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

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

FRONT WHEELS

• Splines (wheel hub) “2”

Wear/damage → Replace the wheel hub.

2. Check:

• Brake disc

EBS30362

Refer to “CHECKING THE FRONT BRAKE

INSTALLING THE FRONT BRAKE DISCS

DISCS” on page 4-31.

The following procedure applies to both of the

EBS30364

front brake discs.

INSTALLING THE FRONT WHEELS

1. Install:

• Brake disc

• Wheel

TIP

Front brake disc bolt

30 Nm (3.0 m·kgf, 22 ft·lbf)

The arrow mark “1” on the tire must point in the

LOCTITE®

direction of wheel rotation.

TIP

Install the brake disc so that the recessed por-

tion of the bolt hole faces away from the hub.

2. Tighten:

• Wheel nuts “1”

Front wheel nut

55 Nm (5.5 m·kgf, 40 ft·lbf)

EBS30363

INSTALLING THE FRONT WHEEL HUBS

EWB03130

The following procedure applies to both of the

WARNING

front wheel hubs.

Tapered wheel nuts are used for both the

1. Install:

front and rear wheels. Install each nut with

• Wheel axle nut

New

its tapered side towards the wheel.

Front wheel axle nut

260 Nm (26 m·kgf, 188 ft·lbf)

TIP

• Do not apply oil to the threads of the nut.

• After tightening the nut, stake the collar of the

nut into the notch of the shaft.

4-22

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REAR WHEELS

EBS20096

REAR WHEELS

Removing the rear wheels and brake discs

30 Nm (3.0 m•kgf, 22 ft•Ibf)

260 Nm (26 m•kgf, 188 ft•lbf)

New

30 Nm (3.0 m • kg, 22 ft • Ib)

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 rear wheels.

Place the vehicle on a level surface.

Rear wheel

Wheel cap

Rear wheel axle nut

TIP

Do not squeeze the rear brake lever and

Rear brake caliper assembly

brake pedal when the brake caliper is off of

the brake disc as the brake pads will be

forced shut.

Rear wheel hub

Rear brake disc

4-23

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REAR WHEELS

EBS30365

3. Check:

REMOVING THE REAR WHEELS

• Wheel balance

1. Place the vehicle on a level surface.

Refer to “CHECKING THE FRONT

2. Elevate:

WHEELS” on page 4-21.

• Rear wheels

EBS30368

TIP

CHECKING THE REAR WHEEL HUBS

Place the vehicle on a suitable stand so that the

The following procedure applies to both of the

rear wheels are elevated.

rear wheel hubs.

3. Remove:

1. Check:

• Rear brake calipers

• Wheel hub “1”

Cracks/damage → Replace.

TIP

• Splines (wheel hub) “2”

Do not apply the brake lever and depress the

Wear/damage → Replace.

brake pedal when removing the brake calipers.

EBS30366

REMOVING THE REAR WHEEL HUBS

The following procedure applies to both of the

rear wheel hubs.

1. Remove:

• Wheel axle nut

Refer to “REMOVING THE FRONT WHEEL

HUBS” on page 4-21.

2. Remove:

• Rear brake caliper

EBS30369

INSTALLING THE REAR BRAKE DISCS

TIP

The following procedure applies to both of the

Do not operate the brake lever or brake pedal

rear brake discs.

when removing the brake caliper.

1. Install:

Brake disc

EBS30367

CHECKING THE REAR WHEELS

Rear brake disc bolt

The following procedure applies to both of the

30 Nm (3.0 m·kgf, 22 ft·lbf)

rear wheels.

LOCTITE®

1. Check:

• Tire

TIP

• Wheel

Install the brake disc so that the recessed por-

Refer to “CHECKING THE TIRES” on page

tion of the bolt hole faces away from the hub.

3-16 and “CHECKING THE WHEELS” on

page 3-15.

2. Measure:

• Radial wheel runout

• Lateral wheel runout

Refer to “CHECKING THE FRONT

WHEELS” on page 4-21.

Over the specified limit → Replace the wheel

or check the wheel bearing play.

Refer to “REAR WHEELS” on page 4-23.

Radial wheel runout limit

EBS30370

1.2 mm (0.05 in)

INSTALLING THE REAR WHEEL HUBS

Lateral wheel runout limit

The following procedure applies to both of the

1.2 mm (0.05 in)

rear wheel hubs.

