Yx70 Viking Assembly Manual

7/27/2019 Yx70 Viking Assembly Manual

1/32

2014

ASSEMBLY MANUAL

1XD F8107 E0

YX70MEYX70MHEYX70MNEYX70MPE

YX70MPHE

YX70MPNEYXM700DEYXM700PE

YXM700PHE


2/32

EBA00002

FOREWORDThis Assembly Manual contains the information required for the correct assembly of this Yamaha vehicleprior to delivery to the customer. Since some external parts of the vehicle have been removed at theYamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It should benoted that the assembled vehicle should be thoroughly cleaned, checked, and adjusted prior to deliveryto the customer.

EBA00003

IMPORTANTThe service specifications given in this assembly manual are based on the model as manufactured. Mod-ifications and significant changes in specifications and/or procedures will be forwarded to authorizedYamaha dealers.The procedures below are described in the order that the procedures are carried out correctly and com-pletely. Failure to do so can result in poor performance and possible harm to the vehicle and/or rider.

CONCERNING CRATE DAMAGE:

Follow the instructions in the Dealer Warranty Handbook, Procedure Section.

Particularly important information is distinguished in this manual by the following notations.This is the safety alert symbol. It is used to alert you to potential personalinjury hazards. Obey all safety messages that follow this symbol to avoidpossible injury or death.

A WARNING indicates a hazardous situation which, if not avoided, couldresult in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid dam-age to the vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

WARNING

NOTICE

TIP

EBA00001

YX70ME/YX70MHE/YX70MNE/YX70MPE/

YX70MPHE/YX70MPNE/YXM700DE/YXM700PE/

YXM700PHEASSEMBLY MANUAL

2013 by Yamaha Motor Co., Ltd.First edition, June 2013

All rights reserved.Any reproduction or unauthorized use

without the written permission ofYamaha Motor Co., Ltd.is expressly prohibited.


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EBA01001

SYMBOLS USED IN THE ASSEMBLY MANUALIn order to simplify descriptions in this assembly manual, the following symbols are used:

SYMBOL DEFINITION SYMBOL DEFINITION

Filling fluid Coat with lithium-soap-based grease.

LubricantTighten to 10 Nm.(10 Nm = 1.0 mkgf, 7.2 ftlbf)

Special tool Towards the front of the vehicle

Tightening torque Clearance required

Wear limit, clearanceInstall so that the arrow mark facesupward.

Engine speed Apply motor oil.

Electrical data Made of rubber or plastics

A: Ref. No. (indicating the order of operations.)B: Part nameC: Quantity of parts per vehicleD: Place where parts are held

(1): Refer to PARTS LOCATION.V: Stored in plastic bagC: Stored in carton boxS: Fixed inside the steel frame and/or con-

tained in the plastic tray (cargo bed): Temporarily installed or secured

Example:(1)-V(1) signifies the location of the parts and V sig-nifies that the part is stored in a plastic bag.

E: Size or material of partsd/D: Diameter of part: Length of part

e.g., 5 (0.20) = 5 mm (0.20 in)

10

FWD

TR..

UP

d D d

d D d

*


4/32

EBA00006

PREPARATIONTo assemble the vehicle correctly, supplies (e.g. oils, greases, and shop rags) and sufficient workingspace are required.WorkshopThe workshop where the vehicle is assembled should be clean, spacious, and have a level floor.Self-protectionProtect your eyes with suitable safety glasses or goggles when using compressed air, when grinding orwhen doing any operation which may cause particles to fly off.Protect hands and feet by wearing safety gloves and shoes.


5/32

EBA00009

PARTS LOCATION

NOTICE

Do not use a cutter, scissors, or other sharp object to open the carton box; otherwise, theincluded parts could be damaged.

Wear suitable protective gear such as gloves when handling and opening the carton box.

1. Plastic tray

2. Skid plates

3. Owners manual (located in the glove com-

partment)

4. Plastic bag 1 (located in the glove compart-

ment)

5. Plastic bag 2 (located in the glove compart-

ment)

A. For CDN

B. For Europe and Oceania

3

4

5

2

A

B

3

2

1


6/32

(1) Plastic tray (for CDN) 1. Rear top frame2. Front top frame

3. Left side frame

4. Right side frame

5. Rear right frame

6. Rear center frame

7. Rear left frame8. Headrest

9. Plastic bags 1-4

Plastic bag 1 (for CDN)(4) Plastic bag 1 (for Europe and Oceania)

1. Flange bolts (front and rear skid plates)

[d = 6 (0.24), = 12 (0.47)]

Plastic bag 2 (for sun top models) (for CDN)(5) Plastic bag 2 (for sun top models) (forEurope and Oceania)

1 2 3 4

1

2

3

4

5

8

9

6 7

1

1

2

3

4

5

6

7

8

9


7/32

1. Sun top front brackets

2. Dampers (sun top front and lower brackets)

3. Sun top rear brackets

4. Dampers (sun top rear brackets)

5. Sun top lower brackets

6. Tapping screws (sun top front and rear brack-

ets)[d = 6 (0.24), = 16 (0.63)]

7. Flange bolts (sun top lower brackets)

[d = 6 (0.24), = 12 (0.47)]

