Yamaha 2016 Grizzly yfm700gdxg Manuals

Manuals and User Guides for Yamaha 2016 Grizzly yfm700gdxg. We have 1 Yamaha 2016 Grizzly yfm700gdxg manual available for free PDF download: Service Manual

Yamaha 2016 Grizzly yfm700gdxg Service Manual (474 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 26.95 MB

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
- 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
- Rear Brake
  
  160
- Handlebar
  
  171
  - Removing the Handlebar
    173
  - Checking the Handlebar
    173
  - Installing the Handlebar
    173
- Steering Stem
  
  176
- Tie-Rods and Steering Knuckles
  
  184
- Front Arms and Front Shock Absorber Assemblies
  
  188
- Rear Knuckles and Stabilizer
  
  193
- Rear Arms and Rear Shock Absorber Assemblies
  
  195
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
- 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
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
- 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
- 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

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Yamaha 2016 Grizzly yfm700gdxg Manuals

Yamaha 2016 Grizzly yfm700gdxg Service Manual (474 pages)

Table of Contents

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

General Chassis (1)

General Chassis (2)

General Chassis (3)

General Chassis (4)

General Chassis (5)

Front Wheels

Rear Wheels

Front Brake

Rear Brake

Handlebar

Steering Stem

Tie-Rods and Steering Knuckles

Front Arms and Front Shock Absorber Assemblies

Rear Knuckles and Stabilizer

Rear Arms and Rear Shock Absorber Assemblies

Engine

Engine Inspection

Engine Removal (1)

Engine Removal (2)

Engine Removal (3)

Camshafts

Cylinder Head, Cylinder, and Piston

Valves and Valve Springs

Ac Magneto and Starter Clutch

Electric Starter

Oil Pump Sprockets

Shift Lever

Primary and Secondary Sheaves

Clutch

Crankcase

Crankshaft and Oil Pump

Transmission

Middle Gear

Cooling System

Oil Cooler

Radiator

Thermostat

Water Pump

Fuel System

Fuel Tank

Throttle Body

Air Induction System

Drive Train

Troubleshooting

Front Constant Velocity Shaft Assemblies, Differential Assembly and Front Drive Shaft

Rear Constant Velocity Shaft Assemblies, Final Drive Assembly and Rear Drive Shaft

Electrical System

Ignition System

Electric Starting System

Charging System

Lighting System

Signaling System

Cooling System

Fuel Injection System

Fuel Pump System

2Wd/4Wd Selecting System

EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS Models)

Electrical Components

Troubleshooting

Troubleshooting

Self-Diagnostic Function and Diagnostic Code Table

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