Yamaha Grizzly 700 Repair Manual

The Yamaha Grizzly 700 is a high-performance all-terrain vehicle (ATV) featuring a 686cc liquid-cooled, SOHC, 4-stroke engine, Ultramatic automatic transmission with On-Command 2WD/4WD, independent rear suspension, electric power steering, and advanced towing capabilities. This repair manual provides comprehensive instructions for maintenance, troubleshooting, and repair procedures to ensure optimal performance and longevity. Below are key sections covering safety, specifications, maintenance schedules, engine repair, transmission service, electrical systems, and troubleshooting.

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

Features at a Glance

Key components: 686cc engine, Ultramatic transmission, On-Command 4WD, Electric Power Steering (EPS), independent rear suspension, front and rear hydraulic disc brakes.

Feature	Description
Engine Type	686cc liquid-cooled, SOHC, 4-stroke, 4-valve
Transmission	Ultramatic automatic V-belt with all-wheel engine braking
Drive System	On-Command 2WD/4WD with differential lock
Steering	Electric Power Steering (EPS)
Suspension Front	Independent double wishbone, 7.1" travel
Suspension Rear	Independent double wishbone, 9.5" travel
Brakes Front/Rear	Hydraulic disc, dual piston
Towing Capacity	Up to 1322 lbs (600 kg)
Fuel Capacity	5.3 gallons (20 liters)
Dry Weight	617 lbs (280 kg)

Safety Precautions

Always follow safety procedures to prevent injury and damage.

Work in a well-ventilated area; keep away from open flames.
Disconnect battery before performing electrical work.
Use proper tools and torque specifications.
Support ATV securely on a stand before lifting or removing wheels.
Wear safety glasses and gloves when handling fluids or sharp components.

WARNING! Engine and exhaust components become extremely hot during operation. Allow to cool before servicing. Always relieve fuel system pressure before disconnecting fuel lines.

Maintenance Schedule

Regular maintenance ensures reliability and performance. Refer to intervals below.

Pre-ride inspection: Check tires, brakes, lights, fluid levels before each use.
Every 100 miles/1 month: Check engine oil, coolant, brake fluid, tire pressure.
Every 600 miles/6 months: Change engine oil and filter, inspect air filter, check drive belt.
Every 1200 miles/12 months: Replace spark plug, inspect brake pads, lubricate chassis points.
Every 2400 miles/24 months: Change coolant, differential fluid, inspect suspension bushings.

CAUTION! Use only Yamaha recommended fluids and parts. Incorrect maintenance can void warranty.

Specifications

Engine: 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: Fuel injection (FI).
Ignition System: DC-CDI.
Starting System: Electric starter.
Transmission: Ultramatic automatic V-belt with high and low ranges, reverse.
Final Drive: Shaft drive.
Suspension Travel (F/R): 7.1 in / 9.5 in.
Brakes: Hydraulic disc, dual piston front and rear.
Tires: AT25 x 8-12 front, AT25 x 10-12 rear.
Fuel: Unleaded gasoline, 87 octane or higher.

Engine Repair

Procedures for engine removal, disassembly, inspection, and reassembly.

Engine Removal: Disconnect battery, drain coolant and oil, remove exhaust, intake, electrical connectors, and mounting bolts. Lift engine out carefully.

Cylinder Head & Valves: Remove camshaft, inspect valves and seats, check clearance (intake 0.10–0.15 mm, exhaust 0.15–0.20 mm).

Piston & Cylinder: Measure cylinder bore (standard 102.000–102.015 mm), piston diameter, check ring end gap.

Lubrication System: Check oil pump clearance, clean strainer, replace oil filter.

Cooling System: Inspect radiator for leaks, test thermostat (opens at 71–85°C), check water pump impeller.

Transmission & Drivetrain

Service for Ultramatic transmission, drive belt, and differential.

Drive Belt Inspection: Check for cracks, wear, and proper tension. Replace if worn.
Transmission Case: Drain fluid, remove cover, inspect sheaves and rollers for wear.
Differential Service: Drain and refill gear oil (SAE 80W-90). Check for leaks.
On-Command System: Test 2WD/4WD engagement. Inspect actuator and wiring.
Shaft Drive: Check universal joints for play. Lubricate splines.

Tip: Always clean area around transmission cover before opening to prevent contamination.

Electrical System

Diagnosis and repair of starting, charging, and lighting circuits.

Battery: Check voltage (12.8V fully charged). Load test if below 12V.
Starter: Test draw current (max 180A). Inspect brushes and commutator.
Charging System: Check stator resistance (0.18–0.27 Ω at 20°C). Regulator output: 14–15V at 5000 RPM.
Ignition System: Test spark plug cap resistance (10 kΩ). Check pickup coil resistance (248–372 Ω).
EPS System: Diagnostic codes via meter. Check torque sensor and motor operation.

WARNING! Disconnect battery before testing. Use multimeter set to correct range.

Suspension & Steering

Front and rear suspension service, wheel alignment, EPS troubleshooting.

Front Suspension: Remove A-arms, inspect bushings and ball joints. Replace if loose. Shock absorber: check for leaks, test damping.

Rear Suspension: Similar procedure. Check axle alignment.

Wheel Alignment: Toe-in: 0–10 mm. Camber: non-adjustable, inspect if bent.

EPS Troubleshooting: If steering feels heavy or uneven, check battery voltage, connections, and diagnostic codes. Replace EPS unit if faulty.

Brake System

Hydraulic disc brake service, pad replacement, bleeding procedure.

Brake Pad Replacement: Remove caliper, compress piston, replace pads. Check rotor thickness (min 3.0 mm front, 3.5 mm rear).

Brake Bleeding: Use DOT 4 fluid. Fill reservoir, attach tube to bleeder valve, pump lever until no bubbles.

Master Cylinder: Inspect for leaks. Rebuild kit available if seals worn.

Parking Brake: Adjust cable at lever. Should hold on incline.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel pump, spark plug, battery voltage, compression (min 128 psi).
Poor performance	Clogged air filter, drive belt	Clean/replace air filter, inspect drive belt for wear.
Overheating	Low coolant, clogged radiator	Check coolant level, clean radiator fins, test thermostat.
4WD not engaging	Actuator, switch, wiring	Test On-Command switch, check actuator operation, inspect wiring.
Electrical failure	Blown fuse, bad ground	Check main fuse (30A), inspect battery connections and grounds.
Brake drag	Stuck caliper, contaminated fluid	Clean caliper slides, rebuild caliper if necessary, flush fluid.

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

Service: Contact Yamaha dealer or visit Yamaha-Motor.com for parts and support.

Wiring Diagrams

Complete wiring schematics included for model years 2007-2016. Diagrams show color codes, connector locations, and ground points. Use for diagnosing electrical faults.

Note: Always refer to specific model year diagram. Colors may vary.