Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 4

 

  Главная      Manuals     Yamaha YF70GG, YF70GPG, YF70GPSG, YF70GPLG, YFM70GDXG, YFM70GDHG, YFM70GPXG, YFM70GPHG, YFM70GPSG, YFM70GPLG, YFM700FWAD. Service manual (2016)

 

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Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 4

 

 

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CABLE ROUTING
1. Front brake hose
2. Throttle cable
3. Rear brake cable
4. Shift control cable
5. Rear brake hose
6. Front brake light switch lead
7. On-Command four-wheel-drive motor switch and
differential gear lock switch lead
8. Meter assembly lead
9. Rear brake light switch lead
10. Handlebar switch lead (left)
11. Horn switch lead (except for CDN)
A. Adjust the front brake hose, throttle cable and rear
brake hose so that the slack in the hoses and cable
is positioned below the handle mounted light cover
and to the front of the steering stem.
B. Pass the rear brake hose through the guide.
C. Pass the rear brake cable and shift control cable
through the guide.
D. Pass the front brake hose and throttle cable
through the guide.
E. Route the leads on top of where the cables cross.
F. Pass the leads through the holder.
G. Do not fasten the throttle cable or rear brake cable.
Make sure that the throttle cable and rear brake
cable are not twisted around the other leads.
H. To meter assembly
I.
To handle mounted light
2-34

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CABLE ROUTING
Handlebar (front view 2)
A
2
B
2
3
1
4
1
11
11
4
3
11
4
10
1
5
C
3
K
6
D
2
J
9
I
8
11
7
E
12
6
5
L
F
H
G
6
2-35

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CABLE ROUTING
1. Front brake light switch lead
2. On-Command four-wheel-drive motor switch and
differential gear lock switch lead
3. Rear brake light switch lead
4. Handlebar switch lead (left)
5. Differential case breather hose
6. Radiator fan motor breather hose
7. Radiator fan motor lead
8. Final drive case breather hose
9. Throttle body breather hose
10. Meter assembly lead
11. Horn switch lead (except for CDN)
12. Horn lead (except for CDN)
A.
Fasten the front brake light switch lead and On-
Command four-wheel-drive motor switch and
differential gear lock switch lead with the plastic
band, making sure to route the lead under the
handlebar and to face the end of the band forward.
Align the plastic band with the portion of the
handlebar where the handlebar begins to bend.
B.
Fasten the rear brake light switch lead, handlebar
switch lead (left), and horn switch lead (except for
CDN) with the plastic band, making sure to route
the lead under the handlebar and to face the end of
the band forward. Align the plastic band with the
portion of the handlebar where the handlebar
begins to bend.
C.
Pass the differential case breather hose through
the hole on the battery cover.
D.
Pass the radiator fan motor breather hose through
the hole on the battery cover.
E.
Route the radiator fan motor breather hose,
differential case breather hose, and horn lead
(except for CDN) in front of the frame.
F.
Fasten the differential case breather hose to the
frame with the plastic band, making sure to face
the end of the band inward.
G.
Route the differential case breather hose to the
inside of the frame.
H.
To differential assembly
I.
Pass the final drive case breather hose through the
hole on the battery cover.
J.
Pass the throttle body breather hose through the
hole on the battery cover.
K.
Fasten the front brake light switch lead, rear brake
light switch lead, On-Command four-wheel-drive
motor switch and differential gear lock switch lead,
handlebar switch lead (left), and horn switch lead
(except for CDN) with the clamp in front of the
steering stem. Be sure to fasten the clamp above
the couplers and fasten it around the protective
sleeves of the leads, not the leads themselves.
L.
Install the horn L-shaped connectors so that the
leads are routed to the left (except for CDN).
2-36

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CABLE ROUTING
Engine (left side view)
K
L
18
13
13
17
15
M
1
1
9
N
J
J
22
10
O
11
11
O
21
20
19
P
3
2
6
7
8
1
2
3
23
4
A
5
I
H
G
9
F
E
15
D
14
13
C
12
B
11
10
16
13
1
J
2-37

