Yamaha GRIZZLY 550 700 Motorcycle 2012 Service Repair Manual

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Type: Motorcycle

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Sku: 104057

Tags: 2012 ATV GRIZZLY 550 GRIZZLY 700 Grizzly Models Motorcycle Powersports Yamaha

Product variants

Description

This manual covers the 550 and 700 All-Terrain Vehicles (ATVs) from the 2012 model year. These vehicles have a distinguished legacy in powersports, renowned for engineering durable and high-performance machines. The line, in particular, has consistently set benchmarks in the utility ATV segment, offering robust capabilities for both work and recreation. These ATVs are characterized by their reliable single-cylinder engines, advanced automatic transmission with engine braking, and the versatile 4WD system, providing exceptional traction and control across varied terrains. With substantial towing capacity and cargo carrying ability, the models are built for demanding conditions and extended use. This comprehensive service and repair manual provides in-depth guidance for owners, mechanics, and technicians. It details every aspect of the vehicle, from complete engine disassembly and reassembly, fuel injection system maintenance, and cooling system service, to drivetrain, suspension, and braking system repairs. The manual includes step-by-step instructions for preventive maintenance, troubleshooting common issues, and detailed procedures for rebuilding key components. Furthermore, it features essential technical specifications, diagnostic code interpretation, and clear electrical system wiring diagrams, ensuring users have the knowledge to maintain their 550 or 700 in optimal condition.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

Grizzly 550 / 700

Model Variant:

ATV (All-Terrain Vehicle)

Year:

👋 Introduction

Market Position

Target Audience:

Yamaha Grizzly 550/700 owners, ATV enthusiasts, independent repair shops, powersports technicians

Competitive Analysis

Manual Advantage:

Provides professional-grade technical data and repair procedures, mirroring dealership service information, enabling cost-effective maintenance and repairs.

Key Features

Information Completeness:

The most complete service and repair manual available, covering every detail of the machine.

Usability:

Easy-to-read text, top-quality diagrams, step-by-step instructions for both novice and experienced users.

Accessibility:

Instant download for immediate access, useful for on-the-trail or on-site repairs with smart devices.

📋 Manual Details

Coverage Areas

Vehicle Models Covered:

Yamaha Grizzly 550 (YFM550), Yamaha Grizzly 700 (YFM700)

Geographic Applicability:

Global (assumed based on standard Yamaha documentation)

Page Count

Estimated Page Count:

Extensive (typical service manuals for this type of vehicle range from 500-1000+ pages)

Manual Type

Type:

Service and Repair Manual

Language

Language:

English (assumed based on product description)

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine disassembly, assembly, inspection, and repair (including cylinder head, pistons, crankshaft, camshafts, valve train)

Engine Fuel System:

Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel filter, fuel tank maintenance

Cooling System:

Radiator, fan, water pump, coolant circulation, thermostat operation and replacement

Ignition System:

CDI unit, ignition coils, spark plugs, timing

Exhaust System:

Muffler, exhaust pipes, catalytic converter (if applicable), gasket replacement

Drivetrain Transmission:

Automatic transmission (CVT), drive clutch, driven clutch, belt inspection and replacement, gear case maintenance, lubrication

Drivetrain Drivability:

Shaft drive system, front and rear differentials, CV joints, propeller shafts, universal joints

Suspension Steering:

Front and rear suspension components (shocks, springs, A-arms, bushings), steering system, tie rods, wheel alignment

Braking System:

Hydraulic disc brakes (front and rear), brake pads, rotors, calipers, master cylinder, brake lines, bleeding procedures

Electrical System Charging:

Stator, voltage regulator/rectifier, battery maintenance, charging system troubleshooting

Electrical System Lighting:

Headlights, taillights, brake lights, accessory lighting, wiring diagrams

Electrical System Starting:

Starter motor, starter solenoid, battery connections

Electrical System Controls:

ECU, sensors (throttle position, crank position, etc.), switches, relays, fuses, diagnostic codes (DTCs)

Body Chassis:

Frame inspection and repair, body panels, fenders, seat, handlebars, rack systems

Wheels Tires:

Tire pressure, tire wear inspection, wheel bearing maintenance, lug nut torque specifications

Procedures Included

Preventive Maintenance:

Oil changes, filter replacements, lubrication points, valve clearance checks, spark plug replacement, brake fluid checks

Troubleshooting:

Diagnostic procedures for engine performance, electrical issues, starting problems, braking malfunctions, and drivetrain anomalies

Repair Procedures:

Step-by-step instructions for component removal, installation, adjustment, and replacement

Rebuilding Procedures:

Detailed instructions for engine and transmission component overhauls

Diagnostic Code Interpretation:

Explanation of diagnostic trouble codes (DTCs) and associated troubleshooting steps

Wiring Diagrams:

Comprehensive electrical system wiring schematics

Technical Depth

Depth Of Coverage:

Comprehensive (covers complete disassembly, assembly, and repair, suitable for professional mechanics and advanced DIY enthusiasts)

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content (typical for professional PDF manuals)

Print Quality

Image Quality:

High-quality diagrams and images for clear illustration

Binding Type

Binding Type:

Digital Download (PDF)

Paper Type

Paper Type Analogy:

N/A (Digital format; printable pages recommended on durable paper)

⚙️ Engine Specifications

Primary Engine

Engine Type 550:

4-stroke, SOHC, 4-valve, single-cylinder

Engine Displacement 550:

530cc

Engine Type 700:

4-stroke, SOHC, 4-valve, single-cylinder

Engine Displacement 700:

686cc

Bore X Stroke 550:

95.0 mm x 73.5 mm

Bore X Stroke 700:

100.0 mm x 85.0 mm

Compression Ratio 550:

9.1 : 1

Compression Ratio 700:

8.1 : 1

Performance

Horsepower 550:

Approximately 35.5 HP @ 6500 RPM (Estimate based on industry standards for this class)

Horsepower 700:

Approximately 46.5 HP @ 6500 RPM (Estimate based on industry standards for this class)

Fuel System

Fuel Delivery:

Yamaha Fuel Injection (YFI)

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Fuel Tank Capacity 550:

4.4 US gal (16.7 L)

Fuel Tank Capacity 700:

4.76 US gal (18 L)

🔧 Transmission

Standard

Transmission Type:

Automatic transmission (Yamaha Constant Velocity Transmission - Ultramatic®)

Drive System:

On-Command®; 4-Wheel Drive with 2-Wheel Drive and Differential Lock

Features

Gear Reduction:

High and Low range with Reverse

Engine Braking:

Utilizes centrifugal clutch for effective engine braking in downhill descents.

Transmission Fluid Type:

Yamalube® 10W-40 or equivalent API SG, Type 1 (specified in manual)

📐 Dimensions

Exterior

Length 550:

81.5 in (2070 mm)

Length 700:

82.1 in (2085 mm)

Width 550:

45.3 in (1150 mm)

Width 700:

45.3 in (1150 mm)

Height 550:

45.7 in (1160 mm)

Height 700:

45.9 in (1165 mm)

Seat Height 550:

33.4 in (850 mm)

Seat Height 700:

33.4 in (850 mm)

Weights

Curb Weight 550:

564 lb (256 kg) (approx.)

Curb Weight 700:

593 lb (269 kg) (approx.)

Towing Capacity:

1,322 lb (600 kg)

Cargo Capacity Front Rack:

99 lb (45 kg)

Cargo Capacity Rear Rack:

187 lb (85 kg)

Ground Clearance 550:

10.1 in (257 mm)

Ground Clearance 700:

10.1 in (257 mm)

🛡️ Safety Features

Ratings

Atv Safety Considerations:

The manual will detail safe operating procedures, pre-ride inspections, and basic maintenance for optimal safety.

Active Features

Braking System Features:

Hydraulic disc brakes with dual front and single rear calipers provide reliable stopping power.

4Wd System:

On-Command® 3-position 4WD (2WD, 4WD, 4WD with differential lock) for traction control in various terrains.

Passive Features

Chassis Design:

Rugged chassis designed for stability and durability in demanding off-road conditions.

💡 Technology Features

Infotainment

Infotainment Features:

N/A (ATV technology focuses on functionality and off-road performance; no infotainment system as typically found in cars).

Driver Assistance

Traction Control:

The 4WD system with differential lock acts as a form of terrain management, improving traction.

Connectivity

Connectivity Features:

N/A (No onboard connectivity or smartphone integration typical for this vehicle class).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 2,500 miles or 6 months, whichever comes first (or as specified by hours of operation).

Air Filter Cleaning:

Inspect every 1,000 miles or 3 months; clean or replace as needed, more frequently in dusty conditions.

Spark Plug Replacement:

Inspect every 2,500 miles or 6 months; replace as needed.

Cv Belt Inspection:

Inspect every 2,500 miles or 6 months; replace if worn, damaged, or showing signs of glazing.

Brake Fluid Flush:

Every 2 years or as needed based on fluid condition.

Fluid Specifications

Engine Oil:

Yamalube® 4M 10W-40 API SG, JASO MA or equivalent.

Engine Oil Capacity:

Approximately 2.4 US qt (2.3 L) with filter change (verify in manual).

Gear Oil:

Yamalube® Hypoid Gear Oil SAE 80 API GL-4 or equivalent.

Gear Oil Capacity:

Approximately 0.21 US qt (0.20 L) for front and rear differentials (verify in manual).

Coolant:

Yamaha's Genuine Antifreeze/Coolant or a high-quality ethylene glycol-based coolant with distilled water (50/50 mix).

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

CV joint boots, suspension bushings, brake pads, and drive belts are common wear items requiring regular inspection and replacement.

Efi System Maintenance:

Keeping the fuel system clean and using quality fuel is crucial for optimal EFI performance and longevity. The manual will guide on injector cleaning and fuel filter replacement.

📚 Vehicle History

Brand Heritage

Yamaha Powersports Legacy:

Yamaha has a long-standing reputation for building durable, high-performance powersports vehicles, including a robust line of ATVs known for their reliability and capability.

Model Evolution

Grizzly Line Development:

The Grizzly line has consistently been a leader in the utility ATV segment, evolving with advancements in engine technology, suspension, and four-wheel-drive systems. The 550 and 700 models represent Yamaha's commitment to offering powerful and versatile machines for work and recreation.

Production

Manufacturing Location:

Yamaha powersports vehicles are primarily manufactured in Japan and the United States (e.g., Yamaha Motor Manufacturing Corporation of America - YMMC in Newnan, Georgia).

🏆 Awards & Recognition

Recognitions

Grizzly Model Accolades:

The Yamaha Grizzly series has historically received numerous accolades from industry publications and consumers for its durability, performance, and off-road capability, often winning 'ATV of the Year' or similar awards in its respective categories.