutter, 35 mm UN/ EX)
Cutter holder, 5.5 mm
077800010400
07781 0010101
or equivalent commercially available in U.S.A.

/
Using a 32 flat cutter, remove 1/4 of the existing

valve seat material.
TOOLS:
OLD SEAT WIDTH
Flat cutter, 38.5 mm (IN) 07780-0012400
Flat cutter, 35 mm (EX) 07780-0012300
Cutter ho lder, 5.5 mm 077810010101
or equivalent (:ommercially available in U.S.A.

32 (
9-14
Using a 60 interior cutter, remove 1/4 of the exist-
ing valve seat material.
TOOLS: OLD SEAT WIDTH

Interior cutter, 34 mm (IN/ EX) 077800014700
Cutter holder, 5.5 mm 077810010101
or equivalent commercially available In U.S.A.
l\
60
0
L
Using a 45~ seat cutter, cuI the seat to the proper ~===================~
width.
VALVE SEAT WIDTH : 1.0 - 1.1 mm ~ O . 039 - 0.043 in) SEAT WIDTH
Make sure all pitting and irregu larities are removed.
Excess ive lappmg After cutting the seat, apply lappi ng compound and
pressure m ay engine oil to the valve face, and lap the valve using HAND-LAPPING TOOL
deform or damage light pressu re.
the seat Change the angle of lapping tool frequently to pre-
Do nor allow vent uneven seal wear.
lappmg compound
After lapping. wash any residual compound off the
to enter the gUides
cylinder head and valve. Recheck the seal conlact
after lapping.
9-15
CAMSHAFT
REMOVAL
Remove the cyli nder head (page 9-9).
Remove the seali ng bolt and washer on the cam
chain tensioner lifter ,
[nstall the special tool so its blade is into the
tensioner lifter and the tabs are just above the slots
in the lifter (there should be space between the bOI-
tom 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 070MG-0010100 or
07AMG-001A100 or
(U.S.A . only)
07AMG-MFJA100
(U.S.A. only)
Refer to CylinderlPiston section for tensioner lifter
service (page 10-4).
Remove the four camshaft holder bolts.
Suspend the cam Raise the holder plate so the dowel pins fitled in the
cIlam WlthS piece camshah holders are removed off the cylinder.
of WIre to prevent ,( Release the cam chain from the cam sprocket to
from fallmg mlO the remove the camshah assembly and ho lder plate.
crankcase
Remove the camshaft holder B from the camshaft

assembly.
HOLDER B
Do flor fOfC,bly Remove the dowel pins .

remove the dowel
pms from the
camshah holders
PINS
9-16
INSPECTION
Re fer Cyllnder/ Check the sprocket tee th for wear or damage.
Piston seC/Ion for
Turn the camshaft holder to check each bearing.
lenSloner lifler
Replace the camshaft assembly if the bearing does
inspectIOn (page
not turn smoothly and quietly .
10-71.
Check the cam surfaces for scoring, scratches or evi-
dence of insufficient lubrication.
Measure each cam lobe height.
SERVICE LIMITS; IN: 34.4488 mm (1.35625 in)
EX; 34.7335 mm (1.36746 in)
Check the decompressor cam operation.

Press on the decompressor cam as shown.
As you p ress on one side, the decompressor cam
sh ould 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.
DEC:OMPRESS()R CAM
INSTALLATION
Careful/yrotare the Turn the crankshaft clockwise using the recoil
crankshaft while starter and align the "T " mark on the flywheel with
holding the cam the index mark i n the crankcase cover.
chain to avoid
Ret ract the tensioner lifter shaft and secure it with
Jammmg the cam
the stopper tool (page 9-16).
chain against the
timing sprocket of
the crankshaft
"T" MARK INDEX MARK
Install the dowel pins if they are removed.

HOLDER B
Install the camshaft holder B onto the camshaft
assembly.
DDINEL PINS
9-17
Before Ins/allmg the Lubricate the camshaft bearings and cam chain with
camshaft, be sure engine oil.
the cylmder boll Install the camshaft holder plate onto the camshaft
(under the cam holders, aligning the holes with the dowel pins.
shaff! is tightened
Place the camshaft assembly onto the cylinder and I~""'~
securelv (page 10-
install the cam chain over the sprocket while align~
9)
ing the timing marks (index l ines) on the sprocket
with the cylinder top surface and holder plate edge.
Locate the dowel pins into the holes in the cylinder
securely.
Be sure the timing marks lines up with the cyl inder ,we"'"'
top surface and holder plate edge.
Install the four holder bolts and tighten them.

Apply molybdenum oil solution to the cam lobes.
Make sure the Remove the stopper tool, and install the sealing bolt
liming mark on the with a new sealing washer and tighten it.
sprocket aligns with
Install the cylinder head !page 9-20).
the cylinder surface
when the r marlc
is aligned with the
index notch.
9-18
CYLINDER HEAD ASSEMBLY
SPRING RETAINER ~-"'o.?,)
OUTER VALVE SPRING --~
INNER VALVE SPR ING - --
STEM SEAL
SPRING SEAT
VALVE G
INTAKE VALVE ----_;1 EXHAUST VALVE
Blow through the oil passage (stud bolt hole) in the

cylinder head with compressed air.
Install the valve spring seats and new stem seals.
~
Lubr icate the va lve stem sliding surface with molyb- VALVE SPRINGS )
"".,,"~.~ ....
denum disulfide grease.
Insert the valve int o the guide while turning it
slowly 10 avoid damaging to the stem seal.
~I \ SPRING SEAT
qI STEM SEAL
Install the inner and outer valve spr ings with the
tightly wound coils faci ng the combustion chamber.
Install the spring retainer.
Combustion chamber side
9-19
CYLINDER HEADIVALVEI CAMSHAFT
Grease the COllers Install the valve cotters using the valve spring com-
ro Base ins/allarlon pressor.
To prevent loss of
tenSIOn, do not TOOL:
compress the valve Valve spring compressor 07757-0010000
sprmgs more than
necessary
SPRING COMPRESSOR
S!.Jpport the Tap the valve stems gently with two plastic ham-
ey/mdor head so mers to seat the cotters firmly.
the valve heads will
not COntBct
anylhmg thaI cause
damage
CYLINDER HEAD INSTALLATION

Clean the mating su rfac e of the cyl inder and head.
DOWEL PINS
Install the dowel pins and a new gasket.
Install the cylinder head on the cylinder.

Ttghten rile cylmder Install the five bolts and temporarily tighten them.
head bolts after
Install the sprak plug .
Installmg the
cylinder head cove~
9-20
Coat a new D -ring with engine oil and install it onto

the Eer sensor.
Install the ECT sensor.
~ bypass hose
- thermostat (page 7-8)
- cylinder head cover (page 9-22)
CYLINDER HEAD COVER ASSEMBLY /

INSTALLATION
ASSEMBLY
EXHAUST ROCKER ARM
SEALING WASHERS
~
/ 8
SETITING BOLTS
Coat new D-rings with engine oil and install them .

~ ROCKER ARM SHAFTS
Apply molybdenum disulfide grease to the rocker
arm shaft sliding surface.
.....:,'"
O-RINGS ""7J
9-21
Install the rocker arms, wave washers (setting bolt
WAVE WASHERS
side) and arm shafts.
ROCKER ARMS
Align the bolt holes in the head cover and rocker

arm shaft by turning the shaft.
Install the setting boils with new sealing washers
and tighten the bolts securely.
....!It!-'
SEALING WASHER ROCKER ARM SHAFT
INSTALLATION
Turn the crankshaft using the recoil stater knob and , - - - - - - - - -- - - - - - ----,
align the uT" mark with the index notch, then check
the cam lobes through the cam follower holes.
If the cam lobes face up, rotate the crankshaft one
full turn and match up the "T~ mark again so the
cam lobes face down.
INDEX MARK
Coat the cam followers with engine oil and install

them into the cylinder head.
9-22
Install the dowel pins and a new gasket. PUSH RODS
~---"".:;;~::;~~:..=:3
Install the push rods in the cam followers and fest . . .!I!. . . . . . .
them on the gasket cu t out as sh own.
Apply engine oil to the rocker arm followers and

adjusting screw tips.
Installmg the head Install the cylinder head cover while holding the
cover incorrectly rocker arms that align the rocker arm f ollowers with
will result in severe the push rod ends.
engine damage Do Be sure to seat the rocker arm followers to the push
nor lighten the rods properly by turning the crankshaft slowly.
head cover
fasteners when the
rocker arm are not
alIgned with /he
push rod end.
Apply engine oil to the cap nut threads and seating

surfaces and install the following fasteners. NUTS ~
A~N~D' ;:::~~~_ _ HEAD CO'.;
V.:;
E.;R ~.."'l
- four washers and cap nuts
- three new washers and seven bolts
Tighten the nuts and bolts (including the cyl inder
and cylinder head bolts) in a crisscross pattern in
several st eps.
TORQUE: Cap nut: 65 N'm (6.6 kgfm , 48 Ibf.ft)
Install the mounting rubbe rs on the upper engine

hanger bushing with the large I.D. side facing in.
Install the uppe r engine hanger bracket and the
three bolts and nut.
Tighten the two hanger bracket bolts.
TORQUE: 32 N 'm (3.3 kgfm, 24 Iblft)
Tighten the hanger nut.
TORQUE: 54 N 'm (5.5 kgfm , 40 Ibfft)
Check the valve clearance (page 4- 11).
Tighten the following components if they were
removed.
TORQUE:
Spark plug: 22 N'm (2.2 kgfm , 16Ibfft)
EeT sensor: 12 Nm (1.2 kgfm , 9Ibfft)
9-23
Connect the EeT sensor 2P (black) connector.
Connect the spark plug cap.
- throttle body (page 646)
- exhaust system (page 326)
- crossbar (page 3-8)
9-24
10. CYLINDER/PISTON
SYSTEM COMPONENTS 10-2 CYLINDER/ PISTON REMOVAL ............... 10-4
SERVICE INFORMATION 10-3 CYLINOER/ PISTON INSPECTION ........... 10-5
TROUBLESHOOTING 10-3 CYLINDER / PISTON INSTALLATION 10-8
10-1
CYLINDER/PISTON
SYSTEM COMPONENTS
10-2
CYLINDER/PISTON
SERVICE INFORMATION
GENERAL
The cylinder and piston can be serviced with the engine installed in the frame.
Take care not to damage the cylinder wall and piston.
Be careful not to damage the mating surfaces when removing the cylinder .
Rocker arm and valve lubricating oil is fed through th e oil passage in the cylinder. Clean the oil passage before install-
ing the cylinder.
When disassembl ing, mark and store the disassembled parts to ensure that they are reinstalled in their origi nal loca-
lions.
SPECIFICATIONS
Unit mm (In)
ITEM STAN CARD SERVICE LIMIT
10 I 102 000 - 102015 (4 .0157 -4.0163) 102.05 (4.018)
Out-of-round 0.05 (0.002)
_ :raper 0.05 (0.002)
Warpage - 0.05 (O.Q02)
Piston, ~~iston 0.0. at 20 (0.8) from bottom 101.960 101.990 (4 .0142 - 4.0153) 101.90 (4.012)
piston pin, _ ~iston pin hole 1.0. 23.002 23.008 (0. 9056 0.9058) 23.03 (D.907)
piston ring Piston pin 0.0. 22.994 23.000 (0. 9053 0.9055) I 22.98 (O.90S)
Piston-to-piston pin clearance 0.002 - 0.014 (0.00 o1 - 0.0006) 0.04 (0.002)
Piston ring end Top 0.25 - 0.35 (0.010 o.014) 0.5 (o.oi)-
gap Second 0.40 -"0".5;;5;;1:;;0".0;;
'6"-::';0.022) 0.7 (0.03)
Oil (side rail) 0.20 - 0.70 (0.008 - 0.028) 0.9 (O.04)
~~~~~-.L_ ~Piston ring-to-ring 1-c';;Co~p,=-~-+ 0.045 - 0.080 (0.0018 - 0.0:~0;;3~'!-I_ _ _+-:0~.0:s9;,5'J1;;0c;:.0~0~37:-!1---c

-,g",."o."ov~e,,-,clearance
Cylinder-to-p iston clearance
Second 0.025 - 0.060 (0.0010;.:-:.:0:c.,,00:<2~4,,1_ _ _-+--;<0."i0ic75~10:ii.0~Oii3",0,-1---i
~~~':::~~~===~oJ.0~,go;-jO~.Og5~5tl~oB.0004 0.0022,""' - __ --1---:0~.~'9~10~.0~0~7~1,,-_1
Connecting rod small end 1.0. 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)
TORQUE VALUES
Cylinder stud bolt 24 N'm (2.4 kgf.m, 18Ibfft) See page 10-7
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 cylinde r 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
10-3
CYLINDER/PISTON
CYLINDER/PISTON REMOVAL
CYLINDER REMOVAL
Remove the camshaft (page 9-16).
two bolts and cam chain tensioner lifter
gasket
bolt and water pipe
- O-ring
Do nor strike the - four bolts and clip stay

cylmder head too - cylinder
hard and do not
damage the mating
surface WIth a
screwdrIVer.
- cam chain guide

- gasket
- dowel pins
PISTON REMOVAL
Place a clean shop towel over the crankcase to pre-
vent the piston pin clip from falling into the crank-
case.
Remove the piston pin clips with pliers.
Push the piston pin out of the piston and connecting
rod, and remove the piston.
10-4
CYLINDER/PISTON
Do no! damage the Spread each piston ring and remove it by lifting up
piston ring by at a point opposite the gap.
spreading the end
too far.
Never use a wire Clean carbon deposits from the piston ring grooves
brush; If wi/I scratch with a r ing tha t will be discarded .
the groove.
CYLINDER/PISTON INSPECTION
CYLINDER
Inspect the cyli nder bore f or scratch or wear.
Measure the cylind er I.D. 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 10-6)
Calcu late the cylinder taper and out-af-round at

three levels in an X an d Y axis. Take the maximum
reading to determine the t aper and out-of-round.
SERVICE LIMITS: Taper: 0.05 mm (0.002 in)

Out of round: 0.05 mm (0.002 in)
-- - - ,
/
,
-- -,
MIDDLE /
/
BOTTOM ,
--- - /
"
10-5
CYLINDER/PISTON
Check the top of the cylinder for warpage with a
straight edge and feeler gauge across the stud
holes.
SERVICE LIMIT: 0.05 mm 10.002 in)
PISTON/PISTON RING
Inspect the piston ri ngs for smooth movement by
rotating the them . The rings should be abl e to move
in thei r grooves without catching.
Push the ring until the outer surface of the piston
ring is nearly flu sh with the piston and measure the
ringlering groove clearance.
SERVICE LIMITS: Top: 0.095 mm (0 .0037 in)
Second: 0.075 mm (0.0030 in)
Insert the piston ring 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)
Oil (side rail) : 0.9 mm (0.04 in)
Measure the piston 0.0. at a point 20 mm (0.8 in)

from the bonom and 90 0 to the piston pin hole.

Compare this measurement against the maximum
cylinder I.D. measurement and calculate the cylin-
der-to-piston clearance (page 10-51.
20mm
(0.8 in)
10-6
CYLINDER/PISTON
Measure the piston pin hole 1.0. Take the maximum
reading to determine the 1.0.
Measure the piston pin 0.0. at three points.

Calculate the pistonto-piston pin clearance.

CONNECTING ROD
Measure the connecting rod small end LD.
Calcu late the connecting rod- to-piston pin clear-

ance.
CAM CHAIN TENSIONER LIFTER

The lifter shaft should not go into the lifter body
when it is pushed .
When the shaft (inside of the body) is turned clock-
wise with a screwdriver, the l ifter shaft should be
pulled i nto the lifter body. The shaft should spring
out of the body as soon as the screwdriver is
re leased.
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.
Install a new stud bolt in the direction as shown.
- Front crankcase: 90033HN80000
(Yellow mark on bolt head)
- Rear crankcase: 90032-HN80000 (No mark)
TORQUE: 24 Nm (2.4 kgfm, 18 Ibfft )
Be sure to verify the stud height from the crankcase
surface . -""
Adjust the height if necessary.
o
10-7
CYLINDER/PISTON
CYLINDER/PISTON INSTALLATION
PISTON RING INSTALLATION
Be careful not fO Carefully install the piston rings into the piston ring ~------------------
damage the Piston grooves with the markings facing up. MARKING
and rings
NME /
Do not confuse the top and second rings.
To install the oil ring, install the spacer first, then '"
120 -
TOP RING
- ('2;/&2
install the side rails.
SECOND RING
Stagger the piston ring end gaps 1200 apan from
each other.
Stagger the side rail end gaps as shown. - wa
Oil RING
~f~~
W
SIDE RAILS
20 mm or more
SPACER
PISTON INSTALLATION
Place a clean shop towel over the crankcase to pre
vent the piston pin clip from falling into the crank-
1:._'"
case.
Apply molybdenum oil solution to the piston pin
outer surface.
Apply engine oil to the piston pin hole and connect -
ing rod inner surface.
Install the piston with the " IN~ mark toward the
intake side and insert the piston pin through the pis-
ton and connecting rod.
Instal new piston pin clips.
NOTE:
Make sure the piston pin clips are seated
securely.
Do not align the clip end gap with the piston cut-
out.
10-8
CYLINDER/PISTON
CYLINDER INSTALLATION
Clean the gasket surface of the crankcase thor-
oughly, 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.
CHAIN GUIDE
Install the cam chain guide into the crankcase so its
end rests in the groove properly.
Install the dowel pins and a new gasket.

Apply engine oi l to the cylinder wall, piston outer
surface and piston rings.
Be careful not 10 Route the cam chain through the cylinder and install
damage the piston the cylinder over the piston while compressing the
rmgs and cylmdef piston rings with your fingers.
wall Align the cam chain guide bosses with the grooves
i n the cylinder properly to seat the cylinder on the ___ \_---'
crankcase.
Tighten the three Make sure that the cylinder touches the crankcase
outside bolts again evenly. Install the four bolts and the clip stay and
after installing the tighten them securely.
cylinder head cover
10-9
CYLINDER/PISTON
Install the cam chain tensioner lifter with a new gas-
ket and tighten the two mou nting bolts.
Coat a new O-ring with coolant and install it on the
waler pipe. Connect the water pipe and secure it
with the bolt.
Instalilhe camshaft (page 9-17).
10-10
11. AL TERNATORISTARTER CLUTCH
SYSTEM COMPONENTS .. 11-2 ALTERNATOR STATOR/

STARTER REDUCTION GEARS .... .... .... 11 -5
SERVICE INFORMATION ......................... 11-3
FLYWHEEL/STARTER CLUTCH .... .... .. 11-10
TROUBLESHOOTING ............................... 114
11-1
AL TERNATORISTARTER CLUTCH
SYSTEM COMPONENTS
16 N'm (1 .6 kgfm , 12Ibf.ft)
108 N 'm (11 .0 kgfm, 80 Ibf.ft)
11-2
SERVICE INFORMATION
GENERAL
This section covers service of the alternator stator and flywheel/starter clutch. These parts can be serviced with the
engine installed in the frame.
Crankshaft lubricating oil is fed through the oil passage in the alternator caver. Clean the oil passage before installing
the alternator cover.
Be careful not to damage the mating surfaces of the alternator and crankcase covers when servicing.
For rear crankcase cover removal/insta l lation, see Sub-transmission/Gearshift linkage section (page 12-5).
For alternator stator inspection, see Battery/Charging System section (page 21-8).
For starter motor service, see Electric Starter section (page 23-6).
SPECIFICATION
Unit' mm (in)
ITEM STANDARD S ERVICE LIMIT
r---sta rter driven gear boss 0.0. 51.705 51.718 (2.0356 2.0361 ) 51.6t (2.032)
Torque limiter slip torque 53 84 N'm (5.4 8.6 kgf.m,
39 - 62 Ibfft)
TORQUE VALUES
Starter clutch socket bolt 30 Nm (3. 1 kgf.m, 22 Ibfft) Apply locking agent to the threads.
Flywheel bolt 108 N'm (11.0 kgfm, 80 lbfft) Apply engine oil to the threads and seating surface.
Alternator slator boll 10 Nm (1.0 kgf.m, 7 Ibfft)
CKP sensor bolt 6 Nm (0.6 kgfm, 4.3 Ibfft) Apply locking agent to the threads.
Gear selector arm pinch bolt 16 N'm (1.6 kgfm, 12 lbfft) Apply locking agent to the threads.
TOOLS
Flywheel holder Rotor puller Remover weight

077250040001 07733-0020001 07741-0010201
or equivalent commercially or 07933-3950000 (U.S.A. only) or 07936-371020A or 079363710200

available in U.S.A. (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)
11-3
Driver Attachment, 24 x 26 mm Pilot, 10 mm

07749-0010000 07746-0010700 07746-0040100
8
Torque limiter attachment B Torque limiter attachment 0
07YMJ -MCF0200 070MJ-HN80100
not available in U.S.A. not available in U.S.A.
TROUBLESHOOTING
Starter motor turns, but engine does not turn
Faulty starter clutch
Damaged reduction gears or torque limiter
11-4
ALTERNATOR ST ATORISTARTER
REDUCTION GEARS
ALTERNATOR COVER REMOVAL
- engine front cover (page 36)
5P CONNECTOR
- rear w heels (page 17-5)
Drain the engine oil (page 4-12),
Disconnect the alternator/CKP sensor 5P (black) con-
nector and release the wire from the two clips.
\~
'\
Disconnect the EOT sensor 2P (black) connector and ; ._ __ _ _ _ __ ;:::~~~;;_ _ ;;

remove the wire band from the cable holder.
Shift the sub-transmission into neutral.

- two bolts and cable holder
- pinch bolt and gear selector arm
11-5
The cover (SlatOl/IS - ten bolts, four sealing washers and clip stay
m8Qnefically - alternator cover
attrlJCted 10 the
flywheel. be careful
dUring removal
- dowel pins
- gasket
- starter torque limiter

- reduction gear
- gear shah
INSPECTION
Check the bearings in the alternator and rear crank-
case 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
tightly in the covers.
Torque limiter bearings replacement (page 11 -8)
11-6
Check the teeth of the reduction gears and torque
li miter for abnormal wear or damage.
Hold the torque limiter in a vise with the special

tool. ATTACHMENT 0
Rep/ace the torque Check the slip torque with the special tool and a
limiter as an torque wrench.
assembly
TOOLS:
Torque limiter attachment B 07YMJ MCF0200 {not
ava ila ble in U.S.A.'
Torque limiter attachment 0 070MJ-HN80100 (not
available in U .S.A.)
STANDARD SLIP TORQUE:

53 - 84 N 'm {S.4 - 8.6 kgfm, 39 - 62 Ibfttl
STATOR/CKP SENSOR REMOVAL!

INSTALLATION
Remove the CKP sensor socket bolts.
BOLTS
Release the wire grommet off the alternator cover.
Remove the four bolts and alternator stator/CKP
sensor assembly.
STATOR
Install the stator/CKP sensor assembly onto the

alternator cover. BOLTS
Apply sealant to the wire grommet seating surface
and insta l l the grommet into the cover groove
securely.
Install and tighten the four bolts.
TORQUE: 10 N 'm (1.0 kgfm , 7 Ibf.ft) STATOR
Apply lockmg agent Install and tighten the socket bolts.

to the CKP sensor
bolt threads. TORQUE: 6 N m (0.6 kgfm , 4.3 Ibf.ftl
SOCKET BOLTS I
11-7
BEARING REPLACEMENT
Remove the torque limiter bearings in the alternator
cover and rear crankcase covers, using the special
tools.
TOOLS:
Beari ng rem ov er head, 10 mm 07936GE00200
Rem oyer shaft, 10 mm 07936GE00100
Rem over weight 077410010201
U.S.A. o n ly tools:
Beari ng rem over, 10 mm 07936GEOAOOO
Remover hand le 07936-3710100
Rem over weig ht 07936-371020 A or
07936-3710200
Drive new Torque limiter bearings in with the marks ... . . , - -...
facing up.
TOOLS:
Driver 017490010000
Attachment , 24 x 26 mm 077460010700
Pilot, 10 mm 077460040100
ALTERNATOR COVER INSTALLATION

NOTE
Route the wires and cables properly (page 1-21 ).
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 into the crankcase
and the reduction gear onto the gear shaft.
Inst all the torque limiter.
Install the two dowel pins and a new gasket.

[Ec>WEL PINS
11-8
The cover (stator! is Ca refulty install the alternator cover.
magnetIcally
STAY
Install the ten bolts with four new sealing washers
at/raeted to the
and the clip stay, and tighten them in a crisscross
flywheel, be careful
pattern in several steps.
not (0 gel anvlhmg
cauQht between NOTE:
Ihese parts w hen The location for the bolt with sealing washer is
Ins tallmg. marked 6. on the cover.
IF!
..;;!;':;:~N" WASHERS
Install the gear selector arm by aligning the slil with
the index line of the spindle.
Install the pinch bolt and tighten it.
TORQUE: 16 N 'm (1 .6 kgfm. 12 [bUt)
Install the cable holder with the two bolts.
Install the wire band into the cable holder.

Connect the EOT sensor 2P (black) connector.
11-9
Connect the alternatorfCKP sensor 5P !black) con-
nector and secure the alternator/CKP sensor and 5P CONNECTOR
gear position switch wi res with the two clips.
- mudguard (page 312)
- rear wheels (page 17-5)
Fill the engine with recommended oil (page 412).
::..,.!f...""
/
CUPS
,
~ --.> ,
L""'--
, '<>
-
,,
l
FLYWHEEL/STARTER CLUTCH
REMOVAL
Remove the rear crankcase cover (page 12-5),
Hold the flywheel with the special tool and remove
the bolt and washer.
TOOL:
Flywheel holder 077250040001 or
equivalent commer-
cially available in
U.S.A.
Remove the flywheel and starter driven gear using

the special toot.
TOOL:
Aotor puller 07733 0020001 or
079333950000
(U.S.A. onlV)
11-10
Remove the needle bearing and thrust washer, and
the woodruff key.
STARTER CLUTCH DISASSEMBLY I

INSPECTION
Make sure that the starter driven gear turns clock-
wise smoothly and does not turn counterclockwise. DRIVEN
Remove the driven gea r while turning it clockwise.
Hold the flywheel with the special tool and remove

the starter clutch bolts.
TOOL:
Flywheel holder on25-0040001 or
equivalent commer-
cially available in
U.S.A .
Remove t he sta rter clutch assembly from the fly -
wheel.
Remove the sprag clutch from the clutch outer.

Check the clutch outer and sprag clutch for abnor-
mal wear or damage.
CLUTCH OUTER
SPRAG CLUTCH
11-11
AL TERNA TOR/STARTER CLUTCH
Check the starter driven gear teeth and needle bear-
ing for wear or damage.
Measure driven gear boss 0.0.
SERVICE LIMIT: 51 .61 mm (2.032 in)
o
STARTER CLUTCH ASSEMBLY
Lubrica te the sprag clutch with engine oil and install
it into the clutch out er with the flanged side facing
the flywheel side.
Apply locking agent to the starter clutch bolt

threads. Install the flywheel onto the clutch outer
and the clutch bolts.
Hold the flywheel with the special tool and tighten
the bolts.
TOOL:
Flywheel holder 07125-0040001 or
equivalent commer-
cially available in
U.S.A.
TORQUE: 30 N 'm (3.1 kgfm, 22 Ibf.ft)
FLYWHEEL HUILU'"
Install the starter driven gear while turning it clock-

wise. DRIVEN GEAR
11-12
INSTALLATION
lubricate the needle bearing with molybdenum oil
solution. Install the washer and bearing onto the
crankshaft.
Install the woodruff key into the key groov e.
Clean any oil from the tapered port ion of the crank-
shaft and flywheel thoroughly.
Install the flywheel/staner driven gear by aligning

the key -way with the key on the crankshaft.
Apply engine oil to the flywheel boll threads and

seating surface, then install the washer and bolt.
Hold the flywheel using the special tool and tighten
the bolt.
TOOL:
Flywheel holder 017250040001 or
equivalent commer-
cially available in
U.S.A .
TORQUE: 108 N 'm (11,0 kgf-m , 80 Ibf.ft)

Install the feaf crankcase cover (page 12-7).
11-13
MEMO
12. SUB-TRANSMISSION/GEARSHIFT LINKAGE
SYSTEM COMPONENTS 122 SUBTRANSMISSION 129
SERVICE INFORMATION 123 GEAR SELECTOR LEVER LINKAGE ...... 1215
TROUBLESHOOTING 124 GEAR SELECTOR CABLE

ADJUSTMENT 121 6
REAR CRANKCASE COVER 125
12-1
SYSTEM COMPONENTS
181bHt)
12 Nm '1.2 kgf-m , 9 Ibf.ft)
12-2
SERVICE INFORMATION
GENERAL
This section covers service of the sub-transmission and gearshift linkage (forward-reverse). These parts can be serviced
with the engine installed in the frame.
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 not to damage the crankcase and cover mating suriaces when servicing.
For automatic transmission service, see Drivetrain System section (page 14-3).
SPECIFICATIONS
Unit: mm (in )
~ ITEM STANDARD SERVICE LIMIT
!Shift fork'---~::I~.D~'~~:~~="- _ _ _ __ _--I_ ll.000 11.021 (0. 4331 0.4339) 11.04(0.435) 1
Claw thickness 4.93 5.00 (0.194 0.197) 4 .5 (D.1S)
Shaft D.D. - -- - - -G '"'0".9"'SSi" 10.984 (0.4317 0.4324) 10.96 (0.431)
Reverse idle Collar 1.0. 13.000 13.034 (0.5 118 0.5131) 13.05 (0.5 14)
gear Shaft 0.0. 12.966 12.984 (0.5 105 0.5112) 12.93 (0.509)
I
L ____ _ _L~C~o~"~''::'r-to.sha.~ft~'~I~
''~'~'~n~'e'__ _ __ ~_ 0.10 (0.004)
TORQUE VALUES
Shift drum stopper arm pivot bolt 12 N'm (1.2 kgf.m, 9 Ibfft) Apply locking agent to the threads.
Engine oil drain bolt 25 N'm (2.5 kgf.m, 18Ibf.ft)
EDT sensor 12 Nm (1.2 kgf.m, 9lbfft)
Gear selector lever pivot nut 26 N'm (2.7 kgf.m, 20 Ibfft)
Gear selector cable nut 26 N'm (2.7 kgfm, 20 Ibfft)
TOOLS
I Remove. we;gh,
07741-0010201
Attachment, 37 x 40 mm
07746-0010200
Pilot, 17 mm
077460040400
or 07936-371020A or 07936-3710200
(U ,S.A. Only)
Pilot, 25 mm Driver Attachment, 28 x 30 mm

07746-0040600 07749-0010000 079461870100
l
12-3
Remover handle Bearing remover, 17 mm

07936-3710100 07936-3710300
TROUBLESHOOTING
NOTE :
Be sure the Mil is not blinking (No drivetrain
OTC) before checking the following (page 14-15).
Exce ssive shift shock or abnormal noise when shift
ing sub-transmissio n (O-N -R)
1. Shift condit ion check
Check gear selector lever freeplay between the
Neutral-Drive and Neutral-Reverse.
Is th e (reap/ay th e same for each gear7
NO - Faulty gearshift linkage (page 12-4),
YES - GO TO STEP 2.
2. Vehicle creep check
Stan 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 14-6) while applying
the brake as same manner as above.
NO - Adjust the selector cable (page 12-16).
Hard t o shift
Bent shift fork claw
Bent shift fork shaft
Damaged shift drum guide groove
Damaged shift fork guide pin
Damaged gearshift spindle and drum teeth
Damaged selector lever linkage
Improperly adjusted selector cable
Improperly installed gearshift spindle and drum
Transmission jumps o ut of g ear
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 center plate
12-4
SUB-TRANSMISSION / GEARSHIFT LINKAGE
REAR CRANKCASE COVER
REMOVAL
- starter motor (page 23-6)
- rear propeller shaft (page 8-6) 3P CONNECTOR
Disconnect the front propeller shaft (page B-7 ),
Remove the alternator cover and reduction gears
(page 11-5),
Disconnect the gear position switch 3P (black) con-
nector.

- EOT sensor and sealing washer
- oil filler hose (from the pipe)
- two bolts, oil filler pipe and D-ring
Release the gear position switch wire from the wire

clamp on the crankcase cover.
Tempora rily install the gear selector arm and make
sure the sub-transmission is into neutral (page 12-
17 ).
8e careful nor to Remove the following:
damage !he switch two bolts and gear position switch
-
pin on the poSItIOn - O-ring
SWitch. - bolt and ground cable
12-5
- two 8 mm bolts
- oit drain bolt, sealing washer and O-ring
- eleven 6 mm bolts
- rear crankcase cover
- two dowel pins

- oil joint collar and O-rings
- gasket
- oil seals (from the rear crankcase cover)
BEARING REPLACEMENT
Refer to Crankcase/Crankshaft/Balancer section for
rear crankcase beari ngs replacement (page 13-10).
OUTPUT SHAFT BEARING
Press the needle bearing out of the crankcase cover.
TOOLS:
Driver 07749-0010000
Attachme nt. 28 x 30 mm 07946, '870100
Pilot, 25 mm 01146-0040600
Press in a new bearing unlil it is seated.
TOOLS:
Driver 077490010000
Attachment, 37 x 40 mm 07746-0010200
Pilot, 25 mm 07746-0040600
COUNTERSHAFT BEARING
Remove the bearing using the special tools.
TOOLS:
Bearing remover, 17 mm 079363710300
Remover handle 07936-3710100
Remover wei9ht 07741 0010201 or
07936-37102OA
(U .S.A . only) or
07936-3710200
(U.S.A. only)
12-6
Drive a new bearing in with the sealed side facing
down.
TOOLS:
Driver 077490010000
Attachment, 37 x 40 mm 07746 0010200
Pilot, 17 mm 07746 0040400
INSTALLATION
Blow through the oil passage in the crankcase cover
wi t h compressed air.
Clean the crankcase and cover mating surfaces.
Apply engine oi l to the lips of new oil seals, and
install them into the crankcase cover until they are
fully seated.
Coat new O-r ings with engine oil and install them
into the joint coll ar grooves. Install the oil joi nt col-
lar into the crankcase.
Install the two dowel pins and a new gasket.

Make sure that the washers are installed on the out-
put shaft, reverse idle shaft and gea r shift spindle,
and that the shift drum position is neutral as shown
(switch pin groove is in positioned lengthwise).
12-7
Install a new sealing washer onto the drain bolt.
the drain bolt groove.
Install the rear crankcase cover with the following
fasteners:
- eleven 6 mm bolts
- two 8 mm bolts
- oil drain bolt
Tighten the bolts in a crisscross pattern in several . .-~!
steps.
TOROUE: Drain bolt: 25 N-m 12.5 kgf-m, 18 Ibfttl
Temporarily install the gear selecto r arm and make

sure the sub-transmission is into neutral (page 12-
17).
the groove in the gear position switch.
Becarefulrlorro Align the long end of the switch pin with the "N"
damage the SWitch mark. Instal! the switch by aligning the switch pin
pm durmg with the slot in the crankcase cover.
installation. Install the bolts and tighten it.
Route the gear position switch wi re properly, secure
the wire with the clamp on the crankcase cover.
Install the ground cable with the bolt.
12-8
Coat a new O'ring with engine oit and install it onto
the oil filler pipe.
Install the filler pipe with the two bolts.
Connect the oil filler hose onto the pipe.
Install the EOT sensor with a new sealing washer
and tighten it.
TORQUE: 12 N m (1.2 kgf-m , 9 Ibf.ft)
Install the reduction gears and alternator cover

(page 11 -8).
Connect the gear position switch 3P (black) connec- ~~~~~'::::::~~~~!':'::~:::~~~

tor.
3P CONNECTOR
Connect the front propel ler shaft (page 810).
- rear propeller shaft (page 8-12)
- starter motor (page 23-11)
- exhaust system (page 326)
SUB-TRANSMISSION
DISASSEMBLY
Remove the rear crankcase cover (page 12-5).
washer
idle gear (25T)
idle gear (13T)
washer
- gear shaft
12-9
SU8-TRANSMISSION/GEARSHIFT LINKAGE
- shih fork shaft
- shift fork
- countershaft assembly
- washer
- output shaft
- output driven gear
Remove the oil seal from the front crankcase cover.
Remove the shift drum while lifting the stopper arm

with a screwdriver.
12-10
- washer
- gearshift spindle
- pivot bolt
- stopper arm
- washer
- relurn spring
Remove the lock washer on the shaft end with a

screwdriver and disassemble the countersha ft .
INSPECTION
COUNTERS HAFT
Check the gear dogs and teeth for abnormal wear or
damage.
Check the gear shifter for smooth operation.
Check the gear shifter groove, dogs and splines for
abnormal wear or damage.
Check the counter shaft and bearings for abnormal
wear or damage.
GEAR
D. GEAR
OUTPUT SHAFT
Check the gear teeth and splines for abnormal wear
or damage.
Check the output shaft for abnormal wear or dam-
age.
12-11
REVERSE IDLE GEAR
Check the gear teeth for abnormal wear or damage.
Check the splines for abnormal wear or damage.
Check the gear shaft for abnormal wear or damage.
Measu re each end of the gear I.D.
Measure the shaft 0.0.

Calculate the gear-la-shaft clearance.
SHIFT FORK AND SHAFT

Check shift fork guide pin for abnormal wear or
damage.
Measure each shift fork claw thickness.
Measure the shift fork I.D.
Measure the shift fork shaft 0.0.

SERVICE LIMIT: 10.96 mm (0.43 1 in )
SHIFT DRUM
Replace the shiff Check the guide groove for abnormal wear or dam-
drum as an age.
assembly. GEAR
Check the drum center plate and shifter gear for
abnormal wear or damage.
GUIDE GROOVE
CENTER PLATE
GEARSHIFT SPINDLE
Check the shifter gear and splines for abnormal
wear or damage.
12-12
SUB-TRANSMISSION/ GEARSHIFT LINKAGE
INSTALLATION
Apply locking agent to the pivot bolt threads.
Install the spring, washer (between the crankcase
and arm) and stopper arm w ith the bolt as shown
and tighten the bolt
TORQUE: 12 N'm (1,2 kgfm, 9 Ibf.ft)
Install the snap ring into the spindle groove with the
chamfered edge facing the crankcase cover side
Install the shifter gear with the inde)( line facing the
snap ring, aligning the wide groove with the wide
tooth.
Install the gearshift spindle and rest it onto the stop
per on the crankcase.
Install the washer onto the spindle.
Apply engine oil to the shift drum guide groove.

Lift the stopper arm and install the shift drum so the
index line on the spindle shifter gear is aligned
between the punch marks.
Turn the shift drum clockwise and set it in neutral
position so its groove position is lengthwise.
Apply engine oil to the lips of a new oil seal, and

install it into the front crankcase covet until fully
sealed.
12-13
SUB TRANSMISSION/GEARSHIFT LINKAGE
Apply engine oil to the gear teeth and set the output
driven gear into the crankcase.
Insert the output shaft through the driven gear and
install it into the crankcase.
Install the washer.
Apply engine oil to the bearings, gear teeth and slid-

ing areas.
Assemble the countershaft.
1--- LOCK WASHER
REVERSE GEAR
WASHER
OUTPUT DAIVE GEAR
BEARING (20 x 24 x 1.3)

WASHER--~
~ : Bearings, Gear teeth and
BEARI NG (20 x 24 x 11) Sliding areas
Install the countershaft assembly by engaging the r;"",,",

splines.
Apply engine oil to the fork shaft outer surface.
Before Installation.Install the shift fork into the gear shifter groove and
be sure that the drum guide groove w ith the mark side facing out.
switch pin groove In Insert the fork shaft through the fork and install it
the shift drum is into the cran kcase.
iengrhwfse as
shown
12-14
Apply engine oil to the gears and sliding surface
and install the following.
gear shaft
washer
idle gear (13T)
- idle gear (25T)
- washer
Install the rear crankcase cover (page 12-5).
GEAR SELECTOR LEVER LINKAGE

DISASSEMBLY
Remove the gear selector lever grip.
Loosen the cable nuts.

- cotter pin and washer
- gear selector cable
- collar
Loosen the lever pivot nut.

Be careful nor to While holding the lever securely, remove the arm
damage the threads pivot bolt (washer-bolt) and the selector lever
in the frame. assembly.
- pivot nut and boll
- selector lever
- spring
12-15
SUBTRANSMISSION/GEARSHIFT LINKAGE
ASSEMBLY
Apply grease to the pivot bolt groove.
Set the spring onto the selector lever and insert the
pivot bolt into the arm and lever.
Install the pivot nut.
Apply grease to the sliding surface of the arm pivot
bolt (washer-bolt).
Install the selector lever assembly and the bolt w hile
hold the lever.
Tighten the arm pivot bolt (washer-bolt).
Tighten the lever pivot nut.
TORQUE: 26 Nm (2.7 kgfm , 20 Ibfft)

- collar
- gear selector cable
- washer
- new cotter pin
- gear selector lever grip

Adjust the gear selector lever cable (page 12-16).
GEAR SELECTOR CABLE

ADJUSTMENT
Set the gear selector lever to the neutral (N) posi~
tion.
12-16
hood.
Completely loosen the upper and lower cable nuts
on the selector cable.
Unlock the cargo bed by pulling the release lever

and raise the bed.
Turn the Ignition Operate the select or arm on the feaf side of the
SWitch to ON (I) and engine by hand and shift the sub-transmissi on into
check that the neutral (the selector arm will be vertical),
neutral mdlcator
comes on at this
r,me
Do not move the Without applying force to move the cables, gradu-
ally screw the cable nut s together by hand until they
selector lever from
the neutral position touch the cable holder.
Tighten the cable nut while holding the other nut.
TORQUE: 26 Nm (2.7 kgf-m, 20 Ibf.ft)
Make sure the gear selector lever free play is as indi-

cated when in the neutral (N ) position . GATE
After adjustment, check that the selector lever oper-

ates properly.
Lower the cargo bed. SELECTOR
Close the front hood and secure it with the straps. LEVER Morethan
I ~;;:~th'_n______
12-17
MEMO
13. CRANKCASE/CRANKSHAFT/BALANCER
SYSTEM COMPONENTS ......................... 13-2 CRANKSHAFT ..................... ............ ......... 13-7
SERVICE INFORMATION ..... ..... ............... 13-3 CRANKCASE BEARING

REPLACEMENT ...................................... 13-10
TROUBLESHOOTING .. .. 13-5
CRANKCASE ASSEMBLy 13-12
CRANKCASE SEPARATION 13-6
13-1
SYSTEM COMPONENTS
13-2
SERVICE INFORMATION
GENERAL
The crankcase halves must be separated to service the crankshaft and NT {mainshaft and 2nd/3rd shift clutch
{cDuntershaft]). To service these parts, t he engine must be removed from the frame (page 8-2),
For AIT service, see Drivetrain System section (page 14-2).
Be careful not to damage the crankcase mating surfaces when servicing.
SPECIFICATIONS
Unit' mm (in)
Crankshaft Runout 0.05 (0.002) 0.15 (0.059)
Big end side ctearance 0.05 0.65 0.002 0.026) 0.8 (0.03)
Big end radial clearance 0.006 0.018 (O.OOO2 0.0007) 0.05 (0.002)
TOOLS
Remover weight Remover handle Bearing remover, 17 mm
07741-0010201 07936-3710100 07936-3710300
or 07936-371020A Of 07936-3710200
(U.S.A. only)
Bearing remover, 20 mm Attachment, 37 x 40 mm Attachment, 42 x 47 mm

07936-3710600 077460010200 07746-0010300
Attachment, 52 x 55 mm Attachment, 62 x 68 mm Driver

07746-0010400 07746-0010500 07749-0010000
13-3
Pilot, 17 mm Pilot, 20 mm Pilot, 28 mm

07746-0040400 07746-0040500 07746-0041100
Pilot, 35 mm Pilot, 40 mm Anachment, 20 mm I.D.

