2008 Yamaha Grizzly 700 Service Manual

The 2008 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.

General Information & Specifications

Key identification: Model code, VIN location, engine serial number. General specifications for the 2008 Yamaha Grizzly 700.

Periodic Maintenance & Tune-Up

Follow the maintenance schedule for optimal performance and longevity.

1. Pre-ride inspection: Check tires, brakes, lights, controls, and fluid levels.
2. Engine oil & filter: Change every 100 hours or 6 months, whichever comes first.
3. Air filter: Clean every 20-50 hours; replace if damaged.
4. Spark plug: Inspect and adjust gap (0.028–0.031 in / 0.7–0.8 mm) every 100 hours.
5. Valve clearance: Check and adjust every 200 hours (intake: 0.004–0.006 in / 0.10–0.15 mm; exhaust: 0.008–0.010 in / 0.20–0.25 mm).
6. Drive belt: Inspect every 100 hours for wear or cracks.
7. Brake fluid: Check level and condition every 200 hours; replace every 2 years.

WARNING! Always perform maintenance with engine off and cool. Use genuine Yamaha parts and recommended lubricants.

Engine & Transmission

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

1. Engine removal: Disconnect battery, drain coolant and oil, remove exhaust, electrical connections, and mounting bolts.
2. Cylinder head: Remove, check for warpage, inspect valves and seats.
3. Cylinder & piston: Measure cylinder bore and piston clearance; replace if out of spec.
4. Crankshaft & bearings: Check runout and bearing clearance.
5. Ultramatic transmission: Inspect drive and driven clutches, V-belt, and weights.
6. Reassembly: Use new gaskets and seals; torque fasteners to specification.

CAUTION! Label all parts and connections during disassembly. Follow torque sequences and values precisely.

Fuel & Exhaust Systems

• Fuel tank: Removal and cleaning procedures.
• Fuel pump: Testing and replacement steps.
• Carburetor: Disassembly, cleaning, jet inspection, float level adjustment, and synchronization (if applicable).
• Throttle body: For fuel-injected models, inspect throttle position sensor and injectors.
• Air intake system: Inspect hoses, joints, and air filter housing for leaks.
• Exhaust system: Remove, inspect for cracks or leaks, and clean spark arrestor.

Chassis & Suspension

Front and rear suspension service: Independent double-wishbone front, fully independent rear.

Front suspension: Remove wheel, shock absorber, upper and lower arms. Inspect bushings, ball joints, and seals. Replace worn components.

Rear suspension: Remove wheel, shock, trailing arms. Check pivot bearings and bushings.

Steering: Inspect tie rods, steering stem bearings, and handlebar mounts. Adjust or replace as needed.

Wheels & tires: Check for damage, runout, and proper inflation (front: 4.9 psi / 34 kPa, rear: 4.4 psi / 30 kPa for standard terrain).

Electrical System

Battery: 12V, 12Ah. Test and maintain charge. Charging system: Stator and regulator/rectifier testing. Starting system: Starter motor and relay checks. Lighting: Headlight, taillight, brake light inspection and bulb replacement. Switches & controls: Handlebar switch continuity tests. Fuses: Location and amperage ratings.

1. Use a multimeter for voltage and continuity tests.
2. Refer to wiring diagrams for circuit tracing.
3. Ensure all connections are clean, tight, and protected from moisture.

Tip: Disconnect battery before performing electrical work to prevent shorts.

Brake System

Dual hydraulic disc brakes front and rear.

1. Brake pads: Inspect thickness; replace if worn to limit.
2. Brake discs: Check for warpage, scoring, or thickness below minimum.
3. Brake fluid: Drain, flush, and refill with DOT 4 fluid. Bleed system to remove air.
4. Brake lines: Inspect for cracks, leaks, or damage.
5. Parking brake: Adjust cable tension for proper engagement.

WARNING! Do not allow brake fluid to contact painted surfaces. Always bleed brakes starting from the caliper farthest from the master cylinder.

Drive System & Final Drive

On-Command® 2WD/4WD system with differential lock.

1. Front differential: Drain and refill gear oil (SAE 80W-90). Inspect seals and bearings.
2. Rear gearcase: Drain, inspect, and refill with recommended oil.
3. Drive shafts: Remove and check for worn CV joints or U-joints. Grease splines.
4. 4WD actuator: Test engagement and disengagement. Replace if faulty.
5. Differential lock: Test operation; adjust cable if necessary.

CAUTION! Ensure the vehicle is in 2WD and differential lock is disengaged when performing maintenance on the drive system.

Body & Frame

Plastic panel removal and installation. Frame inspection for cracks or damage. Seat removal. Storage compartment access. Winch installation guidelines (if equipped).

CAUTION! Use proper tools to remove plastic clips to avoid breakage. Support the ATV securely when working underneath.

Troubleshooting

Reset ECU: Disconnect battery for 10 minutes to clear fault codes (if applicable).

Service: For Yamaha dealer support or genuine parts, visit www.yamahamotorsports.com or contact 1-800-88-YAMAHA.

Wiring Diagrams

Complete wiring schematics for the 2008 Yamaha Grizzly 700, including main harness, lighting, starting/charging, and 4WD system circuits. Use for diagnosing electrical faults and understanding circuit layouts.

Note: Diagrams are specific to model and year. Always verify wire colors and connector positions against the actual vehicle.