Yamaha Grizzly 700 Service Manual

The Yamaha Grizzly 700 is a high-performance all-terrain vehicle (ATV) featuring a 686cc liquid-cooled, 4-stroke, SOHC engine with fuel injection, Ultramatic automatic transmission with On-Command 2WD/4WD, independent rear suspension, disc brakes, electric start, and advanced 4x4 capabilities. This service manual provides comprehensive information for maintenance, troubleshooting, repair, and specifications to ensure optimal performance and longevity.

1. General Information & Safety 2. Periodic Maintenance 3. Engine Service 4. Fuel System 5. Chassis & Suspension 6. Electrical System 7. Transmission & Drive System 8. Brake System 9. Troubleshooting 10. Specifications 11. Wiring Diagrams

General Information & Safety

This manual is intended for qualified service technicians. Always follow safety procedures to prevent injury or damage.

Safety SymbolMeaning
WARNING!Indicates a potential hazard that could result in serious injury or death.
CAUTION!Indicates a potential hazard that could result in minor injury or product damage.
NOTE:Provides helpful information for proper service.

WARNING! Always disconnect the battery before servicing electrical components. Use proper lifting equipment when raising the ATV. Work in a well-ventilated area.

Periodic Maintenance

Regular maintenance is crucial for reliability and safety. Follow the schedule below.

  1. Pre-Ride Inspection: Check tires, brakes, lights, controls, and fluid levels.
  2. Engine Oil & Filter: Change every 100 hours or 6 months (whichever comes first).
  3. Air Filter: Clean every 20-50 hours; replace if damaged.
  4. Spark Plug: Inspect and clean every 100 hours; replace as needed.
  5. Drive Chain/Belt: Check tension and condition every 50 hours.
  6. Brake Fluid/Pads: Inspect fluid level and pad wear every 100 hours.
  7. Differential Oil: Change front and rear every 200 hours.

CAUTION! Use only Yamaha Genuine Parts or equivalents specified in this manual.

Engine Service

The 686cc engine is a liquid-cooled, 4-stroke single cylinder with SOHC and fuel injection.

  1. Cylinder Head & Valves: Valve clearance inspection/adjustment procedure.
  2. Piston & Cylinder: Removal, inspection, and installation steps.
  3. Crankshaft & Connecting Rod: Inspection for wear and runout.
  4. Lubrication System: Oil pump service and oil pressure testing.
  5. Cooling System: Radiator, thermostat, and water pump service.

Torque Specifications: Cylinder head bolts: 40 Nm (29 lbf·ft). Spark plug: 12.5 Nm (9.0 lbf·ft).

Fuel System

Electronic Fuel Injection (EFI) system with throttle body and injector.

WARNING! Relieve fuel pressure before disconnecting lines. No smoking or open flames.

Chassis & Suspension

Double A-arm front suspension with independent rear suspension.

  1. Front Suspension: Shock absorber service, A-arm bushing inspection.
  2. Rear Suspension: Swingarm bearing inspection and lubrication.
  3. Wheel Alignment: Toe-in adjustment procedure.
  4. Steering System: Handlebar and tie-rod inspection.
  5. Frame: Inspection for cracks or damage.

NOTE: Lubricate all suspension pivot points every 100 hours.

Electrical System

12V DC system with battery, starter, charging system, and lighting.

ComponentTest/Service Procedure
BatterySpecific gravity: 1.280; Voltage: 12.8V fully charged.
Starter MotorBrush inspection and commutator service.
AlternatorOutput test: 14V-15V at 5000 RPM.
ECUDiagnostic trouble code reading procedure.
Lights & SwitchesContinuity and voltage drop tests.

Transmission & Drive System

Ultramatic automatic transmission with On-Command 2WD/4WD and differential lock.

  1. Transmission: Belt inspection, replacement, and sheave service.
  2. Drive Shafts: U-joint inspection and lubrication.
  3. Front Differential: Oil change and gear inspection.
  4. Rear Differential: Service and limited-slip clutch inspection.
  5. 4WD System: Actuator testing and engagement verification.

CAUTION! Do not operate with damaged drive belt. Ensure proper belt alignment.

Brake System

Hydraulic disc brakes front and rear with dual-piston calipers.

WARNING! Brake fluid is corrosive. Avoid contact with paint and eyes.

Troubleshooting

Use this guide to diagnose common issues.

SymptomPossible CauseCorrective Action
Engine won't startDead battery, faulty starter, fuel issueCheck battery voltage, fuel pressure, spark.
Poor performanceClogged air filter, dirty injector, worn beltService air filter, clean injector, inspect belt.
OverheatingLow coolant, clogged radiator, bad thermostatCheck coolant level, clean radiator fins.
4WD not engagingActuator failure, wiring issue, low fluidTest actuator, check differential fluid.
Brakes draggingStuck caliper, contaminated fluidRebuild caliper, flush brake fluid.

Specifications

Wiring Diagrams

Complete electrical schematics for the Grizzly 700 are included in the full manual. Key systems:

  1. Starting & Charging System Diagram
  2. Fuel Injection System Diagram
  3. Lighting & Switch Diagram
  4. 4WD Actuator & Indicator Diagram

NOTE: Refer to the diagram pages for wire colors, connector locations, and ground points.

Service Support: For technical assistance, contact Yamaha Motor Corporation at 1-800-88-YAMAHA or visit www.yamahamotorsports.com.

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