Grizzly 700 Fi Manual
Complete service repair workshop manual for the: Yamaha Grizzly 700 FI YFM700FG YFM7FG This is the same manual dealerships use to repair your atv.
. READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM7FGPW WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-20-11 3B4-28199-10.
Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. EBU17330 IMPORTANT MANUAL INFORMATION EBU17341 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting. EBU17350 IMPORTANT NOTICE EBU17360 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Speed limiter.4-14 EWB00010 WARNING Front brake lever.4-15 Brake pedal and rear brake lever.4-15 Indicates a potential hazard that could result in serious injury or death. Drive select lever.4-16 Fuel tank cap.4-16 Fuel.4-17 Seat.4-19 EBU17420 Storage compartments.4-19 TABLE OF CONTENTS.
Instruments, lights and switches.5-9 PERIODIC MAINTENANCE AND MINOR REPAIR.8-1 OPERATION.6-1 Owner’s manual and tool kit.8-1 Starting the engine.6-1 Periodic maintenance chart for the Operating the drive select lever and emission control system.8-3 driving in reverse. Checking the wheel bearings.8-54 Noise regulation.11-3 Lubricating the drive shaft universal Maintenance record.11-4 joint.8-54 YAMAHA MOTOR CORPORATION, Checking the stabilizer bushes.8-54 U.S.A. ATV LIMITED WARRANTY.11-5 Lubricating the upper and lower arm YAMAHA EXTENDED SERVICE pivots. EBU17430 SAFETY INFORMATION EBU27230 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
Always inspect your ATV each time you use it to Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill. steady speed when climbing a hill. If you stall or Always be sure there are no obstacles or people roll backwards, follow the special procedure for behind you when you operate in reverse.
When braking described in this manual. Dismount on it is safe to proceed in reverse, go slowly. EWB02320 HOW TO AVOID THE HAZARD WARNING If you should swallow some gasoline or in- hale a lot of gasoline vapor, or get some gas- POTENTIAL HAZARD oline in your eyes, seek medical help Improper handling of gasoline. If gasoline spills on your skin, WHAT CAN HAPPEN wash with soap and water. EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS. Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation.
Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer. EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Radiator cap 1. Rear shock absorber assembly spring preload adjusting ring 2.
Rear storage compartment and tool kit 3. Fuel tank cap cover 4. Air filter case 4. EBU17712 NOTE: Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual.
Drive select lever 2. Rear brake lever 3.
Handlebar switches 4. Rear brake fluid reservoir 5. Multifunction meter unit 6. EBU17720 INSTRUMENT AND CONTROL FUNCTIONS EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU17760 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light 1.
High-range indicator light “H” checked by turning the key to “ON”. If the light does 4. Neutral indicator light “N” not come on, have a Yamaha dealer inspect the 5. Reverse indicator light “R” electrical circuit. Park indicator light “P”.
Continuous use while checked by turning the key to “ON”. If the warning the warning light is on may cause damage to light does not come on, have a Yamaha dealer the engine. Check the electrical circuit. EBU18001 NOTE: On-Command differential gear lock indicator Due to the synchronizing mechanism in the dif- light “DIFF. LOCK” ferential gear case, the four-wheel-drive indica- This indicator light and the On-Command differen- tor may not come on until the ATV starts moving.
Tial gear lock indicator in the display come on when When the On-Command differential gear lock the On-Command differential gear lock switch is. EBU27291 a clock Multifunction display an hour meter (which shows the total time the key has been turned to “ON”) a fuel meter a self-diagnosis device Odometer and tripmeter modes Pushing the “SELECT” button switches the display between the odometer mode “ODO” and the trip- meter modes “A”. Set the display to the clock mode. Display segments and fuel level warning indicator 2. Push the “SELECT” button and “RESET” but- will start flashing.
If this occurs, have a Yamaha ton together for at least three seconds. Dealer check the electrical circuit. Set this switch to “ ” before starting the engine. Yamaha dealer check the vehicle. The engine stop switch controls the ignition and ECB00810 stops the engine when it is running.
