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Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 1

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EBS20004

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid

out with the individual steps in sequential order.

• The manual is divided into chapters and each chapter is divided into sections. The current section title

“1” is shown at the top of each page.

• Sub-section titles “2” appear in smaller print than the section title.

• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each

removal and disassembly section.

• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-

sembly step.

• Symbols “5” indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation

and assembly procedure, reverse the steps.

• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-

tially.

1

3

2

4

7

5

6

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EBS20005

SYMBOLS

The following symbols are used in this manual for easier understanding.

TIP

The following symbols are not relevant to every vehicle.

SYMBOL

DEFINITION

SYMBOL

DEFINITION

Serviceable with engine mounted

Gear oil

G

Filling fluid

Molybdenum disulfide oil

M

Lubricant

Brake fluid

BF

Special tool

B

Wheel bearing grease

Tightening torque

LS

Lithium-soap-based grease

Wear limit, clearance

M

Molybdenum disulfide grease

Engine speed

S

Silicone grease

Electrical data

Apply locking agent (LOCTITE®).

LT

Engine oil

Replace the part with a new one.

New

E

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IDENTIFICATION

EBS20009

IDENTIFICATION

EBS30003

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped

into the frame.

EBS30004

MODEL LABEL

The model label “1” is affixed at the location in

the illustration. This information will be needed to

order spare parts.

1

1-1

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FEATURES

EBS20010

FEATURES

EBS30007

OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)

1

2

a

3

d

e

c

f

b

4

6

5

7

1-3

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FEATURES

EBS30008

Clock mode

INSTRUMENT FUNCTIONS

Pushing the “CLOCK” button switches the dis-

play between the clock mode “CLOCK” and the

Multi-function display

hour meter mode “HOUR” in the following order:

4

5

CLOCK → HOUR → CLOCK

To set the clock

1

1. Set the display to the clock mode.

2

2. Push the “SELECT” button and “RESET” but-

3

ton together for at least three seconds.

3. When the hour digits start flashing, push the

“RESET” button to set the hours.

7

6

4. Push the “SELECT” button, and the minute

digits will start flashing.

1.

“SELECT” button

5. Push the “RESET” button to set the minutes.

2.

“RESET” button

6. Push the “SELECT” button and then release

3.

“CLOCK” button

it to start the clock.

4. Speedometer

5. Fuel meter

Fuel meter

6. Clock/Hour meter

The fuel meter indicates the amount of fuel in the

7. Odometer/Tripmeter A/Tripmeter B

fuel tank. The display segments of the fuel meter

disappear from “F” (full) towards “E” (empty) as

The multi-function display is equipped with the

the fuel level decreases. When the “E” segment

following:

• a speedometer

disappears and the fuel level warning indicator

flashes, refuel as soon as possible.

• an odometer

• two tripmeters (which show the distance trav-

TIP

eled since they were last set to zero)

This fuel meter is equipped with a self-diagnosis

• a clock

system. If the electrical circuit is not working cor-

• an hour meter (which shows the total time the

rectly, all the display segments and fuel level

engine has been running)

warning indicator will start flashing. If this occurs,

• a fuel meter

check the electrical circuit.

• a self-diagnosis device

Refer to “SIGNALING SYSTEM” on page 9-19.

Odometer and tripmeter modes

1

Pushing the “SELECT” button switches the dis-

play between the odometer mode “ODO” and

the tripmeter modes “TRIP A” and “TRIP B” in

the following order:

2

ODO → TRIP A → TRIP B → ODO

To reset a tripmeter, select it by pushing the “SE-

3

LECT” button, and then push the “RESET” but-

ton for at least three seconds. The tripmeters

can be used to estimate the distance that can be

1. Fuel level warning indicator

traveled with a full tank of fuel. This information

2. Fuel meter

will enable you to plan future fuel stops.

3.

“E” segment

TIP

Pushing and holding in the “SELECT” button,

and turning the key to “

” (on) while the button

is pushed, switches the display between “mph”

and “km/h”.

1-5

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FEATURES

Self-diagnosis device

1

2

1. Fault code display

2. Engine trouble warning light

This model is equipped with a self-diagnosis de-

vice for various electrical circuits.

If a problem is detected in any of those circuits,

the engine trouble warning light will come on or

flash and the multi-function display will indicate

an fault code.

If the multi-function display indicates an fault

code, note the code number, and check the ve-

hicle.

ECB02030

NOTICE

If the display indicates a fault code, the vehi-

cle should be checked as soon as possible

in order to avoid engine damage.

