Yamaha Grizzly 700FI Owner's Manual
  1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Offroad Vehicle
  5. Grizzly 700 FI
  6. Owner's manual

Yamaha Grizzly 700FI Owner's Manual

Special edition
Hide thumbs Also See for Grizzly 700FI:
Table of Contents

Advertisement

Quick Links

See also: Owner's Manual
READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM7FGPSEZ
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-23-52
43P-28199-12

Advertisement

Table of Contents
loading

Related Manuals for Yamaha Grizzly 700FI

Summary of Contents for Yamaha Grizzly 700FI

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM7FGPSEZ WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-23-52 43P-28199-12...
  • Page 2 EBU17092 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold.
  • Page 3 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.
  • Page 4 EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 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: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 5 Please check your local riding laws and regulations before operating this ATV. EBU17382 YFM7FGPSEZ OWNER’S MANUAL ©2009 by Yamaha Motor Corporation, U.S.A. 1st edition, July 2009 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

  • Page 6: Table Of Contents

    EWB00011 Speed limiter ..........4-13 WARNING Front brake lever ........4-14 Indicates a hazardous situation which, if not Brake pedal and rear brake lever .....4-14 avoided, could result in death or serious injury. Drive select lever ........4-15 Fuel tank cap ..........4-15 Fuel ............4-16 Seat ............4-18 EBU17420 Storage compartments ......4-19...
  • Page 7 OPERATION ..........6-1 PERIODIC MAINTENANCE AND Starting the engine ........6-1 ADJUSTMENT..........8-1 Operating the drive select lever and Owner’s manual and tool kit .......8-1 driving in reverse ........6-2 Periodic maintenance chart for the Engine break-in .......... 6-4 emission control system ......8-3 Parking ............
  • Page 8 Checking and lubricating the cables ..8-51 Noise regulation ........11-4 Checking and lubricating the front and Maintenance record ........11-5 rear brake levers ........8-51 YAMAHA MOTOR CORPORATION, Checking and lubricating the brake U.S.A. ATV LIMITED WARRANTY ..11-6 pedal ............8-52 YAMAHA EXTENDED SERVICE Checking the wheel hub bearings ....

  • Page 9: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 10 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. 187 lbs. (85 kg) 99 lbs. (45 kg)
  • Page 11 WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. OPERATING TIRE PRESSURE : Set with tires cold • Recommended : Front : 5.0 psi (35.0 kPa) 1 lb (0.5 kg). Rear : 4.4 psi (30.0 kPa) •...
  • Page 12 Certification of Compliance This ATV complies with applicable provisions of ANSI/SVIA 1-2007 and is subject to an approved ATV action plan submitted by YAMAHA and on file with the U.S. Consumer Product safety Commission. YAMAHA MOTOR CORPORATION U.S.A. 6555 Katella Avenue, Cypress, California 90630-5101, U.S.A.

  • Page 13: Safety Information

    EBU17431 SAFETY INFORMATION EBU27232 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.
  • Page 14 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.
  • Page 15 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.
  • Page 16 EWB00071 Do not run engine outdoors where engine WARNING exhaust can be drawn into a building Avoid Carbon Monoxide Poisoning through openings such as windows and All engine exhaust contains carbon monoxide, doors. a deadly gas. Breathing carbon monoxide can FOR MORE INFORMATION ABOUT ATV SAFE- cause headaches, dizziness, drowsiness, nau- TY, call the Consumer Products Safety Commis-...

  • Page 17: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Radiator cap 1. Rear shock absorber assembly spring preload adjusting ring 2. Battery 2. Rear storage compartment and tool kit 3. Fuses 3. Fuel tank cap cover 4. Air filter case 4.

  • Page 18: Controls And Instruments

    EBU17712 Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Drive select lever 2. Rear brake lever 3. Handlebar switches 4. Rear brake fluid reservoir 5. Multi-function display 6. Front brake fluid reservoir 7.

  • Page 19: Instrument And Control Functions

    EBU17725 INSTRUMENT AND CONTROL FUNCTIONS EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 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.

  • Page 20: Indicator Lights And Warning Lights

    EBU26694 EBU17990 Low-range indicator light “ ” Indicator lights and warning lights This indicator light comes on when the transmis- sion is in the low-range position. EBU17980 High-range indicator light “ ” This indicator light comes on when the transmis- sion is in the high-range position.
  • Page 21 “ON”, or if the warning light re- 4-7 for an explanation of the self-diagnosis device.) mains on, have a Yamaha dealer check the electri- The electrical circuit of the warning light can be cal circuit.
  • Page 22 On-Command differential gear lock checked by turning the key to “ON”. If the warning switch is set to the “LOCK” position. light does not come on, have a Yamaha dealer check the electrical circuit. Due to the synchronizing mechanism in the dif-...

