Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 5

 

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Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 5

 

 

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PERIODIC MAINTENANCE
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
Every 20-40 hours (more often in wet or
1
Air filter element
Clean and replace if necessary.
dusty areas)
Check operation and correct if necessary.
Check fluid level and ATV for fluid leakage, and cor-
2
Front brake
rect if necessary.
Replace brake pads.
Whenever worn to the limit
Check operation and correct if necessary.
Check brake pedal free play and adjust if necessary.
Check fluid level and ATV for fluid leakage, and cor-
3
Rear brake
rect if necessary.
Replace brake pads.
Whenever worn to the limit
Check for cracks or other damage, and replace if nec-
essary.
4
Brake hoses
Replace.
Every 4 years
5
Brake fluid
Change.
Every 2 years
Check runout and for damage, and replace if neces-
6
Wheels
sary.
Check tread depth and for damage, and replace if
necessary.
7
Tires
Check air pressure and balance, and correct if neces-
sary.
Check for looseness or damage, and replace if nec-
8
Wheel hub bearings
essary.
Check for wear, cracks or other damage, and replace
9
V-belt
if necessary.
Make sure that all nuts, bolts, and screws are proper-
10
Chassis fasteners
ly tightened.
Shock absorber as-
Check operation and correct if necessary.
11
semblies
Check for oil leakage and replace if necessary.
Check for cracks or other damage, and replace if nec-
12
Stabilizer bushes
essary.
13
Rear knuckle pivots
Lubricate with lithium-soap-based grease.
14
Steering shaft
Lubricate with lithium-soap-based grease.
Check operation and repair or replace if damaged.
15
Steering system
Check toe-in and adjust if necessary.
Check for cracks or other damage, and replace if nec-
16
Engine mount
essary.
Check for cracks or other damage, and replace if nec-
17
Axle boots
essary.
Change.
18
Engine oil
Check ATV for oil leakage, and correct if necessary.
Engine oil filter car-
19
Replace.
tridge
Change.
20
Differential gear oil
Check ATV for oil leakage, and correct if necessary.
Change.
21
Final gear oil
Check ATV for oil leakage, and correct if necessary.
Check coolant level and ATV for coolant leakage, and
correct if necessary.
22
Cooling system
Replace coolant.
Every 2 years
Moving parts and ca-
23
Lubricate.
bles
Drive select lever
24
*
Check operation and adjust or replace if necessary.
safety system cable
3-2

-------------------------------------------------------------------------------------------------------------------------------------------------------------

PERIODIC MAINTENANCE
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 operation.
25
Throttle lever
• Check throttle lever free play, and adjust if necessary.
• Lubricate cable and lever housing.
Front and rear brake
26
• Check operation and correct if necessary.
switches
• Check operation and correct if necessary.
27
*
Lights and switches
• Adjust headlight beams.
TIP
• Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy
or muddy areas, or at full throttle.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-3

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PERIODIC MAINTENANCE
EBS30027
4.
Check:
CHECKING THE FUEL LINE
• Spark plug type
1. Remove:
Incorrect → Change.
• Side panel (right)
Refer to “GENERAL CHASSIS (1)” on page
Manufacturer/model
4-1.
NGK/CPR7EA-9
• Rear fender
Refer to “GENERAL CHASSIS (3)” on page
5.
Check:
4-8.
• Electrodes “1”
• V-belt cooling exhaust duct
Damage/wear → Replace the spark plug.
Refer to “ENGINE REMOVAL (1)” on page
• Insulator “2”
5-3.
Abnormal color → Replace the spark plug.
2. Check:
Normal color is medium-to-light tan.
• Fuel hose “1”
6.
Clean:
Cracks/damage → Replace.
• Spark plug
Loose connection → Connect properly.
(with a spark plug cleaner or wire brush)
7.
Measure:
• Spark plug gap “a”
1
(with a wire thickness gauge)
Out of specification → Regap.
Spark plug gap
0.8-0.9 mm (0.031-0.035 in)
3. Install:
• V-belt cooling exhaust duct
Refer to “ENGINE REMOVAL (1)” on page
5-3.
• Rear fender
Refer to “GENERAL CHASSIS (3)” on page
4-8.
• Side panel (right)
8. Install:
Refer to “GENERAL CHASSIS (1)” on page
• Spark plug
4-1.
EBS30029
Spark plug (new)
CHECKING THE SPARK PLUG
11 Nm (1.1 m·kgf, 8.0 ft·lbf)
1. Remove:
Spark plug (reused)
Specified angle 30-45°
• Side panel (right)
Refer to “GENERAL CHASSIS (1)” on page
TIP
4-1.
2. Disconnect:
Before installing the spark plug, clean the spark
• Spark plug cap
plug and gasket surface.
3. Remove:
9. Connect:
• Spark plug
• Spark plug cap
ECB01270
10.Install:
NOTICE
• Side panel (right)
Before removing the spark plug, blow away
Refer to “GENERAL CHASSIS (1)” on page
any dirt accumulated in the spark plug well
4-1.
with compressed air to prevent it from falling
into the cylinder.
3-4

