YAMAHA GRIZZLY 450 2009 Owners Manual

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8 3. Push the brake camshaft lever in direction (a)
until it stops [apply approximately 50 N (5.0
kgf, 11.0 lbf) of force], and then turn the brake
pedal free play adjusting nut on the brake ca-
ble at the final gear case so that gap “A” mea-
sures 2.5–3.0 mm (0.10–0.12 in).4. Push the brake camshaft lever in direction (a)
until it stops [apply approximately 50 N (5.0
kgf, 11.0 lbf) of force], and then turn the brake
lever free play adjusting nut on the brake ca-
ble at the final gear case so that gap “B” mea-
sures 4.0–6.0 mm (0.16–0.24 in).
1. Brake lever free play adjusting nut
1. Brake pedal free play adjusting nut
2. Brake camshaft lever
3. Gap “A”
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85. Check the brake lever free play and, if neces-
sary, adjust it by turning the brake lever free
play adjusting bolt at the brake lever. Turn the
brake lever free play adjusting bolt in direction
(a) to increase the free play, and in direction
(b) to decrease it.6. Tighten the locknut at the brake lever.
TIPWhen adjusting the rear brake lever free play:
Be sure not to step on the brake pedal.
Make sure the brake pedal does not move.
Checking the brake pedal position
The top of the brake pedal should be positioned
75.0–85.0 mm (2.95–3.35 in) above the footboard.
If the brake pedal position is incorrect, have a
Yamaha dealer adjust it.
1. Brake lever free play adjusting nut
2. Brake camshaft lever
3. Gap “B”
1. Locknut
2. Brake lever free play adjusting bolt
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8
WARNING
EWB02080Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:
Make sure the brakes operate smoothly and
that the free play is correct.
Make sure the brakes do not drag.
Replacement of brake components requires
professional knowledge. These proceduresshould be performed by a Yamaha dealer.
EBU24230Axle boots The axle boots must be checked for damage at the
intervals specified in the periodic maintenance and
lubrication chart. Check the axle boots for tears or
damage. If any damage is found, have them re-
placed by a Yamaha dealer.
1. Distance between brake pedal and footboard
1. Front axle boot (each side)
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8
EBU24752Brake light switches The operation of the brake light switches must be
checked and, if necessary, adjusted at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
The brake light switch for the brake pedal can be
adjusted as follows, but the other brake light
switches should be adjusted by a Yamaha dealer.
1. Remove panel B. (See page 8-9.)
TIPThe brake light switch is properly adjusted when
the brake light comes on just before braking takeseffect.
2. Turn the brake light switch adjusting nut while
holding the brake light switch in place. To
make the brake light come on earlier, turn the
adjusting nut in direction (a). To make the
brake light come on later, turn the adjusting
nut in direction (b).
3. Install the panel.
1. Rear axle boot (each side)
1. Brake light switch
2. Brake light switch adjusting nut
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8
EBU24900Checking and lubricating the cables The operation and the condition of all control ca-
bles should be checked before each ride, and the
cables and cable ends should be lubricated if nec-
essary. If a cable is damaged or does not move
smoothly, have a Yamaha dealer check or replace
it.
WARNING
EWB02130Inspect cables frequently and replace if dam-
aged. Corrosion can result when the cable
sheaths become damaged, and cables can
also become frayed or kinked, which could re-
strict the operation of controls and lead to anaccident or injury.EBU28711Checking and lubricating the front and
rear brake levers The operation of the front and rear brake levers
should be checked before each ride, and the lever
pivots should be lubricated if necessary.
EBU28832Checking and lubricating the brake
pedal The operation of the brake pedal should be
checked before each ride, and the pedal pivot
should be lubricated if necessary. Recommended lubricant:
Engine oilRecommended lubricants:
Front brake lever:
Silicone grease
Rear brake lever:
Lithium-soap-based grease
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8
TIPTo access the brake pedal pivot, remove panel B.(See page 8-9.)EBU24962Checking the wheel hub bearings The front and rear wheel hub bearings must be
checked at the intervals specified in the periodic
maintenance and lubrication chart. If there is playin a wheel hub or if a wheel does not turn smoothly,
have a Yamaha dealer check the wheel hub bear-
ings.
