2007 Yamaha Grizzly 700 Service Manual

The 2007 Yamaha Grizzly 700 is a high-performance, all-terrain vehicle (ATV) featuring a 686cc liquid-cooled, SOHC, 4-stroke engine with Ultramatic automatic transmission, On-Command 2WD/4WD with differential lock, independent double wishbone front suspension, and a fully independent rear suspension. This manual provides comprehensive service, maintenance, and repair information for owners and technicians. Below are key sections covering specifications, periodic maintenance, engine service, chassis, electrical system, troubleshooting, and more.

1. General Information & Specifications 2. Periodic Maintenance & Lubrication 3. Engine & Transmission 4. Chassis & Suspension 5. Electrical System 6. Fuel & Exhaust Systems 7. Drive System & Brakes 8. Body & Accessories 9. Troubleshooting 10. Wiring Diagrams 11. Safety & Regulatory Information

General Information & Specifications

Key identification: Model code YFM70FGP, VIN location on frame, engine serial number on crankcase.

Feature	Specification
Engine Type	686cc, liquid-cooled, SOHC, 4-stroke, single cylinder
Bore x Stroke	102.0 mm x 84.0 mm
Compression Ratio	9.2:1
Fuel System	Mikuni BSR42 carburetor
Transmission	Ultramatic automatic V-belt with all-wheel engine braking
Drive System	On-Command 2WD/4WD with differential lock
Suspension Front	Independent double wishbone, 7.1 in travel
Suspension Rear	Fully independent, 9.5 in travel
Brakes Front/Rear	Dual hydraulic disc / Sealed wet multi-disc brake
Tires	AT25 x 8-12 front, AT25 x 10-12 rear

Periodic Maintenance & Lubrication

Follow maintenance schedule for optimal performance and longevity.

Pre-ride inspection: Check tires, brakes, lights, controls, and fluid levels.
Engine oil change: Every 100 hours or 6 months; use Yamalube 4 (10W-30) or equivalent.
Oil filter replacement: Every other oil change.
Air filter service: Clean every 20 hours, replace as needed.
Drive belt inspection: Check for wear/cracks every 100 hours.
Lubrication points: Grease suspension, steering, and drive shaft fittings every 20 hours.

WARNING! Allow engine to cool before servicing. Use proper tools and safety equipment.

Engine & Transmission

Service procedures for engine removal, disassembly, inspection, and reassembly.

Engine removal: Disconnect battery, drain coolant/fuel, remove mounting bolts.
Cylinder head: Check for warpage; valve clearance intake 0.10–0.15 mm, exhaust 0.15–0.20 mm.
Piston/cylinder: Inspect for scoring; standard bore 102.000–102.015 mm.
Crankshaft/connecting rod: Check runout and big-end side clearance.
Transmission: Inspect Ultramatic drive belt, sheaves, and rollers for wear.
Clutch service: Clean centrifugal clutch and check spring tension.

CAUTION! Torque all fasteners to specifications. Use new gaskets upon reassembly.

Chassis & Suspension

Frame: Steel double-cradle; inspect for cracks/damage.
Front Suspension: Double wishbone with preload-adjustable shocks.
Rear Suspension: Independent with adjustable preload and rebound damping.
Steering: Handlebar adjustment; check tie-rod ends and ball joints.
Wheels & Tires: Aluminum wheels; tire pressure 3.5 psi front, 3.5 psi rear (standard).
Service: Wheel bearing inspection, axle nut torque (110 Nm).

Electrical System

Battery: 12V 12Ah (YTZ12S). Charging system: AC magneto with regulator/rectifier.

Components: Starter motor, ignition coil, CDI unit, lighting system, switches.

Testing: Use multimeter for continuity, voltage, and resistance checks. Spark plug: NGK CR8E, gap 0.6–0.7 mm. Fuses: Main 30A, sub 15A, 10A. Bulbs: Headlight 12V 35/35W, tail/brake 12V 5/21W.

Fuel & Exhaust Systems

Fuel tank capacity: 19.8 L (5.3 US gal). Carburetor adjustment: Pilot screw 2-1/4 turns out (initial).

Fuel valve: ON, RES, OFF positions; inspect for leaks.
Carburetor overhaul: Clean jets, check float height (13.5 mm).
Throttle cable: Adjust free play (3–5 mm).
Exhaust system: Remove heat shield, inspect for leaks/cracks.

Tip: Use fresh fuel and stabilizer for storage. Clean fuel filter regularly.

Drive System & Brakes

On-Command system: 2WD/4WD switch on handlebar; differential lock engagement.

Front drive shaft: Inspect boots and U-joints for damage.
Rear drive shaft: Check splines and bearing condition.
Brake pads: Replace if thickness < 1.5 mm.
Brake fluid: DOT 4; bleed system annually or if spongy.
Parking brake: Adjust cable; ensure it holds on incline.
Drive belt replacement: Remove cover, sheaves, and install new belt.

WARNING! Do not ride with worn brakes. Test drive system after service.

Body & Accessories

Plastic removal: Fenders, seat, side panels for access. Winch installation (optional).

Troubleshooting

Common issues and diagnostic steps.

Symptom	Possible Cause	Corrective Action
Engine won't start	No spark, fuel, or compression	Check spark plug, fuel flow, compression (standard 1280 kPa).
Poor performance	Clogged air filter, carburetor issues	Clean/replace air filter; service carburetor.
Overheating	Low coolant, clogged radiator	Check coolant level; clean radiator fins.
Transmission slipping	Worn drive belt, sheave wear	Inspect belt and sheaves; replace as needed.
Electrical failure	Blown fuse, bad battery	Check fuses; test battery voltage (12.6V+).

Reset: Disconnect battery to reset ECU if needed.

Wiring Diagrams

Complete color-coded wiring diagrams for entire electrical system. Refer to manual pages.

Safety & Regulatory Information

Always wear helmet, eye protection, and protective clothing. Operate only off-road where permitted. EPA/CARB compliant. Yamaha Motor Corporation, U.S.A. For technical support, contact authorized Yamaha dealer or visit yamahamotorsports.com. Manual part number: LIT-11626-22-84