Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 14

 

  Главная      Manuals     Yamaha YF70GG, YF70GPG, YF70GPSG, YF70GPLG, YFM70GDXG, YFM70GDHG, YFM70GPXG, YFM70GPHG, YFM70GPSG, YFM70GPLG, YFM700FWAD. Service manual (2016)

 

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Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 14

 

 

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CRANKCASE
EBS20045
CRANKCASE
Separating the crankcase
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
17 Nm (1.7 m•kgf, 12 ft•Ibf)
18 Nm (1.8 m•kgf, 13 ft•Ibf)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
E
35 Nm (3.5 m•kgf, 25 ft•Ibf)
E
LT
New
New
New
E
New
E
New
New
New
22 Nm (2.2 m•kgf, 16 ft•Ibf)
35 Nm (3.5 m•kgf, 25 ft•Ibf)
3
New
30 Nm (3.0 m•kgf, 22 ft•Ibf)
E
2
1
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
26 Nm (2.6 m•kgf, 19 ft•Ibf)
E
LT
15 Nm (1.5 m•kgf, 11 ft•Ibf)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
Refer to “ENGINE REMOVAL (3)” on page
Engine
5-8.
Refer to “CYLINDER HEAD, CYLINDER,
Cylinder head/Piston
AND PISTON” on page 5-19.
Refer to “AC MAGNETO AND STARTER
AC magneto rotor
CLUTCH” on page 5-35.
Refer to “ELECTRIC STARTER” on page
Starter motor
5-40.
Refer to “OIL PUMP SPROCKETS” on page
Oil pump sprockets
5-44.
Shift levers
Refer to “SHIFT LEVER” on page 5-47.
Clutch carrier assembly
Refer to “CLUTCH” on page 5-59.
1
Oil filter cartridge
1
2
Oil filter cartridge union bolt
1
3
Adapter
1
5-64

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CRANKCASE
Separating the crankcase
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
17 Nm (1.7 m•kgf, 12 ft•Ibf)
18 Nm (1.8 m•kgf, 13 ft•Ibf)
10
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
E
35 Nm (3.5 m•kgf, 25 ft•Ibf)
9
E
LT
New
11
New
8
New
13
12
E
New
E
New
New
4
New
22 Nm (2.2 m•kgf, 16 ft•Ibf)
35 Nm (3.5 m•kgf, 25 ft•Ibf)
7
New
30 Nm (3.0 m•kgf, 22 ft•Ibf)
5
E
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
26 Nm (2.6 m•kgf, 19 ft•Ibf)
6
E
LT
15 Nm (1.5 m•kgf, 11 ft•Ibf)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
4
Oil pipe (crankcase)
1
5
Timing chain guide (intake side)
1
6
Timing chain
1
7
Speed sensor
1
8
Dipstick
1
9
Reverse switch
1
10
Gear position switch
1
11
Main gallery bolt
1
12
Crankcase (right)
1
13
Crankcase (left)
1
5-65

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CRANKCASE
Removing the crankcase bearings
1
2
New
3
LS
7
E
E
7
4
LT
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
E
7
7
E
7
5
6
7
E
E
E
Order
Job/Parts to remove
Q’ty
Remarks
Refer to “CRANKSHAFT AND OIL PUMP”
Crankshaft/Oil pump
on page 5-70.
Middle drive shaft/Middle driven shaft
Refer to “MIDDLE GEAR” on page 5-81.
Transmission
Refer to “TRANSMISSION” on page 5-75.
1
Collar
1
2
O-ring
1
3
Oil seal
1
4
Bearing retainer
1
5
Spacer
1
6
Crankshaft seal
2
7
Bearing
9
5-66