1-6

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IMPORTANT INFORMATION

EBS20011

IMPORTANT INFORMATION

EBS30009

PREPARATION FOR REMOVAL AND

DISASSEMBLY

1. Before removal and disassembly, remove all

dirt, mud, dust and foreign material.

EBS30011

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all

gaskets, seals and O-rings. All gasket surfac-

es, oil seal lips and O-rings must be cleaned.

2. During reassembly, properly oil all mating

parts and bearings and lubricate the oil seal

lips with grease.

2.

Use only the proper tools and cleaning equip-

ment.

Refer to “SPECIAL TOOLS” on page 1-14.

3.

When disassembling, always keep mated

parts together. This includes gears, cylinders,

pistons and other parts that have been “mat-

ed” through normal wear. Mated parts must

always be reused or replaced as an assem-

bly.

1. Oil

2. Lip

3. Spring

4. Grease

EBS30012

LOCK WASHERS/PLATES AND COTTER

PINS

After removal, replace all lock washers/plates

4.

During disassembly, clean all of the parts and

“1” and cotter pins. After the bolt or nut has been

place them in trays in the order of disassem-

tightened to specification, bend the lock tabs

bly. This will speed up assembly and allow for

along a flat of the bolt or nut.

the correct installation of all parts.

5.

Keep all parts away from any source of fire.

EBS30010

REPLACEMENT PARTS

Use only genuine Yamaha parts for all replace-

ments. Use oil and grease recommended by

Yamaha for all lubrication jobs. Other brands

may be similar in function and appearance, but

inferior in quality.

1-7

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IMPORTANT INFORMATION

EBS30013

EBS30015

BEARINGS AND OIL SEALS

RUBBER PARTS

Install bearings “1” and oil seals “2” so that the

Check rubber parts for deterioration during in-

manufacturer’s marks or numbers are visible.

spection. Some of the rubber parts are sensitive

When installing oil seals, lubricate the oil seal

to gasoline, flammable oil, grease, etc. Do not al-

lips with a light coat of lithium-soap-based

low any items other than the specified one to

grease. Oil bearings liberally when installing, if

contact the parts.

appropriate.

ECB01260

NOTICE

Do not spin the bearing with compressed air

because this will damage the bearing surfac-

es.

EBS30014

CIRCLIPS

Before reassembly, check all circlips carefully

and replace damaged or distorted circlips. Al-

ways replace piston pin clips after one use.

When installing a circlip “1”, make sure the

sharp-edged corner “2” is positioned opposite

the thrust “3” that the circlip receives.

1-8

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BASIC SERVICE INFORMATION

EBS20012

BASIC SERVICE INFORMATION

EBS30016

QUICK FASTENERS

Rivet type

1. Remove:

• Quick fastener

TIP

To remove the quick fastener, push its pin with a

screwdriver, then pull the fastener out.

Screw type

1. Remove:

• Quick fastener

TIP

To remove the quick fastener, loosen the screw

with a screwdriver, then pull the fastener out.

2. Install:

• Quick fastener

TIP

To install the quick fastener, push its pin so that

it protrudes from the fastener head, then insert

the fastener into the part to be secured and push

2. Install:

the pin in with a screwdriver. Make sure that the

• Quick fastener

pin is flush with the fastener’s head.

TIP

To install the quick fastener, insert the fastener

into the part to be secured and tighten the screw.

1-9

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BASIC SERVICE INFORMATION

ECB01520

EBS30017

NOTICE

ELECTRICAL SYSTEM

Be sure to connect the battery leads to the

Electrical parts handling

correct battery terminals. Reversing the bat-

ECB01460

tery lead connections could damage the

NOTICE

electrical components.

Never disconnect a battery lead while the en-

gine is running; otherwise, the electrical

components could be damaged.

ECB01530

NOTICE

When connecting the battery leads to the

ECB01510

battery, be sure to connect the positive bat-

NOTICE

tery lead first, then the negative battery lead.

When disconnecting the battery leads from

If the negative battery lead is connected first

the battery, be sure to disconnect the nega-

and a tool or similar item contacts the vehi-

tive battery lead first, then the positive bat-

cle while the positive battery lead is being

tery lead. If the positive battery lead is

connected, a spark could be generated,

disconnected first and a tool or similar item

which is extremely dangerous.

contacts the vehicle, a spark could be gener-

ated, which is extremely dangerous.

ECB01470

NOTICE

Turn the main switch to “OFF” before dis-

TIP

connecting or connecting an electrical com-

If a battery lead is difficult to disconnect due to

ponent.

rust on the battery terminal, remove the rust us-

ing hot water.

1-10

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BASIC SERVICE INFORMATION

ECB01480

NOTICE

Checking the electrical system

TIP

Handle electrical components with special

care, and do not subject them to strong

Before checking the electrical system, make

shocks.

sure that the battery voltage is at least 12 V.