Use this switch CAUTION: to stop the engine in an emergency situation. EBU18100 EBU18180 Start switch “ ” Override switch “OVERRIDE” Push this switch to crank the engine with the start- ECB00050 CAUTION: See the starting instructions on page 6-1 prior to starting the engine. EBU18151 Light switch “ /OFF” Set this switch to “ ”. “2WD”/“4WD” indicate a malfunction in the electrical system. In This ATV is equipped with a switch to change from this case, take the ATV to a Yamaha dealer at the two-wheel drive to four-wheel drive and vice-versa. First opportunity.
Select the appropriate drive according to the ter- EWB00110 rain and the conditions. To change from two-wheel drive to four-wheel WHAT CAN HAPPEN drive, stop the ATV and push the switch in to the The ATV handles differently in two-wheel “4WD” position. Then, the four-wheel-drive indica- drive than in four-wheel drive in some cir- tor “.
“LOCK” (four-wheel drive with the differential gear locked): Power is supplied to the rear and front wheels and the differential gear is locked. Unlike in four-wheel drive, all wheels turn at the same speed. Differential gear lock lever 2. On-Command four-wheel-drive switch “2WD”/“4WD” Stop the ATV, move the differential gear lock lever to position (a), and then push the differential gear lock switch in to the “LOCK”. WHAT CAN HAPPEN The ATV handles differently in four-wheel drive than in differential gear lock in some circumstances. Changing from four-wheel drive to differential gear lock or vice-versa while moving may cause the ATV to handle differently unexpectedly. This could distract the operator and increase the risk of losing control and causing an accident.
HOW TO AVOID THE HAZARD EBU18270 Throttle lever Always ride at a slow speed when the ATV is Once the engine is running, movement of the throt- in differential gear lock, and allow extra time tle lever will increase the engine speed. And distance for maneuvers. If it does not work smoothly, check for the cause.
Correct the problem before riding the ATV. Locknut Yamaha dealer if you can’t find or solve the 2. Adjusting screw problem yourself. No more than 12 mm (0.47 in) EBU18311 3.
WHAT CAN HAPPEN The throttle cable could be damaged. Im- proper throttle operation could result. You could lose control, have an accident or be in- jured. HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3.0–5.0 mm (0.12–0.20 in). EBU18611 Drive select lever The drive select lever is used to shift your ATV into the low-range, high-range, neutral, reverse and park positions. See the “Operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever operation.
To install the fuel tank cap Install the fuel tank cap by turning it clockwise until a click is heard, and then close the fuel tank cap cover. EBU18730 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. HOW TO AVOID THE HAZARD Your Yamaha engine has been designed to use Do not overfill the fuel tank. Be careful not to regular unleaded gasoline with a pump octane. EBU18880 Seat To remove the seat Pull the seat lock lever upward and pull up the seat at the rear.
Projection 2. Seat holder EBU27361 Storage compartments This ATV is equipped with two storage compart- ments.
Seat The front storage compartment is located at the 2. The rear storage compartment is located under the seat. (See page 4-19.) To access the storage com- partment, remove the storage compartment cover. Front storage compartment cover 1. Rear storage compartment cover 1. Front storage compartment 4-20. Do not exceed the load limit of 0.5 kg (1 lb) for the front storage compartment or 2.0 kg (4 lb) for the rear storage compartment.
Do not exceed the maximum load of 220.0 kg (485 lb) for the ATV. NOTE: A drain plug is fitted at the bottom of each storage compartment. EBU19130 Adjusting the front and rear shock ab- sorber assemblies The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions. Adjust the spring preload as follows.
Turn the adjusting ring in direction (a) to increase the spring preload and thereby harden the suspen- sion, and in direction (b) to decrease the spring preload and thereby soften the suspension. EWB00350 NOTE: WARNING A special wrench can be obtained at a Yamaha POTENTIAL HAZARD dealer to make this adjustment.
Improper shock absorber assembly adjust- ment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. Maximum rated capacity for the auxiliary DC jack: DC 12 V, 120 W (10 A) 4. When the auxiliary DC jack is not being used, cover it with the cap. ECB00120 CAUTION: Do not use accessories requiring more than the above maximum capacity. This may overload the circuit and cause the fuse to 1. Before operating this ATV, be sure to check the items listed in the following table.
NOTE: The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a Yamaha dealer.
ITEM ROUTINE PAGE. Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system.
Check pedal free play, and adjust if necessary. 5-5, 8-45, 8-47, 8-48, Rear brake. Check brake pads for wear, and replace if necessary. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Own- er’s Manual.