4-24

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REAR WHEELS

1. Install:

• Wheel axle nut

New

Rear wheel axle nut

260 Nm (26 m·kgf, 188 ft·lbf)

TIP

• Do not apply oil to the threads of the nut.

• After tightening the nut, stake the collar of the

nut into the notch of the shaft.

EBS30371

INSTALLING THE REAR WHEELS

The following procedure applies to both of the

rear wheels.

1. Install:

• Wheel

TIP

The arrow mark “1” on the tire must point in the

direction of wheel rotation.

2. Tighten:

• Wheel nuts “1”

Rear wheel nut

55 Nm (5.5 m·kgf, 40 ft·lbf)

EWB03130

WARNING

Tapered wheel nuts are used for both the

front and rear wheels. Install each nut with

its tapered side towards the wheel.

4-25

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FRONT BRAKE

EBS20097

FRONT BRAKE

Removing the front brake pads

5 Nm (0.5 m•kgf, 3.6 ft•Ibf)

17 Nm (1.7 m•kgf, 12 ft•Ibf)

2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

30 Nm (3.0 m•kgf, 22 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

The following procedure applies to both of

the front brake calipers.

Front wheel

Refer to “FRONT WHEELS” on page 4-20.

Front brake caliper bolt

Brake pad holding bolt plug

Brake pad holding bolt

Front brake pad

Brake pad spring

4-26

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

FRONT BRAKE

Removing the front brake master cylinder

1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

New

6 Nm (0.6 m•kgf, 4.3 ft•Ibf)

27 Nm (2.7 m•kgf, 20 ft•Ibf)

1.2 Nm (0.12 m•kgf, 0.87 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

Drain.

Brake fluid

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” on page 3-14.

On-Command four-wheel-drive motor switch

Refer to “HANDLEBAR” on page 4-48.

and differential gear lock switch

Brake fluid reservoir cap

Brake fluid reservoir diaphragm holder

Brake fluid reservoir diaphragm

Brake lever

Union bolt

Copper washer

Front brake hose

Disconnect.

Front brake light switch connector

Disconnect.

Front brake light switch

Front brake master cylinder holder

Front brake master cylinder

4-27

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

FRONT BRAKE

Removing the front brake calipers

2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

17 Nm (1.7 m•kgf, 12 ft•Ibf)

27 Nm (2.7 m•kgf, 20 ft•Ibf)

2 New

30 Nm (3.0 m•kgf, 22 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

The following procedure applies to both of

the front brake calipers.

Drain.

Brake fluid

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” on page 3-14.

Front wheel

Refer to “FRONT WHEELS” on page 4-20.

Union bolt

Copper washer

Front brake hose

Disconnect.

Brake pad holding bolt plug

Brake pad holding bolt

Loosen.

Front brake caliper bolt

Front brake caliper assembly

4-29

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

FRONT BRAKE

Disassembling the front brake calipers

17 Nm (1.7 m•kgf, 12 ft•Ibf)

5 Nm (0.5 m•kgf, 3.6 ft•Ibf)

New

22 Nm (2.2 m•kgf, 16 ft•Ibf)

17 Nm (1.7 m•kgf, 12 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

The following procedure applies to both of

the front brake calipers.

Brake pad holding bolt

Brake pad

Brake pad spring

Brake caliper bracket

Brake caliper guide pin

Brake caliper retaining pin

Brake caliper piston

Brake caliper dust seal

Brake caliper piston seal

Bleed screw

4-30

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FRONT BRAKE

EBS30372

INTRODUCTION

EWB02930

WARNING

Disc brake components rarely require disas-

sembly. Therefore, always follow these pre-

ventive measures:

• Never disassemble brake components un-

less absolutely necessary.

• If any connection on the hydraulic brake

system is disconnected, the entire brake

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

system must be disassembled, drained,

4. Measure:

cleaned, properly filled, and bled after reas-

• Brake disc thickness “a”

sembly.

Measure the brake disc thickness at a few dif-

• Never use solvents on internal brake com-

ferent locations.

ponents.

Out of specification → Replace.

• Use only clean or new brake fluid for clean-

ing brake components.

Brake disc thickness limit

• Brake fluid may damage painted surfaces

3.0 mm (0.12 in)

and plastic parts. Therefore, always clean

up any spilt brake fluid immediately.

