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2016 Grizzly yfm700fwad
Yamaha 2016 Grizzly yfm700fwad User Manual
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2016
SERVICE MANUAL
YF70GG
YF70GPG
YF70GPSG
YF70GPLG
YFM70GDXG
YFM70GDHG
YFM70GPXG
YFM70GPHG
YFM70GPSG
YFM70GPLG
YFM700FWAD
2UD-F8197-E0
2
Table of Contents
Table of Contents
7
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Features
12
OUTLINE of the EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS Models)
12
Instrument Functions
14
Important Information
16
Preparation for Removal and Disassembly
16
Replacement Parts
16
Gaskets, Oil Seals and O-Rings
16
Lock Washers/Plates and Cotter Pins
16
Bearings and Oil Seals
17
Circlips
17
Rubber Parts
17
Basic Service Information
18
Quick Fasteners
18
Electrical System
19
Special Tools
23
Specifications
31
General Specifications
32
Engine Specifications
33
Chassis Specifications
38
Electrical Specifications
40
Tightening Torques
43
General Tightening Torque Specifications
43
Engine Tightening Torques
44
Chassis Tightening Torques
49
Lubrication Points and Lubricant Types
54
Engine
54
Lubrication System Chart and Diagrams
56
Engine Oil Lubrication Chart
56
Lubrication Diagrams
58
Cooling System Diagrams
62
Cable Routing
64
Periodic Checks and Adjustments
81
General Maintenance and Lubrication Chart
84
Introduction
84
Periodic Maintenance
84
Periodic Maintenance Chart for the Emission Control System
84
Checking the Fuel Line
87
Checking the Spark Plug
87
Adjusting the Valve Clearance
88
Adjusting the Exhaust Gas Volume
91
Checking the Breather Hoses
91
Checking the Exhaust System
91
Checking the Air Induction System
92
Cleaning the Air Filter Element
92
Cleaning the Spark Arrester
92
Adjusting the Front Disc Brake
94
Checking the Front Brake Pads
94
Checking the Rear Brake Pads
94
Adjusting the Rear Disc Brake
95
Checking the Front Brake Hoses
96
Checking the Rear Brake Hoses
96
Bleeding the Hydraulic Brake System
97
Checking the Brake Fluid Level
97
Checking the Wheels
98
Checking the Tires
99
Checking the V-Belt
100
Adjusting the Front Shock Absorber Assemblies
101
Checking the Fastener
101
Checking the Front Shock Absorber Assemblies
101
Replacing the V-Belt
101
Adjusting the Rear Shock Absorber Assembly
102
Checking the Rear Shock Absorber Assemblies
102
Checking the Stabilizer Bushing
102
Lubricating the Rear Knuckle Pivots
102
Checking the Steering System
103
Lubricating the Steering Shaft
103
Adjusting the Toe-In
104
Checking the Constant Velocity Shaft Assembly Dust Boots
106
Checking the Engine Mount
106
Checking the Engine Oil Level
106
Changing the Engine Oil
107
Measuring the Engine Oil Pressure
108
Changing the Differential Gear Oil
109
Checking the Differential Gear Oil Level
109
Changing the Final Gear Oil
110
Checking the Final Gear Oil Level
110
Checking the Cooling System
111
Changing the Coolant
112
Checking the Coolant Level
112
Checking and Lubricating the Cables
114
Adjusting the Drive Select Lever Control Cable and Shift Rod
115
Lubricating the Levers
115
Lubricating the Pedal
115
Adjusting the Throttle Lever Free Play
116
Adjusting the Speed Limiter
117
Replacing the Handle Mounted Light Bulb
117
Adjusting the Headlight and Handle Mounted Light Beams
118
Chassis
121
General Chassis (1)
124
Installing the Battery Cover
126
Removing the Battery Cover
126
Removing the Top Cover
126
Installing the Top Cover
127
Removing the Side Panels
127
Installing the Side Panels
128
General Chassis (2)
129
Removing the Upper Panel
130
Installing the Upper Panel
130
General Chassis (3)
131
Installing the Rear Fender
133
General Chassis (4)
134
Installing the Footrest Boards
139
General Chassis (5)
140
Installing the Air Filter Case
142
Front Wheels