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PERIODIC MAINTENANCE
EBS30028
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
TIP
1
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
5. Measure:
1.
Remove:
• Valve clearance
• Side panel (left)
Out of specification → Adjust.
• Side panel (right)
Refer to “GENERAL CHASSIS (1)” on page
Valve clearance (cold)
4-1.
Intake
• Footrest board (left)
0.10-0.20 mm (0.0039-0.0079 in)
Refer to “GENERAL CHASSIS (4)” on page
Exhaust
4-11.
0.22-0.32 mm (0.0087-0.0126 in)
• Storage compartment
Refer to “GENERAL CHASSIS (5)” on page
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
4-17.
b. Position the holes “a” in the intake camshaft
2. Disconnect:
sprocket and exhaust camshaft sprocket
• Cylinder head breather hose “1”
above the cylinder head mating surface “b”
Refer to “ENGINE REMOVAL (3)” on page
as shown in the illustration, and align the
5-8.
marks “c” on the sprockets with the cylinder
• Spark plug cap “2”
head mating surface “b”.
Refer to “CAMSHAFTS” on page 5-12.
3.
Remove:
a
c
c
a
c
• Spark plug
• Cylinder head cover “3”
c
b
Refer to “CAMSHAFTS” on page 5-12.
2
1
3
c. Measure the valve clearance with a thickness
gauge “1”.
Thickness gauge
90890-03180
ECB01270
Feeler gauge set
NOTICE
YU-26900-9
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling
into the cylinder.
4. Remove:
• Crankshaft end accessing screw “1”
3-5

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PERIODIC MAINTENANCE
b. Calculate the difference between the speci-
1
fied valve clearance and the measured valve
clearance.
Example:
Specified valve clearance = 0.10-0.20 mm
(0.0039-0.0079 in)
Measured valve clearance = 0.27 mm
(0.0106 in)
0.27 mm (0.0106 in)-0.20 mm (0.0079 in) =
0.07 mm (0.0028 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Check the thickness of the current valve pad,
and then calculate the sum of the values ob-
6. Remove:
• Camshafts
tained to determine the required valve pad
thickness and the valve pad number.
Refer to “CAMSHAFTS” on page 5-12.
7. Adjust:
TIP
• Valve clearance
• The number “a” marked on the valve pad indi-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
cate the valve pad thickness.
a. Remove the valve lifter “1” and the valve pad
• Refer to the following table for the available
“2” with a valve lapper “3”.
valve pads.
• If there are no available valve pads with the
Valve lapper
same thickness as the calculated valve pad
90890-04101
thickness, select the next thickest valve pad.
Valve lapping tool
YM-A8998
a
TIP
177
• Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
• Make a note of the position of each valve lifter
“1” and valve pad “2” so that they can be in-
stalled in the correct place.
Number “a”
Thickness
145
1.450 mm (0.05709 in)
150
1.500 mm (0.05906 in)
155
1.550 mm (0.06102 in)
160
1.600 mm (0.06299 in)
162
1.625 mm (0.06398 in)
165
1.650 mm (0.06496 in)
167
1.675 mm (0.06594 in)
170
1.700 mm (0.06693 in)
172
1.725 mm (0.06791 in)
175
1.750 mm (0.06890 in)
177
1.775 mm (0.06988 in)
180
1.800 mm (0.07087 in)
182
1.825 mm (0.07185 in)
2
1
185
1.850 mm (0.07283 in)
187
1.875 mm (0.07382 in)
3-6