• Avoid brake fluid coming into contact with

the eyes as it can cause serious injury.

FIRST AID FOR BRAKE FLUID ENTERING

THE EYES:

• Flush with water for 15 minutes and get im-

mediate medical attention.

EBS30373

CHECKING THE FRONT BRAKE DISCS

The following procedure applies to both brake

5. Adjust:

discs.

• Brake disc deflection

1. Remove:

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

• Front wheel

a. Remove the brake disc.

Refer to “FRONT WHEELS” on page 4-20.

b. Rotate the brake disc by one bolt hole.

2. Check:

c. Install the brake disc.

• Brake disc

Damage/galling → Replace.

Front brake disc bolt

3. Measure:

30 Nm (3.0 m·kgf, 22 ft·lbf)

• Brake disc deflection

LOCTITE®

Out of specification → Correct the brake disc

deflection or replace the brake disc.

TIP

Install the brake disc so that the recessed por-

Brake disc deflection limit

tion of the bolt hole faces away from the hub.

0.10 mm (0.0039 in)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Hold the dial gauge at a right angle against

the brake disc surface.

b. Measure the deflection 3.0 mm (0.12 in) be-

low the edge of the brake disc.

4-31

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

FRONT BRAKE

d. Measure the brake disc deflection.

e. If out of specification, repeat the adjustment

steps until the brake disc deflection is within

specification.

f. If the brake disc deflection cannot be brought

within specification, replace the brake disc.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6. Install:

• Front wheels

Refer to “FRONT WHEELS” on page 4-20.

b. Loosen the bleed screw and push the brake

EBS30374

caliper piston into the brake caliper with your

REPLACING THE FRONT BRAKE PADS

finger.

The following procedure applies to both brake

c. Tighten the bleed screw.

calipers.

TIP

Brake caliper bleed screw

When replacing the brake pads, it is not neces-

5 Nm (0.5 m·kgf, 3.6 ft·lbf)

sary to disconnect the brake hose or disassem-

d. Install new brake pads and a new brake pad

ble the brake caliper.

spring.

1. Measure:

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

• Brake pad wear limit “a”

3. Install:

Out of specification → Replace the brake

• Brake pad holding bolt

pads and brake pad spring as a set.

• Brake pad holding bolt plug

• Brake caliper

Brake pad lining thickness limit

1.0 mm (0.04 in)

Brake pad holding bolt

17 Nm (1.7 m·kgf, 12 ft·lbf)

Brake pad holding bolt plug

2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)

Front brake caliper bolt

30 Nm (3.0 m·kgf, 22 ft·lbf)

4. Check:

• Brake fluid level

Below the minimum level mark → Add the

specified brake fluid to the proper level.

Refer to “CHECKING THE BRAKE FLUID

2. Install:

LEVEL” on page 3-14.

• Brake pad spring

5. Check:

• Brake pads

• Brake lever operation

TIP

Soft or spongy feeling → Bleed the brake sys-

tem.

Always install new brake pads and a new brake

pad spring as a set.

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” on page 3-14.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Connect a clear plastic hose “1” tightly to the

EBS30375

bleed screw “2”. Put the other end of the hose

DISASSEMBLING THE FRONT BRAKE

into an open container.

CALIPERS

The following procedure applies to both of the

brake calipers.

TIP

Before disassembling the brake caliper, drain

the brake fluid from the entire brake system.

4-32

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

FRONT BRAKE

1. Remove:

1. Check:

• Brake caliper piston “1”

• Brake caliper dust seal “2”

Rust/scratches/wear → Replace the brake

• Brake caliper piston seal “3”

caliper piston.

• Brake caliper cylinder “2”

Scratches/wear → Replace the brake caliper

assembly.

• Brake caliper body “3”

Cracks/damage → Replace the brake caliper

assembly.

• Brake fluid delivery passages

(brake caliper body)

Obstruction → Blow out with compressed air.

EWB03140

WARNING

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Blow compressed air into the brake hose joint

Whenever a brake caliper is disassembled,

opening “a” to force out the piston from the

replace the brake caliper piston dust seals

brake caliper.

and brake caliper piston seals.

EWB02890

WARNING

• Cover the brake caliper piston with a rag.

