How to Rebuild the Clutch on a Yamaha Grizzly YFM700
Sluggish acceleration or stuttering delivery of power is a sign that the clutch in your Yamaha Grizzly is slipping.
This guide will walk you through disassembling, inspecting and rebuilding a Yamaha Grizzly YFM700 clutch. The only specialist tool you'll need for this job is a sheave holder. Watch the video above and use our Yamaha Grizzly clutch diagram for additional reference.
Tools and Parts Needed - YFM700 Primary Clutch Rebuild
- Ratchet and extensions
- 10mm, 22mm sockets
- 10mm, 12mm wrenches
- 4mm Allen
- 6mm bolts (x2)
- Impact driver
- Sheave holder
- Torque wrench
Disassembling Yamaha Grizzly YFM700 Clutch
Step 1. Remove the right footwell cover by taking off the 10mm bolts and the 4mm Allen bolts.
Step 2. Remove the seat.
Step 3. Remove the side cover by taking the plastic rivet and the 10mm bolt off.
Step 4. Loosen the rear brake cable, so there is enough travel in the brake pedal and it can be pressed down to allow access to the crankcase cover's lower bolts. Remove the 10mm crankcase cover bolts and the crankcase cover.
Step 5. Remove the bearing carrier that encloses the primary sheaves. Be careful not to lose the two dowels that the bearing carrier aligns upon, and make sure the dowels are either firmly in the crankcase or the bearing carrier.
NOTE: The carrier has two types of bolts, with the longer bolts in the top right and bottom left, and the shorter bolts in the top left and bottom right.
Step 6. Loosen the secondary sheaves by inserting two 6mm bolts into the outer sheave, then tightening the bolts into the sheave to put tension on the sheaves and open them up slightly.
Step 7. Remove the 22mm nut and washer from the primary sheaves, and pull the primary sheave hub off the driveshaft.
Step 8. Remove the central collar from the primary sheave hub, and slide the collar back onto the driveshaft.
Step 9. Inspect the inner fixed sheave and the outer sliding sheave for wear, and replace them if necessary.
Step 10. Remove the pan head screws. Use an impact driver to avoid damaging the screw heads.
Step 11. Prise apart the primary sliding sheave and the stopper cover.
NOTE: Be careful when performing this step, as the metal of the cover is thin and can be easily damaged.
Step 12. Remove the outer O-ring from the primary sliding sheave.
Step 13. Lift the clutch cam out from the primary sliding sheave. Note that there are four sliders attached to the cam.
Step 14. Remove the eight weights from the primary sliding sheave.
Rebuilding Yamaha Grizzly YFM700 Clutch
Step 1. Thoroughly clean all the parts that make up the primary sheave hub with contact/brake cleaner, and remove every last trace of grease, dirt and debris.
Step 2. Check the inside of the primary sliding sheave for wear, particularly where the sliders sit.
NOTE: Remember, if the primary sliding sheave needs to be replaced, you must replace both the fixed and sliding sheaves together. Do not replace only one.
Step 7. Lightly grease the inside lip of the stopper, and reinstall it onto the primary sliding sheave.
Step 8. Reinstall the primary sheave hub onto the driveshaft.
Step 9. Reinstall the washer and the 22mm nut, and torque the nut to 100 foot-pounds. Use a sheave holder tool to hold the primary sheaves in place so you can torque them.
Step 10. Install a new V-belt over the primary sheaves. Make sure the arrows printed on the V-belt are pointing toward the front of the Grizzly.
Step 11. With the V-belt on the primary sheaves, get the belt partially over the secondary sheaves, then rotate the primary sheaves counterclockwise and walk the V-belt over the secondary sheaves as you do so.
Step 12. Remove the two 6mm bolts from the secondary sheaves, and rotate the sheaves counterclockwise a few times to allow the secondary sheaves to close back together.
Step 13. Grease the end of the driveshaft and the inside of the bearing carrier, and reinstall the bearing carrier. Remember, the longer bearing carrier bolts go in the top right and bottom left, and the shorter bolts in the top left and bottom right. Torque the bolts to 7 foot-pounds.
Step 14. Check that the crankcase cover seal is in good condition (replace it if it is split or cracked), and reinstall the crankcase cover.
Step 15. Tighten the rear brake cable back up again.
Step 16. Reinstall the plastics, the footwell cover and the seat.
Step 17. Refill the motor with oil to the correct level.
All done. We know you love your ATV, so stay tuned to our blog for more Yamaha Grizzly repairs!