Yamaha Yfm 700 Fi Grizzly Service Manual (PS031267)

Yamaha Yfm 700 Fi Grizzly Service Manual (PS031267)

• This manual presented for you in electronic format you can just print out the page you need then dispose of it when you have completed your task. This manual has detailed illustrations as well as step by step written instructions with the necessary diagrams or pictures. These manuals are your number one source for repair and service information, specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle. Using this repair manual is an inexpensive way to keep your car working properly. it is this level of detail, along with illustrations, that guide the reader through each service, repairs, maintenance procedure.
• please view preview at top left page

  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