warning YAMAHA GRIZZLY 700 2008 Workshop Manual

8-50
8 4. Tighten the locknut.
5. Install the panel.
If the correct free play cannot be obtained, have a
Yamaha dealer adjust it.
NOTE:When adjusting the rear brake pedal free play:
Be sure not to step on the brake pedal.
Make sure the rear brake lever and brake pedaldo not move.Checking the brake pedal position
The top of the brake pedal should be positioned
56.7 mm (2.23 in) above the top of the footrest. If
the brake pedal position is incorrect, have a
Yamaha dealer adjust it.
WARNING
EWB02070Operating 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.
1. Locknut
2. Brake pedal free play adjusting nut
1. Distance between brake pedal and footrest
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8-52
8
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.EBU24912Checking 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.Front brake lever
Rear brake lever
Recommended lubricant:
Silicone greaseU3B462E0.book Page 52 Tuesday, March 20, 2007 11:46 AM

8-54
8
EBU25100Lubricating the steering shaft The steering shaft must be lubricated at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
EBU25222Battery This model is equipped with a sealed-type (MF)
battery, which does not require any maintenance.
There is no need to check the electrolyte or to add
distilled water. Check and, if necessary, tighten the
battery lead connections.CAUTION:ECB00620Never attempt to remove the battery cell seals,as this would permanently damage the battery.
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.
1. Grease nippleRecommended lubricant:
Lithium-soap-based grease
U3B462E0.book Page 54 Tuesday, March 20, 2007 11:46 AM

8-58
8
WARNING
EWB02171Always use a fuse of the specified rating, and
never use a substitute object in place of the
proper fuse. An improper fuse or a substitute
object can cause damage to the electrical sys-tem, which could lead to a fire.
3. Turn the key to “ON” and turn on the electrical
circuits to check if the devices operate.
4. If the fuse immediately blows again, have a
Yamaha dealer check the electrical system.EBU27440Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
1. Remove the cover at the rear of the headlight
by pulling it off.2. Remove the headlight bulb cover.
3. Disconnect the headlight coupler.
1. Cover at the rear of the headlight
1. Headlight bulb cover
U3B462E0.book Page 58 Tuesday, March 20, 2007 11:46 AM

8-59
84. Unhook the headlight bulb holder, and then
remove the defective bulb.
WARNING
EWB02220A headlight bulb is hot when it is on and imme-
diately after it is turned off. Wait for the bulb to
cool before touching or removing it. You can
be burned or a fire could start if the bulb touch-es something flammable.
5. Place a new headlight bulb into position, and
then secure it with the bulb holder.
1. Headlight coupler
1. Headlight bulb holder
2. Headlight bulb
U3B462E0.book Page 59 Tuesday, March 20, 2007 11:46 AM

8-63
82. Lower the ATV to the ground.
3. Tighten the wheel nuts to the specified
torques.
EBU25740Troubleshooting Although Yamaha ATVs receive a thorough in-
spection before shipment from the factory, trouble
may occur during operation. Any problem in the fu-
el, compression, or ignition systems, for example,
can cause poor starting and loss of power.
The following troubleshooting charts represent
quick and easy procedures for checking these vital
systems yourself. However, should your ATV re-
quire any repair, take it to a Yamaha dealer, whose
skilled technicians have the necessary tools, expe-
rience, and know-how to service the ATV properly.
Use only genuine Yamaha replacement parts. Im-
itation parts may look like Yamaha parts, but they
are often inferior, have a shorter service life and
can lead to expensive repair bills.
WARNING
EWB02280Do not smoke when checking the fuel system.
Fuel can ignite or explode, causing severe inju-
ry or property damage. Make sure there are no
open flames or sparks in the area, including pi-lot lights from water heaters or furnaces.
1. Tapered nutTightening torques:
Front wheel nut:
55 Nm (5.5 m·kgf, 40 ft·lbf)
Rear wheel nut:
55 Nm (5.5 m·kgf, 40 ft·lbf)
U3B462E0.book Page 63 Tuesday, March 20, 2007 11:46 AM

