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Yamaha Manuals
Offroad Vehicle
Grizzly 450 2007
Service manual
Yamaha Grizzly 450 2007 Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
General Information
Features
Outline of the Eps (Electric Power Steering)
System
Diagram
Special Tools
Specifications
General Specifications
Maintenance Specifications
Engine
Tightening Torques
Chassis
Electrical
Cable Routing (Yfm45Fga/Yfm45Fgha)
Cable Routing (Yfm45Fgpa/Yfm45Fgpha)
Periodic Checks and Adjustments
Introduction
Periodic Maintenance Chart for the Emission Control System
General Maintenance and Lubrication Chart
Seat, Carriers, Fenders and Fuel Tank
Rear Carrier and Rear Fender
Chassis
Adjusting the Rear Brake
Checking the Rear Brake Friction Plates
Checking the Final Gear Oil Level
Changing the Final Gear Oil
Checking the Steering System (Yfm45Fgpa/Yfm45Fgpha)
Drive Train
Troubleshooting
Checking Noises
Rear Constant Velocity Joints and Final Gear Case Assembly
Disassembling the Rear Constant Velocity Joints
Assembling the Rear Constant Velocity Joints
Removing the Final Drive Pinion Gear and Bearing
Installing the Final Drive Pinion Gear and Bearing
Positioning the Final Dr Ive Pinion Gear
Measuring the Final Gear Backlash
Adjusting the Final Gear Backlash
Adjusting the Ring Gear Thrust Clearance
Adjusting the Ring Gear Stopper
Assembling the Final Gear Case
Installing the Final Gear Case
Chassis
Front and Rear Brakes
Brake Pedal
Final Gear Case (Rear Brake)
Disassembling the Final Gear Case (Rear Brake)
Checking the Friction Plates
Checking Th Erear Brake Plates
Checking the Rear Brake Springs
Checking Th Esplined Collar
Assembling the Final Gear Case (Rear Brake)
Steering System
Steering Stem (Yfm45Fga/Yfm45Fgha)
Steering Stem (Yfm45Fgpa/Yfm45Fgpha)
Installing the Steering Stem (Yfm45Fga/Yfm45Fgha)
Installing the Steering Stem
(Yfm45Fgpa/Yfm45Fgpha)
Eps Control Unit's Self-Diagnostic Function
Eps Warning Light During Normal Operation
Diagnostic Mode
Self-Diagnostic Function Table (Eps System)
Troubleshooting Details
Checking the Eps Motor
Checking the Eps Torque Sensor
Specifications
General Specifications
Maintenance Specifications
Engine
Chassis
Electrical
Cable Routing
Periodic Checks and Adjustments
Introduction
Periodic Maintenance/Lubrication
Seat, Carriers, Fenders and Fuel Tank
Chassis
Adjusting the Rear Brake
Checking the Final Gear Oil Level
Checking the Constant Velocity Joint Dust Boots
Adjusting the Rear Shock Absorbers
Engine
Middle Gear
Middle Driven Shaft
Drive Train
Troubleshooting
Front Constant Velocity Joints and Differential Gear
Measuring and Adjusting the Differential Gear Lash
Rear Constant Velocity Joints, Final Drive Gear and Drive Shaft
Assembling the Rear Constant Velocity Joints
Disassembling the Final Drive Gear
Checking the Drive Shaft/Universal Joint Yoke
Front and Rear Wheels
Rear Wheels
Installing the Rear Brake Disc
Installing the Rear Wheel Hubs
Front and Rear Brakes
Rear Brake Pads
Rear Brake Caliper
Installing the Rear Brake Caliper
Front Arms and Front Shock Absorbers
Rear Knuckles and Stabilizer
Checking the Rear Knuckles
Checking the Stabilizer
Rear Arms and Rear Shock Absorbers
Checking the Rear Arms
Installing the Rear Arms and Rear Shock Absorbers
General Information
Features
Override Switch (Deactivating the Speed Limiter When the Differential Is Locked)
Specifications
General Specifications
Maintenance Specifications
Engine
Chassis
Front and Rear Brakes
Rear Brake Master Cylinder
Steering System
Steering Stem
Tie Rod and Steering Knuckle
Electrical
Checkin Gth Eswitch
Checking the Switch Continuity
Signal System
Circuit Diagram
Checking the Final Drive Gear
Positioning the Final Drive Pinion Gear
Assembling the Final Drive Gear
General Information
Special Tools
Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Tightening Torques
Chassis Tightening Torques
Cable Routing
Periodic Checks and Adjustments
Introduction
Periodic Maintenance Chart for the Emission Control System
General Maintenance and Lubrication Chart
Chassis
Adjusting the Brake Pedal Height
Adjusting the Rear Brake
Checking the Rear Brake Friction Plates
Adjusting the Select Lever Control Cable and Shiftrod
Adjusting the Brake Pedal Light Switch
Checking the Final Gear Oil Level
Changing the Final Gear Oil
Checking the Differential Gear Oil Level
Changing the Differential Gear Oil
Drive Train
Front Constant Velocity Joints and Differential Gear
Checking the Differential Gear Motor
Assembling the Front Constant Velocity Joints
Assembling the Differential Gear
Measuring the Differential Gear Lash
Adjusting the Differential Gear Lash