Be careful not to get injured when the pis-

ton is expelled from the brake caliper.

• Never try to pry out the brake caliper pis-

ton.

EBS30376

ASSEMBLING THE FRONT BRAKE

CALIPERS

The following procedure applies to both of the

brake calipers.

EWB03150

WARNING

b. Remove the brake caliper dust seal and

• Before installation, all internal brake com-

brake caliper piston seal.

ponents should be cleaned and lubricated

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

with clean or new brake fluid.

• Never use solvents on internal brake com-

EBS30380

CHECKING THE FRONT BRAKE CALIPERS

ponents as they will cause the brake caliper

The following procedure applies to both of the

piston dust seals and brake caliper piston

brake calipers.

seals to swell and distort.

• Whenever a brake caliper is disassembled,

Recommended brake component replacement

replace the brake caliper piston dust seals

schedule

and brake caliper piston seals.

Brake pads

If necessary

Piston seals, dust seals

Every two years

Specified brake fluid

Brake hoses

Every four years

DOT 4

Every two years and

EBS30377

Brake fluid

whenever the brake is

INSTALLING THE FRONT BRAKE CALIPERS

disassembled

The following procedure applies to both of the

brake calipers.

4-33

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

FRONT BRAKE

1. Install:

• When refilling, be careful that water does

• Brake caliper assembly

not enter the brake fluid reservoir. Water

• Brake caliper bolts “1”

will significantly lower the boiling point of

• Brake hose “2”

the brake fluid and could cause vapor lock.

• Copper washers “3”

New

ECB01320

• Brake hose union bolt “4”

NOTICE

Brake fluid may damage painted surfaces

Front brake caliper bolt

and plastic parts. Therefore, always clean up

30 Nm (3.0 m·kgf, 22 ft·lbf)

any spilt brake fluid immediately.

Brake hose union bolt

27 Nm (2.7 m·kgf, 20 ft·lbf)

3. Bleed:

• Brake system

EWB02870

Refer to “BLEEDING THE HYDRAULIC

WARNING

BRAKE SYSTEM” on page 3-14.

Proper brake hose routing is essential to in-

4. Check:

sure safe vehicle operation.

• Brake fluid level

Below the minimum level mark → Add the

Refer to “CABLE ROUTING” on page 2-33.

ECB02330

specified brake fluid to the proper level.

NOTICE

Refer to “CHECKING THE BRAKE FLUID

When installing the brake hose onto the

LEVEL” on page 3-14.

brake caliper, make sure the brake pipe

5. Check:

touches the projection “a” on the brake cali-

• Brake lever operation

per.

Soft or spongy feeling → Bleed the brake sys-

tem.

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” on page 3-14.

EBS30378

CHECKING THE FRONT BRAKE MASTER

CYLINDER

1. Check:

New

• Brake master cylinder

Damage/scratches/wear → Replace.

• Brake fluid delivery passages

(brake master cylinder body)

2. Fill:

Obstruction → Blow out with compressed air.

• Brake master cylinder reservoir

2. Check:

(with the specified amount of the specified

• Brake master cylinder kit

brake fluid)

Damage/scratches/wear → Replace.

Specified brake fluid

3. Check:

DOT 4

• Brake master cylinder reservoir

Cracks/damage → Replace.

EWB02790

• Brake master cylinder reservoir diaphragm

WARNING

Cracks/damage → Replace.

• Use only the designated brake fluid. Other

4. Check:

brake fluids may cause the rubber seals to

• Brake hoses

deteriorate, causing leakage and poor

Cracks/damage/wear → Replace.

brake performance.

• Refill with the same type of brake fluid that

is already in the system. Mixing brake fluids

may result in a harmful chemical reaction,

leading to poor brake performance.

4-34

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

FRONT BRAKE

EBS30379

EWB02870

ASSEMBLING THE FRONT BRAKE MASTER

WARNING

CYLINDER

Proper brake hose routing is essential to in-

EWB03590

sure safe vehicle operation.

WARNING

• Before installation, all internal brake com-

Refer to “CABLE ROUTING” on page 2-33.

ponents should be cleaned and lubricated

TIP

with clean or new brake fluid.

• While holding the brake hose, tighten the union

• Never use solvents on internal brake com-

bolt as shown.

ponents.