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CRANKCASE
EBS30182
SEPARATING THE CRANKCASE
2
1
1. Remove:
• Crankcase bolts
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
A
EBS30183
CHECKING THE TIMING CHAIN AND TIMING
CHAIN GUIDE
1. Check:
• Timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprocket as a set.
B
2. Check:
• Timing chain guide (intake side)
A. Crankcase (left)
Damage/wear → Replace.
B. Crankcase (right)
EBS30185
2. Remove:
CHECKING THE BEARINGS
• Crankcase (right) “1”
1. Check:
TIP
• Bearings
Clean and lubricate, then rotate the inner
• Remove the crankcase (right) with the crank-
race with a finger.
case separating tool “2”.
Roughness → Replace.
• Make sure the crankcase separating tool is
centered over the crankshaft.
ECB01880
NOTICE
• To protect the end of the crankshaft, place
an appropriate sized socket between the
crankcase separating tool bolt and the
crankshaft.
• Do not tap on the crankshaft.
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
5-67

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CRANKCASE
EBS30186
4. Fit the right crankcase onto the left crank-
CHECKING THE CRANKCASE
case. Tap lightly on the crankcase with a soft-
1. Thoroughly wash the crankcase halves in a
face hammer.
mild solvent.
ECB01730
2. Thoroughly clean all the gasket surfaces and
NOTICE
crankcase mating surfaces.
Before tightening the crankcase bolts, make
3. Check:
sure the transmission gears shift correctly
• Crankcase
when the shift drum assembly is turned by
Cracks/damage → Replace.
hand.
• Oil delivery passages
5. Install:
Obstruction → Blow out with compressed air.
• Crankcase bolts
EBS30187
6. Tighten:
ASSEMBLING THE CRANKCASE
• Crankcase bolts
1.
Install:
• Oil seal “1”
New
Crankcase bolt (M8)
(into the right crankcase “2”)
26 Nm (2.6 m·kgf, 19 ft·lbf)
Crankcase bolt (M6)
Installed depth “a”
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
0.5-1.0 mm (0.02-0.04 in)
M8 × 40 mm “1”
M6 × 90 mm “2”
1 New
M6 × 60 mm “3”
M6 × 30 mm “4”
a
TIP
Tighten the bolts in stages, using a crisscross
2
pattern.
A
2
3
4
2.
Thoroughly clean the crankcase mating sur-
faces.
3.
Apply:
• Sealant “1”
×3
×2
×1
(onto the crankcase mating surfaces)
Yamaha bond No. 1215
4
3
90890-85505
(Three bond No.1215®)
2
TIP
Do not allow any sealant to come into contact
with the oil gallery.
1
1
5-68

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CRANKCASE
B
1
3
4
×3
×2
×6
4
4
4
3
1
4
4
3
4
A. Crankcase (right)
B. Crankcase (left)
7. Apply:
• 4-stroke engine oil
(onto the crankshaft pin, bearings and oil de-
livery hole)
8. Check:
• Crankshaft and transmission operation
Rough operation → Repair.
9. Install:
• Gasket
New
• Oil cooler
• Oil filter cartridge union bolt
Refer to “INSTALLING THE OIL COOLER”
on page 6-3.
5-69

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CRANKSHAFT AND OIL PUMP
EBS20046
CRANKSHAFT AND OIL PUMP
Removing the crankshaft and oil pump
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
5
6
7
3
4
2
1
E
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
Separate.
Crankcase
Refer to “CRANKCASE” on page 5-64.
1
Oil pump
1
2
Crankshaft
1
3
Balancer
1
4
Bearing
1
5
Plug
1
6
Spring
1
7
Steel ball
1
5-70

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CRANKSHAFT AND OIL PUMP
Disassembling the oil pump
3
6
E
2
5
4
1
E
E
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
1
Oil pump housing cover
1
2
Pin
1
3
Oil pump shaft
1
4
Oil pump inner rotor
1
5
Oil pump outer rotor
1
6
Oil pump housing
1
5-71