8. Hexagon socket bolts (sun top lower brackets)

[d = 6 (0.24), = 16 (0.63)]

9. Flange nuts (sun top lower brackets)

[d = 6 (0.24)]

Plastic bag 3 (for CDN)

1. Flange bolts (headrests)[d = 6 (0.24), = 16 (0.63)]

2. Flange bolts (seat belts)

[d =12 (0.47), = 20 (0.79)]

3. Hexagon socket bolts (seat belts)

[d =11 (0.43), = 32 (1.26)]

4. Washers (seat belts)

[d = 11 (0.43), D = 25 (0.98)]

Plastic bag 4 (for CDN)

1. Flange bolts (left and right side frames)

[d = 10 (0.39), = 45 (1.77)]

2. Self-locking nuts (left and right side frames)

[d = 10 (0.39)]

3. Hexagon socket bolts (left and right side

frames)

[d = 10 (0.39), = 70 (2.76)]

4. Washers (left and right side frames)

[d = 10 (0.39), D = 32 (1.26)]

5. Flange bolts (rear center frame)

[d = 10 (0.39), = 16 (0.63)]

1

2

3

4

1

2

3

4

5

6


8/32

6. Hexagon socket bolts (front top, rear

top, rear left, and rear right frames)

[d = 10 (0.39), = 20 (0.79)]

(2) Skid plates

1. Front skid plate

2. Rear skid plate

(3) Owners manual

1. Owners manual

Sun top (for sun top models)

1. Sun top

IP

This part is packaged separately from the vehi-cle.

1

2

1

1


9/32


10/32

1. ENCLOSURE (for CDN)

A: Install the rear center frame.B: Temporarily tighten the bolts.

C: Install the left and right side frames.D: Temporarily tighten the nuts.

E: Install the rear left and right frames.F: Temporarily tighten the bolts.

G: Install the front and rear top frames.H: Temporarily tighten the bolts.

I: Tighten the bolts and nuts to specification.

IP

Tighten the bolts according to the alphabeticalorder shown in the illustration.

2. HEADREST (for CDN)

A: Tighten the bolts to specification.

1 Rear center frame 1 (1)-S

2 Flange bolt 4 (1)-S d = 10 (0.39), = 16 (0.63)

3 Left side frame 1 (1)-S

4 Right side frame 1 (1)-S

5 Flange bolt 4 (1)-S d = 10 (0.39), = 45 (1.77)

6 Hexagon socket bolt 2 (1)-S d = 10 (0.39), = 70 (2.76)

7 Washer 4 (1)-S d = 10 (0.39), D= 32 (1.26)

8 Self-locking nut 6 (1)-S d = 10 (0.39)

9 Rear left frame 1 (1)-S

10 Rear right frame 1 (1)-S


A

12

B

2

B

4

6

7 7

8

8

88

5

5

6

7 7

D

D

C

3

C

D

E

F

11

F

F

10E

911

11

12 Front top frame 1 (1)-S

13 Rear top frame 1 (1)-S


TR..

Bolt and nut48 Nm (4.8 mkgf, 35 ftlbf)

Nut65 Nm (6.5 mkgf, 47 ftlbf)

1 Headrest 3 (1)-S

2 Flange bolt 9 (1)-S d = 6 (0.24), = 16 (0.63)

TR. .

Bolt

7 Nm (0.7 mkgf, 5.1 ftlbf)

G

13

G12

H

14H

14

H

14

H

14

65

65

48

48

48

48

48

48b

b

b b

c

eea

a

a

d

I

1

2 A 72 A 7

2 A 7


11/32

3. SEAT BELT (for CDN)

A: Install the seat belt anchor plates so thatthey contact the stopper.

B: Tighten the bolts to specification.

4. SUN TOP (for sun top models)

(1)-V: For CDN

(5)-V: For Europe and Oceania

A: Tighten the bolts, nuts, and screws to speci-fication.

5. SKID PLATES

(1)-V: For CDN

(4)-V: For Europe and Oceania

A: Tighten the bolts to specification.

6. BATTERY

A: Before installing the battery, charge the bat-tery.

IP

Refer to ADJUSTMENTS AND PREDELIV-ERY SERVICE.

B: First, connect the positive lead (red colorlead) to the positive terminal.

C: Connect the negative leads (black colorlead) to the negative terminal.

1 Seat belt 3 *2 Flange bolt 3 (1)-V d = 12 (0.47), = 20 (0.79)

3 Washer 3 (1)-V d = 11 (0.43), D= 25 (0.98)

4 Hexagon socket bolt 3 (1)-V d = 11 (0.43), = 32 (1.26)

TR..

Bolt59 Nm (5.9 mkgf, 43 ftlbf)

1 Sun top 1

2 Damper 4(1)-V(5)-V

3 Sun top rear bracket 4(1)-V(5)-V

4 Damper 8(1)-V(5)-V

5 Sun top front bracket 4(1)-V(5)-V

6 Screw 16(1)-V

(5)-V

d = 6 (0.24), = 16 (0.63)

7 Sun top lower bracket 2(1)-V(5)-V

8 Flange bolt 4(1)-V(5)-V

d = 6 (0.24), = 12 (0.47)

9 Hexagon socket bolt 4(1)-V(5)-V

d = 6 (0.24), = 16 (0.63)

10 Flange nut 4(1)-V(5)-V

d = 6 (0.24)

2

1

1

4

B 59

B 59B 59

B 59

B 59

2

1

4

2

4

3

3

3

A

A 3A 3

A 74

5

66

210

9

7 4 4 7 8

1

663

TR..

