differential YAMAHA GRIZZLY 450 2009 User Guide

5-1
5
EBU19200
PRE-OPERATION CHECKS
EBU19223Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table.
WARNING
EWB00480Always inspect your ATV each time you use it to make sure it is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Owner’sManual. Failure to inspect increases the possibility of an accident or equipment damage.TIPThe maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodicmaintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
ITEM ROUTINE PAGE
FuelCheck fuel level in fuel tank, and add recommended fuel if neces-
sary.
Check fuel line for leakage. Correct if necessary.4-15, 5-3
Engine oilCheck oil level in engine, and add recommended oil to specified lev-
el if necessary.
Check ATV for oil leakage. Correct if necessary.5-3, 8-17
Final gear oilCheck ATV for oil leakage. Correct if necessary. 5-3, 8-22
Differential gear oilCheck ATV for oil leakage. Correct if necessary. 5-3, 8-25
CoolantCheck coolant level in reservoir, and add recommended coolant to
specified level if necessary.
Check cooling system for leakage. Correct if necessary.5-3, 8-27
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5-3
5
EBU19540Fuel Make sure that there is sufficient fuel in the tank.
(See page 4-15.)
WARNING
EWB00520
Do not overfill the fuel tank. Fuel expands
when it heats up. If the fuel tank is overfilled,
fuel could spill out due to heat from the en-
gine or the sun.
Be careful not to spill fuel, especially on the
engine or exhaust pipe which can cause a
fire and severe injury. Wipe up any spilled
fuel immediately.
Do not refuel right after the engine has been
running and is still very hot.
Be sure the fuel tank cap is closed securely.EBU19560Engine oil Make sure that the engine oil is at the specified lev-
el. Add oil as necessary. (See page 8-17.)EBU19590Final gear oil Make sure that the final gear oil is at the specified
level. Add oil as necessary. (See page 8-22.)
EBU19600Differential gear oil Make sure that the differential gear oil is at the
specified level. Add oil as necessary. (See page
8-25.)EBU19630Coolant Make sure that the coolant is at the specified level.
Add coolant as necessary. (See page 8-27.)TIPThe coolant level must be checked on a cold en-
gine since the level varies with engine tempera-ture.
WARNING
EWB00510Wait for the engine and radiator to cool before
removing the radiator cap. You could be
burned by hot fluid and steam blown out under
pressure. Always put a thick rag over the cap
when opening. Allow any remaining pressureto escape before completely removing the cap.
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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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8-25
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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8-26
8 To change the differential gear oil
1. Place the ATV on a level surface.
2. Place an oil pan under the differential gear
case to collect the used oil.
3. Remove the differential gear oil filler bolt and
the differential gear oil drain bolt to drain the
oil from the differential gear case.
4. Install the drain bolt, and then tighten it to the
specified torque.5. Refill with the recommended differential gear
oil to the brim of the filler hole as shown.
NOTICEECB00410Be sure no foreign material enters the differen-tial gear case.
6. Install the oil filler bolt, and then tighten it to the
specified torque.
1. Differential gear oil drain boltTightening torque:
Differential gear oil drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1. Differential gear oil
2. Differential gear oil filler bolt
3. Correct oil levelRecommended differential gear oil:
See page 10-1.
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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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10-2
10
Engine oil:Type:
SAE 5W-30 or SAE 10W-30 or SAE 10W-40 or SAE
15W-40 or SAE 20W-40 or SAE 20W-50
Recommended engine oil grade:
API service SG type or higher, JASO standard MA
Engine 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)Final gear oil:Type:
Yamaha Friction Modified Shaft Drive Gear Oil (EUR)
Yamaha Friction Modified Shaft Drive Gear Oil (Part No.:
ACC-SHAFT-LU-00) (AUS)(NZL)Quantity:
0.50 L (0.53 US qt, 0.44 Imp.qt)
Differential gear oil:Type:
Yamaha Friction Modified Shaft Drive Gear Oil (Part No.:
ACC-SHAFT-LU-00) or SAE 80 API GL-4 Hypoid gear oil
(AUS)(NZL)
Yamaha Friction Modified Shaft Drive Gear Oil or SAE 80
API GL-4 Hypoid gear oil (EUR)
Quantity:
0.23 L (0.24 US qt, 0.20 Imp.qt)Cooling system:Coolant reservoir capacity (up to the maximum level mark):
0.25 L (0.26 US qt, 0.22 Imp.qt)
Radiator capacity (including all routes):
1.30 L (1.37 US qt, 1.14 Imp.qt)Air filter:Air filter element:
Wet elementFuel:Recommended fuel:
Regular unleaded gasoline only (EUR)
Unleaded gasoline only (AUS)(NZL)
Fuel tank capacity:
15.0 L (3.96 US gal, 3.30 Imp.gal)
Fuel reserve amount:
4.5 L (1.19 US gal, 0.99 Imp.gal)Carburetor:Manufacturer:
MIKUNI
-20 -10 0
1020 304050 ˚C
SAE 15W-40
SAE 20W-40SAE 20W-50
SAE 10W-40
SAE 5W-30
SAE 10W-30
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10-5
10
Reverse indicator light:
LED
Coolant temperature warning light:
LED
Park indicator light:
LED
On-Command four-wheel-drive/differential gear lock
indicator:
LCD
High-range indicator light:
LED
Low-range indicator light:
LED
Differential gear lock indicator light:
LEDFuses:Main fuse:
30.0 A
Headlight fuse:
15.0 A
Signaling system fuse:
10.0 A
Ignition fuse:
10.0 A
Auxiliary DC jack fuse:
10.0 A
Backup fuse:
10.0 A
Four-wheel-drive motor fuse:
10.0 A
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INDEX
AAccessories and loading ................................................ 6-6
Accessories, auxiliary jack ........................................... 4-23
Air filter element, cleaning ............................................ 8-31
Axle boots .................................................................... 8-46BBattery .......................................................................... 8-50
Brake fluid, changing ................................................... 8-41
Brake fluid level, checking ........................................... 8-40
Brake lever free play, checking the front ...................... 8-41
Brake lever, front .......................................................... 4-12
Brake levers, checking and lubricating ........................ 8-48
Brake light switches ..................................................... 8-47
Brake pads and friction plates, checking ..................... 8-39
Brake pedal and brake lever free play (rear) and
brake pedal position, adjusting and checking ............ 8-42
Brake pedal and rear brake lever ................................. 4-13
Brake pedal, checking and lubricating ......................... 8-48
