2011 Yamaha Grizzly 700 Service Manual

The 2011 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 service manual provides comprehensive information for maintenance, troubleshooting, repair, and specifications to ensure optimal performance and longevity of your ATV. Below are key sections covering safety, features, periodic maintenance, engine service, chassis, electrical system, and troubleshooting.

Features at a Glance

Key components: 686cc engine, Ultramatic® transmission, On-Command® 4WD system, independent suspension, electric power steering (EPS), digital instrument panel, and towing capacity.

Safety Precautions

Always follow safety procedures to prevent injury or damage.

1. Work in a well-ventilated area; keep away from open flames.
2. Use proper tools and Yamaha Genuine Parts for repairs.
3. Disconnect battery negative terminal before electrical work.
4. Support ATV securely on a stand before working underneath.
5. Torque fasteners to specified values using a torque wrench.

WARNING! Engine and exhaust components become extremely hot during operation. Allow to cool before servicing. Always wear appropriate safety gear.

Periodic Maintenance

Regular maintenance ensures reliability and performance. Refer to the maintenance schedule for intervals.

1. Engine Oil & Filter: Change every 100 hours or 6 months, whichever comes first.
2. Air Filter: Clean every 20 hours; replace if damaged.
3. Spark Plug: Inspect and adjust gap every 100 hours; replace as needed.
4. Drive Belt: Inspect for wear/cracks every 200 hours.
5. Brake Fluid: Check level and condition every 100 hours; replace every 2 years.
6. Differential Oil: Change front and rear every 200 hours.
7. Tire Pressure: Check and adjust to 3.5 psi (24 kPa) before each ride.

CAUTION! Use only recommended fluids and filters. Incorrect specifications can cause damage.

Specifications

• Engine Displacement: 686cc
• Bore x Stroke: 102.0 x 84.0 mm
• Compression Ratio: 9.2:1
• Fuel System: Fuel injection (Mikuni® 44mm)
• Ignition System: DC-CDI
• Starting System: Electric starter
• Lubrication System: Wet sump
• Transmission: Ultramatic® V-belt automatic
• Final Drive: Shaft drive
• Dimensions (LxWxH): 83.1" x 46.5" x 49.6"
• Dry Weight: 617 lbs (280 kg)
• Ground Clearance: 11.8"

Engine Service

Procedures for cylinder head, valve train, piston, crankshaft, and lubrication system.

Valve Clearance Adjustment: Intake: 0.10–0.15 mm (0.0039–0.0059 in), Exhaust: 0.15–0.20 mm (0.0059–0.0079 in). Adjust when engine is cold.

Oil Change: Capacity: 3.7 US qt (3.5 L) with filter change. Use Yamalube® 4 (10W-30) or equivalent API SG or higher.

Cooling System: Capacity: 1.69 US qt (1.6 L). Use a 50/50 mix of high-quality ethylene glycol antifreeze and distilled water.

Chassis & Suspension

Frame, suspension arms, shocks, and wheel service.

1. Front Suspension: Check ball joints, bushings, and shock absorber for wear or leaks.
2. Rear Suspension: Inspect pivot points and shock condition.
3. Steering System: Check EPS operation, tie-rod ends, and steering play.
4. Wheels & Tires: Inspect for damage, balance, and correct tire pressure.

Tip: Lubricate all suspension pivot points with grease during periodic maintenance.

Electrical System

Battery, charging system, ignition, lighting, and EPS.

1. Battery: 12V, 12Ah. Maintain specific gravity at 1.280 at 20°C (68°F).
2. Charging System: Three-phase AC magneto. Output: 14V 25A at 5,000 rpm.
3. Starter Motor: 0.7 kW. Inspect brushes and commutator.
4. Fuses: Main 30A, Headlight 15A, Signal 10A, EPS 30A.
5. EPS: If malfunction light illuminates, check connections and voltage.

WARNING! Disconnect battery before servicing electrical components to prevent short circuits.

Fuel System

Fuel tank, pump, injector, and throttle body service.

1. Fuel Pump Pressure: 36 psi (250 kPa).
2. Throttle Body: Synchronize using vacuum gauges if multiple cylinders.
3. Fuel Filter: Replace every 200 hours or if clogged.
4. Idle Speed: 1,400 ± 100 rpm (in neutral, engine warm).

CAUTION! Relieve fuel pressure before disconnecting lines. No smoking or open flames.

Drive System

Ultramatic® transmission, drive belt, front and rear differentials.

1. Drive Belt: Width specification: 28.5 mm (1.122 in) minimum. Adjust deflection.
2. Front Differential Oil: Capacity 0.26 US qt (0.25 L). API GL-5 Hypoid gear oil SAE 80W-90.
3. Rear Differential Oil: Capacity 0.42 US qt (0.40 L). Same specification as front.
4. On-Command® System: Test 2WD/4WD and differential lock engagement.

WARNING! Do not operate with damaged drive belt. It can fail unexpectedly.

Brake System

Hydraulic disc brakes (front) and sealed wet multi-disc brake (rear).

Bleed brakes if spongy feel or air in system.

Troubleshooting

Reset ECU: Disconnect battery for 10 minutes to clear fault codes.

Service: For Yamaha dealer support or genuine parts, visit www.yamahamotorsports.com or contact 1-800-962-7926.