07746-0040800 07746-0040900 077460020400
Attachment, 78 x 90 mm Ball joint remover/installer Assembly collar

07GAO-S040101 07WMF-HNOQ100 07965-VM00100 (U.S.A. only)
Assembly collar spacer

07AMf..HM8Al00 (U,S.A only)
Threaded adaptor
07965-VM00300
~f Assembly shaft
07965-VM00200
or 07931-KF00200 (U.S. A . only) or 07931-ME4010B and

07931-HB3020A (U.S.A. Only)
13-4
TROUBLESHOOTING
Excessive engine noise
Worn or damaged connecting rod bearing
Worn crankshaft main journal bearing
Worn connecting rod small end
Worn balancer bearing
Worn, seized or chipped transmission gear
Worn transmission bearings
Abnormal vibration
Improper balancer timing
13-5
CRANKCASE SEPARATION
- engine ~page 8-2)
cylinder and piston (page 10-4)
sub-tra nsmission/gea rshift linkage (page 12-9)
flywhee l/starter clutch (page 11-10)
torque converter (page 14-42)
1st shift clutch (page 1447)
oil pump (page 5-6)
cam chain
oil pump drive chain
pivot bolt
cam chain tensioner and collar
Tile crankcase bolts - nine rear crankcase bolts

are loosened In a
Cflsscross pa lrem
In several steps
- five front crankcase bolts

Place the crankcase assembly with the rear crank-
case down.
Do not orr the Remove the front crankcase while tapping it at S9V-
crankcase apart erallocations with a soh hammer.
with 8 sClilwdrrver,
- crankshaft bearing inner race
- two dowel pins
- oil joint collar and O-rings
13-6
Remove the oil strainers.
Clean each strainer screen thoroughly.
Install the 011 tanl< Install the strainers properly as shown.
strainer wIth rhe
thm edge facing the
crankcase
CRANKSHAFT
REMOVAL
Separate the crankcase (page 13-6).
- oil strainers (page 13-7)
- mainshaft and countershaft
Refer to Drivetrain System section for mainshaft
and coun tershaft (page 14-47).
Be careful nor 10 Remove the crankshaft and balancer from the rear
damage the crankcase using a hydraulic press. Be sure to hold
crankcase matmg the crankshaft and balancer while pressing them
surface and out of the crankcase.
crankshaft
assembly
Remove crankshaft bearing using a bearing puller

with a suitable protector.
NOTE
Always replace the rear crankshaft bearing with a
new one whenever the crankshaft is removed.
PROTECTOR
13-7
INSPECTION
Set the crankshaft in a stand or V-blocks and mea-
sure the runout using a dial indicator.
Measure the side clearance between the connecting

rod big end and crank weight with a feeler gauge.
Measu re the radial clearance at the connecting rod

big end in an X and Y directions.
Check the balancer gear for wear or damage.
13-8
CRANKSHAFT AND BALANCER
INSTALLATION
Apply engine oil to a new rear crankshaft bearing .
Drive the crankshaft bearing into the rear crankcase
with the marking side facing up.
TOOLS:
Driver 07749-0010000
Attachment, 78 x 90 mm 07GAD-SD40101
Pilot, 40 mm 07746-0040900
Other bearing replacement in the crank case halves
(page 13-10)
Engage the crankshaft and balancer by aligning the

ind ex lines on the sides of the balancer drive and
driven gears as shown, and install them together
into the rear crankcase.
Assemble the special tools onto the c rankshaft .

Be careful nor to ler Draw the crankshaft into the bearing inner race by
the connecting rod turning the assembly shaft while holding the shaft
press agamsr rhe nut.
crankcase matmg
surface while
TOOLS:
drawing Ball joint remover / installer 07WMF HN00100
Attachment. 20 mm 1.0. 077460020400
Assembly shaft 07965VM00200
Threaded adapter 07965VM00300
U.S.A. only TOOLS:
Puller shaft 07931 ME4010B
Special nut 07931HB3020A
Threaded adapter 07931 KF00200
Assembly collar 07965VM00100
Assembly collar spacer 07AMFHN8Al00
After inst alling the crankshaft in, make su re the
index line on the crank weight is aligned between
the index lines on the balancer driven gear .
13-9
Install the mai nshaft and countershaft assemblies
as a set into the rea r crankcase.
lnSlalllhe oi l strainers (page 13-71,
Assemble the crankcase halves (page 13-12).
CRANKCASE BEARING REPLACEMENT

REAR CRANKCASE
Remove the balancer, mainshaft and shift drum SHI FT DR UM BEARING
bearings with the special tools.
TOOLS:
Balancer and Shift Drum Bearings:
Bearing remover, 17 mm 0793637 10300
Remover handle 079363710100
Remover weight 077410010201 or
07936371020A or
079363710200
(U.S.A. on ly)
Mainshaft Bearing :
Bearing remover, 20 mm 07936 -37 10600
0793S371020A or
0793637 10200
(U .S.A . on IV)
Drive the countershaft and output shaft bearings

out of the rear crankcase. MAINSHAFT BE,'RING
OUTPUT SHAFT BEARING
13-10
Apply engine oil to new bearings.
Drive the bearings in w ith the ma rks facing up.
The mainsflafr TOOLS:
bearing Is installed Mainshaft Bearing
WJtf1 the sealed Driver 077490010000
side facing down. Attachment, 42 x 47 mm 077460010300
Pilot, 20 mm 077460040500
Countershaft Bearing
Driver 077490010000
Attachment, 52 x 55 mm 077460010400
Pilot, 28 mm 077460041100
Balancer and Shift Drum Bearing

Driver 077490010000
Attachment, 37 x 40 mm 07746 0010200
Pilot, 17 mm 07746 0040400
Output Shaft Bearing

Driver 077490010000
Attachm ent, 62 x 68 mm 077460010500
Pilot, 28 mm 077460041100
FRONT CRANKCASE
Remove the balancer and countershaft bearings
with the special tools. BEARING REMOVER
TOOLS:
Balancer Bearing:
Remover weight 0774' 0010201 or
07936371020A or
079363710200
(U.S.A . only)
Countershaft Bearing :
Remover w eight 07741 0010201 or
07936371020A or
079363710200
(U.S.A . only )
Remove the oil feed pipe oil seal.
Drive the mainsh aft and crankshaft bearings out of
the front crankcase.
Apply engine oil to the l ips of a new feed pipe oil
seal. Install the oil seal with the flat side facing the
crankcase until it is fully seated.
MAINSHAFT BEARING
13-11
Apply engine oil to new bea rings .
Drive the bearings in w ith the ma rks facing up.
TOOLS:
M ainshaft Bearing
Driver 077490010000
Attachme nt, 62 x 68 mm 077460010500
Pilot. 35 mm 077460040800
The COUnt8fShafr Countershaft Beari ng
beann{} IS msral/ed Driver 07749-0010000
wIth the S61J/ed Attachme nt , 42 x 47 m m 07746-0010300
side facmg cIo\.vn Pilot , 20 mm 07746-0040500
Cra nkshaft Bearing

Driver 07749-0010000
Attachme nt, 78 x 90 mm 07GAO-SD40101
Ba lancer Bea ring

Driver 071490010000
Attachment. 37 x 40 mm 077460010200
Pilot, 17 mm 077460040400
CRANKCASE ASSEMBLY
Before installing the front crankcase cover, make fi'A:i"Nif>i:I\Fro--. """"'CaciNirEiiSi<AiFT"W
sure the gear side surfaces (e1 and Ml gears) of the
countershaft and mainshaft are flu sh.
Clean the fron t and rear crankcase mat ing surfaces . - - -

thoroughly, bei ng careful not to dam age them.
Blow through the oil passages i n the cra nkcases
with compressed ai r.
Coat new O-rings w ith engi ne oil and i nstall them
into the joint collar grooves. Instal l the oil joint col-
lar into the crankcase.
13-12
Install the two dowel pins.
DOWEL PINS
Install the bearing inner race onto the crankshaft ..
I~'l
with the flange side facing in.
- . ''\
RACE
ApplV liquid sealant (Three Bond 1215 or equiv8- ~--=:::::::::~II""'"",,~~~'::::':'::::':::'=,
lent) to the mating surface of the front crankcase. .(I~
Meke sure the Install the front crankcase over the rear crankcase,
mating surfaces aligning the oil strainer pipe wi th the pipe hole.
evenly rouch. mar
Install the five front crankcase bolts.
there is no
clearance be/ween Check thaI the mainshaft and crankshaft turns
the cases smooth IV and quietly.
Install the nine rear crankcase boils.

REAR CRIINKCAo;E
Tighten all the crankcase bolts in a crisscross pat-
tern in several steps.
13-13
Apply locking agent to the threads of the tensioner
pivot bolt.
Install the cam chain tensioner and pivot collar with
the flange side of the collar facing to the crankcase,
and tighten the bolt.
Install the oil pump drive and cam chains onto the
crankshaft.
oil pump (page 511)
1st shift clutch and torque converter (page 14-56)
- flywheel/starter clutch (page 11-13)
- sub-transmission/gearshift linkage (page 12-13)
- cylinder and piston (page 10-8)
- engine (page 8-9)
13-14
14. DRIVETRAIN SYSTEM
SYSTEM COMPONENTS ...... .... .. 14-2 DRIVETRAIN DTC INDEX 14-16
SERVICE INFORMATION 14-3 DRIVETRAIN DTC

TROUBLESHOOTING 14-17
SYMPTOM TROUBLESHOOTING 14-6
SHIFT VALVE BODY .. .. 14-28
DRIVETRAIN COMPONENT
LOCATION .. .......... ..... ............. 14-11 FRONT CRANKCASE COVER ................ 14-37
DRIVETRAIN SYSTEM DIAGRAM 14-12 TORQUE CONVERTER 14-42
DRIVETRAIN CONNECTOR SHIFT CLUTCH/MAINSHAFT I

LOCATION 14-13 COUNTERSHAFT ................................... 14-47
DRIVETRAIN TROUBLESHOOTING GEAR POSITION SWITCH ..................... 14-57

INFORMATION 14-15
EOT SENSOR 14-58
14-1
DRIVETRAIN SYSTEM
SYSTEM COMPONENTS
, 101bf.ft)
118 Nm (12 .0 kgfm. 87Ibf-ft)
108 N'm (11.0 kgfm, 80 Ibf.ft)
21 Nm (2 .1 kgfm, 15 Ibf-ft)
14-2
DRIVETRAIN SYSTEM
SERVICE INFORMATION
GENERAL
This "Drivetrain System" section covers service of the Automatic Transmission (AfT) system and drive mode (2WD,
4WD with the rear differential locked, 4WD wi th the fr ont and rear differentials locked) select or.
A faulty drivetrain system is often related to poorly connected or corroded connectors. Check those connections before
proceeding.
Read "Drivetrain Troubleshooting Infor mation" carefully, and inspect and troubleshoot the drivetrain system according
to the Ole. Observe each step of the procedures one by one. Note the OTe and probable faulty part before starting
diagnosis and troubleshooting.
The peM may be damaged if dropped. Also, jf a connector is disconnected when current is flowing, the excessive volt-
age 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 13-6).
The engine oil is used for AfT oil. Lubrication system service (oil pump and oil cooler) (page 5-2).
AfT and lubricating oil is fed through the oit passage in the front crankcase cover. Clean the oil passages before install-
ing 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 f aulty.
Front final clutch and differential lock clutch service (page 19-17).
Rear differential lock clutch service (page 20-15).
Drive mode selector lever service (page 19-42).
Sub-transmission (Forwa rd-Neutral-Reverse) service (page 12-2).
For Driv etrain System Troubleshooting
The dr ivetrain 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 fo l lowing items and refer to the appropriate troubleshooting.
1. MIL blinks or DTC for the PGM-FI system and AfT system (page 6- 12).
2. Symptom troubleshooting of the AfT system (page 14-6).
SPECIFICATIONS
Unit mm (in)
I ITEM I STANDARD SERVICE LIMIT
Oil pressure
at 5,000 rpm
t- Line I 785 kPa (8.0 kgflcm~-;1 1 4 psi)
1st, 2nd and 3rd clutch 785 kPa (8.0 kgflcm , 114 psi)
Shift clutch Initial clearance i 0.7 0.9 (0.03 0.04)
(1st, 2nd and Disc thickness 1.88- 2.00 (0.074 0.079) worn out lining-
3rd) Plate thickness 1.95--- 2.05 (0.077 0.081) discoloration
I Return spring free length 33.8 (1.33) 31.8 (1.25)
TORQUE VALUES
Oil path bolt 18 N'm (1.8 kgfm, 13 Ibl-ft)
Primary driven gear lock nut 108 N'm (11.0 kgfm, 80 Ibfft) Lock nut: replace with a new one.
App ly engine oil t o the t h reads and seating sur-
face. Stake.
Stator shaft inner collar stopper pin 14 N'm (1.4 kgfm, 10 Ibf.ft) Apply locking agent to the threads.
Torque converter lock nut 118 N'm (12.0 kgfm, 87Ibfft) Lock nut: replace with a new one.
Apply engine oil to the th reads and seating sur-
face. Stake.
Oil feed pipe setting cap 21 Nm (2.1 kgf m , 15Ibfft)
EaT sensor 12 N'm (1.2 kgf-m, 9 Ibfft)
14-3
DRIVETRAIN SYSTEM
TOOLS
Pressure gauge set Bearing remover weight Anachment, 42 x 47 mrn
07406-0020005 0774, 0010201 0774&0010300
or 01ZMJ-HN2Al00 and 07AMJ - or 07936-371020A or 07936-3710200

HN8A 100 (U.S.A. only ) (U.S.A. only)
Pilot, 17 mm Pilot, 25 mm Driver
077460040400 077460040600 077490010000
Pulier, 35 x 1.0 mm Bearing remover handle Bearing remover, 17 mm

07933-HA80000 07936-3710100 079363710300
or 07933-HB300QA (U.S.A. only,)

Compressor bolt assembly -
_-j-,,=========,---_--L"'''''==:;,
Clutch compressor attachment SCS connector ---------1
07GAEPG40200 07LAE-PX40100 (2 required) 070PZZY30100
; ''':
or 07GAE-PG4020A (U.S.A. only)
14-4
DRIVETRAIN SYSTEM
HDS pocket tester Test probe, 2 pack
TDS 3557-0112-01 (U.S.A. only) 07ZAJ-ROJA l' 0
14-5
DRIVETRAIN SYSTEM
SYMPTOM TROUBLESHOOTING
GENERAL INFORMATION
When the vehicle has any AfT system trouble, check the DTC or Mil blinking, refer to the Ole index
(page 14 16) and begin the appropriate troubleshooting procedure. If there are no Ole or MIL blinking,
do the diagnostic procedure for the symptom, and check the oil pressure and diagnose according to the
hydraulic ci rcuit troubleshooting chart (page 14-10).
Symptom I Diagnosis procedure Also check for

Vehicle does not start Check the AfT clutch PC solenoid valve operation
(page 14-6).
Check the line oil pressure and 1st clutch oil pressure
(page 14-8).
Check the 1st shift clutch system (page 14-47).
Excessive starting shock Check the line oil pressure and 1st clutch oil pressure
(page 14-8).
~icle creeps (vehicle Check that the emergency valve is not active (page
does not stop) when 14-28).
idling Check the 1st clutch oit pressure (page 14-8).
Driving power falls o-ff- Check the AfT clutch PC solenoid valve operation
Engine oil level
when starting (insuffi- (page 14-6).
(page4-12 )
cienl engine brake) Check the 1st clutch oil pressure (page 14-8).
Engine stalls when Check th e engine idle speed (page 6-55).
starting Check the 1st clutch oil pressure (page 14-8).
AfT does not shift Check the TP sensor installation condition (page 6-51)
Check the VS sensor installation condition (page 6-53)
Check the shift solenoid valve operation (page 14-7).
Check the clutch oil pressures (page 14-8).
Check the 1st/2nd shift clutch system (page 14-47).
['''""iV' 'hift 'hod<.
engine rpm rises or

Check the clutch oil pressures (page 14 8).
Check the 1st/2nd shift clutch system (page 14-47).
driving power falls off
AfT CLUTCH PC SOLENOID VALVE

OPERATION INSPECTION
Remove the left side panel (page 3-1 1).
Turn the ignition switch to ON (I) and check for a
"click" sound from the AfT clutch PC solenoid valve.
If the "click" sound is heard, the AfT clutch PC sole-
noid valve is normal.
14-6
DRIVETRAIN SYSTEM
If the "click" sound is not heard, turn the ignition
switch to OFF and disconnect the AfT clutch PC sole-
noid valve 2P black connector.
2P BlACK CONNECTOR
Connect a 12 V battery to the solenoid valve cannec- ;:::=================~

tor terminals as shown.
The AfT clutch PC solenoid valve should operate
(sound) when the battery is connected.
EEl 8
AfT CLUTCH PC
SOLENOID VALVE
12 V BATIERY
CONNECTOR
(Terminal side of the solenoid valve)
SHIFT SOLENOID VALVE OPERATION

INSPECTION
Remove the valve body cover (page 14-28).
Disconnect the shift solenoid valve 2P black and
brown connectors.
14-7
DRIVETRAIN SYSTEM
Connect a 12 V battery to the solenoid valve connec-
tor terminals as shown.
The shift solenoid valve should operate (sound)
when the battery is connected.
EB 8
SHIFTSOLENOID
12V BATTERY
VALVE A
CONNECTOR
EB 8
SHIFTSOLENOIQ
VALVE 8
12 V BATTERY
CONNECTOR
OIL PRESSURE CHECK

NOTE .
If the oil pressure is abnormal, inspect and clean
the parts according to the hydraulic circuit trou-
bleshooting chart (page 14-10).
Failure to warm the engine will cause very high
oil pressure readings and oi l leaks will cause low
oil pressure reading s.
Check the oil level and add the recommended
engine oil if necessa ry (page 4-12).
Warm the engine to normal operating temperature
and check for external oil leaks.
LINE OIL PRESSURE
Remove the engine front cover (page 3-6).
Clean around the sealing bolt with compressed air.
8e sure thar no dirt Remove the sealing boll and washer from Ihe right
IS allowed to enter side of the shift valve body.
tile 01/ gallery.
14-8
DRIVETRAIN SYSTEM
Connect the oil pressure gauge and adapter to the
sealing bolt hole (hole threads: M8 x 1.25), Oil PRESSURE GAUGE
Except U.S.A. TOOL:

Press ure gauge set 074060020005
U.S.A . TOOLS :
Oil pressure gauge 0-160 psi 07ZMJ-HN2Al00 and
Adaptor, banjo 8 x 1.25 mm 07AMJ-HN8Al00
(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 (80"C/ 176"F):
785 kPa (8 .0 kgf/cm2, 114 psi) at 5,000 rpm
Stop the engine.
Remo ve the pressure gauge and adaptor.
Install the sealing bolt with a new seal ing washer,
and tighten it.
Inst all the engine front cover (page 3-6).
SHIFT CLUTCH Oil PRESSURE

Remove the left side panel (page 3 ' 1).
Be careful not touch Support the vehicle using a hoist or equivalent and
the rota tmg wheels raise all the wheels off the ground .
Duong inspection.
Clean around the sealing bolt with compressed air.
Be sure that no din Remove the sealing bolts and washers from the bot
IS allowed /0 enter tom of the shift valve body.
the oil gallery
Connect the oil pressu re gauges and adaptors to g;~~~~~~~~~~~~~~~~

each seali n g bolt hole (hole threads: M8 x 1.25). ~~~~t~---~ GAUGE
Oil PRESSURE
/ / /
Except U.S.A . TOOL: ,0- .G'"
Pressure g auge set 074060020005 .--0-( f- ~ " "I ~
U.S.A. TOOLS:
Oil pressure gauge 0-160 psi 07ZMJ HN2A100 and
:;,:
......_~:_---:.. ~~
,~
-A.c' l .....~
.-._ --"..:'.J.....::::r---4-L ,.,~
v.
Adapter, banjO 8 x 1.25 mm 07AMJHN8A100 \I . , - ~F'~"'-;F
(U.S.A . only) ;- _ r:;.~::f -:-- l......l.
Start the engine and shift the sub-transmission into ~ < 'y ':- '""" ::z;~y~
Drive (set th e gear selector lever in the front posi ~
tion),
14-9
DRIVETRAIN SYSTEM
Raise the engine speed and measure each shih
clutch oil pressure.
SHIFT CLUTCH Oil PRESSURE (80 C/ 176F):
785 kPa (8.0 kgf/ cm 2 , '14 psi) at 5,000 rpm
Stop the engine.
Remove the pressure gauges and adaptors.
Install the sealing bolts with new sealing washers,
and tighten them.
Instal l the left side panel (page 3-11).
HYDRAULIC CIRCUIT TROUBLESHOOTING CHART

PRESSURE CHECK SECTION MEASUREMENT RESU LT (. : Abnormal I Blank: Normal)
line oil pressure
I
1st clutch o il pressure
Refer
to page
2nd clutch oil pressure

3rd clu t ch oil pressure
AIT clutch PC solenoid
I
0
valve
Emergency valve 0
' -2 shift valve 0 0
2-3 shift valve 0 0
Shift solenoid valve A 0 0 14-28

Shift solenoid valve B 0 0
2nd orifice control valve
3rd orifice control valve
~
8: Shift valve body 0 0 0 0
,
~ Orifice control valve body 0 0 0 0
~ 1st shift clutch 0
:c 2nd shift clu tch 0 14-47

0 "'3rd shift clutch
-
.0
"- Feed pipe A

Feed pipe B
0
0 0
0
0 14-37
Feed pipe C 0 0 0
Torque converter 0 14-42

Oil pump I 0 5-6
Oil pi pe setting collar 0 0 0 0 14-37
Oil filter 4-14
0
,
Oil strainer 0 13-6
Oil level 0 I 4-,,1
14-10
DRIVETRAIN SYSTEM
DRIVETRAIN COMPONENT LOCATION
SHIFT SOLENOID VALVE A

TP SENSOR
SHIFT SOLENOID VALVE 8
REAR VS SENSOR BAITEAY
MAIN RELAY
EOT SENSOR
FUSE BOX
peM
FOOT BRAKE SWITCH
AIT CLUTCH PC
SOLENOID VALVE
14-11
DRIVETRAIN SYSTEM
DRIVETRAIN SYSTEM DIAGRAM
IGN FUSE (IDA) MAIN RELAY
BATIERY
W. ~ 'W
'I:A'N'US':'OA) :N~;: LWIR ~v-
' ---B-- '~ IVWL FI FUSE (10 A) LIGHT FUSE (15 AJ
~
,"G ---8- IVW VW ---8- ""'J
FOOT BRAKE SWITCH
BUG ., MAIN SlOPLAMPSW All GIV - - - - B - BflBr
G ""V5I' 116
,
G "3 LO
G"'"....,",
aENYll At'
"
[G AEARVS
SENSOR
@(11)
PCM c-, C-3

A' A-11 e, Bl1
@( ): MIL Blink ~
A-12 A-22 B12 822
~=c!:, [OODODO~~
BI: Blad:
Sr: Brown
0 : Orange
P: Pink r~fDOCJDO~~
li?PODODDoagGi 1 ~~[J[Joooooo
Bu: Blue
G: Green
R: Red
V: Violet lT c:::;:o 000000000 OODOOOOD~'t
Gr: Grav W; White

Lb: Light blue Y; Yellow
19: Light green
C4 C 5 A23 A33 8-23 8-33
14-12
DRIVETRAIN SYSTEM
DRIVETRAIN CONNECTOR LOCATION
The parts listed below the connector must be removed to disconnect the connector.
peM 5P BUICK CONNECTOR

peM 33P o,""c.CONNECTOR
peM 33P GRAY CONNECTOR
peM connectorsIDLC
)
pLJ~ I
\ J
EDT SENSOR CONNECTOR
EOT sensor 2P connector
- maintenance lid (page 3-16)
14-13
DRIVETRAIN SYSTEM
GEAR POSITION SWITCH SHIFT SOLENOID VALVE 8

3P BLACK CONNECTOR 2P BROWN CONNECTOA
AfT ClUTCH PC SOLENOID VALVE

2P BLACK CONNECTOR
Gear position switch 3P black connector

AfT clutch PC solenoid valve 2P black connector
- left side panel (page 3-")
Shift solenoid valve 2P connectors
- valve body cover (page 14-28)
14-14
DRIVETRAIN SYSTEM
DRIVETRAIN TROUBLESHOOTING
INFORMATION
Refer to "PGM-FI TROUBLESHOOTING INFORMA-
TION" in "FUEL SYSTEM (PGM -FW except following
information (page 6- 1 1),
SELF-DIAGNOSIS SYSTEM
The peM (Powertrain Control Module) integrates
the ECM (Engine Control Module) and the TeM
(Transmission Control Module). Therefore some
detection items are shared by the PGM-FI and driv-
etrain system and they may affect the system opera-
tion of both systems.
The drivetrain system is equipped with the self-
diagnostic system. When any abnormality occurs in
the AfT system, the peM turns on the MIL and
stores a DTe in its erasable memory.
FAIL-SAFE FUNCTION
The drivetrain system is provided with a fail-safe
function to secure a m i nimum running capabili ty
even when there is trouble in the system.
When the peM detects a problem in the AfT system,
the PCM stops the automatic shift function and anti-
creep function, and defaults the transmission into
2nd gear. Also, the MIL blinks to indicate the DTC.
14-15
DRIVETRAIN SYSTEM
DRIVETRAIN DTC INDEX
When the AfT system does not operate properly but no problem code is indicated and retrievable, re fer to the symptom
troubleshooting (page 14-6).
Ole Refer to
Function Failure Symptom/ Fail-safe Function
(MIL blinks) page
4-1 141 NT clutch PC solenoid valve Low input NT shift fu nction and anti-creep function 14-17
Loose or poor con t act of the AfT clutch PC does not work (2nd gear only)
solenoid valve related connector
AfT clutch PC solenoid valve or its circuit mal-
function
4-2 (4) AIT clutch PC solenoid valve High input AfT shift fu nction and ant i-creep function 1418
AfT clu t ch PC solenoid valve or its circu it mal- does not wo rk (2nd gear only)
fu nction
4-3141 AfT clutch PC solenoid valve drive circuit AfT shift function and anti-creep function 14-17
AfT clutch PC solenoid valve or its circu it mal- d oes not work (2nd gear only)
function
8-1181 TP sensor circu it Low voltage (less than 0.22 V) Poor engine acceleration 6-19
TP sensor or its ci rcui t malfunction Fail-safe value: 0
AfT shift fu nction and anticreep fu nction
does not work (2nd gear only)
8-2181 TP sensor circui t High voltage (more than 4.93 V) Poor engine acceleration 6-21
Loose or poor contact of the TP sensor con- Fail-safe value: 0 0
nectar AfT shift fu nction and anti-creep function
TP sensor or its ci rcuit malfunction d oes not work (2nd gear only)
11-1 (11) Rear VS sensor no signal AfT shift function and anti-creep function 6-24
Loose or poor contact of the Rear VS sensor does not work (2nd gear only)
connector
Rear VS sensor or its ci rcuit malfunction
15-1 (15) Shift solenoid valve A (short) AfT shift function and anti-creep function 14-19
Shift solenoid valve A or its circu it malfunction does not work (2nd gea r only)
152 (15) Shift solenoid valve A (open) AfT shift function and anti-creep function 14-20
Shift solenoid valve A or its circu it malfunction does not work (2nd gea r only)
16-1 (16) Shift solenoid valve B (short) AfT shift function and anti-creep function 14-21
Shift solenoid valve B or its circu it malfunction does not work (2nd gear only)
16-2 (16) Shift solenoid valve B (open) AfT shift function and anti-creep function 14-22
Shift solenoid valve B or its circuit malfunction does not work (2nd gear only)
31-1 (31) System voltage Low (less than 9.3 V) AfT shift fu nction and anti-creep function 14-23
PCM power input ci rcuit malfunction does not work (2nd gear only)
32-1 (32) Fail-safe relay circuit AfT shift function and anti-creep fu nction 14-24
Fail-safe relay circuit malfunction does not work (2nd gear only)
33-21331 EEPROM malfunction 6-54
41-1 (411 Gear position switch circuit AfT shift
function and anti-creep fu nction 14-24
Gear position switch circuit malfunction does not work (2nd gea r only)
(Short)
44-' (44) EDT sensor circuit low voltage (less than 0.07 V) AfT shift function and anti-creep fu nction 14-26 -
EOT sensor or its ci rcuit malfunction does not work (2nd gear only)
Cooling fan turns on
44-2 (44) EDT sensor ci rcuit high voltage (more than 4.85 V) AfT shift function and anti-creep fu nction 14-27
Loose or poor contact of the EDT sensor con- does not work (2nd gea r only)
nectar Cooling fan tu rns on
EOT sensor or it s ci rcuit malfunction
14-16
DRIVETRAIN SYSTEM
DRIVETRAIN DTC TROUBLESHOOTING
NOTE:
The connector location and the necessary parts
10 disconnect the connector (page 1413).
Perform inspection with the ignition switch
turned to OFF (0 ) unless otherwise specified.
After troubleshooting, erase the OTe (page 613)
and test-drive the vehicle to be sure that the sys-
tem 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 troubleshoo ting, check the AIT
clutch PC solenoid valve 2P black connector for
loose or poor contacts, and recheck the oTC.
1. Re:heck OTe
Test-drive the vehicle and stop the engine.
Recheck the current DTe with the HOS pockel
tester.
Is DTC 4- 1 or 4-3 indicated?
YES - GO TO STEP 2.
2. A fT Clutch PC Solenoid Valve Inspectio n
Disconnect the AIT clu tch PC solenoid valve 2P AIT CLUTCH PC SOLENOID VALVE
black connector. 2P CONNECTOR (Terminal side of
Measure the resistance between the solenoid the soleno id valve)
valve side 2P connector terminals. n n n
Standard: 5.1 - 5.7 n (2 0~C / 68~F)
.q
Is the resistance within s tandard value?
YES - GO TO STEP 3. II
NO - Fa ulty AIT clutch PC solenoid valve.
~
3. AlT Clutch PC Solenoid Valve Circuit In spection
Measure the voltage between the wire harness AIT CLUTCH PC SOLENOID VALVE
side 2P black connector terminals . 2P BLACK CONNECTOR (Terminal
Connection : Yellow/ red (+) - Btuelred H side of the wire harness)
Blue/red H Yellow/red (+ )
Is the voltage about 11 V?
YES - GO TO STEP 5.
NO - GO TO STEP 4.
'----( V )---'
14-17
DRIVETRAIN SYSTEM
4. AfT Clutch PC Solenoid Valve Line Open Circuit
Inspection
Disconnect the PCM 33P black connector. 2P BLACK
Q
Check Yellow/red and Blue/red wires for continu-
lty between the 33P black connector and 2P
black connector terminals.
33P BLACK CONNECTOR
Irr=;;;;~~~~;;~~~ )----,
CONNECTOR
TOOL:
Test probe, 2 pack 07ZAJ-RDJA110
YES - GO TO STEP 5.
NO _. Open circuit in the Yellow/red wire. Blue/red (A27) Q Blue/red
Open circuit in the Blue/red wire. Yellow/red (A26) Yel low/red
5. Failure Reproduction
Connect the NT clutch PC solenoid valve 2P
black connector and PCM 33P black connector.
Recheck the DTC with the HOS pocket tester.
Is OTC 4 1 or 43 indicated?
YES - Replace the PCM with a new one and
recheck.
DTC 4-2 IAIT CLUTCH PC SOLENOID

VALVE HIGH INPUT)
, . Recheck OTC
Recheck the current DTC with the HDS pocket
tester.
Is ore 4-2 indicated?
YES - GO TO STEP 2.
2. AfT Clutch PC Solenoid Valve Inspection
Disconnect the AIT clutch PC solenoid valve 2P AIT CLUTCH PC SOLENOID VALVE
black connector. 2P CONNECTOR (Terminal side of
Measure the resistance between the solenoid the solenoid valve)
valve side 2P black connector terminals.
Standard: 5.1 - 5.7 0: (ZO~C/68~ F)
YES - GO TO STEP 3.
NO - Faulty AIT clutch PC solenoid valve
valve.
14-18
DRIVETRAIN SYSTEM
3. AIT Clutch PC Solenoid Valve Line Short Circuit
Inspection
Disconnect the PCM 33P black connector.
Check the for continuity between the wire har- AfT CLUTCH PC SOLENOID VALVE
ness side 2P black connector terminal and 2P BLACK CONNECTOR (Termi nal
ground. side of the wire harness)
Connection: Bluelred - Ground Blue/red Yellow/red
Yellow / red - Ground
YES - . Short circuit in the Yellow/red w ire .
Short circuit in the Blue/red wire.
NO - GO TO STEP 4. Q
Connect the AfT clutch PC solenoid valve 2P
black connector and PCM 33P black connector,
Erase the DTe (page 6-13) .
Test-drive the vehicle and stop the eng ine.
Recheck the oTe with the HDS pocket tester.
recheck.
NO - Inter mittent failure.
DTe 15-1 (SHIFT SOLENOID VALVE A-

SHORT)
, . Recheck DTC
tester.
Is DTC 15-1 indicated?
YES - GO TO STEP 2.
ND - Intermittent failure.
2. Shift Solenoid Valve A Inspection
Disconnect the shift solenoid valve A 2P black
connector. SHIFT SO LE NOID VALVE A 2P CONNECTOR
Measure the resistance between the solenoid (Terminal side of the solenoid valve)
valve side 2P connector terminals.
Is th e resist ance within 14.6 - 16.2 il (20 aC/
68F) l
J b
YES - GO TO STEP 3. Ir
u
NO - Faulty shift solenoid valve A.
14-19
DRIVETRAIN SYSTEM
3. Shift Solenoid Valve A Une Short Circuit
Inspection
Check for continuity between the wire harness SHIFT SOLENOID VALVE A 2P BLACK
side 2P black connector termi na ls and ground. CONNECTOR
~Terminal side of the wi re harness)
Connection: Yellow / black - Ground
Green/white - Ground Yellow/black Green/white
YES _ . Short circuit in the Yellow/black wi re .
Short circuit in the Greenlwhite wire.
NO - GO TO STEP 4.
Q
Connect the shift solenoid valve A 2P black con-
nector and PCM 33P black connector.
Erase the OTC (page 613).
Test-drive the vehicle and stop the engi ne.
Recheck the OTe with the HDS pocket tester.
Is OTe 15-1 indicated 7
recheck.
DTC 15-2 (SHIFT SOLENOID VALVE A -

OPEN)
shift solenoid valve A 2P black connector for
loose or poor contacts, and recheck the DTC.
1. Recheck DTC
Testdrive the vehicle and stop the engine.
tester.
Is DTe 15-2 indicat ed?
YES - GO TO STEP 2.
2. Shift Solenoid Valve A In spection
Turn the ignition switch to OFF ~O).
Disconnect the shift solenoid valve A 2P black
connector. SHIFT SOLENOI D VALVE A 2P CONNECTOR
~Terminal side of the solenoid valve)
Measure the resistance between the solenoid
valve side 2P connector terminals. n n n
Is the r esistance within 14.6 - 16.2 n (200(;/ H

68 ~F)?
YES - GO TO STEP 3. II
u
NO - Faulty shift solenoid valve "A".
14-20
DRIVETRAIN SYSTEM
3. Shift Solenoid Valve A line Open Circuit
Inspection
nector. Yellow/bl"k ~
~ :n Q
Disconnect the peM 33P black connector.
Measure the resistance between the wire har-
ness side peM 33P black connector terminals.
TOOL:
Test probe. 2 pack 07ZAJ ROJA1'O ,
Connection:
Yellow/ black (A2) - Green /white (A13)
"~
Green/white (AI3)
Is the rBsistance within 14.6 - 16.2 n (20OC/
68"F}7 PCM 33P BLACK CONNECTOR
YES - GO TO STEP 4.
NO - . Open circuit in the Yellow/black wire .
Open ci rcuit in the Green/white wire.
nector and peM 33P black connector.
Erase the DTC (page 6-13).
Test-drive the vehicle and slop the engine.
Recheck the OTC with the HDS pocket tester.
Is OTC 15-2 indicated?
recheck.
DTe 16-1 (SHIFT SOLENOID VALVE B-

SHORT)
1. Recheck OTe
tester.
Is DTC 16-1 indicated?
YES - GO TO STEP 2.
2. Shift Solenoid Valve B Inspection
Turn the ignition switch to OFF {O J.
Disconnect the shift solenoid valve B 2P brown
connector. SH IFT SOLENOID VALVE B 2P CONNECTOR
Is the resistance within 14.6 - 16.2 {] (20<>(;1 J l
68"Fjl
YES - GO TO STEP 3. Ii'=:
NO - Faulty shift solenoid valve "B".
14-21
DRIVETRAIN SYSTEM
3. Shift Solenoid Valve B line Short Circuit
Inspection
Check for continuity between the wire harness SHIFT SOLENOID VALVE B 2P BROWN
side 2P brown connector terminal and ground. CONNECTOR
Connection: Yellow/green - Ground (Terminal side of the wire harness)
YES - Short circuit in the Yellow/green wire.
NO - GO TO STEP 4.
Connect the shift solenoid valve B 2P brown con-
Erase the DTG (page 6-13).
Test-d rive the vehicle and stop the engine.
Recheck the DTG with the HOS pocket tester.
Is OTe 16-1 indicated 7
recheck.
DTC 16-2 (SHIFT SOLENOID VALVE B -

OPEN)
shift solenoid valve B 2P brown connector for
loose or poor contacts, and recheck the DTC.
1. Recheck OTe
tester.
ts OTC 162 indicated 7
YES - GO TO STEP 2.
2. Shift Solenoid Valve B Inspection
Disconnect the shift solenoid valve B 2P brown
connector. SHIFT SOLENOID VALVE B 2P CONNECTOR
Is the resistance within 14.6 - 16.2 n (20"CI
68CfJ7
YES - GO TO STEP 3.
NO - Faulty shift solenoid valve B.
Q }---'
14-22
DRIVETRAIN SYSTEM
3. Shift Solenoid Valve B Input line Open Circuit
Inspection
Check the Yellow/green wire for continuity 2P BROWN
between the 33P black connector and 2P brown 33P BLACK CONNECTOR CONNECTOR
connector.
TOOL:
Test probe. 2 pack 07ZAJ-ROJA '10
~ .1 ]))
1$ there continuity?
Y."OW/9'~A ~:~/9,een
YES - GO TO STEP 4.
NO - Open circuit in the Yellow/green wire.
121
!Termi nal side of the wire harness)
4. Shift Solenoid Valve B Ground line Open Circuit

Inspection
Check for continuity between the wire harness
side 2P brown connector ter minal and ground. SHIFT SOLENOID VALVE B 2P BROWN
CONNECTOR
YES - Open circuit in the Green wire.
NO - GO TO STEP 5.
Connect the shift solenoid valve B 2P brown con-
Test-drive the veh icle and stop the engine.
Recheck the DTC with the HDS pocket tester.
Is DTe 16-2 indicated 7
recheck.
DTe 31-1 (SYSTEM VOLTAGE LOW)

Before starting the troubleshooting. check that
the battery is in good condition and recheck the
DTC.
1. PCM System Voh:age Inspection
Recheck the battery voltage in the Data list
menu of HDS pocket lester.
15 the voltage less than 9.3 V7
YES - GO TO STEP 2.
14-23
DRIVETRAIN SYSTEM
2. PCM Power Input Line Insp ectio n
Turn the ignition switch OFF.
Turn the ignition switch to ON (1), Black/green (B1)
side 33P gray connector terminal and ground.
TOOL:
Test probe. 2 pack 07ZAJRDJA110
Connectio n: Black/green (81 ) (+J - Gro und (-)

YES - GO TO STEP 3. PCM 33P BLACK CONNECTOR
NO - . Open circuit in the Black/green wire .
Blown IGN fuse.
3. Failure Re production
Connect the PCM 33P gray connector.
Erase the DTG (page 6-13).
Recheck the DTG w ith the HDS pocket tester.
Is OTC 3 1-1 indicated 7
recheck.
DTC 32-1 (FAIL SAFE RELAY CIRCUIT)

1. Recheck OTe
Erase the OTe (page 6-13).
Recheck the OTe with the HOS pocket tester.
Is DTe 32- ' indicated ?
recheck.
DTC 41 -1 (GEAR POSITION SWITCH

