Yamaha Wolverine YXE700E Manuals

Manuals and User Guides for Yamaha Wolverine YXE700E. We have 1 Yamaha Wolverine YXE700E manual available for free PDF download: Service Manual

Yamaha Wolverine YXE700E Service Manual

Yamaha Wolverine YXE700E Service Manual (503 pages)

Brand: Yamaha | Category: Utility Vehicle | Size: 23.33 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  4
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    12
    
    OUTLINE of the EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS Model)
    12
    
    Instrument Functions
    14
  - Important Information
    16
    
    Preparation for Removal and Disassembly
    16
    
    Replacement Parts
    16
    
    Gaskets, Oil Seals and O-Rings
    16
    
    Lock Washers/Plates and Cotter Pins
    16
    
    Bearings and Oil Seals
    17
    
    Circlips
    17
    
    Rubber Parts
    17
  - Basic Service Information
    18
    
    Quick Fasteners
    18
    
    Electrical System
    19
  - Special Tools
    23
Specifications

33
- General Specifications
  34
- Engine Specifications
  35
- Chassis Specifications
  39
- Electrical Specifications
  42
- Tightening Torques
  44
- Lubrication and Sealing Points
  57
  - Engine
    57
- Lubrication System Chart and Diagrams
  58
  - Engine Oil Lubrication Chart
    58
  - Lubrication Diagrams
    60
- Cooling System Diagrams
  66
- Cable Routing
  72
Periodic Checks and Adjustments

105
- General Maintenance and Lubrication Chart
  106
- Introduction
  106
- Periodic Maintenance
  106
- Periodic Maintenance Chart for the Emission Control System
  106
- Adjusting the Valve Clearance
  108
- Checking the Fuel Line
  108
- Checking the Breather Hose
  111
- Checking the Spark Plug
  111
- Adjusting the Exhaust Gas Volume
  112
- Checking the Exhaust System
  112
- Cleaning the Spark Arrester
  112
- Checking the Air Induction System
  113
- Checking the Coolant Level
  113
- Checking the Cooling System
  113
- Changing the Coolant
  114
- Cleaning the Air Filter Element
  116
- Checking the Engine Oil Level
  118
- Changing the Engine Oil
  119
- Measuring the Engine Oil Pressure
  120
- Changing the Final Gear Oil
  121
- Checking the Final Gear Oil Level
  121
- Changing the Differential Gear Oil
  122
- Checking the Differential Gear Oil Level
  122
- Checking the Brake Fluid Level
  123
- Checking the Front Brake Pads
  123
- Checking the Rear Brake Pads
  123
- Bleeding the Hydraulic Brake System
  124
- Checking the Brake Hoses and Brake Pipes
  125
- Adjusting the Brake Pedal
  126
- Adjusting the Parking Brake
  126
- Lubricating the Brake Pedal and Accelerator Pedal
  126
- Adjusting the Accelerator Pedal Free Play
  127
- Checking the V-Belt
  128
- Checking the Wheels
  129
- Replacing the V-Belt
  129
- Checking the Tires
  130
- Adjusting the Front Shock Absorber Assemblies
  131
- Checking the Front Shock Absorber Assemblies
  131
- Adjusting the Rear Shock Absorber Assembly
  134
- Checking the Rear Shock Absorber Assemblies
  134
- Checking the Steering System
  136
- Adjusting the Toe-In
  137
- Checking the Constant Velocity Shaft Assembly Dust Boots
  138
- Checking the Engine Mount
  138
- Checking the Stabilizer Bushing
  138
- Lubricating the Drive Shaft Universal Joints
  138
- Lubricating the Rear Knuckle Pivots
  138
- Checking the Fastener
  139
Chassis

141
- General Chassis (1)
  
  145
  - Installing the Door
    145
- General Chassis (2)
  
  146
  - Removing the Seats
    147
  - Adjusting the Driver Seat Position
    147
  - Installing the Seats
    147
- General Chassis (3)
  
