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Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 10

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TIE-RODS AND STEERING KNUCKLES

EBS30401

2. Check:

REMOVING THE STEERING KNUCKLES

• Front wheel bearing “1”

The following procedure applies to both of the

Rough movement/excessive free play → Re-

steering knuckles.

place.

1. Remove:

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

• Steering knuckle “1”

a. Clean the surface of the steering knuckle.

TIP

b. Remove the circlip “2”.

Use a general puller to separate the ball joints

c. Drive out the bearing.

EWB03790

“2” from the steering knuckle “1” or the front low-

WARNING

er arm “3”.

Eye protection is recommended when using

striking tools.

2

1

EBS30402

CHECKING THE TIE-RODS

d. Apply lithium-soap-based grease to the balls

The following procedure applies to both of the

of the new bearing.

tie-rods.

e. Install the new bearing.

1. Check:

ECB02650

• Tie-rod movement

NOTICE

Rough movement → Replace the tie-rod end.

Do not strike the center race or balls of the

2. Check:

bearing. Contact should be made only with

• Tie-rod

the outer race.

Bends/damage → Replace.

Rubber boot damage → Replace the tie-rod

f. Install a new circlip.

end.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EBS30404

CHECKING THE STEERING KNUCKLE BALL

JOINTS

The following procedure applies to both of the

steering knuckle ball joints.

1. Check:

• Ball joint (steering knuckle)

Damage/pitting → Replace the ball joint.

Rubber boot damage → Replace the ball

joint.

EBS30403

Rough movement → Replace the ball joint.

CHECKING THE STEERING KNUCKLES

AND FRONT WHEEL BEARINGS

The following procedure applies to both of the

steering knuckles and front wheel bearings.

1. Check:

• Steering knuckle

Damage/pitting → Replace.

4-62

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TIE-RODS AND STEERING KNUCKLES

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a. Clean the surface of the steering knuckle.

Ball joint remover

b. Remove the circlip “1”.

90890-01474

Ball joint remover

YM-01474

Ball joint remover attachment set

90890-01480

Ball joint adapter set

YM-01480

Ball joint installer attachment

38mm

90890-01583

1

Ball joint installer attachment

38mm

c. Remove the ball joint “2”.

YM-01583

Ball joint remover short shaft set

TIP

90890-01514

Use a suitable socket “3” to separate the ball

Ball joint remover short shaft set

joint “2” from the steering knuckle “4”.

YM-01514

No.

Tool name

Tool No.

90890-01474

6

Body

YM-01474

4

7

Installer spacer

90890-01480

YM-01480

8

Base

Ball joint installer at-

90890-01583

9

3

tachment 38mm

YM-01583

2

10

Guide bolt

90890-01514

d. Measure the ball joint bore inside diameter

11

Short bolt

YM-01514

“a”.

Out of specification → Replace the steering

knuckle.

Ball joint bore inside diameter

32.45-32.50 mm (1.278-1.280 in)

9

8

10

6

9

5

4

8

a

11

e. Attach the special tools and new ball joint “5”

to the steering knuckle “4”.

TIP

7

• Always use a new ball joint.

10

• Do not tap or damage the top of the ball joint.

f. Hold the base “8” in place while turning in the

short bolt “11” to install the new ball joint “5”

into the steering knuckle “4”.

g. Remove the special tools.

4-63

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TIE-RODS AND STEERING KNUCKLES

h. Install a new circlip.

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a

EBS30405

INSTALLING THE TIE-RODS

1

The following procedure applies to both of the

tie-rods.

1. Install:

a

• Tie-rod

Steering knuckle and tie-rod nut

b

25 Nm (2.5 m·kgf, 18 ft·lbf)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Pitman arm and tie-rod nut

25 Nm (2.5 m·kgf, 18 ft·lbf)

TIP

Install the tie-rod so that the groove “1” is on the

wheel side.

2. Adjust:

• Toe-in

Refer to “ADJUSTING THE TOE-IN” on page

3-21.