CIRCUIT)
gear position switch 3P black connector for loose
or poor contacts, and recheck the OTC.
1. Recheck OTe
Recheck the current OTC with the HOS pocket
tester.
Is DTC 41-1 indicated"
YES - GO TO STEP 2.
14-24
DRIVETRAIN SYSTEM
2. Gear Position Switch Ins pection at peM
Connector
Turn the ignition switch OFF.
Disconnect the peM 33P black connector. PCM 33P BLACK CONNECTOR
Check for continuity between the wire harness (Terminal side of the wire harness)
side 33P black connector termina ls and ground. Gray (A25) Light blue/whit e (A24)
There should be con t inuity in each gear position,
and no continuity in the other posit ion.
r-Gea r posit ion Connector tenninal =
~ronve Light blueJWfii<teiT.IA~2~4nJ-- j
~_~~utral) 19ht green/ red 1 ;q7~
I " (Reverse) Gray {~m J
Are the test results normBI? Light greenJ
red (A17)
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. GEAR POSITION SWITCH 3P BLACK
Check for continuity between the switch side 3P CONNECTOR (Terminal side of the switch)
black connector terminals and ground. Light bluelwhite green
There should be continuity in each gear position,
and no continuity in the other position.
~ ear position Connector tennr.in~'''I---
O- (Dnve 19 t ue white
. (NeufriJ 19 t green
- , everse ray
Are the test results normal?
YES - Open or short circuit in the Light
bluelwhite wire.
Open or short circuit in the Light
green/red or Light green wire.
Open m short circuit in the Gray
wi re.
NO - Faulty gear position switch.
Connect the PCM 33P black connector and gear
position switch 3P black connector.
Erase the DTC (page 6-13).
Testdrive the vehicle and stop the engine .
Recheck the DTC with the HDS pocket tester.
Is Dre 41 1 indicated?
YES - Replace the PCM wi th a new one and
recheck.
14-25
DRIVETRAIN SYSTEM
DTC 44-1 (EOT SENSOR LOW
VOLTAGE)
1. EDT Sensor System Inspection
Check the EDT sensor with the HOS pocket
tester.
YES - GO TO STEP 2.
2. EDT Sensor Inspection
Disconnect the EOT sensor 2P connector.
Check the EDT sensor with the HOS pocket
tester.
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. EDT Sensor Resistance Inspection
Turn the ignition switch t o OFF (0).
Measu re the resistance between the sensor side EOT SENSOR 2P CONNECTOR
2P connect or terminals. (Term inal side of the sensor)
Standard: 2.5 - 2.8 kO (20C/68Fl
15 th8 resistance within standard value?
YES - Replace the peM w ith a new one and
recheck.
NO - Faulty EDT sensor.
4. EDT Sensor line Snort Circuit Inspection

Oiscon nect the PCM 33P gray connector.
Check for con tinuity between tne wire harness EOT SENSOR 2P CO NNECTOR
side 2P connector terminal and ground . (Termi na l side of the w ire narness)
Connection: Orange - Ground
YES - Snort ci rcuit in the Orange wi re.
NO - Replace tne PCM with a new one and
recheck.
Orange
14-26
DRIVETRAIN SYSTEM
DTC 44-2 (EOT SENSOR HIGH
VOLTAGE)
Before starting the troubleshooting, ch eck the
EOT sensor 2P connector for loose or poor con-
tacts, and recheck the DTe.
1. EOT Sensor System Inspection
Check the EDT sensor with the HDS pocket
tester.
YES - GO TO STEP 2.
ND _ . Intermittent failure .
loose or poor contact on the EDT
sensor 2P connector.
2. EDT Sensor Inspection
Turn the ignit ion switch to OFF (0),
Disconnect the EDT sensor 2P connector. EDT SENSOR 2P CONNECTOR
Connect the wire harness side 2P connector ter- (Terminal side of the wire harness)
Connection: Orange - Green / b lack
Turn the ignition switch to ON (I~.
Check the EOT sensor with the HDS pocket
tester.
Orange Green/black
YES - Faulty EDT sensor.
NO - GO TO STE P 3.
JUMPE R WIRE
3. EOT Sensor Line Open Circuit Inspection

Remove the ju mper wire. Green/black (82) EDT SENSOR
~
2P CONNECTOR
Check for continuity between the wire harness PCM 33P GRAY n
side EOT sensor 2P connector and PCM 33P gray CONNECTOR '}G
connect or terminals.
TOOL:
Test probe. 2 pack 07ZAJ RDJA110 ++-t
Connection: Orange (828) - Orange
Green/ black (821- Green/ black
Is there continuity? Orange (828)
Orange
YES - Replace the PCM with a new one, and (Terminal side of the wire harness)
recheck.
NO _ . Open ci rcu it in the Orange wire .
Open ci rcuit in the Green/black wire.
14-27
DRIVETRAIN SYSTEM
SHIFT VALVE BODY
I NOTICE I
Do not drop or strike the solenoid valves when ser
vicing. 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 NT dutch 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 dur-
ing idling .)
The stopper bolt that operates the emergency
vallis is secured with the lock plate. When trou-
ble occurs, remove the lock plate and turn the
stopper bolt all the way in to activate the emer-
gency valve.
REMOVAL
6xlBmmBOlTS VAlVEBODYCOVEA
- left side panel (page 3 1 11
- wire clip
- two 6 x 18 mm bolts and washers
- 6 x 14 mm bolt and setting washer
- valve body cover
Clean around the Disconnect the following:

valve body wlrh
- shift solenoid valve A 2P black connector
compressed aIr ro
- shift solenoid valve B 2P brown connector
remove dust. dm
- AfT clutch PC solenoid valve 2P black connector
andforel{}n
ma renai
14-28
DRIVETRAIN SYSTEM
If the valve body Remove the following
wil/be
- six bolts (small head )
disassembled,
loos en the SIX
- shift valve body assembly
solenOid vawe boilS
and four sealing
bolts (large head)
Place a shop lowel
under the valve
body.
- gasket
- fou r oil joint collars
- O-rings
DISASSEMBLY IINSPECTION
NOTE :
Keep dust and dirt away from all the parts .
Take care not to damage the mati ng surfaces of
the valve bodies.
The emergency SOLENOID AND EMERGENCY VALVES
valvB IS built In rhe
NT clutch PC SHIFT SOLENOID VALVE A STAY
solenoid valve. - tow bolts and valve body cover stay
- shift solenoid valves A and B
- four bolts and AIT clutch PC solenoid valve
assembly
- rubber seal
AfT CLUTCH PC SOLENOID VALVE
14-29
DRIVETRAIN SYSTEM
Use a hand- Connect a pressure pump to the input port (filter
operared 8ft pump side) of the shift solenoid valve.
only Do nOI use 8
Connect a 12 V battery to the shift solenoid valve
high pressure 81f
connector terminals as shown and check for air flow
source
conditions.
SH IFT SOLENOID
VALVE A
12VBATIERY
CONNECTOR
EB 8
SHIFTSOLENOID
VALVE B
12 V BATIERY
CONNECTOR
Air should not flow (the pressure should be main- ~=================~

tained ) while the battery is connected, and should
flow out of the output ports that goes to the shift
valve when the battery is disconnected .
Connect the 12 V battery positive terminal to the AIT ~=================~

clutch PC solenoid valve connector terminals and
check the spool valve through the oil passages for
operation.
EB 8
NT CLUTCH PC
SOLENOID VALVE 12 V BATIERY
CONNECTOR
(Terminal side of the solenoid valve )
14-30
DRIVETRAIN SYSTEM
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 discon-
nected.
SPOOL VALVE
Remove the following from the linear solenoid ~~================~

assembly:
- screw and lock plate
- valve stopper bolt LOCK PLATE
- emergency valve
- valve spring
Blow lhrough all/he Wash aU the parts with a high flash point or non -
fl ammable solvent and blow dry them wi th com-
/ ~
011 passages
thoroughly pressed air to clean completely.
(includmg solenoid
valves}
Check the emergency valve and valve bore for scor- SPRING / ~
ing, scratch or abnormal wear.
EMERGENCY VALVE f
STOPPER BOLT
ORIFICE CONTROL AND SHIFT VALV ES
Remove the following: TS
- four bolts
- orifice control valve body
ORIFICE CONTROL VALVE BODY
- separator plate SEPARATOR PLATE

- shift valve body
SHIFT VALVE BODY
14-31
DRIVETRAIN SYSTEM
- two dowel pins
SEPARATOR PLATE
- separator plate
DOWEL PINS
- four seating bolts and washers
SEALING BOL WASHERS

Remove the following from the orifice control valve
ORIFICE CONTROL SPRING SEAT
body:
VALVE t
- spring seats
- valve springs
- orifice control valves (2nd and 3rdl
~
SPRING SEAT
ORIFICE CONTROL
VALVE t3rdl
Remove the following from the shift valve body:
SHIFT VALVE (1-21 SPRING SEAT
- spring seats
- valve springs
- shih valves (1-2 and 2-3)
81owthrougha/lrhe Wash all the parts with a high flash point or non-
oil passages flammable solvent and blow dry them with com-
thoroughly. pressed air to clea n completely.
Check the orifice control valves, shift valves and
valve bores for scoring. scratch or abnormal wear.
SPRING SHIFT VALVE (2-3)
14-32
DRIVETRAIN SYSTEM
ASSEMBLY
NOTE :
Before assembly, clean all the parts with compressed air. Make sure that there is no dust or lint on
any parts.
VALVE S\PRING ~ ~~ ~
EMERGENCY VALVE U U g NT CLUTCH PC
~.,..,.---,~ -",~iP~
SOLENOID VALVE
. t<i;
STOPPER BOLT - - - - . .
~~ " ~ RUBBER SEAL
?\
~
~@ ~.
SCREW LOCK PLATE (J CJ
SOLENOID VALVE BODY ----I~Qil~F~~'U;;\l SHIFT SOLENOID VALVE B
SEPARATOR PLATE
-
,-
)..
;:::';~_ SHfFTSOLENOlD
VALVE A
"'<'''-./
SHIFT VALVE BODY
SHIFT VALVE 12-3) ~ X'~~ SHIFT VALVE (1-2)
~ _ _----;; SEPARATOR PLATE

SPRING SEAT - _ _ ~ "\ _;& _ '" ~
.?" --
VALVE SPRING /"-: ~~~:.
"-" .J~
VALVE SPRING / <:> ~ IV
\ ~1l0'
SPRINGSEAT--- V
J..
'
~r~~
/
~~
~~
ORIFICE CONTROL
VALVEI2nd)
ORIFICE CONTROL
VALVE (3rd)
~
Jb
ORIFICE CONTROL
VALVE BODY
SHIFT AND ORIFICE CONTROL VA LV ES

Apply engine oil to the shift valves. SHIFT ,,.,,,. (1-2) SPRING SEAT
Install the spring Insert the shift valves (1-2 and 2-3) and spr ings into -:7I!l
seats with the slit the shift valve body and secure them with the - III
facmg away from spring seats.
the ortfice control
valve body (page
14-33J.
~
SPRING SEAT SPRING
,
SHIFT VALVE (2-3)
14-33
DRIVETRAIN SYSTEM
Apply engine oil to the orifice control valves.
ORIFICE CONTROL SPRING SPRING SEAT
~~
Install the sprmg Insert the orifice control valves (2nd and 3rd) and VALVE
seats with rheslit springs into the shift valve body and secure them
facmg away from with the spring seats.
the shift valve body
(page 14-33)
~
SPRING SEAT
\
ORIFICE CONTROL
VALVE (3rd)
Install the four sealing bolts into the solenoid valve

VALVE COVER
body with new sealing washers.
SEALING BOL
....
J"
WASHERS
- two dowel pins
- separator plate
- shift valve body
- separator plate ORIFICE CONTROl VALVE BODY

- orifice control valve body
SEF'ARATC)R PLATE
14-34
DRIVETRAIN SYSTEM
Install the four boils and tighten them securely.
BOLTS
SOLENOID AND EMERGENCY VALV ES

Coat a new O-ring with engine oil and install it into ,----------;;S~C~R~E~W
::---,-
L~O~
C~K~P
=L-A
~T=E:-,
the stopper bolt groove.
Apply engine oil to the emergency valve. STOPPER BOLT
Install the spring and emergency valve inlO the AfT
clutch PC solenoid valve body with the concave end
of the valve facing in.
Install the valve stopper bolt and turn it in until the
groove edge is aligned with the valve body surface.
Secure the stopper bolt with the lock plate as shown
and tighten the screw. ORING II!
SPRING - - - "~ ~,
-"1 EMERGENCY VALVE ~
Coat a new rubber seal with engine oil and install it ~Aff
==C=L=U:T:C:H=P=C======:;:====~
into the groove in the AfT clu tch PC solenoid valve SOLENOID VALVE
body.
Install the AfT clutch PC solenoid valve assembly \
and four bolts onto the solenoid valve body, and
lighten the bolts.
"/II RUBBER ~
Iii SEAL ........
Coat new O-rings with engine oit and install them SHIFT SOLENOID SHIFT SOLENOID
into the grooves in each shift solenoid valves. VALVE B VALVE A
Do nor mrerchange Install shift solenoid valves A and B into the sole-
valves A and B noid valve body.
14-35
DRIVETRAIN SYSTEM
Install the valve body cover stay and two bolts, and COVER STAY
tighten the bolts.
BOLTS
INSTALLATION
Clean the mating surfaces of the valve body assem
bly and front crankcase cover, being careful not to
damage them.
into the grooves in the oil joint collars.
In stall the four joint collars and a new gasket.
Install the shift valve body assembly with the six

bolts and tighten bolts securely.
Connect the following:

- shift solenoid valve A 2P black connector
- shift solenoid valve B 2P brown connector
- AJT clutch PC solenoid valve 2P black connector
14-36
DRIVETRAIN SYSTEM
Install the valve body cover with the three bolts and
CONNECTORS
washers, and lighten bolts.
Install the wire clip into the body cover.
Check the transmission oil pressure if necessary
(page 148) .
- leh side panel (page 3-11)
- driver seat under cover (page 3-6)
FRONT CRANKCASE COVER

REMOVAL
- water pump (page 7-9)
- front propeller shaft (page 19-12)
- shift valve body (page 14-28)
Loosen the pipe setting cap.
fourteen bolts
- front crankcase cover
- two oil joint pipes and O-rings

- oil orifice and O-rings
- two dowel pins
- pipe setting cap and O-ring

- oil feed pipe C
14-37
DRIVETRAIN SYSTEM
- pipe setting collar !by pushing it from the inside
with a suitable rod) and O-rings
- oil feed pipe C and O-ring
- output shaft oil seal
- oil filter (page 4-14) OIL PIPE JOINT OIL PATH BOLT, O-RING
- dipstick
-
-
-
sealing bolts and washers
oil path bolt and O-ring
three bolts, oil pipe joint and O-ring
., ~~)
Wash the crankcase cover with solvent and blow
through all the passages with compressed air to
clean them thoroughly.
'\
~,,'"
DIPSTICK SEALING BDl.TS. WASHERS
INSPECTION
Check feed pipes A, Band C for abnormal wear or
damage.
NOTE .
The operating (engine) oil of each shift clutch is
supplied through the following:
- feed pipe A for the 1st shift clutch
- feed pipe B for the 2nd shift clutch
- feed pipe C for the 3rd shift clutch
Check the crankshaft seal collar 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 14-39),
14-38
DRIVETRAIN SYSTEM
BEARING REPLACEMENT
Remove the crankshaft bearing usin g the special
CRANKSHAFT BEARING
toots.
TOOLS :
07936371020A or
07936-3710200
(U.S.A . only)
Drive the output shaft bearings out of the crankcase
cover.
Remove the snap ring, washer, and the seal coltar.

Coat a new Oring with engine oil and install it in to
the groove in a new collar.
Be careful not /0 Install the collar until it is seated.
damage the mner Install the washer and the snap ring into the cover
surface of the groove properly.
collaf
Drive new bea rings in with the marked side facing

up.
TOOLS:
Crankshaft bearing :
Driver 077490010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 17 mm 07746-0040400
Output shaft bearing :
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot. 25 mm 07746-0040600
INSTALLATION
Clean the crankcase and cover mating surfaces.
Coat a new D-ring with engine oil and inst all it int o
the oil pipe joint groove,
Inst all the oil pipe joint and three bolt s and tighten
the boils.
Coat a new D-ring with engine oil and install it into
the oil path bolt groove.
Install the oil path bolt and tighten it.
TORQUE: 18 N 'm (1 .8 kgfm , 13 Ibf.ft)
14-39
DRIVETRAIN SYSTEM
SEALING BOLTS, WASHERS
- sealing bolts with new washers
- dip stick
- oil filter (page 4-14)
Apply engine oil to the lips of a new oil seal, and

install it into the crankcase cover until it is fully
seated.
Coat new O-rings with engine oil and instal l them

onlo the joint pipes.
Inslallthe joint pipes into the oil pump.
Apply liquid sealant (Three Bond 1215 or equiva- ~=~IIIIIIIIIIII'===-___-=::::::=~IIIIIIIIIIII~

lent) to the mating su rface of the front crankcase
cover as shown.
14-40
DRIVETRAIN SYSTEM
Blow the oil orifice with compressed air to clean the
passage.
into the orifice grooves.
Install the oil orifice with the small end facing out.
Make sure the Install the following front crankcase cover.

mating surfaces Install the fourteen bolts and tighten them in a criss-
touch evenly. There cross pattern in several steps.
should be no
clearance between
rfle cover and
crankcase.
Coat a new O-ring with engi ne oil and install it onto

the flange of the feed pipe B.
Apply engine oil to the outer surface of pipe B.
Align the flange Carefully insert feed pipe 8 wh i le turning it slowly to
tabs with the avoid damaging the oil seal in the cra nkcase.
grooves In the
cover.
14-41
DRIVETRAIN SYSTEM
into the selting collar grooves.
Install the setting collar until it is seated.
Apply engine oil to the outer surface of feed pipe C.

Align the flange Insert feed pipe C while turning it slowly to avoid
labs with the damaging the O-ring in the setting col lar.
grooves In the
collar
the setting cap groove.
Install the setting cap and tighten it.
TORQUE: 21 Nm (2.1 kgfm, 15Ibfft)
- shift valve body (page 1436)
- front propeller shaft (page 1939)
- water pump (page 7-10)
TORQUE CONVERTER
REMOVAL
Remove the front crankcase cover (page 14-37).
Be careful not 10 Unstake the lock nut.
damage the loosen the lock nut while holding the converter
crankshaft threads boss with an open end wrench (width across flats:
32 mm).
Remove the lock nut and washer.
Remove the torque converter assembly using the

special tools.
TOOL
Puller, 35 x 1.0 mm 07933-HABOOOO o r
07933-HB3000A
(U.S.A. only)
14-42
DRIVETRAIN SYSTEM
- stator shaft (while turning it counterclockwise)
- needle bearings
- washers
- thrust needle bearing
- inner colla r
- needle bearing
INSPECTION
NOTE .
Replace the torque converter as an assembly
(from converter to inner collar).
Check the primary drive gear 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.
Check the needle bearings for abnormal wear or

damage. SPRAG CLUTCH
Check the sprag clutch in the stator shaft for abnor-

mal wear, damage or irregular movement.
Check the sprag clutch contacting surface of the
inner collar for abnormal wear or damage.
STATOR SHAFT INNER COLLA.R
14-43
DRIVETRAIN SYSTEM
Check the seal ring on the stator shaft for deteriora-
tion, waar or damage. SEAL RING
Assemble the stator shaft and inner colla r.

Hold the inner collar and turn the stator shaft.
The shaft should turn counterclockwise smoothly
and should not tu rn clockwise.
TORQUE CONVERTER INSTALLATION

Lubricate the bearings, gear teeth and sprag clutch.
INNER COLLAR
TORaUE COIWERTE'R
14-44
DRIVETRAIN SYSTEM
Install the needle bearing into the inner collar.
Install the inner collar onto the crankshaft by align-
ing the cutout with the stopper pin.
Install the thrust needle bearing onto the inner col-
lar with the needle roller side facing in.
Install the washers.
Install the two needle bearings into the stator shaft

NEEDLE BEARINGS
from both sides.
Install the needle bearing onto the stator shaft.
Install the stator shaft onto the crankshaft and t he

inner collar while turning it counterclockwise.
Install the torque converter by aligning the splines

carefully, and engaging the primary drive and
d r iven gear teeth.
Install the washer.
14-45
DRIVETRAIN SYSTEM
Apply engine oil to the threads of a new lock nut.
Install the lock nut and tighten it while holding the

converter boss with an open end wrench (w idth
across flats: 32 mm).
TORQUE : 11 8 N'm (1 2.0 kgfm, 87 rblttl
Be careful flO! to Stake the lock nut into the crankshaft groove.
damage the
Install the front crankcase cover (page 14-39)
crankshaft rhreads
14-46
DRIVETRAIN SYSTEM
SHIFT CLUTCH/MAINSHAFTI
COUNTERSHAFT
1st SHIFT CLUTCH REMOVAL
Remove the torque converter (page 1442).
Be careful nOl to Unstake the lock nut.
damage the
Loosen the lock nut while holding the driven gear
mamshah threads
boss with an open end wrench (width across flals:
29mm).
- lock nut
- washer
- lsI shift clutch assembly
- washer
- Ml gear guide
- a-rings
Remove the primary driven gear by prying it.

DRI'VEN GEAR
Remove the O-rings from the primary driven gear.
MAINSHAFT DISASSEMBLY
Remove the mainshaft (page 13-7). M3 GEAR SNAP RINGS
- Ml gear
- needle bearing
- washer
- M3 gear
- snap rings
- M2 gear
M2 GEAR Ml NEEDLE BE',R"'G
14-47
DRIVETRAIN SYSTEM
COUNTERSHAFT DISASSEMBLY
Remove the countershaft (page 13-7).
C2 GEAR Cl
- end washer
C1 gear
thrust washer
C2 gear
bearing
lock washer
END WASHER
- C3 gear
THRUST WASHER 2nd/3rd SHIFT
- bearing
CLUTCH ASSEMBLY
- thrust washer
- 2ndJ3rd shift clutch assemblv
- O-rings
C3 GEAR ENOWASHER
SHIFT CLUTCH DISASSEMBLY
NOTE:
The following procedures are for the 1st clutch.
The procedures for the 2nd and 3rd clutches are
the sa me as for the 1st clutch.
- stopper ring
- end plate
END
- three clu tch discs and plates
- wave spring CLUTCH DISCS
CLUTCH PLATES
14-48
DRIVETRAIN SYSTEM
If either sup port InstaH the speciallools onto th e shih clutc h.
SUPPC)RT BLOCKS COMPRESSOR BOLT
block end IS set
TOOLS:
over an area of the
Clutch compressor attachment 07LAE-PX40100
(el8mer which IS
unsupported by the (2 required)
rerum sprmg. theCompressor bolt assembly 07GAE-PG40200 or
Support area
retamer may be 07GAE-PG4020A
d8tmJged. (U.S.A. only)
NOTE'
Be sure the special tool is adjusted to have full
contact the stepped areas with the spring
retainer.
ATTACHMENT
To prevenr loss of Compress the return spring by tightening the nut.

spong tens/Ofl, do Remove the snap ring from the boss. RETURN SPRING
not compress more
Loosen the nut and remove the special tools, snap
than necessary.
ring, spr ing retainer and return spring.
RING
Wrap a shop l owel around the clutch drum .
Apply ai r pressure to the oil hole while closing the
other holes with your finger to remove the clutch
piston.
Remove the a -rings from the piston.
Clean all the parts of the shift clu tch in solvent thor-
oughly and blow dry them with compressed air.
INSPECTION
MAINSHAFTt COUNTERSHAFT
The M I gear Check each gear tooth and need le bearing for M1
NEEDLE BEARING
bearing has one abnormal wear or damage.
roller miSSing from
Check the oil holes in the mainshaft and
each cage by
countershaft for dogs.
deSign
M3
14-49
DRIVETRAIN SYSTEM
CLUTCH DRUM AND PISTON
Check the clutch drum for nicks, indentations or
PISTON CHECK VALVE
abnormal wear made by the clutch plates.
Check the oil holes in the drum boss and check
valve in the piston for clogs.
CIIIJTC:H DRUM
CLUTCH DISC AND PLATE
Replace the c/ufch Check the linings of the clutch discs f or wear (disc
DISC PLATE
diSCS and plal8S 85 groove disappearance) .
....../
8set Check the clutch plates for discoloration.
CLUTCH RETURN SPRING

Measure the spring free length.
SERVICE LIMIT: 31.8 mm (1 .25 in)
14-50
DRIVETRAIN SYSTEM
SHIFT CLUTCH ASSEMBLY
1st SHIFT CLUTCH
CLUTCH DISCS (3 pes) CLUTCH PLATES (3 pes)
END PLATE
STOPPER RING
\
/
I PRIMARY DRIVEN GEAR
~-=</
WAVE SPRING
SPRING RETAINER~r;--~
'jVA&
~
~\~ \
O-RINGS
CLUTCH PISTON
SNAP RING RETURN SPRING
2nd/3rd SHIFT CLUTCH
DRUM
CLUTCH PISTON
CLUTCH PLATES (3 pes)
CLUTCH I (3 pes) SPRING RETAINER
END PLATE
WAVE SPR ING /'
RETURN SPRING
RING
14-51
DRIVETRAIN SYSTEM
NOTE:
The following procedures are for the 1st clu tch.
The procedures for the 2nd and 3rd clutches are
the same as for the 1st clutch.
Clean the inner surface of the clutch drum thor-
PISTON
oughly and blow through the oil holes in the drum
boss and check valve in the piston.
Apply engine oil t o new O-rings and install them
into the piston grooves.
Place the clut ch piston into the clutch drum with the
flat side facing in.
Be careful nor tD Install the piston while turning it to ensure proper

ponel! the O-rings seating.
wnh too much
I"".
Place the return spring, spring retainer and snap

ring into the clutch drum.
Install the special tools while adjusting their posi-
tion carefully (page 14-49).
To prevenr loss of Compress the return spring by tightening the nut.
spring tension, do
not compress more
tllan necessary
SNAP RING RETURN SPRING

Al'pn tile end gap Install the snap ring into the groove in the drum
wltll tile groove (3 boss property.
places) In tile spnng
loosen the nut and remove the special tools.
retainer
SNAP RING
14-52
DRIVETRAIN SYSTEM
Install the wave spring into the piston groove.
Coat the clutch discs with engine oil.
Inst all the three clutch plates and discs alternately,
starting with the plate.
CLUTCH PLATES
Install the end plate with the stepped side facing <T(lPPIFR RING
out.
Install the st opper ring into the drum grooves prop-
erly,
Check the clutch initial clearance (page 14-53).
END
CLUTCH INITIAL CLEARANCE CHECK

Set a dial indicator on the end plate with the plate
lowered .
lift the end plate up against the stopper ri ng and
read the clearance. and record it.
Perform this inspection at the three points in 120Q
apart .
STANDARD: 0.7 - 0.9 mm (0.03 - 0.04 in )
If the clearance is not wi thin the st andard value,
select the replacement end plate as follows:
Remove t he stopper ring and end plate.

Measure the flange thickness of the end plate at
several points and record it.
Calculate the new plate thickness using the equa-
tion below. Choose a new plate as close to this
dimension as possible.
A = (8-0.8) + C
A: New plate thickness
8: Recorded clearance
C: Old plate thickness
14-53
DRIVETRAIN SYSTEM
If the calculated Select the end plate from the table below.
STOPPER RING
dimenSion IS over
the thickest plale 1st CLUTCH 2nd/ 3rd CLUTCH
thlCl:ness, rtJPlace Maot Thickness Maot Thickness
the clutch discs and 1 2. 1 mm 1 2.3mm
plates 8S B S81
2 2.2mm 2 2.6mm
3 2.3 mm 3 2.9mm
2.4 mm
3.2mm
2.S mm
2.6mm
3.5mm
6
7 2.7m m "
12
2.15 mm
2.45 mm
1.9mm 13 2.75 mm
- '2" 2.0mm 1. 3.05 mm END PLATE
3.35 mm
"
16 3.65 mm
Install the end plate into the drum.
Install the stopper ring into the drum grooves prop-
erly.
COUNTERSHAFT ASSEMBLY
LOCK WASHER
THRUST WASHER
C1 GEAR
END WASHER
~@~o'
I
2nd13rd SHIFT CLUTCH
Blow through the oil passages in the countershaft

with compressed air.
into the shaft grooves as shown.
Install the countershaft int o the 2ndl3rd shift clutch
bV aligning the splines.
~ O-RINGS :II
2nd/3rd SHIFT CLUTCH
14-54
DRIVETRAIN SYSTEM
Apply engine oil to the gear teeth and needle bear-
ing and install the following: NEEDLE BEARING
- thrust washer
- needle bearing
- C3 gear
- end washer
~ C3
Install the lock washer by aligning the four grooves
with the tabs on the clutch drum boss. LOCK WASH""

ing and install the following:
- needle bearing
- C2 gear
- thrust washer
- C1 gear
- end washer
Install the countershaft assembly (page 1310).
~ C3
MAINSHAFT ASSEMBLY
Blow through the oil passages in the mainshaft with
compressed air.
Ins/all fhe snap ringApply engine oil to the gear teeth and install the
wi th the cham fered following:
(rolled) edge facmg M2 gear
to the gear - snap rings (so that its end gap aligns with the
groove in the splines)
- M3 gear (with the ribs facing out )
Make sure the snap rings are fully seated in the
shaft grooves.
SNAP RINGS
14-55
DRIVETRAIN SYSTEM
The MI gear
bearing has one
roJler mlssmg (rom
ing, and install the following: --"'1 M 1 GEAR
- thrust washer
each cage by
- needle bearing
design
- Ml gear
Install the mainshaft assembly (page 13-10).
THRUST WASH"R NEEDLE BE"RI.'G

1st SHIFT CLUTCH INSTALLATION
Blow through the oil holes in the primary driven
gear boss with compressed air.
Coat new O rings with engine oil and install them
into the grooves in the driven gear boss.
Install the driven gear into the 1st shift clutch until it
is fully seated.
Apply engine oil to the gear teeth and install the Ml

gear guide and washer onto the mainshaft.
into the mainshaft grooves.
Line up the tabs of the three clutch discs in the shift

clutch.
Align the d,scrabs Carefully install the 1st shift clutch assembly onto
w,rh lhe gear gUIde the mainshaft and onto the Ml gear guide until it is
leerh fully seated (the whole of the shaft threads are
exposed).
14-56
DRIVETRAIN SYSTEM
Apply engine oil to the threads of a new lock nut.
Install the washer and Jock nUl.
Tighten the lock nut while holding the driven gear
boss with an open end wrench (width across flats:
29mm).
TORQUE: 108 N'm (11.0 kgfm. 80 Ibfttl
Be careful not to Slake the lock nut into the mainshah groove.
damage the
Install the torque converter (page 14-44).
mamshaft threads

REPLACEMENT
3P BLACK CONNECTOR
Disconnect the gear position switch 3P black con-
nector.
Release the gear position switch wi re from the

clamps.
Shift the sub-transmission into neutral.
Remove the two bolts and the gear position switch
from the rear crankcase cover.
Coat a new O-ring with engine o il and install it onto

a new gea r position switch.
Align the long end of the switch pin with the " N "
ma r k.
Install the gear position switch by aligning the
switch pin with the slot in the crankcase cover being
careful not to damage the switch pin.
Inst all the two bolts and tighten them.
Route the gear position switch wire properly (page
1-2 1 ).
14-57
DRIVETRAIN SYSTEM
Con nect the gear position switch 3P black connec-
3P BLACK CON N ECTOR
tor.
- engine front cover (page 36)
- mudgua rd (page 3-12)
EOT SENSOR
REPLACEMENT
Drain the engine oil (page 4-13)
Remove the maintenance lid (page 3 -16),
Disconnect the 2P black connector from the EDT
sensor.
Remove the EDT sensor and seali ng washer.
Install a new EOT sensor with a new sealing washer
and tighten it.
TORQUE: 12 N-m 11.2 kgfm , 9 Ibf.ft)
Connect the 2P black connector to the EDT sensor.
Install the mai ntenance lid (page 3- 16).
Fill the engine with recommended oil (page 4- 13).
14-58
15. FRONT WHEEL/SUSPENSION
SYSTEM COMPONENTS 152 TIRES 156
SERVICE INFORMATION 153 FRONT WHEEL HUB AND KNUCKLE 1510
TROUBLESHOOTING .... 155 FRONT SUSPENSION ARM .................. 15 17
FRONT WHEEL 156 FRONT SHOCK ABSORBER ............ ...... 1521
15-1
SYSTEM COMPONENTS
12 Nm (1.2 Ibf.ft)
49 N 'm (5.0 Ibf.ft)

11 Nm (1.1 kgfm,
8Ibfft)
, 1 N'm ( 1.1 kgfm,

B Ibf.ft)
108 N'm (11 .0 kgfm,
l' Nm (1,1 kgfm, 8Ibf.ft)
137 Nm (14.0 kgfm,

101 IbUt)
49 Nm (5.0 kgfm, 36 Ibf.ftl
108 N'm (11.0 kgfm , 80 Ibf.ft)
15-2
SERVICE INFORMATION
GENERAL
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
A jack or other support is required to support the vehicle (page 1-48),
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 4-27).
For brake system service, see Brake System section (page 18-2!.
For steering system service, see Steering System section (page 16-2).
SPECIFICATIONS
ITEM _ _----'ST'.!,AN DARD SERVICE LIMIT
Minimum tire tread depth _ _--+--"4 mm (0.2 in)
Cold lire pressure 1I~js~taa~n~d~a!'

With ca ~ d~======j7~oi
rgo k~p!a:tlo[.~7O~k~9~
70 kPa (0.70 kgflcmf/~cm?',~'~Ot'05:fP~Stt;I==_=t=~====j
10.0 psi)
TORQUE VALUES
Wheel nut 108 N 'm ('1.0 kgfm. 80 Ibf.fl)
Wheel hub nut 137 N'm (14.0 kgf.m, 101 Ibfft) Castle nut: tighten to the specified t orque and
further tighten until its grooves aligns with the
cotter pin hole.
Brake disc bolt 42 N'm (4.3 kgfm, 31 Ibf.ft) ALOe bolt: replace with a new one.
Brake disc splash guard socket bolt 11 Nm 0.' kgfm, 8Ibfft) ALoe bolt: replace with a new one.
Drive shaft outboard guard (at caliper) l' N'm (1.1 kgfm, 8Ibfft) ALoe bolt: replace with a new one.
Drive shaft guard bolt (at lower arm) 11 N'm (T.l kgfm, 8Ibfft) ALOe bolt: replace with a new one.
Shock absorber mounting nut 44 N'm (4.5 kgfm, 33 Ibfft) Lock nut: replace with a new one.
Brake hose damp bolt 12 N'm (1.2 kgfm,9Ibf.ft ) ALOe bolt: repla ce with a new one.
Upper and lower arm pivot nut 64 N'm (6.5 kgfm, 47 Ibfft) Lock nut: replace with a new one.
Upper and lower arm ball joint nut 49 N'm (5.0 kgfm, 36 Ibfft) Castle nut: tighten to the specified torque and
cotter pin hole.
Tie-rod joint nut 49 N'm (5.0 kgfm. 36 Ibfft) Castle nut: tighten t o the specified torque and
cotter pin hole.
Front brake caliper mounting bolt 108 N'm (11.0 kgfm, 80 Ibfft) ALoe bolt: replace with a new one.
15-3
TOOLS
Driver Attachment, 62 x 64 mm Oil seal driver attachment

077490010000 07947-6340400 07947-6340201
or 07AMO-HL lA 100 (U.S.A. only) or 07AMO-HL 1A 100 (U.S.A. only)
Ball joint base Installer attachment Driver attachment

079655800300 07LAD-PW50601 07HMOMR70100
or 07JAF-SH20200
Ball joint base Ball joint remover/installer Ball joint base

07JMF HC50120 07JMF-HC501'O 07JAFSH20200
or 07746-0020400
Ball joint remover, 28 mm ATV Bead Buster

07MACSl00200 KlS379024 (U.S.A. only)
15-4
FRONT WHEEl/SUSPENSION
TROUBLESHOOTING
Front wheel wobbling
Bent rim
Worn or damaged knuckle bearing
Faulty tire
loose wheel hub nut
Loose front suspension fasteners
Soft suspension
Weak shock absorber spring
Oil leakage from damper unit
Stiff suspension
Damaged shock absorber damper
Faulty shock absorber pivot bushings
Improperly installed suspension arms
Faulty suspension arm bushings
Front suspension noise
Faulty front shock absorber
Loose front suspension fa steners
Worn suspension pivot bushings
Damaged suspension components
Steers to one side or does not track straig ht
Unequal tire pressure
Damaged suspension arm or frame
Weak shock absorber
Incorrect wheel alignment (page 4-27)
Faulty steering system components (page 16-2)
15-5
FRONT WHEEL
REMOVAL
loosen the wheel nuts.
Raise the front wheels off the ground (page 1-48).
Remove the nuts and wheel.
INSTALLATION
Clean the mating surfaces of the wheel and hub
thoroughly.
Install the wheel and the nuts with the tapered side
facing inward, and tighten them.
TIRES
REMOVAL
NOTE:
This service requires the ATV Bead Buster
(KlS379024) .
Remove and install the lire from the rim side
opposite the valve stem.
Remove the core from the valve stem.
Use a pneumatic tire changer or equivalent to
remove the tire from the rim. If a tire changer is not
available, rim protectors and tire irons may be used.
Adjust the bonom rim supports to the proper rim
size. Align the flat side of Ihe support with the corre- RIM SUPPORTS
sponding rim size indicator.
USB only water 85 8 Lube the bead area of Ihe tire with water, pressing
lubricant when down on the tire sidewall/bead area in several a::1I32 .
remoVlflg or places to allow the water to run into and around the
mounting tires bead. o
Soap or some
mounting lubricants
may leave a sltppery
residue whICh can
00
cause the r,re to
shift on the (1m and
lose /lfe pressure (I. 'l~
during dflvmg
Place the wheel assembly over the center shaft and
use the correct size cone to keep the wheel centered
CENTER SHAFT-----... NUT
during operation.
Install the bonom hold down nut, beating side
down, and finger tighten it so the wheel can rotate CONE
freely du ring operation .
r~
- -----'I e
I..t L'-:
~ ,\;i"1
15-6
Install the breaker arm assembly over the center
shaft and adjust the upper r im supports t o fit the BREAKER ARM ASSV. NUT
outside rim diameter.
Install the top hold down nut and tighten it finger
tight.
UPPER RIM SUPPORTS

Failure 10 back out Pull the leverage bar down so the breaker shoe is
Ihebreakershoe just below the rim lip. Turn the crank to fully push
two rums wl/lcause the breaker shoe between the ti re bead and rim . LEVERAGE BAR
rhe shoe to scratch Once the shoe contacts the rim, back the crank out
the bead lock, two turns to allow the shoe t o clear the rim 's bead
which may cause lock.
rhe /;re /0 leak.
Push down on the leverage bar to push the tire bead

over the bead lock. Use only short strokes on the
handle. While the shoe is still engaged, turn the
wheel as far as it will go between strokes as you
break the bead around the rim.
Remove the breaker arm assembly and flip the
wheel over. Install the breaker arm assembly, adjust
the shoe properly and break the other bead by fol-
lowing the above procedures.
!
Remove the tire from the rim using a tire changing
machine or ti re irons and rim protectors.
15-7
FRONT WHEEUSUSPENSION
TIRE REPAIR
NOTE:
Use the manufacturer's instructions for the tire
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 1518 in)
should be a section repair.
Section repairs should be done by a professional
tire 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.
Becarefulnorro Twist the needle and remove it from the tire; the
push tile plug all /he plug will stay in the tire.
W8V into the /,(e to
prevent from fallmg
mSlde
Trim the plug 6 mm (1/4 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 manufac
turer'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 tire (page 15-6) and apply a cold patch
to the inside of the tire.
15-8
If a plug has been inserted, trim it even with the
inner tire 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 ti re
I
buffer or a wire brush. Clean the rubber dust from
the buffed area .
Apply cement over the area marked and allow it to

dry until tacky.
Do not touch the cement with dirty or greasy hands.
Remove the li ning from the patch and center over
the injury.
Press the patch against the injury using a special
roller.
ASSEMBLY
Install the tire onto the rim , where the rim shoulder
width is the narrowest, to simplify installation.
Clean the rim bead seat and flanges.
Use only water as a Apply clean water to the rim flanges, bead seat and
IUOflcam when base.
(emoVlng Of
Install the valve core in the valve stem.
mountmg tlfes
Install the tire with the arrow mark facing in the nor-
Soap or some
mal rotating direction.
mountmg lubricants
Inflate the tire to seat the tire bead.
may leave a slippery
reSidue which can Deflate the tire. Wait 1 hour and inflate the tire to
cause the fire 10 the specified pressure.
Shift on the rim and
lose IN pressure
RECOMMENDED TIRE PRESSURE:
durmg dovmg FRONT:
Standard: 70 kPa (0.70 kgflcm2, 10.0 psi)
With cargo: 70 kPa (0.70 kgf /cm2, 10.0 psi)
REAR :
Standard: 70 kPa (0.70 kgf/cm2, 10.0 psi)
With cargo: 70 kPa (0.70 kgf/cm2, 10.0 psi)
Check for air leaks and install the valve cap.
15-9
FRONT WHEEL HUB AND KNUCKLE
REMOVAL
Remove the front wheel (page 15-6).
CALIPER
SUppoIl the cal'per Remove the following:
so thallI does no! - two setting bolts and outboard guard
hang from the brake - two mounting bolts and brake caliper
hose. Do not tWIst
or bend the brake
hose
- cotter pin
- hub nul
- wheel hub
- dust seal (from the hub)
,
DUST SEAL
- three socket bolts

- splash guard
GUARD
15-10
brake hose clamp bolt
- coner pins (from the ball joint studs)
Loosen the ball joi nt nuts, but do not remove them
yet.
COTTER PIN
AND NUT
To prevent the knuckle from falling, support it with a
strap.
Release the three ball joints, using the special 1001
according to the following instructions.
TOOL:
Ball joint remover, 28 mm 07MAC-SL00200
BALL JOINT REMOVER

Apply grease 10 the ball joint remover at Ihe point
Apply here BOLT
shown.
This will ease installation of the tool and prevent
damage to the pressure bolt threads.
Insert Ihe jaws carefully, making sure that you do
,,,
not damage the bal l joint boot.
If necessary, apply Adjust the jaw spacing by turning the pressure bolt.
penetraMg type
lubricant to loosen
the bali/oint.
15-11
To prevent the tool from dropping, tie the strap 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, turn the adjusting bolt as

necessary to make the jaws parallel. I~======;';~~~~B;O~LT;=====l
Then hand-tighten the pressu re bolt and recheck the
jaws to make sure they are stil l parallel.
Tighten the pressure bolt with a wrench until the
ball joint stud pops loose.
Remove the ball joint nuts and the knuckle.
ADJUSTING BOLT
INSPECTION
Remove the dust seals from the knuckle.
Turn the inner race of the bearing in the knuckle
with your finger. The bearings should turn smoothly
and quietly. Also check that the bearing outer race
fits tightly knuckle.
Inspect the knuckle for damage or cracks.
Inspect the ball joint boot for tears or other damage
by moving the ball joint stud.
It should move freely and smoothly.
BRAKE DISC REPLACEMENT

Remove the four bolts and brake disc from the
wheel hub.
Do not ge r grease Install a new brake disc with the stamp mark facing
on the brake disc or the hub.
sloppmg power will Instan new disc bolts and tigh ten them.
be reduced.
TORQUE: 42 Nm (4.3 kgfm. 31 Ibf.ftl
BOLTS :11
15-12
FRONT WHEEl/SUSPENSION
BEARING REPLACEMENT
Remove the snap ring.
Press the bearing 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 07749-0010000
Attachment, 62 x 64 mm 07947-6340400 or
Driver attachme nt 07AMD-HllAl00
(U .S.A. only)
Install the snap ring into the knuckle groove with the
chamfered side facing in.
BALL JOINT REPLACEMENT

Remove the snap r ing from the ball joint.
Set the knuckle and special t ools in the vise as

shown.
Press the ball joint out of the knuckle.
TOOLS;
Ball joint b ase 07965-5800300 or
07JAFSH20200
Driver attachment 07HMO-MR70100
15-13
Set the knuckle and special t ools with "An mark side
REM OVE R/INSTALLER
of the removerlinstaller facing to the ball joint in the
vise as shown.
Press the bait joint into the knuckle until it is fully
seated.
TOOLS:
Ball joint remover/ installer 07JMFHC50110
Ball joint base 07JMFHC50120 or
07746-0020400
I NOTICE
If you feel strong resistance when compressing the
vise, stop. Reset the remover/installer of the tool so
that the ball joint can go into the remover/installer
and try again.
Install the snap ring with the chamfered edge facing
in .
INSTALLATION
Install rhe mner seal Coat the tips of new inner and outer dust seals with
first, then install the grease and install each dust seal u ntil it is flush with
ourer seal. the knUCkle, being careful not to damage the lip.
TOOLS:
Driver 077490010000
Oil seal driver attachment 079476340201 or
Driver attachment 07AMDHl1A100
(U .S.A. onIV)
Pack the lip cavities of the inner dust seal with 2.5-
3 g of grease.
15-14
Roure rile brake Install the knuckle onto the drive shaft, and lower
hose properly (page and upper arms with the joint nut.
1-21).
Tighten each joint nut to the specified torque and
further tighten until its grooves align with the cotter
pin hole.
TORQUE: 49 N 'm 15.0 kgf-m , 361bf.ftJ
Install new cotter pins.
KNUCKLE
Connect the tie-rod to the knuckle with the joint nut.

