2007–2008 Yamaha Grizzly 400 ATV Service Manual & Supplement (P/N 5TE-F8197-10)

Yamaha Grizzly 400 4x4 service documentation for 2007–2008 combines base manual 5TE-F8197-10 with a supplement covering the revised rear driveline, brakes, suspension, and electrical components.

• Engine repair: Engine removal, cylinder-head and valve work, piston inspection, crankcase separation, crankshaft and oil-pump service, plus recoil starter and A.C. magneto procedures.

• Belt drive and clutch: V-belt replacement, primary and secondary sheave disassembly, centrifugal clutch inspection, and transmission gear and shift-fork checks.

• Carburetion and cooling: Mikuni BSR33 carburetor overhaul and fuel-level adjustment, radiator pressure checks, thermostat testing, and water-pump disassembly and assembly.

• Shaft drive: Front and rear constant velocity joint service, differential checks, middle-gear shim selection, and final-drive bearing replacement and gear-lash adjustment.

• Brakes and chassis: Master-cylinder and caliper service, hydraulic brake bleeding, steering-knuckle and ball-joint work, plus swingarm and independent rear-suspension coverage.

• Electrical diagnosis: Ignition, starting, charging, lighting, signal, cooling-fan, and 2WD/4WD selecting-system troubleshooting, supported by circuit diagrams and wiring diagrams.

Suited to mechanics equipped for internal engine work and electrical testing; Yamaha assigns marked maintenance items to dealers because they require special tools and technical skills.

Engine Assembly, Belt Drive, and Lubrication

The liquid-cooled SOHC engine chapters cover cylinder-head inspection, valve-guide replacement and seat lapping, piston and ring measurements, and timing-chain tensioner checks. Cylinder-head installation includes the tightening sequence and staged bolt tightening.

Primary and secondary sheave procedures include pulley weights, sliders, guide pins, and spring inspection. The tool references identify the sheave spring compressor YM-04134 and fixed block YM-04135 for secondary-sheave work.

Exploded assembly views, oil-flow diagrams, lubrication charts, and component torque tables support reassembly. Maintenance specification tables provide standard dimensions and wear limits. The instructions identify Yamaha Bond No. 1215 applications and the specified lubricants for oil seals and O-rings.

Mikuni Carburetor and Cooling-System Service

Carburetor coverage extends to the piston-valve diaphragm, coasting enricher, needle valve and seat, and float adjustment. The fuel-level procedure identifies gauge YM-01312-A.

Coolant-flow diagrams accompany radiator, thermostat, and water-pump coverage. Pump inspection includes the impeller shaft, mechanical seal, oil seal, and bearing, with installation-tool references.

Differential and Final-Drive Repair

The shaft-drive troubleshooting chart relates noise and rough operation to wheel bearings, CV joints, and gear engagement. Gear-lash measurement views and shim-selection calculations support middle-gear and final-drive setup.

The internal differential unit is factory assembled and must remain together; the manual covers its removal, inspection, and surrounding components rather than internal differential teardown. Its gear-lash warnings explain how insufficient clearance can damage gear teeth.

Rear Brake and Suspension Variants

The 5TE-series base configuration uses a rear drum brake and monocross swingarm. The 1P1-series supplement covers a rear disc brake, rear CV joints, double-wishbone rear suspension, rear knuckles, and stabilizer.

These sections distinguish the rear assemblies before you select service procedures or parts. Supplement procedures also cover the park mechanism, select-lever safety cable, and rear brake master cylinder.

Brake service notes identify solvent damage that can swell and distort caliper seals. For brake and driveline work, verify measurements and procedures against the complete manual and follow its vehicle-support and safety precautions.

Electrical Fault Tracing and Wiring References

The no-spark troubleshooting chart separates spark-plug, ignition-coil, pickup-coil, and wiring checks from CDI-unit diagnosis, helping narrow the cause before replacement parts are selected.

Electrical coverage includes starter-motor inspection, charging-coil tests, cooling-fan controls, and the 4WD gear motor. The supplement adds park-switch and indicator-light checks. Cable-routing maps and connector views help relate the electrical schematics to the harness.

Sample Engine Checks and Clutch Torque Data

These examples are a small selection of the base manual's engine and clutch specifications.

Standard compression pressure is 1,400 kPa at sea level and 750 r/min; the test procedure specifies a warm engine and fully open throttle. Cold intake valve clearance is 0.06–0.10 mm.

Ignition timing is listed as 10° BTDC at 1,500 r/min. The clutch carrier nut specification is 140 Nm for a new nut lubricated with molybdenum disulfide oil; its locking requirement is covered in the assembly procedure.

Searchable PDF, Bookmarks, and Included Pages

Search and diagram detail: Embedded text supports searching, and PDF bookmarks cover the base and supplement sections. The full wiring diagrams need enlargement for comfortable reading of small wire-color codes and connector labels.

One printable 457-page PDF contains a 360-page base section and a 97-page supplement. Those totals already include 13 contents pages, two manual-use and symbol-guide pages, and one page containing only a section header.