  • Page 23: Multi-Function Display

    EBU27298 an hour meter (which shows the total time the Multi-function display engine has been running) 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 “TRIP A”...
  • Page 24 2. Push the “SELECT” button and “RESET” but- ing indicator will start flashing. If this occurs, have ton together for at least three seconds. a Yamaha dealer check the electrical circuit. 3. When the hour digits start flashing, push the “RESET” button to set the hours.

  • Page 25: Handlebar Switches

    EBU18080 If the multi-function display indicates an error code, Engine stop switch “ ” note the code number, and then have a Yamaha Set this switch to “ ” before starting the engine. dealer check the vehicle. The engine stop switch controls the ignition and ECB00811 stops the engine when it is running.
  • Page 26 EBU18101 EBU18190 Start switch “ ” Override switch “OVERRIDE” Push this switch to crank the engine with the start- er. See the starting instructions on page 6-1 prior to starting the engine. EBU18152 Light switch “ /OFF” Set this switch to “ ”...
  • Page 27 In moving may cause the ATV to unexpectedly this case, take the ATV to a Yamaha dealer at the handle differently. This could distract the oper- first opportunity.
  • Page 28 “4WD” (four-wheel drive): Power is supplied to EBU18255 On-Command differential gear lock switch the rear and front wheels. “4WD”/“LOCK” To change from two-wheel drive to four-wheel EWB00131 drive, stop the ATV and push the switch in to the WARNING “4WD” position.
  • Page 29 control and have an accident if you cannot make a sharp enough turn for the speed you are traveling. This ATV is equipped with a switch allowing you to lock the differential gear when in four-wheel drive. Select the appropriate switch position according to the terrain and the conditions.
  • Page 30 LOCK 1. Differential gear lock lever 1. On-Command differential gear lock switch “4WD”/“LOCK” 2. On-Command four-wheel-drive switch “2WD”/“4WD” To release the differential gear lock, stop the ATV Stop the ATV, move the differential gear lock lever and push the switch to the “4WD” position. to position (a), and then push the differential gear lock switch in to the “LOCK”...

  • Page 31: Throttle Lever

    Riding before the differential gear lock is proper- ly engaged (e.g., when the indicator and indica- tor light are flashing) will cause the vehicle speed to be limited until engagement is com- plete. When the ATV is in four-wheel-drive differential gear lock, the maximum traveling speed is limit- ed to 35 km/h (22 mi/h).

  • Page 32: Front Brake Lever

    crease the maximum engine power available EBU18391 Front brake lever and the maximum speed of the ATV, turn the The front brake lever is located on the right handle- adjusting screw in direction (b). Do not turn bar. To apply the front brake, pull the brake lever the adjusting screw out more than 12 mm toward the handlebar grip.

  • Page 33: Drive Select Lever

    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 6-2 for the drive select lever operation. 1.

  • Page 34: Fuel

    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. EBU18731 Fuel Make sure there is sufficient gasoline in the tank. EWB02521 WARNING Gasoline and gasoline vapors are extremely flammable.
  • Page 35 expands when it heats up, heat from the en- 3. Wipe up any spilled fuel immediately. gine or the sun can cause fuel to spill out of NOTICE: Immediately wipe off spilled fuel the fuel tank. with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts.

  • Page 36: Seat

    Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research oc- tane number of 91 or higher. If knocking (or ping- ing) occurs, use a gasoline of a different brand.

  • Page 37: Storage Compartments

    The front storage compartment is located at the front right side of the ATV. To access the storage compartment, remove the storage compartment cover by turning it counterclockwise. 1. Projection 2. Seat holder EBU27362 Storage compartments 1. Front storage compartment cover This ATV is equipped with two storage compart- ments.
  • Page 38 1. Front storage compartment 1. Rear storage compartment cover The rear storage compartment is located under the seat. (See page 4-18.) To access the storage com- partment, remove the storage compartment cover. 1. Rear storage compartment 4-20...
  • Page 39 When storing any documents in the storage com- partments, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartments. 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.