EBU19530 EBU19590 Fuel Final gear oil Make sure that there is sufficient fuel in the tank. Make sure that the final gear oil is at the specified (See page 4-17.) level. Add oil as necessary. (See page 8-26.) EWB00500 WARNING EBU19600 Differential gear oil POTENTIAL HAZARD. Yamaha dealer adjust Check the operation of the brake levers and pedal. They should move smoothly and there should be a firm feeling when the brakes are ap- plied. If not, have a Yamaha dealer check the brake system.
HOW TO AVOID THE HAZARD vided in this manual, have a Yamaha dealer The tires listed below have been approved check for the cause. By Yamaha Motor Co., Ltd. For this model. Rear: Tire pressure below the minimum speci- Manufacturer/model: fied could cause the tire to dislodge from DUNLOP/KT425 the rim under severe riding conditions. Size: Minimum tire pressure: AT25 x 10-12 Front: Type: 32.0 kPa (4.6 psi) (0.320 kgf/cm²) Tubeless Rear: The tires should be set to the recommend- 27.0 kPa (3.9 psi) (0.270 kgf/cm²) ed pressure.
Recommended pressure: NOTE: Front The low-pressure tire gauge is included as stan- 35.0 kPa (5.0 psi) (0.350 kgf/cm²) dard equipment. Make two measurements of the Rear tire pressure and use the second reading. Dust or 30.0 kPa (4.3 psi) (0.300 kgf/cm²) dirt in the gauge could cause the first reading to be Minimum: incorrect. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.
Read the Owner’s Manual carefully. If there is prior to operating the engine for the first time. A control or function you do not understand, ask your Yamaha dealer.
Turn the main switch to “ON” and the engine stop switch to “. The corresponding indicator light should crank the engine more than 10 seconds on each come on. If the indicator light does not come attempt.
On, have a Yamaha dealer check the electrical 5. Continue warming up the engine until it idles circuit. EBU20430 Operating the drive select lever and driving in reverse ECB00170 CAUTION: Before shifting, stop the ATV, otherwise the transmission may be damaged. Shifting: Neutral to High-range and High-range to Low-range 1. Bring the ATV to a complete stop.
Drive select lever 2. 20 hours of riding.
For When in reverse, the reverse indicator light this reason, you should read the following material should come on. If the indicator light does not carefully. Come on, have a Yamaha dealer check the elec- trical circuit. If any engine trouble should occur during the engine break-in period, immediately have a 1. Bring the ATV to a stop by applying the Yamaha dealer check the ATV.
Stop the engine. Your Yamaha dealer has a variety of gen- when carrying cargo or towing a trailer. Keep the uine Yamaha accessories. Other accessories following points in mind: may also be available on the market. However, it is not possible for Yamaha to test all non. Never exceed the weight limits shown. An over- just the load in the trailer, if necessary, to reduce loaded ATV can be unstable.
The weight on the hitch. If you are carrying cargo and towing a trailer, include the tongue weight in MAXIMUM LOADING LIMIT the maximum ATV load limit. EWB00750 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly.
WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. EBU21131 RIDING YOUR ATV.
EWB00010 ular attention to the safety information on pages WARNING 1-1–1-4. Please also read all caution and warning labels on your ATV. Indicates a potential hazard that could result in serious injury or death. EBU27391 GETTING TO KNOW YOUR ATV This ATV is mainly for utility use, but may also be used for recreation. Beginners should get training from a certified in- course offered by Yamaha. They should then structor. Regularly practice the skills learned in the Become familiar with this ATV at slow speeds first, course and the operating techniques de- even if you are an experienced operator.
WHAT CAN HAPPEN Use by children of ATVs that are not recom- mended for their age can lead to severe inju- ry or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc. This ATV is designed to carry operator and car- go only – passengers prohibited. EWB00910 WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passen- ger.
Apparel HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet EWB00920 WARNING that fits properly. You should also wear: POTENTIAL HAZARD eye protection (goggles or face shield) Operating this ATV without wearing an ap- gloves proved motorcycle helmet, eye protection boots and protective clothing. Do not operate after consuming alcohol or HOW TO AVOID THE HAZARD drugs. Never consume alcohol or drugs before or The operator’s performance capability is reduced while driving this ATV. By the influence of alcohol or drugs. Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for proper care of the ATV and to ensure safety. EWB00950 Do not operate at speeds too fast for your skills WARNING or the conditions.
