brake pads YAMAHA GRIZZLY 700 2009 Owners Manual

Operating the drive select lever and
driving in reverse ...................................... 6-2
Engine break-in .......................................... 6-4
Parking ....................................................... 6-5
Parking on a slope ..................................... 6-5
Accessories and loading ............................ 6-5
RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV............... 7-2
RIDE WITH CARE AND GOOD
JUDGEMENT ............................................ 7-2
BE CAREFUL WHERE YOU RIDE ............. 7-9
TURNING YOUR ATV .............................. 7-13
CLIMBING UPHILL ................................... 7-14
RIDING DOWNHILL.................................. 7-17
CROSSING A SLOPE............................... 7-18
CROSSING THROUGH SHALLOW
WATER ................................................... 7-19
RIDING OVER ROUGH TERRAIN ........... 7-22
SLIDING AND SKIDDING ......................... 7-22
WHAT TO DO IF... .................................... 7-23
WHAT TO DO... ........................................ 7-23
PERIODIC MAINTENANCE AND MINOR
REPAIR .......................................................... 8-1
Owner’s manual and tool kit ....................... 8-1Periodic maintenance chart for
the emission control system .....................8-3
General maintenance and lubrication
chart ..........................................................8-4
Removing and installing panels ..................8-8
Removing the radiator grills ......................8-19
Checking the spark plug ...........................8-20
Engine oil and oil filter cartridge ................8-22
Final gear oil .............................................8-26
Differential gear oil ....................................8-29
Coolant .....................................................8-31
Cleaning the air filter element ...................8-37
Cleaning the spark arrester ......................8-41
V-belt case drain plug ...............................8-43
Adjusting the throttle cable free play .........8-43
Valve clearance ........................................8-44
Adjusting the drive select lever safety
system cable ...........................................8-44
Checking the front and rear brake pads ...8-44
Checking the rear brake hose
protectors ................................................8-45
Checking the brake fluid level ...................8-46
Changing the brake fluid ...........................8-47
Checking the front and rear brake lever
free play ..................................................8-48
Adjusting the brake pedal free play ..........8-49
Axle boots .................................................8-51
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5-2
5
Front brakeCheck operation. If soft or spongy, have Yamaha dealer bleed hy-
draulic system.
Check brake pads for wear, and replace if necessary.
Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.
Check hydraulic system for leakage. Correct if necessary.5-4, 8-44, 8-46, 8-48
Rear brakeCheck operation. If soft or spongy, have Yamaha dealer bleed hy-
draulic system.
Check pedal free play, and adjust if necessary.
Check brake pads for wear, and replace if necessary.
Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.
Check hydraulic system for leakage. Correct if necessary.5-4, 8-44, 8-46, 8-48,
8-49
Throttle leverMake sure that operation is smooth. Lubricate cable and lever hous-
ing if necessary.
Check cable free play, and adjust if necessary.5-4, 8-43
Control cablesMake sure that operation is smooth. Lubricate if necessary. 8-52
Wheels and tiresCheck wheel condition, and replace if damaged.
Check tire condition and tread depth. Replace if necessary.
Check air pressure. Correct if necessary.5-5, 5-6, 5-7
Brake pedal Make sure that operation is smooth. Lubricate pedal pivoting point if
necessary.8-53
Brake leversMake sure that operation is smooth. Lubricate lever pivoting points if
necessary.8-52
Axle bootsCheck for cracks or damage, and replace if necessary. 8-51
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened. 5-7
Instruments, lights and
switchesCheck operation, and correct if necessary. 5-7 ITEM ROUTINE PAGEU43P60E0.book Page 2 Tuesday, May 20, 2008 5:33 PM

5-4
5
EBU29080Front and rear brakes Brake levers and brake pedal
Check that there is no free play in the front and
rear brake levers. If there is free play, have a
Yamaha dealer check the brake system.
Check for correct free play in the brake pedal. If
the free play is incorrect, adjust it. (See page
8-49.)
Check the operation of the brake levers and
pedal. They should move smoothly and there
should be a firm feeling when the brakes are ap-
plied. If not, have a Yamaha dealer check the
brake system.
Brake fluid level
Check the brake fluid level. Add fluid if necessary.
(See page 8-46.)
Brake fluid leakage
Check to see if any brake fluid is leaking out of the
pipe joints or brake fluid reservoirs. Apply the
brakes firmly for one minute. If a lever moves slow-ly inward, there may be a leak in the brake system.
If there is any leakage, the brake system should be
checked by a Yamaha dealer.
Brake operation
Test the brakes at slow speed after starting out to
make sure they are working properly. If the brakes
do not provide proper braking performance, check
the brake pads for wear. (See page 8-44.)