Bolt and nut7 Nm (0.7 mkgf, 5.1 ftlbf)

Screw3.0 Nm (0.30 mkgf, 2.2 ftlbf)

1 Front skid plate 1 (2)-S

2 Rear skid plate 1 (2)-S

3 Flange bolt 8 (1)-V(4)-V

d = 6 (0.24), = 12 (0.47)

TR..

Bolt7 Nm (0.7 mkgf, 5.1 ftlbf)

1 Battery 1 *2 Battery band 2 *3 Bolt 2 * d = 8 (0.31), = 20 (0.79)4 Nut 2

*d = 8 (0.31)

5 Intake duct cover 1 *6 Quick fastener 2 *7 Hood 1 *

A 7A 7

1

33

2

3

3

D 1.5

37

C

B

4

4

A

2

1

6

5


12/32

D: Tighten the nuts to specification.

TR..

Nut1.5 Nm (0.15 mkgf, 1.1 ftlbf)


13/32

CABLE ROUTING

WARNING

Proper cable and lead routing is essential to assure safe vehicle operation.

1. Negative battery lead

2. Positive battery lead

3. Wire harness

4. Battery

12

3

4


14/32


15/32

EBA00102

A. CHECKING AND CHARGING THEBATTERY

IP

The battery used in this vehicle is a VRLA(Valve Regulated Lead Acid) battery, it hasbeen pre-filled with electrolyte at the factory so

there is no need to add fluid at any time.

1. Check:Using a digital voltmeter, the state of a dis-charged VRLA (Valve Regulated LeadAcid) battery can be checked by measuringopen-circuit voltage (the voltage measuredwith the positive and negative terminalsbeing disconnected).

WARNING

Do not attempt boost charging underany circumstances.

Battery electrolyte is poisonous anddangerous, causing severe burns, etc. Itcontains sulfuric acid. Avoid contactwith skin, eyes or clothing.Antidote:

External: Flush with water.Internal: Drink large quantities of wateror milk. Follow with milk of magnesia,beaten egg, or vegetable oil. Call physi-cian immediately.Eyes: Flush with water for 15 minutesand get prompt medical attention. Bat-teries produce explosive gases. Keepsparks, flame, cigarettes, etc., away.Ventilate when charging or using inenclosed space. Always shield eyeswhen working near batteries.KEEP OUT OF THE REACH OF CHIL-DREN.

NOTICE

If the voltage is lower than 12.8 V, thebattery must be charged. If this is notdone, the life of the battery will be short-ened drastically. Since the procedure forcharging the battery is not explained inthe assembly manual, refer to the ser-vice manual for more details.

Never remove the strip of caps, nor addany water or electrolyte.

EBA00105

B. CHECKING THE TIRE PRESSURE

WARNING

Pay attention to the following points:Recommended tire pressure:Vehicle load: 0 - 300 kg (0 - 661 lb):Front: 75 kPa (0.75 kgf/cm2, 11 psi)Rear: 90 kPa (0.90 kgf/cm2, 13 psi)Vehicle load: 300 kg - maximum (661 lb -maximum)Front: 75 kPa (0.75 kgf/cm2, 11 psi)Rear: 125 kPa (1.25 kgf/cm2, 18 psi)Maximum vehicle load: 445 kg (981 lb)Tire size: Front 25 8-12NHS

Rear 25 10-12NHS

1. Excessive tire pressure [over 250 kPa(2.5 kgf/cm2, 36 psi)] may cause tires toburst. Inflate tires very slowly. Fast infla-tion could cause tire to burst.

2. Too low a pressure [Front: 70 kPa (0.70kgf/cm2, 10 psi), Rear: 85 kPa (0.85 kgf/cm2, 12 psi)] will cause the tire to dis-lodge from the rim.

3. Put the same pressure in both rear tires.Uneven tire pressure will severally affectthe handling.

4. Set tire pressure cold.

1. Check: Tire pressure

a. Use an appropriate tire pressure air gauge.Set tire pressures to the following specifica-tions:

Open-cir-cuit voltage

Charging time

12.8 V orhigher

Charging is not necessary

Reference tire pressure:Vehicle load: 0 - 300 kg (0 - 661 lb):Front: 75 kPa (0.75 kgf/cm2, 11 psi)

Rear: 90 kPa (0.90 kgf/cm2

, 13 psi)Vehicle load: 300 kg - maximum(661 lb - maximum)Front: 75 kPa (0.75 kgf/cm2, 11 psi)

Rear: 125 kPa (1.25 kgf/cm2, 18 psi)

Minimum tire pressure:Vehicle load: 0 - 300 kg (0 - 661 lb)Front: 70 kPa (0.70 kgf/cm2, 10 psi)


Vehicle load: 300 kg - maximum(661 lb - maximum)Front: 70 kPa (0.70 kgf/cm2, 10 psi)



16/32

NOTICE

Never use a tire pressure below minimumspecification. The tire could separate fromthe wheel under severe operating condi-tions.

