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Yamaha YFM 700 FI Grizzly Service Manual
2007 - 2008 Yamaha YFM700 yfm 700 FI Grizzly Service Manual
OFFICIAL NON SCANNED CRYSTAL CLEAR SERVICE MANUAL !!
450 PLUS PAGES PDF FORMAT
CONTENTS AS FOLLOWS:
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
MODEL LABEL
FEATURES
OUTLINE OF THE FI SYSTEM
FI SYSTEM
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM
EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM
INSTRUMENT FUNCTIONS
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
REPLACEMENT PARTS
GASKETS, OIL SEALS AND O RINGS
LOCK WASHERS/PLATES AND COTTER PINS
BEARINGS AND OIL SEALS
CIRCLIPS
CHECKING THE CONNECTIONS
SPECIAL TOOLS
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS
ENGINE SPECIFICATIONS
CHASSIS SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES
HOW TO USE THE CONVERSION TABLE
GENERAL TIGHTENING TORQUE SPECIFICATIONS
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
COOLANT FLOW DIAGRAMS
OIL FLOW DIAGRAMS
CABLE ROUTING
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTRO
SYSTEM
GENERAL MAINTENANCE AND LUBRICATION CHART
ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS
ENGINE SKID PLATES
SEAT AND SIDE PANELS
FRONT CARRIER AND FRONT GUARD
FRONT FENDERS AND FRONT GRILL
REAR CARRIER AND REAR FENDER
ELECTRICAL COMPONENTS TRAY
ELECTRICAL COMPONENTS TRAY /
ELECTRICAL COMPONENTS TRAY /
FOOTREST BOARDS
AIR FILTER CASE
ENGINE
ADJUSTING THE VALVE CLEARANCE
ADJUSTING THE ENGINE IDLING SPEED
ADJUSTING THE THROTTLE LEVER FREE PLAY
ADJUSTING THE SPEED LIMITER
CHECKING THE SPARK PLUG
CHECKING THE IGNITION TIMING
MEASURING THE COMPRESSION PRESSURE
CHECKING THE ENGINE OIL LEVEL
CHANGING THE ENGINE OIL
CLEANING THE AIR FILTER ELEMENT
CHECKING THE THROTTLE BODY JOINT
CHECKING THE FUEL HOSE
CHECKING THE BREATHER HOSES
CHECKING THE COOLANT LEVEL
CHANGING THE COOLANT
CHECKING THE COOLING SYSTEM
CHECKING THE COOLANT TEMPERATURE WARNING LIGHT
CHECKING THE V BELT
CHECKING THE EXHAUST SYSTEM
CLEANING THE SPARK ARRESTER
CHASSIS
ADJUSTING THE FRONT BRAKE
ADJUSTING THE REAR BRAKE
CHECKING THE BRAKE FLUID LEVEL
CHECKING THE FRONT BRAKE PADS
CHECKING THE REAR BRAKE PADS
CHECKING THE REAR BRAKE HOSE PROTECTORS
CHECKING THE BRAKE HOSES
BLEEDING THE HYDRAULIC BRAKE SYSTEM
ADJUSTING THE SELECT LEVER CONTROL CABLE AND
SHIFT ROD
CHECKING THE FINAL GEAR OIL LEVEL
CHANGING THE FINAL GEAR OIL
CHECKING THE DIFFERENTIAL GEAR OIL LEVEL
CHANGING THE DIFFERENTIAL GEAR OIL
CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS
CHECKING THE STEERING SYSTEM
ADJUSTING THE TOE IN
CHECKING THE FRONT AND REAR SHOCK ABSORBERS
ADJUSTING THE FRONT SHOCK ABSORBERS
ADJUSTING THE REAR SHOCK ABSORBERS
CHECKING THE TIRES
CHECKING THE WHEELS
CHECKING AND LUBRICATING THE CABLES
LUBRICATING THE LEVERS AND PEDALS
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