  • Page 40: Front Carrier

    2. Position indicator EWB00400 WARNING Always adjust the shock absorber assemblies A special wrench can be obtained at a Yamaha on the left and right side to the same setting. dealer to make this adjustment. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident.

  • Page 41: Auxiliary Dc Jack

    EBU19182 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running and the light switch is set to “OFF”.
  • Page 42 If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine start- ing may become difficult. Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged.

  • Page 43: Pre-Operation Checks

    Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
  • Page 44 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-3, 8-44, 8-46, 8-47 • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.

  • Page 45: Fuel

    They should move smoothly and there specified level. Add oil as necessary. (See page should be a firm feeling when the brakes are ap- 8-29.) plied. If not, have a Yamaha dealer check the brake system. EBU19631 Coolant Brake fluid level Make sure that the coolant is at the specified level.

  • Page 46: Throttle Lever

    (See page 8-44.) pressures to the following specifications: EBU19761 Throttle lever Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if necessary.
  • Page 47 Recommended tire pressure: Front 35.0 kPa (0.350 kgf/cm², 5.0 psi) Rear 30.0 kPa (0.300 kgf/cm², 4.4 psi) Minimum tire pressure: Front 32.0 kPa (0.320 kgf/cm², 4.6 psi) Rear 27.0 kPa (0.270 kgf/cm², 4.0 psi) Maximum tire seating pressure: 1. Low-pressure tire gauge Front 250 kPa (2.5 kgf/cm², 36 psi) Tire wear limit...

  • Page 48: Chassis Fasteners

    After extensive tests, only the tires listed below EBU19840 have been approved for this model by Yamaha Chassis fasteners Motor Co., Ltd. Make sure that all nuts, bolts and screws are prop- erly tightened.

  • Page 49: Instruments, Lights And Switches

    EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.

  • Page 50: Operation

    The corresponding indicator light should EBU27345 Starting the engine come on. If the indicator light does not come on, have a Yamaha dealer check the electrical ECB00150 NOTICE circuit. See the “Engine break-in” section on page 6-4...

  • Page 51: Operating The Drive Select Lever And Driving In Reverse

    EBU20441 Operating the drive select lever and This model is equipped with an ignition circuit cut- driving in reverse off system. The engine can be started under the ECB00170 following conditions: NOTICE The drive select lever is in the neutral or park po- Before shifting, stop the ATV, otherwise the sition.
  • Page 52 reverse, make sure there are no people or ob- stacles behind you. When it is safe to proceed, go slowly. 1. Bring the ATV to a complete stop. 2. Apply the brake pedal. The drive select lever cannot be shifted into or from reverse or park without applying the brake pedal.

  • Page 53: Engine Break-In

    320 km (200 mi) or 20 should come on. If the indicator light does not hours. The various parts in the engine wear and come on, have a Yamaha dealer check the elec- polish themselves to the correct operating clear- trical circuit.

  • Page 54: Parking

    If any engine trouble should occur during the steep you could not walk up them easily. engine break-in period, immediately have a 1. Bring the ATV to a stop by applying the Yamaha dealer check the ATV. brakes. 2. Stop the engine. EBU27321 Parking 3.

  • Page 55: Accessories And Loading

    Yamaha ability to control the ATV. vehicles. Yamaha is not in a position to test the Do not mount an accessory where it could inter- products that these aftermarket companies pro- fere with your ability to control the ATV.
  • Page 56 bulky object attached to the handlebars which Never exceed the weight limits shown. An over- could make steering difficult, an accessory that loaded ATV can be unstable. limits your ability to move around on the seat, or MAXIMUM LOADING LIMIT one that limits your view.
  • Page 57 just the load in the trailer, if necessary, to reduce the weight on the hitch. If you are carrying cargo and towing a trailer, include the tongue weight in EWB00011 the maximum ATV load limit. WARNING Load cargo on the carriers as close to the center Indicates a hazardous situation which, if not of the ATV as possible.

  • Page 58: Riding Your Atv

    EBU21132 RIDING YOUR ATV...

