check engine YAMAHA GRIZZLY 450 2009 User Guide

8-3
8
EBU21742Periodic maintenance chart for the emission control system TIP
For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-
vals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance
intervals should be followed.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,data and technical skills.NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320
1*Fuel lineCheck fuel hoses for cracks or other damage, and
replace if necessary.√√√
2 Spark plugCheck condition and clean, regap, or replace if
necessary.√√√√√
3*ValvesCheck valve clearance and adjust if necessary.√ √√√
4*CarburetorCheck starter (choke) operation and correct if nec-
essary.
Check engine idling speed and adjust if neces-
sary.√√√√
5*Crankcase breather
systemCheck breather hose for cracks or other damage,
and replace if necessary.√√√
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8-6
8
9*Drive shaft univer-
sal jointLubricate with lithium-soap-based grease.√√√
10*Chassis fastenersMake sure that all nuts, bolts, and screws are
properly tightened.√√√√√
11*Shock absorber as-
sembliesCheck operation and correct if necessary.
Check for oil leakage and replace if necessary.√√√
12*Stabilizer bushesCheck for cracks or other damage, and replace if
necessary.√√√
13*Rear knuckle pivotsLubricate with lithium-soap-based grease.√√√
14*Steering shaftLubricate with lithium-soap-based grease.√√√
15*Steering systemCheck operation and repair or replace if damaged.
Check toe-in and adjust if necessary.√√√√√
16*Engine mountCheck for cracks or other damage, and replace if
necessary.√√√
17*Axle bootsCheck for cracks or other damage, and replace if
necessary.√√√√√
18 Engine oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√ √√√
19Engine oil filter car-
tridgeReplace.√√√
20*Engine oil strainerClean.√√√
21 Differential gear oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√√ NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320
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8-14
8 To install the panel
Place the panel in the original position and install
the bolts.
Panel F
To remove the panelPull outward on the areas shown.
To install the panelPlace the panel in its original position.
EBU23221Checking the spark plug The spark plug is an important engine component,
which is easy to check. Since heat and deposits
will cause any spark plug to slowly erode, the spark
plug should be removed and checked in accor-
dance with the periodic maintenance and lubrica-
tion chart. In addition, the condition of the spark
plug can reveal the condition of the engine.
To remove the spark plug
1. Remove panel A. (See page 8-9.)
2. Remove the spark plug cap.
1. Panel FU37S60E0.book Page 14 Thursday, June 5, 2008 6:51 PM

8-15
83. Remove the spark plug as shown, with the
spark plug wrench included in the owner’s tool
kit.To check the spark plug
1. Check that the porcelain insulator around the
center electrode of the spark plug is a medi-
um-to-light tan (the ideal color when the ATV
is ridden normally).
TIPIf the spark plug shows a distinctly different color,
the engine could be operating improperly. Do not
attempt to diagnose such problems yourself. In-stead, have a Yamaha dealer check the ATV.
1. Spark plug cap
1. Spark plug wrench
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8-17
8
TIPIf a torque wrench is not available when installing
a spark plug, a good estimate of the correct torque
is 1/4–1/2 turn past finger tight. However, the spark
plug should be tightened to the specified torque assoon as possible.
4. Install the spark plug cap.
5. Install the panel.EBU23326Engine oil and oil filter cartridge The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter cartridge replaced at the intervals spec-
ified in the periodic maintenance and lubrication
chart.
To check the engine oil level
1. Place the ATV on a level surface.
2. Remove panel F. (See page 8-9.)
3. Check the engine oil level on a cold engine.
TIPIf the engine was started before checking the oil
level, be sure to warm up the engine sufficiently,
and then wait at least ten minutes until the oil set-tles for an accurate reading.
4. Remove the engine oil filler cap, and then
wipe the dipstick off with a clean rag.
5. Insert the dipstick into the filler hole (without
screwing it in), and then remove it again to
check the oil level.1. Engine oil filler cap
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8-21
812. Refill with the specified amount of the recom-
mended engine oil, and then install and tight-
en the engine oil filler cap.
TIPBe sure to wipe off spilled oil on any parts after theengine and exhaust system have cooled down.NOTICEECB00300
In order to prevent clutch slippage (since the
engine oil also lubricates the clutch), do not
mix any chemical additives. Do not use oils
with a diesel specification of “CD” or oils of
a higher quality than specified. In addition,
do not use oils labeled “ENERGY CONSERV-
ING II” or higher.