CHECKING THE FUSES
ADJUSTING THE HEADLIGHT BEAMS
REPLACING THE HEADLIGHT BULBS
CHAPTER 4
ENGINE
ENGINE REMOVAL
AIR DUCTS, MUFFLER AND EXHAUST PIPE
SELECT LEVER UNIT
LEADS, CABLES AND HOSES
ENGINE MOUNTING BOLTS
INSTALLING THE ENGINE
INSTALLING THE SELECT LEVER UNIT
CYLINDER HEAD
REMOVING THE CYLINDER HEAD
CHECKING THE CAMSHAFT SPROCKET
CHECKING THE TAPPET COVERS
CHECKING THE TIMING CHAIN TENSIONER
CHECKING THE CYLINDER HEAD
INSTALLING THE CYLINDER HEAD
ROCKER ARMS AND CAMSHAFT
REMOVING THE ROCKER ARMS AND CAMSHAFT
CHECKING THE CAMSHAFT
CHECKING THE DECOMPRESSION SYSTEM
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS
INSTALLING THE CAMSHAFT AND ROCKER ARMS
VALVES AND VALVE SPRINGS
REMOVING THE VALVES AND VALVE SPRINGS
CHECKING THE VALVES AND VALVE SPRINGS
INSTALLING THE VALVES AND VALVE SPRINGS
CYLINDER AND PISTON
REMOVING THE PISTON
CHECKING THE CYLINDER AND PISTON
CHECKING THE PISTON RINGS
CHECKING THE PISTON PIN
INSTALLING THE PISTON AND CYLINDER
AC MAGNETO
REMOVING THE AC MAGNETO ROTOR
CHECKING THE STATOR COIL AND CRANKSHAFT POSITION
SENSOR
CHECKING THE STARTER CLUTCH
CHECKING THE TORQUE LIMITER
INSTALLING THE AC MAGNETO ROTOR
BALANCER GEARS AND OIL PUMP GEARS
REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP
DRIVEN GEAR
CHECKING THE OIL PUMP DRIVE
CHECKING THE BALANCER DRIVE
INSTALLING THE BALANCER DRIVE GEAR, BALANCER DRIVE
GEAR, AND OIL PUMP DRIVEN GEAR
PRIMARY AND SECONDARY SHEAVES
PRIMARY SHEAVE
SECONDARY SHEAVE
REMOVING THE PRIMARY AND SECONDARY SHEAVES
DISASSEMBLING THE SECONDARY SHEAVE
CHECKING THE PRIMARY SHEAVE
CHECKING THE SECONDARY SHEAVE
ASSEMBLING THE PRIMARY SHEAVE
ASSEMBLING THE SECONDARY SHEAVE
INSTALLING THE PRIMARY AND SECONDARY SHEAVES
CLUTCH
REMOVING THE CLUTCH
CHECKING THE CLUTCH
INSTALLING THE CLUTCH
CRANKCASE
TIMING CHAIN AND OIL FILTER
CRANKCASE
CRANKCASE BEARINGS
SEPARATING THE CRANKCASE
CHECKING THE TIMING CHAIN AND GUIDE
CHECKING THE RELIEF VALVE
CHECKING THE BEARINGS
CHECKING THE CRANKCASE
ASSEMBLING THE CRANKCASE
INSTALLING THE SHIFT LEVER
CRANKSHAFT AND OIL PUMP
OIL PUMP
REMOVING THE CRANKSHAFT
CHECKING THE OIL PUMP
CHECKING THE OIL STRAINER
CHECKING THE CRANKSHAFT
ASSEMBLING THE OIL PUMP
INSTALLING THE CRANKSHAFT
TRANSMISSION
DRIVE AXLE
REMOVING THE TRANSMISSION
CHECKING THE SHIFT FORKS
CHECKING THE SHIFT DRUM
CHECKING THE TRANSMISSION
CHECKING THE SECONDARY SHAFT
CHECKING THE STOPPER LEVER AND STOPPER WHEEL
ASSEMBLING THE SHIFT FORK ASSEMBLY
INSTALLING THE TRANSMISSION
MIDDLE GEAR
MIDDLE DRIVE SHAFT
MIDDLE DRIVEN SHAFT
REMOVING THE MIDDLE DRIVE SHAFT
REMOVING THE MIDDLE DRIVEN SHAFT
CHECKING THE PINION GEARS
SELECTING MIDDLE DRIVE AND DRIVEN GEAR SHIMS
INSTALLING THE BEARING AND OIL SEALS
INSTALLING THE MIDDLE DRIVEN SHAFT
INSTALLING THE MIDDLE DRIVE SHAFT
MEASURING THE MIDDLE GEAR BACKLASH
CHAPTER 5
