Yamaha Grizzly 700 Problems and Solutions

The Yamaha Grizzly 700 is a highly esteemed utility ATV, celebrated for its robust engine, durable build, and comfortable ride, making it ideal for everything from trail riding and hunting to farm work and challenging off-road conditions. Its Electronic Power Steering (EPS), Ultramatic transmission, and On-Command 4WD system contribute to its legendary status. However, like any complex machine, the Grizzly 700 can encounter specific issues over time or with heavy use. Understanding these common problems and their solutions can help owners maintain their ATV’s performance and extend its lifespan.

1. Starting Problems

Symptoms:

• Engine cranks but doesn’t start.
• No response when turning the key.
• Engine turns over slowly or just clicks.

Common Causes and Solutions:

• Weak or Dead Battery:
  • Problem: Insufficient power to turn the engine over, especially in cold weather.
  • Solution: Test battery voltage (should be 12.6V or higher). Charge or replace the battery. Clean corroded terminals and ensure all connections are tight.
• Clogged Fuel Filter/Stale Fuel:
  • Problem: Restricted fuel flow or fuel that has degraded over time, especially with ethanol.
  • Solution: Drain old fuel, replace with fresh, high-octane gasoline. Replace the fuel filter. Use a fuel stabilizer if storing the ATV.
• Fouled Spark Plug:
  • Problem: Dirty, carbon-fouled, or worn spark plugs won’t produce a strong enough spark for ignition.
  • Solution: Remove and inspect the spark plug. Clean or replace if fouled or worn. Ensure proper gap (refer to manual).
• Fuel Pump Issues:
  • Problem: A weak or failing fuel pump may not deliver adequate fuel pressure for starting.
  • Solution: Listen for the fuel pump prime when turning the key. Test fuel pressure if suspected faulty. Replace if necessary.
• Safety Switch Issues:
  • Problem: Faulty or disengaged safety switches (e.g., brake switch, transmission in gear) can prevent starting.
  • Solution: Ensure the brake lever is squeezed, and the transmission is in Park or Neutral. Inspect switches and their wiring.

2. Loss of Power / Engine Performance Issues

Symptoms:

• Engine bogs down under load or on inclines.
• Reduced top speed or acceleration.
• Hesitation or rough running.
• Excessive black smoke from exhaust.

Common Causes and Solutions:

• Clogged Air Filter:
  • Problem: Restricted airflow to the engine, leading to a rich fuel mixture and reduced power.
  • Solution: Regularly inspect, clean, or replace the air filter, especially if riding in dusty or wet conditions.
• Dirty Fuel Injector:
  • Problem: Clogged injectors can lead to an improper fuel spray pattern and inefficient combustion.
  • Solution: Use a quality fuel system cleaner. If issues persist, professional cleaning or replacement of the injector may be necessary.
• Weak Fuel Pump:
  • Problem: (See Starting Problems above) Insufficient fuel pressure due to a failing pump.
  • Solution: Test fuel pump pressure. Replace if faulty.
• Worn Spark Plug:
  • Problem: Degraded spark plugs lead to incomplete combustion and power loss.
  • Solution: Replace spark plugs at recommended intervals.
• CVT Belt Wear/Slipping:
  • Problem: A worn or glazed CVT drive belt can slip, causing the engine to rev high without transferring full power to the wheels.
  • Solution: Inspect the drive belt (under the CVT cover) for fraying, cracks, glazing, or wear. Replace if necessary. Ensure clutch faces are clean.

3. Transmission and Drivetrain Problems

Symptoms:

• Difficulty shifting gears.
• Grinding noises when shifting.
• ATV won’t move when in gear.
• Clunking or clicking noises from axles/CV joints.
• On-Command 4WD not engaging or disengaging.

Common Causes and Solutions:

• Worn CVT Belt:
  • Problem: (See Loss of Power section above) A worn belt prevents effective power transfer.
  • Solution: Inspect and replace the CVT belt.
• Clutch Issues (Primary/Secondary/Wet Clutch):
  • Problem: Worn components within the primary (drive) or secondary (driven) CVT clutches, or issues with the wet clutch (which handles initial engagement), can affect power transfer and cause noises or slipping.
  • Solution: Disassemble the CVT system and inspect clutch components. Clean thoroughly. Replace worn parts. If the wet clutch is slipping, the friction plates may need replacement.
• Low Differential Fluid:
  • Problem: Insufficient or contaminated fluid in the front or rear differential can cause grinding or premature wear.
  • Solution: Check fluid levels in both differentials. Top up or replace fluid as recommended in the manual.
• Worn CV Joints/Axles:
  • Problem: Clicking or popping noises, especially during turns, indicate worn CV joints.
  • Solution: Inspect CV boots for tears. If torn, contamination likely damaged the joint. Replace the entire axle assembly or just the CV joint if repairable.
• On-Command 4WD Issues:
  • Problem: Faulty solenoid, wiring, or a problem with the front differential engagement mechanism.
  • Solution: Check the 4WD switch, wiring, and front differential actuator/solenoid. Ensure the 4WD system fluid is clean and at proper levels.

