2009 YAMAHA GRIZZLY 350 maintenance

8-5
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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 lever and pedal free play, and adjust
if necessary.√√√√√
Replace brake friction plates. Whenever worn to the limit
4*Brake hosesCheck for cracks or other damage, and replace if
necessary.√√√√
Replace. Every 4 years
5*WheelsCheck runout and for damage, and replace if nec-
essary.√ √√√
6*TiresCheck tread depth and for damage, and replace if
necessary.
Check air pressure and balance, and correct if
necessary.√ √√√
7*Wheel hub bearingsCheck for looseness or damage, and replace if
necessary.√ √√√
8*V- b e l tCheck for wear, cracks or other damage, and re-
place if necessary.√ √√√
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8
9*Drive shaft univer-
sal jointLubricate with lithium-soap-based grease.√√√
10*Chassis fastenersMake sure that all nuts, bolts, and screws are
properly tightened.√√√√√
11*Shock absorber as-
sembliesCheck operation and correct if necessary.
Check for oil leakage and replace if necessary.√√√
12*Stabilizer bushesCheck for cracks or other damage, and replace if
necessary.√√√
13*Rear knuckle pivotsLubricate with lithium-soap-based grease.√√√
14*Steering shaftLubricate with lithium-soap-based grease.√√√
15*Steering systemCheck operation and repair or replace if damaged.
Check toe-in and adjust if necessary.√√√√√
16*Engine mountCheck for cracks or other damage, and replace if
necessary.√√√
17*Axle bootsCheck for cracks or other damage, and replace if
necessary.√√√√√
18 Engine oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√ √√√
19Engine oil filter car-
tridgeReplace.√√√
20 Differential gear oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√√ 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
U4S262E0.book Page 6 Tuesday, June 10, 2008 11:40 AM

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8
EBU28390TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.21 Final gear oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√√√
22*Moving parts and
cablesLubricate.√√√√
23*Drive select lever
safety system cableCheck operation and adjust or replace if neces-
sary.√√√
24*Throttle lever hous-
ing and cableCheck operation and correct if necessary.
Check throttle cable free play and adjust if neces-
sary.
Lubricate throttle lever housing and cable.√√√√√
25*Front and rear brake
switchesCheck operation and correct if necessary.√√√√√
26*Lights and switchesCheck operation and correct if necessary.
Adjust headlight beams.√√√√√ 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 320U4S262E0.book Page 7 Tuesday, June 10, 2008 11:40 AM

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EBU23080Removing and installing the panel The panel shown needs to be removed to perform
some of the maintenance jobs described in this
chapter. Refer to this section each time the panel
needs to be removed and installed.EBU23111Panel A
To remove the panelRemove the bolt, and then take the panel off.To install the panel
Place the panel in the original position and install
the bolt.NOTICEECB00380When installing the panel, be sure not to pinchthe cables or wires.EBU23211Checking the spark plug The spark plug is an important engine component,
which is easy to check. Since heat and deposits
will cause any spark plug to slowly erode, the spark
1. Panel A
1. Panel A
2. Bolt
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8-10
8 plug should be removed and checked in accor-
dance with the periodic maintenance and lubrica-
tion chart. In addition, the condition of the spark
plug can reveal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown, with the
spark plug wrench included in the owner’s tool
kit.To check the spark plug
1. Check that the porcelain insulator around the
center electrode of the spark plug is a medi-
um-to-light tan (the ideal color when the ATV
is ridden normally).
TIPIf the spark plug shows a distinctly different color,
the engine could be operating improperly. Do not
attempt to diagnose such problems yourself. In-stead, have a Yamaha dealer check the ATV.
2. Check the spark plug for electrode erosion
and excessive carbon or other deposits, and
replace it if necessary.
1. Spark plug cap
1. Spark plug wrench
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8-11
8To install the spark plug
1. Measure the spark plug gap with a wire thick-
ness gauge and, if necessary, adjust the gap
to specification.
2. Clean the surface of the spark plug gasket
and its mating surface, and then wipe off any
grime from the spark plug threads.3. Install the spark plug with the spark plug
wrench, and then tighten it to the specified
torque.
TIPIf a torque wrench is not available when installing
a spark plug, a good estimate of the correct torque
is 1/4–1/2 turn past finger tight. However, the spark
plug should be tightened to the specified torque assoon as possible.
4. Install the spark plug cap.EBU23315Engine oil and oil filter cartridge The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter cartridge replaced at the intervals spec-
ified in the periodic maintenance and lubrication
chart.
To check the engine oil level
1. Place the ATV on a level surface. Specified spark plug:
NGK/DR8EA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
1. Spark plug gap
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.7 ft·lbf)
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8-16
8 dition, the final gear oil level must be checked and
the oil changed as follows at the intervals specified
in the periodic maintenance and lubrication chart.
To check the final gear oil level
1. Place the ATV on a level surface.
TIPThe final gear oil level must be checked on a coldengine.
2. Remove the final gear oil filler bolt, and then
check the oil level in the final gear case.TIPThe oil level should be at the brim of the filler hole.
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. Install the oil filler bolt, and then tighten it to the
specified torque.
To change the final gear oil
1. Place the ATV on a level surface.
1. Final gear oil filler bolt
2. Correct oil level
3. Final gear oilTightening torque:
Final gear oil filler bolt:
24 Nm (2.4 m·kgf, 17 ft·lbf)
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EBU23422Differential 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.TIPThe differential gear oil level must be checked ona cold engine.
2. Remove the differential gear oil filler bolt, and
then check the oil level in the differential gear
case.
TIPThe oil level should be at the brim of the filler hole.
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. Install the oil filler bolt, and then tighten it to the
specified torque.1. Differential gear oil
2. Differential gear oil filler bolt
3. Correct oil levelTightening torque:
Differential gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
U4S262E0.book Page 19 Tuesday, June 10, 2008 11:40 AM