COOLING SYSTEM
RADIATOR
CHECKING THE RADIATOR
INSTALLING THE RADIATOR
THERMOSTAT
CHECKING THE THERMOSTAT
INSTALLING THE THERMOSTAT
WATER PUMP
DISASSEMBLING THE WATER PUMP
CHECKING THE WATER PUMP
ASSEMBLING THE WATER PUMP
CHAPTER 6
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
CIRCUIT DIAGRAM
ECU SELF DIAGNOSTIC FUNCTION
SELF DIAGNOSTIC FUNCTION TABLE
TROUBLESHOOTING CHART
DIAGNOSTIC MODE
TROUBLESHOOTING DETAILS
CHECKING THE INTAKE AIR PRESSURE SENSOR
CHECKING THE INTAKE AIR TEMPERATURE SENSOR
FUEL TANK
REMOVING THE FUEL TANK
REMOVING THE FUEL PUMP
CHECKING THE FUEL PUMP BODY
CHECKING THE ROLLOVER VALVE
INSTALLING THE FUEL PUMP
INSTALLING THE FUEL HOSE
THROTTLE BODY
REMOVING THE THROTTLE BODY ASSEMBLY
CHECKING THE FUEL INJECTOR
CHECKING THE THROTTLE BODY
INSTALLING THE THROTTLE BODY ASSEMBLY
CHECKING THE FUEL PUMP AND PRESSURE REGULATOR
OPERATION
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR
CHAPTER 7
DRIVE TRAIN
TROUBLESHOOTING
CHECKING NOISES
TROUBLESHOOTING CHART
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR
REMOVING THE DIFFERENTIAL GEAR ASSEMBLY
CHECKING THE FRONT CONSTANT VELOCITY JOINTS
CHECKING THE DIFFERENTIAL GEARS
CHECKING THE DIFFERENTIAL GEAR MOTOR
ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS
ASSEMBLING THE DIFFERENTIAL GEARS
MEASURING THE DIFFERENTIAL GEAR LASH
ADJUSTING THE DIFFERENTIAL GEAR LASH
CHECKING THE DIFFERENTIAL GEAR OPERATION
REAR CONSTANT VELOCITY JOINTS AND FINAL DRIVE GEAR
ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS
DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY
POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR
ADJUSTING THE FINAL DRIVE PINION GEAR BACKLASH
ADJUSTING THE FINAL DRIVEN PINION GEAR BACKLASH
MEASURING THE FINAL DRIVEN PINION GEAR THRUST
WASHER CLEARANCE
MEASURING THE WHEEL GEAR THRUST CLEARANCE
CHECKING THE REAR DRIVE SHAFT
CHECKING THE FINAL DRIVE ASSEMBLY
MEASUREMENT THE FINAL GEAR LASH
ADJUSTING THE FINAL GEAR LASH
ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY
ASSEMBLING THE FINAL GEAR CASE
CHAPTER 8
CHASSIS
FRONT AND REAR WHEELS
FRONT WHEELS
REAR WHEELS
CHECKING THE WHEELS
CHECKING THE WHEEL HUBS
CHECKING THE BRAKE DISCS
INSTALLING THE BRAKE DISCS
INSTALLING THE WHEEL HUBS
INSTALLING THE WHEELS
FRONT AND REAR BRAKES
FRONT BRAKE PADS
REAR BRAKE PADS
REPLACING THE FRONT AND REAR BRAKE PADS
FRONT BRAKE MASTER CYLINDER
REAR BRAKE MASTER CYLINDER
CHECKING THE MASTER CYLINDERS
ASSEMBLING THE FRONT AND REAR BRAKE MASTER
CYLINDERS
INSTALLING THE FRONT BRAKE MASTER CYLINDER
INSTALLING THE REAR BRAKE MASTER CYLINDER
FRONT BRAKE CALIPERS
REAR BRAKE CALIPERS
DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS
CHECKING THE FRONT AND REAR BRAKE CALIPERS
ASSEMBLING THE FRONT AND REAR BRAKE CALIPERS
INSTALLING THE FRONT AND REAR BRAKE CALIPERS
STEERING SYSTEM
HANDLEBAR
REMOVING THE HANDLEBAR GRIPS