EBS30406

INSTALLING THE FRONT ARM

PROTECTORS

The following procedure applies to both of the

front arm protectors.

1. Install:

• Front arm protector “1”

Front arm protector bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Fit the holders “a” on the front arm protector

onto the lower arm.

b. Tighten the bolt “b”.

4-64

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FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES

EBS20031

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES

Removing the front arms and front shock absorber assemblies

45 Nm (4.5 m•kgf, 33 ft•Ibf)

5

5

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

55 Nm (5.5 m•kgf, 40 ft•Ibf)

3

LS

7

7

7

7

9

8

9

9

New

3

LS

9

New

4

New

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

6

30 Nm (3.0 m•kgf, 22 ft•Ibf)

5

1

2

5

45 Nm (4.5 m•kgf, 33 ft•Ibf)

30 Nm (3.0 m•kgf, 22 ft•Ibf)

4

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

New

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

The following procedure applies to both of

the front upper arms, front lower arms, and

front shock absorber assemblies.

Front wheel hub

Refer to “FRONT WHEELS” on page 4-20.

Front brake caliper assembly

Refer to “FRONT BRAKE” on page 4-26.

1

Brake disc guard

1

2

Front arm protector

1

3

Front brake hose holder

2

4

Nut

2

5

Nut/Bolt

2/2

6

Front shock absorber assembly

1

7

Nut/Washer/Bolt

2/2/2

8

Front upper arm

1

9

Nut/Bolt

2/2

4-65

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FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES

Removing the front arms and front shock absorber assemblies

45 Nm (4.5 m•kgf, 33 ft•Ibf)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

55 Nm (5.5 m•kgf, 40 ft•Ibf)

LS

12

12

14

New

13

LS

New

New

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

11

11

30 Nm (3.0 m•kgf, 22 ft•Ibf)

12

12

45 Nm (4.5 m•kgf, 33 ft•Ibf)

10

30 Nm (3.0 m•kgf, 22 ft•Ibf)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

New

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

10

Front lower arm

1

11

Dust cover

2

12

Bushing

4

13

Circlip

1

14

Ball joint

1

4-66

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FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES

EBS30113

• Front shock absorber rod

CHECKING THE FRONT ARMS

Bends/damage → Replace the front shock

The following procedure applies to both of the

absorber assembly.

front upper arms and front lower arms.

• Spring

1. Check:

Move the spring up and down.

• Front arm free play

Fatigue → Replace the front shock absorber

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

assembly.

a. Check the front arm side play “A” by moving

it from side to side.

EBS30117

If side play is noticeable, check the bushings.

CHECKING THE FRONT ARM BALL JOINTS

The following procedure applies to both of the

front arm ball joints.

1. Check:

• Ball joint (front upper arm)

Damage/pitting → Replace the ball joint.

A

Rubber boot damage → Replace the ball

joint.

Rough movement → Replace the ball joint.

A

b. Check the front arm vertical movement “B” by

moving it up and down.

If the vertical movement is tight or rough, or if

there is binding, check the bushings.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

B

a. Clean the surface of the front upper arm.

b. Remove the circlip “1”.

B

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2. Check:

• Front upper arm

• Front lower arm

Bends/damage → Replace.

1

3. Check:

• Bushings

c. Remove the ball joint “2”.

Wear/damage → Replace.

TIP

EBS30116

Use the suitable socket “3” to separate the ball

CHECKING THE FRONT SHOCK ABSORBER

joint “2” from the front upper arm “4”.

ASSEMBLIES

The following procedure applies to both of the

front shock absorber assemblies.

1. Check:

• Front shock absorber assembly

Oil leaks → Replace the front shock absorber

assembly.

4-67

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FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES

6

7

4

8

8

9

2

3

5

4

12

d. Attach the special tools and new ball joint “5”

e. Hold the base “12” in place while turning in

to the front upper arm “4”.

the long bolt “6” to install the new ball joint “5”

TIP

into the front upper arm “4”.