  • Page 59: Getting To Know Your Atv

    Beginning and inexperienced operators should have read this Owner’s Manual completely and un- complete the certified training course offered by derstand the operation of the controls. Pay partic- Yamaha. They should then regularly practice the skills learned in the course and the operating tech-...
  • Page 60 niques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV’s handling and performance characteristics.
  • Page 61 Apparel Always wear the following to reduce risk of injury in an accident: Approved motorcycle helmet that fits properly Eye protection (goggles, helmet face shield, or protective eyewear) Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
  • Page 62 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots 5. Helmet Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance Do not operate after or while consuming alco- procedures and schedules described in the Own- hol or drugs.
  • Page 63 opening, even when the throttle lever is pushed to Do not exceed the maximum loading limits the maximum. Turning in the adjusting screw limits for the vehicle (see box in this section or ve- the maximum engine power available and de- hicle labeling).
  • Page 64 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during op- ATV loading limit (total weight of cargo, rider, eration; otherwise, they may contact the rear accessories, and tongue): wheels. WARNING! Removing even one hand 220.0 kg (485 lb) or foot can reduce your ability to control the Front carrier: ATV or could cause you to lose your balance...
  • Page 65 ATV should be during operation or after leaving the ATV, do not let genuine Yamaha or equivalent components de- brush, grass and other materials collect under the signed for use on this ATV and should be installed vehicle, near the muffler or exhaust pipe, or next to and used according to instructions.

  • Page 66: Be Careful Where You Ride

    To prevent burns, avoid touching the exhaust sys- BE CAREFUL WHERE YOU RIDE tem. Park the ATV in a place where pedestrians or This ATV is designed for off-road use only. children are not likely to touch it. WARNING! Paved surfaces may seriously af- fect handling and control of the ATV, and may cause the ATV to go out of control.
  • Page 67 WARNING! Never operate this ATV on any pub- lic street, road or highway, even a dirt or gravel one. You could collide with another vehicle. [EWB01031] Do not operate on rough, slippery, or loose terrain Know the terrain where you ride. Ride cautiously in until you have learned and practiced the skills nec- unfamiliar areas.
  • Page 68 When riding in an area where you might not easily Do not ride in areas posted “no trespassing”. be seen, such as desert terrain, mount a caution Do not ride on private property without getting per- flag on the ATV. DO NOT use the flag pole bracket mission.

  • Page 69: Turning Your Atv

    Select a large, flat area off-road to become familiar ECB00251 NOTICE with your ATV. Make sure that this area is free of obstacles and other riders. You should practice Do not shift from low-range to high-range or control of the throttle, brakes, shifting procedures, vice versa without coming to a complete stop.

  • Page 70: Climbing Uphill

    As you approach a curve, slow down and begin to may continue to go straight. If the ATV doesn’t turn the handlebars in the desired direction. As you turn, come to a stop and then practice the proce- do so, put your weight on the footboard to the out- dure again.
  • Page 71 Never operate the ATV on hills too steep for the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
  • Page 72 Do not attempt to climb hills until you have mas- If you are climbing a hill and you find that you have tered basic maneuvers on flat ground. Always not properly judged your ability to make it to the check the terrain carefully before attempting any top, you should turn the ATV around while you still hill.

  • Page 73: Riding Downhill

    the ATV around and remount, following the proce- Always check the terrain carefully before dure described Owner’s Manual. you start down any hill. WARNING! Stalling, rolling backwards or im- Never operate the ATV on hills too steep for properly dismounting while climbing a hill the ATV or for your abilities.

  • Page 74: Crossing A Slope

    Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. When this ATV is in “4WD”, all wheels (front and rear) are interconnected by the drive train.

  • Page 75: Crossing Through Shallow Water

    Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill.
  • Page 76 The ATV can be used to cross slow moving, shal- ability. WARNING! Wet brakes may have re- low water of up to a maximum of 35 cm (14 in) in duced stopping ability, which could cause loss depth. Before entering the water, choose your path of control.
  • Page 77 1. Air filter case check hose 1. Storage compartment drain plug 1. Air filter case check hose 1. Storage compartment drain plug 7-20...

  • Page 78: Riding Over Rough Terrain

    cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may re- sult. SLIDING AND SKIDDING EWB01662 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.

  • Page 79: What To Do If

    If the rear wheels of your ATV start to slide side- ways, control can usually be regained (if there is With practice, over a period of time, skill at con- room to do so) by steering in the direction of the trolled sliding can be developed.

  • Page 80: What To Do

    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.

  • Page 81: Periodic Maintenance And Adjustment

    If you are not fa- EBU27111 miliar with vehicle service, have a Yamaha Owner’s manual and tool kit dealer perform the service. Be sure to put this owner’s manual in the plastic bag and to always carry it as well as the owner’s...
  • Page 82 However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

  • Page 83: Periodic Maintenance Chart For The Emission Control System

    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.