4. Electrical System Malfunctions

Symptoms:

• Dashboard warning lights (e.g., Check Engine, EPS).
• Accessories (winch, lights) not functioning.
• Battery not charging.
• Intermittent starting.

Common Causes and Solutions:

• Blown Fuses:
  • Problem: Overloads or shorts cause fuses to blow.
  • Solution: Locate the fuse box(es) (consult manual) and replace any blown fuses with the correct amperage.
• Loose or Corroded Connections:
  • Problem: ATV wiring is exposed to elements, leading to corrosion and loose connections.
  • Solution: Inspect all battery terminals, ground connections, and wiring harnesses for corrosion or looseness. Clean with electrical contact cleaner and apply dielectric grease.
• Faulty Voltage Regulator/Rectifier (VRR):
  • Problem: The VRR controls charging system output; a faulty one can overcharge or undercharge the battery.
  • Solution: Test the charging system output at the battery. If voltage is too high or too low while running, the VRR is likely faulty and needs replacement.
• Faulty Sensors:
  • Problem: A malfunctioning sensor (e.g., TPS, speed sensor, coolant temp sensor) can trigger a Check Engine Light and affect performance.
  • Solution: If a specific error code is displayed, consult the manual for the sensor it points to. Test the sensor if possible or replace it if faulty.

5. Steering and Suspension Problems

Symptoms:

• Loose or excessive play in the steering.
• Squeaking or clunking noises from suspension.
• Uneven tire wear.
• ATV pulls to one side or is hard to control.
• EPS not working.

Common Causes and Solutions:

• Worn Tie Rod Ends/Ball Joints:
  • Problem: Play in these components leads to loose steering and poor handling.
  • Solution: Inspect for excessive play. Replace worn tie rod ends or ball joints.
• Worn A-Arm Bushings:
  • Problem: Degraded bushings can cause squeaking, clunking, and poor ride quality.
  • Solution: Inspect bushings in A-arms. Replace if worn. Lubricate if they have grease zerks.
• Low/Uneven Tire Pressure:
  • Problem: Affects handling, stability, and tire wear.
  • Solution: Maintain recommended tire pressure for all four tires.
• Damaged Shock Absorbers:
  • Problem: Leaking or worn shocks will reduce ride quality and handling stability.
  • Solution: Inspect shocks for leaks or damage. Replace if necessary.
• EPS (Electronic Power Steering) System Issues:
  • Problem: Failure of the EPS motor, control unit, or related sensors (e.g., speed sensor, torque sensor) can cause loss of power steering.
  • Solution: Check for specific EPS error codes (if displayed). Inspect wiring to EPS unit. Requires professional diagnosis for internal EPS component failures.

Preventive Maintenance is Key

Many common problems can be avoided with consistent and thorough maintenance:

• Follow Service Intervals: Adhere strictly to the maintenance schedule in your owner’s manual for fluid, filter, and lubrication changes.
• Daily Checks: Before riding, quickly check fluid levels, tire pressure, and visually inspect for leaks or damage.
• Keep it Clean: Regularly wash the ATV, paying attention to mud and debris buildup, especially around the engine, cooling fins, and undercarriage.
• Use Quality Fluids & Parts: Use Yamaha-recommended fluids and quality parts for optimal performance and longevity.

Yamaha Grizzly 700 Specifications

The Yamaha Grizzly 700 is a flagship utility ATV known for its powerful engine, robust construction, and advanced features like Electronic Power Steering (EPS), Ultramatic transmission, and On-Command 4WD. Specifications can vary slightly by model year and regional variants (e.g., California emissions models). The data below is typical for recent generations of the Grizzly 700.

Yamaha Grizzly 700 Error Codes

The Yamaha Grizzly 700, equipped with a sophisticated ECU (Engine Control Unit) and electronic systems (like YFI and EPS), is capable of generating and displaying Diagnostic Trouble Codes (DTCs) on its LCD multi-function display. These codes help in identifying specific system malfunctions.

How Error Codes Are Displayed

On the Grizzly 700, error codes are typically displayed directly on the LCD multi-function meter.