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PERIODIC MAINTENANCE
• Position the holes “a” in the intake camshaft
Number “a”
Thickness
sprocket and exhaust camshaft sprocket
190
1.900 mm (0.07480 in)
above the cylinder head mating surface “b” as
192
1.925 mm (0.07579 in)
shown in the illustration, and align the marks
“c” on the sprockets with the cylinder head mat-
195
1.950 mm (0.07677 in)
ing surface “b”.
197
1.975 mm (0.07776 in)
• Turn the crankshaft counterclockwise several
200
2.000 mm (0.07874 in)
full turns to seat the parts.
202
2.025 mm (0.07972 in)
a
c
c
a
c
205
2.050 mm (0.08071 in)
207
2.075 mm (0.08169 in)
c
210
2.100 mm (0.08268 in)
b
212
2.125 mm (0.08366 in)
215
2.150 mm (0.08465 in)
220
2.200 mm (0.08661 in)
225
2.250 mm (0.08858 in)
230
2.300 mm (0.09055 in)
f. Measure the valve clearance again.
Example:
g. If the valve clearance is still out of specifica-
1.775 mm (0.06988 in) + 0.07 mm (0.0028 in)
tion, repeat all of the valve clearance adjust-
= 1.845 mm (0.07264 in)
ment steps until the specified clearance is
The valve pad number is 185.
obtained.
d. Install a new valve pad “1” and the valve lifter
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
“2”.
8. Install:
TIP
• O-ring
New
• Lubricate the valve lifter with engine oil.
• Crankshaft end accessing screw
• Install the valve lifter and the valve pad in the
correct place.
Crankshaft end accessing screw
• The valve lifter must turn smoothly when rotat-
11 Nm (1.1 m·kgf, 8.0 ft·lbf)
ed by hand.
9. Install:
2
• Cylinder head cover gasket
New
• Cylinder head cover
Refer to “CAMSHAFTS” on page 5-12.
• Spark plug
1
TIP
Before installing the spark plug, clean the spark
plug and gasket surface.
Cylinder head cover bolt
e. Install the exhaust and intake camshafts, tim-
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
ing chain and camshaft caps.
Spark plug (new)
11 Nm (1.1 m·kgf, 8.0 ft·lbf)
Camshaft cap bolt
Spark plug (reused)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Specified angle 30-45°
TIP
10.Connect:
• Refer to “CAMSHAFTS” on page 5-12.
• Spark plug cap
• Lubricate the camshaft lobes and camshaft
Refer to “CAMSHAFTS” on page 5-12.
journals with engine oil.
3-7

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PERIODIC MAINTENANCE
EBS30031
11.Connect:
CHECKING THE EXHAUST SYSTEM
• Cylinder head breather hose
1. Check:
Refer to “ENGINE REMOVAL (3)” on page
• Exhaust pipe “1”
5-8.
• Muffler “2”
12.Install:
• Exhaust pipe protector “3”
• Storage compartment
• Muffler bracket “4”
Refer to “GENERAL CHASSIS (5)” on page
• Springs “5”
4-17.
Cracks/damage → Replace.
• Footrest board (left)
• Gaskets “6”
Refer to “GENERAL CHASSIS (4)” on page
Exhaust gas leaks → Replace.
4-11.
2. Check:
• Side panel (right)
• Tightening torque
• Side panel (left)
Refer to “GENERAL CHASSIS (1)” on page
Exhaust pipe nut “7”
4-1.
20 Nm (2.0 m·kgf, 14 ft·lbf)
Muffler bracket bolt “8”
EBS30030
20 Nm (2.0 m·kgf, 14 ft·lbf)
CHECKING THE BREATHER HOSES
Muffler bolt “9”
1. Remove:
33 Nm (3.3 m·kgf, 24 ft·lbf)
• Side panel (left)
Exhaust pipe protector bolt “10”
Refer to “GENERAL CHASSIS (1)” on page
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
4-1.
• Air filter case
Refer to “GENERAL CHASSIS (5)” on page
4-17.
10
2. Check:
3
8
9
• Cylinder head breather hose “1”
• Throttle body breather hose “2”
8
Cracks/damage → Replace.
Loose connection → Connect properly.
2
ECB01680
5
1
NOTICE
4
Make sure the cylinder head breather hose is
routed correctly.
6
5
6
7
1
2
EBS30574
3. Install:
ADJUSTING THE EXHAUST GAS VOLUME
• Air filter case
TIP
Refer to “GENERAL CHASSIS (5)” on page
• Be sure to set the CO density level to standard,
4-17.
and then adjust the exhaust gas volume.
• Side panel (left)
• To adjust the exhaust gas volume, use the CO
Refer to “GENERAL CHASSIS (1)” on page
adjustment mode of the Yamaha diagnostic
4-1.
tool. For more information, refer to the opera-
tion manual of the Yamaha diagnostic tool.
3-8

