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

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MIDDLE GEAR

EBS30203

REMOVING THE MIDDLE DRIVE SHAFT

Coupling gear/middle shaft tool

1. Straighten:

90890-01229

• Punched portion of the middle drive pinion

Gear holder

gear nut

YM-01229

2. Loosen:

• Middle drive pinion gear nut “1”

TIP

Wrap the middle drive shaft in a folded rag, and

then secure it in a vise.

2. Remove:

• Rear drive shaft coupling gear nut “1”

• Washer

• Rear drive shaft coupling gear “2”

TIP

3. Remove:

Use the coupling gear/middle shaft tool “3” to

• Middle drive pinion gear nut

hold the rear drive shaft coupling gear.

• Middle drive pinion gear

• Shim(s)

Coupling gear/middle shaft tool

4. Remove:

90890-01229

• Middle driven gear “1”

Gear holder

• Circlip

YM-01229

• Middle drive shaft “2”

TIP

Press the middle drive shaft end and remove the

middle driven gear.

3. Remove:

• Bearing housing assembly “1”

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Clean the surface of the bearing housing as-

EBS30204

sembly.

REMOVING THE MIDDLE DRIVEN SHAFT

b. Place the bearing housing assembly onto a

1. Remove:

hydraulic press.

• Front drive shaft coupling gear nut “1”

ECB01900

• Washer

NOTICE

• Front drive shaft coupling gear “2”

• Never directly press the middle driven pin-

TIP

ion gear end with a hydraulic press, this will

Use the coupling gear/middle shaft tool “3” to

result in damage to the middle driven pin-

hold the front drive shaft coupling gear.

ion gear thread.

5-84

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MIDDLE GEAR

• Install a suitable socket “2” on the middle

Ring nut wrench

driven pinion gear end to protect the thread

90890-01430

from damage.

Ring nut wrench

c. Press the middle driven pinion gear end and

YM-38404

remove the bearing housing.

ECB01750

NOTICE

The middle driven shaft bearing retainer has

left-hand threads. To loosen the retainer turn

it clockwise.

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4. Remove:

• Middle driven pinion gear bearing retainer

• Bearing

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Wrap the bearing housing in a folded rag “1”,

and then secure the bearing housing edge in

a vise.

b. Attach the bearing retainer wrench “2”.

Bearing retainer wrench

90890-04128

Middle gear bearing retainer

YM-04128

ECB01740

NOTICE

6. Remove:

The middle driven pinion gear bearing retain-

• Middle driven shaft “1”

er has left-hand threads. To loosen the re-

(with bearing)

tainer, turn it clockwise.

EBS30205

CHECKING THE PINION GEARS

c. Remove the bearing retainer and bearing.

1. Check:

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

• Drive pinion gear teeth

5. Remove:

• Driven pinion gear teeth

• Oil seal “1”

Pitting/galling/wear → Replace.

• Middle driven shaft bearing retainer “2”

2. Check:

TIP

• Bearings

Attach the ring nut wrench “3”.

Pitting/damage → Replace.

5-85

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MIDDLE GEAR

EBS30206

INSTALLING THE BEARING AND OIL SEALS

Ring nut wrench

1. Install:

90890-01430

• Bearing “1”

Ring nut wrench

YM-38404

• Oil seal “2”

New

(into the bearing housing “3”)

ECB01760

NOTICE

Installed depth “a” of bearing

0.9-1.4 mm (0.035-0.055 in)

The middle driven shaft bearing retainer has

Installed depth “b” of oil seal

left-hand threads. To tighten the retainer turn

1.0-1.5 mm (0.039-0.059 in)

it counterclockwise.

2 New

2. Install:

• Oil seal “1”

New

(into the crankcase “2”)

Installed depth “a” of oil seal

1.0-1.5 mm (0.039-0.059 in)

New

2. Install:

• Middle driven pinion gear bearing retainer “1”

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Wrap the bearing housing in a folded rag, and

then secure the bearing housing edge in a

vise.

b. Attach the bearing retainer wrench “2”.

EBS30207

Bearing retainer wrench

INSTALLING THE MIDDLE DRIVEN SHAFT

90890-04128

1. Install:

Middle gear bearing retainer

• Middle driven shaft bearing retainer “1”

YM-04128

Middle driven shaft bearing re-

c. Tighten the bearing retainer.

tainer

80 Nm (8.0 m·kgf, 58 ft·lbf)

Middle driven pinion gear bearing

LOCTITE®

retainer

130 Nm (13 m·kgf, 94 ft·lbf)

TIP

LOCTITE®

Attach the ring nut wrench “2”.