Tighten the joint nut to t he specified torque and fur
ther tighten until its grooves align wi th the cotter
pin hole.
TORQUE: 49 N 'm (5.0 kgfm, 36 IbHt)
Install a new cotter pins.
Install the hose clamp with a new clamp bolt and
tighten it.
TORQUE: 12 N-m (1 .2 kgfm , 9Ibf.ft)
Install the splash guard with new bolts and tighten

them.
TORQUE: 11 N 'm (1,1 kgf-m , 8lbf.ftl
_......-
BOLTS
Inslall a new dust seal into the hub with the metal
!'d!
side facing out until it is flush with the hub surface. HUB DUST SEAL
....
15-15
FRONT WHEEUSUSPENSION
Apply molybdenum disulfide grease to the drive
shaft splines.
Pack the lip cavities of the outer dust seal with 2.5-
3 9 of grease.
Do nor ger grease Coat the dust seal in the wheel hub with molybde-
on rhe dnve shafr num disulfide grease and install the wheel hub.
threads
Install the hub nut and tighten it to the specified

torque and further tighten until its grooves align
with the cotter pin hole.
TORQUE: 137 N'm (14.0 kgfm, 101 IbUt)
Install a new cotter pin.
. : :~i;
' iJ-!e'......... ~!
. 1.\
Install the brake caliper with new mounting bolts

and tighten them.
Install the outboard guard with new bolts and
tighten them.
TORQUE: 11 N 'm (1 .1 kgfm , 8Ibfft)
InslaUthe front w heel (page 15-6),
15-16
FRONT SUSPENSION ARM
REMOVAL
Remove the front wheel (page 15-6) ,
Remove the two hose damp bolts.
Remove the two bolts and drive shaft guard .
Remove the cotter pins from the ball joint studs.

Loosen t he ba ll jOint nuts, but do not remove them
yet.
Loosen the pivot nut s and shock absorber mounting

nuts.
To prevent the wheel hub/knuckle assemb ly from

falling, hang it with a strap.
Release the ball joints, using the special tool accord-
ing to the instructions (page 15-" ),
TOOL:
Ball joint remover, 28 mm 07MAC-Sl00200
Remove the ball joint nuts and the wheel hubl
knuckle assembly from the arms and drive shaft.
and support it securely.
BALL JOINT REIMC'VER
15-17
- pivot nuts, bolts and lower arm
- shock absorber (page 15-21)
- pivot nuts, bolts and upper arm
INSPECTION
Check the pivot bushings for wear or damage.
BUSHINGS
Inspect the ball joint boot on the upper arm for tears
For ball jOint
repl8cemenl (page or other damage by moving the ball joint stud.
15-IB) It should moves freely and smoothly.
BALL JOINT
BUSHINGS
BALL JOINT REPLACEMENT

Remove the snap ring from the ball joint.
SNAP RING
15-18
Support the upper arm with the special tool and
press the ball joint out of the upper arm.
TOOL:
Installe r attachment 01LAD-PW50601
Set the upper arm and special tools with "B " mark
side of the remover/i nstaller facing to the ball joint
as shown,
Press the baJJ joint into the upper arm until it is fully
seated.
TOOLS:
Ball joint re move r/ insta ller 01JMF-HC50110
Ball joint base 01JAF-SH20200
I NOTICE I
If you feel strong resistance when lowering the
press, stop. Reset the jOint base of the tool so the
ball joint head can go into the hollow of the joint
base and try again.
Install the snap ring with the chamfered edge facing
in. SNAP RING
INSTALLATION
Rou te the brake Install each arm into the frame with the pivot bolts
hose properly (page and new nuts, and loosely tighten them .
1-21).
Insert all the bolts
from the outSIde of
the arm .
15-19
Install the wheel hub/knuckle assembly onto the
drive shaft and arms, and install the ball joint nuts. ~~~D. em,..R PINS
Tighten each nut to the specified torque and further
tighten until its grooves align wi th the cotter pin
g
hole.
TORQUE: 49 Nm (5.0 kgfm , 36 Ibf.ftJ
Install new cotter pins.
Adjust the suspension arm angle with a jack sup- , - - - - - - - - - - - - - - - - - - ,

porting the lower arm so that the distance between
the centers of the shock absorber mounting bolt
holes is 394 mm (15.5 in).
After adjusting the angle, tighten all the upper and
lower arm pivot fasteners to the specified torque.
TORQUE (Upper and lower) :
64 N'm (S.S kg'm, 47 Ibf.ftl
Install the shock absorber (page 15-21).
Support
Install the drive shaft guard with new bolts and

tighten them.
TORQUE: 11 N'm (1 .1 kgfm. 8 Ibf.ft)
Install the hose clamps with new clamp bolts and

tighten them.
TORQUE: 12 N'm (1 .2 kgfm. 9 Ibf.ftJ

Install the front wheel (page 15-6). .-.~ BOLTS fI
15-20
FRONT SHOCK ABSORBER
REMOVAL
Raise the front wheels off the ground (page 1~48).
Support the lower arm. Remove the mounting nuts,
bolts and shock absorber.
INSPECTION
Remove the pivot collar.
Check the damper unit for leaks or other damage.
Replace the shock absorber assembly if necessary.
COLLAR
INSTALLATION
Install new dust seals into the lower pivot with the
lips side facing out until they are fully seated. $'" ~ DUST SEALS
Apply molybdenum disulfide grease to the lower
pivot bushing and dust seal lips.
Install the pivot collar.
~
LOWER BUSHING COLLAR
Insert the boilS Install the shock absorber wi t h the mounting bolts
from the front side and new nuts, and tighten them.
TORQUE: 44 N'm (4.5 kgfm, 33 Ibf.ft )
15-21
MEMO
16. STEERING SYSTEM
SYSTEM COMPONENTS ......................... 162 STEERING COLUMN AND SHAFT .......... 165
SERVICE INFORMATION ......................... 163 TIE ROD BALL JOINT 167
TROUBLESHOOTING .... 164 STEERING GEAR BOX 169
STEERING WHEEL 165
..
16-1
STEERING SYSTEM
SYSTEM COMPONENTS
36Ibfft)
39 N'm (4.0 29Ibfft)
27 N'm (2.8 kgfm, 20 Ibf.ft)
49 Nm (5.0 kgfm, 36 Ibf.ft)
49 N' m (5.0 kgfm,

36Ibf.ft)
27 N'm (2.8 kgfm, 20 Ibf.ft)
16-2
STEERING SYSTEM
SERVICE INFORMATION
GENERAL
A jack or other support is required to support the vehicle (page 1-48).
Do not disassemble the steering column . Replace the column as an assembly when it is faulty.
Use Honda Genuine replacement bolts and nuts for all joint and mounti ng poi nts.
Adjust toe whenever the knuckle o r steering gear box components are replaced or removed (page 4-27) .
For knuckle and wheel hub service, see Front WheefiSuspension section (page 15-2),
SPECIFICATIONS
Steering wheel Rotational play o ~ 10 mm (0 - 2/5 in)
Initial turning load 13.7 N (1.4 kgf, 3.1Ibf)
Wheel turning radius angle Inward: 40, Outward: 33 (reference)
Toe Toe-in: 0 10 mm (0 2/5 in)
TORQUE VALUES
Steering whee! nut 49 N 'm (5.0 kgfm, 36Ibfft)
Steering column mounting bolt 27 N 'm (2.8 kgfm , 20 Ibfft) Aloe bolt: replace with a new one
Steering shaft pinch bolt 27 N'm (2.8 kgfm , 20 Ibfft)
Tie-rod joint nut 49 N 'm (5.0 kgfm. 36Ibfft ) Castle nut: tighten to the specified torque and further
tighten until its grooves aligns with the cotter pin hole.
Rack end joint 54 N'm (5.5 kgfm, 40 Ibfft)
Steering gear box mounting nut 39 N'm (4.0 kgfm, 29Ibfft) lock nut: rep lace with a new one
Final gear case mounting nut 54 N'm (5.5 kgfm , 40 Ibfft) Lock nut: rep lace with a new one
Final clutch arm cover base bolt 10 N' m ( 1.0 kgfm , 7 Ibf.ft)
TOOLS
Ball joint remover, 28 mm Driver, 22 mm 1.0. Base collar

07MAC-SL00200 07746-0020100 07GAJ-PG20120
c.
Lock nut clinch pilot
07NAZ-SR30100
16-3
STEERING SYSTEM
TROUBLESHOOTING
Hard st eering
Insufficient tire pressure
Faulty front tire
Incorrect rack guide adjustment
Worn or damaged steering column bearing
Damaged steering shaft
Worn or damaged steer ing gear box components
Damaged suspension components (page 15-2)
Steers to one side or does not track straight
Damaged tie-rod, st eering gear box or column components
Incorrect wheel alignment (page 427)
Faulty suspension or wheel components (page 15-5 and 17-4)
Steering wheel wobbles
loose steering wheel or colu mn fa steners
Worn steering shaft spl ines
Noise or vibration when turn ing the steering wheel
Incorrect rack guide adjustment
Worn or damaged steer ing colu mn bearing
loose steering shaft joint fasteners
loose tie-rod joint fast eners
Damaged tie-rod ball joint
Damaged or deteriorated mounting bushings
Loose steering gear box mounting fasteners
Worn or damaged steering gear box component s
16-4
STEERING SYSTEM
STEERING WHEEL
Mark the steering Remove the following:
wheel and shaft - center cover (by releasing the three bosses
before removing to from the steering w h eel) COVER
identify ils original - nut
pOSl/lon, - steering wheel
- washer
NUT
TORQUE: 49 N m (5.0 kgfm, 36 IbUt)
WASHER
./'. . /J
Y SHAFT
STEERING WHEEL
STEERING COLUMN AND SHAFT

REMOVAL
Remove the steering wheel (page 16-5).
Raise the front wheels off the ground (page' 48).
hood.
- upper pinch bolt and lock washer
- four column mounting bolts (while supporting
the steering column securely)
Lift the steering col u mn assembly to disconnect the
steering shaft and remove it out of the frame.
Remove the lower pinch bolt and lock washer, and

the steering shaft.
16-5
STEERING SYSTEM
INSPECTION
Rep/ace the Turn the column shaft, it should turn smoothly and
steering column as quietly without binding.
anassemb/y. If the shaft does not turn smoothly or quietly, the
bearings may be damaged or faulty.
Check the dust seals for fatigue, wear or damage.
Check the shaft splines for wear or damage.
If the they are damaged, check the steering wheel
and steering shaft splines also.
Check that the universal joint moves smoothly with-

out binding or noise.
Check the steer ing shaft for deformation or other
damage.
Check the shaft splines for wear or damage .
If the they are damaged, check the column and pin-
ion splines.
INSTALLATION
Be careful not to Install the steering shaft onto the steering pinion on
damage the shaft the gear box with the stepped side facing up.
splines
Install the pinch bolt with the lock washer while
aligning the bolt hole in the universal joint with the
groove in the steering pinion properly.
16-6
STEERING SYSTEM
Place the steering column assembly into the instru-
ment panel, then connect the steering shah so the
groove in the column shaft is aligned with the bolt
hole in the universal joint.
Before installing the column, i nstall the pinch bolt
w ith the lock washer to be sure the shahs are
aligned properly.
Install the steering column onto the frame with new
four mounting bolts.
Tighten the mounting bolts, then tighten the pinch
bolts.
TORQUE:
Mounting bolt : 27 N 'm !2.8 kgfm, 20 Ibf.ft)
Pinch b olt: 27 N 'm (2.8 kgfm , 20 Ibfhj
Install the steering wheel (page 16-5).
Ch eck that the steering wheel rotates smoothly
from lock-to-Iock, without binding.
TIE-ROD BALL JOINT

REMOVAL
loosen the tie-rod end lock nut while holding the
ball joint.
Remove the cotter pin from the ball joint stud.
loosen the ball joint nut, but do not remove it yet.
Release the ball joint, using the special tool accord-

ing to the following inst ructions.
TOOL:
Ball joint remover. 28 rnm 07MAC Sl00200
16-7
STEERING SYSTEM
Apply grease to the ball joint remover at the point
shown.
This will ease installation of the tool and prevent Apply grease here PRESSURE BOLT
damage to the pressure bolt threads.
Insert the jaws carefully, making sure that you do
not damage the ball jOint boot.
,,,
If nfJCflssary. apply Adjust the jaw spacing by turning the pressure bolt.
penefrBtIflg type
lubricant /0 loosen
Ihe ball JOlnl
To prevent the tool from dropping, tie the strap on a

neighboring solid part such as the upper arm, frame STRAP
pipe, etc. before operation.
NOTE:
00 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, turn the adjusting bolt as

necessary to make the jaws parallel. PRESSURE BOLT
Then hand-tighten the pressure bolt and recheck the
jaws to make sure they are still parallel.
Tighten the pressure bolt with a wrench until the
ball joint stud pops loose.
Remove the ball joint nut and disconnect the tie-rod
from the knuckle.
ADJUSTING BOLT
Remove the ball joint from the tie~rod.
INSPECTION
BALL JOINT
Inspect the ball joint boot for tears or other damage
and the ball joint for looseness by moving the ball
joint stud.
They should move freely and smoothly without
binding.
16-8
ST EERING SYSTEM
INSTALLATION
Install the ball joint onto the tie-rod and screw it , - - - - - - - - - - -- - - - - - - - ,
Tlght emng of this
against the lock nut so that the thread length is 11
nUllO Ihe specified 11 mm
torque IS performedmm (0.4 in ) for initial reference. BALL JOINT (0.4 in ) TIE-ROD
whenadJUstmg the Temporarily tighten the lock nut while holding the
wh86! alignment. ball jOint.
LOCK NUT
Connect the tie-rod to the knuckle with the joint nut.

Tighten the join t nut to the specified torque and fur-
ther lighten until it s grooves align with the cotter
pin hole.
TORQUE: 49 N'm (5.0 kgfm, 36 Ibf.ft )
Install new cotter pin .
Install the fran! wheel (page 15-6 )
Adjust the wheel alignment (page 4-27 )
STEERING GEAR BOX

REMOVAL
Remove rhe tie-rod Disconnect the tie-rods (page 16-7 ),
ball jOintS if rhe gear
Remove the fronl bumper (page 3-16).
box will be
disassembled. Move the front final gear case forward to get the
clearance for steering gear box removal as follows.
Remove the following from the final gear case:

- breather hose
16-9
STEERING SYSTEM
- cover bolt
- clutch arm cover (by releasing the two tabs)
- adjusting nut
- cable retaining plate
- 2WDf4WD selector cable (remove from the cable
holder and joint pin)
- cable spri ng
- joint pin
NUT
- base boil s
- arm cover base
- holder bracket
16-10
STEERING SYSTEM
loosen the two bracket bolts (10 mm) and remove
the lower mounting nut and bolt (12 mmJ.
Remove the bracket bolts and mounting bracket.
remove the upper mounting nul and bolt (12 mm).
BRACKET

engine.
Pull the shaft joint out of the output shaft of the
engine.
Remove the O-ring.
Remove the pinch bolt and lock washer on the

lower side of the steering shaft.
16-11
STEERING SYSTEM
Be care/ulnor to Support the steering gear box securely and remove
damage the tle-<od the four mounting nuts and bolts, then disconnect-
boots and shaft in9 the steering shaft.
splines Remove the gear box assembly out of the frame to
the left.
Remove the mounting brackets and bushi ngs.

Check the mounting bushings for damage or deteri-
oration.
16-12
STEERING SYSTEM
DISASSEMBLY
Cut off the boot band in the pOSition as shown and
remove it , I
'------:::===:::::--------l
Remove the boot clip and the tie-rod boot.
BAND
CUP
~& -'"-'\\
loosen the rack end joint of the tie-rod while hold-

ing the steering rack to remove the tie-rod. RACK END JOINT
LOCK
Remove the lock washer.
STEERING RACK

- lock nut
- rack guide screw
- cone washer
- pressure spri ng
- rack guide
RACK GUIDE SCREW LOCK NUT
16-13
STEERING SYSTEM
- dust cover
- dust seal ~DUSTCOVEA
- snap ring
} - - - DUST SEAL
SNAP RING
Hold the steering pinion in a vise with soft jaws or ~==============:G=E:A:R:8:0=X~

shop towels.
Take care not to Drive the gear box housing on contact with 8
damage the wooden block at the point as shown (a rrows) evenly
housmg to remove the steering pinion/bearing assembly.
Replace the pmlOfl
Do not reuse the pinion and/or bearing.
and bearmg as an
assembly
Be careful not to Remove the following :

damage the sliding - steering rack
surface snd tee th - end bushing
of the rack
Clean the disassembled pans with a high flash point
or non-flammable solvent and dry them with com-
pressed air.
INSPECTION
Replace the needle Check the rack end bushing and the needle bearing
beaflngandhousmg in the housing for wear or damage.
as an assembly Check the rack and pinion teeth for wear, chipping
or damage.
Check the rack and rack guide screw sliding surface
for score marks or abnormal wear. RACK
BUSHING
16-14
STEERING SYSTEM
Check the tie-rod for distortion or damage.
Check that the rack end joint (universal joint) moves
smoothly without binding or noise.
TIE-ROD
RACK END
JOINT
ASSEMBLY
NOTE:
Keep dust and dirt out of the gear box housing.
~. -DUSTCOVER
@ . DUST SEAL
'='
- - - - - SNAP RING
I -- - STEERING PINION/BEARING
GUIDE SPRING
CONE WASHER
RACK GUIDE
SCREW ~ '"
RACK END BUSHING
_.~li'\lm l
LOCK NUT
LOCK WASHER --....:

,
~ / sTEERING RACK
BOOT
TIE-ROD
BOOT CUP
~~
16-15
STEERING SYSTEM
Apply 1 - 3 9 of grease to the inner surface of the
end bushing.
Install the bushing by aligning the bosses with the
grooves in the housing.
(1 - 3 g)
BUSHING
Apply 5 - 10 9 of grease to the teeth of the steering ~=============~===~

rack evenly.
Be careful nor 10 Insert the rack into the gear box housing slowly in
damage the the direction as shown .
busfHng by rhe rack.
end edge
~
(5 - 10 g)
Apply grease to the needle bearing in the gear box ~=================~
housing and the ball bearing on the steering pinion . DRIVER I
~..v;;;..
Make sure the reck teeth cen be seen through the
pinion hole and insert a new pinion/bearing assem-
bly into the housing.
"'... '
(0.2 - 0.5 g)
Press the bearing in until it is fully seated, using the
special tool.
TOOL:
Driver, 22 mm 1.0. 07746-0020100
,.JiiM.
(0.2 - 0.5 g)
16-16
STEERING SYSTEM
Make sure the snap Install the snap ring into the groove in the housing
ring is firmly seated
in the groove .
with the chamfered side facing down.
Wrap vinyl tape around the pinion splines and
rum
W.2 - 0.5 9)
DRIVER
groove, and coat it with grease to avoid damaging

the dust seal lip.
Apply grease to a new dust seal lips. Install the dust
\
~ SNAP RING
seal with the flat side facing up until it is fuJly
seated. SPLINES ~
TOOLS:
COLLAR
Driver, 22 mm 1.0. 07746-0020100
Base collar 07GAJ-PG20120
Remove the tape.
DUST SEAL _ , ...."
Pack 2 - 5 9 of grease in between the dust seal and

cover (shadowed area) .
...$iiiiiW GROOVE
12-59) DUST
Be sure the dust Install the dust cover and fit it into the pinion COVER
cover does not groove.
comact the gear
box housing
Apply grease to the sliding surface (rack side) of the

ra ck guide.
~========~::=~~=======;
Apply sealant to the threads of the ra ck guide screw. WASHER

- rack guide
- cone washer (with the concave side facing out)
- pressu re spring
- rack guide screw
- lock nut
Perform the rack guide adjustment (page 4-26).
Check the rack and pinion for smooth movement.
16-17
STEERING SYSTEM
Install a new lock washer onto the steering rack,
aligning the tabs with the grooves, then install the RACK END JOINT ~
tie-rod. lOCK ....,..
Hold the rack and tighten the rack end joint of the WASHER
lie-rod.
TORQUE: 54 Nm (5 .5 kgfm , 40 Ibf.ft)
''''#:b-. STEER"iG RACK
Use Vblock to hold

the rBck end
Clinch the lock washer onto the rack end notches in
four places, using the special tool and a hydraulic
~==::::=:::======~======l
CLINCH
press. PilOT
I NOTICE I
If the special rool is tilted or is misaligned from the
center of the lock washer, it will cause the tool to
pop our. Set the components in a hydraulic press Clinch
properly and hold the special tool and gear box Points
securely.
TOOL:
l ock w asher clinch p ilot 07NAZ-SR30100
Install the other side tie-rod in the same procedure
as above.
Clean off any grease or con tamination from the ~=================~

boot groove in the housing end.
Apply 1 - 2 9 of grease to the Quter surface of the
rack end joint.
"'& ~\\
Apply 0.5 - 0.8 9 of silicone grease (Dow Corning CLIP
Molykote EM30L or Kluber Noxlub 554012) to the Clean
boot groove in the tierod.
Do not get grease Install the tie-rod boot and fit it in the boot grooves
OIl the tlfHod in the housing and tie-rod.
threads
Install boot clip.
~...mm.
~ (1 - 2 g)
(0.5 -0.8 g)
16-18
STEERING SYSTEM
Install a new boot band by setting the tabs into the
holes with the pinch point facing rearward. BOOT BAND 111
BAND
- Rear
HOU SING
Pinch the ear portion of the boot band with a com- ~=================;
mercially available pincher (Oetiker 1098 or equiva- PINCHER
lent) until the pinched area clearance is 1 - 3.5 mm
as shown to secure tie-rod boot.
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
- -
1-3.5mm
INSTALLATION
Install the mounting bushings and brackets onto the
steering gear box as shown.
left:
Square
16-19
STEERING SYSTEM
8e careful not toPlace the gear box assembly into the frame from the
damage Ihe /l9-fOO left side.
boots and shaft Hold the gear box securely and connect the steering
splmes pinion to the steering shaft carefully. Align the bolt
holes in the brackets and frame properly, then
install the four bolt s (lower) and new nuts (upper).
Be sure to louch each bracket onto the frame and
lighten all the fasteners.
TORQUE: 39 N-m (4.0 kgfm , 29 Ibf.ft)
Install the pinch bolt with the lock washer and
tighten it.
TORQUE: 27 N'm (2.8 kgfm, 20 Ibf.ft)

grease and install it into the output shaft groove.
clearance between the shah joint and output shaft.
move the gear case assembly rearward .
16-20
STEERING SYSTEM
The mountmg boils Al ign the upper mounting bolt holes in the gear
are ins/ailed from case and frame, then install the mounting bolt (12
tneleft Side mm) and a new mounting nut.
Install the mounting bracket with the two bolts (10
mm).
Install the upper mounting bolt (12 mm) and a new
mounting nut.
Tighten the all the gear case mounting fasteners.
TORQUE : 12 mm : 54 N' m (5.5 kgfm , 40 Ibfft)
10mm
BOLTS
Install the holder bracket and cover base with the

two bolts, and tighten them.
TORQUE : 10 Nm (1.0 kgfm. 7 Ibf.ft)
Sel the drive mode selector lever to the 2WD posi r-------~----------__,
tion.
Install the spring onto the 2WD/4WDselector cable.
Insert the cable into the cable holder and connect it
to the clutch arm with the joint pin and adjusting
nut.
Set the groove in the cable grommet onto the cover
base end properly.
Install the retaining plate onto the cable with the
concave facing the cable holder to secure the cable.
Adjust the selector cable (page 19-46).
16-21
STEERING SYSTEM
Connect the differential lock switch connector.
Connect the 4WD select switch connector.

- tie-rod ball joints (page 16-9)
- front bumper (page 3- 16)
16-22
17. REAR WHEEL/SUSPENSION
SYSTEM COMPONENTS .......... .. .. 17-2 REAR WHEEL HUB/ KNUCKLE ................ 17-5
SERVICE INFORMATION ........................ 17-3 REAR SUSPENSION ARM ................ .. ... 17-11
TROUBLESHOOTING .............................. 1 7-4 REAR SHOCK ABSORBER .................. .. 17-16
REAR WHEEL ............................................ 17-5
17-1
REAR WHEEL/SUSPENSION
SYSTEM COMPONENTS
44 Ibf.ft)
64 N-m (6.5 kgfm,

