Master Workshop Manual for Yamaha Grizzly 550/700 Utility ATV (2009) | 447-Page Technical File

Yamaha Grizzly 550/700 Service Manual

Maintaining high-performance fuel-injected systems on Yamaha utility platforms requires precision data and factory-verified tolerances. Service procedures in this comprehensive technical guide focus on the 550 FI and 700 FI powerplants, providing master-level mechanics with the exact benchmarks needed for engine overhauls and electronic power steering (EPS) diagnostics. Utilizing these OEM protocols ensures every repair restores the vehicle to original air-fuel and mechanical efficiency standards.

Technical Document Logistics

• Total Pages: 447
• Publication Date: May 2008
• Print/LIT Number: LIT-11616-22-19 / 34D-28197-10
• File Format: PDF

Equipment Stewardship & Performance Retention

• Eliminate costly trial-and-error by following structured Yamaha factory diagnostic flowcharts.
• Prevent premature drivetrain failure through precise valve clearance and V-belt width monitoring.
• Secure long-term equipment value by adhering to official lubrication schedules and fluid specifications.
• Minimize downtime during critical seasons with professional-grade electrical system troubleshooting.

Niche-Specific Compatibility & Series Coverage

Active technical data and repair procedures cover the 2009 model year for the following series and editions:

• Grizzly 550 FI Series: YFM5FGY (Standard), YFM5FGPY (EPS Model)
• Grizzly 700 FI Series: YFM7FGY (Standard), YFM7FGPY (EPS Model)
• Regional Revision Codes: 28P1, 28P5, 34D1, 34D5, 34D8, 5C0A, 5C0C, 43P1, 43P5, 43P8, 43PA
• Special Coverage: Dedicated Electric Power Steering (EPS) system logic and Fuel Injection (FI) architecture.

Technical Performance Matrix

High-Resolution System Visualization

This manual features high-density exploded diagrams for the 4-stroke SOHC single-cylinder engine, including detailed cylinder head and piston assembly sequences. Precise cable and hose routing paths—including the radiator fan motor breather, EPS motor breather, and differential case lines—are mapped to prevent interference with moving chassis components. Wiring and hydraulic circuit diagrams provide high-res clarity for tracing the signaling system and brake lines.

Advanced Diagnostics & System Logic

The integrated self-diagnosis device utilizes a two-digit fault code system displayed on the multi-function meter. Critical monitoring includes the FI system (intake air pressure, throttle position, coolant temperature) and the EPS control unit. Troubleshooting procedures involve checking the lean angle sensor, ISC (idle speed control) unit, and speed sensor inputs to ensure the ECU maintains the optimum air-fuel ratio and steering assist levels.

Professional Service Sequence

• 1. General Information (Identification, Features, Special Tools)
• 2. Specifications (Engine, Chassis, Tightening Torques)
• 3. Periodic Checks (Maintenance Charts, Engine/Chassis Adjustments)
• 4. Chassis Architecture (Brakes, Steering, Suspension, Wheels)
• 5. Engine Overhaul (Camshaft, Valves, Crankcase, Transmission)
• 6. Cooling & Fluid Systems (Radiator, Water Pump, Thermostat)
• 7. Fuel Injection (FI) (Throttle Body, Sensors, Pump Logic)
• 8. Drivetrain & Final Drive (Differential, CV Shafts, Middle Gear)
• 9. Electrical Systems (Charging, Lighting, EPS, ECU Logic)

FAQ

Q: Which specific Grizzly 550 and 700 series variations are documented for fuel injection and EPS service? A: This technical archive provides factory-level coverage for the 2009 YFM5FGY and YFM7FGY standard models, as well as the YFM5FGPY and YFM7FGPY Electronic Power Steering (EPS) editions. It includes specific logic for regional revision codes such as 28P, 34D, 5C0, and 43P, ensuring that technicians can verify sensor outputs and ECU mapping across all 558cc and 686cc fuel-injected platforms.

Q: What are the critical valve clearance benchmarks for maintaining engine thermal efficiency? A: To prevent top-end wear and ensure optimal compression, the intake valves must be set to a cold clearance of 0.09–0.13 mm (0.0035–0.0051 in), while the exhaust valves require a wider gap of 0.16–0.20 mm (0.0063–0.0079 in). Adhering to these precise tolerances prevents valve recession and maintains the stoichiometric balance required for high-altitude operation.

Q: How is the Ultramatic CVT system inspected to prevent field slippage or belt failure? A: Master technicians must verify that the V-belt width remains above the service limit of 30.0 mm (1.18 in). If the belt measures below this threshold from the standard 33.3 mm, the transmission will suffer from heat-induced glazing and reduced torque transfer, potentially resulting in drive failure during high-load utility tasks.

Q: What diagnostic protocol should be followed for EFI system troubleshooting via the digital meter? A: The onboard self-diagnosis system identifies faults using two-digit codes, such as Code 12 for the crankshaft position sensor or Code 15 for the throttle position sensor. Testing the fuel pump requires a verified pressure benchmark of 324 kPa (46.1 psi) at the rail; failure to meet this pressure usually indicates a clogged internal filter or a failing pressure regulator, which directly impacts cold-start reliability.

Q: What are the primary fluid capacities and tightening torques for a full chassis service? A: A standard oil change with filter replacement requires 2.10 liters (2.22 US qt) of SAE 10W-30 or 20W-40 oil, while the cooling system demands 2.00 liters (2.11 US qt) of ethylene glycol antifreeze. During reassembly, the rear wheel axle nut must be torqued to a critical 260 Nm (190 ft-lb) to ensure hub stability and prevent catastrophic bearing play during aggressive off-road maneuvers.