EWB00960 POTENTIAL HAZARD WARNING Operating this ATV with improper tires, or with improper or uneven tire pressure. POTENTIAL HAZARD WHAT CAN HAPPEN Operating this ATV at speeds too fast for Use of improper tires on this ATV, or opera- your skills or the conditions.
Speed limiter Loading and accessories For riders less experienced with this model, the Use extra caution when riding the ATV with addi- throttle lever housing is equipped with a speed lim- tional loads, such as accessories or cargo. The speed limiter keeps the throttle from fully ATV’s handling may be adversely affected. EWB00970 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in ATV handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
During operation WHAT CAN HAPPEN Always keep your feet on the footboards during op- Removing even one hand or foot can reduce eration, otherwise they may contact the rear your ability to control the ATV or could wheels. Cause you to lose your balance and fall off of the ATV. Never modify this ATV through improper in- stallation or use of accessories. All parts and accessories added to this ATV should be genuine Yamaha or equivalent compo- nents designed for use on this ATV and should be installed and used according to instructions. Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system.
Park the ATV in a place where pedestrians or children are not likely to touch it. EWB01010 WARNING POTENTIAL HAZARD Hot exhaust system. HOW TO AVOID THE HAZARD EWB01030 WARNING Always avoid paved surfaces, including sidewalks, driveways, parking lots and POTENTIAL HAZARD streets. Operating this ATV on public streets, roads or highways.
WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset.
EWB01040 WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slip- pery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especial- ly cautious on these kinds of terrain. When riding in an area where you might not easily HOW TO AVOID THE HAZARD be seen, such as desert terrain, mount a caution Always mount a caution flag on the ATV to flag on the ATV. DO NOT use the flag pole bracket make you more visible.
surfaces: the ATV is designed for off-road use ECB00250 CAUTION: only, and handling maneuvers are more difficult to perform on pavement. Do not shift from drive position low-range to Shift to the park position and follow the instruction high-range or vice versa without coming to a on page 6-1 to start the engine.
TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off-road Always follow proper procedures for turning in 2WD or 4WD, the two rear wheels turn together as described in this Owner’s Manual. Prac- at the same speed. Furthermore, when riding in tice turning at low speeds before attempting 4WD-LOCK (“DIFF. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip.
If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside. CLIMBING UPHILL EWB01180 WARNING Use proper riding techniques to avoid ATV over- turns on hills. Be sure that you can maneuver your POTENTIAL HAZARD ATV well on flat ground before attempting any in- Climbing hills improperly. Cline and then practice riding first on gentle slopes.
WHAT CAN HAPPEN Try more difficult climbs only after you have devel- Could cause loss of control or cause the. If you are climbing a hill and you find that you have When crossing the side of a hill: not properly judged your ability to make it to the Always follow proper procedures as de- top, you should turn the ATV around while you still scribed in the Owner’s Manual. If you start to roll backwards, DO NOT apply either If you begin rolling backwards: brake abruptly. If you are in 2WD, apply only the Keep weight uphill. If you are in 4WD or 4WD-LOCK, be- 2WD: Never apply the rear brake while roll- cause all wheels are interconnected by the drive ing backwards.
RIDING DOWNHILL Whenever possible, ride your ATV straight down- When riding your ATV downhill, shift your weight hill. Avoid sharp angles which could allow the ATV as far to the rear and uphill side of the ATV as pos- to tip or roll over. Carefully choose your path and sible.
CROSSING A SLOPE HOW TO AVOID THE HAZARD Traversing a sloping surface on your ATV requires Never attempt to turn the ATV around on any you to properly position your weight to maintain hill until you have mastered the turning tech- proper balance. CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shal- low water of up to a maximum of 35 cm (14 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Air filter case check hose ECB00840 CAUTION: After riding your ATV in water, be sure to drain the trapped water by removing the check hos- es at the bottom of the air filter case. Also, re- move the drain plugs from the front and rear storage compartments and the V-belt case to drain any water that may have accumulated. V-belt case drain plug 1.
Storage compartment drain plug RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with cau- tion. Look out for obstacles which could cause damage to the ATV or could lead to an upset or ac- cident.
WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for ob- stacles.
Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual. If the rear wheels of your ATV start to slide side- EWB01170 WARNING ways, control can usually be regained (if there is room to do so) by steering in the direction of the POTENTIAL HAZARD slide. Applying the brakes or accelerating is not Skidding or sliding improperly.
WHAT TO DO. If your ATV is traversing a sloping surface: If your ATV doesn’t turn when you want it to: Be sure to ride with your weight positioned to- Bring the ATV to a stop and practice the turning wards the uphill side of the ATV to maintain maneuvers again. Safety is an obligation of the owner. Periodic in- nance unless otherwise specified.
Have a spection, adjustment and lubrication will keep your Yamaha dealer perform the service if you are ATV in the safest and best operating condition not familiar with maintenance work. Yamaha ATV dealer. Additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
EBU21863 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element. Clean and replace if necessary. Dusty areas). INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours. Check for looseness or damage, and replace if √ √ √ √ Wheel bearings necessary. Upper and lower √. INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours.
Change. √ √ √ √ Engine oil. Check ATV for oil leakage, and correct if neces- sary. INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours.
Check operation and correct if necessary. √ √ √ √ √ Lights and switches. Adjust headlight beams. EBU23070 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. EWB00010 WARNING Indicates a potential hazard that could result in serious injury or death. EBU23090 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter.
Refer to this section each time a panel needs to be removed and installed. Panel H To install the panel 3.
Panel I Place the panel in the original position. EBU27381 Panel A To remove the panel Pull upward on the areas shown.
Panel B To remove the panel 1. Remove panel A. Remove the front carrier by removing the bolts. Carrier bolt (top) 3. Remove the front carrier stays by removing the bolts. Carrier bolt (under the fenders) 1. Front carrier stay 8-10.
Front carrier stay bolt 1. Quick fastener screw 4. Remove the quick fastener screws, and then pull the panel upward to remove it. To install the panel 1.
Place the panel in the original position, and then install the quick fastener screws. Tightening torques: Carrier bolt (top): 26 Nm (2.6 mkgf, 19 ftlbf) Carrier bolt (under the fenders): 7 Nm (0.7 mkgf, 5.1 ftlbf) 4. Install panel A. Panel C To remove the panel 1.
Remove the seat. (See page 4-19.) 2.
Install the front carrier stays by installing the 2. Install panel A. Quick fastener screw 3. Install the seat. To install the panel Panels D and E 1. Place the panel in the original position, and then install the quick fastener screws.
To remove one of the panels 1. Quick fastener screw 2. Quick fastener screw 1. To install one of the panels Panel F 1. Place the panel in the original position, and To remove the panel then install the bolt and quick fastener screw. Pull outward on the areas shown.
Panel F To install the panel Place the panel in the original position. Panel G Panel G 2.
Bolt To remove the panel 4. Quick fastener Remove the nut, bolts, and quick fastener, and 5. Tab then pull the panel downward while pushing the To install the panel tab. Place the panel in the original position, and then in- stall the bolts, nut, and quick fastener. Panel H Panel H 2. Bolt To remove the panel 4. Quick fastener Remove the nut, bolts, and quick fasteners, and 5.
Tab then pull the panel downward while pushing the To install the panel tab. Place the panel in the original position, and then in- stall the bolts, nut, and quick fasteners. Carrier bolt (under the fenders) Panel I To remove the panel 1.
Remove the seat. (See page 4-19.) 2. Remove the rear carrier by removing the bolts. Carrier bolt (upper) 8-18. Carrier bolt (lower) 2. Quick fastener 3. Remove the quick fasteners, and then push inward on the areas shown.
To install the panel 1. Place the panel in the original position, and then install the quick fasteners. EBU23211 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica- tion chart. (the ideal color when the ATV is ridden normally). NOTE: If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself.
In- stead, have a Yamaha dealer check the ATV. NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.
09 Grizzly 700 Fi Repair Manual
Remove the dipstick, and then wipe it off with a clean rag. Maximum level mark 2. Minimum level mark 1. Dipstick NOTE: 5. Insert the dipstick completely into the oil filler The engine oil should be between the minimum hole, and then remove it again to check the oil and maximum level marks. Oil filter cartridge 2.