1. Warning Light: The “Check Engine” light (or a specific warning icon) will illuminate.
2. Diagnostic Code: The display will show an alphanumeric code, often preceded by a “d” (for diagnostic mode) or “E” (for error). Yamaha typically uses a two-digit code.

Example Code Display: You might see E-21 or d:03.

Accessing Error Codes (Diagnostic Mode)

To enter diagnostic mode and view specific fault codes, a common procedure (which may vary slightly by model year) is:

1. Turn the main switch to OFF.
2. Set the engine stop switch to RUN position.
3. Simultaneously press and hold the MODE button and the SELECT button.
4. Turn the main switch to ON (while holding MODE and SELECT).
5. Continue holding the buttons for approximately 8 seconds until “dIAG” appears on the display.
6. Release the buttons.
7. Press MODE briefly to cycle through the diagnostic codes (d:01, d:03, etc.). The specific values or statuses will be displayed. Fault codes are usually marked by a flashing segment or an “Error” indication.
8. To exit diagnostic mode, turn the main switch to OFF.

Always consult your specific Yamaha Grizzly 700 Owner’s Manual and Service Manual for the exact diagnostic procedure and a comprehensive list of all codes and their meanings for your model year.

Common Error Code Categories and Their General Meaning

Here’s a list of some common areas where the Grizzly 700 generates error codes:

• d:01 – Throttle Position Sensor (TPS): Indicates issues with the throttle position sensor’s voltage or signal.
• d:03 – Ignition Coil: Problems with the primary side of the ignition coil circuit.
• d:05 – Cylinder Identification Sensor: Issues with the camshaft position sensor.
• d:06 – Crankshaft Position Sensor: Problems with the crankshaft position sensor’s signal.
• d:07 – Vehicle Speed Sensor: Faults with the speed sensor.
• d:08 – Engine Temperature Sensor: Issues with the engine’s coolant temperature sensor.
• d:09 – Intake Air Pressure Sensor (MAP): Problems with the MAP sensor’s signal.
• d:10 – Intake Air Temperature Sensor (IAT): Issues with the IAT sensor.
• d:12 – Crankshaft Position Sensor (no normal signal detected): A critical code indicating no signal from the crank sensor, preventing engine start.
• d:15 – Throttle Body Motor: Problems with the electronic throttle motor itself (on models with electronic throttle control).
• d:21 – Power Source for ECU: Indicates a voltage problem to the ECU.
• d:30 – Lean Angle Sensor: Faults with the tip-over sensor.
• d:41 – Wheel Sensor (if equipped, related to 4WD/EPS): Issues with wheel speed sensors.
• d:43 – Fuel System Voltage: Indicates low or high voltage to fuel pump or injectors.
• d:46 – Charging System: Problem with the battery charging voltage (e.g., voltage regulator/rectifier).
• d:51 – Fuel Injector: Issues with the fuel injector circuit.
• d:52 – Ignition Coil: Issues with secondary side of ignition coil circuit.

General Fixes for Error Codes

1. Record the Code: Always write down the full code (e.g., d:21).
2. Consult Service Manual: This is paramount. The service manual will provide a detailed diagnostic procedure for each code, often including specific resistance readings, voltage checks, and wiring diagrams.
3. Basic Checks:
   • Battery: Ensure the battery is fully charged and terminals are clean and tight. Low voltage can trigger many false codes.
   • Fuses: Check all fuses (main and accessory) for blown ones.
   • Connections: Inspect wiring harnesses and connectors associated with the code’s system for corrosion, looseness, or damage. Clean with electrical contact cleaner and apply dielectric grease.
   • Fluid Levels: Ensure engine oil and coolant are at proper levels.
4. Clear Codes: After addressing the underlying issue, you typically need to clear the codes from the ECU memory. The diagnostic mode often has a specific option to clear all DTCs (e.g., set to d:60 and press a button for a few seconds). The code will return if the fault is still present.
5. Professional Diagnostic Tool: For persistent or complex codes, especially those related to engine management or EPS, a Yamaha dealership uses specialized diagnostic tools that can read all stored codes, view live sensor data, and perform advanced tests.

Conclusion

The Yamaha Grizzly 700 is a formidable and reliable ATV, built for demanding use. Most common problems are typical for any high-performance off-road machine and can be effectively managed with proactive maintenance and prompt troubleshooting. By staying vigilant about routine checks and addressing issues early, you can ensure your Grizzly 700 continues to perform reliably for all your adventures and tasks. For complex issues or those indicated by specific error codes, consulting an authorized Yamaha dealer is recommended.

David Holtzman

I’m David man behind Lawn Mowerly; I’ve been dealing with lawnmowers and Tractors with my father since I was a kid. I know every make and model and what each one is capable of and love helping people find the perfect equipment for their needs.