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CRANKSHAFT AND OIL PUMP
EBS30188
REMOVING THE CRANKSHAFT
b
1. Remove:
1
• Crankshaft “1”
• Balancer “2”
TIP
• Remove the crankshaft with the crankcase
2
separating tool “3”.
a
• Make sure the crankcase separating tool is
3
centered over the crankshaft.
• Remove the crankshaft “1” and balancer “2” at
1. Inner rotor
the same time.
2. Outer rotor
ECB01880
3. Oil pump housing
NOTICE
3. Check:
• To protect the end of the crankshaft, place
• Oil pump operation
an appropriate sized socket between the
Rough movement → Replace the oil pump.
crankcase separating tool bolt and the
crankshaft.
• Do not tap on the crankshaft.
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
2
EBS30190
1
CHECKING THE OIL STRAINER
1. Check:
• Oil strainer
Damage → Replace the oil pump.
Contaminants → Clean with solvent.
EBS30184
3
CHECKING THE RELIEF VALVE
1. Check:
EBS30189
CHECKING THE OIL PUMP
• Steel ball “1”
1. Check:
• Spring “2”
• Oil pump
Damage/wear → Replace the defective
Cracks/damage/wear → Replace the oil
part(s).
pump.
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance
2
“b”
1
Inner-rotor-to-outer-rotor-tip
clearance limit
0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance limit
0.240 mm (0.0094 in)
5-72

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CRANKSHAFT AND OIL PUMP
EBS30191
CHECKING THE CRANKSHAFT
Recommended lubricant
1.
Measure:
Engine oil
• Crankshaft width “a”
Out of specification → Replace the crank-
2. Install:
shaft.
• Oil pump housing “1”
• Oil pump outer rotor “2”
Crank assembly width
• Oil pump inner rotor “3”
65.68-65.76 mm (2.586-2.589 in)
• Oil pump shaft “4”
• Pin “5”
2.
Measure:
TIP
• Crankshaft runout “b”
To install the oil pump shaft “4”, align the pin “5”
Out of specification → Replace the crank-
with the groove “a” in the inner rotor “3”.
shaft.
Runout limit
2
1
0.030 mm (0.0012 in)
3
a
3.
Measure:
• Big end side clearance “c”
Out of specification → Replace the crank-
a
shaft.
4
Big end side clearance
5
0.090-0.500 mm (0.0035-0.0197
in)
3. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-72.
c
EBS30193
b
b
INSTALLING THE CRANKSHAFT
1. Install:
• Balancer “1”
• Crankshaft “2”
ECB01890
NOTICE
a
Apply engine oil to each bearing to protect
4.
Check:
the crankshaft against scratches and to
• Crankshaft sprocket
make installation easier.
Damage/wear → Replace the crankshaft.
• Bearing
TIP
Cracks/damage/wear → Replace.
• Install the balancer “1” and crankshaft “2” at the
5.
Check:
same time.
• Crankshaft journal
• Align the hole “a” in the balancer with the
Scratches/wear → Replace the crankshaft.
punch mark “b” on the crankshaft.
• Crankshaft journal oil passage
• Install the crankshaft with the crankshaft in-
Obstruction → Blow out with compressed air.
staller pot “3”, crankshaft installer bolt “4”,
adapter (M16) “5”, and spacer (crankshaft in-
EBS30192
ASSEMBLING THE OIL PUMP
staller) “6”.
1. Lubricate:
• Hold the connecting rod at top dead center
• Inner rotor
(TDC) with one hand while turning the nut of
• Outer rotor
the crankshaft installer bolt with the other. Turn
• Oil pump shaft
the crankshaft installer bolt until the crankshaft
(with the recommended lubricant)
assembly bottoms against the bearing.
5-73

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CRANKSHAFT AND OIL PUMP
3
Crankshaft installer pot
90890-01274
Installing pot
1
YU-90058
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
2
Adapter (M16)
90890-04130
Adapter #13
YM-04059
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
1
a b
2
4
3
1
5
6
2
EBS30445
INSTALLING THE OIL PUMP
1. Install:
• Oil pump
Oil pump bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
Tighten the bolts to specification in the proper
tightening sequence as shown.
5-74

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TRANSMISSION
EBS20047
TRANSMISSION
Removing the transmission, shift drum and shift forks
1
18 Nm (1.8 m•kgf, 13 ft•Ibf)
New
2
New
3
E
E
E
4
E
E
E
New
E
E
9
5
8
E
E
7
6
M
New
M
Order
Job/Parts to remove
Q’ty
Remarks
Separate.
Crankcase
Refer to “CRANKCASE” on page 5-64.
Middle driven gear
Refer to “MIDDLE GEAR” on page 5-81.
1
Shift drum stopper bolt
1
2
Spring
1
3
Ball
1
4
Shift drum
1
5
Shift fork assembly
1
6
Shift fork “R”
1
7
Spring
1
8
Shift fork “L”
1
9
Shift fork guide bar
1
5-75