Oil filter wrench NOTE: An oil filter wrench is available at a nearby Yamaha dealer. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. Engine oil drain bolt. Torque wrench Tightening torque: NOTE: Oil filter cartridge: Make sure that the O-ring is properly seated. 17 Nm (1.7 mkgf, 12 ftlbf) 8. Install the new oil filter cartridge with an oil fil- ter wrench, and then tighten it to the specified 9. The final gear case must be checked for oil leak- age before each ride.
If any leakage is found, have ECB00300 a Yamaha dealer check and repair the ATV. In ad- CAUTION: dition, the final gear oil level must be checked and. NOTE: The oil level should be at the brim of the check hole.
Final gear oil filler bolt 4. Install the oil level check bolt and oil filler bolt, and then tighten them to the specified torques. Final gear oil Tightening torques: 2. Remove the final gear oil filler bolt, final gear oil level check bolt, and the final gear oil drain bolt to drain the oil from the final gear case.
Final gear oil 2. Final gear oil level check bolt 3. The differential gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV.
In addition, the differential gear oil level must be 1. Differential gear oil checked and the oil changed as follows at the in- 2. Tightening torque: Tightening torque: Differential gear oil filler bolt: Differential gear oil drain bolt: 23 Nm (2.3 mkgf, 17 ftlbf) 10 Nm (1.0 mkgf, 7.2 ftlbf) 5. Add the recommended differential gear oil to To change the differential gear oil the brim of the filler hole as shown. ECB00410 NOTE: CAUTION: The coolant level must be checked on a cold en- Be sure no foreign material enters the differen- gine since the level varies with engine tempera- tial gear case.
Install the oil filler bolt, and then tighten it to the 2. If water has been added to the coolant, have a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, oth- 1. Coolant reservoir cap erwise the effectiveness of the coolant will 2. EBU27552 To change the coolant EWB01880 WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure.
HOW TO AVOID THE HAZARD Wait for the engine to cool before removing 1. Radiator cap 1. Coolant reservoir hose 6. Remove the coolant reservoir cap. After draining the coolant, thoroughly flush the 7.
Disconnect the hose on the coolant reservoir cooling system with clean tap water. Side, and then drain the coolant from the cool- 9.
If water has been added to the coolant, have Recommended antifreeze: a Yamaha dealer check the antifreeze con- High-quality ethylene glycol antifreeze con- tent of the coolant as soon as possible, oth- taining corrosion inhibitors for aluminum en. When coolant begins to flow out of the bolt 17.
Loosen the cylinder head air bleed bolt, with- hole, tighten the water pump air bleed bolt to out removing it, to allow all of the air to escape the specified torque. From the air bleed bolt hole. Start the engine, and then check for coolant leakage. NOTE: If any leakage is found, have a Yamaha dealer check the cooling system. Install the V-belt cooling duct, and then tighten the clamp screw. Air filter case check hose 1. Air filter case holder 2.
Air filter case cover 1. Remove panel C. (See page 8-9.) 3. Remove the sponge material and the mesh 2.
Remove the air filter case cover by unhooking from the air filter case. Check the sponge material and replace it if damaged. Sponge material 2. Air filter mesh 8. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material.
Clean the mesh with solvent, and then wipe the solvent off. ECB00760 CAUTION: Make sure that the air filter element is prop- erly seated in the air filter case. Never operate the engine with the air filter el- ement removed. This will allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage. Spark arrester 2. Remove the tailpipe, by pulling it out of the 3.
Gasket muffler, and then remove the gasket. Install the gasket, and then insert the tailpipe 3.
Tap the tailpipe lightly, and then use a wire into the muffler and align the bolt holes. EWB01930 WARNING POTENTIAL HAZARD Improperly purging the exhaust system. Hot exhaust system. WHAT CAN HAPPEN Could injure the eyes.
Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. Purging bolt HOW TO AVOID THE HAZARD When purging the exhaust system: 7. NOTE: If water drains from the V-belt case after removing A diagnostic tachometer is needed to make this the plug, have a Yamaha dealer check the ATV as adjustment.
The water may affect other engine parts. Start the engine and warm it up. To decrease If the specified idling speed cannot be obtained as the throttle cable free play, turn the adjusting described above, have a Yamaha dealer make the bolt in direction (b). Install the panel.
To prevent this from occurring, the valve clearance NOTE: must be adjusted by a Yamaha dealer at the inter- The wheels need to be removed to check the vals specified in the periodic maintenance and lu- brake pads. Each brake hose protector is provided with a wear indicator. If a protector wears to the point that its indicator be- comes visible, have a Yamaha dealer replace the protector. NOTE: The wheels need to be removed to check the 1. EBU24251 Rear brake Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective.
Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- sary. Always clean up spilled fluid imme- ver should have a free play of zero mm (zero in) as diately.
If the free play is incorrect, have a Yamaha As the brake pads wear, it is normal for the brake dealer check the brake system. Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU27520 Adjusting the brake pedal free play and 1.
Brake lever free play. Tighten the locknut.
Grizzly 700 Fi Service Manual
Install the panel. Brake pedal free play If the correct free play cannot be obtained, have a Yamaha dealer adjust it. Remove panel H. (See page 8-8.) 2. Loosen the locknut.
Turn the brake pedal free play adjusting nut in. Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge.
These procedures should be performed by a Yamaha dealer. EBU24230 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart.
If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Engine oil 1. EBU24911 Rear brake lever Checking and lubricating the front and rear brake levers The operation of the front and rear brake levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Front brake lever EBU24950. Checking the stabilizer bushes The stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer replace the stabilizer bush- es if necessary.
EBU25040 EBU24961 Lubricating the upper and lower arm. EBU25100 Recommended lubricant: Lubricating the steering shaft Lithium-soap-based grease The steering shaft must be lubricated at the inter- vals specified in the periodic maintenance and lu- brication chart. Recommended lubricant: Lithium-soap-based grease EBU25212 Battery This model is equipped with a sealed-type (MF) battery, which does not require any maintenance. Ventilate when charg- ing or using in a closed space. To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- cal accessories.
To charge a sealed-type (MF) battery, a spe- cial constant-voltage battery charger is re- quired. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charg- er, have a Yamaha dealer charge your bat- tery. ECB00640 CAUTION: To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse.
Remove the blown fuse, and then install a new fuse of the specified amperage. Ignition fuse 2. Headlight fuse 3. Four-wheel-drive motor fuse 4.
10.0 A circuits to check if the devices operate. Signaling system fuse: 4. If the fuse immediately blows again, have a 5.0 A Yamaha dealer check the electrical system. Auxiliary DC jack fuse: EBU27430 15.0 A Replacing a headlight bulb Radiator fan fuse: If a headlight bulb burns out, replace it as follows.
Cover at the rear of the headlight 1. Headlight coupler 2. Remove the headlight bulb cover. Unhook the headlight bulb holder, and then remove the defective bulb.
Headlight bulb cover 3. Disconnect the headlight coupler. Place a new headlight bulb into position, and then secure it with the bulb holder. Headlight bulb holder 2.
Headlight bulb 1. Do not touch the glass part of the bulb. EWB02180 WARNING ECB00650 CAUTION: POTENTIAL HAZARD Do not touch the glass part of the headlight A headlight bulb is hot when it is on and im- bulb to keep it free from oil, otherwise the mediately after it is turned off. Adjust the headlight beam if necessary. EBU25550 Adjusting a headlight beam ECB00690 CAUTION: It is advisable to have a Yamaha dealer make 1. Headlight beam adjusting screw this adjustment. EBU25640 Replacing the tail/brake light bulb To raise a headlight beam, turn the adjusting screw in direction (a).
Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. Install the bulb holder (together with the bulb) by turning it clockwise. Install the panel. EBU25650 Removing a wheel 1. EBU25700 Installing a wheel 1. Install the wheel and the nuts.
NOTE: The arrow mark on the tire must point toward the rotating direction of the wheel. Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side to- wards the wheel. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.
EBU27680 Troubleshooting charts Starting problems or poor engine performance 1. Compression 3. Battery 8-66. Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system.
NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible. EBU25860 CLEANING AND STORAGE EBU25870 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. Only enhance its appearance but will improve its 4.
Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components. EWB02300 To prevent corrosion, avoid damp cellars, WARNING stables (because of the presence of ammo- nia) and areas where strong chemicals are POTENTIAL HAZARD stored. Operation with wet brakes after washing.
WHAT CAN HAPPEN Wet brakes may have reduced stopping abil- Long-term ity, increasing the chance of an accident. Install the spark plug cap onto the spark °F) or more than 30 °C (90 °F). For more in- plug, and then place the spark plug on the formation on storing the battery, see page cylinder head so that the electrodes are 8-55.