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PERIODIC MAINTENANCE
1. Connect the Yamaha diagnostic tool to the
Spark arrester bolt
coupler. For information about connecting the
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Yamaha diagnostic tool, refer to “YAMAHA
DIAGNOSTIC TOOL” on page 9-32.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Yamaha diagnostic tool
EBS30033
90890-03231
CHECKING THE AIR INDUCTION SYSTEM
Refer to “CHECKING THE AIR INDUCTION
EBS30032
SYSTEM” on page 7-13.
CLEANING THE SPARK ARRESTER
EBS30037
1. Clean:
CLEANING THE AIR FILTER ELEMENT
• Spark arrester
EWB03080
1. Check:
WARNING
• Air filter check hose “1”
TIP
• Select a well-ventilated area free of com-
bustible materials.
There is an air filter check hose “1” at the bottom
• Always let the exhaust system cool before
of the air filter case. If dust and/or water collects
performing this operation.
in this hose, empty the hose and clean the air fil-
• Do not start the engine when removing the
ter element, filter frame, and air filter case.
tailpipe from the muffler.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bolts “1”.
b. Remove the tailpipe “2” by pulling it out of the
1
muffler and gasket “3”.
1
1
2. Remove:
2
• Seat
Refer to “GENERAL CHASSIS (1)” on page
4-1.
3. Remove:
• Air filter case cover “1”
3
1
2
c. Tap the tailpipe lightly with a soft-face ham-
mer or suitable tool, then use a wire brush to
4. Remove:
remove any carbon deposits from the spark
• Air filter element assembly “1”
arrester portion of the tailpipe and the inner
contact surfaces of the muffler.
d. Install a new gasket, and then insert the tail-
pipe into the muffler and align the bolt holes.
e. Install the bolts “1” and tighten them.
3-9

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PERIODIC MAINTENANCE
1
5. Disassemble:
b. After cleaning, squeeze the air filter element
• Air filter element holder “1”
to remove the excess solvent.
ECB01290
• Air filter element “2”
NOTICE
• Air filter element frame “3”
ECB01800
Do not twist the air filter element when
NOTICE
squeezing it.
The engine should never be run without the
air filter; excessive piston and/or cylinder
wear may result.
3
1
2
c. Properly dispose of the used solvent.
d. Carefully wash the air filter element in soap
water.
6. Check:
• Air filter element
• Air filter element frame
• Air filter element holder
Damage → Replace.
7. Clean:
• Air filter element
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Carefully wash the air filter element in sol-
vent.
EWB02760
e. Thoroughly rinse the air filter element with
WARNING
water, and then let it dry.
Never use low flash point solvents, such as
ECB01290
gasoline, to clean the air filter element. Such
NOTICE
solvents may cause a fire or an explosion.
Do not twist the air filter element when
squeezing it.
f. Pour the recommended oil into a storage bag
large enough for the air filter element.
Air filter oil grade
Foam air-filter oil
3-10

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PERIODIC MAINTENANCE
g. Place the air filter element into the storage
bag and repeatedly squeeze the element un-
til the air filter element is saturated with oil.
TIP
The air filter element should be wet but not drip-
ping.
4. Install:
• Front wheels
Refer to “FRONT WHEELS” on page 4-20.
EBS30050
CHECKING THE REAR BRAKE PADS
The following procedure applies to all of the rear
brake pads.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Remove:
8. Assemble:
• Rear wheels
• Air filter element frame
Refer to “REAR WHEELS” on page 4-23.
• Air filter element
2. Operate the brake.
• Air filter element holder
3. Check:
9. Install:
• Rear brake pads
• Air filter element assembly
Wear indicator grooves “a” have almost dis-
10.Install:
appeared → Replace the brake pads and
• Air filter case cover
brake pad spring as a set.
11.Install:
Refer to “REAR BRAKE” on page 4-37.
• Seat
Refer to “GENERAL CHASSIS (1)” on page
4-1.
EBS30044
CHECKING THE FRONT BRAKE PADS
The following procedure applies to all of the front
brake pads.
1. Remove:
• Front wheels
Refer to “FRONT WHEELS” on page 4-20.
2. Operate the brake.
4. Install:
3. Check:
• Rear wheels
• Front brake pads
Refer to “REAR WHEELS” on page 4-23.
Wear indicator grooves “a” have almost dis-
EBS30580
appeared → Replace the brake pads and
ADJUSTING THE FRONT DISC BRAKE
brake pad spring as a set.
1. Check:
Refer to “FRONT BRAKE” on page 4-26.
• Front brake lever free play “a”
Out of specification → Bleed the front brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-14.
Front brake lever free play (lever
end)
0 mm (0 in)
3-11