143
Removing the Front Wheels
144
Removing the Front Wheel Hubs
144
Checking the Front Wheels
144
Checking the Front Wheel Hubs
144
Installing the Front Brake Discs
145
Installing the Front Wheel Hubs
145
Installing the Front Wheels
145
Rear Wheels
146
Removing the Rear Wheels
147
Removing the Rear Wheel Hubs
147
Checking the Rear Wheels
147
Checking the Rear Wheel Hubs
147
Installing the Rear Brake Discs
147
Installing the Rear Wheel Hubs
147
Installing the Rear Wheels
148
Front Brake
149
Introduction
154
Checking the Front Brake Discs
154
Replacing the Front Brake Pads
155
Disassembling the Front Brake Calipers
155
Checking the Front Brake Calipers
156
Assembling the Front Brake Calipers
156
Installing the Front Brake Calipers
156
Checking the Front Brake Master Cylinder
157
Assembling the Front Brake Master Cylinder
158
Installing the Front Brake Master Cylinder
158
Rear Brake
160
Introduction
166
Checking the Rear Brake Discs
166
Replacing the Rear Brake Pads
166
Removing the Rear Brake Master Cylinder
167
Disassembling the Rear Brake Calipers
167
Checking the Rear Brake Calipers
168
Assembling the Rear Brake Calipers
168
Installing the Rear Brake Calipers
168
Checking the Rear Brake Master Cylinder
169
Assembling the Rear Brake Master Cylinder
169
Installing the Rear Brake Master Cylinder
169
Handlebar
171
Removing the Handlebar
173
Checking the Handlebar
173
Installing the Handlebar
173
Steering Stem
176
REMOVING the BEARING RETAINER (Except for EPS Models)
180
Checking the Steering Stem
180
INSTALLING the STEERING STEM (Except for EPS Models)
180
INSTALLING the STEERING STEM (for EPS Models)
181
INSTALLING the PITMAN ARM (Except for EPS Models)
182
INSTALLING the PITMAN ARM (for EPS Models)
182
Tie-Rods and Steering Knuckles
184
Removing the Steering Knuckles
185
Checking the Tie-Rods
185
Checking the Steering Knuckles and Front Wheel Bearings
185
Checking the Steering Knuckle Ball Joints
185
Installing the Tie-Rods
187
Installing the Front Arm Protectors
187
Front Arms and Front Shock Absorber Assemblies
188
Checking the Front Arms
190
Checking the Front Shock Absorber Assemblies
190
Checking the Front Arm Ball Joints
190
Installing the Front Arms and Front Shock Absorber Assemblies
191
Installing the Front Arm Protectors
192
Rear Knuckles and Stabilizer
193
Checking the Rear Knuckles and Rear Wheel Bearings
194
Checking the Stabilizer
194
Installing the Rear Arm Protectors
194
Rear Arms and Rear Shock Absorber Assemblies
195
Checking the Rear Arms
196
Checking the Rear Shock Absorber Assemblies
196
Installing the Rear Arms and Rear Shock Absorber Assemblies
196
Engine
199
Engine Inspection
202
Measuring the Compression Pressure
202
Engine Removal (1)
204
Installing the Exhaust Pipe and Muffler
205
Installing the V-Belt Cooling Ducts
205
Engine Removal (2)
206
Installing the Drive Select Lever Unit
208
Engine Removal (3)
209
Installing the Engine
212
Camshafts
213
Removing the Camshafts
215
Checking the Camshafts
216
Checking the Camshaft Sprockets
217
Checking the Timing Chain Tensioner
217
Installing the Camshafts
217
Installing the Breather Plate
219
Cylinder Head, Cylinder, and Piston
220
Removing the Cylinder Head
223
Removing the Piston
223
Checking the Cylinder Head
224
Checking the Cylinder and Piston
224
Checking the Piston Rings
225
Checking the Piston Pin
226
Installing the Piston and Cylinder
226
Installing the Cylinder Head
227
Valves and Valve Springs
230
Removing the Valves
230
Checking the Valves and Valve Guides
230
Checking the Valve Seats
232
Checking the Valve Springs
233
Checking the Valve Lifters
234
Installing the Valves
234
Ac Magneto and Starter Clutch
236
Removing the Ac Magneto Rotor
238
Removing the Starter Clutch
238
Checking the Starter Clutch