• Always use a new ball joint.

f. Remove the special tools.

• Do not tap or damage the top of the ball joint.

g. Install a new circlip.

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Ball joint remover

EBS30118

90890-01474

INSTALLING THE FRONT ARMS AND

Ball joint remover

FRONT SHOCK ABSORBER ASSEMBLIES

YM-01474

The following procedure applies to both of the

Ball joint remover attachment set

front upper arms, front lower arms, and front

90890-01480

shock absorber assemblies.

Ball joint adapter set

1. Install:

YM-01480

• Front upper arm

• Front lower arm

No.

Tool name

Tool No.

• Front shock absorber assembly

6

Long bolt

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Install the front upper arm “1” and front lower

7

Body

90890-01474

arm “2”.

YM-01474

8

Guide bolt

TIP

9

Remover attachment

• Lubricate the front upper and lower arm bolts

10

Installer spacer

“3” with lithium-soap-based grease.

90890-01480

11

Installer washer

• Be sure to position the front upper and lower

YM-01480

arm bolts “3” so that the bolt heads face for-

12

Base

ward.

• Install the washers “4”.

9

• Temporarily tighten the front upper and lower

10

8

7

arm nuts “5”.

b. Install the front shock absorber assembly “6”,

11

6

bolts “7”, and nuts “8”.

Front shock absorber assembly

nut

12

45 Nm (4.5 m·kgf, 33 ft·lbf)

c. Install the steering knuckle, upper steering

knuckle nut “9”, and lower steering knuckle

nut “10”.

4-68

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FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES

b. Tighten the bolt “b”.

Steering knuckle and front upper

arm nut

30 Nm (3.0 m·kgf, 22 ft·lbf)

a

Steering knuckle and front lower

arm nut

1

30 Nm (3.0 m·kgf, 22 ft·lbf)

a

d. Install the new cotter pins.

e. Tighten the front upper and lower arm nuts

“5” to specification.

b

Front upper arm nut

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55 Nm (5.5 m·kgf, 40 ft·lbf)

Front lower arm nut

55 Nm (5.5 m·kgf, 40 ft·lbf)

7,8

6

1

3,4,5

9

7,8

3,5

2

10

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EBS30407

INSTALLING THE FRONT ARM

PROTECTORS

The following procedure applies to both of the

front arm protectors.

1. Install:

• Front arm protector “1”

Front arm protector bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Rear arm protector nut

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Fit the holders “a” on the front arm protector

onto the lower arm.

4-69

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REAR KNUCKLES AND STABILIZER

EBS20032

REAR KNUCKLES AND STABILIZER

Removing the rear knuckles and stabilizer

56 Nm (5.6 m•kgf, 41 ft•Ibf)

30 Nm (3.0 m•kgf, 22 ft•Ibf)

10

10

11

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

9

11

3

12

9

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

LS

LS

5

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

6

5

5

LS

2

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

8

4

1

6

5

45 Nm (4.5 m•kgf, 33 ft•Ibf)

7

New

56 Nm (5.6 m•kgf, 41 ft•Ibf)

45 Nm (4.5 m•kgf, 33 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

The following procedure applies to both of

the rear knuckles.

Rear wheel hub

Refer to “REAR WHEELS” on page 4-23.

1

Brake disc guard

1

2

Rear arm protector

1

3

Rear brake disc cleaning plate

1

4

Rear knuckle

1

5

Spacer cover

4

6

Spacer

2

7

Circlip

1

8

Wheel bearing

1

9

Stabilizer joint

2

10

Stabilizer holder

2

11

Bushing

2

12

Stabilizer

1

4-70

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REAR KNUCKLES AND STABILIZER

EBS30119

CHECKING THE REAR KNUCKLES AND

Rear arm protector bolt

REAR WHEEL BEARINGS

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

The following procedure applies to both of the

Rear arm protector nut

rear knuckles and rear wheel bearings.

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

1. Check:

• Rear knuckle

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Fit the holders “a” on the rear arm protector

Damage/pitting → Replace.

onto the lower arm.

