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Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 7

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GENERAL CHASSIS (1)

Removing the seat and side panels

0.4 Nm (0.04 m•kgf, 0.29 ft•Ibf)

8

2

1

10

7

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

3

4

5 6

2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

9

2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

1

Seat

1

2

Battery cover

1

3

Throttle body breather hose

1

Disconnect.

4

Final drive case breather hose

1

Disconnect.

5

Differential case breather hose

1

Disconnect.

6

Radiator fan motor breather hose

1

Disconnect.

7

Top cover

1

8

Storage compartment lid

1

9

Side panel (left)

1

10

Side panel (right)

1

4-2

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GENERAL CHASSIS (1)

EBS30449

REMOVING THE BATTERY COVER

c

1. Remove:

a

• Battery cover “1”

d

1

c

d

b

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EBS30451

REMOVING THE TOP COVER

1. Remove:

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• Top cover “1”

a. Lift the rear of the battery cover to remove the

• Storage compartment lid “2”

projections “a” on the cover from the grom-

mets “b”.

2

b. Slide the battery cover rearward to unhook its

projections “c” from the holes “d” in the upper

1

panel.

a

c

b

a

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a. Remove the quick fasteners, screws, and

b

bolts.

b. Slide the top cover rearward and lift it up to

d

unhook its projections “a” from the holes “b” in

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the side panels.

EBS30450

INSTALLING THE BATTERY COVER

1. Install:

• Battery cover “1”

a

1

b

c. Place the top cover upside down.

d. Remove the storage compartment lid from

the left end of the hinge “3”.

e. Remove the left end of the hinge from the top

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cover, and then remove the hinge and stor-

a. Fit the projections “a” on the battery cover

age compartment lid from the top cover.

into the holes “b” in the upper panel.

b. Fit the projections “c” on the battery cover into

the grommets “d”.

4-3

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GENERAL CHASSIS (1)

3

3

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d. Fit the projections “a” on the top cover into the

holes “b” in the side panels and slide the cov-

EBS30452

INSTALLING THE TOP COVER

er forward.

1. Install:

• Storage compartment lid “1”

• Top cover “2”

a

Top cover bolt

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

1

b

2

e. Install the bolts, screws, and quick fasteners.

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EBS30453

REMOVING THE SIDE PANELS

The following procedure applies to both of the

side panels.

The following procedure applies to both of the

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

side panels.

a. Place the top cover upside down.

1. Remove:

b. Fit the right end of the hinge “3” into the stor-

• Side panel “1”

age compartment lid and top cover.

c. Fit the left end of the hinge into the top cover,

and then fit the storage compartment lid onto

the left end of the hinge.

4-4

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GENERAL CHASSIS (1)

1

1

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▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Remove the bolt.

a. Fit the projections “a” on the side panel into

b. Lift the side panel and remove it.

the holes “b” in the front fender, fit the projec-

tions “c” on the panel into the holes “d” in the

A

footrest board, and fit the projection “e” on the

panel into the hole “f” in the rear fender.

A

a

e

f

B

b

B

a

e

c

A. Left side

f

B. Right side

b

d

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A. Right side

EBS30454

B. Left side

INSTALLING THE SIDE PANELS

The following procedure applies to both of the

b. Install the bolt.

side panels.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

1. Install:

• Side panel “1”

Side panel bolt

2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)

4-5

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GENERAL CHASSIS (2)

EBS20087

GENERAL CHASSIS (2)

Removing the front carrier and front guard

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

3

5

2

34 Nm (3.4 m•kgf, 25 ft•Ibf)

4

1

6

7

8

10

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

7

9

8

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

34 Nm (3.4 m•kgf, 25 ft•Ibf)

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

9

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

Refer to “GENERAL CHASSIS (1)” on page

Front skid plate/Battery cover

4-1.

1

Front carrier

1

2

Battery holding bracket

1

3

Battery lead

2

Disconnect.

4

Battery

1

5

Upper panel

1

6

Front carrier bracket

2

7

Headlight coupler

2

Disconnect.

8

Headlight unit

2

9

Front guard cover

2

10

Front guard

1

4-6

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GENERAL CHASSIS (2)

EBS30455

REMOVING THE UPPER PANEL

1. Remove:

• Upper panel “1”

a

b

1

b

a

b. Install the quick fasteners.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Remove the quick fasteners.

b. Slide the upper panel forward and lift it up to

remove it.

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EBS30456

INSTALLING THE UPPER PANEL

1. Install:

• Upper panel “1”

1

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Fit the projections “a” on the upper panel into

the holes “b” in the front fender, and then

slide the panel rearward.

4-7

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GENERAL CHASSIS (3)

EBS20088

GENERAL CHASSIS (3)

Removing the front fenders and front grill

8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

4

3

2

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

5

1

4

8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

1

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

Front skid plate/Battery cover/Seat/Top cov-

Refer to “GENERAL CHASSIS (1)” on page

er/Side panels

4-1.

Refer to “GENERAL CHASSIS (2)” on page

Front carrier/Front guard

4-6.