238
Installing the Starter Clutch
239
Installing the Ac Magneto Rotor
239
Electric Starter
241
Checking the Starter Motor
243
Assembling the Starter Motor
243
Oil Pump Sprockets
245
Removing the Oil Pump Drive Sprocket and Oil Pump Driven Sprocket
246
Checking the Oil Pump Sprockets
246
Installing the Oil Pump Drive Sprocket and Oil Pump Driven Sprocket
246
Shift Lever
248
Checking the Stopper Lever
249
Checking the Shift Levers
249
Installing the Shift Levers
249
Primary and Secondary Sheaves
250
Removing the Primary and Secondary Sheaves
253
Disassembling the Secondary Sheave
253
Checking the V-Belt
254
Checking the Primary Sheave
254
Checking the Primary Sheave Weights
254
Checking the Primary Sheave Sliders
254
Checking the Secondary Sheave
254
Assembling the Primary Sheave
255
Assembling the Secondary Sheave
256
Installing the Primary and Secondary Sheaves
257
Clutch
260
Removing the Clutch
262
Checking the Clutch
262
Checking the Clutch Shoe
262
Assembling the Clutch Housing
263
Installing the Clutch
263
Crankcase
265
Separating the Crankcase
268
Checking the Timing Chain and Timing Chain Guide
268
Checking the Bearings
268
Checking the Crankcase
269
Assembling the Crankcase
269
Crankshaft and Oil Pump
271
Removing the Crankshaft
273
Checking the Oil Pump
273
Checking the Oil Strainer
273
Checking the Relief Valve
273
Checking the Crankshaft
274
Assembling the Oil Pump
274
Installing the Crankshaft
274
Installing the Oil Pump
275
Transmission
276
Removing the Transmission
279
Disassembling the Drive Axle
279
Checking the Shift Forks
279
Checking the Shift Drum
279
Checking the Transmission
280
Checking the Secondary Shaft
280
Checking the Stopper Lever and Stopper Wheel
280
Assembling the Drive Axle
280
Assembling the Shift Fork
280
Installing the Shift Forks and Shift Drum
281
Middle Gear
282
Removing the Middle Drive Shaft
285
Removing the Middle Driven Shaft
285
Checking the Pinion Gears
286
Installing the Bearing and Oil Seals
287
Installing the Middle Driven Shaft
287
Installing the Middle Drive Shaft
288
Measuring the Middle Gear Backlash
289
Aligning the Middle Gear
290
Cooling System
293
Oil Cooler
294
Checking the Oil Cooler
296
Installing the Oil Cooler
296
Radiator
297
Checking the Radiator
299
Installing the Radiator
299
Thermostat
300
Checking the Thermostat
301
Installing the Thermostat
301
Water Pump
303
Disassembling the Water Pump
305
Checking the Water Pump
305
Assembling the Water Pump
305
Installing the Water Pump Housing
306
Installing the Water Jacket Joint
306
Fuel System
307
Fuel Tank
308
Checking the Fuel Pump Body
309
Checking the Fuel Tank Breather Hose Joint
309
Installing the Fuel Pump
309
Removing the Fuel Pump
309
Removing the Fuel Tank
309
Installing the Fuel Tank
310
Throttle Body
311
Removing the Throttle Body Assembly
313
Checking the Injector
313
Checking the Throttle Body
313
Installing the Throttle Body Assembly
313
Checking the Fuel Pressure
314
Adjusting the Throttle Position Sensor
314
Air Induction System
316
Checking the Air Induction System
320
Installing the Air Induction System
320
Drive Train
321
Troubleshooting
322
Checking Noises
323
Troubleshooting Chart
324
Front Constant Velocity Shaft Assemblies, Differential Assembly and Front Drive Shaft
325
Disassembling the Front Constant Velocity Shaft Assemblies
330
Checking the Front Constant Velocity Shaft Assemblies
330
Assembling the Front Constant Velocity Shaft Assemblies
331
Removing the Differential Gear Assembly
332
Checking the Differential Assembly
332
Checking the Differential Motor Operation
332
Assembling the Differential Assembly
333
Measuring the Differential Gear Backlash
334
Adjusting the Differential Gear Backlash
334
