2012 Yamaha Grizzly 700 Service Manual

The 2012 Yamaha Grizzly 700 is a high-performance, four-wheel-drive 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 sealed wet brake system. This service manual provides comprehensive information for maintenance, repair, and troubleshooting. Below are key sections covering safety, specifications, periodic maintenance, engine service, chassis, electrical system, and troubleshooting.

Features at a Glance

Key components: 686cc liquid-cooled engine, Ultramatic automatic transmission, On-Command 2WD/4WD with diff lock, independent front suspension, sealed wet brakes, electric power steering (EPS) on select models, and digital instrumentation.

Safety Precautions

Always follow safety procedures when servicing the ATV.

1. Work in a well-ventilated area; keep away from open flames.
2. Use proper tools and Yamaha Genuine Parts or equivalents.
3. Support the ATV securely on a stand before working underneath.
4. Disconnect battery negative terminal before electrical work.
5. Relieve fuel system pressure before disconnecting fuel lines.

WARNING! Engine and exhaust components become extremely hot. Allow to cool before servicing. Gasoline is highly flammable; handle with care.

Periodic Maintenance

Refer to the maintenance schedule for service intervals.

1. Engine oil & filter: Change every 100 hours or 6 months (whichever comes first).
2. Air filter: Clean every 20-50 hours; replace if damaged.
3. Spark plug: Inspect/clean every 100 hours; replace every 200 hours.
4. Drive belt: Inspect every 200 hours for wear/cracks.
5. Brake fluid: Check level monthly; replace every 2 years.
6. Wheel nuts & fasteners: Check torque before each ride.

CAUTION! Use recommended Yamalube oils and fluids. Incorrect lubricants can cause damage.

Specifications

• 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 (or Fuel Injection on FI models).
• Ignition System: DC-CDI.
• Starting System: Electric starter with auxiliary recoil.
• Transmission: Ultramatic automatic V-belt with H, L, N, R, P ranges.
• Final Drive: Shaft drive.
• Suspension Travel (F/R): 7.1 in / 9.5 in.
• Brakes: Dual hydraulic disc front, sealed wet multi-disc rear.
• Tires: AT25 x 8-12 front, AT25 x 10-12 rear.
• Dry Weight: 604 lbs (274 kg).
• Fuel: Unleaded gasoline, 87 octane or higher.

Engine Service

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

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

Compression Pressure: Standard: 128 psi (8.8 kg/cm²) at 450 rpm. Minimum: 114 psi (8.0 kg/cm²).

Oil Pressure: 4.3 psi (0.3 kg/cm²) at idle, 28–43 psi (2.0–3.0 kg/cm²) at 5,000 rpm.

Torque Specifications: Cylinder head bolts: 37 ft-lb (50 Nm). Spark plug: 13 ft-lb (18 Nm). Oil drain plug: 20 ft-lb (27 Nm).

Chassis & Suspension

Front suspension: Independent double wishbone with preload-adjustable shocks. Rear: Swingarm with adjustable shock.

1. Check for loose bolts, worn bushings, or leaking shock seals.
2. Lubricate suspension pivots every 100 hours.
3. Wheel alignment: Toe-in: 0–10 mm (0–0.39 in). Camber: 0° ± 1°.
4. Steering stem bearing adjustment: Adjust if freeplay exists.

Tip: Inspect tie rods and ball joints for wear before each ride.

Electrical System

12V DC system with battery, starter, charging system, lighting, and instrumentation.

1. Battery: YTZ7S (12V, 6.3 Ah). Maintain specific gravity at 1.280 at 20°C (68°F).
2. Charging voltage: 13.5–15.5 V at 5,000 rpm.
3. Starter draw: 90 A max.
4. Fuses: Main 30A, Headlight 15A, Signaling 10A, Ignition 10A.
5. Bulbs: Headlight 12V 35/35 W, Tail/Brake 12V 5/21 W.

WARNING! Disconnect battery before welding or performing major electrical repairs.

Transmission & Drive System

Ultramatic automatic transmission with high/low range, reverse, and park.

1. Drive belt inspection: Remove cover, check for cracks, fraying, or glazing. Width limit: 27.9 mm (1.098 in).
2. Differential oil: SAE 80W-90 API GL-5. Capacity: 0.35 qt (0.33 L). Change every 200 hours.
3. On-Command system: Check 4WD engagement and differential lock operation.
4. Shaft drive: Inspect boots for cracks; lubricate splines every 400 hours.

CAUTION! Do not engage differential lock on hard surfaces to avoid driveline damage.

Brake System

Front: Dual hydraulic disc brakes. Rear: Sealed wet multi-disc brake.

Front Brake: Disc thickness: Standard 4.0 mm (0.16 in), Limit 3.0 mm (0.12 in). Pad thickness limit: 1.0 mm (0.04 in). Fluid: DOT 4.

Rear Brake: Check operation; adjust lever freeplay. Fluid change every 2 years.

Bleeding Procedure: Fill reservoir, attach tube to bleeder, pump lever, open bleeder, close, repeat until air-free.

Troubleshooting

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

Wiring Diagrams

Refer to the separate wiring diagram section at the end of this manual for complete electrical schematics, including color codes and connector locations for the main harness, lighting, ignition, and accessory circuits.

Note: Diagrams are specific to the 2012 Yamaha Grizzly 700 (including EPS and non-EPS models). Use a multimeter for continuity and voltage checks.