Grizzly 700 Service Manual

The Grizzly 700 is a rugged all-terrain vehicle (ATV) featuring a 686cc liquid-cooled, fuel-injected engine, Ultramatic automatic transmission with engine braking, On-Command 2WD/4WD with differential lock, independent double wishbone front suspension, and a towing capacity of 1300 lbs. This service manual provides comprehensive information for maintenance, troubleshooting, and repair. Below are key sections covering safety, specifications, maintenance procedures, and technical data.

1. Features at a Glance 2. Safety Precautions 3. Specifications 4. Maintenance Schedule 5. Engine Service 6. Transmission & Drivetrain 7. Electrical System 8. Suspension & Steering 9. Brake System 10. Troubleshooting 11. Wiring Diagrams

Features at a Glance

Key components: 686cc 4-stroke engine, Ultramatic transmission, On-Command 4WD system, independent front suspension, sealed hydraulic disc brakes, and digital instrumentation.

Feature	Description
Engine	686cc liquid-cooled, SOHC, 4-stroke, fuel-injected
Transmission	Ultramatic automatic with engine braking and high/low range
Drivetrain	On-Command 2WD/4WD with differential lock
Suspension Front	Independent double wishbone, 7.1 inches travel
Suspension Rear	Swingarm with mono-shock, 9.5 inches travel
Brakes	Dual hydraulic disc front, sealed hydraulic disc rear
Towing Capacity	1300 lbs (with optional hitch)
Fuel Capacity	5.3 gallons
Dry Weight	617 lbs
Instrumentation	Digital display with speedometer, odometer, trip meter, hour meter, gear position, fuel gauge, 4WD indicator

Safety Precautions

Always follow safety procedures when servicing the Grizzly 700.

Work in a well-ventilated area; keep away from open flames.
Disconnect battery negative terminal before electrical work.
Use proper tools and torque specifications.
Support ATV securely on a stand; never work under unsupported vehicle.
Allow engine to cool before servicing.

WARNING! Fuel and battery gases are flammable. Wear eye protection. Use jack stands; the ATV is heavy and can cause serious injury if it falls.

Specifications

Engine Type: 686cc liquid-cooled, 4-stroke, SOHC, 4-valve
Bore x Stroke: 102.0 mm x 84.0 mm
Compression Ratio: 9.5:1
Fuel System: Yamaha Fuel Injection (YFI)
Starting System: Electric start with auxiliary recoil
Lubrication System: Wet sump
Transmission: Ultramatic automatic V-belt with all-wheel engine braking
Drive System: Shaft drive
Suspension Front/Rear: Independent double wishbone / Swingarm with mono-shock
Brakes Front/Rear: Dual hydraulic disc / Sealed hydraulic disc
Tires Front/Rear: AT25 x 8-12 / AT25 x 10-12
Dimensions (LxWxH): 81.5 in x 46.5 in x 48.4 in
Ground Clearance: 11.8 in

Maintenance Schedule

Refer to the following intervals for routine maintenance (based on hours of operation or miles, whichever comes first).

Item	Every 20 hrs / 100 mi	Every 100 hrs / 500 mi	Every 200 hrs / 1000 mi
Engine oil & filter	Inspect	Replace	Replace
Air filter	Clean	Replace	Replace
Spark plug	Inspect	Replace	Replace
Drive belt	Inspect	Inspect	Replace
Brake fluid	Inspect level	Replace	Replace
Differential oil	Inspect	Replace	Replace
Wheel nuts / bolts	Tighten	Tighten	Tighten
Steering system	Inspect	Lubricate	Lubricate

Note: Service more frequently under severe conditions (mud, dust, water, prolonged low-speed operation).

Engine Service

Procedures for engine maintenance and repair.

Oil Change: Warm engine, drain plug on bottom of crankcase, replace with SAE 10W-40 Yamalube (3.7 qt with filter change).
Oil Filter: Replace with genuine Yamaha filter (part # 5GH-13440-30-00).
Air Filter: Remove side panel, clean foam element with solvent, re-oil with Yamaha foam air filter oil.
Spark Plug: NGK CR7E, gap 0.028-0.031 in. Torque to 13 ft-lb.
Valve Clearance: Check cold. Intake: 0.004-0.006 in. Exhaust: 0.008-0.010 in.
Cooling System: Check coolant level in reservoir. Use Yamaha Coolant or equivalent ethylene glycol. Capacity: 2.12 qt.

