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

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OIL PUMP SPROCKETS

EBS20114

OIL PUMP SPROCKETS

Removing the oil pump sprockets

25 Nm (2.5 m•kgf, 18 ft•Ibf)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

Refer to “AC MAGNETO AND STARTER

AC magneto rotor

CLUTCH” on page 5-35.

Timing chain stopper guide (lower)

Oil pump driven sprocket

Washer

Oil pump drive sprocket

Chain

5-44

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OIL PUMP SPROCKETS

EBS30524

TIP

REMOVING THE OIL PUMP DRIVE

Install the oil pump drive sprocket so that the

SPROCKET AND OIL PUMP DRIVEN

SPROCKET

protruding portion “a” of the sprocket is facing to-

ward the crankcase.

1. Loosen:

• Oil pump driven sprocket nut “1”

• Oil pump drive sprocket nut “2”

2. Install:

• Washer “1”

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

• Oil pump drive sprocket nut

a. Temporarily install the AC magneto rotor.

TIP

Refer to “AC MAGNETO AND STARTER

CLUTCH” on page 5-35.

Install the washer with its rounded side “a” facing

b. Hold the AC magneto rotor “3” with the rotor

away from the crankcase.

holding tool “4” while loosening the oil pump

driven sprocket nut and oil pump drive

sprocket nut.

Rotor holding tool

90890-04166

YM-04166

3. Install:

• Oil pump driven sprocket “1”

• Chain “2”

• Oil pump driven sprocket nut

TIP

Install the oil pump driven sprocket with the

“23A” mark “a” facing out.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EBS30525

CHECKING THE OIL PUMP SPROCKETS

1. Check:

• Oil pump drive sprocket

• Oil pump driven sprocket

Cracks/wear/damage → Replace.

EBS30526

INSTALLING THE OIL PUMP DRIVE

SPROCKET AND OIL PUMP DRIVEN

SPROCKET

4. Tighten:

1. Install:

• Oil pump drive sprocket nut “1”

• Oil pump drive sprocket “1”

• Oil pump driven sprocket nut “2”

5-45

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OIL PUMP SPROCKETS

Oil pump drive sprocket nut

25 Nm (2.5 m·kgf, 18 ft·lbf)

LOCTITE®

Oil pump driven sprocket nut

25 Nm (2.5 m·kgf, 18 ft·lbf)

LOCTITE®

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Temporarily install the AC magneto rotor.

Refer to “AC MAGNETO AND STARTER

CLUTCH” on page 5-35.

b. Hold the AC magneto rotor “3” with the rotor

holding tool “4” while tightening the oil pump

drive sprocket nut and oil pump driven

sprocket nut.

Rotor holding tool

90890-04166

YM-04166

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5-46

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SHIFT LEVER

EBS20042

SHIFT LEVER

Removing the shift levers and stopper lever

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

New

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

14 Nm (1.4 m•kgf, 10 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

Refer to “ENGINE REMOVAL (2)” on page

Drive select lever unit/shift arm

5-6.

Shift lever cover

Shift lever cover gasket

Dowel pin

Oil seal

Shift lever 1

Stopper lever spring

Shift lever 2

Stopper lever

5-47

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SHIFT LEVER

EBS30163

CHECKING THE STOPPER LEVER

1. Check:

• Stopper lever

Damage/wear → Replace.

• Stopper lever spring

Damage/wear → Replace.

EBS30164

CHECKING THE SHIFT LEVERS

1. Check:

• Shift lever 1

3. Install:

• Shift lever 2

• Shift lever 1 “1”

Damage/wear → Replace.

TIP

EBS30165

When installing shift lever 1, align the alignment

INSTALLING THE SHIFT LEVERS

mark “a” on shift lever 1 with the punch marks “b”

1. Install:

on shift lever 2 “2”.

• Collar “1” (onto the stopper lever “2”)

• Shift lever 2 “3”

• Washer “4”

• Stopper spring “5”

TIP

• Make sure the projection “a” on the stopper le-

ver “2” facing toward the collar.

• Install the shift lever 2 “3” with the marks “b”

facing the stopper spring.

Install:

• Oil seal “1”

New

(into the shift lever cover “2”)

Installed depth “a”

1.0-1.5 mm (0.04-0.06 in)

2. Install:

New

• Shift lever 2 assembly “1”

Shift lever 2 bolt

14 Nm (1.4 m·kgf, 10 ft·lbf)

TIP

Align the projection “a” on the shift drum with the

slit “b” in the stopper lever.