EBA00109

C. CHECKING THE ENGINE OIL LEVEL1. Place the vehicle on a level surface.2. Check the engine oil level on a cold engine.

IP

If the engine was started before checking theoil level, be sure to warm up the engine suffi-ciently, and then wait at least 10 minutes untilthe oil settles for an accurate reading.

3. Lift the cargo bed.4. Check: Engine oil level

The engine oil level should be between theminimum level mark a and maximum levelmark b.Below the minimum level mark Add therecommended engine oil to the proper level.

IP

Be sure to insert the dipstick completely intothe oil filler hole after wiping it clean.

NOTICE_

Engine oil also lubricates the clutch andthe wrong oil types or additives couldcause clutch slippage. Therefore, do notadd any chemical additives or useengine oils with a grade of CD or higherand do not use oils labeled ENERGY

CONSERVING II. Do not allow foreign material to enter the

crankcase.

5. Check the engine oil level again.

NOTICE_

Be sure the engine oil is at the correctlevel, otherwise engine damage may result.

6. Lower the cargo bed.

EBA00114

D. CHECKING THE DIFFERENTIAL GEAROIL LEVEL

1. Place the vehicle on a level surface.2. Remove: Differential gear oil filler bolt 1

3. Check: Differential gear oil level

The differential gear oil level should be upto the brim 2 Add the recommended dif-ferential gear oil to the proper level.

Recommended brand

YAMALUBETypeSAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W-50

Recommended engine oil gradeAPI service SG type or higher,JASO standard MA

Oil quantity (periodic oil change)Engine2.20 L (2.33 US qt, 1.94 lmp.qt)

b

a

Recommended oilSAE 80 API GL-4 Hypoid gear oil

Oil quantity (periodic oil change)

0.18 L (0.19 US qt, 0.16 Imp.qt)

0 10 30 50 70 90 110 130 F

20 10 0 10 20 30 40 50 C

SAE 5W-30

SAE 10W-30

SAE 10W-40

SAE 15W-40

SAE 20W-40

SAE 20W-50

1

2


17/32

NOTICE

Take care not to allow foreign material toenter the differential gear case.

4. Install: Differential gear oil filler bolt

EBA00115

E. CHECKING THE FINAL GEAR OIL LEVEL1. Place the vehicle on a level place.2. Remove: Final gear oil filler bolt 1

3. Check: Final gear oil level

The final gear oil level should be up to thebrim of the filler hole.Below the brim 2 Add the recom-

mended final gear oil to the proper level.

NOTICE_

Take care not to allow foreign material toenter the final gear case.

4. Install: Final gear oil filler bolt

EBA00119

F. CHECKING THE COOLANT LEVEL1. Place the vehicle on a level surface.2. Check: Coolant level

The coolant level should be between theminimum level mark a and maximum levelmark b.

Below the minimum level mark

Add therecommended coolant to the proper level.

NOTICE_

Adding water instead of coolant lowersthe antifreeze content of the coolant. Ifwater is used instead of coolant, checkand if necessary, correct the antifreezeconcentration of the coolant.

Use only distilled water. However, soft

water may be used if distilled water isnot available.

3. Start the engine, warm it up for several min-utes, and then turn it (off).

4. Check: Coolant levelIP

Before checking the coolant level, wait a fewminutes until the coolant has settled.

EBA00122

G. ADJUSTING THE ACCELERATORPEDAL FREE PLAY1. Check: Accelerator pedal free play a

Out of specification Adjust.

2. Adjust: Accelerator pedal free play

a. Lift the cargo bed.b. Remove the frame cross member.

c. Remove the throttle valve cover 1.

TR..

Differential gear oil filler bolt23 Nm (2.3 mkgf, 17 ftlbf)

Recommended oilSAE 80 API GL-4 Hypoid gear oil

Oil quantity (periodic oil change)0.40 L (0.42 US qt, 0.35 Imp.qt)

TR..

Final gear oil filler bolt22 Nm (2.2 mkgf, 16 ftlbf)

2

1

Accelerator pedal free play12.032.0 mm (0.471.26 in)

b

a

a


18/32

d. Slide back the rubber cover 2.e. Loosen the locknut 3.f. Turn the adjusting bolt 4 in direction b or

c until the correct free play is obtained.

g. Tighten the locknut.h. Slide the rubber cover to its original posi-

tion.IP

If the length of d is 8.5mm (0.33 in) or more,loosen locknut 5 and turn the adjusting nut6 in direction e or f until the correct freeplay is obtained.

i. Check the throttle valve pulley stopper gap.

IP

When the accelerator pedal is fully depressed(throttle valve fully open), the gap g betweenthe throttle valve pulley 7 and the pulley stop-per 8 should be 1 mm (0.04 in) or less. Thethrottle valve pulley should not contact the pul-

ley stopper.

j. Install the throttle valve cover.k. Install the frame cross member.

l. Lower the cargo bed.

H. ADJUSTING THE BRAKE PEDAL1. Check: Brake pedal free play a

Out of specification

Adjust.IPThe end of the brake rod should lightly contactthe brake master cylinder.