  148
- General Chassis (4)
  
  149
  - Installing the Seat Belts
    151
- General Chassis (5)
  
  152
  - Installing the Enclosure
    154
- General Chassis (6)
  
  155
- General Chassis (7)
  
  155
  - Removing the Steering Wheel
    159
  - Installing the Steering Wheel
    159
- General Chassis (8)
  
  160
- General Chassis (9)
  
  161
  - Installing the Cargo Bed
    163
- General Chassis (10)
  
  164
  - Installing the V-Belt Cooling Ducts
    165
- Front and Rear Wheels
  
  166
  - Removing the Wheels
    167
  - Removing the Wheel Hubs
    167
  - Checking the Wheels
    167
  - Checking the Wheel Hubs
    168
  - Installing the Brake Discs
    168
  - Installing the Wheel Hubs
    168
  - Installing the Wheels
    169
- Front and Rear Brakes
  
  170
  - Introduction
    177
  - Checking the Brake Discs
    177
  - Replacing the Brake Pads
    178
  - Disassembling the Brake Calipers
    179
  - Checking the Brake Calipers
    179
  - Assembling the Brake Calipers
    179
  - Installing the Brake Calipers
    180
  - Checking the Brake Master Cylinder
    181
  - Checking the Brake Pipes
    181
  - Installing the Brake Master Cylinder
    181
- Parking Brake
  
  183
  - Checking the Friction Plates
    185
  - Checking the Parking Brake Plates
    185
  - Checking the Parking Brake Springs
    185
  - Checking the Parking Brake Boss
    185
  - Installing the Parking Brake
    185
  - Installing the Parking Brake Lever
    186
- Pedal Assembly
  
  187
  - Installing the Pedal Assembly
    189
- Steering System
  
  190
  - Removing the Tie-Rod
    192
  - Checking the Steering Joint
    192
  - Checking the Tie-Rod Ends
    192
  - Installing the Steering System
    192
  - Lubricating the Steering Shaft
    194
- Steering Knuckles
  
  195
- Front Arms and Front Shock Absorber Assemblies
  
  198
- Rear Knuckles and Stabilizer
  
  203
Engine

211
- Engine Inspection
  
  214
  - Measuring the Compression Pressure
    214
- Engine Removal (1)
  
  216
  - Installing the Exhaust Pipe and Muffler
    217
- Engine Removal (2)
  
  218
  - Installing the Engine
    222
- Camshafts
  
  223
  - Removing the Camshafts
    225
  - Checking the Camshafts
    226
  - Checking the Camshaft Sprockets
    227
  - Checking the Timing Chain Tensioner
    227
  - Installing the Camshafts
    227
  - Installing the Breather Plate
    229
- Cylinder Head, Cylinder, and Piston
  
  230
  - Removing the Cylinder Head
    233
  - Removing the Piston
    233
  - Checking the Cylinder Head
    234
  - Checking the Cylinder and Piston
    234
  - Checking the Piston Rings
    235
  - Checking the Piston Pin
    236
  - Installing the Piston and Cylinder
    236
  - Installing the Cylinder Head
    237
- Valves and Valve Springs
  
  240
  - Removing the Valves
    240
  - Checking the Valves and Valve Guides
    240
  - Checking the Valve Seats
    242
  - Checking the Valve Springs
    243
  - Checking the Valve Lifters
    244
  - Installing the Valves
    244
  - Engine
    246
- Ac Magneto and Starter Clutch
  
  246
  - Checking the Starter Clutch
    248
  - Removing the Ac Magneto Rotor
    248
  - Removing the Starter Clutch
    248
  - Installing the Ac Magneto Rotor
    249
  - Installing the Starter Clutch
    249
- Electric Starter
  
  251
  - Checking the Starter Motor
    253
  - Assembling the Starter Motor
    254
- Oil Pump Sprockets
  