47 Ibf.ft)
~
_
___ ____ --=-~ 64 N'm (6.5 kgfm,
47 I
12Nm(1.2kgfm, - -....
9lbfhl :~
,.,lJ'Il? _ _ _-=:~~~~
49 N' m (5.0 kgfm,

~~~_ _ -:::--~\ 36 Ibf.ft)
137 Nm (14.0
> -c-- 44 N'm (4.5 kgfm, 33 Ibfft) ~
27 Nm (2.8 kgf.m, 20 Ibf.ft)
I
J j \
~.~~
46 N'm (4.7 kgfm, 34 Ibf.ft)
108 Nm (11.0 kgf.m. 80 Ibf.ft)
17-2
SERVICE INFORMATION
GENERAL
A contaminated brake disc or pad reduces slopping power. Discard contaminated pads and clean a contaminated disc
A jack or other support is required to support the vehicle (page 1-48).
Do nol twist or bend the brake hose and pipe when serving.
Use Honda Genuine replacement bolts and nuts for all suspension pivots and mounting points.
For tire information, see Front Wheel/Suspension section (page' 5-6).
For brake system service, see Brake System section (page 18-2).
SPECIFICATIONS
ITEM STANDARD
------------S~
E~RV
~I~C<
ETln,
M ,T
~ ..
Minimum tire tread depth 4 mm (0.2 in)
Cold tire pressu re Standard _ _-+~70:c;:'~P=_a:(0.70 kgf/cm2, 10.0 psi)
'--________________'---W=;t"h-'c"a"'9,,o'---_ _____-'--,,
70__' ''Pa (0.70 kgf/cm2, 10.0 P
"'s"O'---_ _ _"-_ _ _ _ _--l
TORQUE VALUES
Wheel nut 108 N'm (11.0 kgfm, 80 Ibfh)
Wheel hub nut 137 Nm (14.0 kgfm, 101 Ibfh) Castle nut: tighten to the specified torque and fur-
ther tighten until its grooves aligns with the coner
pin hole.
Brake disc bolt 42 N'm (4.3 kgfm, 31 Ibf.ft) AlOC bolt: replace with a new one.
Brake disc splash guard socket bolt 11 N'm ( 1.1 kgfm, B Ibf.ft) AlOC bolt: replace with a new one.
Shock absorber mounting nut 59 N'm (6.0 kgfm, 44 Ibf.ft) lock nut: replace with a new one.
Brake hose clamp bolt 12 N'm (1.2 kgfm,9 Ibf.ft) AlOC bolt: replace with 8 new one.
Upper arm pivot nut 64 N'm (6.5 kgfm, 47 Ibf.ft) lock nut: replace with 8 new one.
lower arm pivot nut (frame side) 64 N'm (6.5 kgfm, 47 Ibf.ft) lock nut: replace with a new one.
lower arm pivot nut (knuckle side) 44 Nm (4.5 kgfm, 33 Ibf.ft) lock nut: replace with 8 new one.
Stabilizer arm mounting bolt 27 N'm (2.B kgfm, 20 Ibfft) ALOe bolt: replace with 8 new one.
Stabilizer link nut 46 N'm (4.7 kgfm, 34lbfft) Lock nut : replace with a new one.
Rear brake caliper mounting bolt 49 N-m (5.0 kgfm. 36 Ibf.ft) ALOC bolt: replace with a new one.
TOOLS
Driver Attachment, 62 x 64 mm Oil seal driver attachment

07749-0010000 07947-6340400 079476340201
or 07AMD-HL lA 100 (U.S.A. only) or 07AMD-HL lA 100 (U.S.A. only)
17-3
TROUBLESHOOTING
Rear wheel wobbling
Bent rim
Faulty tire
Loose wheel hub nut
Loose rear suspension fasteners
Soft suspension
Weak shock absorber spring
Oi/leakage from damper unit
5tiH suspension
Damaged shock absorber damper
Faulty shock absorber pivot bushings
Improperly installed suspension arms
Faulty suspension arm bushings
Rea r suspension noise
Faulty rear shock absorber
Loose rear suspension fasteners
Worn suspension pivot bushings
Damaged suspension components
Steers to one side or does not track straight
Damaged suspension arm or frame
Weak shock absorber
17-4
REAR WHEEL
REMOVAL
Loosen the wheel nuts.
Raise the rear wheels off the ground (page 1-48).
Remove the nuts and wheel.
For tire remova l/installation and repair, see Front
Wheel/Suspension section (page 15-6).
INSTALLATION
Clean the mating surfaces of the wheel and hub
thorough ly.
Install the wheel and the nuts with the tapered side
facing inward, and tighten them .
TORQUE: 108 N'm 111.0 kgfm, 80 IbUt)
REAR WHEEL HUB/KNUCKLE

REMOVAL
Remove the rear wheel (page 17-5),
- brake hose clamp bolt
Suppon the caliper - two mounting bolts and brake caliper

so that II does not
hang from the
brake hose. Do nor
tWist or bend the
brake hos e
17-5
- cotter pin
- hub nut
- wheet hub
- dust seal (from the hub)
cmeTE",p'N
- three socket bolts
- splash guard
,",-,,,.M GUARD
- lower arm pivot nut and bolt
- upper arm pivot nut and bolt
- knuckle (from the drive shaft)
BOLTS
INSPECTION
Remove the seal caps and pivot collar.
Check the pivot collar and bushings for wear or
damage.
Inspect the knuckle for damage or cracks.
SEAL CAPS
17-6
Remove the dust seals.
T urn the inner race of the b ea ring in the knuckle
with you r finger. The bearing should turn smoothly
and quietly. Also check that the bearing outer race
fits tightly in the knuckle.
BRAKE DISC REPLACEMENT

Remove the four bolts and b rake disc from the
wheel hub. DISC
Do not get grease Inst all a new brake disc with the stamp mark faCing
on the brake dIsc or the h ub.
stopping power will Install new disc bolts and tighten them.
be reduced.
TORQUE: 42 Nm (4.3 kgfm, 31 IbUt)
....
T5 ~,.,
BEARING REPLACEMENT
Remove the snap ring.
SNAP RING
Press the bearing 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;
Driller 07749-0010000
Attachment, 62 )( 64 mm 079476340400 or
Driver attachment 07AMDHL1A100
(U.S.A. only)
Install the snap r ing into the knuckle groove with the
chamfered edge facing in .
17-7
REAR WHEEl/SUSPENSION
INSTALLATION
Install the mner seal Coat the lips of new inner and outer dust seals wi th
'ITsr, then Ins /all the grease and install each dust seal until it is flush with
ourer se~1 the knuckle, being careful not to damage the lip.
TOOLS:
Driver 07749-0010000
Oil seal driver attachment 07947-6340201 or
Driver attachment 07AMO-HllAl00
(U.S.A . only)
Apply molybdenum disulfide grease to the sl iding

surfaces of the lower bush i ngs and install them into
the knuckle until they afe fully seated.
Install new dust seals wi th the lip side facing ou t
until the depth from the bushing end is 0.5 mm.
Apply molybdenum disulfide grease to the sliding
surfaces of the pivot collar and install it.
Apply 2.5 - 3 9 of molybdenum disulfide grease to
the lip of each dust seal and install the seal caps
over the dust seals securely.
BUSHINGS
SEAL CAPS
. - 3 g)
O.5mm O.5mm
17-8
Pack the lip cavities of the inner dust seal with 2.5-
3 g of grease and install the knuckle over the drive INNER DUST SEAL
shaft.
Inserr the bolts Connect the knuckle to the upper and lower arms
from rhe rear Side. with the pivot bolts.
Install new pivot nuts and tighten them.
_...m;;..
(2.5 - 3 g)
TORQUE :
Upper ann : 64 N'm (6.5 kgfm . 47 IbUt)
Lower ann : 44 Nm (4.5 kgfm . 33 Ibf.ft)
\ r
BOLTS
Install the splash guard with new bolts and tighten

them .
TORQUE: 11 N'm (1. 1 kgfm. 8 IbUt) BOl_TS f!
Install a new dust seal into the hub with the metal
side facing out until it is flush with the hub surface. HUB SEAL
....<:>.,
17-9
Apply molybdenum disulfide grease to the drive
shaft splines.
Pack the lip cavities of the outer dust seal with 2.5 -
3 9 of grease.
Do not ,get grease Coat the dust seal in the wheel hub with molybde-
on the drl'l6shafr nurn disulfide grease and install the wheel hub.
threads
HUB
Install the hub nut and tighten it to the specified
torque and further lighten until its grooves align
with the coner pin hole.
TORQUE: 137 Nm '14.0 kgfm, 101Ibf.ft)
Install a new coner pin.
111 COITER PIN

Install the caliper with new mounting bolts and
tighten them. S!I'
TORQUE: 49 N'm (5.0 kgfm, 36 Ibf.ftl
CALIPER
17-10
Install the brake hose clamp with a new bolt and
tighten it.
TORQUE: 12 N 'm (1.2 kgfm. 9 IbUt)

Install the rear wheel (page 17-5).
REAR SUSPENSION ARM

REMOVAL
Remove the rear wheel (page 17-5).
Support the wheel hub/knuckle assembly secu rely.
LOWER ARM
- lower arm pivot nut and bolt (to disconnect the
arm from the knuckle)
- lower arm pivot nuts and bolts

- lower arm
17-11
UPPER ARM
- brake hose damp bolt
- stabilizer link nut (while holding the stud bolt
end)
- rear shock absorber (page 17-16)

- upper arm pivot nuts and bolts
- upper arm (while disconnecting the stabi lizer
link)
STABILIZER ARM AND LINK

- link nuts (while holding the stud bolt end )
- stabilizer links
- four bolls and nuts

- holders
- stabilizer arm
- stabilizer bushings
17-12
INSPECTION
For pivot bushing inspection of the knuckle side, see
Rear Wheel Hub/Knuckle (page 17-6),
BUSHINGS
Check the stabi l izer bushings for wear or damage.

Check the stabilizer arm fo r distortion or damage. BOOTS
Inspect t he ball joint boots of the link for tears or BUSHING
other damage by m oving the ball joint stud.
LINK
INSTALLATION
NOTE:
The upper and lower arm pivot fastener tighten-
ing is performed after adjusting the suspension
arm angle (page 17-15).
STABILIZER ARM AND LINK
Install the stabilizer bushings and holders onto the
st abilizer arm.
Inst all the stabilizer arm onto the frame with new
bolts and the nuts. Tighten the four bolts while
holding the nuts alternately.
TORQUE: 27 N'm (z.a kgfm , 20 Ibf.ft)
17-13
The stabilizer links have the identification paint:
Left link: Yellow
Right fink: White
Install the stabilizer links with new nuts and tighten
them while holding the stud bolt end.
TORQUE: 46 Nm (4.7 kgfm, 34 Ibf.ft)
UPPER ARM
Insert the frame Install the upper arm into the frame with the pivot ~~':"
sIde Pivo t bolts bolts and new nuts while inserting the stabilizer link
from the outside of into the upper arm.
Ihearm.
Insert the knuckle Connect the upper arm to the knuckle with the pivot
Side Pivot bolt from bolt and a new nut.
the rear Side
Before installing the shock absorber, tighten the
pivot fasteners with both the upper and lower arms
installed (page 17-15),
Install a new stabilizer link nut and tighten it while

holding the stud bolt end.
TORQUE: 46 Nm (4.7 kgfm . 34 Ibf.ftl
Install the brake hose clamp with a new bolt and
tighten it.
TORQUE: 12 Nm (1.2 kgfm, 9Ibf.ft)
17-14
LOWER ARM
insen the frame Install the lower arm into the frame with the pivot
s,de PIvot boltS bolts and new nuts.
from Ihe outside of
me arm
Insert the knuckle Connect lower arm to the knuckle with the pivot bolt
and a new nut.
Side pi\Itll bolt from
the rear side
Before installing the shock absorber, tighten the
pivot fasteners with both the upper and lower arms
installed (page 17-15).
SUSPENSION ARM FASTENER TIGHTENING

Adjust the suspension arm angle with a jack sup- , - - - - - - -- - - -- - - - - - - - 1
porting the lower arm so that the distance between
the centers of the shock absorber mounting bolt
holes is 388 mm '15.3 in) .
After adjusting the angle, tighten all the upper and
lower arm fasteners to the specified torque.
TORQUE:
Upper arm pivot nut (at frame and knuckle):
64 N 'm (6.5 kgfm, 47 IbHt)
lower ann pivot nut:
Frame s ide: 64 N 'm (6.5 kgfm , 47 Ibf.ft)
Knuckle side: 44 N 'm (4.5 kgfm, 33 Ibf.ft)
- shock absorber (page 17-16)
- rear wheel (page 17-5)
t
Support
17-15
REAR SHOCK ABSORBER
REMOVAL
Raise the rear wheels off the ground (page 1-48).
Support the lower arm . Remove the mounting nuts,
bolts and shock absorber.
INSPECTION
Check the damper unit for leaks or other damage.
Replace the shock absorber assembly if necessary.
INSTALLATION
Insert the bolts
from the rear side
Install the shock absorber with the mounting bolts
and new nuts, and tighten them.
"""""'==c::c=-
TORQUE : 59 N'm (6.0 kgf-m , 44 Ibf.ft)
BOLT(12x65mm)
~AiiNiiiDiiiNiUiT 111
17-16
18. BRAKE SYSTEM
SYSTEM COMPONENTS 18-2 MASTER CYLINDER .... 18-11
SERVICE INFORMATION 18-4 FRONT BRAKE CALIPER 18-15
TROUBLESHOOTING 18-5 REAR BRAKE CALIPER .......................... 18-19
BRAKE FLUID REPLACEMENT! BRAKE PEDAL ................ ...... ....... ..... ... ... 18-27
AIR BLEEDING .......................................... 18-6
PARKING BRAKE LEVER ................... .... 18-29
BRAKE PAD/ DiSC 18-8
18-1
BRAKE SYSTEM
SYSTEM COMPONENTS
Front: Rear:
49 Nm (5.0 kgfm, 36 Ibf.ft)
108 Nm (11.0 kgfm, 80 Ibf.ft)
34 Nm (3.5 kgfm, 25 Ibfh)

11 N'm (1. 1 kgfm, 8 Ibf.ft)
18-2
BRAKE SYSTEM
-,.-- - )
. i)
,
o
'Cl 'C\ "\)\ '0

'C) 'C)
\) t)'C)
18-3
BRAKE SYSTEM
SERVICE INFORMATION
GENERAL
ACAUTION
Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your h~
alth .
Avoid breathing dust particles .
Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
I NOTICE I
Spilled brake fluid will severely damage the plastic parts and painted surfaces. It is also 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
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.
SPECIFICATIONS
Unit mm !in)
Recommended brake fluid
Brake disc thickness
Honda DOT 4 brake fluid
6.8 7.2 (0.27 0.28)
I 6.0 (0.24) ,
8rake disc runout -25-40( 1 0.30 (0.012)
r-Srake pedal height (from accelerator pedal)
Parking brake lever locked clicks 3-7 clicks
1-3/5)
I j
TORQUE VALUES
Brake hose oil bolt 34 N'm (3.5 kgfm, 25 Ibf.ft)
Caliper bleed valve 8.5 N'm (0.87 kgfm, 6.3 Ibf.ftj
Brake pipe joint nut 14 N'm (1.4 kgfm, 10 Ibftt)
Master cylinder/brake pedal bracket mounting nut 27 N'm (2.8 kgfm, 20 Ibf.ft)
Master cylinder push rod joint nut 17.2 N'm (1.8 kgfm, 13lbfft)
Master cylinder reservoir bolt 2.5 Nm (0.25 kgfm, 1.8 Ibfft)
Front brake caliper mounting bolt 108 Nm (1 1.0 kgfm, 80 Ibftt) ALoe bolt: replace with a new one.
Front brake caliper slide pin bolt 22.5 Nm (2.3 kgfm, 17 Ibfft)
Rear brake caliper mounting bolt 49 Nm (5.0 kgfm, 36 Ibfft) ALoe bolt: replace with a new one.
Rear brake caliper slide pin bolt 22.5 N'm (2.3 kgfm, 17 Ibfft)
Rear brake caliper parking brake arm nut 27.5 Nm (2.8 kgfm, 20 Ibfft)
Parking brake cable holder cover socket bolt 11 N'm (1.1 kgfm, 8 Ibfft) Aloe bolt: replace with a new one.
Parking brake cable clamp bolt 27 N'm (2.8 kgf,m, 20 Ibrft) AlOe bolt: replace with a new one.
Parking brake cable holder bolt 41 N'm (4.2 kgfm, 30 Ibfft)
Drive shaft outboard guard bolt 11 N'm (1.1 kgf.m, 8 Ibfft) Aloe bolt: replace with a new one.
18-4
BRAKE SYSTEM
TOOLS
Lock nut wrench Snap ring pliers

07716-0020100 07914-SA50001
TROUBLESHOOTING
Brake pedal soft or spongy
Ai r in hydraulic system
Leaking hydraulic system
Contaminat ed brake pad/disc
Worn caliper piston seal
Worn master cyl inder pist on cups
Worn brake pad/disc
Contaminat ed caliper
Contaminat ed master cylinder
Caliper not slidi ng properly
low brake fluid level
Clogged fl u id passage
Warped/def ormed brake disc
Sticking/worn caliper piston
Sticking/worn master cylinder piston
Incorrect pedal height adjustment (page 4-21 )
Brake pedal hard
Clogged/restricted brake system
Sticking/worn caliper piston
Sticking/worn master cylinder piston
Caliper not sliding properly
Bent b rake pedal
Brake drags
Contaminated brake pad/disc
Bad ly worn brake pad/d isc
Warped/ def ormed brake disc
Caliper not sliding properly
Clogged/restricted fluid passage
Sticking caliper piston
Incorrect parking brake adjustment (page 4-21)
18-5
BRAKE SYSTEM
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
BRAKE FLUID DRAINING
hood.
Release the parking brake lever.
Remove the rubber cap out of the reservoir tank.
Remove the reservoir cap by turning it counter-
clockwise.
Remove the bleed valve cap.

Connect the bleed hose to the caliper bleed valve.
loosen the bleed valve and pump the brake pedal
until no more fluid flows out of the bleed valve.
Perform above procedure f or each caliper bleed

valve.
Right rear caliper: left rear caliper:
18-6
BRAKE SYSTEM
BRAKE FLUID FILLING/BLEEDING
Release the parking brake lever.
Close each caliper bleed valve.
Fill the reservoir with DOT 4 brake fluid from a
sealed container.
Follow the Connect a commercially available brake bleeder to
manu facturer's the bleed valve.
operating
Operate the brake bleeder and loosen the bleed
instructions
valve.
Check the flUid level If an automatic refill system is not used, add fluid
offen while when the fluid level in the reservoir is low.
bleeding the brake
to prevent air from
bemg pumped into
the system
If atr enters the Perform the bleeding procedure until the system is
bleeder from completely flushed/bled.
around file bleed
Tighten t he bleed valve.
valve threads, seal
Ihe threads with TORQUE: 8.5 N-m (0.87 kgfm. 6.3 IbUt)
teflon tape
Install the valve cap.
Perform the above procedure at each remaining
bleed valve (3 places).
After bleeding air, operate the brake pedal. If it still
feels spongy, bleed the system again.
If the brake bleeder is not available, perform the fo l -

lowing procedure:
Pump up the system pressure with the brake pedal
until the pedal resistance is felt.
Connect a bleed hose to the caliper bleed valve and
bleed the system as fo l lows:
Do not release the 1. Depress the brake pedal all the way and loosen
brake pedal until the bleed valve 1/4 of a turn. Wait several sec-
the bleed valve has onds and then close the bleed valve.
been closed
2. Release the brake pedal slowly and wait several
seconds afte r 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: 8.5 Nm (0.87 kgfm , 6.3 Ibfft )
Install the valve cap

Perform the above pr ocedure at each remaining
bleed valve (3 places).
After bleeding air, operate the brake pedal. If it still
feels spongy, bleed the system again.
18-7
BRAKE SYSTEM
Fill the reservoir to the MAX line with DOT 4 brake
fluid from a sealed container.
Install the reservoir cap so the arrow is facing for-
MAX LINE
ward.
Turn the rubber cap inside out and install it over the ;::=========J111I111I111I111I111I111I111I111I111~
reservoir cap securely.
Close the fron t hood and secure it with the straps. """"....~
RUBBER CAP
BRAKE PAD/DISC
FRONT BRAKE PAD REPLACEMENT
Push the caliper piston all the way in by push ing the LA '""" BODY
Che'* the flUid level
in the master caliper body against the disc to allow installation of
cylmder reservoir as new brake pads.
thiS operation
Remove the lower sl ide pi n bolt.
causes the fluid
level to flS8
Pivot the caliper body up and remove the brake

pads from the caliper bracket.
Always rep/ace the Install new pads onto the cali per bracket properly so
brake pads In pairsthe wear indicator on the inner pad is facing the
to ensure even disc upper side.
pressure
BRIIKEPADS
18-8
BRAKE SYSTEM
lower the caliper body, install the slide pin bolt and
tighten it. CAI.!P,'R BDDY
TORQUE: 22.5 N'm (2.3 kgfm, 17 Ibf.ftl

Operate the brake pedal to seat the caliper piston
agai nst the pad.
Install the front w heel (page 15-6).
REAR BRAKE PAD REPLACEMENT

Release the parking brake.
Remove the sl ide pin bolts and the caliper body
from the caliper bracket.
Remove the brake pads from the caliper bracket.

Always replace rhe Install new pads onto the caliper bracket properly so
brake pads m p8IfS the wear indicator on the inner pad is facing the
to ensure even disc upper side.
pressUle
Turn the caliper piston using the special tool or

equivalent to retract it and position the piston so its
groove is aligned with the locating pin of the inner
pad .
TOOL:
lock nut wrench 077160020100
Install the caliper body over the pads and caliper
bracket.
18-9
BRAKE SYSTEM
Install the slide pin bolts and lighten them.
TORQUE: 22.5 Nm 12.3 kgfm, 17 IbUt)
Operate the brake pedal to seat the caliper piston

against the pad.
Install the rear wheel (page 17-5),
BRAKE DISC INSPECTION

Remove the brake pad (page 18-8).
Visually inspect the brake d isc for damage or crack.
Measure the brake disc thickness at several points.
Replace the brake disc if the smallest measurement

is less than service limit.
Check the brake disc for warpage.

Check the knuckle bearing for excessive play, jf the

warpage exceeds the service limit.
Replace the brake disc if the bearing is normal.
Brake disc replacement:
front (page 15-12)
- rear (page 17 -7)
18-10
BRAKE SYSTEM
MASTER CYLINDER
DfSASSEMBL Y
Drain the brake fluid (page 1S-6).
Remove the cotter pin and joint pin to disconnect
the push rod.
When removmg the Loosen the joint nuts to disconnect the brake pipes.
JOint nut. cover the
Remove the two mounting nuts, bolts and master
ends of the brake
cylinder from the frame.
pipeS to prevent
brake flUid leakage
BOLTS

- bolt
- reservoir
- oil seals
- boot (from the master cylinder body)

- push rod (from the boot)
PUSH
18-11
BRAKE SYSTEM
- snap ring
-
-
secondary piston assembly
primary piston assembly PRIMARY PISTON t
SECONDARY PISTON
~~1AP
Clean the reservoir, master cylinder and pistons in
clean brake fluid.
INSPECTION
~
Check the piston cups and boot for wear, deteriora-
tion or damage. RING
Check the piston springs for damage. CUPS
Check the master cylinder and piston for scoring,
scratches or damage. SPRING
ASSEMBLY
RESERVOIR
SNAP RING 1/
~~ ~sHROO
~\ SECONDARY PISTON
ASSEMBLY
PRIMARY PISTON
ASSEMBLY
Do not allow the

Coat the pistons and cups with clean DOT 4 brake
fluid.
Install the primary and secondary piston assemblies
I CUPS
piSton cup lIps to into the master cylinder.

rurn inSIde our
PISTON I CUPS I
18-12
BRAKE SYSTEM
8e certam the snap Install the snap ring into the groove in the master
rmg IS flfmo/ seated cylinder with the chamfered edge facing in.
10 the groove
SNAP RING
If the rod joint of push rod is reinstalled, adjust the

push rod length so that the distance between the
center of the joint pin hole and rod end is 91 1 JOINT
NUT
mm. After adjustment, tighten the lock nut.
TORQUE: 17.2 Nm (1 .8 kgfm, 13 Ibf.ft)
91 1 mm
Apply 0.1 g of silicone grease to the boot groove in

the push rod. Install the boot into the boot groove.
Apply 0.1 g of silicone grease to the boot groove in
the master cylinder body and to the push rod end.
Install the push rodlboot assembly into the piston
and boot groove in the master cylinder.
18-13
BRAKE SYSTEM
Install new oi l seals onto the reservoir.
Install the reservoir into the master cylinder and
secure it with the bolt.
TORQUE: 2. 5 N'm (0.25 kgfm, 1.8 Ibf.ft)
RESERVOIR
Insert the bolts Install the master cylinder with the mounting bolts
from the pedal side. and the nut, aligning the push rod slit with the brake
pedal.
8e careful no! 10 Connect the brake pipes to the master cylinder with
cross-thread the the joint nuts.
IOlnt nuts.
Tighten the mounting nut s, then tighten the joint
nuts.
TORQUE:
M o unting nut: 27 N'm 12.8 kgfm , 20 Ibf.ft)
Joint nut: 14 N m (1 .4 kgfm , 10 Ibfft)
Connect the push rod to the pedal with the joint pin
and secure it with a new cotter pin.
Check the brake pedal height (page 4-21).
Fill and bleed the hydraulic system (page 18-7).
18-14
BRAKE SYSTEM
FRONT BRAKE CALIPER
DISASSEMBLY
Drain the brake fluid (page 186).
Remove the two bolts and outboard guard.
Disconnect the brake hose by removing the oil bolt

and sealing washers.
loosen the two slide pin bolts.

Remove the two mounting bolts and brake caliper.
PIN BOLTS
Remove the two slide pin bolts and separate the cal-
iper bracket from the caliper body. PADS
Remove the brake pads.
BRACKET
18-15
BRAKE SYSTEM
Release the boot rib from the pin groove and
RETAINERS
remove each slide pin . Remove the boots from the
caliper bracket.
Remove the pad retainers.
Place a shop towel over the piston.

Do not use high Position the caliper body with the piston down and
pressure 8f( or brmgapply small squirts of ai r pressure to the fluid inlet
the nozzle too close to remove the piston.
to the mlet
Remove the piston boot.
:, .
,"!'
~
~ i,

t
-
4 .,
I
8e careful not to Push the piston seal in and lift it out.

damage the pis/on
slldmg surface
Clean the boot and seal grooves, caliper cylinder,
and piston with clean brake fluid.
18-16
BRAKE SYSTEM
INSPECTION
Check the caliper cylinder and piston for scoring,
scratches or damage.
ASSEMBLY
PIN BOLTS SLICE PIN A
BRAKE PADS
CALIPER BODY
~
BOOT
CALIPER BRACKET
PISTON SEAL
PAD RETAINERS
PISTON BOOT
CALIPER PISTON
18-17
BRAKE SYSTEM
Coat a new piston seal with clean brake fluid and
install it into the seal groove in the cal iper cylinder.
Pack the inside of a new piston boot with 2 - 3 9 of
si licone grease and apply 0.8 9 of silicone g rease to
the seal areas (boot ribs).
Install the inside boot rib of piston boot into the
-- I
!III>-"
PISTON SEAL
boot groove in the caliper cylinder properly.

Coat the caliper piston 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 out-
side boot rib into the boot groove in the piston to
seat the piston.
Instatllhe pad retainers onto the bracket.

Install new pin boots into the grooves in the bracket. PIN A ...-'iSiII
(Upper side)
Apply 0.4 9 of silicone grease to the sliding area of
each slide pin.
Do not interchange Install slide pin A (flat surfaces) and pin B (round
rhe pm A and 8 surface) into the caliper bracket to be sure each boot
rib is seated to the boot groove in the pin.
-=:C. PIN B
~ (l ower side)
Install the brake pads onto the caliper bracket so the

wear indicator on the inner pad is facing the upper
side.
Install the bracket onto the caliper body with the
slide pin bolts.
BRACKET TS
18-18
BRAKE SYSTEM
Install the brake caliper onto th e knuckle with new
mounting bolts, and tighten them.
CALIPER
TORQUE: 108 Nm (11.0 kgfm , 80 Ibfft)
Tighten the slide pin bolts while holding the slide

pin.
TORQUE: 22.5 Nm 12.3 kgfm. 17 IbUt)
PIN BOLTS
Set the hose Jomt Connect the brake hose to the brake caliper with the
In/o the stopper oi l bolt and new seal ing washers, and tighten it.
groove.
TORQUE: 34 N'm (3.5 kgfm, 25 IbUt)
Install the outboard guard with new bolts and

tighten them.
TORQUE: 11 N 'm (1 .1 kgfm, 8 Ibf.tt)

Fill and bleed the hyd raulic system (page 18-7).
Install the front wheel (page 156).
REAR BRAKE CALIPER

OISASSEMBL Y
Drain the brake fluid (page 18-6).
Remove the two bolts and cable holder cover.
18-19
BRAKE SYSTEM
Remove the retaining plate and disconnect the park-
ing brake cable by moving the brake arm inward.
Remove the cable out of the cable holder while
aligning the flat surfaces.
Remove the washer-bolt and cable holder.
Disconnect the brake hose by removing the oil bolt

and sealing washers.
~;;;;
Remove the two mounting bolts and the brake cali-
per.
Loosen the two slide pin bolts.

Remove the two mounting bolts and brake caliper.
PIN
BOLTS
CALIPER
Remove the two slide pin bolts and separate the cal-
PADS
iper bracket from the caliper body.
Remove the brake pads.
BRACKET
18-20
BRAKE SYSTEM
Release the boot rib from the pin groove and
remove each slide pins. Remove the boots from the BOOTS
SPRING
ca liper bracket.
Remove the pad retainers and the pad spring.
PIN B
RETAINERS
Remove the caliper piston by turning it counter-
clockwise, using the special tool or equivalent.
TOOL:
Lock nut wrench 077160020100
Remove the piston boot.
Be careful not to Push the piston seal in and lift it out.

damage the piston
sliding surface.
Remove the snap ring using the special tooL
TOOL:
Snap ring pliers 07914-SA50001
18-21
BRAKE SYSTEM
- spring guide
- adjusting spring
- spacer
- beari ng CUP
- adjusting bolt
- cup BEARING
- sleeve piston
- rod
- O ring SPRING \
00
? \
GUIDE SPACER
BOLT
PISTON
- return spring
- nut SPRING NUT AND WASHER
- spring washer
- brake arm
- brake cam
- dust seat DUST SEAL BRAKE CAM
Clean the seal and boot grooves, caliper cylinder
and disassembled parts in clean brake fluid.
INSPECTION
Check the caliper cvlinder and piston for scoring or
other damage.
18-22
BRAKE SYSTEM
ASSEMBLY
DUST SEAL
SLEEVE PISTON
ADJUSTING BOLT
SPACER
SPRING GUIDE
BEARING
ADJUSTING SPRING BRAKE PADS

PISTON BOOT
CAUPER BRACKET
CALIPER PISTON SNAP RING
ApplV 0.5 9 of silicone grease to the brake cam bear-

ing in the caliper body.
Apply 0.1 9 of silicone grease to the groove in a new
dust seal, and install it into the caliper body.
Apply 0.1 9 of silicone grease to the seal groove in
the brake cam, and install it with the rod hole facing
the piston side.
Install the brake arm with the spring washer and nut
in the direction as shown. NUT AND WASHER
TORQUE: 27.5 N 'm 12.8 kgfm , 20 Ibf.ft)
Install the return spring as shown.
18-23
BRAKE SYSTEM
Coat a new O-ring with silicone grease and install it
into the sleeve piston groove.
Apply 0.' 9 of silicone grease to a new cup and
g .AiSiti
install it onto the adjusting bolt. D-RING
Instal! the adjusting bolt into the sleeve piston.
Apply 0.15 9 of silicone grease to the ends of the 111 .AiSiti CUP \ ~~'\:
rod and install it into the sleeve piston.
BEARING \
Install the piston assembly into the caliper cylinder
by aligning the pins of the piston with the holes in
the caliper.
Install bearing, spacer, adjusting spring and spring
SPRING \~ .
PISTON
guide onto the adjusting bolt.
~ BOLT
GUIO: SPACER
Be cenain the snap Install the snap ring into the groove in the caliper
ring IS firmly sBared body with the chamfered edge facing in.
In the groove
TOOL:
Snap ring pliers 07914-SA50001
Coat a new piston seal with clean brake fluid and

install it into the seal groove in the caliper cylinder.
Pack the inside of a new piston boot with 0.5 - 0.7 9
of silicone grease and apply 0.2 g of silicone grease
to the seal areas (boot ribs).
Install the inside boot rib of piston boot into the
boot groove in the caliper cylinder properly.
Coat the caliper piston 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 install the piston onto the
adjusting bolt by turning il clockwise to retract it,
using the special 1001 or equivalent.
Be sure to set the outside boot rib into the boot
groove in the piston.
TOOL:
l ock nut wrench 07716-0020100
18-24
BRAKE SYSTEM
Install the pad retainers onto the bracket.
PINA ~
Install new pin boots into the grooves in the bracket.
Apply silicone g rease to the sliding area of the slide
tI BOOTS IUI'D'" side)
SPRING
pins.
Do nor interchange Install slide pin A (flat surfaces) and pin B (round
the pin A and 8. su rface) into the caliper bracket to be sure each boot
rib is seated to the boot g roove in the pin .
Install the pad spring as shown.
- - - PI N B .--'IIISJII
(Lower side)
Inst all the brake pads onto the caliper bracket so the
wear indicator on the inner pad is facing the upper
side.
Install the caliper body onto the caliper bracket with
the slide pin bolts.
BRACKET
Install the brake caliper onto the knuckle with new

mounting bolts, and lighten them.
PIN
TORQUE: 49 N'm (5.0 kgfm, 36 IbUt) BOLTS
Tighten the slide pin bolts while holding the slide
pin.
TORQUE: 22.5 Nm 12.3 kgf.m, 17 IbUt)
Set the stopper pin Connect the brake hose with the oil bolt and new I";::::--;;;::;-;~
tnto the hole tn the sealing washers, and tighten it.
caliper
TORQUE : 34 Nm (3.5 kgfm , 25 Ibf.ft)
18-25
- - - - - - -- - - - - - - - -- - - - - - - - - - - - - - -- ------- -
BRAKE SYSTEM
Inst all the cable holder w ith the washer-bolt, align-
i ng the locating pin wi th the hole, and tighten it.
TORQUE: 41 N'm (4.2 kgfm . 30 IbUt)

Insert the parking brake cable i nto the holder by
aligning the flat surfaces and connect it to the brake
arm. Secure the cable with the retaining plate.
Install the holder cover with new bolts and tighten

them.
TORQUE : 11 N-m (1 .1 kgf-m . 8lbBt)
Fill and bleed the brake hydraulic system (page 18-
7).
Check the parking brake lever freeplay (page 4-2 1I.
Install the rear wheel (page 17-5).
18-26
BRAKE SYSTEM
BRAKE PEDAL
REMOVAL
hood.
Unhook the return and switch springs from the
brake pedal.
Remove the cotter pin and joint pin to disconnect
the push rod .
Do not force tile Remove the two nuts and four bolts, and the brake
mastsr cylinder pedal assembly _
after removing the
brake pedal INSTALLATION
assembly or the Install the brake pedal assembly with the four bolts
brake pipeS will be and two nuts, aligning the pedal arm with the push
deformed rod slit. Tighten the fasteners alternately.
TORQU E: 27 N' m !2.8 kgfm, 20 Ibf.ft)
Connect the push rod t o the pedal with the joint pin
and secure it with a new cotter pin.
Hook the return spring and switch spring.
Check the brake pedal height (page 4 21).
RETURN SPRING SWITCH SPRIN G BOLTS

(8 x 35 mm)
COTTER PIN
NUTS
PUSH ROD
\ BOLTS
(8x20mm)
BRAKE PEDAL
DISASSEMBLY
Remove the fo llowing:
- cotter pi n and washer
- pivot shaft
- brake pedal
- dust seals
SHAFT
18-27
BRAKE SYSTEM
ASSEMBLY
Coal the lips of new dust seals with grease .
Install the dust seals into the brake pedal with the
flat side facing out until they are fully seated.
Apply grease to the groove in the pivot shaft.
Install the brake pedal into the bracket by inserting
the pivot shaft from the left side, and align the flat
surfaces of the shaft and bracket.
Install the washer and new cotter pin .
18-28
BRAKE SYSTEM
PARKING BRAKE LEVER
Remove the seat center cover (page 3-5),
Remove the parking brake switch 2P (black) connec-
tor from the lever bracket and disconnect it. Release
the switch wire from the two clips.
Remo v e the adjusting nut and the joint pin while
moving the lever upward to disconnect the brake
rod . Remove the rod spring .
Remove the two bolt s and parki ng brake lever.
Route the SWitch Installation is i n the reverse order of removal.
wire properly (piJge Adjust the parki ng brake lever freeplay (page 4-21 ).
1-2 /},
NUT
SPR'\ /
/~JO'NTP'N
~
CONNECTOR
CLIPS ,
\
\ ,,
--'
BRAKE LEVER
18-29
MEMO
19. FRONT DRIVING MECHANISM
SYSTEM COMPONENTS 19-2 FRONT FINAL GEAR OISASSEMBLY!

INSPECTION .. 19-28
SERVICE INFORMATION 19-3
CASE BEARING REPLACEMENT .......... 19-34
TROUBLESHOOTING 19-6
FRONT FINAL GEAR ASSEMBLy 19-36
FRONT DRIVE SHAFT .. 19-7
FRONT FINAL DRIVE
FRONT FINAL DRIVE REMOVAL 19-12 INSTALLATION .... 19-39
FRONT PROPELLER SHAFT 19-15 DRIVE MODE SELECTOR LEVER

LINKAGE ....... ................. ......................... 19-42
FRONT FINAL CLUTCH 19-17

DRIVE MODE SELECTOR CABLE
ADJUSTMENT 19-44
FRONT DIFFERENTIAL LOCK
CLUTCH 19-23
19-1
SYSTEM COMPONENTS
54 Nm (5.5 ,40Ibfft )
19-2
SERVICE INFORMATION
GENERAL
Periorm the gear contact panern and backlash inspection whenever you replace the bearings, gears, differential or gear
case. The extension li nes from the gear engagement surfaces should intersect at one point.
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.
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 specification given is the actual torque applied to the lock nut, not the 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 parts.
SPECIFICATIONS
Unit mm (in)
Front final Oil capacity At draining 665 cm (22.5 US OZ , 23.4 Imp oz)
drive At disassembly 760 cm 3 (25.7 US OZ, 26.8 Imp oz)
Gear backlash 0.05 0.25 (0.002 - 0.010) 0.4 (0.02 )
Backlash difference - 0.2 (0.01 )
TORQUE VALUES
Final gear case mounting nut 54 N'm (5.5 kgfm, 40 Ibf.ft) Lock nut: replace with a new one.
Final gear case cover 10-mm bolt 46.5 N'm (4.7 kgfm, 34 Ibf.ft) Apply locking agent to the threads.
Final gea r case cover 8-mm bolt 25 N'm (2.6 kgfm, 19 Ibf.ft)
Differential ring gear bolt 49 N'm {5.0 kgfm, 36 Ibf.ft} ALOe bolt: replace with a new one .
Final dutch housing bolt 25 N'm (2.6 kgfm , 19 Ibf.ft)
Pinion bearing lock nut 98 N'm {10.0 kgfm, 72 IbUt} Lock nut: replace with a new one. Stake.
Final clutch shift fork bolt 10 N 'm (1.0 kgfm , 7 Ibfft) ALOe bolt: replace with a new one.
4WO select switch 12 N' m {1.2 kgfm. 9lbfft}
Differential lock switch 12 N'm (1 .2 kgf.m. 9lbf.ft)
Final clutch arm cover and base bolt 10 N'm (1.0 kgfm , 7 Ibfft)
Differential lock stopper spring plug 21.6 N'm (2.2 kgfm, 161bf.ft)
Differential lock stopper arm bolt 20 Nm (2.0 kgf.m, 14 Ibf.ft)
Differential lock shift fork bolt 10 N' m {1.0 kgf.m, 7 Ibfft} ALOe bolt: replace with a new one.
Differential lock clutch housing bolt 25 N'm (2.6 kgfm, 19 Ibf. ft)
Drive mode selector lever pivot nut 26 Nm (2.7 kgfm, 20 Ibf.ft)
Front differential lock cable nut 26 N'm (2 .7 kgfm, 20 Ibf.ft)
Rear differential lock cable nut 26 N'm (2 .7 kgf.m, 20 Ibf.ft)
19-3
TOOLS
Driver Driver Attachment, 22 x 24 mm

07749-0010000 079493710001 07746-0010800
,
Attachment, 42 x 47 mm Attachment, 52 x 55 mm Attachment, 62 x 68 mm
07746-0010300 07746-0010400 077460010500
or 07JAD-PH80101
Attachment, 72 )( 75 mm Attachment, 30 mm 1.0. Oil seal driver attachment

077460010600 07746-0030300 07JAD-PH801Q1
Pilot, 12 mm Pilot, 15 mm Pilot. 32 mm

077460040200 07746-0040300 07MADPR90200
19-4
Pilot, 35 mm Pilot, 40 mm Fork seal driver weight
07746-0040800 07746-0040900 07747-0010100
or 07947-3710101
Fork seal driver attachment, Bearing remover head, 12 mm Bearing remover head, 15 mm
33 mm 1.0. 07936-1660110 07936KC10200
07747-0010501
or 07936 KC10500
or 07HMD-MR70100
Bearing remover shaft, 12 mm Bearing remover shaft, 15 mm Remover weight

07936-1660120 07936-KC10100 07741 -0010201
or 07936 166010A (U.S.A. only) or 07936-KC10500 or 07936-3710200 or 07936-371020A

(U.S.A. only)
Lod< nut wrench lock nut wrench, 30 x 64 mm Pinion puller base

07716-0020203 0791S-MBOD002 07HMC MMBO"0
or 07HMC-MMB011A (U.S.A. only )
19-5
Pul ler shah and nut Th readed adaptor Bearing clip compressor, 25 mm
07965-VM00200 Q70MF-H P50100 070M EHN80100
or 07931-ME4010B and or 070MF.HP5Al00 (U.s.A. only) or 070ME-HN8A 100 (U.S.A. only)

07931-HB3020A (U.S.A. only)
TROUBLESHOOTING
Consistent noise du ring cruising
Oil level too low
Foreign matter contaminating gear oil
Worn or damaged bearing
Worn or damaged ring gear and pinion gear
Deformed ring gear or gear case
Improper tooth contact between ri ng gea r and pinion gear
Gear noises while ru nning
Oil level too low
Chipped or damaged gears
Improper tooth contact between ring gear and pinion gear
Gear noise w hile coasti ng
Abn ormal noises when t urning
Worn or damaged ring gear bearing
Damaged differential components (side gear, pinion or shaft)
Worn or damaged differential housing
Abnormal noises at start or du ring accelerat ion
Excessive backlash between ring gear and pi nion gear
Worn differential splines
Loose fasteners
Oil leak
Oil level too high
Clogged breather
Damaged seals
loose case cover bolt
Overheat ing
Oil level t oo low
Insufficient backlash between ring gear and pinion gea r
19-6
FRONT DRIVE SHAFT
REMOVAL
Remove the knuckle (page 15-10).
Topreventdamage Hold the inboard joint of the drive shah and tug
to the gear case 011firmly to force the stopper ring on the inboard joint
seal, hold the end past the groove while prying with a screw-
mboafdptnt driver.
horlZOfllal until the
drIVe shah IS clear
of the gear case
Remove the stopper ring from the inboard joint.
STCIPPI'R RING
DISASSEMBLYIINSPECTION
NOTE
Do not confuse the left and right drive shaft OUTBOARD JOINT
parts.
Check the boots for cuts or other damage.
Check the drive shaft joints 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 repla ced.
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 inboard end of the shaft.
The outboard joint cannot be disassembled .
Replace the band Bend up the lock tabs and raise the band ends to
BAND ENDS
wl rh newOIles loosen the bands on the inboa rd side.
whenever Remove the boot bands from inboard boot.
f9mOVlflg rhem. Remove the boot from the inboard joint.
19-7
- stopper ring
- inboard joi nt
INBOARD
JOINT
- snap ring
- bearing
- inboard boot
- shaft boot band
Rep/ace rhese Check the following for wear or damage:

components as an - bearing cage
assembly. - race INBOARD JOINT
- steel balls
- inboard joint

- shaft boot band
- outboard boot band OUTBOARD BOOT BAND
- outboard boot
SHAFT BOOT
BAND
19-8
ASSEMBLY
DRIVE SHAFT
INBOARD JOINT
o
OUTBOARD JOINT
((j
OUTBOARD\ BOOT BAND
SHAFT BOOT BAND
1.0. 0 0 ~ot interchange them .

b 01 is large I. 0 . and the inboard boot "128-71L"
The
is outboard
small "134-71 '
INBOARD BOOT OUTBOARD BOOT
.
Note the installation direct ion of the boot bands.
FO~~:_ _ _..~
d rOlation direction
__
BAND
19-9
Pack the outboard joint with 35 - 55 9 of the sped-
fied grease.
SPECIFIED GREASE: NKG708 (Kvodo Vushi)

- outboard boot
- new shaft boot bands
- inboard boot
Do not lighten the bands at this time.
Install the bearing with the small D.D. facing the

drive shaft.
Install the snap ring with the chamfered side facing
the bearing .
The shaft 0.0 of Pack the inboard joint with 60 - 809 of the specified
the lefllnboard JOint grease.
IS larger than lhe
SPECIFIED GREASE: NKG708 (Kyodo Yushi)
fight inboard Jomt.
Do not mterchange NKG708
Inslall the inboard joint over the bearing.
them . (60 -80
Install the stopper ring into the groove in the
inboard joint properly.
Install the boot over the inboard joint securely.
Adjust the length of the drive shaft to the figu re

given below.
DRIVE SHAFT LENGTH:

Left: 582 mm (22.9 in)
Right: 486 mm (19.1 in)
19-10
NOle rne ,nSlaJ/81l{)n Install the shaft boot band and a new outboard boot
d.recrlOn of the band onto the outboard boot. SHAFT BOOT BAND
band (page 19-9/ Bend down each band end and secure it with the TABS
lock tabs. Tap the lock tabs with a plastic hammer.
OUTBOARD BAND 111

Install the shaft boot band and a new inboard boot
f3Il!
band onto the inboard boot.
Bend down each band end and secure it with the
OUTBOARD BOOT BAND
.....
SHAFT BOOT BAND INBOAFIO JOINT
INSTALLATION
Install a new stopper ring into the groove in the
inboard joint splines.
STOPPER RING II
The left drive shaft Install the drive shaft by holding the inboard joint
IS longer lhan rhe until the stopper ring seats in the groove of the
fIght dfive shaft. Do differential.
not mrerdlange Make sure that the stopper ring is seated properly
them
by pulling on the inboard joint lightly.
Be care ful nat /0
damage thB 01/ seal InSlalllhe knuckle !page 15-14).
/fl the gear case
19-11
FRONT FINAL DRIVE REMOVAL
Drain the differential oil (page 4-17).
- front wheels (page 15-6)
- left drive shaft (page 19-7)
Remove the following from the gear case:

- breather hose

- differential lock cable (loosen the cable nut and
remove from the cable holder and lock arm)
- cover bolt
- clutch arm cover (releasi ng from the two tabs)
19-12
- adjusting nut
- cable retaining plate HOLDER
- selector cable (remove from the cable holder and
joint pin)
cable spring
joint pin
NUT
- base bolts
- arm cover base
- holder bracket
Loosen t he two bracket bol ts (10 mm) and remove

the lower mounting nut and bolt (12 mm).
Remove the bracket bolts and mounti ng bracket.
remove the upper mounting nut and boll (12 mm).
19-13
engine.
Pull the propeller shaft joint to disconnect it from
the output shaft of the engine .
Remove the boot band and release the propeller
shaft boot off the pinion joint off the gear case.
Pull the propeller shaft to force the stopper ring past
the groove in the pinion joint to disconnect it.
Remove the propeller shaft out of the frame.
Remove the stopper ring from the propeller shaft.
Remove the O-ring from the output shaft.
Separate the right drive shaft from the gear case as

you remove it.
Remove the gear case assembly Qut of the frame.
OPERATION CHECK
Turn the pinion joint while the clutch arm is set to
the upper side (4WD position). and check that the
gear turns smoothly and quietly without binding.
LOCK
If the gear does not turn smoothly or quietly, the ARM
pinion gear, ring gear, bearing and/or clutch compo-
nents may be damaged or faulty. They must be
checked after disassembly; replace them if neces'
sary.
Operate the 2WD/4WD change-over mechanism
while turning the pinion joint, check for smooth
engagement/disengagement.
Check the differential lock Change-over mechanism
while turning the pinion joint; both differential
shafts in the gear case should turn each other when
the differential lock arm is in the lock position , and CLUTCH ARM
the right shaft should not turn when the lock arm is
in the unlock (lock free ) position.
19-14
FRONT PROPELLER SHAFT
DISASSEMBLY !INSPECTION
Remove the outer boot band and the shaft boot
from the propeller shaft joint to remove the shaft
joint.
SH,"FT JOINT

- joint spring
- inner boot bands
- shaft boots
SPRING
Check the propeller shaft for deformation or dam-
~
age.
Check the splines 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 for cuts, deterioration or damage.
Check the seal lip in each boot for damage.
19-15
ASSEMBLY
~ ~
SEAL LIP SEAL LIP
PROPElLER SPLINES PROPELLER

SHAFT ~ SHAFT JOINT
15-89)
Place the inner boot bands on the propeller shatto

BOOT ~
Do not allow the Apply molybdenum disulfide grease to the seal lip
sea/lip to rum of each boot. J SPRING
.1,
outside m Install the boots onto the shaft grooves, being care-
ful not to damage the seal lip.
Install the inner boot bands into the each boot
groove.
Install the joint spring into the propeller shaft
securely.
BANDS
~ BOOT
Apply 5 - 8 9 of molybdenum disulfide grease to the
propeller shaft joint splines.
Set the shaft joint onto the propeller shaft while
compressing the spring, then install the boot over
~ 15-89)
the shaft joint groove and the outer boot band into
the boot groove to secure it.
SHAFT J OINT
19-16
FRONT FINAL CLUTCH
The housing is Remove the following:
under spong - 4WD select switch and sealing washer
pressure, hold the three bolts
housing when final clutch housing (by releasing the sh ift fork
loosenmg the bolt from the sleeve) HOUSING
clutch sleeve
D-ring
dowel pins
Check the splines of the pinion joint, clutch sleeve
and pinion gear shaft for wear or damage.
Check the needle bearing i n the pinion gear shaft for
wear or damage.
DO>VELPINS
Release the clutch spring end from the stopper plate

by pulling the arm shaft.
Remove the fork bolt.

Pry the clutch arm tab to release it from the collar
and slide the shaft outward.
ARM SHAFT
19-17
- clutch spring CLUTCH SPRING
stopper p late
shift fork
clutch arm shaft
lock spring
collar
O-ring
oil sea l
ARM
SHAFT
C-RING
Check the shift fork claws for wear or damage.

Check the arm shaft and stopper plate for deforma-
tion or damage.
Check the each spring for fatigue or damage.
PINION JOINT BALL BEARING

REPLACEMENT
Remove the snap ring and drive the pinion joi nt out
of the bearing.
Remove the oil seal and the snap ring.

OIL SEAL SNAP RING
Dr ive the bearing out of the housing.
19-18
Drive a new bearing into the housing .
TOOLS;
Driver 07749-0010000
Attachme nt, 52 )( 55 mm 07746-0010400
Pilot, 32 mm 07MAOPR90200
Install the snap ring into the housing groove

securely with the chamfered edge facing the bear- SNAP RING
ing.
Pack the seal lips of a new oil seal with grease.
Install the oi l seal so that its rubber area flush with
the housi ng end.
8e careful nor to Hold the bearing inner race and press the pinion
damage the 011 seal joint into the bearing until it is fully seated .
lips
TOOLS;
Fon: se al driver weight 077470010100
Driver attachme nt, 33 mm 1.0 . 077470010501
0'
Driver attachment 07HMDMR70100
Install the snap ring into the pinion joint groove

securely with the chamfered edge facing the bear-
ing.
19-19
ASSEMBLY
PINION JOINT
CLUTCH SPRING
Oil SEAL
~ OIL SEAL
STOPPER PLATE
C1J
SHIFT FORK I
~~~~G
1 ~-
COLLAR ~RING ~+.- - SHAFT
CLUTCH ARM
Coat a new D-ring with grease and install it into the

arm shaft groove.
Apply grease to the arm shaft outer surface (collar,
fork and housing contacting area). COLLAR
Install the collar and the lock spring with the short
end toward the collar, and set the spring end into LOCK SPRING
the hole in the collar.
LOCK SPRING
Collar
side
Apply grease to the lips of a new oil seal and install

it into the clutch housing until it is fully seated.
Ta/(ecare not to let Install the arm shaft assembly, being careful not to
Ifle /oct spnng damage the oil seal.
come off rhe collar
dunng assembly.
ARM SHAFT
1920
Install the shift fork and align the groove with the
lock spring end.
While holding the Install the stopper plate by aligning the flat surfaces
shift fork, push the so the plate is attached onto the fork l ug.
arm shaft to slide It
Install the clutch spring with the bended end toward
Inward and install
the shift fork.
rhe shaft end into
the Pivot hole in the
housing.
Turn the arm shaft clockwise by holding the collar r---------------------

with a open end w rench and align the arm tab with
the 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 bo lt .
Tighten the fork bolt.
TORQUE: 10 N'm (1 .0 kgfm, 7 Ibf.ft)
ARM SHAFT
19-21
Turn the arm shaft and set the clutch spring ends
onto the housing groove and the reverse side of the CLUTCH SPRING
stopper plate as shown.
Check the arm shaft for smooth operation.
......
Install the clutch sleeve with the large 0.0. side fac- Dm_ELPINS
ing the inside.
Coat a new O-r ing with grease and install it into the
lit O-RII'G
case groove.
Aligning the fork claws with the sleeve groove,

install the final clutch housing while turning the
clutch arm, then secure it with the bolts.
Tighten the three bolts.
TORQUE: 25 Nm (2.5 kgfm, 18 Ibf.ft)
Install the 4WD select switch with a new sealing
washer and tighten it.
TORQUE: 12 N'm (1.2 kgf-m , 9 Ibf.ft) FORK
Check the final clutch operation (page 19-141,
19-22
FRONT DIFFERENTIAL LOCK CLUTCH
- differential lock switch and sealing washer
- stopper spri ng plug and sealing washer BOLTS
- stopper spring
- steel ball
four bolts and cable holder
/.~
BALL I ~
SPRING
- differential lock clutch housing tby releasing the

shift fork from the sleeve)
- differential half shaft
- lock sleeve
- O-ring
- two dowel pins
Check the spl ines of the lock sleeve and ha lf shaft
for wear or damage.
Check the steel ball and stopper spring for wear or
damage.
DOWEL PINS
19-23
Remove the oil seaL
Oil SEAL
Remove the fork bolt.

SPRING
Slide the shjft fork to release its spring pin from the
spring ends.
Release the fork spring from the spring pin on the
stopper arm. ARM

- arm bolt and washer BOLT AND
- stopper arm
WASHER
- fork spring
- shift fork
- lock arm shaft OIL SEAL ~-ARM
- oil seal
ARM - - '' ' '

SHAFT
Check the shift fork claws for wear or damage.