2. Adjust: Brake pedal free play

a. Loosen the locknut 1.b. Turn the brake rod 2 in direction b or c

until the correct free play is obtained.

Direction b Free play is increased.

Direction c Free play is decreased.

Direction e Free play is increased.

Direction f Free play is decreased.

1

3b

c2

4

e

f

d

56

TR..

Frame cross member bolt17 Nm (1.7 mkgf, 12 ftlbf)

Brake pedal free play0 mm (0 in)

g

87

a


19/32

c. Tighten the locknut to specification.

WARNING

After this adjustment is performed, lift thefront and rear wheels off the ground by

placing a block under the engine, and spinthe front and rear wheels to ensure there isno brake drag. If any brake drag is noticedperform the above steps again.

I. ADJUSTING THE BRAKE LIGHT SWITCHIP

The rear brake light switch is operated bymovement of the brake pedal.

The rear brake light switch is properlyadjusted when the brake light comes on justbefore the braking effect starts.

1. Check: Rear brake light operation timing

Incorrect Adjust.2. Adjust: Rear brake light operation timing

a. Turn the adjusting nut 1 in direction a orb until the rear brake light comes on at theproper time.

J. ADJUSTING THE PARKING BRAKELEVER

1. Shift the drive select lever into low gear L.2. Check: Parking brake lever free play a

3. Adjust: Parking brake lever free play

a. Slide back the rubber cover 1.b. Loosen the locknut 2.c. Turn the adjusting nut 3 in direction b or

c until the correct free play is obtained.

d. Tighten the locknut to specification.



TR..

Brake pedal rod locknut17 Nm (1.7 mkgf, 12 ftlbf)

Direction aBrake light comes onsooner.

Direction bBrake light comes onlater.

1

2

b

c



TR..

Parking brake lever cable locknut16 Nm (1.6 mkgf, 12 ftlbf)

a

b

1

a

1

b

c

3

2


20/32


21/32

h. Tighten the bleed screw when the pedallimit has been reached, then release thepedal.

i. Repeat steps (e) to (h) until all the air bub-bles have disappeared from the fluid.

j. Tighten the bleed screw to specification.

IP

If bleeding is difficult, it may be necessary tolet the brake fluid settle for a few hours.Repeat the bleeding procedure when the tinybubbles in the system have disappeared.

k. Add brake fluid to the proper level.

WARNINGAfter bleeding the hydraulic brake system,check the brake operation.

3. Install: Front wheel Rear wheel

Tighten the nuts 3 to specification.

WARNING

Install the nut with its tapered side towardsthe wheel.

EBA00133

M. ADJUSTING THE DRIVE SELECT LEVERSHIFT CABLE

WARNING

Before moving the drive select lever, bringthe vehicle to a complete stop and take

your foot off the accelerator pedal. Other-wise the transmission may be damaged.

1. Check: Drive select lever free play a

Out of specification Adjust the driveselector shift cable.

2. Adjust: Drive select lever shift cable length b

a. Loosen the locknut 1.b. Turn the adjusting nut 2 in direction c or

d until the specified cable length isobtained.

TR..

Front brake caliper bleed screw5 Nm (0.5 mkgf, 3.6 ftlbf)

Rear brake caliper bleed screw5 Nm (0.5 mkgf, 3.6 ftlbf)

TR..

Front wheel nut75 Nm (7.5 mkgf, 54 ftlbf)

Rear wheel nut75 Nm (7.5 mkgf, 54 ftlbf)

3

Drive select lever free play4 mm (1.6 in)

Direction cShift cable length isincreased.

Direction dShift cable length isdecreased.

Drive select lever shift cable length165 mm (6.50 in)

a

a

c

d

2

1

b


22/32

IP

When checking the drive select lever shiftcable length, shift the drive select lever into N(neutral).

c. Tighten the locknut to specification.

d. Turn the main switch to (on), and thencheck that the drive select lever can beshifted to each shift position and that theappropriate indicator light comes on whenthe lever is in each position.

EBA00138

N. ADJUSTING THE HEADLIGHT BEAMS1. Adjust:

Headlight beam (vertically)Turn the adjusting screw 1 in direction aor b.

O. LUBRICATING THE AIR FILTERELEMENT

1. Remove:

Center passenger seat cushion 1

2. Remove: Air filter case cover 2

3. Remove: Air filter element 3

NOTICE

The engine should never be run without theair filter; excessive piston and/or cylinderwear may result.

4. Apply: Yamaha foam air filter oil

a. Squeeze the initial oil out of the element.

NOTICE

Do not twist or wring out the element. Thiscould damage the foam material.

b. Apply Yamaha foam air filter oil or otherquality foam air filter oil.

c. Squeeze out the excess oil.IP

The element should be wet but not dripping.

5. Install: Air filter element6. Install: Air filter case coverIP

Fit the holders a on the air filter case coveronto the projections b on the air filter case,and then install the air filter case cover byhooking the holders onto the cover.

TR..

Drive select lever shift cable locknut39 Nm (3.9 mkgf, 28 ftlbf)

Direction aHeadlight beam israised.

Direction bHeadlight beam is low-ered.