5-86

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MIDDLE GEAR

ECB01770

NOTICE

The middle driven pinion gear bearing retain-

er has left-hand threads. To tighten the re-

tainer turn it counterclockwise.

5. Install:

• Front drive shaft coupling gear “1”

• Washer

• Front drive shaft coupling gear nut “2”

Front drive shaft coupling gear

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

nut (middle gear side)

3. Install:

115 Nm (11.5 m·kgf, 83 ft·lbf)

• Middle driven pinion gear shim(s) “1”

LOCTITE®

• Bearing housing “2”

TIP

• Install the shim(s) so that the tabs are posi-

Use the coupling gear/middle shaft tool “3” to

tioned as shown in the illustration.

hold the front drive shaft coupling gear.

• Make sure that the arrow “a” on the bearing

housing points upward.

Coupling gear/middle shaft tool

90890-01229

Gear holder

YM-01229

4. Install:

• Rear drive shaft yoke “1”

• Washer

• Rear drive shaft yoke nut “2”

EBS30208

INSTALLING THE MIDDLE DRIVE SHAFT

Rear drive shaft coupling gear

1. Install:

nut (middle gear side)

• Circlip

150 Nm (15 m·kgf, 108 ft·lbf)

• Middle driven gear “1”

LOCTITE®

(onto the middle drive shaft “2”)

TIP

Installed depth “a” of middle

Use the coupling gear/middle shaft tool “3” to

driven gear

hold the rear drive shaft coupling gear.

24.7-24.9 mm (0.972-0.980 in)

Coupling gear/middle shaft tool

90890-01229

Gear holder

YM-01229

5-87

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MIDDLE GEAR

2. Install:

EBS30209

• Bearing

MEASURING THE MIDDLE GEAR

• Bearing retainers “1”

BACKLASH

1. Measure:

• Bearing retainer bolts “2”

New

• Middle gear backlash

Middle drive shaft bearing retain-

Out of specification → Adjust.

er bolt

Refer to “ALIGNING THE MIDDLE GEAR” on

29 Nm (2.9 m·kgf, 21 ft·lbf)

page 5-89.

LOCTITE®

Middle gear backlash

0.10-0.30 mm (0.004-0.012 in)

TIP

Stake the bearing retainer bolts at the cutouts “a”

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

in the bearing retainers “1”.

a. Temporarily install the left crankcase.

b. Wrap a rag “1” around a screwdriver “2”, and

New

then insert it into the installation hole “a” of the

left crankcase speed sensor to hold the mid-

dle driven gear.

New

3. Tighten:

• Middle drive pinion gear nut “1”

New

Middle drive pinion gear nut

190 Nm (19 m·kgf, 137 ft·lbf)

c. Attach the final gear backlash band “3” and

dial gauge “4”.

TIP

Final gear backlash band

• Wrap the middle drive shaft in a folded rag, and

90890-01511

then secure it in a vise.

Middle drive gear lash tool

• Lock the threads with a drift punch.

YM-01230

5-88

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MIDDLE GEAR

b a

44.9 mm (1.77 in)

19.7 mm (0.78 in)

d. Measure the gear lash while rotating the mid-

dle driven shaft back and forth.

TIP

Measure the gear lash at 4 positions. Rotate the

middle driven gear 90° each time.

e. If the gear lash is incorrect, adjust the gear

lash by middle driven pinion gear shim(s).

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A. Middle drive pinion gear shim thickness

EBS30210

B. Middle driven pinion gear shim thickness

ALIGNING THE MIDDLE GEAR

TIP

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a. Position the middle gears with the appropri-

Aligning the middle gear is necessary when any

ate shim(s) that has had its respective thick-

of the following parts are replaced:

ness calculated from information marked on

• Crankcase

the crankcase, bearing housings, and pinion

• Middle drive pinion gear

gears.

• Middle driven pinion gear

b. To find middle drive pinion gear shim thick-

• Middle driven shaft bearing housing

ness “A”, use the following formula.