• Turn the handlebar to the left and right to make

• Whenever a master cylinder is disassem-

sure the brake hose does not touch other parts

bled, replace the brake master cylinder kit.

(e.g., wire harness, cables, leads). Correct if

necessary.

Specified brake fluid

DOT 4

EBS30381

INSTALLING THE FRONT BRAKE MASTER

CYLINDER

1. Install:

40-50˚

• Brake master cylinder “1”

• Brake master cylinder holder “2”

Front brake master cylinder hold-

er bolt

3. Fill:

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

• Brake master cylinder reservoir

(with the specified amount of the specified

TIP

brake fluid)

• Align the end of the brake master cylinder hold-

er with the punch mark “a” on the handlebar.

Specified brake fluid

DOT 4

• Install the brake master cylinder holder with the

“UP” mark “b” facing up.

EWB02880

• First, tighten the upper bolt, then the lower bolt.

WARNING

• Use only the designated brake fluid. Other

brake fluids may cause the rubber seals to

deteriorate, causing leakage and poor

brake performance.

• Refill with the same type of brake fluid that

is already in the system. Mixing brake fluids

may result in a harmful chemical reaction,

leading to poor brake performance.

• When refilling, be careful that water does

not enter the brake master cylinder reser-

2. Install:

voir. Water will significantly lower the boil-

• Brake hose

ing point of the brake fluid and could cause

vapor lock.

• Copper washers

New

• Brake hose union bolt

ECB01320

NOTICE

Brake hose union bolt

Brake fluid may damage painted surfaces

27 Nm (2.7 m·kgf, 20 ft·lbf)

and plastic parts. Therefore, always clean up

any spilt brake fluid immediately.

4-35

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

REAR BRAKE

EBS20098

REAR BRAKE

Removing the brake pedal

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

New

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

New

Order

Job/Parts to remove

Q’ty

Remarks

Refer to “GENERAL CHASSIS (1)” on page

Seat/Top cover/Side panels

4-1.

Refer to “GENERAL CHASSIS (3)” on page

Front fender inner panel (right)

4-8.

Refer to “GENERAL CHASSIS (4)” on page

Footrest board (right)

4-11.

Brake pedal cable

Disconnect.

Brake pedal spring

Brake pedal

4-37

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

REAR BRAKE

Removing the rear brake pads

5 Nm (0.5 m•kgf, 3.6 ft•Ibf)

2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

30 Nm (3.0 m•kgf, 22 ft•Ibf)

17 Nm (1.7 m•kgf, 12 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

The following procedure applies to both of

the rear brake calipers.

Rear wheel

Refer to “REAR WHEELS” on page 4-23.

Rear brake caliper bolt

Brake pad holding bolt plug

Brake pad holding bolt

Rear brake pad

Brake pad spring

4-38

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

REAR BRAKE

Removing the rear brake master cylinder

1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

New

6 Nm (0.6 m•kgf, 4.3 ft•Ibf)

1.2 Nm (0.12 m•kgf, 0.87 ft•Ibf)

New

6 Nm (0.6 m•kgf, 4.3 ft•Ibf)

27 Nm (2.7 m•kgf, 20 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

Drain.

Brake fluid

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” on page 3-14.

Brake fluid reservoir cap

Brake fluid reservoir diaphragm holder

Brake fluid reservoir diaphragm

Shift control cable

Disconnect.

Rear brake cable

Disconnect.

Brake lever

Brake lever bracket

Union bolt

Copper washer

Rear brake hose

Disconnect.

Rear brake light switch connector

Disconnect.

Rear brake light switch

Rear brake master cylinder holder

Rear brake master cylinder

4-39

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

REAR BRAKE

Removing the rear brake calipers

2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

17 Nm (1.7 m•kgf, 12 ft•Ibf)

30 Nm (3.0 m•kgf, 22 ft•Ibf)

27 Nm (2.7 m•kgf, 20 ft•Ibf)

2 New

Order

Job/Parts to remove

Q’ty

Remarks

The following procedure applies to both of

the rear brake calipers.

Drain.

Brake fluid

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” on page 3-14.

Rear wheel

Union bolt

Copper washer

Rear brake hose

Disconnect.

Brake pad holding bolt plug

Brake pad holding bolt

Loosen.

Rear brake caliper bolt

Rear brake caliper assembly

4-41

Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 8