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PERIODIC MAINTENANCE
a
a
3. Adjust:
EBS30581
• Brake pedal free play
ADJUSTING THE REAR DISC BRAKE
EWB03730
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the front fender inner panel (right).
WARNING
Refer to “GENERAL CHASSIS (3)” on page
Always adjust both the brake pedal and the
4-8.
rear brake lever whenever adjusting the rear
b. Loosen the adjusting nut “1” and locknut “2”.
brake.
c. Turn the adjusting nut “1” in direction “a” until
1. Check:
the rear brake cable “3” is taut.
• Rear brake lever free play “a”
d. Turn the adjusting nut “1” one turn in direction
Out of specification → Bleed the rear brake
“b”, and then tighten the locknut “2”.
system.
e. While holding the locknut “2”, tighten the ad-
Refer to “BLEEDING THE HYDRAULIC
justing nut “1”.
BRAKE SYSTEM” on page 3-14.
Brake pedal free play adjusting
Rear brake lever free play (lever
nut
end)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
0 mm (0 in)
3
a
b
1
a
2
f. Check that there is a gap between the rear
2. Check:
brake cable joint (rear brake master cylinder
• Brake pedal free play “a”
side) “4” and the pin “5”.
Out of specification → Adjust.
g. Check that the brake pedal free play is within
the specified limits.
Brake pedal free play
TIP
1.0-6.0 mm (0.04-0.24 in)
When checking the brake pedal free play, make
sure that the brake lever bracket “6” does not
move.
3-12

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PERIODIC MAINTENANCE
1
6
5
4
6
4
5
1
1
2. Check:
h. Adjust the drive select lever control cable.
• Brake hose holders
Refer to “ADJUSTING THE DRIVE SELECT
Loose → Tighten the holder bolt.
LEVER CONTROL CABLE AND SHIFT
3. Apply the brake several times.
ROD” on page 3-32.
4. Check:
EWB03740
• Brake hoses
WARNING
Brake fluid leakage → Replace the damaged
After this adjustment is performed, lift the
hose.
front and rear wheels off the ground by plac-
Refer to “FRONT BRAKE” on page 4-26.
ing a block under the engine, and spin the
rear wheels to ensure there is no brake drag.
EBS30582
CHECKING THE REAR BRAKE HOSES
If any brake drag is noticed perform the
The following procedure applies to all of the
above steps again.
brake hoses and brake hose clamps.
i. Install the front fender inner panel (right).
1. Check:
Refer to “GENERAL CHASSIS (3)” on page
• Rear brake hoses “1”
4-8.
Cracks/damage/wear → Replace.
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EBS30461
1
CHECKING THE FRONT BRAKE HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:
• Front brake hoses “1”
Cracks/damage/wear → Replace.
3-13

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PERIODIC MAINTENANCE
B
a
1
1
2. Check:
A. Front brake
• Brake hose holders
B. Rear brake
Loose → Tighten the holder bolt.
EWB02790
3. Apply the brake several times.
WARNING
4. Check:
• Use only the designated brake fluid. Other
• Brake hoses
brake fluids may cause the rubber seals to
Brake fluid leakage → Replace the damaged
deteriorate, causing leakage and poor
hose.
brake performance.
Refer to “REAR BRAKE” on page 4-37.
• Refill with the same type of brake fluid that
EBS30045
is already in the system. Mixing brake fluids
CHECKING THE BRAKE FLUID LEVEL
may result in a harmful chemical reaction,
1. Place the vehicle on a level surface.
leading to poor brake performance.
TIP
• When refilling, be careful that water does
When checking the brake fluid level, make sure
not enter the brake fluid reservoir. Water
that the top of the brake fluid reservoir is horizon-
will significantly lower the boiling point of
tal.
the brake fluid and could cause vapor lock.
ECB01320
2. Check:
NOTICE
• Brake fluid level
Brake fluid may damage painted surfaces
Below the minimum level mark “a” → Add the
and plastic parts. Therefore, always clean up
specified brake fluid to the proper level.
any spilt brake fluid immediately.
Specified brake fluid
TIP
DOT 4
In order to ensure a correct reading of the brake
fluid level, make sure the top of the brake fluid
A
reservoir is horizontal.
EBS30046
BLEEDING THE HYDRAULIC BRAKE
2WD
4WD
SYSTEM
EWB02800
WARNING
Bleed the hydraulic brake system whenever:
a
• the system is disassembled.
• a brake hose is loosened, disconnected or
replaced.
• the brake fluid level is very low.
• brake operation is faulty.
TIP
• Be careful not to spill any brake fluid or allow
the brake fluid reservoir to overflow.
3-14