  • Page 84: General Maintenance And Lubrication Chart

    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.
  • Page 85 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses • Replace. Every 4 years Rear brake hose •...
  • Page 86 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ Engine mount necessary. • Check for cracks or other damage, and replace if √...
  • Page 87 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. Throttle lever hous- • Check throttle cable free play and adjust if neces- √...

  • Page 88: Removing And Installing Panels

    EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 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.
  • Page 89 1. Panel A 1. Panel E 2. Panel H To install the panel 3. Panel I Place the panel in the original position. EBU27382 Panel A To remove the panel Pull upward on the areas shown.
  • Page 90 Panel B To remove the panel 1. Remove panel A. 2. Remove the front carrier by removing the bolts. 1. Carrier bolt (top) 3. Remove the front carrier stays by removing the bolts. 1. Carrier bolt (under the fenders) 1. Front carrier stay 8-10...
  • Page 91 1. Front carrier stay bolt 1. Panel B 2. Quick fastener 4. Remove the quick fasteners, 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 fasteners. 8-11...
  • Page 92 Tightening torques: Carrier bolt (top): 26 Nm (2.6 m·kgf, 19 ft·lbf) Carrier bolt (under the fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 4. Install panel A. Panel C To remove the panel 1. Remove the seat. (See page 4-18.) 2. Install the front carrier stays by installing the 2.
  • Page 93 1. Panel C 2. Install panel A. 2. 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.
  • Page 94 1. Panel D 1. Panel E 2. Quick fastener screw 2. Quick fastener screw 1. Bolt 1. Bolt 8-14...
  • Page 95 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. 1. Panel F To install the panel Place the panel in the original position.
  • Page 96 1. Panel G Panels G and H 2. Nut 3. Bolt To remove one of the panels 4. Projection Remove the nut and bolts, and then pull the panel downward while pushing the projection. 8-16...
  • Page 97 1. Panel H 2. Nut 3. Bolt 4. Projection To install one of the panels Place the panel in the original position, and then in- stall the bolts and nut. Panel I To remove the panel 1. Remove the seat. (See page 4-18.) 8-17...
  • Page 98 2. Remove the rear carrier by removing the bolts. 1. Carrier bolt (lower) 3. Remove the quick fasteners, and then push 1. Carrier bolt (under the fenders) inward on the areas shown. 1. Carrier bolt (upper) 8-18...
  • Page 99 1. Panel I 2. Install the rear carrier by installing the bolts 2. Quick fastener and tightening them to the specified torques. To install the panel Tightening torques: 1. Place the panel in the original position, and Carrier bolt (upper): then install the quick fasteners.

  • Page 100: Removing The Radiator Grills

    EBU28671 EBU23213 Removing the radiator grills Checking the spark plug The radiator grills can be removed to access the The spark plug is an important engine component, radiator for cleaning. which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark To remove a radiator grill plug should be removed and checked in accor- Remove the quick fastener, pull the radiator grill...
  • Page 101 Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

  • Page 102: To Install The Spark Plug

    Tightening torque: Spark plug: 12.5 Nm (1.25 m·kgf, 9.0 ft·lbf) If a torque wrench is not available when installing the 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.
  • Page 103 If the engine was started before checking the oil The engine oil should be between the minimum level, be sure to warm up the engine sufficiently, and maximum level marks. and then wait at least 10 minutes until the oil settles for an accurate reading.
  • Page 104 1. Oil filter cartridge 2. Oil filter wrench An oil filter wrench is available at a nearby Yamaha dealer. 1. Engine oil drain bolt 7. Apply a thin coat of engine oil to the O-ring of 2.
  • Page 105 1. O-ring 1. Torque wrench Tightening torque: Oil filter cartridge: Make sure that the O-ring is properly seated. 17 Nm (1.7 m·kgf, 12 ft·lbf) 8. Install the new oil filter cartridge with an oil fil- ter wrench, and then tighten it to the specified 9.

  • Page 106: Final Gear Oil

    The final gear case must be checked for oil leak- engine and exhaust system have cooled down. age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- ECB00300 dition, the final gear oil level must be checked and...
  • Page 107 1. Final gear oil 1. Final gear oil filler bolt 2. Gasket 2. Gasket 3. Final gear oil level check bolt 4. Check the gaskets for damage, and replace 4. Correct oil level them if necessary. 3. If the oil is below the brim of the check hole, 5.
  • Page 108 To change the final gear oil Tightening torque: 1. Place the ATV on a level surface. Final gear oil drain bolt: 2. Place an oil pan under the final gear case to 23 Nm (2.3 m·kgf, 17 ft·lbf) collect the used oil. 3.