Make sure that no foreign material enters thecrankcase.
13. Start the engine, and then let it idle for several
minutes while checking it for oil leakage. If oil
is leaking, immediately turn the engine off and
check for the cause.
14. Turn the engine off, wait at least ten minutes,
and then check the oil level and correct it if
necessary.
15. Install panel F. Recommended oil:
See page 10-1.
Oil quantity:
Without oil filter cartridge replacement:
2.30 L (2.43 US qt, 2.02 Imp.qt)
With oil filter cartridge replacement:
2.40 L (2.54 US qt, 2.11 Imp.qt)1.“CD” specification
2.“ENERGY CONSERVING II”
1
2
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8-22
8
EBU28572Final gear oil The final gear case must be checked for oil leak-
age before each ride. If any leakage is found, have
a Yamaha dealer check and repair the ATV. In ad-
dition, the final gear oil level must be checked and
the oil changed as follows at the intervals specified
in the periodic maintenance and lubrication chart.
To check the final gear oil level
1. Place the ATV on a level surface.TIPThe final gear oil level must be checked on a coldengine.
2. Remove the final gear oil filler bolt, and then
check the oil level in the final gear case.TIPThe oil level should be at the brim of the filler hole.3. If the oil is below the brim of the filler hole, add
sufficient oil of the recommended type to raise
it to the correct level.
4. Install the oil filler bolt, and then tighten it to the
specified torque.
To change the final gear oil
1. Place the ATV on a level surface.
1. Final gear oil filler bolt
2. Correct oil level
3. Final gear oilTightening torque:
Final gear oil filler bolt:
24 Nm (2.4 m·kgf, 17 ft·lbf)
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8-24
8
TIPIf the recommended oil is not available, SAE80W-
90 API GL-5 Hypoid gear oil may be used instead.
However, when using this oil, noise from the final
gear case may occur when applying the rearbrake.
NOTICEECB00420Be sure no foreign material enters the finalgear case.
7. Install the oil filler bolt, and then tighten it to the
specified torque.
8. Check the final gear case for oil leakage. If oil
is leaking, check for the cause.
9. Install the engine guard and the final gear
case guard by installing the bolts, and then
tightening them to the specified torques.
1. Final gear oil filler bolt
2. Correct oil level
3. Final gear oilRecommended final gear oil:
See page 10-1.
Tightening torque:
Final gear oil filler bolt:
24 Nm (2.4 m·kgf, 17 ft·lbf)
Tightening torques:
Engine guard bolt:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Final gear case guard bolt:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
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8-25
8
EBU23422Differential gear oil The differential gear case must be checked for oil
leakage before each ride. If any leakage is found,
have a Yamaha dealer check and repair the ATV.
In addition, the differential gear oil level must be
checked and the oil changed as follows at the in-
tervals specified in the periodic maintenance and
lubrication chart.
To check the differential gear oil level
1. Place the ATV on a level surface.TIPThe differential gear oil level must be checked ona cold engine.
2. Remove the differential gear oil filler bolt, and
then check the oil level in the differential gear
case.
TIPThe oil level should be at the brim of the filler hole.
3. If the oil is below the brim of the filler hole, add
sufficient oil of the recommended type to raise
it to the correct level.
4. Install the oil filler bolt, and then tighten it to the
specified torque.1. Differential gear oil
2. Differential gear oil filler bolt
3. Correct oil levelTightening torque:
Differential gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
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8-27
87. Check the differential gear case for oil leak-
age. If oil is leaking, check for the cause.
EBU23470Coolant The coolant level should be checked before each
ride. In addition, the coolant must be changed at
the intervals specified in the periodic maintenance
and lubrication chart.EBU27123To check the coolant level
1. Place the ATV on a level surface.TIPThe coolant level must be checked on a cold en-
gine since the level varies with engine tempera-ture.
2. Check the coolant level in the coolant reser-
voir.
TIPThe coolant should be between the minimum andmaximum level marks.
3. If the coolant is at or below the minimum level
mark, remove panel D. (See page 8-9.)
4. Remove the coolant reservoir cap, add cool-
ant or distilled water to the maximum level
mark, install the reservoir cap, and then install
the panel. Tightening torque:
Differential gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)1. Coolant reservoir cap
2. Maximum level mark
3. Minimum level mark
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