Check the arm shaft and stopper arm for deforma-
tion or damage.
Check the spring for fatigue or damage.
19-24
HALF SHAFT BEARING
REPLACEMENT
Drive the bearing out of the housing.
Drive a new bearing into the housing with the mark-
ing facing up.
TOOLS:
Driver 07749-0010000
Attachment, 62 x 68 mm 07746-0010500
Pilot, 35 mm 077460040800
PILOT ATIACHMENT
ASSEMBLY
DIFFE RENTIAL LOCK
OILSEAL ~
( O,/~~ ARM SHAFT
)
@. BEARING IS007)
STOPPER ARM --~~, ~ , FORK SPRING

SHIFT FORK
Apply grease t o the lips of a new oi l seal and install

it into the ctutch housing until it is fully seated.
Apply grease to the lock arm shaft outer surface
(fork and housing contacting surface).
Install the arm shaft, bei ng careful not to damage
the oil seal, then insta l the shift fork with the bolt
hole facing up.
ARM
SHAFT
Install the fork spring and stopper arm and set the WAS HE R AND
shaft end into the pivot hole i n the housing so the
spring end rest onto the spr ing pin on the stopper
arm as shown.
SPRING BOLT 0
....
Apply locking agent to the threads of the stopper
arm bolt.
STOPPER
Align the bolt holes with the shaft arm facing down,
ARM
then install the arm bol t with the washer and tighten
it.
TORQUE: 20 N'm (2.0 kgfm , 14 Ibf.ft)
19-25
Hook the fork side spri ng end o nto the underside of
the spring pin on the stopper arm , using a screw-
driver.
Slide the shift fork and set its spring pin between
the spring ends.
Align the bolt hole in the fork with the groove in the
shaft and inst all a new fork bol t.
Tighten the fork bolt.
....
~ BOLT
TORQUE : 10 N'm !1 .0 kgfm, 7 Ibf.ft)
Install a new oil seal so that it is flush with the hous-

ing end, being careful not to damage the lip.
TOOLS:
Driver 077490010000
Oil seal driver attachment 07JAOPH80101
Pack the seal lips of the oil seal with grease.
19-26
Install the lock sleeve and half shaft in the direction
as shown.
case groove.
Install the two dowel p ins.
Install the differential lock clutch housing by align-

ing the fork claws with the sleeve groove.
Install the four bolts with the cable holder and
t ighten them .
19-27
Install the steel ball and stopper spring.
Install the spring plug with a new sealing washer
and tighten it.
TORQUE: 21.6 N 'm (2.2 kgfm , 16 Ibf.ft)
Install the differential lock switch with a new sealing
washer and tighten it.
fI
WASHER
TORQUE: 12 N'm (1.2 kgfm , 9Ibf.ft)
Check the differential lock clutch operation (page
19-14).
BALL--,..., I
SPRl , PLUG
FRONT FINAL GEAR DISASSEMBLY I

INSPECTION
- final clutch housing (page 19-17)
- diHerentiallock clutch housing (page 19-23)
BACKLASH INSPECTION
Sel the final gear case into a jig or vise with soft
jaws.
Remove the o il filler cap.
Cover the c/urell Hold the pinion gear with the special tools.
hOUSing mating TOOLS :
SlJrf~ce with
pro/ectlVe tape Of Pinion puller base 07HMC-MM80110
an equIValent to Puller shaft and nut 07965VM00200
prBvent damaglflg Threaded adaptor 070MF HP50100
II U.S.A. TOOLS:
Pinion puller base 07HMC MM8011A
Puller shaft 07931ME4010B
Special nut 07931H83020A
Threaded adaptor 070MFHP5A100
19-28
Set a horizontal type dial indicator on the ring gear
through the filler hole.
Turn the ring gear back and forth using the lock nut LOCK NUT
w rench to read backlash. y"" WRENCH
TOOL:
Lo:k nut w rench 07716-0020203
STANDARD: 0.05 - 0.25 mm (0.002 - 0.010 in)

SERVICE LIMIT: 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.
If the difference in measurements exceeds the ser-

vice limit, it indicates that 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 '-------;:~!;:;---------l
side shim with a thinner one. I
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
RIGHT SHIM
in) when the thickness of the shim is changed by
0.10 mm (0.004 in).
NOTE :
LEFT SHIM ~~:~~
Fifteen d ifferent left shims (from A to 0) and sev-
enteen different right shims (from A to Q) are
available in thickness increments of 0.06 mm
(0.002 in).
RING GEAR SHIMS:

Right side:
A : (thinnest): 0.64 mm (0.025 in)
G: (standard): 1.00 mm (0.039 in)
0 : (thickest): 1.48 mm (0.058 in )
Left side:
A : (thinnest): 0.64 mm (0.025 in)
G: (standard): 1.00 mm (0.039 in )
0 : (thickest): 1.60 mm (0.063 in )
Change the right side shim as follows: If the left

shim was replaced with a 0.10 mm (0.004 in) thicker
shim, replace the right shim with one that is 0.10
mm (0.004 in) thinner.
DIFFERENTIAL REMOVAL
Loosen the six cover bolts in a crisscross pattern in BOLTS
several steps and remove them. PRYING POINTS
Pry the case cover at the points as shown and
remove it.
CASE COVER
19-29
Remove the O-ring.
Remove the differential assembly and shims. C-RING
DIFFERENTIAL
BEARING INSPECTION
Turn the inner race of each bearing in the gear case
and cover with your finger. The bearings should
turn smoothly and quietly. Also check that the bear-
ing outer race fits tightly in the case or cover.
Differential bearing replacement (page 19-34)
GEAR TOOTH CONTACT PATTERN

CHECK
Keep dust and dirt Apply thin coat of Prussian Blue to the pinion gear
our of the case and teeth for a tooth contact pattern check.
cover. Apply Prussian Blue
Install the ring gear shims onto the differential
assembly.
LEFT
Install the differential assembly into the gear case.
19-30
It IS important to Install the case cover and tighten the bolts in several
turn the pinIOn gear steps until the cover evenly touches the gear case.
while tightening the Then, while rotating the pinion gear, tighten the Bmm
boilS. If the ring bolts to the specified torque in a cr isscross pattern
gear shim IS /00 in several steps.
thiCk. the gears will
lock after only light TORQUE : 10 mm bo lt: 46.5 N 'm (4.7 kgfm , 34 Ibf.ttJ
tlghtemng 8 mm bott: 25 N'm (2.6 kgfm , 19 Ibf.tt)
COVER
Remove the oil filler cap.

Rotate the ring gear several times in both di rections
NORMAL:
HEEL ~
of rotation.
TOE
Check the gear tooth contact pattern through the oil
filler hole.
~
rt
~
FACE __ ____ FACE
.~
The pattern is indicated by the Prussian Blue
applied to the pinion.
Contact is normal if the Prussian Blue is transferred
to the approximate center of each tooth, but slightly r:;:::: Q1. ic9 ~i
FLANK FLANK
to the heel side and to the flank side. c1 ~ ~ - , In! Drive side Coast side
If the patterns are not correct, remove and change

the pinion shim with one of an alternate thickness.
- =.!"""'~--..,;;,'S - '",
Replace the pinion shim with a thicker one if the

contact pattern is too high, toward the face. TOO HIGH: ~ ,1 ~
rT.
PINION
SHIM
<;= . ,.
ritJiI.lJ!ii ~
Cd .--.::- . .. _ .._
FACE FACE =
Drive side
leY' ~l
Coast side
+,
Replace the pinIOn shim with a thinner one if the
TOO lOW:
contact pattern is too low, toward the flank.
The pattern will shift about 0.5 - 1.0 mm (0.02 - 0.04
I!: I III PINION
SHIM
0.12 mm (0.005).
NOTE:
Fifteen different thickness shims (from A to 0) clJ_
<;=
,IE. "'~ l,
=~~-~-
are available in thickness increments of 0.06 mm
(0.002 in).
I~ ~ I
PINION GEAR SHIMS:
A: (thinnest): 1.64 m m (0.064 in)
G: (standard ): 2. 00 mm (0.079 in ) Drive side Co",, 'ide
FLANK
0 : (thickest ): 2.48 mm (0.086 in)
Pinion shim replacement (page 19-33).
19-31
DIFFERENTIAL INSPECTION
Rep/ace the Turn the differential gears in the housing and check
dlfferentialas8n that the gears turns smoothly and quietly without
assembly. binding .
Check each gear for wear or damage.
RING GEAR REMOVAL

Remove the ten bolts and the ring gear.
RING GEAR
PINION GEAR REMOVAL
Be carefulrhat Unstake the bearing lock nut with a drill or grinder.
metal partie/es do
nor enter the
bearmg and the
threads of the case
are nOI damaged.
Remove the lock nut and discard it.
TOOL: LOCKNUT
Lock nut wrench, 30 x 64 mm 07916-MB00002 WRENCH ~~
19-32
Covertheclulch Install the special toots onto the pinion gear shaft
housing matmg and gear case. Using a heal gun, heat the case.
surface with
aluminum shims or TOOLS: PULLER
an equIValent to Pinion puller base 07HMC-MMB0110 - -SHAFT
prevent damagmg Puller shaft and nut 07965-VM00200
It Threaded adaptor 070MF-HP50100
U .S.A. TOOLS:
Pinion puller base 07HMCMM8011A PULLER _ _+
Puller shaft 0193'ME4010B BASE
Special nut 01931HB3020A ADAPTOR
Threaded adapt o r 070MFHP5Al00
Pull the pinion assembly out from the gear case .
PINION BALL BEARING AND SHIM

REPLACEMENT
Take care not to Press the pinion gear out of the bearing.
contact the support
Remove the pinion shim.
blocks agamst the
gear teeth. Replace the pinion jOint needle bearing in the shaft
end if necessary (pa ge 19-34).
Install the shim and bearing onto the pinion gear.

PINION GEAR
NOTE:
When the gear set, differential bearing, differen-
tial and/or gear case has been replaced, use a
2.00 mm (0.079 in) thick shim for initial reference.
Press the pinion gear into a new bearing until it is

fully seated by supporting the bearing inner race.
TOOL:
Attachment, 30 mm 1.0 . 017460030300
19-33
PINION JOINT NEEDLE BEARING
REPLACEMENT
Remove the pi nion ball bearing (page 19-33).
PI NION GEAR
Be sure to wear Heat the pinion gear to about 80'" C (176 C F) and
heavy gloves to remove the needle bearing, using the special tools.
avo-d burns when
TOOLS:
handl.ng the healed
gear Remover head, 12 mm 07936- 1660110
USing a fOrd! to Remover shaft, 12 mm 07936 16601 20 or
heal the gear may 07936-166010A
cause warpage (U.S.A. only)
Remover weight 0774'0010201 or
07936371020A
(U.S.A . only) or
07936-3710200
(U.S.A. on ly) BEARING
Press a new bearing into the pinion gear with the

marking facing up so that it is flush with the shaft
end.
TOOLS:
Driver 07749-0010000
Attachment, 22 II 24 mm 077460010800
Pilot, 12 mm 07746-0040200
Install the pi nion ball beari ng (page 19-33) ,
PILOT - -
CASE BEARING REPLACEMENT

DIFFERENTIAL BEARING
Remove the oil seal from the gear case.
Dr ive the bearings out of the case and cover.
Drive new bea rings into the gear case and cover.
TOOLS:
Cover Side:
Driver 07749-0010000
Attachment, 72 )I 75 mm 07746-0010600
Case Side:
Driver 077490010000
Attachment. 62)1 68 mm 077460010500
Pilot, 40 mm 07746-0040900
19-34
Install a new oil seal so that it is flush with the gea r
case, being careful not to damage the lip.
TOOLS:
Driver 07749-0010000
Oil seal driver attachment 07JAD-PH80101
Pack the seal lips of the dust seal with grease.
PINION NEEDLE BEARING

Rotate the stopper ring until its end appears in the
access hole.
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
heavy gloves ro remove the needle bearing, using the special lools.
avoid burns when
handling rhe heared
TOOLS:
gear case Remover head, 15 mm 07936-KC10200
Using a torch ro Remover shaft, 15 mm 07936-KC10100 or
hear the gear case Bearing remover, '5 mm 07936-KC10500
may cause Remover weight 07741-0010201 or
warpage. 07936-371020A
(U.S.A. only) or
07936-3710200
(U.S.A. only)
Remove the bearing cage and bearings from the
inside of the pinion bea r ing to allow the special tool
to grip the bearing.
Install a new stopper ring into the groove in a new ~---------------------,
Make sure the

bearing .
Install the bearing into the compressor until the
STOPPER RING fI
stopper ring stays stopper ring is flush with the end of the tool.
In rhe groove
TOOL:
Bearing clip compressor, 070ME-HN80100 or
25mm 070MEHN8A100
(U.S.A. only)
COM PRESSOR
19-35
Place the driver, attachment and pilot on the top of
the bearing and tape the driver to the compressor.
TOOLS :
Driver 079493710001
Attachme nt, 22 x 24 mm 077460010800
Pilot, 15 mm 077460040300
Place the bearing and tool assembly into a freezer
for at least 30 minutes.
Using a heat gun, heat the gear case to 80~C (176 c 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 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.
FRONT FINAL GEAR ASSEMBLY

CABLE
SEALING
SPRING WASHER DIFFERENTIAL
PLUG
\~~KSWITCH
GEAR CASE
COVER SEALING
WASHER ---"y- O-RING
FINAL CLUTCH
HOUSING
STOPPER ______/ HALF SHAFT

SPRING
DOWEL PINS
c STEEL BAll
DIFFERENTIAL lOCK
CLUTCH HOUSING LOCK
PINS SLEEVE
WASHER
DIFFERENTIAL SLEEVE PINION BEARING (6206)
PINION JOINT NEEDLE LOCK

DIFFERENTIAL NUT
BEARING (6009) ,
BEARING (12 x 18 x 12)
PIN ION NEEDLE

BEARING (15 25 x 16)
RING GEAR PINION

SHIM
I I
GEAR
RING
GEAR CASE
OIL SEAL
19-36
PINION GEAR INSTALLATION
Dr ive the pinion gear assembly into the gear case.
TOOLS:
Driver 077490010000
Attachment. 42 x 47 mm 07746 0010300 or
Oil seal driver attachment 07JAD PH80101
Fork seal driver weight 077470010100 or
Fork seal driver, 37 mm 07947 3110101
Install a new lock nut and tighten it.
TOOL:
Lock nut wrench, 30 x 64 mm 07916MB00002
Refer to the SerVice TORQUE: Actual: 98 N 'm (10.0 kgfm , 12 Ibf.ft)

Information for Indicated: 89 N'm (9.1 kgfm , 66 Ibf.ft)
torque wrencfJ
reading information
(page 19-3).
iii LOCK
Be careful not to Stake the lock nut into the case groove.
damage the threads
of the case
RING GEAR INSTALLATION

Clean t he mating su rfaces of t he ri ng gear and dif-
fe rential h ousing thoroughly and install the ring
gear, aligning the bolt holes in the gear and hous-
ing. iii
BOLTS
Install new ri ng gear bolts and tighten them in a
crisscross pattern in several steps.
TORQUE: 49 Nm (5.0 kgfm, 36 Ibfft )
GEAR
19-37
FINAL GEAR CASE ASSEMBLY
NOTE:
When the gear set, bearing, differential andlor
gear case has been replaced, check the tooth
contact pattern (page 19-30) and check the gear
backlash (page 19-28).
Keep dust and din Clean the mating surface of the gear case and cover,
our of the case and being careful not to damage them.
cover
Blow compressed air th rough the breather hole in
the case cover.
Install the proper ring gear shims onto the differen-

SHIMS
tial assembly _

case cover groove .
Install the case cover over the gear case.
19-38
I( IS Impommt to Apply locking agent to the threads of the two 10-
turn Ifle PInion gear mm bolts. 10 mm BOLTS
whIle Ilghtemng the Install the six bolts and tighten them in several 8 mm BOLTS
bolts If the ring steps until the cover evenly touches the case. Then , '1"
gear shIm IS roo while rotating the pinion gear, tighten the bolts to
thlCt the gears Will the specified torque in a crisscross pattern in sev-
,. I
locle after only light eral steps. \;
\
/Ightenmg
TORQUE: 10 mm bolt: 46.5 N' m (4.7 kg'm, 34Ibf.ft)
8 mm bolt: 25 N m (2 .6 kg f m , 19 Ibf.ft)
;
J)
Make sure that the gear assembly rotates smoothly 1''';- {)
without binding. L
Install the following : r
,J.
- final clu t ch housing (page 19-22)
- differential lock clutch housing (page 19-27 )
FRONT FINAL DRIVE INSTALLATION

Place the gear case assembly into the frame.
Install the righ t drive shaft into the gear case (page
19-11 ).
Install a new st opper ring into the groove in the pro-

peller shaft . ~ STOPPER
....... RING
Apply molybdenum disulfide grease to the seal lip
of the front side boot.
Make sure the seal lip is not turned outside in.
Apply molybdenum disulfide grease to the fron t
/(i~~::,~:l~\_
end of the propelle r shaft
~ PROPELLER
BOOT SHAFT
19-39
Apply 5 - 89 of molybdenum disulfide grease to the
pinion joint splines.
Place the boot band over the pinion joint tempo-
rarily.
Install the propeller shah into the pinion joint. align-
ing 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 over the pinion joint groove securely
and the boot band into the boot groove.
grease and install it into the output shaft groove. ~~~~:;~;~
clearance between the shaft joint and output shaft.
move the gear case assembly rearward .
The mounMg bolts Inst all the mounting bracket ont o the gear case with
are Installed from the lower mounting bolt (12 mm) and a new mount-
the leh SJde ing nut.
Align the upper mounting bolt holes in the gear
case and frame, then install the mounting bolt (12
mm) and a new moun ting nut.
Install the two bracket bolts (10 mm).
Tighten the bracket bolts.
Tighten the gear case mounting nuts.
TORQUE: 12 mm : 54 N'm 15.5 kgfm , 40 Ibf.ft)
19-40
Install the holder bracket and cover base with the
two bolts, and tighten them .
TORQUE: 10 N'm 11.0 kgfm . 7 Ibf.ft J
Set the drive mode se lector lever to the 2WD posi , - -- - - - - - - , -- - -- - - - - - -- ,

tion.
Install the spring onto the selector cable.
Insert the cable into the cable holder and connect it
to the clutch arm with the joint pin and adjusting
nut.
Set the groove in the cable grommet onto the cover
base end properly. RETAINING
Install the retaining plate ont o the cable with the
concave facing the cable holder to secure the cable. PLATE "J"!jL~,gr\t i1'-'i'--
~ PIN
Operate the differential lock arm to the upper side to

set it to the lock free position .
Connect the differential lock cable to the lock arm
and install it into the cable holder by aligning the
flat surfaces.
Install the washer and a new cotter pin.
Make sure that the Screw the cable nuts t ogether gradually {to move
dnve mode selector both nuts to the cable holder side) by your hands so
leveris2WD that the cable does not forced until they are touched
position and the to the cable holder.
differential lock arm Tighten the cable nut while holding the other nut.
IS 1rx.J< free (upperl
position. TORQUE: 26 Nm (2.7 kgfm , 20 Ibfft)
Connect the breather hose and the different ial lock

switch connector.
19-41
Connect the 4WD select switch connector.
- left drive shaft (page 19-11)
- front bumper (page 3- 16)
16).
DRIVE MODE SELECTOR LEVER

LINKAGE
REMOVAL
Remove the battery box cover (page 21 -6).
tion.
- selector lever g rip
- cable joint nut

- front differential lock cable
- lever pivot nut and bolt
- selector lever
- lever spring
- cotter pi n and washer

- rear differential lock cable
- arm pivot bolt
- lever arm (from the frame)
- 2WD/4WD selector cable (from the arm)
19-42
INSTALLATION
Apply grease to the selector lever arm pivot.
Connect lever arm to the 2WO/4WD selector cable
and install the lever arm onto the frame with the
pivot bolt (washer-bolt).
Connect the rear differential lock cable to the lever

arm and secure it with the washer and a new coner
pin.
Tighten the pivot bolt.
Apply grease to the groove in the selector lever

pivot bolt.
Install the lever spring onto the selector lever in the
direction as shown.
Install the selector lever through the lever gale and
onto the lever arm by setting the lower spring end
into the arm groove. Hold the lever pivot securely to
align the bolt holes, then install the pivot bolt
(socket bolt).
Install the pivot nut and tighten it.
Connect the front differential lock cable to the selec-

tor lever from the lower side. Install the joint nut
and tighten it.
19-43
Install the lever grip with the tab facing forward.
Check the selector lever for smooth operation
Perform the cable adjustment if necessary (page 19-
44).
Install the battery box cover (page 21-6).
DRIVE MODE SELECTOR CABLE

ADJUSTMENT
right front wheel (page 15-6)
- regulator/rectifier (page 21-8)
tion.
Remove the bolt and the clutch arm cover by releas-

ing it from the two tabs.
Loosen the adjusting nut on the 2WD/4WD selector ,---~~~~--:-~~~~~~~~~~-,
cable thoroughly until the cable is not forced (to get SELECTOR
the clearance between the joint pin and upper side CABLE
of the arm slot).
~~
"f: SLOT
'"
JOINT PIN V""' __ ADJUSTING
NUT
19-44
FRONT ORIVING MECHANISM
Release the retaining straps and open the front'
hood .
Do not loosen the Loosen the selector lever side cable nuts (both
gear case side lad: lower and upper) on each differential lock cable
nuts. thoroughly.
Operate the differential lock ar m on each differential

by your hand and set it to the lock free position.
Tum the Ignition - front differential lock arm: upper side
switd! to ON (I) and - rear differential lock arm: front side
check that the all
differential lock
indicator does not
come on {this
mdicator IS
detected the only
the front dlfferenual
lock}.
Do not move the Screw the cable nuts on each differential lock cable
selector lever from together gradually (to move both nuts to the cable
the 2WD position. holder side) by your hands so that the cable does
not forced until they are touched to the cable
holder.
Tighten the cable nut while holding the other nut.
TORQUE: 26 Nm (2.7 kgfm, 20 Ibf ft )
19-45
Make sure the freeplay lengthwise at the 2WD and
the 4WO-Rear Oiff lock position in the direction as GATE
shown. SELECTOR
Morethan
Make su re the free play crosswise at the 4WD-Rear LEVER
2mm
Diff Lock and the 4WD-AII Diff Lock position in the
direction as shown. _t
2WO
----f
; i Mo rethan
2mm
Mo rethan
Morethan
2mm
2mm
4WO-AII
Oiff Lock
Set the drive mode selector lever to the 2WD pasi- ~==================::::;
tion. Be sure the clutch arm position is between the
2WD marks.
Turn the adjusting nut on the 2WD/4WD selector
&
cable clockwise until the joint pin just touches the
clutch arm slot w ith the nut ends are contact ed the
~: O.25-
joint pin (cutout is not seated), Then furthe r turn it ~) 2mm
clockwise 1/4 of a turn to seat the cu t out in the nut
onto the joint pin.
Make sure thai the clearance between the joint pin
and arm slot is 0.25 - 2 mm. Nut ends
After adjustment, check the selector lever for
smooth operation. SLOT
Install the arm cover by aligning the slits with the

tabs and tighten the bolt.
TORQUE: 10 N' m (1 .0 kgfm , 7 Ibf.ft)

- front wheel (page 15-6)
- regulator/rectifier (page 21-8)
19-46
20. REAR DRIVING MECHANISM
SYSTEM COMPONENTS ............... .......... 20-2 REAR DIFFERENTIAL LOCK CLUTCH ... 20-15
SERVICE INFORMATION .............. ..... ...... 20-3 REAR FINAL GEAR DISASSEMBLY I
INSPECTION ........................................... 20-21
TROUBLESHOOTING ............................... 20-6
CASE BEARING REPLACEMENT .......... 20-26
REAR DRIVE SHAFT .. 20-7
REAR FINAL GEAR ASSEMBLy 20-29
REAR FINAL DRIVE REMOVAL ............. 20-12
REAR FINAL DRIVE INSTALLATION ..... 20-32
20-1
SYSTEM COMPONENTS
54 N'm (5.5 kgfm , 40 IbUt)
j
II
202
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 the gear engagement surfaces should intersect at one point.
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.
When using the lock nut wrench (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 the lock nut. The specification given is the actual torque applied to the lock nut, not the 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.
For drive mode selector lever service and adjustmen t, see Front Driving Mechanism section (page 19-42).
SPECIFICATIONS
Unit mm (in)
Rear final Oil capacity At draining 465cm (15.7 US OZ, 16.4 Imp oz)
drive At disassembly 520 cm (17.6 US OZ, 18.3 1mp oz)
t--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)
Ring gear-to-stop pin clearance 0.3 0.6 (0.01 0.02)
TORQUE VALUES
Final gear case mounting nut 54 Nm (5.5 kgfm, 40 Ibfft) lock nut: replace with a new one.
Final gear case cover 10 mm bolt 46.5 N'm (4.7 kgfm , 34 Ibfft) Apply locking agent.
Final gear case cover 8 mm bolt 25 Nm (2.6 kgfm, 19 Ibfft)
Differential ring gea r bolt 58 Nm (5.9 kgfm, 43 Ibfft) left-hand threads. Apply locking agent.
Pinion bearing lock nut 98 Nm (10.0 kgfm, 721bf.ft) lock nut: replace with a new one.
Stake.
Differential lock stopper spr ing plug 21.6 N'm (2.2 kgfm, 16Ibfft)
Differential lock stopper arm bolt 20 N'm (2.0 kgfm, 14 Ibfft) Apply locking agent.
Differential lock shift fork bolt 10 N'm (1.0 kgfm, 7 Ibfft) AlOe bolt: replace with a new one.
Differential lock clutch housing bolt 25 N'm (2.6 kgfm, 19 Ibfft)
20-3
TOOLS
Bearing remover. 17 mm Remover handle Remover weight

07936-3710300 07936-3710100 07741-0010201
or 079363710200 or 07936-37 1020A

(U.S.A. only)
Driver Driver Attachment, 24)( 26 mm

07949-3710001 07749-0010000 07746-0010700
Attachment, 62 x 68 mm Attachment, 72 x 75 mm Oil seal driver auachment

077460010500 07746-0010600 07JAD-PH80101
=
Driver attachment Pilot, 17 mm Pilot, 35 mm
07LAD-PW50500 07746-0040400 07746-0040800
or 07AMD-HL1Al00 (U.S.A. only) or 07YMC-GCS0100 (not available in

U.S.A.)
20-4
Pilot, 40 mm Fork seal driver attachment Bearing dip compressor. 28 mm
07746-0040900 07947-KF00100 070ME HN80200
or 070ME- HN8A200 (U.S.A. onlv)
Pinion puller base Puller shaft and nut Threaded adaptor

07HMC-MM80110 07965VM00200 070MF-HP50100
~
~
or 07HMC-MM8011 A (U.S.A. only) or 07931 ME4010B and or 07QMF-H P5A 100 (U.S.A. only)
07931-H83020A (U.S.A. onlv)
Lock nut wrench Holding tool

077160020203 Snap-on YA6010A or equivalent
20-5
TROUBLESHOOTING
Consistent n oise during cruising
Oil level too low
Worn or damaged bearing
Worn or damaged ring gear and pinion gear
Deformed ring gear or gear case
Improper tooth contact between ring gear and pi nion gear
Gear noises w hile running
Oil level too low
Improper tooth contact between (ing gear and p inion gear
Gea r noise while coasting
Abnormal noises when turning
Worn or damaged ring gea r bea ri ng
Damaged differential components (side gea r, pi nion or shaft)
Worn or damaged differential housing
Abnormal noises at start or during accelerat ion
Excessive backlash between ring gear and pinion gear
Worn differential splines
Loose fasteners
Oil leak
Oil level too h igh
Clogged breather
Damaged seals
loose case cover bolt
Overheating
Oil level too tow
Insufficient backlash between ri ng gear and p inion gea r
20-6
REAR DRIVE SHAFT
REMOVAL
Remove the knuckle (page 17-5).
Topreventdamage Hold the inboard joint of the drive shaft and tug
/0 the gear case 011 firm ly to f orce the stopper ring on the inboa rd joint
seal, hold the end past the groove while prying with a screw
inboardJomt driver.
hOriZontal until the
drtve shah IS clear
of rhe gear case
Remove the stopper ring from the inboard jOint.
STOPPER RING
NOTE:
Do not confuse the left and right drive shaft
OUTBOARD JOINT
parts.
Check the boots for cuts or other damage.
Check the drive shaft joints 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
inhoard boot as described in the following steps.
Then remove the bands and outboard boot from
the inboard end of the shaft.
The outboard joint cannot be disassembled.
INB'O AfmJOINT
Replace the band Bend up the lock tabs and raise the band ends to
With new ones loosen the boot bands on the inboard side. BAND ENDS
INBOARD BOOT BAND
whenever Remove the boot bands from the in board boot.
removmg them .
Remove the boot from the inboard jOint.
20-7
- stopper ring
- inboard joint
- snap ring
- bearing
- inboard boot
- shaft boot band
SNAP RING
BEARING
Rep/ace theirCheck the following for wear or damage:

INBOARD JOINT
components as an _ bearing cage
assembly _ race
- steel balls
- inboard joint

OUTB()Afm BOOT BAND
- shaft boot band
- outboard boot band
- outboard boot
20-8
ASSEMBLY
DRIVE SH,'FT
INBOARD JOINT
SNAP RING -='"Yn

BEARING /(
C1==f1 STOPPER RING
,~ INBOARD BOOT BAND
(n) BEARING RACE

OUTBOARD BOOT BAN 0
~ INBOARD BOOT
SHAFT BOOT BAND

BEARING CAGE
Each boot has an identification mark shown below.

Do not interchange them. IDENTIFICATION MARKS
RighI drive shaft: Inboard: "12871 l ~

Outboard: " '3471"
Left drive shaft : Inboard: "'7242NBJ75 "
Outboard: " '347' "
OUTBOARD BOOT INBOARD BOOT
Note the installation direction of the boot bands.

Forward rotation direction
BAND
20-9
Pack the each outboard joint with 35 - 55 9 of the
OUTB')AFm BOOT
specified grease.
SPECIFIED GREASE: NKG708 (Kyodo Yu shiJ SHAFT BOOT BANOS

Install the following :
- outboard boot
- new shaft boot bands
- inboard boot
Do not tighten the bands at this time.
NKG708
(35 - 559)
INB'OAFID BOOT
Install the bearing with the small 0 .0 . facing the
drive shaft.
Install the snap ring with the chamfered side facing
the bearing.
The shafl o.D. of Pack the specified grease to the each inboard joint
fhe left mboard JOint shown below.
IS larger than the RING
fight mboard Jomt SPECIFIED GREASE: NKG108 (Kyodo Yu shi)
Do nor Interchange Right inboard joint: 60 - 80 9
them Left Inboard joint: 80 - 100 9
Install the inboard joint over the bearing .
Install the stopper ring into the groove in the
inboard joint properly.
Install the boot over the inboard joint securely.
Adjust the length of the drive shaft to be set the fig-

ure given below.
DRIVE SHAFT lENGTH:

Right: 578 mm (22.8 In)
l eft: 499 mm (19.6 in)
20-10
No te the installation Install the shaft boot band and a new outboard boot
direcrton of Ihe band onto the outboard boot.
band (page 20-9) Bend down each band end and secure it with the
OUTBC)AFID BOOT BAND tI

Install the shaft boot band and a new inboard boot
band ont o the inboard boot.
INBOARD BOOT BAND S"
INBOARD JOINT
INSTALLATION
Install a new stopper ring into the groove in the
inboard joint splines.
The fight dflve shaft Install the drive shaft by holding the inboard joint
is longer than the until the stopper ring seats in the groove of the
left drive shaft. Do differential.
nor mterchange Make sure the stopper ring is seated properly by
them.
pulling on the inboard joint lightly.
Be careful nOllO
damage rhe oil seal Install the knuckle (page 17-8).
in rhe gear case
20-11
REAR FINAL DRIVE REMOVAL
Drain the differential oil (page 4-17).
- drive shafts (page 20-7)
- cargo bed damper (page 316)
- two bolts and damper stay
- VS sensor (page 653)

- wire band
- breather hose

- differential lock cable (loosen the cable nul and
remove it from the clip, cable holder and lock
arm)
20-12
Support the gear case with wooden blocks to relieve
stress for ease of bolt removal, and remove the gear
case mounting nuts and bolts.
Release the gear case assembly from the mounting
points to disconnect the propeller shaft. Move the
p ropeller shaft aside and remove the gear case
assembly out of the frame.

- propeller shaft
- universal joint
- joint spring (from the propeller shaft)
- O-rings (from the propeller shaft and output
shaft of the engine)
INSPECTION
PROPELLER SHAFT
Check the splines of the propeller shaft for wear or
damage.
If the they are damaged, check the pinion and uni-
versa! joint splines also.
20-13
UNIVERSAL JOINT
Check the boot for cuts or other damage.
Check that the joint moves smoothly without bind-
ing or noise.
OPERATION CHECK
Temporarily install the propeller shaft.
Turn the pinion gear and check that the gear turns
smoothly and quietly without binding.
If the gears do nOI turn smoothly or quietly, the
gears andlor bearing may be damaged or fau lty.
They must be checked after disassembly; repl ace
them jf necessary.
Check the differential lock change-over mechanism LOCK
while turning the pinion gear; both differential ARM
shafts in the gear case should turn each other when
the differential lock arm is in the lock position, and
the right shaft should not turn when the lock arm is
in the unlock (lock free) position.
SHAFT
UNIVERSAL JOINT DISASSEMBLY I

ASSEMBLY
Bend up the lock tabs and ra ise the band ends to
loosen the boot bands.
Remove the joint boot.
Apply grease to the jOint bear ing.
Install the boot and set it onto the universal joint
properly.
TABS
20-14
Install new boot bands so the band ends are facing
opposite the forward direction. Viewed from the rear side:
d;"CtiOn~
Fo"",d
1)._ TABS
" \ND
~ Bl
REAR DIFFERENTIAL LOCK CLUTCH
- stopper spring plug and sealing washer BOLTS HOLDER
- stopper spring
- steel ball
- four bolts and cable holder
/0\ ..
BALL SPRING
20-15
- differential lock clutch housing (by releasing the
shift fork from the sleeve)
- differential half shaft
- lock sleeve
- O-ring
- two dowel pins
Check the splines of the lock sleeve and half shaft
for wear or damage.
Check the steel ball and stopper spring for wear or
damage.
DOWEL PINS SHAFT
Remove the oil seal.

OIL SEAL
Remove the fork boll. SPRING

Slide the shift fork to release its spring pin from the
spring ends.
Release the fork spring from the spring pin on the ARM
stopper arm.
20-16
Remove the follow i ng:
- arm bolt and washer BOLT AND
- stopper arm WASHER
- fork spring
- shift fork
- lock arm shaft OI L SEAL _ - ARM
- oil seal
FORK
ARM
SHAFT
Check the fork claws for wear or damage.

Check the ar m shaft and stopper arm for deforma-
tion or damage.
Check the spr ing for fatigue or damage.
HALF SHAFT BEARING

REPLACEMENT
Remove the bearing of the housing .
Drive a new bearing into the housing with the mak-
ing facing up.
TOOLS:
Driver 07749-0010000
Attachment, 62 x 68 mm 077460010500
Pilot, 35 mm 077460040800
,
PILOT
20-17
ASSEMBLY
DIFFERENTIAL LOCK
OILSEAL ~
o O,/~~ARM SHAFT
Q\
@. BEARING (6007)
STOPPER ARM -, SPRING

SHIFT FORK

it into the clutch housing until it is fully seated.
Apply grease to the lock arm shaft outer surface
(fork and housing contacting surface).
Install the arm shaft, being careful not to damage
the oil seal, then install the shift fork with the bolt
hole facing up. FORK
ARM
SHAFT
OIL SEAL
fI~~
Install the fork spring and stopper arm and set the
SPRING WASHER AND BOLT
shaft end into the pivot hole in the housing so the
spring end rest onto the spring pin on t he stopper
arm as shown.
C1m:J
Apply locking agent to the threads of the stopper
arm bolt.
Align the bolt holes wi th the shaft arm facing down,
then install the arm bolt with the washer and tighten
it.
ST(lPPI'R ARM
Hook the fork side spring end onto the underside of

the spring pin on the stopper arm, using a screw
driver.
iPRll NG END
20-18
Slide the shift f ork and set its spring pin between
the spring ends.
Align the bolt hate in the fo rk with the groove in the

shaft and install a new fork bolt.
Tighten the fo rk bolt.
!II BOLT
TORQUE: 10 Nm (1 .0 kgf-m , 7 Ibf.ft)
Apply grease to the lips of a new oil seal and insta l l

it so that it is fl ush with the housing end.
TOOLS:
Driver 07749-0010000
ATIACHMENT
Install the lock sleeve and half shaft in the direction

as shown .
Coat a new D-ring with grease and install it into the
case groove.
20-19
Al igning the fork claws with the sleeve groove,
install the differential lock dutch housing. HOUSING
Install the four bolts with the cable holder and

tighten them.
TORQUE: 25 N m (2.6 kg'm , 19 Ibf.ft)
Install the steel ball and stopper spring.
Install the spring plug with a new sealing washer
and tighten it.
TORQUE: 21.6 N'm (2.2 kgfm , 16Ibf.ft)
Check the differential lock clutch operation (page
20-14).
PLUG
"
BALL
e~ WASHER
20-20
REAR FINAL GEAR DISASSEMBLYI
INSPECTION
BACKLASH INSPECTION
Set the final gear case into a jig or vise with soft
PULLER BASE
jaws. ADAPTOR
Remove the oil fitler ca p.
Hold the pinion gear with the special tools.
TOOLS:
Pi nion puller ba se 07HMC MM80110
Puller shaft and nut 07965VM00200
Threaded adaptor 070MFHP50100
U.S.A. TOOLS:
Pinion puller base 07HMC MM8011A
Puller shaft 07931 ME4010B
Special nut 07931-HB3020A
Threaded adaptor 070MF-HP5A 100
Set a horizontal type dial indicator on the ring gear
through the filler hole. RING GEAR
Turn the ring gear Heft side} back and forth to read
backlash, using the lock nut wrench or the drive
-\0.
shaft. !
TOOL:
Lo ck nut w rench 017160020203
STANDARD: 0.05-0.25 mm (0.002-0.010 in)

SERVICE LIMIT: 0.4 mm (O.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 mm 10.01 in )
If the difference in measurements exceeds the ser

vice limit, it indicates that the bearing is not RIGHT SHIM "",;;=;.,
installed squarely, or the case is deformed.
Inspect the bearings and case.
If the backlash is excessive, replace the ring gear
right shim with a thinner one.
If the backlash is too small, repla ce the ring gear
right shim with a th icker one.
Backlash is changed by about 0.06 mm (0.002 in)
when thickness of the spacer is changed by 0.12
mm (0.005 in).
NOTE :
Seventeen different thickness right shims are
LEFT SHIM
available from the thinnest 10.64 mm thickness:
AI shim to the thickest (1.60 mm thickness: Q) in
intervals of 0.06 mm.
Fifteen different thickness left shims are available
from the thinnest (0.64 mm th ickness: A) shim to
the thickest (1.48 mm thickness: 0) in intervals of
0.06 mm.
Right ring gear shims:
A: (thinnest): 0.64 mm (0.025 in )
G: (stand ard): 1.00 mm (0.039 in)
Q: (thickest ): 1.60 mm (0.063 in)
20-21
l eft ring gea r shims :
A: !th lnnest ): 0.64 mm 10.025 in )
G: (standard): 1.00mm (0.039 in )
0 : (t hickest ): 1.48 mm (0.058 in )
Change the right side shim as follows: If the left
shim was replaced with a 0.10 mm (0.004 in) t hicker
shim, replace the right shim with one that is 0. 10
mm (0.004 in) thi nner
DIFFERENTIAL REMOVAL
Remove the differential lock clutch (page 20-15). Tap
Loosen the six cover bolts in a crisscross pattern in
several steps and remove them.
Tap the cover with a soft mallet to rotate the cover
sl ightly and then tap up to remove r the cover.
Remove the O-ring.

D-RING
Remove the differential assembly and shims.
DIFFERENTIAL
BEARING INSPECTION
Turn the inner race of each bearing in the gear case
and cover with your finger. The bearings should
turn smoothly and quietly. Also check that the bear-
ing outer race fits tightly in the case and cover.
Differential bearing replacement (page 20-26)
20-22
GEAR TOOTH CONTACT PATTERN
CHECK
Keepdusranddlrr Apply thin coat of Prussian Blue to the pinion gear
our of the case and teeth for a tooth contact pattern check.
cover.
Install the ring gear shims onto the differentia l
assembly.

DIFFERENTIAL
It IS ImPOrtanllO Install the case cover and tighten the bolts in several
10 COVER
turn the pinIOn steps until the cover evenly touches the gear case.
while tightening the Then, while rotating th e pi nion gear, tighten the
boits. If the ring bolts to the specified torque in a crisscross pattern
gear shims IS 100 in severa l steps.
thick, the gears will
lock after only light TORQUE: 10 mm bolt: 46.5 N 'm 14.7 kgf m , 34Ibf.ft)
tightenmg, 8 mm bott: 25 N'm 12.6 kgf.m, 19 Ibf.ft)
8 mm BOLTS
Remove the oil filler cap.

NORMAL: HEEL ~
Rotate the ring gear several times in both directions
of rotation. TOE
Check the gear tooth contact pattern through the oil
filler hole. --- FACE
~I
The pattern is indicated by the Prussian Blue
applied to the pinion. FLANK
Contact is normal if the Prussian Blue is transferred
to the approximate center of each too t h, b ut slightly Coast
side
to the heel side and t o the flank side.
If the pattern are not correct, remove and change
the pinion shim with one of an alternate thickness.
20-23
Replace the pinion shim with a th icker one if the
TOO HIG H:
contact pattern is too high. toward the face.
FACE FACE
Drive side I
t e:::> ~ Coast side
Replace the pinion shim with a thinner one if the ~T~O~Oi'i:L~O~W~'===;:;~;;==========
contact pattern is too low, toward the flank.
The pattern will shift about 0.5 - '.0 mm (0.02 - 0.04
0,12 mm (0.005 in).
NO TE:
Eleven different thickness shims are available
from the thinnest (1.26 mm thickness: A) shim to
the thickest 11.B6 mm thickness: K) in intervals of
0.06 mm.
Pinion gear shims:
A: (thinnest): 1.26 mm (0.050 i n)
Drive side Ic:::::" ~ I
FLANK
Coast side
FLANK
E: (standard) : 1.50 mm (0.060 in)
K: (thickest): 1.86 mm (0.073 in)
Pinion shim replacement (page 20-26)
DIFFERENTIAL INSPECTION
Rep/ace the Turn the differential gears in the housing and check
differentia/assn tha t the gears turns smoothly and quietl y without
assembly binding.
Check the each gear for wear or damage.
RING GEAR REMOVAL

Remove the ten bolts and ring gear.
RING GEAR
20-24
PINION GEAR REMOVAL
Remove the oil seal.
OIL
Be careful that Unstake t he bearing lock nut with a drill or grinder.

meta! particles do Unstake NUT
not enter the
bearing and the
threads of the case
are not damaged.
Remove the lock nul and discard it.