WARNING
EWB00580Always check the brakes at the start of every
ride. Do not ride the ATV if you find any prob-
lem with the brakes or you could lose braking
ability, which could lead to an accident. If a
problem cannot be corrected by the adjust-
ment procedures provided in this manual, havea Yamaha dealer check for the cause.EBU19761Throttle lever Check the operation of the throttle lever. It must
open smoothly and spring back to the idle position
when released. Have a Yamaha dealer correct if
necessary. Recommended brake fluid:
DOT 4
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8-4
8
EBU21864General maintenance and lubrication chart 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
1 Air filter elementClean and replace if necessary.Every 20–40 hours (more often in wet or
dusty areas)
2*Front brakeCheck operation and correct if necessary.
Check fluid level and ATV for fluid leakage, and
correct if necessary.√√√√√
Replace brake pads. Whenever worn to the limit
3*Rear brakeCheck operation and correct if necessary.
Check brake pedal free play and adjust if neces-
sary.
Check fluid level and ATV for fluid leakage, and
correct if necessary.√√√√√
Replace brake pads. Whenever worn to the limit
4*Brake hosesCheck for cracks or other damage, and replace if
necessary.√√√√
Replace. Every 4 years
5*Rear brake hose
protectorsCheck for wear, cracks or other damage, and re-
place if necessary.√√√√√
6*WheelsCheck runout and for damage, and replace if nec-
essary.√ √√√
7*TiresCheck tread depth and for damage, and replace if
necessary.
Check air pressure and balance, and correct if
necessary.√ √√√
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8-44
8
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).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.EBU27470Checking the front and rear brake pads The front and rear brake pads must be checked for
wear at the intervals specified in the periodic main-
tenance and lubrication chart. Each brake pad is
provided with a wear indicator groove, which al-
1. Rubber cover
2. Throttle cable free play adjusting bolt
3. Locknut
4. Throttle cable free play
2WD
4WD
3
2
1
4 (b)
(a)
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8-45
8lows you to check the brake pad wear without hav-
ing to disassemble the brake. If a brake pad has
worn to the point that the wear indicator groove has
almost disappeared, have a Yamaha dealer re-
place the brake pads as a set.
TIPThe wheels need to be removed to check thebrake pads. (See page 8-63.)
Front brakeRear brake
EBU27842Checking the rear brake hose protec-
tors The rear brake hoses protectors must be checked
for wear at the intervals specified in the periodic
maintenance and lubrication chart. Each brake
hose protector is provided with a wear indicator. If
a protector wears to the point that its indicator be-
comes visible, have a Yamaha dealer replace the
protector.
1. Wear indicator groove
1. Wear indicator groove
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8-46
8
TIPThe wheels need to be removed to check thebrake hose protectors. (See page 8-63.)EBU24251Checking 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 worn
brake 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.
Front brake1. Rear brake hose protector
2. Wear indicator
3. Protector is normal.
4. Protector is worn.
1. Minimum level mark
2WD
4WD
1
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8-47
8Rear brake
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.
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.EBU24291Changing 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 master cylinders and cali-
pers as well as the brake hoses replaced at the in-
tervals listed below or whenever they are damaged
or leaking.
Oil seals: Replace every two years.
Brake hoses: Replace every four years.
1. Minimum level markRecommended brake fluid:
DOT 4
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8-49
8Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.EBU29071Adjusting the brake pedal free play The brake pedal free play must be 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.
Before adjusting the brake pedal free play,check the rear brake pads for wear.
The brake pedal free play should measure 0.0–5.0
mm (0.00–0.20 in) as shown. If the free play is in-
correct, adjust it as follows.1. Remove panel H. (See page 8-8.)
2. Loosen the locknut.
3. Turn the brake pedal free play adjusting nut in
direction (a) to increase the free play, and in
direction (b) to decrease it.
1. Brake pedal free play
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INDEX
AAccessories and loading ................................................ 6-5
Accessories, auxiliary jack ........................................... 4-22
Air filter element, cleaning ............................................ 8-37
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, adjusting ................................... 8-49
Brakes, front and rear .................................................... 5-4CCables, checking and lubricating ................................. 8-52
Carrier, front ................................................................. 4-21
Carrier, rear .................................................................. 4-21
Chassis fasteners ........................................................... 5-7
Cleaning ......................................................................... 9-1
Coolant .................................................................. 5-3, 8-31
Coolant temperature warning light ................................. 4-2DDifferential gear lock indicator light ................................ 4-4
Differential gear oil ................................................ 5-3, 8-29Drive 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 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 ........................................................... 8-57HHandlebar switches ........................................................ 4-7
Headlight beam, adjusting ............................................ 8-62
Headlight bulb, replacing .............................................. 8-59
High-range indicator light ............................................... 4-4
Horn switch .................................................................... 4-8IIdentification numbers .................................................. 11-1
Indicator lights and warning lights .................................. 4-2
Instruments, lights and switches .................................... 5-7
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