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PERIODIC MAINTENANCE
• When bleeding the hydraulic brake system,
h. Tighten the bleed screw, and then release
make sure there is always enough brake fluid
the brake lever.
before applying the brake. Ignoring this pre-
i. Repeat steps (e) to (h) until all of the air bub-
caution could allow air to enter the hydraulic
bles have disappeared from the brake fluid in
brake system, considerably lengthening the
the plastic hose.
bleeding procedure.
j. Tighten the bleed screw to specification.
• If bleeding is difficult, it may be necessary to let
Brake caliper bleed screw
the brake fluid settle for a few hours. Repeat
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
the bleeding procedure when the tiny bubbles
in the hose have disappeared.
k. Fill the brake fluid reservoir to the proper level
1. Bleed:
with the specified brake fluid.
• Hydraulic brake system
Refer to “CHECKING THE BRAKE FLUID
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LEVEL” on page 3-14.
a. Fill the brake fluid reservoir to the proper level
EWB02810
with the specified brake fluid.
WARNING
b. Install the diaphragm (brake fluid reservoir).
After bleeding the hydraulic brake system,
c. Connect a clear plastic hose “1” tightly to the
check the brake operation.
bleed screw “2”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
A
EBS30057
2
CHECKING THE WHEELS
1
The following procedure applies to all of the
wheels.
1. Check:
• Wheel “1”
Damage/bends → Replace.
EWB03010
WARNING
• Never attempt even small repairs to the
B
wheel.
• Ride conservatively after installing a tire to
allow it to seat itself properly on the rim.
2
1
A. Front brake
B. Rear brake
d. Place the other end of the hose into a con-
tainer.
2. Measure:
e. Slowly apply the brake several times.
• Radial wheel runout
f. Fully pull the brake lever and hold it in posi-
• Lateral wheel runout
tion.
Refer to “CHECKING THE FRONT
g. Loosen the bleed screw.
WHEELS” on page 4-21 and “CHECKING
TIP
THE REAR WHEELS” on page 4-24.
Loosening the bleed screw will release the pres-
sure and cause the brake lever to touch the
throttle grip.
3-15

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PERIODIC MAINTENANCE
3. Check:
Front
• Wheel bearings
250 kPa (2.5 kgf/cm²) (36 psi)
Refer to “CHECKING THE STEERING
Rear
KNUCKLES AND FRONT WHEEL BEAR-
250 kPa (2.5 kgf/cm²) (36 psi)
INGS” on page 4-62 and “CHECKING THE
Higher pressures and fast inflation may
REAR KNUCKLES AND REAR WHEEL
cause a tire to burst. Inflate the tires very
BEARINGS” on page 4-71.
slowly and carefully.
EBS30058
CHECKING THE TIRES
Tire air pressure (measured on
The following procedure applies to all of the
cold tires)
Recommended
tires.
EWB02960
Vehicle load
WARNING
0 - maximum
Front
This model is equipped with low-pressure
35.0 kPa (0.350 kgf/cm², 5.0
tires. It is important that they be inflated cor-
psi)
rectly and maintained at the proper pres-
Rear
sures.
30.0 kPa (0.300 kgf/cm², 4.4
psi)
Tire characteristics
Minimum
EWB02970
Vehicle load
WARNING
0 - maximum
Front
Tire characteristics influence the handling of
32.0 kPa (0.320 kgf/cm², 4.6
vehicles. The tires listed below have been
psi)
approved by Yamaha Motor Co., Ltd. for this
Rear
model. If other tire combinations are used,
27.0 kPa (0.270 kgf/cm², 4.0
they can adversely affect your vehicle’s han-
psi)
dling characteristics and are therefore not
recommended.
Maximum loading limit
EWB02990
Front tire
WARNING
Type
Be extra careful of the vehicle balance and
Tubeless
stability when towing a trailer.
Size
AT26 × 8-12
Manufacturer/model
Maximum loading limit
MAXXIS/MU05Y
240.0 kg (530 lb) (Total weight of
Rear tire
rider, cargo, accessories, and
Type
tongue)
Tubeless
Loading
Size
Front carrier load limit
AT26 × 10-12
50.0 kg (110 lb)
Manufacturer/model
Rear carrier load limit
MAXXIS/MU06Y
90.0 kg (198 lb)
Storage compartment load limit
4.0 kg (9 lb)
Tire pressure
Trailer hitch pulling load limit
EWB02980
5880 N (600 kgf, 1322 lbf)
WARNING
Trailer hitch vertical load limit
• Tire pressure below the minimum specifi-
147 N (15 kgf, 33 lbf)
cation could cause the tire to dislodge from
the rim under severe riding conditions.
1. Measure:
• Use no more than the following pressures
• Tire pressure
when seating the tire beads.
Out of specification → Adjust.
3-16