  255
- Shift Lever
  
  258
  - Checking the Stopper Lever
    260
  - Checking the Shift Levers
    260
  - Installing the Shift Levers
    260
  - Adjusting the Drive Select Lever Shift Rod
    261
- Primary and Secondary Sheaves
  
  263
  - Removing the Primary and Secondary Sheaves
    266
  - Disassembling the Secondary Sheave
    266
  - Checking the V-Belt
    267
  - Checking the Primary Sheave
    267
  - Checking the Primary Sheave Weights
    267
  - Checking the Primary Sheave Sliders
    267
  - Checking the Secondary Sheave
    267
  - Assembling the Primary Sheave
    268
  - Assembling the Secondary Sheave
    269
  - Installing the Primary and Secondary Sheaves
    270
- Clutch
  
  273
  - Removing the Clutch
    275
  - Checking the Clutch
    275
  - Checking the Clutch Shoe
    275
  - Assembling the Clutch Housing
    276
  - Installing the Clutch
    276
- Crankcase
  
  278
  - Separating the Crankcase
    281
  - Checking the Timing Chain and Timing Chain Guide
    281
  - Checking the Bearings
    281
  - Checking the Crankcase
    282
  - Assembling the Crankcase
    282
- Crankshaft and Oil Pump
  
  284
  - Removing the Crankshaft
    286
  - Checking the Oil Pump
    286
  - Checking the Oil Strainer
    286
  - Checking the Relief Valve
    286
  - Checking the Crankshaft
    287
  - Assembling the Oil Pump
    287
  - Installing the Crankshaft
    287
  - Installing the Oil Pump
    288
- Transmission
  
  293
  - Removing the Transmission
    293
  - Disassembling the Drive Axle
    293
  - Checking the Shift Forks
    293
  - Checking the Shift Drum
    293
  - Checking the Transmission
    294
  - Checking the Secondary Shaft
    294
  - Assembling the Drive Axle
    294
  - Assembling the Shift Fork
    294
  - Installing the Shift Forks and Shift Drum
    295
- Middle Gear
  
  296
  - Removing the Middle Drive Shaft
    300
  - Removing the Middle Driven Shaft
    300
  - Checking the Pinion Gears
    301
  - Installing the Bearing and Oil Seals
    302
  - Installing the Middle Driven Shaft
    302
  - Installing the Middle Drive Shaft
    303
  - Measuring the Middle Gear Backlash
    304
  - Aligning the Middle Gear
    305
Cooling System

309
- Oil Cooler
  
  312
  - Checking the Oil Cooler
    312
  - INSTALLING the HORN (Except for CDN)
    312
- Radiator
  
  313
  - Checking the Radiator
    315
  - Installing the Radiator
    315
- Thermostat
  
  317
  - Checking the Thermostat
    318
  - Installing the Thermostat
    318
- Water Pump
  
  320
  - Disassembling the Water Pump
    321
  - Checking the Water Pump
    321
  - Assembling the Water Pump
    321
  - Installing the Water Jacket Joint
    322
Fuel System

323
- Fuel Tank
  
  324
  - Checking the Fuel Pump Body
    325
  - Checking the Fuel Tank Breather Hose Joint
    325
  - Removing the Fuel Pump
    325
  - Removing the Fuel Tank
    325
  - Installing the Fuel Pump
    326
  - Installing the Fuel Tank
    326
  - Checking the Fuel Pressure
    327
- Air Filter Case
  
  328
  - Installing the Air Filter Case
    330
- Throttle Body
  
  331
  - Removing the Throttle Body
    334
  - Checking the Fuel Injector
    334
  - Checking the Throttle Body
    334
  - Checking the Throttle Body Joint
    334
  - Installing the Throttle Body
    334
  - Adjusting the Throttle Position Sensor
    336
- Air Induction System
  
  337
  - Checking the Air Induction System
    340
  - Installing the Air Induction System
    340
Drive Train

341
Electrical System

373
- Ignition System
  
  376
  - Circuit Diagram
    376
  - Troubleshooting
    378
- Electric Starting System
  