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

TRANSMISSION
Removing the transmission, shift drum and shift forks
18 Nm (1.8 m•kgf, 13 ft•Ibf)
New
New
16
E
E
E
17
E
10
15
E
E
New
13
14
E
E
12
11
E
E
M
New
M
Order
Job/Parts to remove
Q’ty
Remarks
10
Secondary shaft
1
11
Drive axle assembly
1
12
Collar
1
13
Reverse idle gear
1
14
Bearing
1
15
Reverse idle gear shaft
1
16
Stopper lever
1
17
Stopper lever shaft
1
5-76

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TRANSMISSION
Disassembling the drive axle assembly
8
New
9
M
LS
7
6
2
16
5
17
4
15
3
18
14
M
13
1
12
11
LS
10
New
New
Order
Job/Parts to remove
Q’ty
Remarks
1
Washer
1
2
Collar
1
3
High wheel gear
1
4
Washer
1
5
Clutch dog
1
6
Circlip
1
7
Washer
1
8
Collar
1
9
Low wheel gear
1
10
Washer
1
11
Circlip
1
12
Middle drive gear
1
13
Circlip
1
14
Washer
1
15
Bearing
1
16
Reverse wheel gear
1
17
Stopper wheel
1
18
Drive axle
1
5-77

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TRANSMISSION
EBS30194
REMOVING THE TRANSMISSION
1. Remove:
• Shift drum “1”
• Shift fork assembly “2”
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pull out the guide bar from the left crankcase,
and then remove the shift fork cam followers.
2
b. Remove the shift drum.
c. Remove the shift fork assembly.
2. Check:
• Shift fork guide bar
1
Roll the shift fork guide bar on a flat surface.
2
Bends → Replace.
EWB02750
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30195
DISASSEMBLING THE DRIVE AXLE
1. Remove:
• Stopper wheel “1”
• Drive axle “2”
TIP
Press the drive axle end and remove the stopper
wheel.
3. Check:
• Shift fork movement
(along the shift fork guide bar)
1
Rough movement → Replace the shift forks
and shift fork guide bar as a set.
2
EBS30196
CHECKING THE SHIFT FORKS
The following procedure applies to both of the
4. Check:
shift forks.
• Spring
1. Check:
Cracks/damage → Replace.
• Shift fork cam follower “1”
EBS30197
• Shift fork pawl “2”
CHECKING THE SHIFT DRUM
Bends/damage/scoring/wear → Replace the
1. Check:
shift fork.
• Shift drum grooves
Damage/scratches/wear → Replace the shift
drum.
5-78

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

TRANSMISSION
EBS30199
CHECKING THE SECONDARY SHAFT
1. Check:
• Gear teeth
Blue discoloration/pitting/wear → Replace.
EBS30555
CHECKING THE STOPPER LEVER AND
STOPPER WHEEL
1. Check:
EBS30198
• Stopper lever pawl “1”
CHECKING THE TRANSMISSION
Bends/damage/wear → Replace the stopper
1. Measure:
lever and stopper wheel as a set.
• Drive axle runout
• Stopper wheel “2”
(with a centering device and dial gauge “1”)
Damage/wear → Replace the stopper wheel
Out of specification → Replace the drive axle.
and stopper lever as a set.
• Stopper lever shaft “3”
Drive axle runout limit
Bends/damage/wear → Replace.
0.06 mm (0.0024 in)
1
2. Check:
EBS30200
• Transmission gears
ASSEMBLING THE DRIVE AXLE
Blue discoloration/pitting/wear → Replace
1. Install:
the defective gear(s).
• Washer “1”
• Transmission gear dogs
Cracks/damage/rounded edges → Replace
• Circlip “2”
New
the defective gear(s).
TIP
• Be sure the circlip sharp-edged corner “a” is
positioned opposite side to the washer and
gear.
• Be sure the circlip ends “b” are positioned at
axle spline groove “c”.
New
2
b
3. Check:
• Transmission gear engagement
(each pinion gear to its respective wheel
gear)
c
Incorrect → Reassemble the transmission
a
1
axle assemblies.
EBS30201
4. Check:
ASSEMBLING THE SHIFT FORK
• Transmission gear movement
1. Install:
Rough movement → Replace the defective
• Shift fork guide bar “1”
part(s).
5-79