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PERIODIC MAINTENANCE
TIP
TIP
• The tire pressure gauge “1” is included as stan-
The arrow mark “1” on the tire must point in the
dard equipment.
direction of wheel rotation.
• In order to insure an accurate reading, make
sure that the gauge is clean before use.
EBS30055
CHECKING THE V-BELT
EWB03000
1. Remove:
WARNING
• Drive belt cover
Uneven or improper tire pressure may ad-
Refer to “PRIMARY AND SECONDARY
versely affect the handling of this vehicle
SHEAVES” on page 5-49.
and may cause loss of control.
2. Check:
• Maintain proper tire pressures.
• V-belt “1”
• Set tire pressures when the tires are cold.
Cracks/damage/wear → Replace.
• Tire pressures must be equal in both front
Grease/oil → Clean the primary and second-
tires and equal in both rear tires.
ary sheaves.
Refer to “REPLACING THE V-BELT” on
2. Check:
page 3-18.
• Tire surfaces
3. Measure:
Wear/damage → Replace.
• V-belt width “a”
Wear limit (front)
Out of specification → Replace.
3.0 mm (0.12 in)
Refer to “REPLACING THE V-BELT” on
Wear limit (rear)
page 3-18.
3.0 mm (0.12 in)
V-belt width limit
EWB03100
31.3 mm (1.23 in)
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, re-
place the tire immediately.
4. Install:
• Drive belt cover
Refer to “PRIMARY AND SECONDARY
SHEAVES” on page 5-49.
a. Wear limit
3-17

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PERIODIC MAINTENANCE
EBS30056
d. Remove the bolts.
REPLACING THE V-BELT
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1. Remove:
EBS30069
• Drive belt cover
CHECKING THE FASTENER
Refer to “PRIMARY AND SECONDARY
1. Check:
SHEAVES” on page 5-49.
• Fasteners
2. Replace:
Damage/pitting → Replace.
• V-belt
Refer to “GENERAL CHASSIS (1)” on page
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4-1.
a. Install the bolts “1” (90101-06016) into the
secondary fixed sheave holes.
EBS30059
TIP
CHECKING THE FRONT SHOCK ABSORBER
ASSEMBLIES
Tightening the bolts “1” will push the secondary
The following procedure applies to both of the
sliding sheave away, causing the gap between
front shock absorber assemblies.
the secondary fixed and sliding sheaves to wid-
1. Place the vehicle on a level place.
en.
2. Check:
• Front shock absorber assembly
Refer to “CHECKING THE FRONT SHOCK
ABSORBER ASSEMBLIES” on page 4-67.
3. Check:
• Operation
Pump the front shock absorber assembly up
and down several times.
Unsmooth operation → Replace front shock
absorber assembly.
Refer to “FRONT ARMS AND FRONT
b. Remove the V-belt “2” from the primary
SHOCK ABSORBER ASSEMBLIES” on
sheave and secondary sheave.
page 4-65.
EBS30430
ADJUSTING THE FRONT SHOCK
ABSORBER ASSEMBLIES
The following procedure applies to both of the
front shock absorber assemblies.
EWB03760
WARNING
Always adjust the spring preload for both
front shock absorber assemblies to the
same setting. Uneven adjustment can cause
c. Install a new V-belt.
poor handling and loss of stability.
TIP
1. Adjust:
Install the new V-belt so that its arrow faces the
• Spring preload
direction shown in the illustration.
Turn the adjuster “1” in direction “a” or “b”.
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
3-18