CHECKING THE HANDLEBAR
INSTALLING THE HANDLEBAR
INSTALLING THE HANDLEBAR GRIPS
INSTALLING THE REAR BRAKE MASTER CYLINDER
INSTALLING THE FRONT BRAKE MASTER CYLINDER
INSTALLING THE THROTTLE LEVER ASSEMBLY
STEERING STEM
CHECKING THE STEERING STEM
INSTALLING THE STEERING STEM
INSTALLING THE PITMAN ARM
TIE RODS AND STEERING KNUCKLES
REMOVING THE STEERING KNUCKLES
CHECKING THE TIE RODS
CHECKING THE STEERING KNUCKLES
INSTALLING THE TIE RODS
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
REMOVING THE FRONT ARMS
CHECKING THE FRONT ARMS
CHECKING THE FRONT SHOCK ABSORBERS
INSTALLING THE FRONT ARMS AND FRONT SHOCK
ABSORBERS
REAR KNUCKLES AND STABILIZER
CHECKING THE REAR KNUCKLES
CHECKING THE STABILIZER
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES
CHECKING THE REAR ARMS
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES
INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER
ASSEMBLIES
CHAPTER 9
ELECTRICAL
ELECTRICAL COMPONENTS
CHECKING SWITCH CONTINUITY
CHECKING THE SWITCHES
CHECKING THE BULBS AND BULB SOCKETS
TYPES OF BULBS
CHECKING THE CONDITION OF THE BULBS
CHECKING THE CONDITION OF THE BULB SOCKETS
IGNITION SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
STARTING CIRCUIT OPERATION
TROUBLESHOOTING
STARTER MOTOR
CHECKING THE STARTER MOTOR
ASSEMBLING THE STARTER MOTOR
CHARGING SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
LIGHTING SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
CHECKING THE LIGHTING SYSTEM
SIGNALING SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
CHECKING THE SIGNALING SYSTEM
COOLING SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
FUEL PUMP SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
WD/ WD SELECTING SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
EPS (ELECTRIC POWER STEERING) SYSTEM
CIRCUIT DIAGRAM
EPS CONTROL UNITS SELF DIAGNOSTIC FUNCTION
EPS WARNING LIGHT DURING NORMAL OPERATION
DIAGNOSTIC MODE
SELF DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)
TROUBLESHOOTING DETAILS (EPS SYSTEM)
CHECKING THE EPS MOTOR
CHECKING THE EPS TORQUE SENSOR
CHAPTER 10
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING
FUEL SYSTEM
ELECTRICAL SYSTEM
COMPRESSION SYSTEM
POOR IDLE SPEED PERFORMANCE
POOR IDLE SPEED PERFORMANCE
POOR MEDIUM AND HIGH SPEED PERFORMANCE
POOR MEDIUM AND HIGH SPEED PERFORMANCE
FAULTY DRIVE TRAIN
FAULTY GEAR SHIFTING
HARD SHIFTING
SHIFT LEVER DOES NOT MOVE
JUMPS OUT OF GEAR
FAULTY CLUTCH PERFORMANCE
ENGINE OPERATES BUT VEHICLE WILL NOT MOVE
CLUTCH SLIPPING
POOR STARTING PERFORMANCE
POOR SPEED PERFORMANCE
OVERHEATING
OVERHEATING
OVERCOOLING
COOLING SYSTEM
FAULTY BRAKE
POOR BRAKING EFFECT
SHOCK ABSORBER MALFUNCTION
MALFUNCTION
UNSTABLE HANDLING
UNSTABLE HANDLING
LIGHTING SYSTEM
HEADLIGHT DOES NOT COME ON
BULB BURNT OUT
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