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CABLE ROUTING
1. Coolant reservoir hose
2. Radiator fan motor breather hose
3. Differential case breather hose
4. Ground lead
5. Coolant reservoir breather hose
6. Throttle body breather hose
7. TPS lead
8. Intake air pressure sensor lead
9. Final drive case breather hose
10. Speed sensor lead
11. AC magneto/crankshaft position sensor lead
12. Water pump breather hose
13. Radiator outlet hose
14. Differential motor lead
15. EPS torque sensor lead (for EPS models)
16. Air induction system solenoid lead
17. Shift control cable
18. Gear position switch lead
19. Reverse switch lead
20. Negative battery lead
21. Starter motor lead
22. Wire harness
23. Horn lead (except for CDN)
A.
Face the end of the coolant reservoir breather
hose downward.
B.
Pass the AC magneto/crankshaft position sensor
lead through the holder.
C.
Fasten the radiator outlet hose to the frame with
the plastic band, making sure to face the end of the
band inward.
D.
Place the differential motor lead and EPS torque
sensor lead (for EPS models) in the holder, and
then insert the ends of the holder into the hole in
the stay on the frame.
E.
Route the differential case breather hose to the
inside of the frame.
F.
Fasten the differential case breather hose to the
frame with the plastic band, making sure to face
the end of the band inward.
G.
Connect the air induction system solenoid coupler
to the air cut-off valve assembly.
H.
Attach the ground lead terminal to the frame using
the bolt.
I.
Route the radiator fan motor breather hose,
differential case breather hose, and horn lead
(except for CDN) to the inside of the radiator outlet
hose.
J.
Face the end of the plastic band inward.
K.
For EPS models
L.
Except for EPS models
M. Pass the hose and leads through the guide in the
order listed.
N.
Route the final drive case breather hose above the
reverse switch lead and negative battery lead.
O.
Route the speed sensor lead and AC
magneto/crankshaft position sensor lead above the
reverse switch lead.
P.
Route the shift control cable below the gear
position switch lead, speed sensor lead, AC
magneto/crankshaft position sensor lead, and final
drive case breather hose.
2-38

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CABLE ROUTING
Engine (right side view 1)
H
14
3
7
15
J
4
9
13
J
5
1
4
3
9
5
7
I
18
3
6
C
10
11
12
13
14
15
7
8
9
1
2
A
3
4
5
6
B
16
17
D
23
E
22
21
G
20
19
18
F
14
15
13
K
L
20
14
M
14
20
H
13
19
H
15
2-39

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CABLE ROUTING
1. AC magneto/crankshaft position sensor lead
2. ISC unit lead
3. Final drive case breather hose
4. Negative battery lead
5. Starter motor lead
6. Throttle body breather hose
7. Coolant temperature sensor lead
8. Throttle cable
9. Wire harness
10. Main switch lead
11. Auxiliary DC jack lead
12. Ignition coil lead
13. EPS motor coupler (for EPS models)
14. Differential motor lead
15. EPS torque sensor coupler (for EPS models)
16. Radiator inlet hose
17. Radiator fan motor lead
18. Spark plug lead
19. Brake pedal cable
20. Shift control cable
21. Gear position switch lead
22. Speed sensor lead
23. Reverse switch lead
A.
Route the ISC unit lead to the inside of the fuel
hose and AC magneto/crankshaft position sensor
lead.
B.
Route the throttle body breather hose under the
throttle cable.
C.
Pass the final drive case breather hose and throttle
body breather hose through the hole on the battery
cover.
D.
Route the radiator fan motor lead between the
electrical components tray and the radiator inlet
hose.
E.
Fasten the radiator fan motor lead and radiator fan
motor breather hose to the frame with the plastic
band, making sure to face the end of the band
inward. Be sure to fasten the plastic band around
the protective sleeve of the lead, not the lead itself.
F.
Route the spark plug lead to the inside of the rear
brake cable and shift control cable.
G.
Fasten the hose, leads, and wire harness with the
plastic band, making sure to position the band near
the split in the wire harness.
H.
Face the end of the plastic band inward.
I.
45°
J.
Insert the projection on each coupler into the hole
in the frame from the inside of the frame.
K.
For EPS models
L.
Except for EPS models
M. Fasten the spark plug leads with the larger
diameter section of each holder.
2-40

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CABLE ROUTING
Engine (right side view 2)
1
E
6
9
E
9
1
C
E
10
10
9
5
B
1
C
2
3
4
5
D
6
A
8
7
2-41

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CABLE ROUTING
1. Tail/brake light lead
2. Fuel tank breather hose
3. Circuit breaker
4. Rectifier/regulator lead
5. AC magneto/crankshaft position sensor lead
6. Wire harness
7. Speed sensor lead
8. Final drive case breather hose
9. Fuel hose
10. Fuel pump lead
A. To tail/brake light
B. Fasten the tail/brake light lead to the frame with a
plastic locking tie, making sure to face the end of
the tie downward.
C. Route the tail/brake light lead to the outside of the
frame.
D. Install the plastic band near the split in the wire
harness.
E. Face the end of the plastic band downward.
2-42

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CABLE ROUTING
Electrical components tray (top view)
1
B
2
3
4
5
6
7
8
A
C
B
34
7
33
35
P
O
32
D
31
9
N
10
E
M
30
11
29
12
28
13
27
F
26
14
15
7
16
17
G
L
25
24
23
K
22
J
I
21
H
20
19
18
5
6
S
13
13
35
23
10
34
R
33
1
25
Q
I
23
K
T
22
18
2-43