• Middle drive shaft bearing housing

Middle drive pinion gear shim thickness

1. Select:

“A” = “e” + “d” - “b” - “c” - “a”

• Middle drive pinion gear shim(s) “1”

• Middle driven pinion gear shim(s) “2”

“a” = a numeral (usually a decimal number)

on the bearing housing is either added to or

subtracted from “0.6”

“b” = 17.0

“c” = 55.0

“d” = a numeral (usually a decimal number)

on the crankcase (right) specifies a thickness

of “65.0”

“e” = a numeral (usually a decimal number)

on the crankcase (left) specifies a thickness

of “9.0”

Example:

If the bearing housing is marked “-02”,

“a” is 0.58

5-89

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MIDDLE GEAR

Middle drive pinion gear shim

Thickness (mm)

0.50 0.55 0.60 0.70 0.80 0.90 1.00

c. To find middle driven pinion gear shim thick-

ness “B”, use the following formula.

Middle driven pinion gear shim thickness

“B” = “f” - “g” + “h” - “i” - “j”

“f” = a numeral (usually a decimal number) on

“b” is 17.0

the bearing housing is either added to or sub-

“c” is 55.0

tracted from “77.5”

If the crankcase (right) is marked “64.96”,

TIP

“d” is 64.96

After replacing any part in the middle driven pin-

ion gear assembly, the overall length of the as-

sembly will change. Therefore, be sure to

measure distance “f” to select the correct middle

driven pinion gear shim thickness.

If the crankcase (left) is marked “9.01”,

“e” is 9.01

“g” = a numeral (usually a decimal number)

on the middle driven pinion gear is either add-

ed to or subtracted from “49.0”

“h” = a numeral (usually a decimal number)

on the middle driven pinion gear is either add-

ed to or subtracted from “80.5”

“i” = a numeral (usually a decimal number) on

Therefore, “A” is 1.39.

the left crankcase specifies a thickness of

“A” = 9.01 + 64.96 - 17.0 - 55.0 - 0.58

“99.98”

= 1.39

“j” = a numeral (usually a decimal number) on

Round off hundredths digit and select appro-

the right crankcase specifies a thickness of

priate shim(s).

“8.12”

In the above example, the calculated shim

Example:

thickness is 1.39 mm. The following chart in-

If the bearing housing is marked “+03”,

structs you, however, to round off 9 to 10.

“f” is 77.53

Hundredth

Rounded value

0, 1, 2

3, 4, 5, 6, 7

8, 9

Shims are supplied in the following thickness-

es.

5-90

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MIDDLE GEAR

If the driven pinion gear is marked “+02”,

Therefore, “B” is 0.81.

“g” is 49.02

“B” = 77.53 - 49.02 + 80.40 - 99.98 - 8.12 =

0.81

Round off hundredth digit and select appro-

priate shim(s).

In the above example, the calculated shim

thickness is 0.81 mm. The chart instructs

you, however, to round off 1 to 0.

Hundredth

Rounded value

0, 1, 2

3, 4, 5, 6, 7

If the driven pinion gear is marked “-10”,

8, 9

“h” is 80.40

Shims are supplied in the following thickness-

es.

Middle driven pinion gear shim

Thickness (mm)

0.10 0.15 0.20 0.30 0.40 0.50 0.60

TIP

• If the specified middle gear backlash cannot be

obtained with a calculated shim thickness, in-

crease or decrease the shim thickness.

If the left crankcase is marked “99.98”,

• If the shim thickness is increased, the actual

“i” is 99.98

middle gear backlash will increase and, if the

shim thickness is decreased, the actual middle

gear backlash will decrease.

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If the right crankcase is marked “8.12”,

“j” is 8.12

5-91

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COOLING SYSTEM

OIL COOLER

6-1

CHECKING THE OIL COOLER

6-3

INSTALLING THE OIL COOLER

6-3

RADIATOR

6-4

CHECKING THE RADIATOR

6-6

INSTALLING THE RADIATOR

6-6

THERMOSTAT

6-7

CHECKING THE THERMOSTAT

6-8

INSTALLING THE THERMOSTAT

6-8

WATER PUMP

6-10

DISASSEMBLING THE WATER PUMP

6-12

CHECKING THE WATER PUMP

6-12

ASSEMBLING THE WATER PUMP

6-12

INSTALLING THE WATER PUMP HOUSING

6-13

INSTALLING THE WATER JACKET JOINT

6-13

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OIL COOLER

EBS20050

OIL COOLER

Removing the oil cooler

18 Nm (1.8 m•kgf, 13 ft•Ibf)

New

18 Nm (1.8 m•kgf, 13 ft•Ibf)

New

35 Nm (3.5 m•kgf, 25 ft•Ibf)

30 Nm (3.0 m•kgf, 22 ft•Ibf)

New

15 Nm (1.5 m•kgf, 11 ft•Ibf)

18 Nm (1.8 m•kgf, 13 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

Front skid plate/Center skid plate/Top cov-

Refer to “GENERAL CHASSIS (1)” on page

er/Side panel (left)

4-1.