HOLDING
TOOL: TOOL
Holding tool Snap-on YA6010A or equiva-
lent
Inst all the special tools onto the pinion gear shaft
PULLER SH,'FTAND NUT
and gear case.
TOOLS :
Pinion puller base 07HMC-MM801'O
Pull er shaft and nut 07965-VM00200
Threaded adaptor 070MF-HP50100
U.S.A. TOOLS:
Pinion puller base 07HMC-MM8011A
Puller shaft 07931-ME4010B
Special nut 0793,-HB3020A
Threaded adaptor 070MF-HP5Al00 BASE
Pull the pinion gear assembly out from the gear
case.
20-25
PINION GEAR BEARING AND SHIM
REPLACEMENT
Talee care not to Press the pinion gear ou l of the bearing.
comact the support
Remove the pinion shim.
blocks agamst the
gear teeth,
Install the shim and bearing onto the pinion gear.

NOTE :
When the gear set, differential bearing, differen-
tial andlor gear case has been replaced, use a
1.50 mm (0.060 in} thick shim for initial reference.
BEARING
Press the pinion gear in a new bearing until it is fullv

seated bv supporting the bearing inner race with the
special tool.
TOOL:
Fork sea l driver attachment 07947 KF00100
CASE BEARING REPLACEMENT

DIFFERENTIAL BEARING
Remove the oil seals from the case cover.
Oil SEAL
Drive the bearings out of the gear case and cover.
\'
;
-
;~
,
~,
20-26
Drive new bea rings into the gear case and cover .
TOOLS:
Case cover:
Driver 077490010000
Anachment, 62 x 68 mm 077460010500
Pilot, 40 mm 077460040900
Gear case:
Drive r 077490010000
Attachme nt, 72 x 75 mm 077460010600
Apply g r ease to the lips of a new oil seal and install

it so that it is flush with the cover.
TOOLS :
Driver 077490010000
PINION NEEDLE BEARING

Rotate the stopper r ing untit its end appea rs in the
access hole.
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 t he access
hole.
Be sure to wear Heat the gear case to about 80C (176F) and
heavy gloves 10 remove the needle bea ring, using the special tools.
avoid burns when
handling the heated
TOOLS:
gear case Bearing remover, 17 mm 07936-3710300
Using a torch to Remover handle 07936-3710100
heat the gear case Remover weight 07741-0010201 or
may cause 07936-3710200 or
warpage. 07936-371020A
(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.
20-27
Install a new stopper ring i nto the groove in a new
bearing. " . STOPPER RING
Make sure the Install the bearing into the compressor u ntil the
stopper nng stays bearing is flush with the end of the tool.
In the groove
TOOL:
Bearing clip compressor, 070ME-HN80200 or
28mm 070ME-HN8A200
(U.S.A . only)
COMPR ESSOR
Place the driv er and attachment o n the t op of the

bearing and tape the dr iver to the compressor.
TOOLS:
Driver 07949-3710001
Attachment, 24 x 26 mm 07746-0010700
Puller attachment 01VMC-GCS0100
(not avai lable in
U.S.A.) or
Pilot , 17 mm 07746-0040400
Place the bearing and tool assembly into a freezer
for at least 30 minutes.
Using a heat gu n, heat the gear case to 80C (176F).
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 may slip o ut of the groove.
If this happens, remove the ring and beari ng, and
install a new ring.
Make sure that the stopper ri ng is securely set in the
groove of the gear case.
20-28
REAR DRIVING M ECHANISM
REAR FINAL GEAR ASSEMBLY
DIFFERENTIAL LOCK
CLUTCH HOUSING
GEAR
DOWEL
PINS
CABLE HOLDER
D-RING
SHAFT
SPRING
~ PLUG -_~ ~"'I 1:+-- - LOCK SLEEVE
'1iO tJ!!i:~ BALL
1'-""".'
BEARING (6009) RIGHT I
GEAR SHIM
PINION
GEAR RING
LOCK NUT
STOP
PIN STCIPPIN
SHIM DIFFER"mA
I I
BEARING (B008)
OIL SEAL
GEAR CASE COVE R
PINION GEAR INSTALLATION

Drive the pinion gear assembly into the gear case.
DRIVER
TOOLS:
Driver 07749-001000
ATIACHMENT
Driver attachment 07LAO-PWS0500
20-29
Install a new lock nut and tighten it.
HOLDING
TOOL: TOOL
Holding tool Snap-on VA6010A or
equivalent
Refer to the SerVICe TORQUE:
InformallOll fOl Actual : 98 N m 110.0 kgf-m , 72lbfft )
to/que wrench Indicat ed : 82 N'm (8 .4 kgf-m , 60 lbf.ft)
readmg mformatlOn
(page 20-3).
Be care ful notfO Stake the lock nut into the case g roove.
damage rhe threads
Stake
of the case

it so that it is flush with the gear case.
TOOLS :
Driver 077490010000
Driver attachment 07LADPW50500 or
07AMD HL lAl00
!U.S.A. only)
RING GEAR INSTALLATION

Clean the mating surfaces of t he ring gear and dif
ferential housing thoroughly and install the ring BOLTS (l eft
GEAR
gear, aligning the bolt holes in the gear and hous- hand !h""ds)
The nng gear boilS

ing .
Apply locking agent to the threads of the ring gear
1m
has lefr-hand bolts.
threads Install the ring gear bolts and tighten them in a
crisscross pal1ern in several steps.
TORQUE: 58 N m (5.9 kgfm . 43 IbUt)
20-30
RING GEAR CLEARANCE INSPECTION
Install the differential assem bly with the shim into
the case cover.
Measure the clearance between the ring gear and
stop pin w ith a feeler gauge.
CLEARANCE: 0.3 - 0.6 m m (0.01 - 0.02 in )
STOP PIN
Remove the differential assembly.
8e sure to wear If the clearance is not within specification, heat the
heavy gloves to case cover to approximately 80C ~176F) and
avoid burns when remove the slop pin by tapping the cover.
handlmg the heated
Instatl a stop pin shim to obtain the correct clear
case cover. Usmg a
ance.
torch to heal the
case cover may Stop pin shim s:
cause warpage A: 0.10 mm (0.004 in)
B: 0.15 mm (0 .006 in )
Drive the stop pin into the case cover.
,
STOP I SHIM
FINAL GEAR CASE ASSEMBLY

NOTE:
When the gear set, bearing, differential and/or
gear case has been replaced, check the tooth
contact pattern check (page 20-23) and check the
gear backlash (page 20-21).
Keep dust and dirt Clean the mating surface of the gear case and cove r,
out of the case and being careful not 10 damage them.
cover
Blow compressed air through the breather hole in
the gear case.
20-31
Install the proper ring gear shims onto the differen-
tial assembly.

cover groove.
Install the case cover onto the gear case.
Apply locking agent to the threads of the two 10- o 10 mm BOLTS

mm bolts. 1Il!iI
It IS Importam fO Install the six bolts and tighten them in several
tum the pinion gear steps until the cover evenly touches the case. Then,
while tlgh/enmg the white rotating the pinion gear, tighten the bolts to
baits, If the flng the specified t orque in a crisscross pattern in sev-
gear shim IS too eral steps.
thIck, the gears will
lock after only light
TORQUE: 10 mm bolt: 46.5 N 'm (4 .7 kgfm , 34Ibf.ft)
/lgtJrenmg. 8 mrn bolt: 25 N m (2.6 kgfm , 19 Ibf.ft)
Make sure that the gear case assembly rotates
smoothly without binding.
Install the differential lock clutch housing (page 20-
19).
REAR FINAL DRIVE INSTALLATION

Coat a new a-ring with molybdenum disulfide r-::o:-- -=-
grease and install it int o the groove in the output
shaft.
Apply molybdenum disulfide grease to the splines
of the both sides in the universal joint.
Install the universal joint onto the output shaft until
it is fully seated.
20-32
Coat a new Cring with molybdenum disulfide
grease and install it into groove in the propeller
shaft groove.
Install the propeller shaft into the universal joint
until it is fully seated.
Apply molybdenum disulfide grease to the splines

of the propeller shaft.
Install the joint spring into the propeller shaft firmly.
Place the gear case assembly into the frame.

Connect the propeller shaft, aligning the splines
properly while compressing the joint spring, then
align the bolt holes and install the mounting bolts
from the right si de.
Install new mounting nuts and tighten them.
20-33
Sel the drive mode selector lever to the 2WD posi-
tion (differential lock free position).
Operate the differential lock arm to the front side to
set it to the lock free position.
Install the differential lock cable into the clip and the
cable holder by aligning the flat surfaces, and con-
nect the cable to the lock arm.
Install the washer and a new cotter pin.
Make sure that tne Screw the cable nuts together gradually (to move
drive mode selector both nuts to the cable holder side ) by your hands so
/ever 15 2WD that the cable does not forced until they are touched
position and the to the cable holder.
dlffel8ntlilllock arm Tighten the cable nut while holding the other nut.
IS lock free (front)
POSition.
TORQUE: 26 Nm (2.7 kg fm. 20 Ib'tt)
InSl all the VS sensor (page 6-53).

Install the sensor wire band onto the cable holder.
Install the damper stay and tighten the two bolts.

- cargo bed damper (page 3-16)
- drive shafts (page 20-11 )
17) .
20-34
21. BATTERY/CHARGING SYSTEM
COMPONENT LOCATION ........................ 21-2 BA TIERY .................................................. 21-6
SYSTEM DIAGRAM .. .. 21 -2 CHARGING SYSTEM INSPECTION 21-7
SERVICE INFORMATION 2 1-3 ALTERNATOR CHARGING COIL 21-8
TROUBLESHOOTING ............................... 21 -5 REGULATOR/RECTIFIER ......................... 21-8
EI
21-1
BATTERY/CHARGING SYSTEM
COMPONENT LOCATION
REGULATOR/RECTIFIER
BATTERY
ALTERNATOR
MAIN FUSE (30 A)
SYSTEM DIAGRAM
MAIN f USE 30 A
G: Green
R; Red
Y:Yeliow
y R
G
ALTERNATOR
REGULATOR/RECTIFIER BATTERY
21-2
SERVICE INFORMATION
GENERAL
AWARNING
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 ski n o r eyes may cause severe burns. Wear protective
clothing and a face shield.
- If elect rolyte 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.
NOTICE
Always turn OFF the ignition switch before disconnecting any electrical component.
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni-
tion switch is ON and current is present.
For extended st orage, 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 reach es the end of its service life.
The battery can be damaged if overcharged or undercharged, or if left to discharge for long period. These same condi
tions contribute to shortening the "life span" of the battery. Even under no rma l use, the performance of the battery
deteriorates after 2-3 years.
Battery vol t age may recover after battery charging, but under heavy load, the battery voltage will drop q u ickly and
eventually die out. For this reason, the charging system is often suspected as the problem. Battery overcharge often
results from problems in the battery itself, which may appea r to be an overcharging symptom. If one of the battery cell s
is shorted and battery voltage does not increase, the regulator/rectifier suppl ies excess voltage to the battery. Under
these conditions, the electrolyte level goes down quickly.
Before troubleshooting the charging system, check for proper use and maintena nce of the battery. Check if the battery
is frequently under heavy load, such as having the headlight and tai l light on fo r long periods of time without driving the
vehicle.
The battery wilt selfdischarge when the vehicle is not in use. For this reason, cha rge the battery every two weeks to pre
vent sulfation from occurring.
Filling a new battery with elect rolyte will produce some voltage, but in order to achieve it s maximum performance,
always charge the battery. Also, the battery lif e is lengthened when it is i nit ially charged.
When checking the charging system, always follow the steps in the troubleshooting (page 21-5).
Alternator removal /installation (page 115).
BATTERY CHARGING
Turn power ON/OFF at the charger, not at the battery terminal.
For battery charging, do not exceed the charging curr ent and time specified on the battery. Using excessive cu rrent or
extending the charging time may damage the battery.
Ouick charging should only be done in an emergency; slow charging is preferred.
BATTERY TESTING
Refer to the instructions in the Operation Manual for the recommended battery tester for det ails abou t battery testing. The
recommended battery tester puts a "load" on the battery so that the actual battery condition can be measured.
RECOMMENDED BATTERY TESTER: Micro 404XL (U.S.A. only)
21-3
SPECIFICATIONS
ITEM SPECIFICATIONS
--
I sattery
(YTX14BS)
Capacity
Current leakage
12V-12Ah
0.1 mA max.
Voltage Fully charged 13.0 -13.2 V
(20cC/6BOF) t--~eeds charging Below 12.3 V
Charging cur=- Normal 1.4 AJ5 - 10 h
rent Quick 6.0 AltO h
I Alternator Capacity 410 W/5,OOO rpm
Charging coil resistance (20 a C/68 e F) 0.1 1.00
TOOLS
Motorcycle battery analyzer Ch ristie battery charger
Micro 404XL (U.S.A. only) MC1Q12/2 (U.S.A. only)
21-4
BATIERY/CHARGING SYSTEM
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. Banery Test
Remove the battery (page 21-6).
Check the battery condition using the recommended battery tester.
RECOMMENDED BATTERY TESTER: Micro 404XL (U.S.A. only)
Is the baHery in good condition?
YES - GO TO STEP 2.
No - Faulty battery
2. Current Leakage Test
Install the battery (page 21-6),
Check the battery current leakage test (Leak test: page 21-7).
Is the current leakage below 1 mA l
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. Current leakage Test With Regulator/ Rectifier Connector Disconnected
Disconnect the regulator/rectifier connector and recheck the battery current leakage.
Is the current leakage below 1 mA 7
YES - Faulty regulator/rectifier
NO - . Shorted wire harness
Faulty ignition switch
4. Alternator Charging Coil Inspection
Check the alternator charging coil (page 21-8).
Is the alternator charging coif resistance within 0.1 - 1.0n (20CCI68"'F)?
YES - GO TO STEP 5.
NO - Faulty charging coil
5. Charging Voltage Inspection
Measure and record the battery voltage using a digital multi meter (pa ge 21-6).
Start the engine.
Measure the charging voltage (page 21-7).
Compare the measurements to the results of the following calculation.
STANDARD: Measured BV < Measured CV < 15.5 V
=
BV Battery voltage
=
CV Charging voltage
Is the measured charging voltage within the standard voltage?

YES _ . Intermittent failure
Loose or poor contacts of related terminal
NO - GO TO STEP 6.
6. Regulator/ Rectifier System Inspection
Perform the regulator/rectifier wire harness inspection (page 21-8).
Are the measurements correct?
YES - Faulty regulator/rectifier
NO _ . Open circuit in related wire
Loose or poor contacts of related terminal
Shorted wire harness
21-5
BATTERY
BATTERY REMOVAlIlNSTALLATION
Open the front hood.
Release the tab by pushing it in and remove the bat-
tery box cover.
With the ignition switch turned to OFF (0), discon~

nect the negative (-) cable first, then disconnect the
positive (+) cable by removing each terminal bolt.
Remove the battery holder band.
Remove the battery.
ConneCl the Install the battery in the reverse order of removal
poSI/1V1 (+) cable with the proper wi ring as shown.
first and tIlen the
negative H cable,
VOLTAGE INSPECTION
Remove the battery box cover (page 21 6).
Measure the battery voltage using a commercially
available digital multi meter.
VOLTAGE (20 C C/ 68F) : Fully charged: 13.0 - 13.2 V
Under charged: Below 12.3 V
BATTERY TESTING
Refer to the instructions that are appropriate to the
battery testing equipment available to you.
TOOL:
Battery tester Micro 404Xl (U .S .A. only)
BATTERY CHARGING (U .S.A . only)

Refer to the instructions that are appropriate to the
battery charging equipment available to you.
TOOL:
Christie battery charger MC1012 / 2T (U.S.A. only)
21-6
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION
Wi th the ignition switch turned to OFF (0), discon-
nect the negative H cable from the battery.
Connect the ammeter (+) probe to the negative H
cable and the ammeter H probe to the battery H
terminal.
With the ignition switch turned to OFF (0), check for
current leakage.
NOTE :
When measuring current using a tester, set it to a
high range, and then bring the range down to an
appropriate level. Current flow higher than the
range selected may blowout the fuse in the
tester.
While measuring current, do not turn the ignition
switch to ON (I). A sudden surge of current may
blowout the fuse in the tester.
SPECIFIED CURRENT LEAKAGE: 1 rnA m aximum

If current leakage exceeds the specified value, a
shorted circuit is likely.
Locate the short by disconnecting connections one
by one and measu ring the current.
CHARGING VOLTAGE INSPECTION