5-48

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PRIMARY AND SECONDARY SHEAVES

EBS20043

PRIMARY AND SECONDARY SHEAVES

Removing the primary and secondary sheaves

New

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

New

100 Nm (10.0 m•kgf, 72 ft•Ibf)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

(8)

New

(11)

140 Nm (14 m•kgf, 100 ft•lbf)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

Refer to “GENERAL CHASSIS (4)” on page

Footrest board (right)

4-11.

Refer to “ENGINE REMOVAL (1)” on page

V-belt cooling ducts

5-3.

Drive belt cover

Rubber gasket

Bearing housing

Dowel pin

Primary sheave assembly

V-belt

Primary fixed sheave

Secondary sheave assembly

Drive belt case

Rubber gasket

5-49

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PRIMARY AND SECONDARY SHEAVES

EBS30167

REMOVING THE PRIMARY AND

Sheave fixed block

SECONDARY SHEAVES

90890-04135

1. Loosen:

Sheave fixed bracket

• Primary sheave assembly nut “1”

YM-04135

Locknut wrench

TIP

90890-01348

Use the rotor holding tool “2” to hold the primary

Locknut wrench

sheave.

YM-01348

Sheave spring compressor

Rotor holding tool

90890-04134

90890-04166

Sheave spring compressor

YM-04166

YM-04134

Place the sheave fixed block in a vise and se-

cure it.

Tighten the sheave spring compressor nut “5”

and compress the spring.

Loosen the secondary sheave spring retain-

ing nut “1” with the locknut wrench “3”.

Remove the secondary sheave spring retain-

ing nut “1”.

Remove the sheave spring compressor and

locknut wrench.

2. Loosen:

• Secondary sheave assembly nut “1”

TIP

Shift the transmission into “R” (reverse), set the

parking brake, and then loosen the secondary

sheave assembly nut.

EBS30168

DISASSEMBLING THE SECONDARY

SHEAVE

1. Remove:

• Secondary sheave spring retaining nut “1”

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Attach the sheave fixed block “2”, locknut

wrench “3” and sheave spring compressor “4”

to the secondary sheave assembly.

5-52

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PRIMARY AND SECONDARY SHEAVES

2. Check:

• Primary sliding sheave

• Primary fixed sheave

Cracks/damage → Replace.

EBS30171

CHECKING THE PRIMARY SHEAVE

WEIGHTS

The following procedure applies to all of the pri-

mary sheave weights.

1. Check:

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

• Primary sheave weight

EBS30169

Cracks/damage/wear → Replace.

CHECKING THE V-BELT

2. Measure:

1. Check:

• Primary sheave weight outside diameter “a”

• V-belt “1”

Out of specification → Replace.

Cracks/damage/wear → Replace.

Primary sheave weight outside

Grease/oil → Clean the primary and second-

diameter

ary sheaves.

30 mm (1.18 in)

2. Measure:

Limit

• V-belt width “a”

29.5 mm (1.16 in)

Out of specification → Replace.

V-belt width limit

31.3 mm (1.23 in)

EBS30172

CHECKING THE PRIMARY SHEAVE

SLIDERS

The following procedure applies to all of the pri-

EBS30170

mary sheave sliders.

CHECKING THE PRIMARY SHEAVE

1. Check:

• Primary sheave slider

• Primary sliding sheave splines

Cracks/damage/wear → Replace.

Wear/cracks/damage → Replace.

• Primary sheave cam

EBS30173

Cracks/damage → Replace.

CHECKING THE SECONDARY SHEAVE

1. Check:

• Secondary fixed sheave

• Secondary sliding sheave

Cracks/damage/wear → Replace the sec-

ondary fixed and sliding sheaves as a set.

2. Check:

• Torque cam grooves “1”

Damage/wear → Replace the secondary

fixed and sliding sheaves as a set.

5-53

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PRIMARY AND SECONDARY SHEAVES

3. Check:

• Guide pins “2”

Damage/wear → Replace the secondary

fixed and sliding sheaves as a set.

2. Install:

• Oil seals “1”

New

(into the primary sliding sheave “2”)

Check:

Installed depth “a”

• Secondary sheave spring

0 mm (0 in)

Damage → Replace.

Measure:

New

• Secondary sheave spring free length “a”

Out of specification → Replace the second-

ary sheave spring.