  • Page 109: Differential Gear Oil

    2. Gasket leakage before each ride. If any leakage is found, 3. Differential gear oil have a Yamaha dealer check and repair the ATV. 4. Correct oil level In addition, the differential gear oil level must be 3. If the oil is below the brim of the filler hole, add...
  • Page 110 5. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) To change the differential gear oil 1. Place the ATV on a level surface. 2.

  • Page 111: Coolant

    8. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause. EBU23470 Coolant The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 112 Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. [ECB01011] 1. Maximum level mark 2. Minimum level mark 3.
  • Page 113 The radiator fan is automatically switched on or off according to the coolant temperature in the radiator. If the engine overheats, see page 8-65 for fur- ther instructions. EBU27764 To change the coolant EWB01890 WARNING 1. Coolant drain bolt Wait for the engine and radiator to cool before 2.
  • Page 114 5. Remove the radiator cap. 1. Coolant reservoir hose 1. Radiator cap 8. After draining the coolant, thoroughly flush the 6. Remove the coolant reservoir cap. cooling system with clean tap water. 7. Disconnect the hose on the coolant reservoir 9.
  • Page 115 12. Pour the recommended coolant into the reser- voir to the maximum level mark, and then in- stall the reservoir cap. NOTICE: antifreeze with distilled water only. Howev- er, if distilled water is not available, soft water may be used for refilling. Do not use hard water or salt water since they are harmful to the engine.
  • Page 116 1. V-belt cooling duct 1. Cylinder head air bleed bolt 2. Clamp screw 18. When coolant begins to flow out of the bolt 17. Loosen the cylinder head air bleed bolt, with- hole, tighten the cylinder head air bleed bolt to out removing it, to allow all of the air to escape the specified torque.

  • Page 117: Cleaning The Air Filter Element

    23. Start the engine, and then check for coolant leakage. If any leakage is found, have a Yamaha dealer check the cooling system. 24. Install the V-belt cooling duct, and then tighten the clamp screw.
  • Page 118 1. Air filter case check hose 1. Air filter case cover holder 2. Air filter case cover 1. Place the ATV on a level surface. 4. Remove the sponge material and the mesh 2. Remove panel C. (See page 8-9.) from the air filter case.
  • Page 119 2. Air filter mesh damaged. 5. Clean the mesh with solvent, and then wipe 9. Apply Yamaha foam air filter oil or other qual- the solvent off. ity foam air filter oil to the sponge material. 6. Wash the sponge material gently, but thor- oughly, in solvent.
  • Page 120 engine damage. Additionally, operation without the air filter element will affect the fuel injection system with subsequent poor performance and possible engine overheating. [ECB00761] 11. Insert the projections on the air filter case cov- er into the holders on the air filter case, and then install the air filter case cover by hooking the holders onto the cover.

  • Page 121: Cleaning The Spark Arrester

    EBU27812 Cleaning the spark arrester Select a well-ventilated area free of combustible materials and make sure the exhaust and muffler are cool. 1. Remove the bolts. 1. Tailpipe 2. Spark arrester 3. Gasket 4. Check the gasket for damage, and replace it if necessary.

  • Page 122: V-Belt Case Drain Plug

    Tightening torque: Purging bolt: 27 Nm (2.7 m·kgf, 19 ft·lbf) EWB02380 WARNING Never run the engine in an enclosed area when purging the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monox- ide poisoning, possibly leading to death, and start a fire.

  • Page 123: Adjusting The Throttle Cable Free Play

    If water drains from the V-belt case after removing ically check the throttle cable free play and, if nec- the plug, have a Yamaha dealer check the ATV as essary, adjust it as follows. the water may affect other engine parts.

  • Page 124: Valve Clearance

    To prevent this from occurring, the valve clearance EBU27470 must be adjusted by a Yamaha dealer at the inter- Checking the front and rear brake pads vals specified in the periodic maintenance and lu- The front and rear brake pads must be checked for brication chart.

  • Page 125: Checking The Rear Brake Hose Protectors

    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. The wheels need to be removed to check the 1.

  • Page 126: Checking The Brake Fluid Level

    Front brake 1. Rear brake hose protector 1. Minimum level mark 2. Wear indicator 3. Protector is normal. Rear brake 4. Protector is worn. EBU29840 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective.