Refer to “GENERAL CHASSIS (3)” on page

Front fender inner panel (left)

4-8.

Refer to “GENERAL CHASSIS (4)” on page

Footrest board (left)

4-11.

Drain.

Engine oil

Refer to “CHANGING THE ENGINE OIL” on

page 3-24.

Drain.

Coolant

Refer to “CHANGING THE COOLANT” on

page 3-29.

Oil cooler outlet hose/Oil cooler inlet hose

Refer to “WATER PUMP” on page 6-10.

6-1

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OIL COOLER

Removing the oil cooler

18 Nm (1.8 m•kgf, 13 ft•Ibf)

New

18 Nm (1.8 m•kgf, 13 ft•Ibf)

New

35 Nm (3.5 m•kgf, 25 ft•Ibf)

30 Nm (3.0 m•kgf, 22 ft•Ibf)

New

15 Nm (1.5 m•kgf, 11 ft•Ibf)

18 Nm (1.8 m•kgf, 13 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

Oil filter cartridge

Oil filter cartridge union bolt

Oil cooler

Oil pipe (crankcase)

Oil hose (crankcase to cylinder head)

Oil hose joint

Oil pipe (AC magneto cover)

6-2

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OIL COOLER

EBS30211

Refer to “CHANGING THE COOLANT” on

CHECKING THE OIL COOLER

page 3-29.

1. Check:

• Crankcase

• Oil cooler

(with the specified amount of the recom-

Cracks/damage → Replace.

mended engine oil)

2. Check:

Refer to “CHANGING THE ENGINE OIL” on

• Oil hose joint

page 3-24.

• Oil pipe (crankcase)

Check:

• Oil pipe (AC magneto cover)

• Cooling system

Cracks/damage/wear → Replace.

Leaks → Repair or replace any faulty part.

3. Check:

Measure:

• Oil hose (crankcase to cylinder head)

• Radiator cap opening pressure

Cracks/damage → Replace.

Below the specified pressure → Replace the

EBS30212

radiator cap.

INSTALLING THE OIL COOLER

Refer to “CHECKING THE RADIATOR” on

1. Install:

page 6-6.

• Oil hose (crankcase to cylinder)

• Clamps

• Oil hose joint

• Gaskets

New

• Oil hose bolt (crankcase to cylinder)

Refer to “INSTALLING THE CYLINDER

HEAD” on page 5-26.

2. Clean:

• Mating surfaces of the oil cooler and the

crankcase

(with a cloth dampened with lacquer thinner)

3. Install:

• Gasket

New

• Oil cooler “1”

• Oil filter cartridge union bolt “2”

TIP

Make sure the projection “a” on the oil cooler

touches the projection “b” on the crankcase.

Oil filter cartridge union bolt

30 Nm (3.0 m·kgf, 22 ft·lbf)

4. Fill:

• Cooling system

(with the specified amount of the recom-

mended coolant)

6-3

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RADIATOR

EBS20051

RADIATOR

Removing the radiator

(4)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

Front skid plate/Center skid plate/Top cov-

Refer to “GENERAL CHASSIS (1)” on page

er/Side panels

4-1.

Refer to “GENERAL CHASSIS (2)” on page

Front guard

4-6.

Refer to “GENERAL CHASSIS (3)” on page

Front fenders

4-8.

Refer to “GENERAL CHASSIS (4)” on page

Footrest board (left)

4-11.

Drain.

Coolant

Refer to “CHANGING THE COOLANT” on

page 3-29.

Radiator fan motor coupler

Disconnect.

Radiator fan motor breather hose

Coolant reservoir hose

Coolant reservoir breather hose

Coolant reservoir cap

6-4

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RADIATOR

EBS30213

CHECKING THE RADIATOR

1. Check:

• Radiator fins

Obstruction → Clean.

Apply compressed air to the rear of the radia-

tor.

Damage → Repair or replace.

TIP

Straighten any flattened fins with a thin, flat-head

screwdriver.

b. Apply the specified pressure for ten seconds

and make sure there is no drop in pressure.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4. Check:

• Radiator fan

Damage → Replace.