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

TRANSMISSION
• Shift fork “L” “2”
2. Check:
• Spring “3”
• Shift operation
• Shift fork “R” “4”
Rough operation → Repair.
• Circlips “5”
New
TIP
TIP
• Oil each gear and bearing thoroughly.
Install the shift forks with the “R” mark “a” and “L”
• Before assembling the crankcase, make sure
that the transmission is in neutral and that the
mark “b” facing away from each other.
gears turn freely.
New
5
1
b
3
2
New
5
a
4
EBS30202
INSTALLING THE SHIFT FORKS AND SHIFT
DRUM
1. Install:
• Reverse idle gear “1”
• Drive axle assembly “2”
• Secondary shaft “3”
• Shift fork assembly “4”
• Shift drum “5”
TIP
Install the shift fork assembly “4” with the “L”
mark “a” facing the left crankcase.
3
2
5
1
4
4
a
5-80

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

MIDDLE GEAR
EBS20048
MIDDLE GEAR
Removing the middle drive shaft
190 Nm (19 m•kgf, 137 ft•lbf)
38 Nm (3.8 m•kgf, 27 ft•Ibf)
E
LT
9
LT
5
10
6
New
8
7
11
12
E
10
New
1
LT
LT
29 Nm (2.9 m•kgf, 21 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
Separate.
Crankcase
Refer to “CRANKCASE” on page 5-64.
1
Middle drive shaft/Bearing housing assembly
1
2
Middle drive pinion gear nut
1
3
Middle drive pinion gear
1
Refer to “ALIGNING THE MIDDLE GEAR”
4
Middle drive pinion gear shim
on page 5-89.
5
Middle drive shaft assembly
1
6
Middle driven gear
1
7
Circlip
1
8
Middle drive shaft
1
9
Middle drive shaft bearing housing assembly
1
10
Bearing retainer
2
11
Bearing
1
12
Bearing housing
1
5-81

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

MIDDLE GEAR
Removing the middle driven shaft
115 Nm (11.5 m•kgf, 83 ft•lbf)
LT
25 Nm (2.5 m•kgf, 18 ft•Ibf)
New
M
E
80 Nm (8.0 m•kgf, 58 ft•Ibf)
3
130 Nm (13 m•kgf, 94 ft•lbf)
4
9
6
150 Nm (15 m•kgf, 108 ft•lbf)
8
5
6
7
M
Order
Job/Parts to remove
Q’ty
Remarks
Front drive shaft coupling gear nut (middle gear
1
1
side)
Front drive shaft coupling gear (middle gear
2
1
side)
Rear drive shaft coupling gear nut (middle gear
3
1
side)
Rear drive shaft coupling gear (middle gear
4
1
side)
5
Middle driven pinion gear assembly
1
Refer to “ALIGNING THE MIDDLE GEAR”
6
Middle driven pinion gear shim
on page 5-89.
7
Middle driven pinion gear
1
8
Bearing
1
9
Oil seal
1
5-82

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

MIDDLE GEAR
Removing the middle driven shaft
115 Nm (11.5 m•kgf, 83 ft•lbf)
LT
25 Nm (2.5 m•kgf, 18 ft•Ibf)
15
New
14
M
17
16
E
80 Nm (8.0 m•kgf, 58 ft•Ibf)
130 Nm (13 m•kgf, 94 ft•lbf)
13
12
150 Nm (15 m•kgf, 108 ft•lbf)
11
10
M
Order
Job/Parts to remove
Q’ty
Remarks
10
Middle driven pinion gear bearing retainer
1
Left-hand thread
11
Bearing
1
12
O-ring
1
13
Bearing housing
1
14
Oil seal
1
15
Middle driven shaft bearing retainer
1
Left-hand thread
16
Bearing
1
17
Middle driven shaft
1
5-83

 

 

 

 

 

 

 

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