EBU24970Lubricating the drive shaft universal
joint The drive shaft universal joint must be lubricated at
the intervals specified in the periodic maintenance
and lubrication chart.
Lubricate the universal joint using a grease gun.EBU25021Checking the stabilizer bushes The stabilizer bushes must be checked for cracks
or damage at the intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer replace the stabilizer bush-
es if necessary. Recommended lubricant:
Lithium-soap-based greaseRecommended lubricant:
Lithium-soap-based grease
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8
EBU25051Lubricating the rear knuckle pivots The rear knuckle pivots must be lubricated at the
intervals specified in the periodic maintenance and
lubrication chart.
Lubricate the pivoting points using a grease gun.
EBU25102Lubricating the steering shaft The steering shaft must be lubricated at the inter-
vals specified in the periodic maintenance and lu-
brication chart.EBU29182Battery This model is equipped with a VRLA (Valve Regu-
lated Lead Acid) battery. There is no need to check
the electrolyte or to add distilled water. However,
the battery lead connections need to be checked
and, if necessary, tightened.NOTICEECB00620Never attempt to remove the battery cell seals,as this would permanently damage the battery. Recommended lubricant:
Lithium-soap-based grease
1. Grease nipple
Recommended lubricant:
Lithium-soap-based grease
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8
WARNING
EWB02160Battery electrolyte is poisonous and danger-
ous, as it contains sulfuric acid, which can
cause severe burns. Avoid contact with skin,
eyes or clothing. Always shield your eyes
when working near batteries.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten egg
or vegetable oil. Call a physician immediately.
EYES: Flush with water for 15 minutes and get
prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes or other sources of ig-
nition away. Ventilate when charging or using
in an enclosed space.KEEP OUT OF REACH OF CHILDREN.
To remove the battery
1. Remove the seat. (See page 4-18.)
2. Remove the battery holding plate by removing
the bolts.3. Disconnect the negative battery lead first,
then the positive battery lead by removing
their bolt.
4. Pull the battery out of its compartment.
To charge the battery
Have a Yamaha dealer charge the battery as soon
as possible if it seems to have discharged. Keep in
mind that the battery tends to discharge more
quickly if the ATV is equipped with optional electri-
cal accessories.
1. Bolt
2. Battery holding plate
3. Positive battery lead (red)
4. Negative battery lead (black)
3
4
12
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8
NOTICEECB00930To charge a VRLA (Valve Regulated Lead Acid)
battery, a special (constant-voltage) battery
charger is required. Using a conventional bat-
tery charger will damage the battery. If you do
not have access to a constant-voltage battery
charger, have a Yamaha dealer charge yourbattery.
To store the battery
If the ATV will not be used for more than one
month, remove the battery, fully charge it, and
then place it in a cool, dry place.
If the battery will be stored for more than two
months, check it at least once a month and fully
charge it if necessary.
To install the batteryTIPBe sure the battery is fully charged.
1. Place the battery in its compartment.
2. Connect the positive battery lead first, then
connect the negative battery lead by installing
their bolt.3. Install the battery holding plate by installing
the bolts.
4. Install the seat. (See page 4-18.)
NOTICEECB00940Always keep the battery charged. Storing a dis-
charged battery can cause permanent batterydamage.EBU25325Replacing a fuse The main fuse and the fuse box are located under
the seat. (See page 4-18.)1. Positive battery lead (red)
2. Negative battery lead (black)
1
2
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8
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off all electrical
circuits.
NOTICEECB00640To prevent accidental short-circuiting, turn off
the main switch when checking or replacing afuse.
1. Main fuse
2. Fuse box
1. Main fuse
2. Spare main fuse
1. Headlight fuse
2. Ignition fuse
3. Auxiliary DC jack fuse
4. Four-wheel-drive motor fuse
5. Signaling system fuse
6. Backup fuse (for odometer and clock)
7. Spare fuse
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