Rear Constant Velocity Joints, Final Drive Gear and Drive Shaft
Checking the Final Drive Gear
Disassembling the Final Drive Pinion Gear and Bearing
Installing the Final Drive Pinion Gear and Bearing
Positioning the Final Drive Pinion Gear and Ring Gear
Measuring the Ring Gear Thrust Clearance
Measurement the Final Gear Lash
Adjusting the Final Gear Lash
Assembling the Final Drive Gear
Installing the Final Gear Case
Chassis
Front and Rear Wheels
Front Wheels
Installing the Wheel Hubs
Front and Rear Brakes
Brake Pedal
Checking the Friction Plates
Checking the Rear Brake Plates
Checking the Rear Brake Springs
Checking the Pressure Plate
Checking the Ring Gear
Steering System
Tie Rod and Steering Knuckle
Rear Knuckles and Stabilizer
Electrical
Electrical Components
Checking the Switches
Checking the Switch Continuity
Lighting System
Circuit Diagram
Troubleshooting
Checking the Lighting System
Specifications
General Specifications
Chassis Specifications
Electrical Specifications
Tightening Torques
Engine Tightening Torques
Cable Routing
Periodic Checks and Adjustments
Seat, Carriers, Fenders and Fuel Tank
Engine
Middle Gear
Middle Driven Shaft
Chapter 1. General Information
Machine Identification
Vehicle Identification Number
Model Label
Features
Liquid Cooling Engine
Park Position
Front Differential
Important Information
Preparation for Removal Procedures
Bearings and Oil Seals
Checking of Connections
Special Tools
Chapter 2. Specifications
General Specifications
Maintenance Specifications
Engine
Chassis
Electrical
How to Use the Conversion Table
General Torque Specifications
Lubrication Points and Lubricant Types Engine
Coolant Flow Diagrams
Oil Flow Diagrams
Cable Routing
Chapter 3. Periodic Checks and Adjustments
Periodic Maintenance/Lubrication
Seat and Side Panels
Footrest Boards
Adjusting the Valve Clearance
Adjusting the Idling Speed
Adjusting the Starter Cable
Free Play
Spark Plug
Engine Oil Level
Engine Oil
Coolant Level
T He Coolant
Adjusting the Rear Brake
Checking the Brake Fluid Level
Checking the Front Brake Pad
Checking the Rear Brake Pad
Checking the Brake Hose
Bleeding the Hydraulic Brake System
Adjusting the Select Lever Control Cable and Shift Rod
Adjusting the Rear Brake Light Switch
Checking the Final Gear Oil Level
Changing the Final Gear Oil
Checking the Differential Gear Oil
Changing the Differential Gear Oil
Checking the Constant Velocity Joint Dust Boot
Checking the Steering System Adjusting the Toe-In
Adjusting the Front Shock Absorber
Adjusting the Rear Shock Absorber
Checking the Tire
Checking the Wheel
Checking and Lubricating the Cable
Lubricating the Levers, Pedal, Etc
Electrical
Checking the Batiery
Checking the Fuse
Adjusting the Headlight Beam
Changing the Headlight Bulb
Chapter 4. Engine
Engine Removal
Air Ducts, Muffler and Exhaust Pipe
Select Lever Unit and Coolant Reservoir
Hoses and Leads
Engine Mounting Bolts
Installing the Engine
Cylinder Head
Removing the Cylinder Head
Checking the Tappet Cover
Checking the Timing Chain Tensioner
Checking the Camshaft Sprocket
Checking the Cylinder Head
Installing the Cylinder Head
Camshaft, Rocker Arms and Valves
Removing the Camshaft and Rocker Arm
Removing the Valve and Valve Spring
Checking the Camshaft
Checking the Rocker Arm and Camshaft
Checking the Valve and Valve Spring
Installing the Valve and Valve Spring
Installing the Camshaft and Rocker Arm
Cylinder and Piston
Removing the Piston
Checking the Timing Chain Guide
Checking the Cylinder and Piston
Checking the Piston Ring
Checking the Piston Pin
Installing the Piston
Installing the Cylinder
Recoil Starter and A.C. Magneto
Magneto
Disassembling the Recoil Starter
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Table of
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Chapters
Table of Contents
10
Table of Contents
123
Table of Contents
195
Checking the Final Drive Gear/Positioning the Final Drive Pinion Gear
221
Table of Contents
303
Table of Contents
326
. Troubleshooting
335
Table of Contents
Troubleshooting
DRIVE TRAIN
64
TROUBLESHOOTING DETAILS
107
DRIVE TRAIN
151
TROUBLESHOOTING
291
CHAPTER 10. TROUBLESHOOTING
670
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This manual is also suitable for:
Grizzly 450 2008
Grizzly 450 2009
Grizzly 450 2010
Grizzly 450 2011
Grizzly 450 2012
Grizzly 450 2013
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Grizzly 450 2014
Kodiak 450 2003
Kodiak 450 2004
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Kodiak 450 2006
Yfm45fga
Yfm45fgha
Yfm45fgpa
Yfm45fgpha
Yfm45fgx
Yfm45fgy
Yfm450far
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