Malfunction → Check and repair.

Refer to “COOLING SYSTEM” on page 9-25.

EBS30214

INSTALLING THE RADIATOR

1. Fill:

2. Check:

• Cooling system

• Radiator hoses

(with the specified amount of the recom-

Cracks/damage → Replace.

mended coolant)

3. Measure:

Refer to “CHANGING THE COOLANT” on

• Radiator cap opening pressure

page 3-29.

Below the specified pressure → Replace the

2. Check:

radiator cap.

• Cooling system

Leaks → Repair or replace any faulty part.

Radiator cap opening pressure

3. Measure:

107.9-137.3 kPa (1.1-1.4

• Radiator cap opening pressure

kgf/cm², 15.6-19.9 psi)

Below the specified pressure → Replace the

radiator cap.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Install the radiator cap tester “1” and radiator

Refer to “CHECKING THE RADIATOR” on

cap tester adapter “2” to the radiator cap “3”.

page 6-6.

Radiator cap tester

90890-01325

Mityvac cooling system tester kit

YU-24460-A

Radiator cap tester adapter

90890-01352

Pressure tester adapter

YU-33984

6-6

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

THERMOSTAT

EBS20052

THERMOSTAT

Removing the thermostat

20 Nm (2.0 m•kgf, 14 ft•Ibf)

New

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

Top cover/Side panel (right)

4-1.

Drain.

Coolant

Refer to “CHANGING THE COOLANT” on

page 3-29”.

Radiator inlet hose

Disconnect.

Thermostat cover

Thermostat

Coolant temperature sensor coupler

Disconnect.

Coolant temperature sensor

6-7

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

THERMOSTAT

EBS30215

2. Check:

CHECKING THE THERMOSTAT

• Thermostat housing cover

1. Check:

• Thermostat housing (cylinder head)

• Thermostat

Cracks/damage → Replace.

Does not open at 69-73 °C (156.2-163.4 °F)

→ Replace.

EBS30216

INSTALLING THE THERMOSTAT

1. Install:

• Copper washer

New

• Coolant temperature sensor

Coolant temperature sensor

20 Nm (2.0 m·kgf, 14 ft·lbf)

ECB01910

NOTICE

Use extreme care when handling the coolant

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

temperature sensor. Replace any part that

Suspend the thermostat “1” in a container “2”

was dropped or subjected to a strong im-

filled with water.

pact.

Slowly heat the water “3”.

Place a thermometer “4” in the water.

2. Install:

While stirring the water, observe the thermo-

• Thermostat “1”

stat and the temperature indicated on the

• Gasket “2”

New

thermometer.

• Thermostat cover “3”

Thermostat cover bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

TIP

Install the thermostat with its breather hole “a”

facing up.

2 New

8 mm

(0.31 in)

3. Fill:

71±2°C

84°C

(159±3°F)

(183°F)

• Cooling system

(with the specified amount of the recom-

A. Fully closed

mended coolant)

B. Fully open

Refer to “CHANGING THE COOLANT” on

page 3-29.

TIP

4. Check:

If the accuracy of the thermostat is in doubt, re-

• Cooling system

place it. A faulty thermostat could cause serious

Leaks → Repair or replace any faulty part.

overheating or overcooling.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6-8

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WATER PUMP

EBS20053

WATER PUMP

Removing the water pump

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

New

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

Front skid plate/Center skid plate/Top cov-

Refer to “GENERAL CHASSIS (1)” on page

er/Side panel (left)

4-1.

Refer to “GENERAL CHASSIS (3)” on page

Front fender inner panel (left)

4-8.

Refer to “GENERAL CHASSIS (4)” on page

Footrest board (left)

4-11.

Refer to “AC MAGNETO AND STARTER

AC magneto cover

CLUTCH” on page 5-35.

Drain.

Coolant

Refer to “CHANGING THE COOLANT” on

page 3-29.

Radiator outlet hose

Disconnect.

Water jacket joint

Water pump outlet hose

Water pump outlet pipe

Oil cooler outlet hose

6-10

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

WATER PUMP

Removing the water pump

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

New

1312

New

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

Order

Job/Parts to remove

Q’ty

Remarks

Water pump inlet hose

Cooling water hose joint

Oil cooler inlet hose

Water pump breather hose

Water pump housing

Gasket

Impeller

Left-hand thread

Washer

Impeller shaft

Water pump seal

Bearing

Oil seal

6-11

Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 15