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Wolverine YXE700E
Yamaha Wolverine YXE700E User Manual
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201
6-1
7
SERVICE MANUAL
YX70EPNG
YXE70WPXG
YXE70WPHG
YXE70WDXG
YXE700E
YXE700SE
2MB-
G
819
8
-E0
2
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
General Tightening Torque Specifications
44
Engine Tightening Torques
45
Chassis Tightening Torques
50
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
Removing the Steering Knuckles
196
Checking the Steering Knuckles and Front Wheel Bearings
196
Checking the Steering Knuckle Ball Joints
196
Front Arms and Front Shock Absorber Assemblies
198
Checking the Front Arms
200
Handling the Front Shock Absorber Assemblies
200
Disposing of a Front Shock Absorber Assembly
200
Checking the Front Shock Absorber Assemblies
200
Checking the Front Arm Ball Joints
201
Installing the Front Arms and Front Shock Absorber Assemblies
202
Rear Knuckles and Stabilizer
203
Checking the Rear Knuckles and Rear Wheel Bearings
205
Checking the Stabilizer
205
Installing the Stabilizer
205
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
Removing the Oil Pump Drive Sprocket and Oil Pump Driven Sprocket
256
Checking the Oil Pump Sprockets
256
Installing the Oil Pump Drive Sprocket and Oil Pump Driven Sprocket
256
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
Troubleshooting
342
Checking Noises
343
Troubleshooting Chart
344
Front Constant Velocity Shaft Assemblies, Differential Assembly and Front Drive Shafts
345
Disassembling the Universal Joints
351
Disassembling the Front Constant Velocity Shaft Assemblies
351
Checking the Front Constant Velocity Shaft Assemblies
352
Assembling the Front Constant Velocity Shaft Assemblies
352
Removing the Front Drive Shaft Yoke
353
Removing the Differential Gear Assembly
354
Checking the Front Drive Shaft
354
Checking the Differential Assembly
354
Checking the Differential Motor Operation
354
Assembling the Front Drive Shaft
355
Assembling the Differential Assembly
355
Assembling the Universal Joint
356
Measuring the Differential Gear Backlash
357
Adjusting the Differential Gear Backlash
358
Rear Constant Velocity Shaft Assemblies, Final Drive Assembly and Rear Drive Shaft
359
Disassembling the Rear Constant Velocity Shaft Assemblies
366
Checking the Rear Constant Velocity Shaft Assemblies
366
Assembling the Rear Constant Velocity Shaft Assemblies
366
Disassembling the Final Drive Assembly
368
Checking the Rear Drive Shaft
369
Checking the Final Drive Assembly
369
Adjusting the Ring Gear Stopper
369
Measuring the Final Gear Backlash
370
Adjusting the Final Gear Backlash
370
Assembling the Final Drive Assembly
371
Installing the Final Drive Assembly
372
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
Circuit Diagram
448
Eps Control Unit's Self-Diagnostic Function
450
Eps Warning Light During Normal Operation
450
Diagnostic Mode
451
Self-Diagnostic Function Table (Eps System)
453
Troubleshooting Details (Eps System)
454
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
Default Chapter
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
5
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Yamaha Wolverine YXE700E Specifications
General
Brand
Yamaha
Model
Wolverine YXE700E
Category
Utility Vehicle
Language
English
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