8-65
8Engine overheating
WARNING
EWB02290Wait 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 pressure to escape before completely removing the cap.NOTE:If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec-ommended coolant as soon as possible.Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer check
and repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
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9-2
9
WARNING
EWB02310Wet brakes may have reduced stopping ability,
increasing the chance of an accident. Test the
brakes after washing. Apply the brakes several
times at slow speeds to let friction dry out thelinings.EBU27260Storage Short-term
Always store your ATV in a cool, dry place and, if
necessary, protect it against dust with a porous
cover.CAUTION:ECB00720
Storing the ATV in a poorly ventilated room
or covering it with a tarp while it is still wet,
will allow water and humidity to seep in and
cause rust.
To prevent corrosion, avoid damp cellars,
stables (because of the presence of ammo-
nia) and areas where strong chemicals arestored.Long-term
Before storing your ATV for several months:
1. Follow all the instructions in the “Cleaning”
section of this chapter.
2. Fill up the fuel tank and add fuel stabilizer (if
available) to prevent the fuel from deteriorat-
ing.
3. Perform the following steps to protect the cyl-
inder, piston rings, etc. from corrosion.
a. Remove the spark plug cap and spark
plug.
b. Pour a teaspoonful of engine oil into the
spark plug bore.
c. Install the spark plug cap onto the spark
plug, and then place the spark plug on the
cylinder head so that the electrodes are
grounded. (This will limit sparking during
the next step.)
d. Turn the engine over several times with the
starter. (This will coat the cylinder wall with
oil.) Specified amount:
7.5 ml of stabilizer to each liter of fuel (or 1 oz
of stabilizer to each gallon of fuel)
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10-5
10
Tail/brake light:
12 V, 5.0/21.0 W
Meter lighting:
EL
Neutral indicator light:
LED
Reverse indicator light:
LED
Coolant temperature warning light:
LED
Engine trouble warning light:
LED
EPS 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:
40.0 A
Fuel injection system fuse:
15.0 A
EPS fuse:
40.0 AHeadlight fuse:
15.0 A
Signaling system fuse:
5.0 A
Ignition fuse:
10.0 A
Auxiliary DC jack fuse:
15.0 A
Four-wheel-drive motor fuse:
10.0 A
Radiator fan fuse:
15.0 A
U3B462E0.book Page 5 Tuesday, March 20, 2007 11:46 AM

INDEX
AAccessories and loading ................................................ 6-6
Accessories, auxiliary jack ........................................... 4-22
Air filter element, cleaning ............................................ 8-36
Axle boots .................................................................... 8-51BBattery .......................................................................... 8-54
Brake fluid, changing .................................................... 8-47
Brake fluid level, checking ............................................ 8-46
Brake hose protectors, checking the rear .................... 8-45
Brake lever, front .......................................................... 4-14
Brake levers, checking and lubricating ......................... 8-52
Brake pads, checking the front and rear ...................... 8-44
Brake pedal and rear brake lever ................................. 4-14
Brake pedal, checking and lubricating ......................... 8-53
Brake pedal free play and brake pedal position,
adjusting and checking .............................................. 8-49
Brakes, front and rear .................................................... 5-4CCables, checking and lubricating ................................. 8-51
Carrier, front ................................................................. 4-21
Carrier, rear .................................................................. 4-21
Chassis fasteners ........................................................... 5-7
Cleaning ......................................................................... 9-1
Coolant .................................................................. 5-3, 8-30
Coolant temperature warning light ................................. 4-2DDifferential gear lock indicator light ................................ 4-4Differential gear oil ................................................ 5-3, 8-28
Drive select lever .......................................................... 4-15
Drive select lever and driving in reverse ........................ 6-2
Drive select lever safety system cable, adjusting ......... 8-44
EEngine break-in .............................................................. 6-4
Engine idling speed ...................................................... 8-42
Engine oil ....................................................................... 5-3
Engine oil and oil filter cartridge ................................... 8-22
Engine stop switch ......................................................... 4-7
Engine trouble warning light ........................................... 4-3
EPS warning light ........................................................... 4-3FFinal gear oil .......................................................... 5-3, 8-26
Four-wheel-drive/differential gear lock indicator ............ 4-3
Front and rear brake lever free play, checking ............. 8-48
Fuel ....................................................................... 4-16, 5-3
Fuel tank cap ................................................................ 4-15
Fuses, replacing ........................................................... 8-56HHandlebar switches ........................................................ 4-7
Headlight beam, adjusting ............................................ 8-60
Headlight bulb, replacing .............................................. 8-58
High-range indicator light ............................................... 4-4
Horn switch .................................................................... 4-8IIdentification numbers .................................................. 11-1
Indicator lights and warning lights .................................. 4-2
U3B462E0.book Page 1 Tuesday, March 20, 2007 11:46 AM