YAMAHA GRIZZLY 450 2010 Owners Manual

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8 8. Check the sponge material and replace it if
damaged.
9. Apply Yamaha foam air filter oil or other qual-
ity foam air filter oil to the sponge material.
TIPThe sponge material should be wet but not drip-
ping.10. Pull the sponge material over the air filter ele-
ment frame, and then install the lock plate.
11. Insert the air filter element into the air filter
case, and then install the air filter case cover
by hooking the holders onto the air filter case.
NOTICE: Make sure that the air filter ele-
ment is properly seated in the air filtercase. Never operate the engine with the air
filter element removed. This will allow un-
filtered air to enter the engine, causing rap-
id engine wear and possible engine
damage. Additionally, operation without
the air filter element will affect carburetor
jetting with subsequent poor performance
and possible engine overheating.
[ECB00461]
12. Install the seat.TIPThe air filter element should be cleaned every 20–
40 hours. It should be cleaned and lubricated more
often if the ATV is operated in extremely dusty ar-
eas. Each time the air filter element maintenance
is performed, check the air inlet of the air filter case
for obstructions. Check the air filter case rubber
joint to the carburetor fittings and the rubber joint
manifold fittings for an air-tight seal. Tighten all fit-
tings securely to avoid the possibility of unfiltered
air entering the engine.EBU27081Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be-
fore cleaning the spark arrester.
1. Remove the bolts.
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82. Remove the tailpipe by pulling it out of the
muffler.
3. Tap the tailpipe lightly, and then use a wire
brush to remove any carbon deposits from the
spark arrester portion of the tailpipe and inside
of the tailpipe housing.4. Insert the tailpipe into the muffler and align the
bolt holes.
5. Install the bolts and tighten them to the speci-
fied torque.
1. Bolt
2. Tailpipe
1. Tailpipe
2. Spark arresterTightening torque:
Tailpipe bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
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8
WARNING
EWB02340Do not start the engine when cleaning the
spark arrester, otherwise it could cause injury
to the eyes, burns, carbon monoxide poison-
ing, possibly leading to death, and start a fire.
Always let the exhaust system cool prior to
touching exhaust components.EBU23920V-belt cooling duct check hose If dust or water collects in the V-belt cooling duct
check hose, remove the hose and clean it.
EBU23930V-belt case drain plug After riding in water deep enough to allow it to en-
ter the V-belt case, remove this plug to drain the
water from the case.TIPIf water drains from the V-belt case after removing
the plug, have a Yamaha dealer check the ATV as
the water may affect other engine parts.
1. V-belt cooling duct check hose (left front side of ATV)
1. V-belt case drain plug
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8
EBU23940Adjusting the carburetor The carburetor should be checked and, if neces-
sary, adjusted at the intervals specified in the peri-
odic maintenance and lubrication chart. The
carburetor is an important part of the engine and
requires very sophisticated adjustment. Therefore,
most carburetor adjustments should be left to a
Yamaha dealer, who has the necessary profes-
sional knowledge and experience. The adjustment
described in the following section, however, may
be performed by the owner as part of routine main-
tenance.NOTICEECB00480The carburetor has been set and extensively
tested at the Yamaha factory. Changing these
settings without sufficient technical knowl-
edge may result in poor performance of or
damage to the engine.EBU24010Adjusting the engine idling speed The engine idling speed must be checked and, if
necessary, adjusted as follows at the intervals
specified in the periodic maintenance and lubrica-
tion chart.
TIPA diagnostic tachometer is needed to make this
adjustment.1. Start the engine and warm it up.TIPThe engine is warm when it quickly responds to the
throttle.2. Remove panel D. (See page 8-9.)
3. Attach the tachometer to the spark plug lead.
4. Check the engine idling speed and, if neces-
sary, adjust it to specification by turning the
throttle stop screw at the carburetor. To in-
crease the engine idling speed, turn the throt-
tle stop screw in direction (a), and to decrease
it, turn the screw in direction (b).
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8
TIPIf the specified idling speed cannot be obtained as
described above, have a Yamaha dealer make the
adjustment.5. Install the panel.
EBU24045Adjusting the throttle cable free play The throttle cable free play should be checked
and, if necessary, adjusted at the intervals speci-
fied in the periodic maintenance and lubrication
chart.
The throttle cable free play should measure 3.0–
5.0 mm (0.12–0.20 in) at the throttle lever. Period-
ically check the throttle cable free play and, if nec-
essary, adjust it as follows.TIPThe engine idling speed must be checked, and ad-
justed if necessary, before adjusting the throttle ca-
ble free play.1. Slide the rubber cover back.
2. Loosen the locknut.
3. To increase the throttle cable free play, turn
the throttle cable free play adjusting bolt in di-
rection (a). To decrease the throttle cable free
play, turn the adjusting bolt in direction (b).
1. Throttle stop screwEngine idling speed:
1450–1550 r/min
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8
4. Tighten the locknut.
5. Slide the rubber cover to its original position.
EBU24060Valve clearance The valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
EBU24071Adjusting the drive select lever safety
system cable The drive select lever safety system cable stretch-
es with use, which can result in improper function.
Therefore, the safety system cable should be
checked and adjusted by a Yamaha dealer at the
intervals specified in the periodic maintenance and
lubrication chart.EBU29601Brakes Replacement of brake components requires pro-
fessional knowledge. Brake service should be per-
formed by a Yamaha dealer.
WARNING
EWB02571Operating with improperly serviced or adjust-
ed brakes could lead to a loss in braking ability
and an accident.
1. Rubber cover
2. Throttle cable free play adjusting bolt
3. Locknut
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8
EBU28413Checking the front brake pads and rear
brake friction plates The front brake pads and the rear brake friction
plates must be checked for wear at the intervals
specified in the periodic maintenance and lubrica-
tion chart.TIPThis ATV is equipped with a wet, multiple-disc type
rear brake, which is located inside of the final gear
case.EBU24171Front brake pads
Check each front brake pad for damage and mea-
sure the lining thickness. If a brake pad is dam-
aged or if the lining thickness is less than 1.0 mm
(0.04 in), have a Yamaha dealer replace the brake
pads as a set.
TIPThe wheels need to be removed to check the
brake pads. (See page 8-59.)EBU28421Rear brake friction plates
The rear brake is provided with a wear indicator,
which allows you to check the brake friction plate
wear without having to disassemble the brake. To
check the brake friction plate wear, check the posi-
tion of the wear indicator while applying the brake.
If a brake friction plate has worn to the point that1. Lining thickness
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8the wear indicator reaches the wear limit mark,
have a Yamaha dealer replace the brake friction
plates as a set.
EBU29840Checking the brake fluid level Insufficient brake fluid may allow air to enter the
brake system, possibly causing it to become inef-
fective.
Before riding, check that the brake fluid is above
the minimum level mark and replenish if neces-
sary. A low brake fluid level may indicate wornbrake pads and/or brake system leakage. If the
brake fluid level is low, be sure to check the brake
pads for wear and the brake system for leakage.
Observe these precautions:

When checking the fluid level, make sure that
the top of the brake fluid reservoir is level.
Use only the recommended quality brake fluid,
otherwise the rubber seals may deteriorate,
causing leakage and poor braking performance.
1. Wear indicator
2. Wear limit mark
1. Minimum level markRecommended brake fluid:
DOT 4
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8

Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor braking performance.
Be careful that water does not enter the brake
fluid reservoir when refilling. Water will signifi-
cantly lower the boiling point of the fluid and may
result in vapor lock.
Brake fluid may deteriorate painted surfaces or
plastic parts. Always clean up spilled fluid imme-
diately.
As the brake pads wear, it is normal for the brake
fluid level to gradually go down. However, if the
brake fluid level goes down suddenly, have a
Yamaha dealer check the cause.EBU24281Changing the brake fluid Have a Yamaha dealer change the brake fluid at
the intervals specified in the TIP after the periodic
maintenance and lubrication chart. In addition,
have the oil seals of the brake master cylinder and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are dam-
aged or leaking.
Oil seals: Replace every two years.
Brake hoses: Replace every four years.
EBU24394Checking the front brake lever free play The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever should have no
free play as shown. If there is free play, have a
Yamaha dealer check the brake system.1. No brake lever free play
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8
EBU28637Adjusting the brake pedal and rear
brake lever free play and checking the
brake pedal position The brake pedal and brake lever free play and the
brake pedal position must be checked and, if nec-
essary, adjusted at the intervals specified in the
periodic maintenance and lubrication chart.TIP
Always perform this maintenance completely in
the following order whenever adjusting the rear
brake.
When adjusting the rear brake, be sure to adjust
both the brake pedal and the brake lever.
Before adjusting the brake lever and brake pedal
free play, check the rear brake friction plates for
wear.Adjusting the brake pedal and brake lever free
play
The brake pedal free play should measure 17.0–
20.0 mm (0.67–0.79 in). The brake lever free play
should measure 8.0–10.5 mm (0.31–0.41 in). If ei-
ther free play is incorrect, adjust it as follows.
1. Loosen the locknut at the brake lever and fully
turn in the brake lever free play adjusting bolt.
1. Brake pedal free play
1. Brake lever free play
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