2. Check:

b. Tighten the bolts “b”

• Rear wheel bearing “1”

c. Tighten the nut “c”

Rough movement/excessive free play → Re-

place.

a

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

c

1

a. Clean the surface of the rear knuckle.

b. Remove the circlip “2”.

c. Drive out the bearing.

EWB03790

a

WARNING

Eye protection is recommended when using

striking tools.

b

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2

1

d. Apply lithium-soap-based grease to the bear-

ing.

e. Install the new bearing.

ECB02650

NOTICE

Do not strike the center race or balls of the

bearing. Contact should be made only with

the outer race.

f. Install the new circlip.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EBS30120

CHECKING THE STABILIZER

1. Check:

• Stabilizer

Bends/cracks/damage → Replace.

EBS30408

INSTALLING THE REAR ARM PROTECTORS

The following procedure applies to both of the

rear arm protectors.

1. Install:

• Rear arm protector “1”

4-71

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REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES

EBS20033

REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES

Removing the rear arms and rear shock absorber assemblies

55 Nm (5.5 m•kgf, 40 ft•Ibf)

45 Nm (4.5 m•kgf, 33 ft•Ibf)

2

4

2

LS

7

4

4

7

4

6

10

LS

1

7

10

7

5

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

9

10

3

9

55 Nm (5.5 m•kgf, 40 ft•Ibf)

2

10

8

2

45 Nm (4.5 m•kgf, 33 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

The following procedure applies to both of

the rear upper arms, rear lower arms, and

rear shock absorber assemblies.

Refer to “REAR KNUCKLES AND STABI-

Rear knuckle/Stabilizer

LIZER” on page 4-70.

1

Rear brake hose guide

1

2

Nut/Washer/Bolt

2/1/2

3

Rear shock absorber assembly

1

4

Nut/Washer/Bolt

2/2/2

5

Rear upper arm

1

6

Dust cover

1

7

Nut/Bolt

2/2

8

Rear lower arm

1

9

Dust cover

2

10

Bushing

4

4-72

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REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES

EBS30122

• Rear shock absorber rod

CHECKING THE REAR ARMS

Bends/damage → Replace the rear shock

The following procedure applies to both of the

absorber assembly.

rear upper arms and rear lower arms.

• Spring

1. Check:

Move the spring up and down.

• Rear arm free play

Fatigue → Replace the rear shock absorber

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

assembly.

a.

Check the rear arm side play “A” by moving it

from side to side.

EBS30126

If side play is noticeable, check the bushings.

INSTALLING THE REAR ARMS AND REAR

SHOCK ABSORBER ASSEMBLIES

The following procedure applies to both of the

rear upper arms, rear lower arms, and rear

shock absorber assemblies.

1. Install:

• Rear upper arm

• Rear lower arm

A

• Rear shock absorber assembly

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

A

a. Install the rear upper arm “1” and rear lower

arm “2”.

b.

Check the rear arm vertical movement “B” by

TIP

moving it up and down.

If the vertical movement is tight or rough, or if

• Lubricate the rear upper and lower arm bolts

there is binding, check the bushings.

“3” with lithium-soap-based grease.

• Be sure to position the rear upper and lower

arm bolts “3” so that the bolt heads face out-

ward.

• Installed the washers “4”.

• Temporarily tighten the rear upper and lower

arm nuts “5”.

B

b. Install the rear shock absorber assembly “6”,

bolts “7”, washer “8”,and nuts “9”.

B

Rear shock absorber assembly

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

nut

2. Check:

45 Nm (4.5 m·kgf, 33 ft·lbf)

• Rear upper arm

c. Install the rear knuckle and nuts “10”.

• Rear lower arm

Bends/damage → Replace.

Rear knuckle nut

3. Check:

45 Nm (4.5 m·kgf, 33 ft·lbf)

• Bushings

Wear/damage → Replace.

d. Tighten the rear upper and lower arm nuts “5”

EBS30125

to specification.