1

Front fender inner panel

2

2

Main switch coupler

1

Disconnect.

3

Auxiliary DC jack coupler

1

Disconnect.

4

Front fender

2

5

Front grill

1

4-8

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GENERAL CHASSIS (3)

Removing the rear carrier and rear fender

3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)

60 Nm (6.0 m•kgf, 43 ft•Ibf)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

3

34 Nm (3.4 m•kgf, 25 ft•Ibf)

2

6

5

4

7

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

8

1

60 Nm (6.0 m•kgf, 43 ft•Ibf)

(6)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

(6)

Order

Job/Parts to remove

Q’ty

Remarks

Refer to “GENERAL CHASSIS (1)” on page

Seat/Top cover/Side panels

4-1.

1

Rear carrier bracket

2

2

Rear carrier

1

3

Rear storage compartment cover

1

4

Tail/brake light coupler

1

Disconnect.

5

Fuel tank breather hose

1

Disconnect.

6

Fuel tank breather hose joint

1

7

Fuel tank cap

1

8

Rear fender

1

4-9

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GENERAL CHASSIS (3)

EBS30356

INSTALLING THE REAR FENDER

1. Install:

• Rear fender

Rear fender bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

TIP

The bolts may be tightened to the specified

torque in any tightening sequence. However, in-

stall the front bolts “1” and tighten them tempo-

rarily before installing the rear bolts “2”.

1

2

4-10

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GENERAL CHASSIS (4)

EBS20089

GENERAL CHASSIS (4)

Removing the electrical components tray 1/2

2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

1

4

2

5

2

3

2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

Front skid plate/Battery cover/Seat/Top cov-

Refer to “GENERAL CHASSIS (1)” on page

er/Side panels

4-1.

Refer to “GENERAL CHASSIS (2)” on page

Front carrier/Front guard

4-6.

Refer to “GENERAL CHASSIS (3)” on page

Front fenders/Front grill

4-8.

Refer to “GENERAL CHASSIS (5)” on page

Air intake duct/Storage compartment

4-17.

V-belt cooling exhaust duct/V-belt cooling intake

Refer to “ENGINE REMOVAL (1)” on page

duct

5-3.

1

Battery holding bracket

1

2

Battery lead

2

Disconnect.

3

Battery

1

4

Lean angle sensor coupler

1

Disconnect.

5

Lean angle sensor

1

4-11

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GENERAL CHASSIS (4)

Removing the electrical components tray 1/2

2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

10

12

11

9

8

7

11

6

2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

9

9

9

13

Order

Job/Parts to remove

Q’ty

Remarks

6

Four-wheel-drive motor relay 1

1

7

Four-wheel-drive motor relay 2

1

8

Headlight relay 1

1

Disconnect.

9

EPS control unit coupler

5

For EPS models

10

EPS (electric power steering) control unit

1

For EPS models

11

ECU coupler

2

Disconnect.

12

ECU (Engine Control Unit)

1

13

Radiator fan motor coupler

1

Disconnect.

4-12

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GENERAL CHASSIS (4)

Removing the electrical components tray 2/2

7

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

8

6

3

4

5

3.6 Nm (0.36 m•kgf, 2.6 ft•Ibf)

1

10

2

9

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

1

Starter relay coupler

1

Disconnect.

2

Starter relay

1

3

Fuse box

1

4

EPS fuse

1

For EPS models

5

Main fuse

1

6

Radiator fan motor relay

1

7

Fuel injection system relay

1

8

Headlight relay 2

1

9

Frame ground terminal

1

10

Air cut-off valve coupler

1

Disconnect.

4-13

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GENERAL CHASSIS (4)

Removing the electrical components tray 2/2

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

18

3.6 Nm (0.36 m•kgf, 2.6 ft•Ibf)

17

16

15

12

14

11

11

19

13

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

11

Ignition coil connector

2

Disconnect.

12

Differential motor coupler

1

Disconnect.

Disconnect.

13

Horn connector

2

Except for CDN

Disconnect.

14

Horn switch coupler

1

Except for CDN

15

Coolant reservoir breather hose

1

Disconnect.

16

Radiator fan motor breather hose

1

Disconnect.

17

Differential case breather hose

1

Disconnect.

18

Wire harness

1

19

Electrical components tray

1

4-14

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GENERAL CHASSIS (4)

Removing the footrest boards

16 Nm (1.6 m•kgf, 12 ft•Ibf)

8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

(4)

(5)

2

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

(5)

(4)

2

3

(5)

1

(5)

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

16 Nm (1.6 m•kgf, 12 ft•Ibf)

3

Order

Job/Parts to remove

Q’ty

Remarks

Refer to “GENERAL CHASSIS (1)” on page

Seat/Top cover/Side panels

4-1.

1

Dipstick accessing cover

1

2

Footrest board

2

3

Footrest bracket

2

4-15

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GENERAL CHASSIS (4)

EBS30357

INSTALLING THE FOOTREST BOARDS

The following procedure applies to both of the

footrest boards.

1. Install:

• Footrest board

Footrest board bolt

8 Nm (0.8 m·kgf, 5.8 ft·lbf)

TIP

Tighten the footrest board bolts to the specified

torque in the proper tightening sequence as

shown.