Brakes, front and rear .................................................... 5-4CCables, checking and lubricating ................................. 8-48
Carburetor, adjusting ................................................... 8-36
Carrier, front ................................................................. 4-21
Carrier, rear .................................................................. 4-21
Chassis fasteners .......................................................... 5-7
Cleaning ......................................................................... 9-1
Coolant .................................................................. 5-3, 8-27
Coolant temperature warning light ................................. 4-2
DDifferential gear lock indicator light ................................ 4-3
Differential gear oil ................................................ 5-3, 8-25
Drive select lever ......................................................... 4-14
Drive select lever and driving in reverse ........................ 6-3
Drive select lever safety system cable, adjusting ........ 8-39
Drive shaft universal joint, lubricating .......................... 8-49EEngine break-in .............................................................. 6-5
Engine, cold start ........................................................... 6-1
Engine idling speed ..................................................... 8-36
Engine oil ....................................................................... 5-3
Engine oil and oil filter cartridge ................................... 8-17
Engine, starting a warm ................................................. 6-3
Engine stop switch ......................................................... 4-6FFinal gear oil ......................................................... 5-3, 8-22
Four-wheel-drive/differential gear lock indicator ............ 4-3
Fuel ....................................................................... 4-15, 5-3
Fuel cock ..................................................................... 4-16
Fuel gauge ..................................................................... 4-5
Fuel tank cap ............................................................... 4-14
Fuses, replacing .......................................................... 8-52HHandlebar switches ....................................................... 4-5
Headlight beam, adjusting ........................................... 8-56
Headlight bulb, replacing ............................................. 8-54
High-range indicator light ............................................... 4-3
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Horn switch .................................................................... 4-6IIdentification numbers .................................................. 11-1
Indicator lights and warning light .................................... 4-2
Instruments, lights and switches .................................... 5-7KKey identification number ............................................. 11-1LLabel locations ............................................................... 2-1
Light switch .................................................................... 4-6
Low-range indicator light ................................................ 4-3MMain switch .................................................................... 4-1
Maintenance and lubrication chart ................................. 8-5
Maintenance chart, emission control system ................. 8-3
Model label ................................................................... 11-2
Multifunction display ....................................................... 4-4NNeutral indicator light ..................................................... 4-2OOn-Command differential gear lock switch .................... 4-8
On-Command four-wheel-drive switch ........................... 4-7
Override switch .............................................................. 4-6
Owner’s manual and tool kit ........................................... 8-1PPanels, removing and installing ..................................... 8-9
Park indicator light .......................................................... 4-3
Parking ........................................................................... 6-6
Parking on a slope ......................................................... 6-6
Part locations ................................................................. 3-1
Pre-operation check list .................................................. 5-1
RRear knuckle pivots, lubricating ................................... 8-50
Recoil starter ................................................................ 4-14
Reverse indicator light .................................................... 4-2
Riding your ATV ............................................................. 7-1SSafety information .......................................................... 1-1
Seat .............................................................................. 4-18
Shock absorber assemblies, adjusting the front and
rear ............................................................................ 4-21
Spark arrester, cleaning ............................................... 8-34
Spark plug, checking .................................................... 8-14
Specifications ............................................................... 10-1
Speed limiter ................................................................ 4-12
Stabilizer bushes, checking .......................................... 8-49
Starter (choke) ............................................................. 4-17
Start switch ..................................................................... 4-6
Steering shaft, lubricating ............................................. 8-50
Storage ........................................................................... 9-2
Storage compartments ................................................. 4-19TTail/brake light bulb, replacing ..................................... 8-56
Throttle cable free play, adjusting ................................ 8-38
Throttle lever ......................................................... 4-11, 5-4
Tire pressure, measuring ............................................... 5-6
Tires ............................................................................... 5-5
Tire wear limit ................................................................. 5-7
Troubleshooting ........................................................... 8-60
Troubleshooting charts ................................................. 8-61VValve clearance ............................................................ 8-38
V-belt case drain plug .................................................. 8-36
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