Free length

130.6 mm (5.14 in)

Limit

128.0 mm (5.04 in)

New

3. Lubricate:

• Spacer inner surface

• Primary sliding sheave inner surface

Recommended lubricant

Yamaha Grizzly grease or

Yamaha grease F

TIP

• Apply Yamaha Grizzly grease or Yamaha

EBS30174

grease F (2.5 g) to the inner surface of the

ASSEMBLING THE PRIMARY SHEAVE

spacer.

1. Clean:

• Apply Yamaha Grizzly grease or Yamaha

• Primary sliding sheave “1”

grease F (2.5 g) to the inner surface of the pri-

• Spacer “2”

mary sliding sheave.

• Primary sheave weights “3”

• Primary sheave cam

TIP

Remove any excess grease.

5-54

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PRIMARY AND SECONDARY SHEAVES

4. Install:

• Primary sheave weights “1”

TIP

Apply Yamaha Grizzly grease or Yamaha

grease F (90 g) to the whole outer surface of the

weights and install.

3. Install:

• Secondary sliding sheave

4. Install:

• Guide pins “1”

EBS30175

ASSEMBLING THE SECONDARY SHEAVE

1. Install:

• Oil seals “1”

New

(into the secondary sliding sheave “2”)

Installed depth “a”

0 mm (0 in)

5. Lubricate:

• Guide pin grooves “1”

(with the recommended lubricant)

New

Recommended lubricant

Yamaha grease H or POLYREX

EM®

TIP

Apply Yamaha grease H or POLYREX EM® (5.0

New

g) to the guide pin grooves.

2. Lubricate:

• Secondary sliding sheave “1”

• Secondary fixed sheave “2”

(with the recommended lubricant)

Recommended lubricant

Yamaha grease H or POLYREX

EM®

TIP

Apply Yamaha grease H or POLYREX EM® (15

6. Install:

g) to the inner surfaces of the secondary

• Lower spring seat “1”

sheaves.

• Compression spring “2”

• Upper spring seat “3”

• Secondary sheave spring retaining nut “4”

5-55

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PRIMARY AND SECONDARY SHEAVES

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

Attach the sheave fixed block “5”, locknut

wrench “6” and sheave spring compressor “7”

to the secondary sheave.

Sheave fixed block

90890-04135

Sheave fixed bracket

YM-04135

Locknut wrench

90890-01348

Locknut wrench

e. Remove the sheave spring compressor, lock-

YM-01348

nut wrench, and sheave fixed block.

Sheave spring compressor

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

90890-04134

Sheave spring compressor

EBS30176

INSTALLING THE PRIMARY AND

YM-04134

SECONDARY SHEAVES

Place the sheave fixed block in a vise and se-

1. Install:

cure it.

• Secondary sheave

Tighten the sheave spring compressor nut “8”

• V-belt

and compress the spring.

• Primary fixed sheave

Install the secondary sheave spring retaining

• Primary sheave

nut “4” and tighten it to specification using the

• Washer

locknut wrench.

• Nuts

TIP

Secondary sheave spring retain-

• Be sure to push in the primary sheave cam “1”

ing nut

when installing the primary sheave so that the

90 Nm (9.0 m·kgf, 65 ft·lbf)

primary sheave weights “2” will be properly po-

sitioned “a”.

TIP

• Install the washer “3” with its rounded side “b”

Install the secondary sheave spring retaining nut

facing away from the primary shave assembly.

“4” with its tapered side “a” facing the secondary

• Tightening the bolts “4” (90101-06016) will

sheaves.

push the secondary sliding sheave away,

causing the gap between the secondary fixed

and sliding sheaves to widen.

• Install the V-belt so that its arrow points in the

direction of rotation as shown in the illustration.

5-56

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PRIMARY AND SECONDARY SHEAVES

A. Correct position

B. Incorrect position

3. Tighten:

• Primary sheave assembly nut “1”

Primary sheave assembly nut

140 Nm (14 m·kgf, 100 ft·lbf)

TIP

Use the rotor holding tool “2” to hold the primary

sheave.

2. Check:

• Primary sheave weights position

Rotor holding tool

Out of specification → Repeat step (1).

90890-04166

TIP

YM-04166

To check that the primary sheave weights “1”

are installed correctly, make sure that the sec-

ondary sheave “2”, primary sheave “3”, and V-

belt “4” are positioned as shown in the illustra-

tion.