  • Page 127: Changing The Brake Fluid

    EBU24291 Changing the brake fluid When checking the fluid level, make sure that Have a Yamaha dealer change the brake fluid at the top of the brake fluid reservoir is level. the intervals specified in the TIP after the periodic Use only the recommended quality brake fluid, maintenance and lubrication chart.

  • Page 128: Adjusting The Brake Pedal Free Play

    Front brake EBU29072 Adjusting the brake pedal free play The brake pedal free play must be adjusted at the intervals specified in the periodic maintenance and lubrication chart. Always perform this maintenance completely in the following order whenever adjusting the rear brake.
  • Page 129 1. Brake pedal free play 1. Locknut 2. Brake pedal free play adjusting nut 1. Remove panel H. (See page 8-8.) 4. Tighten the locknut. 2. Loosen the locknut. 5. After adjusting, there should be slight play at 3. Turn the brake pedal free play adjusting nut in the brake pedal cable joint as shown.

  • Page 130: Axle Boots

    Check the axle boots for tears or damage. If any damage is found, have them re- placed by a Yamaha dealer. 1. Brake pedal cable joint 2. Slight play 6. Install the panel.

  • Page 131: Checking And Lubricating The Cables

    If a cable is damaged or does not move The operation of the front and rear brake levers smoothly, have a Yamaha dealer check or replace should be checked before each ride, and the lever pivots should be lubricated if necessary.

  • Page 132: Checking And Lubricating The Brake Pedal

    Front brake lever EBU28832 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary. To access the brake pedal pivot, remove panel H. (See page 8-8.) Recommended lubricant: Lithium-soap-based grease...

  • Page 133: Checking The Wheel Hub Bearings

    If there is play lubrication chart. in a wheel hub or if a wheel does not turn smoothly, Lubricate the pivoting points using a grease gun. have a Yamaha dealer check the wheel hub bear- Recommended lubricant: ings. Lithium-soap-based grease...

  • Page 134: Lubricating The Steering Shaft

    EBU25103 EWB02160 Lubricating the steering shaft WARNING The steering shaft must be lubricated by a Yamaha Battery electrolyte is poisonous and danger- dealer at the intervals specified in the periodic ous, as it contains sulfuric acid, which can maintenance and lubrication chart.
  • Page 135 4. Disconnect the negative battery lead first, then the positive battery lead by removing their bolt. NOTICE: When removing the bat- tery, the main switch must be off, and the negative lead must be disconnected be- fore the positive lead. [ECB01001] 1.
  • Page 136 To charge the battery ECB00940 NOTICE Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in Always keep the battery charged. Storing a dis- mind that the battery tends to discharge more...

  • Page 137: Replacing A Fuse

    EBU27751 Replacing a fuse 1. Positive battery lead (red) 2. Negative battery lead (black) 1. Fuse box 3. Install the battery holding plate by installing 2. Main/EPS spare fuse the nuts. 3. Main fuse 4. Install the front carrier by installing the bolts 4.
  • Page 138 ECB00640 NOTICE To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. WARNING! Always use a fuse of the spec- ified rating, and never use a substitute ob- ject in place of the proper fuse.

  • Page 139: Replacing A Headlight Bulb

    2. Remove the headlight bulb cover. EPS fuse: 40.0 A 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 8-59...
  • Page 140 4. Unhook the headlight bulb holder, and then remove the burnt-out bulb. 1. Headlight bulb cover 3. Disconnect the headlight coupler. 1. Headlight bulb holder 2. Headlight bulb 5. Place a new headlight bulb into position, and then secure it with the bulb holder. NOTICE: Do not touch the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the luminos-...

  • Page 141: Adjusting A Headlight Beam

    EBU25551 follows. Adjusting a headlight beam 1. Remove panel I. (See page 8-8.) ECB00690 2. Remove the bulb holder (together with the NOTICE bulb) by turning it counterclockwise. It is advisable to have a Yamaha dealer make this adjustment. 8-61...

  • Page 142: Removing A Wheel

    4. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 5. Install the bulb holder (together with the bulb) by turning it clockwise. 6. Install the panel. EBU25651 Removing a wheel 1.

  • Page 143: Installing A Wheel

    EBU25701 Installing a wheel 1. Place the ATV on a level surface. 2. Install the wheel and the nuts. 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.

  • Page 144: Troubleshooting

    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.

  • Page 145: Troubleshooting Charts

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.
  • Page 146 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. 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.