Rear Constant Velocity Shaft Assemblies, Final Drive Assembly and Rear Drive Shaft
336
Disassembling the Rear Constant Velocity Shaft Assemblies
342
Checking the Rear Constant Velocity Shaft Assemblies
343
Assembling the Rear Constant Velocity Shaft Assemblies
343
Disassembling the Final Drive Pinion Gear Assembly
344
Checking the Rear Drive Shaft
345
Checking the Final Drive Assembly
345
Assembling the Final Drive Case
345
Assembling the Final Drive Pinion Gear Assembly
345
Selecting the Final Drive Pinion Gear Shim(S)
346
Selecting the Final Driven Pinion Gear Shim (Final Drive Case Side) and Thrust Washer
347
Selecting the Final Driven Pinion Gear Shim (Final Drive Case Cover Side)
348
Selecting the Wheel Gear Shim(S)
349
Measuring the Final Gear Backlash
350
Adjusting the Final Gear Backlash
350
Electrical System
353
Ignition System
356
Circuit Diagram
356
Troubleshooting
358
Electric Starting System
360
Circuit Diagram
360
Starting Circuit Cut-Off System Operation
362
Troubleshooting
363
Charging System
366
Circuit Diagram
366
Troubleshooting
368
Lighting System
370
Circuit Diagram
370
Troubleshooting
372
Signaling System
374
Circuit Diagram
374
Troubleshooting
376
Cooling System
380
Circuit Diagram
380
Troubleshooting
382
Fuel Injection System
384
Circuit Diagram
384
Ecu Self-Diagnostic Function
386
Troubleshooting Method
387
Yamaha Diagnostic Tool
387
Troubleshooting Details (Fuel Injection System)
390
Fuel Pump System
414
Circuit Diagram
414
Troubleshooting
416
2Wd/4Wd Selecting System
418
Circuit Diagram
418
Troubleshooting
420
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS Models)
422
Circuit Diagram
422
Eps Control Unit's Self-Diagnostic Function
424
Eps Warning Light During Normal Operation
424
Diagnostic Mode
425
Self-Diagnostic Function Table (Eps System)
427
Troubleshooting Details (Eps System)
428
Electrical Components
432
Checking the Switches
436
Checking the Bulbs and Bulb Sockets
438
Checking the Fuses
439
Checking and Charging the Battery
440
Checking the Relays
443
Checking the Diode
445
Checking the Spark Plug Cap
445
Checking the Ignition Coil
446
Checking the Crankshaft Position Sensor
446
Checking the Lean Angle Sensor
447
Checking the Starter Motor Operation
447
Checking the Stator Coil
448
Checking the Rectifier/Regulator
448
Checking the Fuel Sender
448
Checking the Speed Sensor
449
Checking the Radiator Fan Motor
449
Checking the Radiator Fan Motor Circuit Breaker
450
Checking the Coolant Temperature Sensor
450
Checking the Throttle Position Sensor
451
Checking the Fuel Injector
451
Checking the Air Induction System Solenoid
451
Checking the Intake Air Pressure Sensor
452
Checking the Intake Air Temperature Sensor
452
CHECKING the EPS MOTOR (for EPS Models)
453
CHECKING the EPS TORQUE SENSOR (for EPS Models)
453
Troubleshooting
455
Default Chapter
455
General Information
455
Troubleshooting
456
General Information
456
Starting Failures
456
Incorrect Engine Idling Speed
456
Poor Medium-And-High-Speed Performance
457
Faulty Drive Train
458
Faulty Gear Shifting
459
Shift Lever Does Not Move
459
Jumps out of Gear
459
Faulty Clutch
459
Overheating
459
Overcooling
460
Poor Braking Performance
460
Faulty Shock Absorber Assembly
460
Unstable Handling
460
Faulty Lighting or Signaling System
460
Self-Diagnostic Function and Diagnostic Code Table
462
Self-Diagnostic Function Table
462
Communication Error with the Meter
462
Diagnostic Code: Sensor Operation Table
462
Diagnostic Code: Actuator Operation Table
464
Wiring Diagram
466
4
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Yamaha 2016 Grizzly yfm700fwad Specifications
General
Brand
Yamaha
Model
2016 Grizzly yfm700fwad
Category
Offroad Vehicle
Language
English
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