CAUTION! Do not over-tighten drain plug or filter. Ensure oil seal is properly seated.

Transmission & Drivetrain

Servicing the Ultramatic transmission and driveline.

Drive Belt Inspection: Remove left side cover. Check for cracks, fraying, excessive wear. Replace if width is less than 1.18 in.
Belt Replacement: Remove clutch cover, primary and secondary clutches. Install new belt (Yamaha part # 5GH-17641-00-00).
Differential Oil: Front and rear differentials use SAE 80W-90 API GL-5 gear oil. Capacity: 0.42 qt each. Drain and refill every 1000 mi.
On-Command System: Check operation of 2WD/4WD and differential lock. If system fails, inspect wiring, switches, and actuator.

Tip: Keep belt area clean from mud and debris to prevent slippage and overheating.

Electrical System

Battery, charging, and lighting system service.

Battery: 12V, 12Ah. Maintain terminals clean and tight. Specific gravity: 1.280 at 68°F.
Charging System Output: 350W at 5000 rpm. Test stator resistance: 0.21-0.31 Ω at 68°F.
Fuses: Main fuse 30A, other fuses in fuse box under front hood.
Headlight/Taillight: Headlight: 12V 30/30W. Taillight/Brake light: 12V 21/5W.

WARNING! Always disconnect battery negative terminal first. Avoid short circuits.

Suspension & Steering

Maintenance of front and rear suspension components.

Front Suspension: Check for loose bolts, worn bushings, leaking seals on shocks. Torque pivot bolts to 65 ft-lb.
Rear Suspension: Inspect mono-shock for leaks. Preload adjustable via wrench on shock collar.
Steering: Check for free play. Adjust if necessary. Lubricate steering stem bearings every 100 hrs.
Wheel Alignment (Toe-in): 0-10 mm (0-0.4 in). Adjust tie-rod lengths.

CAUTION! Support ATV securely before removing wheels or suspension components.

Brake System

Hydraulic disc brake service procedures.

Brake Fluid: Use DOT 4. Check level in reservoirs. Replace fluid every 2 years or 500 mi.
Brake Pads: Inspect thickness. Replace if less than 0.12 in. Pad part # front: 5GH-W0041-00-00, rear: 5GH-W0041-10-00.
Bleeding Brakes: Use standard bleeding procedure. Start with rear caliper, then front.
Parking Brake: Adjust cable tension at lever. Should hold ATV on a 15° slope.

WARNING! Brake fluid is corrosive. Do not spill on paint or plastic. Use clean fluid from sealed container.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Dead battery, faulty spark plug, fuel issue	Check battery voltage (12.6V+), inspect spark, check fuel pump operation and filter.
Poor performance/loss of power	Clogged air filter, dirty fuel injector, restricted exhaust	Clean/replace air filter, inspect fuel injector, check for exhaust obstruction.
Transmission slipping/overheating	Worn drive belt, dirty clutches	Inspect belt, clean primary and secondary clutch sheaves.
4WD not engaging	Faulty switch, actuator, wiring	Test switch continuity, check actuator operation, inspect wiring harness.
Brakes feel spongy	Air in lines, low fluid, worn pads	Bleed brake system, top up fluid, inspect pad thickness.
Electrical failure (no lights, no start)	Blown fuse, bad ground, faulty ignition switch	Check all fuses, inspect ground connections, test ignition switch.

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

Service: For technical support, contact Yamaha customer service or refer to an authorized Yamaha dealer.

Wiring Diagrams

Refer to separate fold-out pages for complete wiring diagrams of the Grizzly 700 electrical system, including main harness, lighting, ignition, and sensor circuits. Diagrams are located at the end of this manual.

Note: Use a multimeter for continuity and voltage checks. Diagram symbols are standard ISO/DIN.