  • Page 147: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25881 tion of wheel bearings, brakes, transmis- Cleaning sion seals and electrical devices. Many Frequent, thorough cleaning of your ATV will not expensive repair bills have resulted from only enhance its appearance but will improve its improper high-pressure detergent applica- general performance and extend the useful life of tions such as those available in coin-oper-...

  • Page 148: Storage

    EBU27261 3. Perform the following steps to protect the cyl- Storage inder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark Short-term plug. Always store your ATV in a cool, dry place and, if b. Pour a teaspoonful of engine oil into the necessary, protect it against dust with a porous spark plug bore.
  • Page 149 6. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 7. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an exces- sively cold or warm place [less than 0 °C (30 °F) or more than 30 °C (90 °F)].

  • Page 150: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Compression ratio: 9.20 :1 Overall length: Starting system: 2065 mm (81.3 in) Electric starter Overall width: Lubrication system: 1180 mm (46.5 in) Wet sump Overall height: Engine oil: 1240 mm (48.8 in) Seat height: Recommended brand: 905 mm (35.6 in) YAMALUBE Wheelbase: Type:...
  • Page 151 Engine oil quantity: Fuel injection: Without oil filter cartridge replacement: Throttle body: 2.00 L (2.11 US qt, 1.76 Imp.qt) ID mark: With oil filter cartridge replacement: 43PG 10 2.10 L (2.22 US qt, 1.85 Imp.qt) Spark plug (s): Final gear oil: Manufacturer/model: Type: NGK/LMAR6A-9...
  • Page 152 Chassis: Minimum: Front: Frame type: 32.0 kPa (0.320 kgf/cm², 4.6 psi) Steel tube frame Rear: Caster angle: 27.0 kPa (0.270 kgf/cm², 4.0 psi) 5.0 ° Front wheel: Trail: 26.0 mm (1.02 in) Wheel type: Front tire: Panel wheel Rim size: Type: 12 x 6.0AT Tubeless...
  • Page 153 Front suspension: Tail/brake light: 12 V, 5.0/21.0 W × 1 Type: Meter lighting: Double wishbone Spring/shock absorber type: Neutral indicator light: Coil spring/oil damper Wheel travel: Reverse indicator light: 180 mm (7.1 in) Rear suspension: Coolant temperature warning light: Type: Double wishbone Engine trouble warning light: Spring/shock absorber type:...
  • Page 154 Headlight fuse: 15.0 A Signaling system fuse: 5.0 A Ignition fuse: 15.0 A Auxiliary DC jack fuse: 15.0 A Four-wheel-drive motor fuse: 15.0 A Radiator fan fuse: 20.0 A 10-5...

  • Page 155: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 156 Model label ment Canada. The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- 11-2...
  • Page 157 1. Vehicle Emission Control Information label 11-3...

  • Page 158: Noise Regulation

    EBU26060 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ul- timate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 159: Maintenance Record

    EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required.

  • Page 160: Yamaha Motor Corporation, U.s.a. Atv Limited Warranty

    (6) months from the date of purchase. appropriate owner’s manual; YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO 2. Give notice to an authorized Yamaha ATV dealer OTHER WARRANTY OF ANY KIND, EXPRESSED OR of any and all apparent defects within ten (10) days DURING THE PERIOD OF WARRANTY any authorized IMPLIED.
  • Page 161 Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

  • Page 162: Yamaha Extended Service (Y.e.s.)

    Yamaha people who handle your warranty – and it Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn’t limited to much more valuable! “moving par ts”...
  • Page 163 Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
  • Page 164 EBU26132 11-10...
  • Page 165 INDEX Drive select lever ............4-15 Drive select lever and driving in reverse ......6-2 Accessories and loading ..........6-6 Drive select lever safety system cable, adjusting ..8-44 Accessories, auxiliary jack ........... 4-23 Air filter element, cleaning ..........8-37 Axle boots ..............
  • Page 166 Seat ................4-18 Shock absorber assemblies, adjusting the front and Label locations ............... 1-1 rear ................4-22 Light switch ..............4-8 Spark arrester, cleaning ..........8-41 Low-range indicator light ..........4-2 Spark plug, checking ............ 8-20 Specifications ............... 10-1 Main switch ..............4-1 Speed limiter ..............
  • Page 168 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2009.07-0.3×1 CR...

This manual is also suitable for:

Grizzly 550 yfm5fgaGrizzly 550 yfm5fghaGrizzly 550 yfm5fgpaGrizzly 550 yfm5fgphaGrizzly yfm7fgpsez

Table of Contents