CHECKING THE REAR SHOCK ABSORBER

Rear upper arm nut

ASSEMBLIES

55 Nm (5.5 m·kgf, 40 ft·lbf)

The following procedure applies to both of the

Rear lower arm nut

rear shock absorber assemblies.

55 Nm (5.5 m·kgf, 40 ft·lbf)

1. Check:

• Rear shock absorber assembly

Oil leaks → Replace the rear shock absorber

assembly.

4-73

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REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES

7, 9

6

3, 4, 5

1

10

3, 5

10

7, 8, 9

2

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4-74

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ENGINE INSPECTION

EBS20105

7. Measure:

ENGINE INSPECTION

• Compression pressure

Out of specification → Refer to steps (b) and

EBS30135

MEASURING THE COMPRESSION

(c).

PRESSURE

Standard compression pressure

TIP

(at sea level)

Insufficient compression pressure will result in a

650-1000 kPa (6.5-10.0 kgf/cm²,

loss of performance.

92.4-142.2 psi)

1. Measure:

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

• Valve clearance

a. With the throttle wide open, crank the engine

Out of specification → Adjust.

by pushing the start switch “

” until the read-

Refer to “ADJUSTING THE VALVE CLEAR-

ing on the compression gauge stabilizes.

ANCE” on page 3-5.

EWB03200

2. Start the engine, warm it up for several min-

WARNING

utes, and then turn it off.

To prevent sparking, ground the spark plug

3. Remove:

lead before cranking the engine.

• Top cover

b. If the compression pressure is above the

• Side panel (right)

maximum specification, check the cylinder

• Storage compartment

head, valve surfaces and piston crown for

Refer to “GENERAL CHASSIS (2)” on page

carbon deposits.

4-6.

Carbon deposits → Eliminate.

4. Disconnect:

c. If the compression pressure is below the min-

• Spark plug cap

imum specification, pour a teaspoonful of en-

5. Remove:

gine oil into the spark plug bore and measure

• Spark plug

again.

ECB01870

NOTICE

Refer to the following table.

Compression pressure (with oil applied into the

Before removing the spark plug, use com-

cylinder)

pressed air to blow away any dirt accumulat-

ed in the spark plug well to prevent it from

Reading

Diagnosis

falling into the cylinder.

Piston ring(s) wear or

Higher than without oil

damage → Repair.

6. Install:

Piston, valves, cylinder

• Extension “1”

head gasket, or piston

• Compression gauge “2”

Same as without oil

ring(s) possibly defec-

tive → Repair.

Extension

90890-04136

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Compression gauge

8. Install:

90890-03081

• Spark plug

Engine compression tester

YU-33223

Spark plug (reused)

Specified angle 30°-45°

TIP

2

Before installing the spark plug, clean the spark

plug and gasket surface.

1

9. Connect:

• Spark plug cap

10.Install:

• Storage compartment

• Side panel (right)

5-1

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ENGINE REMOVAL (1)

EBS20034

ENGINE REMOVAL (1)

Removing the V-belt cooling ducts, muffler and exhaust pipe

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

33 Nm (3.3 m•kgf, 24 ft•Ibf)

20 Nm (2.0 m•kgf, 14 ft•Ibf)

5

7

6

10

9

New

8

6

11

New

20 Nm (2.0 m•kgf, 14 ft•Ibf)

1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

4

3

1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

1

2

1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

Refer to “GENERAL CHASSIS (3)” on page

Front fender/Rear fender

4-8.

Refer to “GENERAL CHASSIS (4)” on page

Footrest board (left)

4-11.

1

V-belt cooling exhaust duct

1

2

V-belt cooling exhaust duct joint

1

3

V-belt cooling intake duct joint

1

4

V-belt cooling intake duct

1

5

Exhaust pipe protector

1

6

Spring

2

7

Muffler

1

8

Gasket

1

9

Muffler bracket

1

10

Exhaust pipe

1

11

Gasket

1

5-3

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