Grizzly 700 Parts Manual

The Grizzly 700 is a rugged all-terrain vehicle (ATV) featuring a 686cc liquid-cooled engine, selectable 2WD/4WD with differential lock, independent double wishbone front suspension, Ultramatic automatic transmission with engine braking, electric power steering, and a towing capacity of 1,322 lbs. This manual provides detailed parts identification, diagrams, ordering information, maintenance specifications, and assembly instructions for the Grizzly 700 model. Below are key sections for parts overview, engine components, chassis, electrical, drive system, and maintenance.

1. Parts Overview & Diagrams 2. Engine Assembly Parts 3. Chassis & Frame Components 4. Drive System Parts 5. Suspension & Steering Parts 6. Electrical System Parts 7. Body & Accessory Parts 8. Maintenance Parts & Kits 9. Parts Ordering Information 10. Assembly Instructions 11. Troubleshooting & Replacement Guide

Parts Overview & Diagrams

Key components: Engine assembly, chassis frame, drive train, suspension system, electrical harness, body panels.

Component Group	Description
Engine Assembly	Complete 686cc liquid-cooled engine with cylinder head, crankcase, and internal components
Chassis Frame	Main steel frame with subframe, mounting points, and protective skid plates
Drive System	Ultramatic transmission, drive shaft, front/rear differentials, and axles
Suspension	Independent double wishbone front, rear swingarm with shock absorbers
Steering	Electric power steering assembly, tie rods, steering shaft
Electrical	Wiring harness, ECU, battery, lighting, switches, and sensors
Body Panels	Front fenders, rear fenders, seat base, fuel tank cover, and storage compartments
Braking System	Dual hydraulic disc brakes front and rear, parking brake assembly
Exhaust System	Exhaust pipe, muffler, heat shields, and mounting hardware
Fuel System	Fuel tank, fuel pump, injectors, throttle body, and air intake

Engine Assembly Parts

Detailed parts list for the 686cc liquid-cooled 4-stroke engine.

Cylinder Head Assembly: Includes valves, springs, camshaft, and head gasket.
Crankcase & Cylinder: Piston, connecting rod, crankshaft, and bearings.
Cooling System: Radiator, water pump, hoses, and thermostat.
Lubrication: Oil pump, filter, and oil cooler components.
Fuel Injection: Throttle body, fuel injector, pressure regulator.

WARNING! Engine components are precision parts; handle with care to avoid damage. Use proper torque specifications during assembly.

Chassis & Frame Components

Frame parts including main frame, subframe, and protective elements.

Main Frame: Steel construction with welded joints and mounting brackets.
Subframe: Rear section supporting seat, cargo rack, and body panels.
Skid Plates: Underbody protection for engine and drive components.
Footrests & Floorboards: Rubber-coated footrests and floorboard assemblies.
Cargo Racks: Front and rear racks with tie-down points.

CAUTION! Inspect frame for cracks or damage before installation. Use appropriate lifting equipment for handling.

Drive System Parts

Transmission: Ultramatic automatic CVT with primary/secondary clutches.
Drive Shaft: Front and rear drive shafts with universal joints.
Differentials: Front differential with locking mechanism, rear differential.
Axles: CV axles with boots and joints for front and rear.
Wheels & Tires: Aluminum wheels, ATV tires with specified load ratings.
Brakes: Hydraulic disc brakes, calipers, rotors, brake pads.
Final Drive: Gear reduction unit and sprockets.
4WD Components: Shift motor, actuator, and related linkage.

Suspension & Steering Parts

Front independent suspension with double wishbones, rear swingarm with shock.

Front Suspension: Upper/lower A-arms, ball joints, shock absorbers, springs. Rear Suspension: Swingarm, linkage, shock absorber, spring. Steering: Electric power steering unit, steering column, tie rods, ends. Wheel Components: Hubs, bearings, seals, and mounting hardware.

Electrical System Parts

Wiring harness, battery, lighting, switches, and electronic controls.

Disconnect battery before working on electrical components.
Identify connectors by color and position in diagrams.
Test components with multimeter before replacement.

Tip: Use dielectric grease on connectors to prevent corrosion.

Body & Accessory Parts

Plastic body panels, seat, storage, and optional accessories.

Front Fenders: Left and right fender assemblies with mounting brackets.
Rear Fenders: Complete rear fender set with integrated taillight housing.
Seat Assembly: Seat base, foam, cover, and latch mechanism.
Fuel Tank Cover: Plastic cover with integrated instrument panel mounting.
Storage Compartments: Front storage box and under-seat storage.
Optional Accessories: Winch mounts, brush guards, cargo racks, and lighting kits.

WARNING! Ensure proper alignment of body panels before tightening fasteners to avoid stress cracks.

Maintenance Parts & Kits

Common replacement parts and maintenance kits for scheduled service.

Parts Ordering Information

Use genuine Yamaha parts for optimal performance and warranty coverage.

CAUTION! Counterfeit parts may compromise safety and performance. Order from authorized dealers only.

Assembly Instructions

Step-by-step assembly guidelines for major component installation.

Component	Tools Required	Torque Specifications
Engine Mounting	Torque wrench, socket set	Main bolts: 45 ft-lbs
Front Suspension	Ball joint separator, wrench set	Upper ball joint: 18 ft-lbs
Steering Assembly	Steering wheel puller, hex keys	Steering stem nut: 65 ft-lbs
Drive Shaft	Snap ring pliers, grease gun	U-joint bolts: 22 ft-lbs
Body Panels	Trim removal tools, screwdriver	Panel screws: 7 ft-lbs

Note: Refer to service manual for complete torque specifications and sequences.

Troubleshooting & Replacement Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, or compression issue	Check fuel pump, spark plug, compression; inspect electrical connections.
4WD not engaging	Actuator or shift motor failure	Test actuator operation; check wiring; replace shift motor if needed.
Steering feels heavy	EPS failure or low battery voltage	Check battery voltage; test EPS unit; inspect steering linkage.
Excessive vibration	Unbalanced tires or worn U-joints	Balance tires; inspect drive shaft U-joints for wear.
Brake drag or noise	Stuck caliper or worn pads	Clean and lubricate caliper slides; replace brake pads if worn.

Service Support: Contact authorized Yamaha dealer or visit Yamaha's official website for technical assistance.