  380
  - Circuit Diagram
    380
  - Starting Circuit Cut-Off System Operation
    382
  - Troubleshooting
    383
- Charging System
  
  386
  - Circuit Diagram
    386
  - Troubleshooting
    388
- Lighting System
  
  390
  - Circuit Diagram
    390
  - Troubleshooting
    392
- Signaling System
  
  394
  - CIRCUIT DIAGRAM (Except for EPS Models)
    394
  - CIRCUIT DIAGRAM (for EPS Models)
    396
  - Troubleshooting
    398
- Cooling System
  
  404
  - Circuit Diagram
    404
  - Troubleshooting
    406
- Fuel Injection System
  
  408
  - CIRCUIT DIAGRAM (Except for EPS Models)
    408
  - CIRCUIT DIAGRAM (for EPS Models)
    410
  - Ecu Self-Diagnostic Function
    412
  - Troubleshooting Method
    413
  - Yamaha Diagnostic Tool
    414
  - Troubleshooting Details (Fuel Injection System)
    416
- Fuel Pump System
  
  440
  - Circuit Diagram
    440
  - Troubleshooting
    442
- 2Wd/4Wd Selecting System
  
  444
  - Circuit Diagram
    444
  - Troubleshooting
    446
- EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS Models)
  
  448
- Electrical Components
  
  458
  - Checking the Switches
    464
  - Checking the Bulbs and Bulb Sockets
    467
  - Replacing the Headlight Bulbs
    468
  - Adjusting the Headlight Beams
    469
  - Checking the Fuses
    469
  - Checking and Charging the Battery
    470
  - Checking the Relays
    472
  - Checking the Spark Plug Cap
    475
  - Checking the Ignition Coil
    475
  - Checking the Ignition Spark Gap
    476
  - Checking the Crankshaft Position Sensor
    476
  - Checking the Lean Angle Sensor
    477
  - Checking the Starter Motor Operation
    477
  - Checking the Stator Coil
    478
  - Checking the Rectifier/Regulator
    478
  - Checking the Fuel Sender
    478
  - Checking the Fuel Meter/Fuel Level Warning Light
    479
  - Checking the Speed Sensor
    479
  - Checking the Parking Brake Buzzer
    480
  - Checking the Radiator Fan Motor
    480
  - Checking the Radiator Fan Motor Circuit Breaker
    480
  - Checking the Coolant Temperature Sensor
    481
  - Checking the Throttle Position Sensor
    481
  - Checking the Intake Air Pressure Sensor
    482
  - Checking the Intake Air Temperature Sensor
    482
  - Checking the Fuel Injector
    483
  - Checking the Air Induction System Solenoid
    483
  - Checking the Differential Motor Position Switch
    484
  - CHECKING the EPS MOTOR (for EPS Models)
    484
  - CHECKING the EPS TORQUE SENSOR (for EPS Models)
    485
Troubleshooting

487
- General Information
  487
- Troubleshooting
  
  488
  - General Information
    488
  - Starting Failures
    488
  - Incorrect Engine Idling Speed
    488
  - Poor Medium-And-High-Speed Performance
    489
  - Faulty Drive Train
    490
  - Faulty Gear Shifting
    491
  - Shift Lever Does Not Move
    491
  - Jumps out of Gear
    491
  - Faulty Clutch Performance
    491
  - Overheating
    491
  - Overcooling
    492
  - Poor Braking Performance
    492
  - Faulty Shock Absorber Assembly
    492
  - Unstable Handling
    492
  - Faulty Lighting or Signaling System
    492
- Self-Diagnostic Function and Diagnostic Code Table
  
  494
  - Self-Diagnostic Function Table
    494
  - Communication Error with the Meter
    494
  - Diagnostic Code: Sensor Operation Table
    495
  - Diagnostic Code: Actuator Operation Table
    496
  - Wiring Diagram
    498

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