differential YAMAHA GRIZZLY 450 2013 User Guide

4-12
4
●Riding before the differential gear lock is proper-
ly engaged (e.g., when the indicator and indica-
tor light are flashing) will cause the vehicle
speed to be limited until engagement is com-
plete.●When the ATV is in four-wheel-drive differential
gear lock, the maximum traveling speed is limit-
ed to 35 km/h (22 mi/h). However, if conditions
require full engine power to be available, push
and hold the override switch to disable the differ-
ential gear lock speed limiter. (See page 4-7 for
a detailed explanation of this switch.)EBU18282Throttle lever Once the engine is running, pushing the throttle le-
ver will increase the engine speed.
Regulate the speed of the ATV by varying the
throttle position. Because the throttle is spring-
loaded, the ATV will decelerate, and the engine will
return to an idle any time the throttle lever is re-
leased.Before starting the engine, check the throttle to be
sure it is operating smoothly. Make sure it returns
to the idle position as soon as the lever is released.
EBU18323Speed limiter Your ATV is equipped with an adjustable speed
limiter. The speed limiter keeps the throttle from
fully opening, even when the throttle lever is
pushed to the maximum.
1. Loosen the locknut.
2. To increase the maximum engine power avail- able and the maximum speed of the ATV, turn
the adjusting screw in direction (a). To de-1. Throttle lever
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5-1
5
EBU19201
PRE-OPERATION CHECKS
EBU19224Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always
follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWB00481Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equip-
ment damage. Do not operate the vehicle if you find any problem. If a problem cannot be corrected
by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEMROUTINE PAGE
Fuel Check 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 oil Check 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 oil Check ATV for oil leakage. Correct if necessary. 5-3, 8-21
Differential gear oil Check ATV for oil leakage. Correct if necessary. 5-3, 8-24
Coolant Check coolant level in reservoir, and add recommended coolant to
specified level if necessary.
Check cooling system for leakage. Correct if necessary. 5-3, 8-26
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5-3
5
EBU19541Fuel Make sure that there is sufficient fuel in the tank.
(See page 4-15.)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 8-21.)EBU19600Differential gear oil Make sure that the differential gear oil is at the
specified level. Add oil as necessary. (See page
8-24.)EBU19631Coolant Make sure that the coolant is at the specified level.
Add coolant as necessary. (See page 8-26.)
TIPThe coolant level must be checked on a cold en-
gine since the level varies with engine tempera-
ture.EBU28532Front and rear brakes Brake levers and brake pedal●Check that there is no free play in the front brake
lever. If there is free play, have a Yamaha dealer
check the brake system.●Check for correct free play in the rear brake lever
and brake pedal. If the free play is incorrect, ad-
just it. (See page 8-41.)●Check operation of the levers and pedal. They
should move smoothly and there should be a
firm feeling when the brake is applied. If not,
have a Yamaha dealer check them.
Brake fluid level (front brake)
Check the brake fluid level. Add fluid if necessary.
(See page 8-40.)
Specified brake fluid:DOT 4
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8-7
8
13*Rear knuckle pivots Lubricate with lithium-soap-based grease. √√√
14 *Steering shaft Lubricate with lithium-soap-based grease. √√√
15 *Steering system Check operation and repair or replace if damaged.
Check toe-in and adjust if necessary. √√√√√
16 *Engine mount Check for cracks or other damage, and replace if
necessary. √√√
17 *Axle boots Check for cracks or other damage, and replace if
necessary. √√√√√
18 Engine oil Change.
Check ATV for oil leakage, and correct if neces-
sary. √ √√√
19 Engine oil filter car-
tridge Replace.
√√√
20 *Engine oil strainer Clean. √√√
21 Differential gear oil Change.
Check ATV for oil leakage, and correct if neces-
sary. √√
22 Final gear oil Change.
Check ATV for oil leakage, and correct if neces-
sary. √ √√√
NO. ITEM
CHECK OR MAINTENANCE
JOB INITIAL EVERY
Whichev- er comes first month136612
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320U1CT62E0.book Page 7 Friday, May 11, 2012 9:03 AM

8-24
87. Check the oil filler bolt gasket for damage, and
replace it if necessary.
8. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.
9. Check the final gear case for oil leakage. If oil is leaking, check for the cause.
10. Install the engine guard and the final gear case guard by installing the bolts, and then
tightening them to the specified torques.
EBU23426Differential 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.
2. Remove the differential gear oil filler bolt and its gasket, and then check the oil level in the
differential gear case. The oil level should be
at the brim of the filler hole.
Tightening torque:
Final gear oil filler bolt:22 Nm (2.2 m·kgf, 16 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)
1. Differential gear oil filler bolt
2. Gasket
3. Differential gear oil
4. Correct oil level
1
2
3
4
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8-25
8
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. Check the gasket for damage, and replace it if necessary.
5. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.
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, the differential gear oil drain bolt and their gasket
to drain the oil from the differential gear case. 4. Install the drain bolt and its new gasket, and
then tighten the bolt to the specified torque.