1

a b

1

2

3


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24/32

EBA00200

APPENDICESSERVICE DATA

EBA00210

STANDARD EQUIPMENT

EBA00220

OWNERS TOOL KIT

Engine idling speed 15501650 r/min

Spark plug

Type/Manufacturer CPR7EA-9/NGK

Gap 0.80.9 mm (0.0310.035 in)Fuel

Recommended fuel Regular unleaded gasoline only

Fuel tank capacity 36.7 L (9.70 US gal, 8.07 Imp.gal)

Valve clearance (cold)

IN 0.090.13 mm (0.00350.0051 in)

EX 0.160.20 mm (0.00630.0079 in)

1. Owners manual 1 pc.

2. Owners tool kit 1 pc.3. Tire pressure gauge

[measurement range: 55110kPa (0.551.10 kgf/cm2, 816 psi)]

1 pc.

4. Tire pressure gauge[measurement range: 70400kPa (0.704.00 kgf/cm2,1057 psi)]

1 pc.

5. Safety handbook (for CDN) 1 pc.

1. Owners tool bag 1 pc.2. Spark plug wrench 1 pc.

3. Screwdriver grip 1 pc.

4. Screwdriver bit(Phillips head and slotted head)

1 pc.

5. Pliers 1 pc.

6. Wrench (10-12) 1 pc.

7. Wrench (14-17) 1 pc.


25/32


26/32

Air filter case bolt M6 7 0.7 5.1

Coolant reservoir bolt M6 7 0.7 5.1

Door hinge nut M6 1.3 0.13 0.94

Door hinge bolt M6 7 0.7 5.1

Door handle latch nut M6 7 0.7 5.1

Front skid plate bolt M6 7 0.7 5.1

Rear skid plate bolt M6 7 0.7 5.1

Lower panel and floor board bolt M6 4.0 0.40 2.9

Lower panel and frame bolt M6 7 0.7 5.1

Frame cross member bolt M8 17 1.7 12

Exhaust pipe heat protector M6 17 1.7 12

Exhaust pipe heat protector M6 7 0.7 5.1

Front wheel axle nut M24 350 35 253

Front wheel nut M12 75 7.5 54

Rear wheel axle nut M24 350 35 253

Rear wheel nut M12 75 7.5 54

Front brake disc guard bolt M6 9 0.9 6.5

Front brake caliper bolt M10 48 4.8 35

Front brake disc bolt M8 30 3.0 22

Front brake caliper retaining pin M8 22 2.2 16

Front brake pad bolt M10 17 1.7 12

Front brake caliper guide pin M8 17 1.7 12

Front brake caliper bleed screw M8 5 0.5 3.6

Rear brake disc guard bolt M6 9 0.9 6.5

Rear brake disc cleaning plate bolt M6 9 0.9 6.5

Rear brake disc bolt M8 30 3.0 22

Rear brake caliper bolt M10 48 4.8 35

Rear brake caliper retaining pin M8 22 2.2 16

Rear brake pad bolt M10 17 1.7 12

Rear brake caliper guide pin M8 17 1.7 12

Rear brake caliper bleed screw M8 5 0.5 3.6

Brake pipe flare nut M10 19 1.9 14

Front brake hose joint bolt M6 10 1.0 7.2

Rear brake hose joint bolt M6 10 1.0 7.2

Front brake hose holder bolt M6 7 0.7 5.1

Rear brake hose holder bolt M6 7 0.7 5.1

Front brake hose union bolt M10 27 2.7 20

Rear brake hose union bolt M10 27 2.7 20

Brake master cylinder reservoir cap 3.5 0.35 2.5

Brake master cylinder reservoir clamp screw M6 6 0.6 4.3

Parking brake cable holder M6 12 1.2 8.7

Parking brake caliper guide pin M8 17 1.7 12

Parking brake caliper guide pin nut M8 22 2.2 16Parking brake pad bolt M8 17 1.7 12

Part to be tightenedThread

size

Tightening torque

Nm mkgf ftlbf


27/32

Parking brake caliper arm nut M8 17 1.7 12

Brake master cylinder bolt M8 16 1.6 12

Pedal assembly bolt M8 16 1.6 12

Brake pedal rod locknut M8 17 1.7 12

Throttle cable locknut (accelerator pedal end) M6 2.5 0.25 1.8

Parking brake lever bolt M6 13 1.3 9.4

Parking brake caliper bolt M10 40 4.0 29

Parking brake disc nut M6 10 1.0 7.2

Parking brake cable locknut M6 16 1.6 12

Front upper arm nut M10 45 4.5 33

Front lower arm nut M10 45 4.5 33

Front shock absorber assembly nut M10 45 4.5 33

Front upper arm and steering knuckle nut M12 30 3.0 22

Front lower arm and steering knuckle nut M12 30 3.0 22

Front arm protector bolt M6 7 0.7 5.1

Steering wheel nut M12 35 3.5 25

Steering column bolt (except for EPS models) M8 21 2.1 15

Steering joint bolt M8 27 2.7 20

Steering assembly bolt M10 See TIP.