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CABLE ROUTING
1. Headlight lead (left)
L.
Pass the coolant reservoir breather hose through
2. Four-wheel-drive motor relay 1
the guides on the electrical components tray and
route it under the positive battery lead and starter
3. Four-wheel-drive motor relay 2
motor lead.
4. Headlight relay
M. Route the hoses under the positive battery lead,
5. Battery
and then route them upward, to the inside of the
6. ECU (Engine Control Unit)
coolant reservoir breather hose and horn lead
7. Negative battery lead
(except for CDN).
8. Headlight lead (right)
N.
Fasten the coolant reservoir breather hose with the
9. Radiator fan motor lead
holder on the electrical components tray.
10. EPS (electric power steering) control unit (for EPS
O.
Route the hoses under the positive battery lead,
models)
and then route them upward, to the inside of the
coolant reservoir breather hose.
11. Auxiliary DC jack lead
P.
Pass the hoses and ground lead, and horn lead
12. Main switch lead
(except for CDN) through the opening in the
13. EPS control unit lead (for EPS models)
electrical components tray.
14. Radiator fan motor relay
Q.
Route the coolant reservoir breather hose above
15. Fuel injection system relay
the other hoses.
16. Headlight relay 2
R.
Route the hoses to the inside of the screw.
17. Final drive case breather hose
S.
Except for EPS models
18. Differential motor lead
T.
Fasten the meter assembly lead with the holder.
19. EPS motor lead (for EPS models)
20. EPS torque sensor lead (for EPS models)
21. Starter motor lead
22. Meter assembly lead
23. Wire harness
24. Lean angle sensor lead
25. Coolant reservoir breather hose
26. Fuse box
27. Main fuse
28. EPS fuse (for EPS models)
29. Starter relay
30. Positive battery lead
31. Ground lead
32. Coolant reservoir hose
33. Differential case breather hose
34. Radiator fan motor breather hose
35. Horn lead (except for CDN)
A. To headlight (left)
B. Connect the headlight coupler, and then fasten the
coupler with the holder on the electrical
components tray.
C. To headlight (right)
D. Route the negative battery lead along the guide on
the electrical components tray.
E. Place the couplers on the inside of the electrical
components tray.
F. To main switch and auxiliary DC jack
G. Route the final drive case breather hose above the
leads in the electrical components tray.
H. Route the starter motor lead above the leads in the
electrical components tray.
I.
Fasten the EPS control unit leads with the holder.
(for EPS models)
J. Fasten the meter assembly lead and EPS control
unit lead with the twist tie. (for EPS models)
K. Fasten the handlebar switch lead (left), On-
Command four-wheel-drive motor switch and
differential gear lock switch lead, front brake light
switch lead, rear brake light switch lead, and horn
switch lead (except for CDN) with the holder.
2-44

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CABLE ROUTING
Engine (top view)
4
5
A
3
6
2
7
1
8
B
9
22
10
21
11
11
20
19
12
13
14
C
18
15
16
17
17
17
2-45

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CABLE ROUTING
1. Throttle cable
2. Rear brake cable
3. Rear brake hose
4. Shift control cable
5. Front brake hose
6. Negative battery lead
7. Final drive case breather hose
8. Starter motor lead
9. Throttle body breather hose
10. Coolant temperature sensor lead
11. Wire harness
12. ISC unit lead
13. Rectifier/regulator lead
14. AC magneto lead
15. Fuel hose
16. Circuit breaker
17. Tail/brake light lead
18. Fuel pump lead
19. Intake air temperature sensor lead
20. TPS lead
21. Intake air pressure sensor lead
22. Fuel injector lead
A. Route the throttle cable between the air duct and
the frame.
B. Fasten the throttle body breather hose with the
holder.
C. Make sure that the fuel hose and fuel pump lead
are not pinched between the frame and the rear
fender.
2-46

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CABLE ROUTING
Front and rear brake hoses
2
4
D
A
B
1
G
H
C
4
2
D
I
E
F
3
3
F
3
3
F
2-47

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CABLE ROUTING
1. Front brake pipe
2. Front brake hose
3. Rear brake pipe
4. Rear brake hose
A. Face the mark on the front brake pipe upward.
B. Route the front brake hose above the frame.
C. Pass the front brake hose through the holder.
D. Fasten the front brake hose with the holder.
E. Connect the end of the front brake hose that is
identified by the green paint mark to the left front
brake caliper.
F. Pass the rear brake pipe through the holder.
G. Fasten the rear brake hose with the holder.
H. Route the rear brake hose above the frame.
I.
Connect the end of the rear brake hose that is
identified by the green paint mark to the left rear
brake caliper.
2-48