5. Refill with the recommended differential gear oil to the brim of the filler hole as shown.
NOTICE: Be sure no foreign material en-
ters the differential gear case.
[ECB00411]
Tightening torque: Differential gear oil filler bolt:23 Nm (2.3 m·kgf, 17 ft·lbf)
1. Differential gear oil drain bolt
2. GasketTightening torque: Differential gear oil drain bolt:9.8 Nm (0.98 m·kgf, 7.1 ft·lbf)
12
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8-26
86. Check the oil filler bolt gasket for damage, andreplace it if necessary.
7. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque. 8. 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.EBU27126To check the coolant level1. 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 and
maximum level marks.
1. Differential gear oil filler bolt
2. Gasket
3. Differential gear oil
4. Correct oil levelRecommended differential gear oil:See page 10-1.
Tightening torque: Differential gear oil filler bolt:23 Nm (2.3 m·kgf, 17 ft·lbf)
1
2
3
4
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10-2
10
Lubrication system:Wet sumpEngine oil:Recommended brand:
YAMALUBE
Type: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 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
Quantity:
0.38 L (0.40 US qt, 0.33 Imp.qt)Differential gear oil:Type:Yamaha Friction Modified Shaft Drive Gear Oil or SAE 80
API GL-4 Hypoid gear oil
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): 1.32 L (1.40 US qt, 1.16 Imp.qt)Air filter:Air filter element:Wet elementFuel:Recommended fuel:
YFM450FAD Unleaded gasoline only
YFM450FAPD Unleaded gasoline only
YFM45FGD Regular unleaded gasoline only
YFM45FGPAD Regular unleaded gasoline only
YFM45FGPD Regular unleaded gasoline only
YFM45FGPHD Regular unleaded gasoline only
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)
0 10 30 50 70 90 110 130 F
–20 –10 0 10 20 30 40 50 CSAE 5W-30
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-40SAE 20W-50
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10-5
10
Battery:Model:YTX20L-BS
Voltage, capacity:
12 V, 18.0 AhHeadlight:Bulb type:Krypton bulbBulb voltage, wattage × quantity:Headlight:
12 V, 30.0/30.0 W × 2
Tail/brake light: 12 V, 5.0/21.0 W × 1
Meter lighting:
EL (Electroluminescent)
Neutral indicator light: LED
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: LED EPS warning light:
YFM450FAPD 12 V, 1.7 W
YFM45FGPAD 12 V, 1.7 W
YFM45FGPD 12 V, 1.7 W
YFM45FGPHD 12 V, 1.7 W
Fuses:Main fuse:
30.0 A
EPS fuse: YFM450FAPD 40.0 A
YFM45FGPAD 40.0 A
YFM45FGPD 40.0 A
YFM45FGPHD 40.0 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:
YFM450FAD 10.0 A
YFM450FAPD 5.0 A
YFM45FGD 10.0 A
YFM45FGPAD 5.0 A
YFM45FGPD 5.0 A
YFM45FGPHD 5.0 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 ............................................ 8-30
Axle boots .................................................................... 8-47BBattery .......................................................................... 8-52
Brake fluid, changing ................................................... 8-41
Brake fluid level, checking ........................................... 8-40
Brake lever free play, checking the front ...................... 8-41
Brake lever, front .......................................................... 4-13
Brake levers, checking and lubricating ........................ 8-49
Brake light switches ..................................................... 8-48
Brake pads and friction plates, checking ..................... 8-39
Brake pedal and rear brake lever ................................. 4-13
Brake pedal, checking and lubricating ......................... 8-49
Brakes .......................................................................... 8-38
Brakes, front and rear .................................................... 5-3CCables, checking and lubricating ................................. 8-48
Carburetor, adjusting ................................................... 8-36
Carrier, front ................................................................. 4-22
Carrier, rear .................................................................. 4-22
Chassis fasteners .......................................................... 5-7
Cleaning ......................................................................... 9-1
Coolant .................................................................. 5-3, 8-26
Coolant temperature warning light ................................. 4-3
DDifferential gear oil ................................................ 5-3, 8-24
Drive select lever ......................................................... 4-14
Drive select lever and driving in reverse ........................ 6-3
Drive select lever safety system cable, adjusting ........ 8-38
Drive shaft universal joint, lubric ating .......................... 8-50EEngine 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 ......................................................... 4-7
EPS warning light (for EPS model) ................................ 4-3FFinal gear oil ......................................................... 5-3, 8-21
Four-wheel-drive/differential gear lock indicator ............ 4-4
Fuel ....................................................................... 4-15, 5-3
Fuel cock ..................................................................... 4-16
Fuel gauge ..................................................................... 4-6
Fuel tank cap ............................................................... 4-14
Fuses, replacing .......................................................... 8-55HHandlebar switches ....................................................... 4-6
Headlight beam, adjusting ........................................... 8-59
Headlight bulb, replacing ............................................. 8-58
High-range indicator light ............................................... 4-2
U1CT62E0.book Page 1 Friday, May 11, 2012 9:03 AM