Tie-rod end locknut M12 40 4.0 29

Steering knuckle and tie-rod end nut M12 39 3.9 28

EPS unit bolt (for EPS models) M8 21 2.1 15

EPS unit bracket bolt (for EPS models) M6 10 1.0 7.2

Rear upper arm nut M10 45 4.5 33

Rear lower arm nut M10 45 4.5 33

Rear shock absorber assembly nut M12 82 8.2 59

Stabilizer joint nut M10 60 0.6 43

Stabilizer holder bolt M10 85 8.5 61

Rear upper arm and rear knuckle nut M12 85 8.5 61

Rear lower arm and rear knuckle nut M12 85 8.5 61

Rear arm protector bolt M6 7 0.7 5.1

Rear knuckle grease nipple M6 3.8 0.38 2.8

Differential gear oil filler bolt M14 23 2.3 17

Differential gear oil drain bolt M10 10 1.0 7.2

Differential motor bolt M6 11 1.1 8.0

Front drive shaft yoke nut M14 62 6.2 45

Differential case bolt M8 24 2.4 17

Front drive shaft universal yoke joint nut M16 150 15 108

Differential assembly nut M12 105 10.5 76

Differential assembly bolt M10 60 6.0 43

Support bearing bracket bolt M8 18 1.8 13

Final gear oil filler bolt M10 23 2.3 17

Final gear oil drain bolt M10 23 2.3 17Final drive assembly bracket bolt M8 33 3.3 24


size

Tightening torque

Nm mkgf ftlbf


28/32

Final drive assembly nut M12 105 10.5 76

Rear drive shaft yoke nut M14 97 9.7 70

Final drive pinion gear bearing housing bolt M8 26 2.6 19

Ring gear stopper nut M8 16 1.6 12

Final drive case cover bolt M10 52 5.2 38

Driver seat frame bolt M8 23 2.3 17

Center passenger seat frame bolt M8 23 2.3 17

Outer passenger seat frame bolt M8 23 2.3 17

Seat back bolt M6 6 0.6 4.3

Headrest bolt M6 7 0.7 5.1

Seat belt bolt M12 59 5.9 43

Seat belt buckle bolt M12 59 5.9 43

Seat belt guide bolt M11 59 5.9 43

Handhold bracket bolt M8 16 1.6 12

Handhold stopper nut M6 3.0 0.30 2.2

Left floor board and frame bolt M6 4.0 0.40 2.9

Center floor board and frame bolt M6 4.0 0.40 2.9

Right floor board and frame bolt M6 4.0 0.40 2.9

Left floor board and center floor board bolt M6 4.0 0.40 2.9

Center floor board and right floor board bolt M6 4.0 0.40 2.9

Instrument panel bolt M6 4.0 0.40 2.9

Meter assembly nut M5 3.8 0.38 2.8

Meter assembly bracket bolt M6 7 0.7 5.1

Glove compartment latch plate screw M4 1.3 0.13 0.94

Gas spring assembly ball stud nut M8 16 1.6 12

Tailgate cable bolt M6 7 0.7 5.1

Tail/brake light nut M6 7 0.7 5.1

Cargo bed release lever bolt M6 7 0.7 5.1

Cargo bed release lever holder bolt M6 7 0.7 5.1

Cargo hook nut M6 7 0.7 5.1

Tailgate shaft bolt M6 7 0.7 5.1

Tailgate cable bracket bolt M6 9 0.9 6.5

Cargo bed heat protector M6 8 0.8 5.8

Left side frame nut (front side) M10 65 6.5 47

Left side frame nut (rear side) M10 48 4.8 35

Right side frame nut (front side) M10 65 6.5 47

Right side frame nut (rear side) M10 48 4.8 35

Front top frame bolt M10 48 4.8 35

Rear top frame bolt M10 48 4.8 35

Rear center frame bolt M10 48 4.8 35

Rear left frame bolt M10 48 4.8 35

Rear right frame bolt M10 48 4.8 35

Front guard bolt M10 48 4.8 35Front guard cover screw M6 2.5 0.25 1.8


size

Tightening torque

Nm mkgf ftlbf


29/32

IP

Enclosure bolt and nutTighten the enclosure bolts and nuts to specification in the proper tightening sequence.

Enclosure tightening sequence:

IP

Steering assembly boltTighten the steering assembly bolts to 48 Nm (4.8 mkgf, 35 ftlbf) in the proper tightening sequence.

Steering assembly tightening sequence:

IP

Fuel pump nut

Tighten the fuel pump nuts to 7 Nm (0.7 mkgf, 5.1 ftlbf) in the proper tightening sequence.

Sun top holder screw (for sun top models) M6 3.0 0.30 2.2

Sun top holder nut (for sun top models) M6 7 0.7 5.1

Sun top holder bolt (for sun top models) M6 7 0.7 5.1

Sun top lower bracket bolt (for sun top models) M6 7 0.7 5.1

Sun top lower bracket nut (for sun top models) M6 7 0.7 5.1

Intake air temperature sensor screw M5 1.5 0.15 1.1

Rectifier/regulator bolt M6 7 0.7 5.1

Ground lead bolt M6 7 0.7 5.1

Ignition coil bolt M6 7 0.7 5.1

Horn bolt (for Europe and Oceania) M6 7 0.7 5.1

Horn lead nut (for Europe and Oceania) 2.3 0.23 1.7


size

Tightening torque

Nm mkgf ftlbf

2

1

53

3

4

4

5

22

1

1 1

2

3

24

1

FWD


30/32

Fuel tank tightening sequence:

IP

Fuel tank boltTighten the fuel tank bolts and fuel tank retainer bolts to specification in the proper tighteningsequence.