Be sure the battery is i n good condition before per-
r
)
.. ,
'
, , /''-
forming this test. , ' '
d"\.
Q .
Warm up the engine to normal operating tempera- .'
ture.
Connect the multimeter between the battery posi-
tive (+) and negative (-) terminals.
NOTE:
j '"
4 I ~.
-
! .; - .
To prevent a short, make absolutely certain
which are the positive (+) and negative (-) termi- ..I
. ~'*j l
nals or cables.
Do not disconnect the battery or any cable in the
charging system without fi rst switchi ng off the
..... ~ .
'.. J """'U"
'. I:':II~
' _J
ignition switch. Failure to follow this precaution
can damage the tester o r elect rical components.
With the headlights on, measure the voltage on the
multi meter when the engine runs at 5,000 rpm.
STANDARD: Measured BV < M easured CV < 15.5 V
=
BV Battery voltage (page 21-6)
=
CV Charging voltage
21-7
ALTERNATOR CHARGING COIL
INSPECTION
Remove the engine front cover (page 3-6),
5P BLACK CONNECTOR
~~~~
Remove the alternator 5P black connector from the
stay and disconnect it.
Check the connector fo r loose contacts or corroded
terminals.
Measure the resistance between the Yellow wire
terminals of the alternator side connector.
STANDARD: 0. 1 - 1.0 0 (at 20C/68" F)
Check for continuity between each Yellow wire ter-
minal of the alternator side connector and ground.
There should be no continuity. !
!
Replace the alternator stator if resistance is out of
specification, or if any wire has continuity to J
ground.
Alternator stator replacement (page 11 -5).
REGULATOR/RECTIFIER
WIRE HARNESS INSPECTION
Open the front hood .
Disconnect the regulator/rectifier 3P black and gray
connectors.
Check the connectors for loose contacts or corroded
terminals.
Check the following at the wire harness side
connectors.
Banery line:
Measure the voltage between the Red wire termi-
nal and ground.
There should be battery voltage at all times.
Ground Line:
Check the continuity between the Green wire ter-
minal and ground.
There should be continuity at all times.
Charging Coil Line:
Measure the resistance between the Yellow wire
terminals.
STANDARD: 0.1 - 1.0 n (at 20C /68~F )
Check for continuity between each Yellow wire

terminal and ground.
There should be no continuity.
Disconnect the regulator/rectifier 3P black and gray
connectors.
Remove the two bolts and regulator/rectifier.
21-8
22. IGNITION SYSTEM
COMPONENT LOCATION ........................ 22-2 IGNITION SYSTEM INSPECTION 22-5
SYSTEM DIAGRAM .............. .................... 22-2 IGNITION COIL ......................................... 22-7
SERVICE INFORMATION .................. ...... . 22-3 IGNITION TIMING ................................ .... 22-8
TROUBLESHOOTING ............................... 22-4
22-1
IGNITION SYSTEM
COMPONENT LOCATION
(c~;;'~~'tr\~e~O~IL~~~=='~G~N;ITION SWITCH
BATIERY
MAIN RELAY
~I
eKP SEr<seIR
BOX
SYSTEM DIAGRAM
peM MAIN RELAY
61: Bla'*
Bu: Blue
G: Green
R: Red
V: Violet
W:While
V:Yel!ow
~ ~ I'-------~f-> ~I ~~L_ _ _ _ _ _ _ _ _ _ __

L._ _ _ _ _ _ _ _ _ _ _ _ _ _ : : : 3
BIIG~J r ~IG~IWIR
I
IGNITION SWITCH cr
IGNITION
[
R---{).../'()--R-
COIL MAIN FUSE (30 AI rrr~~_~~,:",""
~
CKP SENSOR
1 SPARK
PLUG t
BATTERY
22-2
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 PCMIECM. Always turn the ignition switch to OFF before selVicing.
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 whi le the igni-
tion switch is ON and cu rrent is present.
When servicing the ignition system, always follow the steps in the troubleshooting chart (page 22-4),
This ignition system is controlled by PCM.
The transistorized ignition system uses an electrically controlled ignition timing 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 11-5).
Ignition switch servicing (page 24-7).
Main relay inspection (page 6-38).
SPECIFICATIONS
ITEM SPECIFICATIONS
Spark plug BKR5E-11 (NGK), K16PR-U11 (DENSO)
Spark plug gap 1.0 1.1 mm (0.039 0.043 in)
Ignition coil peak voltage 100 V minimum
CKP sensor peak voltage 0.7 V minimum
~gnition timing 15 BTDC at idle
-
TORQUE VALUES
Spark plug 22 Nm (2.2 kgfm, 16 Ibfft)
Timing hole cap 10 Nm (1.0 kgfm, 7 Ibfft)
TOOLS
IgnitionMate peak voltage tester Peak voltage adaptor Test probe, 2 pack
MTP07-0286 (U.S.A. only) 07HGJ-0020100 07ZAJ-ROJA 11 0
(not available in U.S.A.) with com-

mercially available digital
multimeter (impedance 10 MntDCV
minimum)
L
22-3
IGNITION SYSTEM
TROUBLESHOOTING
Inspect the following before diagnosing the system:
- Faulty spark plug
- loose spark plug cap or spa rk plug wire connection
- Water got into the spark plug cap (leaking the ignition coil secondary voltage)
Wlnitial voltage" of the ignition primary coil is the battery voltage with the ignition switch turned to ON (I). (The engine is
not cranked by the starter motor.)
No spa rk at spa rk plug
iii I ; ,
ignition switch to ON 2. An open circuit Black/yellow wire between the ignition coil
voltage {II. (Other electrical compo- and main relay.
nents are normaL) 3. loose or poor connection of the primary termi nal, or an open
circuit in the ignition primary coit.
4. Faulty peM (in case w hen the initial voltage is normal with the
PCM
;
it drops by 4 V wh ile 2. Battery is undercharged. drops largely when the engine
cranking the engine. is started.)
3. No voltage at the Black/green wi re of the peM gray connector, or
loose or poorly connected PCM gray connector.
4. Loose or poor con nection, or an open circu it in the Green
(ground) wi re of the PCM.
5. Loose or poor connection, or an open circuit in the Green/orange
wire between the ignition coil and PCM.
6. A short circuit in the ignition primary coil.
7. CKP sensor. (Measure the voltage.)
8. PCM
there is no peak vol t age

while cranking the engine.
2. voltage adaptor.
3. "'''0'. (Measure the peak volt,!,e.)
, ,
peak voltage is lower than 2. Cranking speed is too slow. is undercharged.)
the standard value. 3. The sampling timing of the test er and measured pulse were not
synch ronized. (System is nor mal if measured voltage is over the
standard at least once.)
I.
current.
sensor too I ,
2. Cranking speed is too slow. (Battery is undercharged.)
3. The sampl ing timing of the tester and measured pu lse were not
synch ronized. (System is normal if measu red voltage is over the
standard voltage at least once.)
4. Faulty CKP sensor (in case when above No.1 through 3 are nor-
)
22-4
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION
PEAK VOLTAGE ADAPTOR
CONNECTION
NOTE :
If there is no spark at the plug, check all con nec-
tions f or loose o r poor co ntact before measuring
the peak voltage.
Use a commercia lly available digita l multi meter
with an impedance of 10 MQlOCV minimum.
The display value differs depending upon the
imernal impedance of the multimeter.
Use the peak voltage tester or connect the peak
voltage adaptor to the digital multi meter. DIGITAL MULTIMETER
TOOLS :
IgnitionMate peak voltage MTP070286 or
t este r (U.S.A . only)
Peak voltage adaptor 07HGJ0020100
with commercia lly available (not available in
digital multimeter U.S.A .) (V )
(i mpedance 10 MlliOCV mini-
mum)
IGNITION COIL PRIMARY PEAK

VOLTAGE
NOTE:
Check all system connections before this inspec-
tion. Poor connected connectors can cause incor-
rect readings.
Check the cylinder compression and check that
the spark plug is installed correctly in the cylin-
der head.
- seat center cover (page 3-5)
Disconnect the spa rk plug cap from the spark plug .
Connect a known-good spark plug to the spark plug
cap and ground the spark plug to the cylinder head
as done in a spark test.
KNOWN -G OOD SPARK PLUG
22-5
IGNITION SYSTEM
With the connector connected, connect the peak
voltage tester or adaptor probes to the ignition coil
primary terminal and body ground.
CONNECTION: Green /orange (+) - Body ground H

Check the initial voltage at this time.
The banery voltage should be measured.
If the initial voltage cannot be measured, follow the
checks in the trouble shooting chart (page 22-4).
Shih the transmission into neutral.
Crank the engine with the starter motor and read
the ignition coil primary peak voltage.
PEAK VOLTAGE: 100 V minimum Green/orange (+)
If the peak voltage is lower than the standard val ue,
follow the checks described in the troubleshooting
chart (page 22-4).
CKP SENSOR PEAK VOLTAGE

NOTE
Check that the cylinder compression is nor mal
and the spark plug is installed correctly in the
cylinder head.
Disconnect the 33P gray connector from the PCM.
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
terminals. (Viewed from the terminal side) Green/white
IB12I1-1
Refer to page 6-13 TOOL:
fOf test probe Test probe, 2 pack 07ZAJ-ROJAl10
US8QIJ
CONNECTION :
Blue/yellow (B23) (+1- Green/ white (B12) H
Bluelyel low
Shift the transmission into neutral. (823 ) (+)
Crank the engine with the starter motor and read
the CKP sensor peak vol tage.
PEAK VOLTAGE: 0.7 V minimum PEAK VOLTAGE ADAPTOR
If the voltage measured at the PCM connector is

abnormal, measure the peak voltage at the
alternator connector.
22-6
IGNITION SYSTEM
5P BLACK CONNECTOR
Remove the engine front cover (page 36).
Remove the alternator 5P black connector from the
st ay and disconnect it.
Connect the peak vol t age tester or adaptor probes
to the alternato r side connector terminals.
CONNECTION: Blue/ yellow 1+) - Green / white H
In the same manner as at the peM connector,
measu re the peak vo ltage and compare it to the
voltage measu red at the pe M connector.
If the peak vol t age measured at the peM
connector is abnormal and the one measured at
the alternato r connector is normal, the Blue/
yellow or Greenlwhite wire has an open or short
circuit, or loose connection.
If both peak voltages are abnormal , follow the
checks described in the troubleshooting chart
(page 22-4).
If the CKP sensor is faulty, replace the stator/CKP
sensor assembly (page 11-7).
IGNITION COIL
Disconnect the plug ca p from the plug.
Remove the two ignition coil mounting bolts.

Disconnect the primary wire connectors and
remove the ignition coil.
Installation is i n the reverse order of removal.
22-7
IGNITION SYSTEM
IGNITION TIMING
Remove the mudguard (page 3-12).
Start the engine and warm it up to operating
temperature.
Stop the engine and remove the timing hole cap
from the rear crankcase cover.
Connect the timing light and tachometer.

Start the engine, let it idle and check the ignition
timing.
The ignition timing is correct if the "F" mark on the ,-----------:::c-:c-c:---:--:::-----,

flywheel is visible from the timing hole in the rear TIMING HOLE
crankcase cover at idle.
Increase the engine speed and make sure the "F"
mark begins to move.
"F" MARK
Coat a new O-ring with oil and install it onto the

timing hole cap.
liiiiiji3~~~~~~~~iii.
I
Install the timing hole cap and tighten it.
TORQUE: 10 N'm (1.0 kgf-m , 7Ibf.ft)
Install the mudguard (page 3- 12).
22-8
23. ELECTRIC STARTER
COMPONENT LOCATION ........................ 23-2 STARTER MOTOR ............................ ........ 23-6
SYSTEM DIAGRAM .. ....... ......................... 23-2 STARTER RELAY SWiTCH 23-12
SERVICE INFORMATION ......................... 23-3 DIODE 23-13
TROUBLESHOOTING ._ ............................. 23-4 BRAKE INHIBITOR RELAy 23-14
EI
23-1
ELECTRIC STARTER
COMPONENT LOCATION
IGNITION SWITCH
BATTERY
SWITCH
--
<T -' MOTOR

FUSE (10A)
GEAR pO'SITioN
SYSTEM DIAGRAM
81: Black
Sr: Brown
STARTER
RELAY
8 G: Green
19: Ught green
SWITCH A: Red
Y:Yeliow
BATTERY
M STARTER
MOTOR
"~ "-t-.--<Y~ "M ------,

MAIN FUSE ~30A)
VI"
IGNITION SWITCH
19lR ~L9IBI-----'>- l9/BI~ VIR - *-- VIR -:)...../""()- VIR - - -- - - - - - - - '

~ ~ START FUSE (lOA)
DIODE DIODE
GEAR POSITION SWITCH BRAKE INHIBITOR RELAY

o
o LgfBl--1--0
19/R --10---<;1 o
N
"
L---- GfY ----0~BIIB'~"MI -----'
FOOT BRAKE SWITCH UGHTFUSE(15A)
23-2
ELECTRIC STARTER
SERVICE INFORMATION
GENERAL
I NOTICE
If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor
may be damaged.
Always turn the ignition switch OFF before servicing the slarter mot or. 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 steps in the troubleshooting (page 23-4),
A weak battery may be unable to turn the starter motor quickly enough. or supply adequate ignition current.
Starter dutch servicing (page 11-5),
Ign ition switch servicing (page 24-7).
Eng ine stop switch and starter switch inspection (page 24-8) .
FOOl brake switch inspection (page 24- 16).
Gear position switch inspection (page 1424).
Gear position switch rep lacement (page 1457).
SPECIFICATIONS
Unit : mm (in)
Starter motor brush length 12.0 13.0 (0.47 0.51) 6.5 (0.26)
23-3
ELECTRIC STARTER
TROUBLESHOOTING
NOTE:
The starter motor should operate when the transmission is in neutral or when the transmission is in
drive and the foot brake or parking brake is applied.
Starter motor does not turn
, . Fuse Inspection
Check for blown main fuse (30 A) or START fuse (10 Al .
Is the fuse blown?
YES - Replace the fuse.
NO - GO TO STEP 2.
2. Battery Inspection
Check that the battery is fully charged and In good condition.
Is the battery in good condition?
YES - GO TO STEP 3.
NO - Charge the battery (page 21-6).
3. Starter Relay Switch Operation Inspection
Check the operation of the starter relay switch (page 23-12).
Does the starter relay switch click?
YES - GO TO STEP 4.
NO - GO TO STEP 5.
4. Starter Motor Ins pection
Apply battery voltage to the starter motor directly.
Does the starter motor turn?
YES _ . Poorly connected starter motor cable.
Faulty starter relay switch (page 2313).
NO - Faulty starter motor (page 236).
Turn the ignition switch to OFF (o).
Check the ground line of the starter relay switch (page 2312).
Is the ground line normal?
NO _ . Faulty gear position switch (page 14 24).
Faulty diode (page 2313).
Faulty ignition switch (page 24.7).
Faulty foot brake switch (page 2416)
Faulty brake inhibitor relay (page 23 14)
loose or poor contact of the related connector terminal.
Open circuit in the wire harness.
YES - GO TO STEP 6.
6. Relay Coil Power Input line Inspection
Check the power input line of the starter relay switch (page 2312).
Is the power input line normal?
NO _. Faulty ignition switch (page 24 7).
Loose or poor contact of the rel ated connector term inal.
Open circuit in the wire harness.
YES - GO TO STEP 7.
23-4
ELECTRIC STARTER
7. Starter Relay Switch Inspection
Check the function of the starter relay switch (page 23- 13).
Does the starter relay switch function properly?
NO - Faulty starter relay switch.
YES - Loose or poor contact of the starter relay switch connec tor terminal.
Sta rter motor turns engine slowly
Low battery voltage
Poorly connected battery cable
Poorly connected starter motor cable
Faulty starter motor
Poorly connected ground cable terminal
Starter motor turns, but engine does not turn
Faulty starter clutch
Damaged starter gear train
Starter relay switch clicks, but engine does not turn over
Crankshaft does not turn du e to engine problems
23-5
ELECTRIC STARTER
STARTER MOTOR
REMOVAL
Remove the passenger seat under cover (page 3-6).
Disconnect the negative H cable from the battery
(page 21-6) .
Slide the rubber cap off the starter motor cable ter-
minal and remove the terminal nut and starter
molor cable.
Remove the two mounting bolts and hose guide.
,
TERMINAL NUT MOTOR CABLE
Remove the starter motor from the rear crankcase
caver.
Tr~~~~~~
Remove the a ' ring from the starter motor.
MOTOR CASE BOLTS
- two starter motor case bolts
- rear cover assembly

REAR COVER ASSEMBLY
23-6
ELECTRIC STARTER
- front cover
- seal rings SEAL r
- armature
Check the dust seal and ball bearing in the front

cover for deterioration, wear or damage. DUST SEAL
Check the bushing in the rear cover for wear or

damage.
BALL BE,'RING BUSHING
Check the commutator bars of the armature for dis-

coloration.
NOTE:
Do not use emery or sand paper on the commu-
tator.
COMMUTATOR BARS
Check for continuity between pairs of commutator CONTINUITY:

bars.
There should be continuity.
23-7
ELECTRIC STARTER
Check for conti nuity between each commu tat or bar
NO CONTI NUITY:
and the armature shaft.
Check for continuity between the insulated brush

CONTINUITY:
and cable terminal.
Check for conti nuity between the insulated brush

and motor case. NO CONTINUITY:
Remove the four brushes from the brush holder.

Measure the brush length,
23-8
ELECTRIC STARTER
Remove the following from the rear cover:
- four brush springs
- screwlwasher
- brush set B
BRUSH SPRINGS
- nut
D-RING
- washer
- insulator
- terminal stopper
- D-ring
- t erminal bolt
- brush set A
- brush holder
BAUSH
SETA
WASHER HOLDER
ASSEMBLY
INSULATOR
NUT REAR COVEA
BRUSH
HOLDER BRUSH SeT A
TERMINAL BOLT
,-,_ _ _ SCREW
SEAL RING
BAUSH SET B
BOLTS
MOTOA CASE
SEAL -' " --......::
FRONT COVER ~
23-9
ELECTRIC STARTER
D-RING
- brush holder
- brush set A
- terminal bolt
- new O-ring
- terminal stopper with the cutout facing as shown
- insulator
- washer
- nut
BRUSH
SETA
BRUSH
HOLDER
TERMINAL STOPPER
- brush set B
BRUSH SeT B SCREWI BRUSH SPRINGS
- screwlwasher
- brush springs
Install the brushes into the brush holder.
BRUSH SPFIIN(;S
Install the armature in the motor case so the case
MOTOR CASE
groove is facing the rear cover side.
When installing the armature into the motor case,
hold the armature tightly to prevent the magnet of
the case from pulling the armature against it.
I NOTICE I
The coil may be damaged if the magnet pulls the
armature against the case.
ARMATURE GROOVE
23-10
ELECTRIC STARTER
Install new sea l rings onto the motor case.
Install the front cover onto the armature shaft and $" SEAL
motor case.
ARMATURE
Install the rear cover assembly onto the motor case
REAR COVER ASSEMBLY
by aligning the lug and the groove (index lines).
Align the bolt holes in the front and rear covers by

aligning the index lines on the front cover and INDEX LINES II O-RING
motor case.
Install new O-rings onto the motor case boils.
Install the bolts and tighten them.
5" O-RING
INSTALLATION
Coat a new O-ring with oil and install it in the starter
m otor g roove.
Install t he starter motor into the rear cr ankcase
cover and onto the crankcase.
23-11
ELECTRIC STARTER
Install the hose guide and mounting bolts, then
tighten the bolts securely.
Install the starter motor cable and terminal nut, and
tighten the nut.
Install the rubber cap over the cable terminal.
Install the passenger seat under caver (page 36).
TERMINAL NUT MOTOR CABLE

OPERATION INSPECTION
Shift the sub-transmission into Neutral (set the gear
selector lever in the center position).
Turn the ignition switch to STAAT (il).
The coli is normal if the starter relay switch clicks.
If you don't hear the switch click, inspect the relay
switch circuits (page 23-12).
CIRCUIT INSPECTION
Remove the battery box cover (page 2'-6).
Disconnect the starter relay switch 2P green connec-
tor.
GROUND LINE
Check for continuity between the light green/black
wire terminal of the wire harness side con nector
and ground.
If there is continuity when the sub-transmission is in
Neutral, or when the brake pedal is depressed with
the ignition switch turned t o ON (I), the ground cir-
cuit is normal.
POWER INPUT LINE
Measure the voltage between the Yellow/red wire
terminal (+1 of the wire harness side connector and
ground (-).
If the battery voltage appears only when the ignition
switch is turned to START (II), Ihe power input cir-
cuil is normal.
23-12
ELECTRIC STARTER
FUNCTION INSPECTION
Disconnect the negative (-) cable from the battery ' S-T-A-R-T-E-R--------------'
(page 21 -6).
RELAY SWITCH
Disconnect the starter relay switch 2P green connec-
tor.
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 terminal and nega-
tive (-) terminal to the Light green/red wire terminal
of the starter relay switch side connector.
There should be continuity between t he cable termi- 1+1 1'----'; H
nals while the battery is connected, and no continu-
ity when the battery is disconnected. 1--_ 12 V SA TTERY
DIODE
INSPECTION
Remove the 2P diode from the wire harness.
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.

Remove the fuse box cover and the 3P diode from
the fuse box.
23-13
ELECTRIC STARTER
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 relay box cover.
Remove the brake inhibitor relay from the relay box.

RELAY INSPECTION
Remove the brake inhibitor relay (page 23-14).
Check for continuity between the No. 1 and No.2 No.2 No.1
terminals.
~
Connect the fully charged 12-V battery (+) terminal
to the relay NO.4 terminal and the (-) terminal to the
No.3 terminal.
There should be continuity when the battery is con-
nected , and no continuity when the battery is dis-
~
connected.
NO.3 No.4
23-14
ELECTRIC STARTER
CIRCUIT INSPECTION
NOTE:
Before this inspectio n, 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 23-14).
Check for continuity between the Green wire ter- BRAKE INHIB ITOR RELAY CONNECTOR
minals of the brake inhibitor re lay (relay box) (Terminal side of the relay box)
connector and ground.
Is there continuity? Q }--t-- ~I--- Green
YES - GO TO STEP 2.
NO - Open circuit in the Green w i re between
the relay box and ground terminal.
Green
2. Relay Coil Power Input Line Inspection

Measure the voltage between the Green/yellow BRAKE INHIBITOR RELAY CONNECTOR
wire terminal (+) of the brake inhibitor relay (Terminal side of the relay box)
(relay box ) connector and ground H.
Is there battery voltage."
YES - GO TO STEP 3.
NO - Open circuit in the Greenlyellow wire
brake inhibitor relay connector.
\--L--'------.J
Greenlyellow (+)
3. Starter Relav Switch Line Inspection

Measure the voltage between the Light greenl , - - - - - - - - - - - - - - - - - ,
black wire terminals (+) of the main relay (relay BRAKE INHIBITOR RELAY CONNECTOR
box) connector and ground (-). (Terminal side of the relay box)
There should battery voltage when the ignition
switch is turned to STAAT (Ill).
Is there battery voltage.?
YES - The brake inhibitor relay circuits are
normal.
e-+-~ V
NO - Open circuit in the Light green/black
wire between the junction connector
and brake inhibitor relay connector.
Light green/black (+)
23-15
MEMO
24. LIGHTS/METERS/SWITCHES
COMPONENT LOCATION ........ ................ 24-2 LIGHTING/DIMMER SWITCH ... .......... ..... 24-8
SERVICE INFORMATION .......... ............ ... 24-3 ENGINE TEMPERATURE INDiCATOR 24-9
HEADLIGHT 24-4 COOLING FAN MOTOR ......................... 24-11
BRAKE/TAILLIGHT ... ................................ 24-5 LOW FUEL INDiCATOR .. 24-13
INDICATORS ............................ ...... ........... 24-5 FOOT BRAKE SWiTCH .. .. 24-16
ACCESSORY SOCKET .. .. 24-6 PARKING BRAKE SWITCH .................... 24-17
IGNITION SWiTCH .... 24-7
24-1
LIGHTS/ METERS/SWITCHES
COMPONENT LOCATION
INDICATORS
LIGHTING/or SWITCH
ACCESSORY SOCKET PARKING SWITCH
FUEL SENSOR
IGNITION SWITCH
24-2
SERVICE INFORMATION
GENERAL
I NOTICE
Note the following when rep/acing the halogen headlight bulb.
- Wear clean gloves while replacing the bulb. Do nor 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 fo r a while after it is turned off.
Be sure to let it cool down before servicing.
A continuity test can be made with the switches installed on the vehicle.
All plastic connectors have locking tabs that must be released before disconnecting, and must be aligned when recon-
necting.
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.
The following color codes are used throughout this section.
Bu: Blue G: Green Lg: Light Green A: Red

BI: Blaclc. Gr: Gray 0: Orange W: White
Sr: Brown Lb: Light Blue P: Pink Y: Yellow
SPECIFICATIONS
ITEM SPECIFICATIONS
Bulb Headlight 12V -30/30Wx2
Brake/t aillight LED x 2
Neutral indicator 12V -3.4W
Reverse indicato r 12V-3.4W
4WD indicator 12V-3.4W
Engine temperature ind icator 12V -3. 4W
MIL (PGM-FI indicator ) 12V-3.4W
Low fuel indicator 12V-3.4W
Front differential lock indicator 12V-3.4W
Parking brake indicato r 12V -3.4W
f--F'use Main 30Ax2
~
t- Sub-fuse 15Ax2, 10Ax4
TORQUE VALUES
Ignition switch nut 4.9 Nm (0.50 kgfm, 3.6 Ibf.ft)
Parking brake switch screw 0.4 Nm (0.04 kgfm, 0.3 Ibf.ft)
TOOLS
Test probe, 2 pack
07ZAJ-RDJAll0
J
24-3
HEADLIGHT
BULB REPLACEMENT
Remove the headlight cove r cap.
Disconnect the headlight 3P connector.
Remove the headlight bulb by turning it clockwise
for the left headlight and counterclockwise for the
right headlight.
I NOTICE I
Avoid touching a halogen headlight bulb. Finger
prints can create hot spots that cause a bulb to
break.
Align thB bulb tabs Install a new bulb in the reverse order of removal.
with the headlight
grooves properly_
HEADLIGHT BULB
HEADLIG HT ASSEMBLY CAP
- wire band (right headlight only)
-
-
-
headlight cover cap
three tapping screws
three mounting bolts
GUIDE
CONNECTOR
d
- headlig ht wire (from the guid e)
- headlight 3P connector
- headlight assembly
\35 ~\
~---=-~c--J 1
BOLTS
SCREWS
BAND (Right headlight only)
- adjusting screw
- washer NUT SCREW
- nut
- spring
- headlight unit from the cover by releasing the
bosses from the holes
SPRING
BOSSES
COVER
24-4
LIGHTS/METERS/ SWITCHES
Route the headlight Install the headlight unit in the re verse order of
WIre Into the gUIde removal.
In the headiJghl
cover properly.
After installing the headlight, align the reference
mark on the headlight with top of the index mark on
the cove r by turning the adjusting screw.
BRAKE/TAILLIGHT
REPLACEMENT
Remove the trim clip, three screws and the taillight , - - - - - - - - - - - - - - - - - ,
cover. ~ \. TAILLIGHT COVER
Remove the brake1taillight from the taillight cove r ~ ~"" BRAKEI
by releasing the bosses from the grommets. --......#
Disconnect the 3P connector from the brakeltail- ~ 0'"
light.
-.....
~ ~ TRIM<""'CLIP. . . .""J-...
~~
",]
"'i1 jTAILLIGHT
Be careful not to Install a new brakeltaillight in the reverse order of "<:' -

ru_
damsge the seal removal. , ...-.....
~
,P""<
~~
~- -<f},
<\"r- -" ",4'
1 ~_ /:
~ \
Y /
SCREW
SEAL
RUBBE R
TAPPING CONNECTOR
SCREWS
INDICATORS
BULB REPLACEMENT
Release the two wire hands. BANDS
Remove the four screws and the indicator cover.
~~ r
INDICATOR COVER
- ~\
SCREWS
24-5
Remove the indicator lens from the bulb socket by
prying it. INSTRUMENT PANEL
Remove the bulb socket from underside of the
instrument panel.
/ BULB
j~
Pull the bulb out of the socket.
Pass the bulb socket through the instrument panel.
Install a new bulb into the socket.
Install the tens into the socket and fit the socket into
the instrument panel property.
Install the removed parts in the reverse order of
/
removal.
LENS SOCKET
ACCESSORY SOCKET
INSPECTION
Measure the voltage between the White/black (+)
and Green H 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 brown ACe fuse (10
A) and an open circuit in the wire harness.
Remove the accessory socket cap.

Check for continuity between the White/black wire
terminal of the socket side 2P connector and bottom
center terminal of the socket, and between the
Green wire terminal and side wall terminal.
If there is no continuity, check the sub-wire harness
for open circuit.
If the sub-wire harness is OK, replace the accessory
socket.
REPLACEMENT
Disconnect the 2P black connector from the acces-
sory socket.
Loosen the nut and remolle the accessory socket
from the center frame cOlier.
24-6
Install a new accessory socket by aligning the lug
with the groove in the center frame cover.
Install the nut and tighten it securely.
Connect the 2P black connector to th e accessory
socket.
Install the center frame cover (page 3-7).
IGNITION SWITCH
INSPECTION
Open the front food.
Disconnect the ignition switch 5P black connector.
Check for continuity between the switch side con -
nector terminals in each switch position.
Continuity should exist between the color coded
wires as follows:
.,
I~
Positien
RIBI A AIW VIA
ST(l1l
ON (I)
}-- C--<
}-- t-<
)-- r-o- t-O
)-- f-O
OFF (e )
REPLACEMENT
Disconnect the ignition switch 5P black connecto r , - - - -- - - -- - - - - - - - - - -
(page 24-7 ). IGN ITION SWITCH NUT
IGNITION SWITCH
Remove the ignition switch nut and ignition switch
from the instrument panel.
Install a new ignition switch into the instrument
panel by aligning the flat surfaces.
Install the ignition switch nut and tighten it.
TORQUE: 4.9 N 'm (0.50 kgfm, 3.6 Ibf-tt)
Connect the ignition switch 5P black connector. , 0
Close the front hood.
Align
24-7
LIGHTING/DIMMER SWITCH
INSPECTION
Release the wire band and disconnect the lighting!
dimmer switch 4P green connector.
Check for continuity between the switch side con-
nector terminals in each switch position.
Continuity should exist between the color coded
wi res as shown below:
~
Position
OFF
BI/Br Bu/BI W B.
.0 ( -()- --0
(N) ( --{
!D 0- --f). -<
REPLACEMENT
Disconnect the lighting/dimmer switch 4P green , - - - - - - - - - - - -- - - - - - - ,
connector (page 24-8).
Align STOPPERS
I
Remove the screw and switch holder. SWITCH
Remove the lighting/dimmer switch from the instru- HOLDER
ment panel by pushing in the two stoppers.
Install a new lighting/dimmer switch into the instru-
ment panel by aligning the lug with the groove.
Install the switch holder and tighten the screw.
Connect the lighting/dimmer switch 4P green con-
nector and secu re the wires with the wire band on
the indicator cover.
Close the front hood.
SCREW LIG HTING/DIMM ER SWITCH
24-8
ENGINE TEMPERATURE INDICATOR
SYSTEM INSPECTION
NOTE :
When the ignition switch is turned to ON (I ), the
engi ne temperature indicator shou ld come on fo r TEMPERATUR\ INDICATOR
a few seconds and go off.
l7~e @l@ '.,,&

'.' c.,
,-
0
I
,
l l~H~ ------'"
I
I
Temperature indicator does not come on when the

ignition switch is turned to ON (I)
1. Indicator Power Input Inspect ion
Check that the neutral ind icator, reverse indica-
tor and 4WD i ndicat or function properly _
Do the indicators function properly?
YES - GO TO STEP 2.
NO - Open ci rcui t in the Black/yellow wire
indicator 10P connector.
2. PCM In spection
Remove the battery box cover (page 21 -6 ).
Grou nd the Blue/red wire (A19 ) terminal of the

wire harness side connector with a jumper wire PCM 33P GRAY CONNECTOR
(Terminal side of t he wi re harness)
TOOL:
Test probe. 2 pack 07ZAJRDJAll0 ,.,
Turn the ignition switch to ON (I) and ch eck the
temperature indicator.
Does the indicator come on7
YES - Replace the PCM with a known good i\,
one and recheck.
NO - GO TO STE P 3.
--=~ ""
Blue/red (A 19)
24-9
Turn the ignition switch to OFF {oj.
Remove the wire band from the indicator cover
and disconnect the indicator 10P connector.
Check for continuity between the indicator side , - - - - - -- - - - - - - - - - - ---,

lOP connector terminals. INDICATOR 10P CONNECTOR
CONNECTION: Black/yellow _ Blue/ red (Te rminal side of the wire harness)
YES - Open circuit in the Blue/red wire
between the PCM and indicator lOP
connector.
NO - . Faulty indicator bulb.
Blue/red BlaCk/yellow
Temperature indicator stays on after the ignition

switch is turned to ON (I)
1. OTe Inspection
Check the current OTG (page 6-'2).
Is DTe 7-1 {7} or 44-1 {44} indicated?
YES - Perform appropriate troubleshooting.
OTG 7-1 (7): page 6-17
DTC 44-1 (44): page 14-26
NO - GO TO STEP 2.
2. Temperature Indicator Une Short Circuit
Inspection
Turn the ignition switch to OFF {oj.
Disconnect the PCM 33P black connector (page
24-9).
Turn the ignition switch to ON (I) and check the
temperature indicator.
YES - Short circuit in the Blue/red wire
between the PCM and indicator.
one and recheck.
24-10
COOLING FAN MOTOR
SYSTEM INSPECTION
Cooling fan motor does not start
, . Fuse Inspection
Check the FAN fuse (15 AJ.
Is the (use blown?
YES - Replace the FAN fuse.
NO - GO TO STEP 2.
2. PGM-FI System OTe Inspection
Check t he PGM-FI system DTe (page 6-12).
Is DTe 7-1 and/or 7-2 indicated?
YES - . Perform the DIC 7-1 troubleshooting
(page 6-17),
Perform the DIC 7-2 troubleshooting
(page 6-'8).
NO - GO TO STEP 3.
3. Ground line Inspection
Check for continuity between the Green wire ter-

minal of the wire harness side 5P connector and PCM/ECM 5P BLACK CONNECTOR
ground. (Terminal side of the wire harness)
YES - GO TO STEP 4.
NO - Open circuit in the Green wire.
24-11
4. Cooling Fa n Motor Operation Inspection
Connect the Green/black and Green wire termi- , - - - - - - - - - - - - - - - - - - -
nals of the wire harness side 5P connector with PCM 5P BLACK CONNECTOR
the jumper wire. (Terminal side of the wi re harness)
Turn the ignition switch to ON and check the Green/black
cooling fan.
r J/,
~
Does the cooling fan start?

one, and recheck.
NO - GO TO STEP 5.
~~
JUMPER WIRE
\
Green
5. Cooling Fan Motor Ground line Inspection

Turn the ignition switch to OFF.
Disconnect the cooling fan 2P brown connector.
With the jumper wire connected to the peM 5P

connector, check for continuity between the COOLING FAN 2P BROWN CONNECTOR
Green/black wi re terminal of the wire harness (Term inal side of the wire harness)
side 2P connector and ground.
YES - GO TO STE P 6.
NO - Open circuit in the Green/black wire.
Green/black Q
6. Cooling Fan Motor Power Input Line Inspection
Turn the ignition switch to ON.
Measure the voltage between the Blue wire ter- COOLING FAN 2P BROWN CONNECTOR
minal (+) of the wire harness side 2P connector (Terminal side of the wire harness)
and ground (-).
Is there battery voltage ?
YES - Replace the cooling fan motor with a
new one (page 7-11).
r,
NO - Open circuit in the Blue wire between
the cooli ng fan and fuse box.
8~V Blue
24-12
LOW FUEL INDICATOR
SYSTEM INSPECTION
NOTE:
When the ignition switch is turned to ON (0, the
low fuel indicator should come on for a few sec-
onds and go off.
~
. -':\
~
e

I 0 ~
,;
s
,
L . .1
0 0 )' .
I
l OW FUEL ~DICATOR
low fuel indicator does not come on when the
ignition switch is turned to ON (I)
1. PCM Inspection
Disconnect the PCM 33P black connecto r.
Ground the Yellow wire (A2l ) terminal of the

wire ha rness side connector with a jumper wire PCM 33P GRAY CONNECTOR
TOOL: (Terminal side of the wire harness)
Test probe, 2 pack 01ZAJROJA110 rl I
low fuel indicator.
Does the indicator come on 7
YES - Replace the PCM with a known good I\.
one and recheck.
NO - GO TO STEP 2.
-==-
-
""
Yellow (A21)
24-13
Turn the ignition switch to OFF (0),
Remove the wire band from the indicator cover
and disconnect the indicator 6P connector.
Check for continuity between the indicator side

6P connector terminals. INDICATOR 6P CONNECTOR
(Terminal side of the indica tor harness)
CONNECTION: Black/ brown - Yellow/ blue
Is there continuity? r----' Yellow/blue
YES - GO TO STE P 3.
NO _. Faulty indicator bulb .
Black/brown
3. Indicator Power Input Inspection

Measure the voltage between the wire harness INDICATOR 6P CONNECTOR
side 6P connector terminal and ground. (Terminal side of the wire harness)
CONNECTION : Black/ brown 1+) - ground H
Is there battery voltage ?
YES - Open circuit in the Yellow wire between
the peM and indicator 6P connector.
NO - Open circuit in the Black/brown wire
indicator 6P connector. 7
Black/brown
Low fuel indicator does not come on when the fuel

level is low
1. Fuel Level Sensor Inspection
Remove the passenger seat under cover (page 3-
6).
24-14
Connect the Yellow and Green wire terminals of
the wire harness side connector using a jumper JUMPER WIRE
wire.
low fuel indicator. Yellow
\ Green
Does the indicator come on7 n
YES
NO
- Faulty fuel level sensor.
- . Open circuit the Yellow wire
r" I"
J
between the indicato
" r 6P connector

and fuel pump 5P connector.
Open circuit
between the fuel
the Green wire
" pump 5P connector
\
FUEL PUMP 5P CONNECTOR
and ground terminal. (Termi nal side of the wire harness)
Temperature indicator stays on with the enough

fuel in the fuel tank
1. DTe Inspection
Remove the battery box cover (page 21-6),
Turn the ignition switch 10 ON (I) and check the
low fuel indicator.
Does the indicator come on?
YES - GO TO STEP 2.
one and rech eck.
2. Fuel level Senso r Inspection

Turn the ignition switch to OFF 10}.
Remove the passenger seat under cover (page 3-
61.
Tu rn the ignition switch to ON (I) and check the
low fuel indicator.
YES - Short circuit in the Yellow wire.
NO - Faulty fuel level sensor.
24-15
FOOT BRAKE SWITCH
INSPECTION
Check the foot brake pedal height and adjust it if
necessary (page 4-21 ).
Disconnect the foot brake switch 2P gray connector
and check for continuity between the switch sid e
There should be continuity with the brake pedal
depressed and no con tinuity with the pedal
released.
REPLACEMENT
Unhook the brake switch springs from the brake r- - - - -- -BRM:e-;SY;iiTiCHS,;;;;;Ni:ii-
pedal and brake switch
Disconnect the foot brake switch 2P gray connector
(page 24-16).
Release the foot brake switch wire from the three
clamps.
Remove the foot brake switch from the stay of the ~iiii~~~~~~~~~~~r.;~;;;;;iiiiiiiiii
frame by push i ng the two stoppers.
~ \
/
Route the foot Installation is in the reverse order of removal.
\"..
brake switch wire
properly (page 1-
27).
After installing the foot brake switch, adjust it (page
4-19).
-
.~.
"i,
,
':"li..,~
,I
~I ~;I:lIII r-::==-
,
.'
' t-
,
\
o .
24-16
PARKING BRAKE SWITCH
INSPECTION
2P BLACK CONNECTOR
Remove the pa r king brake switch 2P black connec-
tor from the lever bracket and remove it .
Check for continuity between the wire harness side
There should be continuity when the parking brake
is applied, and no continuity when the parking brake
is released.
REPLACEMENT
Remove the parking br ake switch 2P black connec-
tor from the lever bracket and remove it. Release
the switch wire from the two clamps.
CLAMPS PARKING BRAKE SWITCH
pun the pa rking brake lever fully and remove the

screw and parking brake switch.
.iiiiire;~~~~;;~~~5iiil
Install a new parking brake switch by aligning the
pin and hole, and tighten the screw.
TORQUE : 0 .4 N 'm (0.04 kgfm, 0 .3 Ibf.ft)
Route the parking brake switch wire properly and
connect t he 2P black connector.
Install the seat center cover (page 3"5).
24-17
MEMO
25. WIRING DIAGRAM
WIRING DIAGRAM ........... ... ..................... 25-3
EI
25-1
26. TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD POOR PERFORMANCE AT LOW AND

TO START ..... ....... ..................................... 26-2 IDLE SPEED .............................................. 26-5
ENGINE LACKS POWER 26-3 POOR PERFORMANCE AT HIGH

SPEED .................. ..................................... 26-6
26-1
TROUBLESHOOTING
ENGINE DOES NOT START OR IS HARD TO START
1. Spark Plug Inspection
Remove and inspect spa rk plug.
Is the spark plug in good condition?
NO - . Incorrect spa rk plug heat range
Incorrect spa rk plug gap
Dirty air cleaner
YES - GO TO STEP 2.
2. Spark Test
Perform spark test.
Is there weak or no spark?
YES - . Loose or disconnected ignit ion system wire
Faulty ignitio n coil
Broken or shorted spark plug wire
Loose or disconnected ignition system wires
Fau lty CKP sensor
Faulty engine stop swit ch
Faulty ig nition switch
Faulty PCM
NO - GO TO STEP 3.
3. Fuel Pump Inspection
Check fo r operation of the fuel pump and inspect the fuel flow.
Is the futl! pump unit normal?
NO _. Faulty fuel pump unit
YES - GO TO STEP 4.
4. PGM- FI System Inspection
Check the PGM-FI system .
Is the PGM-FI s ystem normal?
NO - Faulty PGM- FI system
Yes - GO TO STEP 5.
5. Cylinde r Compression
Test cylinde r compression.
Is the compression low?
YES _ . Valve clearance too small
Valve stuck open
Worn cyli nder and piston rings
Damaged cylinder head gasket
Seized valve
Improper valve timing
NO - GO TO STEP 5.
6. Engine Start Condition
Start by followi ng normal procedure.
Did the engine start but s tops?
YES - . Leaki ng intake manifold
Leaking intake pipe
Improper ig nition timing !Fau lty PCM or CKP sensor)
Contaminated fuel
26-2
TROUBLESHOOTING
ENGINE LACKS POWER
1. Drivetrain Inspection
Raise wheel off the ground and spin by hand.
Does the wheel spin freely?
NO _. Brake dragging
Worn or damaged wheel bearing
Damaged differential or fina l drive bearing
Faulty differential or final drive
YES - GO TO STEP 2.
2. Tire Pressure Inspection
Check ti re pressure.
Are the tire pressures correct?
NO _ . Faulty tire valve
Punctured tire
YES - GO TO STEP 3.
3. Engine Condition Inspection
Accelerate lightly.
Does the engine speed increase?
NO -. Clogged air cleaner
Restricted fuel flow
Clogged muffler
Restricted fuel tank breather
YES - GO TO STEP 4.
4. Engine Condition Inspection
Accelerate or run at high speed.
Is there knocking ?
YES -. Worn piston and cylinder
Use of poor quality fuel
Excessive carbon build-up in combustion chamber
Ignition timing too advance (Faulty PCM )
NO - GO TO STEP 7.
5. Spark Plug Inspection
Remove and inspect spark plug.
Is the spark plug fouled or discolored?
YES _ . Plug not serviced frequently enough
Incorrect spark plug used
NO - GO TO STEP 6.
6. Engine Oil Inspection
Check oil level and condition.
Is there correct level Bnd good condition ?
NO - . Oil level too high
Oil level too low
Contaminated oil
YES - GO TO STEP 7.
7. Ignition Timing Inspection
Check the ignition timing.
Is the ignition timing correct?
NO - . Faulty PCM
Faulty CKP sensor
YES - GO TO STEP 8.
26-3
TROUBLESHOOTING
8. Cylinder Compression Inspection
Test cylinder compression.
Is th e compression low?
YES _ . Valve clearance too small
Valve stuck open
Worn cylinder and piston rings
Damaged cylinder head gasket
Seized valve
Improper valve timing
NO - GO TO STEP 9.
9. Fuel pump Inspection
Inspect the fuel flow.
Is the fuel pump unit normal?
NO - Faulty fuel pump unit (page 6-36)
YES - GO TO STEP 10.
10. PGM-FI System Inspection
Check the PGM-FI system.
Is the PGM- FI System normal?
NO - Faulty PGM-FI system (page 6~ 11)
YES - GO TO STEP 11 .
11 . lubrication Inspection
Remove cylinder head cover and inspect lubrication.
Is the valva train lubricated properly?
NO _ . Clogged oil passage
Clogged oil o rifice
YES _ . Faulty AfT system
26-4
TROUBLESHOOTING
POOR PERFORMANCE AT LOW AND IDLE SPEED
1. Spark Test
Perform spa rk test.
Is there weak or intermittent spark?
YES _ . Faulty spark plug
Fouled spark plug
loose or disconnected ignition system wires
Broken or shorted spark plug wire
Faulty ignition coil
Faulty CKP sensor
Faulty engine stop switch
Faulty ignition switch
Faulty PCM
NO - GO TO STEP 2.
Is the fuel pump unit normal?
NO - Faulty fuel pump unit {page 6-36}
YES - GO TO STEP 3.
3. PGM-FI System In spection
Check the PGM-FI system.
Is the PGM- FI system normal?
NO - Faulty PGM-FI system (page 6- 11 )
YES - GO TO STEP 4.
4. Intake Air Leak Inspection
Check for leaks at the intake manifold pipes.
Are there leaks?
yeS _. loose insulator bands
Damaged insulator
NO - GO TO STEP 5.
Check the ignition timing .
NO _ . Faulty PCM
Faulty CKP sensor
YES _ . Faulty AIT system
26-5
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED
Is the fuel pump unit operation normsl?
NO - Faulty fuel pump unit (page 6-36)
YES - GO TO STEP 2.
2. PGM-FI System Inspection
Check the PGM-FI system .
Is the PGM- FI system normal?
NO - Faulty PGM- FI system (page 6-11)
YES - GO TO STEP 3.
Check ignition timing.
NO _ . Faulty peM
Faulty CKP sensor
YES - GO TO STEP 4.
4. Valve Timing Inspection
Check valve timing.
Is the valve timing correct?
NO - Camshaft not installed properly
YES - GO TO STEP 5.
5. Valve Spring Inspection
Check val ve spri ngs.
Are the valve springs weak?
yeS _. Faulty valve spri ng
NO _ . Faulty AfT system
26-6
27. INDEX
ACCELERATOR PEDAL 6-42 DTC TROUBLESHOOTING ......................................... 6-15
ACCESSORY SOCKET ................................................. 246 ECT SENSOR .. .. .. .. 6-53
AlA CLEANER4-6 EMISSION CONTROL SySTEMS .. .. .. 1-46
AlA CLEANER HOUSING 641 ENGINE FRONT COVER 36
AIR CLEANER HOUSING DRAIN TUBE .. .. .... 4-8 ENGINE IDLE SPEED 6-55
ALTERNATOR CHARGING COIL 21-8 ENGINE INSTALLATION 8-9
ALTERNATOR STATOR/S TARTER REDUCTION ENGINE OIL ...................................................... 4-12
GEARS ......................... , ' -5 ENGINE REMOVAL ....................................................... 8-4
BATIERY ENGINE TEMPERATURE INDICATOR ....................... 24-9
BATTERY/CHARGING SYSTEM216 EOT SENSOR ....................................... ................ 14-58
MAINTENANCE4-9 EXHAUST SYSTEM
BODY PANEL LOCATIONS .... .... .. .... .... .. .... .. 3-3 FRAME/BODY PANELS/EXHAUST SYSTEM ........ 3-25
BRAKE FLUiD .. .. .. .... .. .. 4-18 MAINTENANCE ...................................................... 4-24
BRAKE FLUID REPLACEMENT/AIR BLEEDING .. .. 186 FLOOR CROSS PLATE ................................................ 313
BRAKE INHIBITOR RELAY 23-14 FLOOR PANEL 312
BRAKE PAD/DISC ........................................... ............. 188 FLYWHEEUSTARTER CLUTCH .. .. .. .. .. .. ...... 11-10
BRAKE PADS WEAR .. .. .. .. .. .. 4- 19 FOOT BRAKE SWITCH
BRAKE PEDAL ............................................................ 18-27 LIGHTS/METERS/SWITCHES .. .. .. 24-16
BRAKE SYSTEM ....................................................... 4-20 MAINTENANCE ......................................... ............. 4-19
BRAKEIT AILLlGHT ...................................................... 24-5 FOOTREST PANEL 314
CABLE & HARNESS ROUTING ...... .. .. .. .... ........ '-21 FRONT BRAKE CALIPER .... .... .. .... .. .. .... .. 1815
CAMSHAFT .... ....................................... 9-16 FRONT BUMPER ............................ .. .... .... 3- 16
CARGO BED .. .. .. .. .. 316 FRONT CARRIER ......................................................... 3-13
CENTER FRAME COVER .. .. 37 FRONT CRANKCASE COVER ................................... 14-37
CHARGING SYSTEM INSPECTION .. .. .. .... ........ 21-7 FRONT DIFFERENTIAL LOCK CLUTCH .. .... ............ 1923
CHASSIS LUBRICATION POINTS .. .. .. .. 4-29 FRONT DRIVE SHAFT 19-7
COMPONENT LOCATION FRONT FINAL CLUTCH ............ .. .. .. .. .. .. .. 1917
BATTERY/CHARGING SYSTEM .. .. ...... ............ 2 1-2 FRONT FINAL DRIVE INSTALLATION 19-39
DRIVETRAIN SYSTEM .......................................... 14-11 FRONT FINAL DRIVE REMOVAL .. ...... ...... ...... 1912
ELECTRIC STARTER .. .. .. .... .. .. .. .. ........ .... 23-2 FRONT FINAL GEAR ASSEMBLy .. ........ .. .... ...... 1936
IGNITION SYSTEM .... .. .. .... .. .... ...... .... .... .... 22-2 FRONT FINAL GEAR CASE BEARING
LlGHTS/M ETEAS/ SWITCHES ................................. 24-2 REPLACEMENT .................. .. ............ 19-34
PGM-FI SySTEM .. .. .. 5-7 FRONT FINAL GEAR DISASSEMBLY!
COOLANT REPLACEMENT ........................................... 7-5 INSPECTION .. .. .. .. .. ................ .. .... .. .............. 19-28
COOLING FAN .. ........ ........ .... ...... .... ...... .... ...... 7-11 FRONT GRILLE ....................................................... 315
COOLING FAN MOTOR .. .......... ...... ............ .... .... 24- 11 FRONT HOOD .... .. 3-1 4
COOLING SySTEM .. 415 FRONT PROPELLER SHAFT ..................................... 19-15
COOLING SYSTEM FLOW PATTERN .. .. .. .... ...... .. 7-2 FRONT SHOCK ABSORBER ..................................... 15-21
COOLING SYSTEM TESTING ....................................... 7-4 FRONT SUSPENSION ARM .. .. .. .. .... .... .. .... 15-17
CRANKCASE ASSEMBLY .. ............ ............ .... ...... 13- I 2 FRONT WHEEL .. .... .. .. .. .. 156
CRANKCASE BEARING REPLACEMENT ................. 13- 10 FRONT WHEEL HUB AND KNUCKLE .. .... .. .. .. 15-10
CRANKCASE SEPARATION .... .... .. .... .... .. .... .. .... 13-5 FUEL LINE .. 4-5
CRANKSHAFT13-7 FUEL LINE INSPECTION .... .. .. .. .. .... ...... .... .... 6-31
CROSSBAR ............ .......................................... 3-8 FUEL PUMP .. .. .. .. .. .... .. .. .... ........ ...... .... .... 636
CYLINDER COMPRESSION .. .. .. 9-6 FUEL SYSTEM (PGM FI) .... .. ............ .... ...... .... .... .. 6-2
CYLINDER HEAD ASSEMBLY ..................................... 9-19 FUEL TANK .. 6-40
CYLINDER HEAD COVER ASSEMBLY/ FUEL TANK PLATE/COVER .................. .. .................... 3-24
INSTALLATION .. .. .. .. 9-21 GEAR POSITION SWITCH ........................................ 14-57
CYLINDER HEAD COVER REMOVAU GEAR SELECTOR CABLE ADJUSTMENT ............... 12-16
DISASSEMBLY ........................................................ 9-6 GEAR SELECTOR LEVER LINKAGE ...... .. .. ........ 1215
CYLINDER HEAD DISASSEMBL Y910 HEADLIGHT .......................................................... 244
CYLINDER HEAD INSPECTION .. .. .. 9-10 IACV ......................................................... 648
CYLINDER HEAD INSTALLATION .. .... ............ ...... 9-20 IGNITION COIL ......................................................... 22-7
CYLINDER HEAD REMOVAL .. .. 9-9 IGNITION SWITCH ......................................... ............. 24-7
CYLINDER/PISTON INSPECTION .. 105 IGNITION SYSTEM INSPECTION ...... .................. .. 225
CYLINDER/PISTON INSTALLATION 10-8 IGNITION TIMING ....................................................... 228
CYLINDER/PISTON REMOVAL .... ....... . .. .... 104 INDICATORS ......................................................... .. 245
DIFFERENTIAL OIL .. .. 4-16 INJECTOR .. 6-49
DIODE ................................................................. 2313 INTAKE AIR DUCT .. .... ...... .... .. ........ .. .... .... 6-42
DOOR .. 39 LIFT AND SUPPORT POINTS .... .... ...... .... .. .. 1-48
DRIVE MODE SELECTOR CABLE ADJUSTMENT .. 19-44 LIGHTING/DIMMER SWITCH ............ _........................ 24-8
DRIVE MODE SELECTOR LEVER LINKAGE .. ...... 19-42 LOW FUEL INDiCATOR .. .. .... 24-13
DRIVE SHAFT BOOTS .. .. .. .. .. .... .. 416 LUBRICATION & SEAL POINTS .... .. .. ...... .... .... 118
DRIVETRAIN CONNECTOR LOCATION 14-13 LUBRICATION SYSTEM DIAGRAM .. 5-2
DRIVETRAIN DTC INDEX .. .. ............ ........ ........ 1416 MAIN RELAY/FUEL PUMP RELAy .. .. .. .. .. .. .... 6-38
DRIVETRAIN DTC TROUBLESHOOTING .. .. .. 14-17 MAINTENANCE UD .. .. .. .. 3-16
DRIVETRAIN SYSTEM DIAGRAM 1 4-12 MASTER CYUNDER18-11
DRIVETRAIN TROUBLESHOOTING MIL CIRCUIT INSPECTION ................ ..... .... ... ............. 6-30
INFORMATION ........................................................ 14-15 MODEL IDENTIFiCATION .. '3
27-1
INDEX
MUDGUARD .................. 3-12 SPECIFICATIONS
OCCUPANT PROTECTIVE STRUCTURE (OPS) .. 321 BATIERY/CHARGING SYSTEM ' 1-10
Oil COOLER ............. .... .... .. ......................................... 513 BRAKE SYSTEM 1-10
Oil PRESSURE CHECK COOLING SySTEM 1-7
DRIVETRAIN SYSTEM .... .... ..... .............. ..... .. .... ..... 14-8 CRANKCASE/CRANKSHAFT/BALANCER ' -9
LUBRICATION SySTEM 5-5 CYLINDER HEADNALVE/CAMSHAFT 1-8
OIL PUMp 5-6 CYLIN DER/PISTON ' -8
PARKING BRAKE LEVER .... .. .... .. .. .. .. 18-29 DRIVETRAIN SYSTEM ... ... ...... .... .. .... .. .. ... ....... .. ... .... , -9
PARKING BRAKE LEVER BRACKET .. ............ 3-7 ELECT RIC STARTER ' -11
PARKING BRAKE SWITCH ... .... ..... 2417 FRONT DRIVING MECHAN ISM 1-10
PCM 6-54 FRONT WHEEl/SUSPENSION ............................. .... ' -9
PGM -FI CONNECTOR LOCATION 6-9 FUEL SYSTEM ... .. ... ............................................. .1 -7
PGM FI DTC INDEX 6-14 GENERAL ..... .. ............................................... ' -5
PGM -FI SYSTEM DIAGRAM 68 IGNITION SYSTEM 1- 11
PGM FI TROUBLESHOOTING INFORMATION 611 LIGHTS/METERS/ SWITCHES 1- 11
RADIATOR 7- 13 LUBRICATION SYSTEM 1-7
RADIATOR RESERVE TANK 7-14 REAR DRIVING MECHANISM .. .. 1-10
REAR BRAKE CALIPER 18-19 REAR WHEEUSUSPENSION 1-9
REAR CRANKCASE COVER 12-5 STEERING SYSTEM 1-9
REAR DIFFERENTIAL LOCK CLUTCH 20-15 SUB-TRANSMISSION/GEARSHIFT L1NKAGE ' -9
REAR DIFFERENTIAL REMOVAL 20-12 STARTER MOTOR 23-6
REAR DRIVE SHAFT 20-7 STARTER RELAY SWITCH 23'2
REAR FINAL DRIVE INSTALLATION 20-32 STEERING COLUMN AND SHAFT 16-5
REAR FINAL GEAR ASSEMBLy 20-29 STEERING GEAR BOX 16-9
REAR FINAL GEAR CASE BEARING STEERING SYSTEM 4-25
REPLACEMENT ...................................................... 2026 STEERING WHEEL ...................................................... 16-5
RE A R FI NAL GEAR DISASSEMBLYI SUBTRANSMISSION 12-9
INSPECTION 20-21 SUSPENSION ...................................................... 4-23
REAR SHOCK ABSORBER 17-16 SYMPTOM TROUBLESHOOTING
REAR SUSPEN SION ARM 17-11 DRIVETRAIN SYSTEM 14-6
REAR WHEEL ................ ...................................... 17-5 FUEL SYSTEM (PGM -FI) .... ... ...... .. ... .... .... ... .... .. ... ... . 6-6
REAR WHEEL HUB/KNUCKLE 175 SYSTEM COMPONENTS
REGULATOR/RECTIFIE R 218 ALTERNATOR/STARTER CLUTCH 11-2
SEAT ................. ... .... .. ...... ...................... 3-4 BRAKE SYSTEM .. .. 18-2
SEAT BELT .. .. 3-22 CRANKCASE/CRANKSHAFT/BALANCER 13-2
SEAT CENTER COVER 3-5 CYLINDER HEADN ALVE/CAMSHAFT 9-2
SEAT UNDER COVER .. .. ..... .. .................................... ... . 3-6 CYLlNDERiPISTON 10-2
SERVICE INFORMATION 4-4 DRIVETRAIN SYSTEM 14-2
ALTERNATOR!STARTER CLUTCH 11 -3 ENGINE REMOVALIINSTALLATION 8-2
BATIERYtCHARGING SYSTEM 21-3 FRONT DRIVING MECHANISM 19-2
BRA KE SYSTEM ....... ... ... .... .. .... .. ......... ..... .. ... .. .... ... 18-4 FRONT WHEEUSUSPENSION 15-2
COOLING SYSTEM ..... .. .... ... ......... .................. ...... ... 7-3 FUEL SYSTEM (PGM-FIl 6-2
CRANKCASE/CRANKSHAFT/BALANCER .... ... .... .. 133 REAR DRIVING MECHANISM ... .... .. ... .. .. ... .. ... ..... .. . 20-2
CYLINDER HEADNALVE/CAMSHAFT .......... ...... .... 9-3 REAR WHEEUSUSPENSION .. 17-2
CyLINDER/PiSTON 10-3 STEERING SYSTEM 16-2
DRIVETRAIN SYSTEM ........................................... 14-3 SUB-TRANSMISSION/ GEARSHIFT LINKAGE 12-2
ELECTRIC STARTER 23-3 SYSTEM DIAGRAM
ENGINE REMOVA U INSTALLATION 8-3 BATIERY/CHARGING SYSTEM 21-2
FRAM E/BODY PANELSfEXHAUST SySTEM 32 ELECTRIC STARTER ... .............................. .. .. ... .. ... .. 232
FRONT DRIVING MECHANISM ............................. 19-3 IGNITION SYSTEM ................................... ... ........... 22-2
FRONT WHEE U SUSPENSION .............................. 15-3 TECHNICAL FEATURES
FUEL SYSTEM (PGM -FI) 6-4 AUTOMATIC TRANSMISSION SYSTEM 2-7
IGNITION SySTEM 22-3 MUV OVERViEW 2-2
LIGHTS/METERS/SW ITCHES ................................ 24-3 PGM -FI SySTEM 2-4
LUBRICATION SySTEM 5-3 SELECTABLE 4WD AND DIFFERENTIAL LOCK
MAINTENANCE ....... ... ..... .. .................................. ... .. 4-2 SYSTEM ....... .. .. ... .. .. .... ....................................... 2-14
REAR DRIVING MECHANiSM .. 20-3 THERMOSTAT .. .. ..... ..... ......... .......... ........ .. .. ... ... .. ......... . 7-7
REAR WHEEUSUSPENSION ..... ......................... ... 17-3 THROTILE BODY ... .. ............................... ... ..... .... .. ... .. . 6-45
STEERING SYSTEM 16-3 THROTILE OPERAT ION 4-5
SU B-TRANSMISSION/GEARSHIFT LINKAGE ... ... 12-3 TIE-ROD AND JOINT BOOT 4-25
SERVICE RULES 1-2 TIE-ROD BALL JOINT 16-7
SHIFT CLUTCH/MAINSHAFT/COUNTERSHAFT ..... 14-47 TIRES 15-6
SHIFT VALVE BODy 14-28 TORQUE CONVERTER '4-42
SIDE NET ...................................................... 3-21 TORQUE VALUES
SIDE PANEL 3- 11 ENGINE & FRAME .. .. 1- 12
SPA RK ARRESTER 4-23 STANDARD 1- 12
SPARK PLUG 4-8 TP SENSOR/MAP SENSOR (SENSOR UNIT) 6-51
SPECIFICATIONS TROUBLESHOOTING
ALTERNATOR/STARTER CLUTCH ....... .. 1-8 AL TERNATORISTA RTER CLUTCH 1 1-4
27-2
INDEX
TR OU BLESHOOTING POOR PERFORMANCE AT HIGH SPEED .. .... . .... .. 26-6
BATIERY/CHAAGING SVSTEM .. 2 1-5 POOR PERFORMANCE AT LOW AND IDLE
BRAKE SySTEM 185 SPEED .. ..... ..... ... .. .. .. ... .. ... ... .. ... ... ..... .... .. .. 26-5
COOLING SYSTEM .. .. ....... .. .. ... .. ............................... 7-3 REAR DRIVING MECHANiSM .. .. .. 20-6
CRANKCASE/CRANKSHAFT/BALANCER .. ... .. .... .. . , 3-5 REAR WHEEUSUSPENSION .. .. .. .. .. ...... .. .. .. ...... 17 -4
CYLINDER HEADN AlVE fCAMSHAFT 9-S STEERING SYSTEM .. 16-4
CYLINDERJPISTON 10-3 SUB-TRANSMISSION/GEARSHIFT LINKAGE .. .. 12-4
ELECTRIC STARTER 23-4 UNDERBODy 4-22
ENGINE DOES NOT START OR IS HARD TO VALVE CLEARANCE 4-10
START ... ... . 26-2 VALVE GUIDE REPLACEMENT .... .... .... ... .. ...... ... ... ... .. 9-1 2
ENGINE LACKS POWER ... .. .... .. ............ .. .. .. .... .... .... 26-3 VALVE SEAT INSPECTION/REFACING 9-13
FRAME/BODY PANELS/EXHAUST SYSTEM 3-2 VS SENSOR .. ..... .. ... ... .... .. ... .. .. ... ... .. .. .. ... ... .. ... ... . 6-53
FRONT DRIVING MECHANISM 19-6 WATER PUMP 7-9
FRONT WHEEUSUSPENSION .. .. 15-5 WHEELSfTIRES 4-24
IGNITION SYSTEM .. .. .. 22-4 WIRING DIAGRAM 25-3
LUBRICATION SYSTEM .. .. .. .. 5-4
27-3

2009-12 MUV 700 Big Red 700 Service Manual

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2009-12 MUV 700 Big Red 700 Service Manual

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A Few Words About Safety

For Your Customer's Safety

Important Salety Precautions

Use only a nonflammable solvent, not gasoline. to clean paris.

NeYer drain or store gasoline In an open container.

PertOlnung II\ei ',rsl SCheduled malOll1011nce IS WIry mportant. II

~ Example: Molykole BR2 plus manufactured by Dow Corning U.S.A.

.,('61ll Apply sealant.

Use fork or suspension ftuid.

SERVICE RULES ......................................... '2 REAR WHEEL/SUSPENSION

COOLING SYSTEM SPECIFICATIONS ...... ' -7 BATIERY/ CHARGING SYSTEM

CYLINDER HEADIVALVE/ CAMSHAFT

CYLINDER/PISTON SPECIFICATIONS ...... ' -8 ELECTRIC STARTER SPECIFICATIONS .. ,."

ALTERNATOR/STARTER CLUTCH LIGHTS / METERS/ SWITCHES

SUB-TRANSMISSION/GEARSHIFT STANDARD TORQUE VALUES .............. 1-12

DRIVETRAIN SYSTEM CABLE & HARNESS ROUTING ............... '2'

STEERING SYSTEM SPECIFICATIONS .... ' -9

The vehicle emission control information label is attached on the front

- + " -0" mm (114.7 in)

system and ,e',e,,,:

FUEL SYSTEM SPECIFICATIONS

Fuel injector resistance (at 20C !6BOF) 11.1 12.30

COOLING SYSTEM SPECIFICATIONS

Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality

ITEM STANDARD SERVICE LIMIT

ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

DRIVETRAIN SYSTEM SPECIFICATIONS

FRONT WHEEL/SUSPENSION SPECIFICATIONS

STEERING SYSTEM SPECIFICATIONS

REAR WHEEL/SUSPENSION SPECIFICATIONS

FRONT DRIVING MECHANISM SPECIFICATIONS

REAR DRIVING MECHANISM SPECIFICATIONS

BATTERY/CHARGING SYSTEM SPECIFICATIONS

ELECTRIC STARTER SPECIFICATIONS

ENGINE & FRAME TORQUE VALUES

Apply locking agent.

ITEM Q'TV THREAD TORQUE REMARKS

Fuel pump lock nut --===C::J==

REAR DRIVING MECHANISM

LIGHTS/ METERS/S WITCHES

Right Headlig ht Left Headlight

N~b'i7,~;;t-- HEADLlGHT3P (Black)

Inside of front hood:

COOLING FAN MOTOA FOOT BRAKE SWITCH

FRONT FINAL GEAR CASE

FUSE BOX WIRES ....""'::::;

FUSE BOX 4WQ SELECT SWITCH!

STARTER RELAY SWITCH

STARTER RELAY SWITCH

FAN MOTOR 2P (Brown)

HEADLIG HT WIRE _ -.J,---',\\',,%

4WD SELECT SWITCHI ~......" ---- Front

Reverse side of instrument panel :

-:~~- -_.-------- -_ .. ---_.. ...- ._---_._-......_----

FRONT DIFFERENTIA L ~\\\ 1- GEAR SELECTOR CABLE

REAR DIFFERENTIAL 2WD/4WQ SELECTOR CABLE

Reverse side of floor panel:

\\ ~.~_ _ FRONT DIFFERENTIAL

.\ ~.~_ _ _ FRONT FINAL

Inside of floor panel:

2WD/4WD SELECTOR f4'-f-__ MAIN WIRE

-"""To differential lock switch

Inside of floor panel:

GEAR SELECTOR f~~~ HARNESS -

RUBBERS AND COLLARS ="""~g<