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CABLE ROUTING
2-49

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PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE
3-1
INTRODUCTION
3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM
3-1
GENERAL MAINTENANCE AND LUBRICATION CHART
3-1
CHECKING THE FUEL LINE
3-4
CHECKING THE SPARK PLUG
3-4
ADJUSTING THE VALVE CLEARANCE
3-5
CHECKING THE BREATHER HOSES
3-8
CHECKING THE EXHAUST SYSTEM
3-8
ADJUSTING THE EXHAUST GAS VOLUME
3-8
CLEANING THE SPARK ARRESTER
3-9
CHECKING THE AIR INDUCTION SYSTEM
3-9
CLEANING THE AIR FILTER ELEMENT
3-9
3
CHECKING THE FRONT BRAKE PADS
3-11
CHECKING THE REAR BRAKE PADS
3-11
ADJUSTING THE FRONT DISC BRAKE
3-11
ADJUSTING THE REAR DISC BRAKE
3-12
CHECKING THE FRONT BRAKE HOSES
3-13
CHECKING THE REAR BRAKE HOSES
3-13
CHECKING THE BRAKE FLUID LEVEL
3-14
BLEEDING THE HYDRAULIC BRAKE SYSTEM
3-14
CHECKING THE WHEELS
3-15
CHECKING THE TIRES
3-16
CHECKING THE V-BELT
3-17
REPLACING THE V-BELT
3-17
CHECKING THE FASTENER
3-18
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES
3-18
ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES
3-18
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES
3-19
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
3-19
CHECKING THE STABILIZER BUSHING
3-19
LUBRICATING THE REAR KNUCKLE PIVOTS
3-19
LUBRICATING THE STEERING SHAFT
3-20
CHECKING THE STEERING SYSTEM
3-20
ADJUSTING THE TOE-IN
3-21
CHECKING THE ENGINE MOUNT
3-23
CHECKING THE CONSTANT VELOCITY SHAFT ASSEMBLY DUST
BOOTS
3-23
CHECKING THE ENGINE OIL LEVEL
3-23
CHANGING THE ENGINE OIL
3-24
MEASURING THE ENGINE OIL PRESSURE
3-25
CHECKING THE DIFFERENTIAL GEAR OIL LEVEL
3-26
CHANGING THE DIFFERENTIAL GEAR OIL
3-26
CHECKING THE FINAL GEAR OIL LEVEL
3-27
CHANGING THE FINAL GEAR OIL
3-27
CHECKING THE COOLING SYSTEM
3-28
CHECKING THE COOLANT LEVEL
3-29
CHANGING THE COOLANT
3-29
CHECKING AND LUBRICATING THE CABLES
3-31

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LUBRICATING THE LEVERS
3-32
LUBRICATING THE PEDAL
3-32
ADJUSTING THE DRIVE SELECT LEVER CONTROL CABLE
AND SHIFT ROD
3-32
ADJUSTING THE THROTTLE LEVER FREE PLAY
3-33
ADJUSTING THE SPEED LIMITER
3-34
REPLACING THE HANDLE MOUNTED LIGHT BULB
3-34
ADJUSTING THE HEADLIGHT AND HANDLE MOUNTED LIGHT
BEAMS
3-35

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PERIODIC MAINTENANCE
EBS20023
PERIODIC MAINTENANCE
EBS30024
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EBS30025
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
TIP
• For vehicles not equipped with an odometer or an hour meter, follow the month maintenance intervals.
• For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance
intervals. However, keep in mind that if the vehicle isn’t used for a long period of time, the month main-
tenance intervals should be followed.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
INITIAL
EVERY
month
1
3
6
6
12
CHECK OR MAINTENANCE
NO.
ITEM
Whichever
JOB
320
1300
2500
2500
5000
comes first
km (mi)
(200)
(800)
(1600)
(1600)
(3200)
hours
20
80
160
160
320
• Check fuel hoses for cracks or other damage, and re-
1
Fuel line
√
√
√
place if necessary.
• Check condition and clean, regap, or replace if nec-
2
Spark plug
√
√
√
√
√
essary.
3
Valves
• Check valve clearance and adjust if necessary.
√
√
√
√
Crankcase breather
• Check breather hose for cracks or other damage, and
4
√
√
√
system
replace if necessary.
• Check for leakage and replace gasket(s) if neces-
sary.
5
Exhaust system
√
√
√
• Check for looseness and tighten all screw clamps
and joints if necessary.
6
Spark arrester
• Clean.
√
√
√
• Check the air cut-off valve, reed valve, and hose for
7
Air induction system
damage.
√
√
√
√
√
• Replace any damaged parts if necessary.
EBS30026
GENERAL MAINTENANCE AND LUBRICATION CHART
TIP
• For vehicles not equipped with an odometer or an hour meter, follow the month maintenance intervals.
• For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance
intervals. However, keep in mind that if the vehicle isn’t used for a long period of time, the month main-
tenance intervals should be followed.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
3-1

 

 

 

 

 

 

 

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