Fuel tank tightening sequence:

IP

Final drive assembly bolt and nutTighten the final drive assembly bolts and nuts to specification in the proper tightening sequence.

Final drive assembly tightening sequence:

6

13

5

2 4

1 2

543

6

4

9 8

2 1

7

3

5

FWD


31/32

white : customer copy / yellow : dealer copy YMC-PDIEN-00-OV

SSV Pre-delivery Inspection Checklist

ASSEMBLY1. Inspect for shipping damage and missing parts.2. Assemble per YamahaAssembly Manualand specifications. 3. Clean and inspect product to exceed customers expectations. 4. Install skid plates, roof supports, seat belt stay and roof (if applicable).

PRE-DELIVERY INSPECTIONIf any item of this schedule is found to be defective, take the necessary action and re-test.

Brakes1. Inspect brake system for correct operation and performance. 2. Check and adjust parking brake operation. 3. Clean brake discs using an oil-free solvent (if applicable).

Clutch4. Check for correct clutch operation.

Fluid Levels5. Check and adjust brake reservoir fluid level (if applicable). 6. Drain carburetor float bowl. 7. Check and adjust engine oil level. 8. Check and top-up front and rear gear housing oil levels.

Drive System9. Check and adjust the shift linkage as necessary.

Cooling System (if applicable)

10. Check and adjust coolant strength and level. 11. Visually inspect coolant system. 12. Bleed coolant system if necessary.

Fuel System13. Remove, clean and oil air filter as perService Manualwith Yamaha-approved

air filter oil and re-install. 14. Check and adjust full choke operation. 15. Check fuel system for leaks and operation. 16. Install correct fuel as perOwners Manualrequirements.

Throttle System17. Check for correct throttle cable routing, adjustment and operation.

Wheels/Tires18. Check wheel nuts for correct torque. 19. Check and adjust tire pressures as per the Owners Manual. 20. Check and adjust wheel alignment as required.

Suspension

21. Lubricate all grease points. 22. Check suspension settings and operation.

Steering and Controls23. Check for smooth steering operation. 24. Check for steering wheel alignment. 25. Check and adjust controls for fit and comfort.

Electrical System26. Charge battery (if applicable) as per Yamaha specifications. 27. Check all lights including safety-warning systems. 28. Check and adjust starter system, including safety switches.

Other Items29. Check all fasteners, nuts and bolts. 30. Seat belts (if applicable) check smooth operation and proper latching. 31. Cargo bed check for proper latching.

Test Ride32. Instrumentation and warning lights/systems. 33. Brake operation. 34. Cold and hot start performance. 35. Gear change, clutch, forward and reverse operation. 36. Engine performance, throttle response and idle speed. 37. Steering and suspension ride quality and comfort.

Post-Test38. Recheck engine oil level. 39. Check for coolant, oil and fluid leaks. 40. Inspect all bodywork for paint damage and defects. 41. Clean all areas prior to final delivery.

Comments:

YEAR ____________ MODEL __________________________ VIN ___________________________________ ENGINE # ___________________

DATE_________________ Place a check mark only when completed. KEY # ______________________

DEALER STAMP

Assembly Date (YYYYMMDD): ____________

I ___________________________ confirm that I have assembled the abovelisted product to the full specifications listed and notified to me by YamahaMotor Canada Ltd. in regards to assembly and that it is damage free andready for the pre-delivery operation and customer set-up.

Pre-Delivery Inspection Date: ____________I ___________________________ confirm that I have carried out the PDI asper Yamaha Motor Canada Ltd. requirements and specifications listed in thisdocument. I have also visually inspected this product. I have adjusted therequired items to meet all specifications.

Test Ride Date: ____________

I ___________________________ have tested the product and confirm thatit meets all requirements for this product. It has been cleaned and preparedfor delivery to the new owner. The Owners Manual is available and thelicense plate (if applicable) is suitably installed.

Technicians signature___________________________________________

Salespersons signature _________________________________________

The Warranty has been fully explained. Yes

No

The dealer has explained the benefits ofYamalube engine oil. Yes No

Yamaha Protection Plus

Yamaha Protection Plus has been explainedand offered to me. Yes No

Yamaha Protection Plus has been purchased. Yes No The dealer has provided me warranty information

as per Bill 60, Quebec CPA LaLoi sur la protectiondu consommateur et le domaine de lautomobile. Yes No

I have inspected the product and found that it meets all of my expectationsand that there are no outstanding issues to be discussed with the dealer. TheOwners Manual, Warranty Guide and tool kit have been supplied andexplained to me.

Signed _______________________________________________________

Customer name ________________________________________________

Date of delivery ________________________________________________

Customer comments _________________________________________________________________________________________________________


32/32

Yx70 Viking Assembly Manual

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Transcript of Yx70 Viking Assembly Manual