2009 Yamaha Grizzly 550/700 Utility ATV Service Manual (P/N LIT-11616-22-19)

This Yamaha service manual, P/N LIT-11616-22-19, covers the 2009 Grizzly 550 and Grizzly 700 in YFM5FGY, YFM5FGPY, YFM7FGY, and YFM7FGPY versions. The first edition is dated May 2008 and carries cover reference 34D-28197-10.

• Engine repair: Engine removal and internal overhaul procedures, including cylinder-head inspection, valve service, piston measurements, crankshaft checks, and oil-pump inspection.

• CVT and transmission: V-belt replacement, primary and secondary sheave service, automatic centrifugal clutch inspection, and transmission gear and shift-fork checks.

• Shaft drive: Front and rear constant velocity shaft assemblies, differential and final drive repair, gear backlash adjustment, and shim selection.

• Brakes and chassis: Hydraulic brake bleeding, caliper and master-cylinder repair, double-wishbone suspension service, steering inspection, and wheel-bearing replacement.

• Fuel injection: Fuel-pump pressure testing, throttle-body and injector checks, throttle-position sensor adjustment, and FI diagnostic fault-code tables.

• Cooling system: Radiator and cap testing, thermostat inspection, water-pump disassembly, seal replacement, and coolant filling and air-bleeding procedures.

• Electrical systems: Ignition and starting-circuit troubleshooting, charging checks, 2WD/4WD diagnostics, EPS fault tracing, and wiring diagrams with cable-routing references.

Written primarily for Yamaha dealers and qualified mechanics, the manual assumes basic knowledge of mechanics and ATV repair techniques.

Engine, CVT, and Transmission Repair

Internal engine work: Exploded views and inspection procedures cover valve guides and seats, camshaft and rocker arms, and piston-to-cylinder clearances. Cylinder-head reassembly includes a bolt-specific tightening sequence; the reference tables also cover engine and chassis fasteners.

CVT service: Secondary-sheave disassembly identifies the required compression tools, including YM-04134. Separate procedures cover the AC magneto and starter clutch, crankcase separation, and transmission inspection.

Differential and Final Drive Setup

Backlash checks are paired with differential shim selection and final-drive pinion preload procedures. The shaft-drive troubleshooting section combines a test chart with noise-diagnosis notes to help distinguish gear faults from wheel-bearing problems.

The differential case and bearings have service procedures, but the factory-assembled ring gear and differential gear unit is not intended for internal disassembly.

FI Diagnostics and EPS Coverage

FI troubleshooting: The multifunction meter's diagnostic mode supports sensor checks and actuator tests. ECU fault-code tables connect symptoms with circuit, connector, and component checks, helping separate a wiring fault from a failed sensor before parts are replaced.

Before working on pressurized fuel components or electrical circuits, follow the manual's safety precautions and use the specified diagnostic tools.

EPS variants: Electric Power Steering coverage applies to YFM5FGPY and YFM7FGPY. Warning-light fault codes, motor continuity tests, and torque-sensor resistance checks support diagnosis; the EPS block diagram explains the system layout.

The EPS unit is serviced as an assembly: Yamaha warns that disassembly can damage it, and failed motor or torque-sensor checks call for unit replacement.

Chassis Service and Cooling-System Checks

Chassis repair: Suspension procedures extend to control-arm ball joints, steering knuckles, and toe-in checks. The chassis torque tables distinguish wheel nuts from axle nuts.

Brake sections include piston and seal inspection; the manual warns that solvents can swell and distort internal brake seals.

Cooling and lubrication: Radiator-cap and thermostat tests accompany water-pump seal service. Lubrication charts and cooling-system diagrams show oil and coolant paths, while the periodic maintenance charts organize scheduled inspections.

Valve, Spark Plug, and Coolant Specification Examples

These examples are a small selection of the manual's engine service specifications. For all four covered models, valve clearances with the engine cold at room temperature are 0.09–0.13 mm at the intake and 0.16–0.20 mm at the exhaust.

The specified NGK LMAR6A-9 spark plug has a gap of 0.8–0.9 mm. Radiator capacity, including all coolant routes, is listed as 1.99 L; the coolant reservoir has a separate capacity specification.

PDF Navigation and Wiring Detail

Text search and navigation: Searchable text and embedded chapter and section bookmarks help locate procedures and specifications. Small connector labels and wire-color codes in the wiring diagrams are readable when enlarged.

The download contains one printable English-language 447-page PDF: eight opening pages, 435 chapter pages, and four closing pages. Covers, introductory material, blank pages, the wiring legend, and the final color wiring-diagram sheet are all included in that total.