Grizzly ATV Parts Manual

The Grizzly ATV Parts Manual provides comprehensive information on parts identification, ordering, assembly, and maintenance for Grizzly All-Terrain Vehicles. This manual covers model variations, part numbers, exploded diagrams, torque specifications, and safety guidelines for proper parts installation and replacement. Below are key sections for safety, parts identification, ordering, installation procedures, specifications, and troubleshooting.

Parts Identification

Key components: Engine assembly, Transmission system, Suspension components, Brake system, Electrical parts, Body panels, Wheels and tires.

Part Category	Description
Engine Assembly	Includes cylinder head, pistons, crankshaft, camshaft
Transmission System	Gears, clutch assembly, drive shaft, differential
Suspension Components	A-arms, shock absorbers, springs, bushings
Brake System	Brake pads, rotors, calipers, brake lines
Electrical Parts	Starter motor, alternator, wiring harness, switches
Body Panels	Fenders, hood, seat assembly, cargo racks
Wheels and Tires	Rims, tires, valve stems, lug nuts
Fuel System	Fuel pump, injectors, tank, fuel lines
Exhaust System	Muffler, header pipe, exhaust gaskets
Cooling System	Radiator, hoses, water pump, thermostat

Ordering Parts

Use exploded diagrams and part numbers to order correct components.

1. Identify part: Use diagram reference numbers and descriptions.
2. Verify part number: Cross-reference with model/year specifications.
3. Contact dealer: Provide part number, model, and serial number.
4. Check availability: Confirm stock and delivery time.

WARNING! Always use genuine Grizzly parts to maintain warranty and ensure proper fit and function.

Installation Procedures

Follow step-by-step instructions for safe parts installation.

1. Prepare workspace: Clean, well-lit area with proper tools.
2. Disconnect battery: For electrical safety during installation.
3. Remove old parts: Follow reverse of installation procedure.
4. Install new parts: Use correct torque specifications and alignment.
5. Test operation: Verify proper function before full use.

CAUTION! Wear appropriate safety gear including gloves and eye protection.

Specifications

• Engine Type: 4-stroke, liquid-cooled, SOHC.
• Displacement: Varies by model (e.g., 686cc).
• Transmission: Automatic CVT with high/low range.
• Suspension: Independent double wishbone front, swingarm rear.
• Brakes: Dual hydraulic disc front, single disc rear.
• Electrical: 12V DC system with electric start.
• Fuel Capacity: Typically 4.8 gallons.
• Tire Size: Front: 25x8-12, Rear: 25x10-12.
• Weight: Approximately 600 lbs dry weight.
• Torque Specifications: Provided in each section.

Tools and Equipment

Required tools for parts installation and maintenance.

Basic Tools: Socket set, wrenches, screwdrivers, pliers, torque wrench.

Specialized Tools: Bearing puller, clutch holder, valve spring compressor, chain breaker.

Measuring Tools: Calipers, feeler gauges, multimeter, compression tester.

Safety Equipment: Gloves, safety glasses, jack stands, lift.

Assembly Diagrams

Exploded views showing part relationships and installation order.

1. Engine assembly diagram with numbered components.
2. Transmission breakdown showing gear relationships.
3. Suspension system with A-arms and linkage.
4. Brake system showing caliper and rotor placement.
5. Electrical system wiring diagram.

Tip: Refer to diagram numbers when ordering or installing parts.

Maintenance Parts

Common replacement parts for routine maintenance.

1. Oil filter and drain plug gasket.
2. Air filter element and pre-filter.
3. Spark plug with proper gap specification.
4. Brake pads and fluid.
5. Drive belt and variator rollers.
6. Wheel bearings and seals.
7. CV boot kits and axle nuts.
8. Battery and terminal connectors.

WARNING! Replace maintenance parts at recommended intervals for optimal performance.

Safety Guidelines

Always follow safety procedures when working on ATV parts.

Personal Protection: Wear gloves, eye protection, and appropriate clothing. Workspace Safety: Ensure adequate ventilation, proper lighting, and clean work area. Lifting Safety: Use proper jack points and secure with stands. Electrical Safety: Disconnect battery before electrical work. Chemical Safety: Handle fluids properly and dispose according to regulations.

Care & Storage

Proper care extends part life and maintains performance.

Cleaning: Use appropriate cleaners for different materials (metal, plastic, rubber). Storage: Store parts in clean, dry environment away from moisture. Protection: Apply anti-corrosion spray to metal parts. Organization: Keep fasteners organized during disassembly.

CAUTION! Do not use harsh chemicals that may damage part surfaces.

Regulatory Information

This manual contains proprietary information. All parts meet or exceed OEM specifications. Copyright © 2025 Grizzly ATV Parts. For genuine parts, contact authorized dealers only. Counterfeit parts may compromise safety and void warranty. For support, visit www.grizzlyatvparts.com or contact 1-800-555-ATVP.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Part doesn't fit	Wrong part number	Verify part number matches model/year; check for updates.
Excessive vibration	Improper installation	Check torque specifications; verify alignment.
Leaks after installation	Damaged seals/gaskets	Replace seals; ensure proper seating.
No electrical function	Incorrect wiring	Verify wiring diagram; check connections.
Poor performance	Worn related components	Check adjacent parts; replace as set when recommended.

Technical Support: 1-800-555-ATVP; www.grizzlyatvparts.com

Warranty: Genuine parts include 12-month limited warranty.