2016 Yamaha Grizzly 700 Service Manual

The 2016 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, Electric Power Steering (EPS), independent double-wishbone front and rear suspension, disc brakes, and a durable chassis. This manual provides comprehensive information for maintenance, troubleshooting, and repair procedures to ensure optimal performance and safety.

Features at a Glance

Key components: 686cc engine, Ultramatic transmission, On-Command 4WD system, Electric Power Steering (EPS), digital instrument panel, and robust chassis.

Installation & Assembly

Unpack and inspect all components. Assemble on a clean, level surface.

1. Install handlebars and controls: Align and tighten to specified torque.
2. Mount wheels and tires: Ensure proper alignment and inflation.
3. Connect battery: Attach positive then negative terminals.
4. Install accessories: Follow manufacturer instructions for racks, winches, etc.
5. Add fluids: Engine oil, coolant, and differential fluid as per specifications.

WARNING! ATV is heavy; use proper lifting equipment or assistance. Ensure all fasteners are torqued to specification.

First-Time Setup & Pre-Ride Inspection

Before first ride, perform thorough inspection and setup.

1. Check fluid levels: Engine oil, coolant, brake fluid, and differential oil.
2. Inspect tires: Pressure and condition.
3. Test controls: Throttle, brakes, steering, and drive selectors.
4. Verify lighting: Headlights, taillights, and indicators.
5. Adjust suspension: Pre-load settings for rider weight and cargo.
6. Break-in period: Follow recommended break-in procedure for first 10 hours of operation.

CAUTION! Always wear appropriate safety gear. Never operate without proper inspection.

Specifications

• Engine Type: 686cc liquid-cooled, SOHC, 4-stroke
• Bore x Stroke: 102.0 x 84.0 mm
• Compression Ratio: 9.2:1
• Fuel Delivery: Fuel injection
• Transmission: Ultramatic automatic V-belt with all-wheel engine braking
• Drive System: On-Command 2WD/4WD with diff lock
• Suspension Front/Rear: Independent double-wishbone, 7.9 in travel
• Brakes Front/Rear: Dual hydraulic disc
• Tires Front/Rear: AT25 x 8-12 / AT25 x 10-12
• Fuel Capacity: 5.3 gal (20 L)
• Dry Weight: 617 lb (280 kg)
• Towing Capacity: 1,322 lb (600 kg)

Controls and Indicators

Instrument panel includes speedometer, odometer, trip meter, fuel gauge, gear position, 4WD indicator, diff lock indicator, and warning lights.

Main Controls: Electric start, throttle, brake levers, On-Command switch (2WD/4WD/Diff Lock), high/low range selector, reverse lever, light switch, and EPS mode button.

Indicator Lights: Oil pressure, coolant temperature, battery charge, engine warning, and differential lock engagement.

Maintenance Procedures

Regular maintenance is crucial for safety and longevity.

1. Daily/Pre-ride: Check tires, controls, lights, and fluid levels.
2. Every 100 mi/160 km: Lubricate drive chain (if equipped), check brake pads.
3. Every 500 mi/800 km: Change engine oil and filter, inspect air filter.
4. Every 1,000 mi/1,600 km: Change differential oil, inspect brakes and suspension.
5. Every 2,000 mi/3,200 km: Replace spark plug, check valve clearance.
6. Seasonal: Check coolant concentration, battery condition, and storage procedures.

Tip: Always use genuine Yamaha parts and recommended fluids.

Engine Service

Detailed procedures for engine maintenance and repair.

1. Oil change: Warm engine, drain oil, replace filter, refill with 3.7 qt of 10W-40.
2. Valve clearance: Check and adjust when engine is cold (spec: 0.10–0.15 mm).
3. Spark plug: Replace with CR7E (gap: 0.7–0.8 mm).
4. Cooling system: Check coolant level, test radiator cap, flush every 2 years.
5. Fuel system: Inspect fuel lines, clean injector, replace fuel filter.
6. Compression test: Perform if engine lacks power or hard starting.

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

Drivetrain & Suspension

Service procedures for transmission, drive system, and suspension.

1. Ultramatic transmission: Inspect belt for wear, check sheave operation.
2. Differential oil: Change front and rear (capacity: 0.42 qt each).
3. Drive shaft: Lubricate splines and U-joints.
4. Suspension: Inspect A-arms, bushings, and shock absorbers for leaks or damage.
5. Wheel bearings: Check for play and replace if necessary.
6. Steering: Check EPS operation, inspect tie rods and ball joints.

Electrical System

Diagnosis and service of electrical components.

Battery: Maintain charge, clean terminals, test voltage (12.8V fully charged). Charging system: Test stator and regulator/rectifier output. Lighting: Replace bulbs, check wiring harness for damage. Starting system: Test starter motor, solenoid, and relay. Fuses: Locate and replace blown fuses (main: 30A, others: 10-15A).

CAUTION! Disconnect battery before electrical work. Follow wiring diagrams.

Safety & Regulatory Information

This vehicle complies with EPA and CARB emissions standards. Always follow local ATV laws and regulations. Operate only by licensed adults 16 and older. Always wear helmet, eye protection, gloves, boots, and protective clothing. Never carry passengers unless vehicle is specifically designed for them. Avoid paved surfaces; ATVs are for off-road use only. For support, contact Yamaha Customer Relations at 1-800-962-7926 or visit yamahamotorsports.com.

Troubleshooting

Reset: Disconnect battery for 10 minutes to reset ECU if experiencing electronic glitches.

Service: 1-800-962-7926; yamahamotorsports.com