2009 Yamaha Grizzly 550 FI / 700 FI Service Manual (P/N LIT-11616-22–19, LIT-11626-24-04)

This Yamaha OEM workshop manual covers the 2009 Grizzly 550 FI and 700 FI (YFM series), including base and EPS-equipped models. Designed for professional technicians and serious DIY mechanics, its ten chapters cover maintenance, component checks, and repair work from engine teardown to electrical fault tracing.

• Engine repair covers removal from the chassis, cylinder-head and valve-train disassembly, valve-guide replacement, cam timing, piston inspection, and crankshaft removal.
• The V-belt automatic transmission sections detail primary and secondary sheave service, wet centrifugal clutch inspection, and high/low/reverse gearbox and shift-mechanism repair.
• Shaft-drive coverage extends to middle-gear alignment, front differential and rear final-gear backlash adjustment, shim selection, pinion-bearing preload, and CV-joint and boot replacement.
• Fuel injection (FI) troubleshooting combines fault-code diagnosis with fuel-pressure testing, injector checks, and throttle-position sensor adjustment.
• EPS-equipped models get separate steering-stem procedures, torque-sensor and motor tests, and warning-light diagnostics.
• Chassis work includes brake-caliper and master-cylinder overhaul, hydraulic bleeding, ball-joint replacement, and steering toe-in adjustment.
• Cooling-system procedures cover radiator-cap and thermostat tests, water-pump seal replacement, and coolant bleeding.

Model Coverage and Included PDFs

The set contains 619 PDF pages: a 447-page Service Manual, Yamaha publication LIT-11616-22-19 (First Edition, May 2008), plus a 172-page Owner’s Manual, LIT-11626-24-04 (First Edition, February 2010).

Workshop coverage is YFM5FGY and YFM7FGY without EPS, and YFM5FGPY and YFM7FGPY with electric power steering. The manual separates the steering components and electrical circuits for these configurations.

The separate Owner’s Manual is for YFM7FGA/YFM7FGHA. It covers controls, On-Command four-wheel-drive and differential-lock operation, pre-ride checks, loading and towing, basic maintenance, cleaning, and storage.

FI, EPS, and Electrical Troubleshooting

The FI section explains the multi-function display’s diagnostic mode and sensor-output checks. Actuator tests cover the injector, ignition coil, control relays, and ISC (idle speed control) valve. Fault charts provide probable causes, wiring checks, fault-history handling, and post-repair verification.

EPS diagnosis uses its own signal connectors and warning-light blink codes, with present and past malfunction modes. For a failed motor or torque sensor, the specified repair is EPS-unit replacement, not internal overhaul. Yamaha warns that dismantling the unit can damage it.

Separate starting and charging checks cover the starter motor, starting interlocks, AC magneto, and rectifier/regulator. Lighting and signaling circuits have their own troubleshooting sections.

Wiring Diagrams and Factory Repair Reference

The full 2009 wiring diagram is accompanied by dedicated Fuel Injection System and 2WD/4WD Selecting System circuit diagrams. The EPS System Block Diagram explains steering-assist inputs, while Lubrication Diagrams and Cooling System Diagrams show oil and coolant routing. Exploded assemblies identify parts, lubrication points, replacement items, and fastener locations for reassembly.

Factory tables provide model-specific engine dimensions, inspection limits, valve clearances, engine-oil and coolant capacities, and electrical test values. Cylinder-head and chassis torque specifications include fastener-specific notes and tightening sequences. Periodic service coverage also includes compression testing, engine-oil-pressure checks, and drive-select cable and shift-rod adjustment.

Special-tool references include the sheave spring compressor YM-04134, fuel-pressure gauge YU-03153, and middle drive gear lash tool YM-01475. The shaft-drive cautions specifically address gear-tooth damage caused by insufficient backlash after reassembly.

Working with pressurized fuel systems or heavy chassis components carries inherent risks. Always consult the proper technical reference values before beginning any teardown to ensure personal safety and equipment integrity.

Note: This page outlines the contents of the manual for review purposes and does not contain the actual step-by-step diagnostic or repair procedures.