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PERIODIC MAINTENANCE
EWB03770
WARNING
Direction “a”
Spring preload is increased (suspen-
Always adjust the spring preload for both
sion is harder).
rear shock absorber assemblies to the same
Direction “b”
setting. Uneven adjustment can cause poor
Spring preload is decreased (suspen-
handling and loss of stability.
sion is softer).
1.
Adjust:
• Spring preload
Front and rear suspension spring
Turn the adjuster “1” in direction “a” or “b”.
preload adjusting positions
Minimum
Ring nut wrench
1
90890-01268
Standard
Spanner wrench
2
YU-01268
Maximum
5
Direction “a”
Spring preload is increased (suspen-
1
2
sion is harder).
3
4
5
Direction “b”
Spring preload is decreased (suspen-
sion is softer).
1
a
Front and rear suspension spring
b
preload adjusting positions
Minimum
1
EBS30060
Standard
CHECKING THE REAR SHOCK ABSORBER
2
ASSEMBLIES
Maximum
The following procedure applies to both of the
5
rear shock absorber assemblies.
1. Place the vehicle on a level place.
2. Check:
1
2
3
4
• Rear shock absorber assembly
5
1
Refer to “CHECKING THE REAR SHOCK
ABSORBER ASSEMBLIES” on page 4-73.
3. Check:
b
• Operation
a
Pump the rear shock absorber assembly up
and down several times.
Unsmooth operation → Replace rear shock
absorber assembly.
EBS30064
CHECKING THE STABILIZER BUSHING
Refer to “REAR ARMS AND REAR SHOCK
1. Check:
ABSORBER ASSEMBLIES” on page 4-72.
• Stabilizer bushings
EBS30431
Damage/wear → Replace.
ADJUSTING THE REAR SHOCK ABSORBER
Refer to “REAR KNUCKLES AND STABILIZ-
ASSEMBLY
ER” on page 4-70.
The following procedure applies to both of the
rear shock absorber assemblies.
EBS30065
LUBRICATING THE REAR KNUCKLE
PIVOTS
1. Lubricate:
• Rear knuckle pivots
3-19

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PERIODIC MAINTENANCE
Recommended lubricant
Lithium-soap-based grease
3. Check:
• Tie-rod ends
Free play → Replace the tie-rod end.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EBS30063
a. Turn the handlebar left until it stops.
LUBRICATING THE STEERING SHAFT
b. Move the handlebar slightly to the right and
Lubricate the pivoting point and metal-to-metal
left.
moving parts of the shaft.
c. Check for play in the tie-rod ends.
d. Turn the handlebar right until it stops.
Recommended lubricant
e. Move the handlebar slightly to the left and
Lithium-soap-based grease
right.
f. Check for play in the tie-rod ends.
A
B
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4. Raise the front end of the vehicle so that
there is no weight on the front wheels.
5. Check:
• Ball joints and wheel bearings
Move the wheels laterally back and forth.
Excessive free play → Replace the front
arms (upper and lower) and/or wheel bear-
ings.
A. Except for EPS models
B. For EPS models
EBS30061
CHECKING THE STEERING SYSTEM
1. Place the vehicle on a level surface.
2. Check:
• Steering assembly bushings
Move the handlebar up and down, and back
and forth.
Excessive play → Replace the steering stem
bushings.
3-20

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PERIODIC MAINTENANCE
6. Measure: (for EPS models)
• Steering tension
Above specification → Adjust.
Steering tension
50 N (5.0 kgf)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “
” (off).
b. Place the vehicle on a suitable stand so that
1
the front wheels are elevated.
c. Point the front wheels straight ahead.
d. Hold the belt tension gauge “1” at a 90° angle
to the handlebar, push the gauge against the
handlebar, and then record the measurement
when the handlebar starts to turn.
Belt tension gauge
90890-03170
Rear drive belt tension gauge
YM-03170
2
c.
Tighten the steering stem bracket bolts to
specification.
Steering stem bracket bolt
51 Nm (5.1 m·kgf, 37 ft·lbf)
LOCTITE®
1
d.
Tighten the steering stem pinch bolt to speci-
fication.
Steering stem pinch bolt (for EPS
models)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
35 Nm (3.5 m·kgf, 25 ft·lbf)
7. Adjust: (for EPS models)
LOCTITE®
• Steering tension
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
e.
Measure the steering tension again.
a. Remove the electrical components tray.
f.
Repeat the above procedure until the steer-
Refer to “GENERAL CHASSIS (4)” on page
ing tension is below specification.
4-11.
b. Loosen the steering stem bracket bolts “1”
Steering tension
and steering stem pinch bolt “2” completely.
50 N (5.0 kgf)
TIP
g.
Install the electrical components tray. Refer
After loosening the bolts, be sure to check that
to “GENERAL CHASSIS (4)” on page 4-11.
the steering stem moves smoothly on the serra-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
tions of the shaft of the EPS unit.
EBS30062
ADJUSTING THE TOE-IN
1. Place the vehicle on a level surface.
2. Measure:
• Toe-in
Out of specification → Adjust.
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