4. Tighten:

• Secondary sheave assembly nut “1”

Secondary sheave assembly nut

100 Nm (10 m·kgf, 72 ft·lbf)

5-57

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PRIMARY AND SECONDARY SHEAVES

TIP

Shift the transmission into “L” (low) or “H” (high),

set the parking brake, and then tighten the sec-

ondary sheave assembly nut.

5. Lubricate:

• Bearing housing bearing inner surface and

ball

(with the recommended lubricant)

Recommended lubricant

Shell Sunlight Grease 3®

TIP

Apply 2.3 g or more of Shell Sunlight Grease 3®

to the bearing inner surface and ball as shown in

the illustration.

5-58

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CLUTCH

EBS20044

CLUTCH

Removing the clutch

190 Nm (19 m•kgf, 137 ft•lbf)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

New

(7)

Order

Job/Parts to remove

Q’ty

Remarks

Refer to “PRIMARY AND SECONDARY

Drive belt case

SHEAVES” on page 5-49.

Clutch housing assembly

Clutch housing assembly gasket

Dowel pin

Clutch carrier assembly nut

Left-hand thread

Clutch carrier assembly

5-59

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CLUTCH

EBS30177

• One-way clutch bearing

REMOVING THE CLUTCH

Chafing/wear/damage → Replace.

1. Remove:

TIP

• Clutch housing assembly

• Replace the one-way clutch bearing and clutch

TIP

housing as a set.

Working in crisscross pattern, loosen each bolt

• The one-way clutch bearing must be installed

1/4 of a turn. Remove them after all of them are

with the flange side facing inward.

loosened.

2. Check:

• One-way clutch operation

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Install the one-way clutch bearing and clutch

carrier assembly to the clutch housing and

hold the clutch carrier assembly.

b. When turning the clutch housing clockwise

“A”, it should turn freely; otherwise, the one-

way clutch assembly is faulty and must be re-

placed.

c. When turning the clutch housing counter-

2. Straighten:

clockwise “B”, the clutch housing and crank-

• Punched portion “a” of the clutch carrier as-

shaft should engage; otherwise, the one-way

sembly nut “1”

clutch assembly is faulty and must be re-

3. Remove:

placed.

• Clutch carrier assembly nut “1”

ECB01710

NOTICE

The clutch carrier assembly nut has left-

hand threads. To loosen the clutch carrier

assembly nut, turn it clockwise.

TIP

Use a universal clutch holder “2” to hold the

clutch carrier assembly.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Universal clutch holder

90890-04086

EBS30179

Universal clutch holder

CHECKING THE CLUTCH SHOE

YM-91042

1. Check:

• Clutch shoe

Damage/wear → Replace.

Glazed areas → Sand with coarse sandpa-

per.

TIP

After sanding the glazed areas, clean the clutch

with a cloth.

2. Measure:

• Clutch shoe thickness

Out of specification → Replace.

EBS30178

Clutch shoe thickness limit

CHECKING THE CLUTCH

1.0 mm (0.04 in)

1. Check:

• Clutch housing

Damage/wear → Replace.

5-61

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CLUTCH

New

a. Clutch shoe wear limit

EBS30181

INSTALLING THE CLUTCH

EBS30180

1. Install:

ASSEMBLING THE CLUTCH HOUSING

• Clutch carrier assembly

1. Install:

• Bearing “1”

• Clutch carrier assembly nut “1”

New

(into the clutch housing “2”)

Clutch carrier assembly nut

190 Nm (19 m·kgf, 137 ft·lbf)

Installed depth “a”

2.5-2.7 mm (0.10-0.11 in)

ECB01720

NOTICE

The clutch carrier assembly nut has left-

hand threads. To tighten the clutch carrier

assembly nut, turn it counterclockwise.

TIP

• Lubricate the threads of the clutch carrier as-

sembly nut with engine oil.

• Use a universal clutch holder “2” to hold the

clutch carrier assembly.

2. Install:

Universal clutch holder

• One-way clutch bearing

90890-04086

TIP

Universal clutch holder

The one-way clutch bearing should be installed

YM-91042

in the clutch housing with the “OUT SIDE” mark

2. Lock the threads with a drift punch.

“a” facing the clutch housing.

1 New

3. Install:

• Dowel pins “1”

• Oil seal “1”

New

• Gasket

New

(into the bearing housing “2”)

• Clutch housing assembly

Installed depth “a”

Clutch housing assembly bolt

0 mm (0 in)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

5-62

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Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 13