4

1

2

3

FWD

4-16

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GENERAL CHASSIS (5)

EBS20090

GENERAL CHASSIS (5)

Removing the air filter case

3

0.8 Nm (0.08 m•kgf, 0.58 ft•Ibf)

2

5

4

6

1

3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

New

7

9

8

New

1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

Refer to “GENERAL CHASSIS (1)” on page

Seat/Top cover/Side panels

4-1.

1

Air filter case cover

1

2

Air intake duct clamp screw

1

Loosen.

3

Air intake duct

1

4

Air filter element

1

5

Air filter element holder

1

6

Air filter element frame

1

7

Storage compartment

1

8

Intake air temperature sensor coupler

1

Disconnect.

Air induction system hose

9

1

Disconnect.

(air cut-off valve assembly to air filter case)

4-17

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GENERAL CHASSIS (5)

Removing the air filter case

0.8 Nm (0.08 m•kgf, 0.58 ft•Ibf)

12

3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

New

14

11

13

10

15

11

New

1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

10

Cylinder head breather hose

1

Disconnect.

11

Air filter case joint clamp screw

2

Loosen.

12

Rectifier/regulator coupler

2

Disconnect.

13

Air filter case

1

14

Air filter case joint

1

15

Intake air temperature sensor

1

4-18

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GENERAL CHASSIS (5)

EBS30457

INSTALLING THE AIR FILTER CASE

1

1. Install:

• Intake air temperature sensor

2

• Air filter case

• Air filter case joint “1”

(to the air filter case)

Intake air temperature sensor

a

screw

b

1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)

Air filter case bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Air filter case joint clamp screw

(throttle body side)

3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)

Air filter case joint clamp screw

(air filter case side)

0.8 Nm (0.08 m·kgf, 0.58 ft·lbf)

TIP

Fit the projection “a” on the air filter case joint be-

tween the projections “b” on the air filter case.

1

a

b

2. Connect:

• Cylinder head breather hose

• Air induction system hose (air cut-off valve

assembly to air filter case)

• Intake air temperature sensor coupler

3. Install:

• Air filter element assembly

• Air intake duct “1”

(to the air filter case cover)

• Air filter case cover

• Storage compartment

Air intake duct clamp screw

0.8 Nm (0.08 m·kgf, 0.58 ft·lbf)

Storage compartment bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

TIP

Fit the projection “a” on the air intake duct be-

tween the projections “b” on the air filter case

cover “2”.

4-19

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FRONT WHEELS

EBS20095

FRONT WHEELS

Removing the front wheels and brake discs

30 Nm (3.0 m•kgf, 22 ft•Ibf)

260 Nm (26 m•kgf, 188 ft•lbf)

LT

1

2

LT

6

5

3 New

4

30 Nm (3.0 m•kgf, 22 ft•Ibf)

55 Nm (5.5 m•kgf, 40 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

The following procedure applies to both of

the front wheels.

Place the vehicle on a level surface.

1

Front wheel

1

2

Wheel cap

1

3

Front wheel axle nut

1

TIP

Do not squeeze the front brake lever when

4

Front brake caliper assembly

1

the brake caliper is off of the brake disc as

the brake pads will be forced shut.

5

Front wheel hub

1

6

Front brake disc

1

4-20

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FRONT WHEELS

EBS30358

REMOVING THE FRONT WHEELS

Radial wheel runout limit

1. Place the vehicle on a level surface.

1.2 mm (0.05 in)

2. Elevate:

Lateral wheel runout limit

• Front wheels

1.2 mm (0.05 in)

TIP

Place the vehicle on a suitable stand so that the

front wheels are elevated.

EBS30359

REMOVING THE FRONT WHEEL HUBS

The following procedure applies to both of the

front wheel hubs.

1. Straighten the wheel axle nut rib “a”.

a

2. Remove:

• Wheel axle nut

3. Remove:

3. Check:

• Front brake caliper

• Wheel balance

TIP

Out of balance → Adjust.

Do not operate the brake lever when removing

EWB03020

the brake caliper.

WARNING

After replacing the tire, ride conservatively to

EBS30360

allow the tire to be properly seated in the rim.

CHECKING THE FRONT WHEELS

Failure to do so may cause an accident re-

The following procedure applies to both of the

sulting in vehicle damage and possible inju-

front wheels.

ry.

1. Check:

• Tire

• Wheel

Refer to “CHECKING THE TIRES” on page

3-16 and “CHECKING THE WHEELS” on

page 3-15.

2. Measure:

• Radial wheel runout “1”

• Lateral wheel runout “2”

Over the specified limit → Replace the wheel

or check the wheel bearing play.

Refer to “CHECKING THE STEERING

EBS30361

CHECKING THE FRONT WHEEL HUBS

KNUCKLES AND FRONT WHEEL BEAR-

The following procedure applies to both of the

INGS” on page 4-62.

front wheel hubs.

1. Check:

• Wheel hub “1”

Cracks/damage → Replace.

4-21

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