ECB01490

ECB01440

NOTICE

NOTICE

Electrical components are very sensitive to

Never insert the tester probes into the cou-

and can be damaged by static electricity.

pler terminal slots. Always insert the probes

Therefore, never touch the terminals and be

from the opposite end “a” of the coupler, tak-

sure to keep the contacts clean.

ing care not to loosen or damage the leads.

a

ECB01500

TIP

NOTICE

When resetting the ECU by turning the main

For waterproof couplers, never insert the

switch to “OFF”, be sure to wait approximately 5

tester probes directly into the coupler. When

seconds before turning the main switch back to

performing any checks using a waterproof

“ON”.

coupler, use the specified test harness or a

suitable commercially available test har-

ness.

1-11

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BASIC SERVICE INFORMATION

2. Check:

Checking the connections

• Lead

Check the leads, couplers, and connectors for

• Coupler

stains, rust, moisture, etc.

• Connector

1. Disconnect:

Moisture → Dry with an air blower.

• Lead

Rust/stains → Connect and disconnect sev-

• Coupler

eral times.

• Connector

ECB01540

NOTICE

• When disconnecting a coupler, release the

coupler lock, hold both sections of the cou-

pler securely, and then disconnect the cou-

pler.

• There are many types of coupler locks;

therefore, be sure to check the type of cou-

pler lock before disconnecting the coupler.

3. Connect:

• Lead

• Coupler

• Connector

TIP

• When connecting a coupler or connector, push

both sections of the coupler or connector to-

gether until they are connected securely.

• Make sure all connections are tight.

ECB01550

NOTICE

When disconnecting a connector, do not pull

the leads. Hold both sections of the connec-

tor securely, and then disconnect the con-

nector.

1-12

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BASIC SERVICE INFORMATION

TIP

The resistance values shown were obtained at

the standard measuring temperature of 20 °C

(68 °F). If the measuring temperature is not 20

°C (68 °F), the specified measuring conditions

will be shown.

Intake air temperature sensor re-

sistance

5.40-6.60 kΩ at 0 °C (32 °F)

4. Check:

290-390 Ω at 80 °C (176 °F)

• Continuity

(with the pocket tester)

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

TIP

• If there is no continuity, clean the terminals.

• When checking the wire harness, perform

steps (1) to (3).

• As a quick remedy, use a contact revitalizer

available at most part stores.

5. Check:

• Resistance

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

1-13

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SPECIAL TOOLS

EBS20013

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use only

the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools

or improvised techniques. Special tools, part numbers or both may differ depending on the country.

When placing an order, refer to the list provided below to avoid any mistakes.

TIP

• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, “YS-”, “YK-”, or “ACC-”.

• For others, use part number starting with “90890-”.

Reference

Tool name/Tool No.

Illustration

pages

Pocket tester

1-13, 1-13, 9-82,

90890-03112

9-83, 9-84, 9-84,

Analog pocket tester

9-88, 9-90, 9-91,

YU-03112-C

9-91, 9-91, 9-92,

9-92, 9-93, 9-93,

9-94, 9-94, 9-95,

9-95, 9-96, 9-96,

9-96, 9-97, 9-97,

9-98, 9-98

Thickness gauge

3-5

90890-03180

Feeler gauge set

YU-26900-9

Valve lapper

3-6

90890-04101

90890-04101

Valve lapping tool

YM-A8998

YM-A8998

Yamaha diagnostic tool

3-9, 9-33

90890-03231

Ring nut wrench

3-18, 3-19

90890-01268

Spanner wrench

YU-01268

1-14

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SPECIAL TOOLS

Reference

Tool name/Tool No.

Illustration

pages

Belt tension gauge

3-21

90890-03170

Rear drive belt tension gauge

YM-03170

Oil filter wrench

3-24

90890-01426

Oil filter wrench

YU-38411

Pressure gauge

3-25, 7-7

90890-03153

Pressure gauge

YU-03153

Oil pressure adapter H

3-25

90890-03139

Damper rod holder (30 mm)

4-57, 4-57

90890-01327

Damper rod holder (30 mm)

YM-01327

Ball joint remover

4-63, 4-68

90890-01474

Ball joint remover

YM-01474

Ball joint remover attachment set

4-63, 4-68

90890-01480

Ball joint adapter set

YM-01480

Ball joint installer attachment 38mm

4-63

90890-01583

Ball joint installer attachment 38mm

YM-01583

ø38

Ball joint remover short shaft set

4-63

90890-01514

Ball joint remover short shaft set

YM-01514

1-15

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