2009 YAMAHA GRIZZLY 450 Owners Manual

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8
WARNING
EWB02471Operating 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 there is no free play.
Make sure the brakes do not drag.
Make sure the brakes are not spongy. All air
must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These proceduresshould be performed by a Yamaha dealer.EBU28635Adjusting the brake pedal and rear
brake lever free play and checking the
brake pedal position The brake pedal and brake lever free play and the
brake pedal position must be checked and, if nec-
essary, 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.
When adjusting the rear brake, be sure to adjust
both the brake pedal and the brake lever.
Before adjusting the brake lever and brake pedal
free play, check the rear brake friction plates forwear.
Adjusting the brake pedal and brake lever free
play
The brake pedal free play should measure 17.0–
20.0 mm (0.67–0.79 in). The brake lever free play
should measure 8.0–10.5 mm (0.31–0.41 in). If ei-
ther free play is incorrect, adjust it as follows.
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1. Loosen the locknut at the brake lever and fully
turn in the brake lever free play adjusting bolt.2. Fully loosen the brake lever free play adjust-
ing nut on the brake cable at the final gear
case.
1. Brake pedal free play
1. Brake lever free play
1. Locknut
2. Brake lever free play adjusting bolt
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8 3. Push the brake camshaft lever in direction (a)
until it stops [apply approximately 50 N (5.0
kgf, 11.0 lbf) of force], and then turn the brake
pedal free play adjusting nut on the brake ca-
ble at the final gear case so that gap “A” mea-
sures 2.5–3.0 mm (0.10–0.12 in).4. Push the brake camshaft lever in direction (a)
until it stops [apply approximately 50 N (5.0
kgf, 11.0 lbf) of force], and then turn the brake
lever free play adjusting nut on the brake ca-
ble at the final gear case so that gap “B” mea-
sures 4.0–6.0 mm (0.16–0.24 in).
1. Brake lever free play adjusting nut
1. Brake pedal free play adjusting nut
2. Brake camshaft lever
3. Gap “A”
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85. Check the brake lever free play and, if neces-
sary, adjust it by turning the brake lever free
play adjusting bolt at the brake lever. Turn the
brake lever free play adjusting bolt in direction
(a) to increase the free play, and in direction
(b) to decrease it.6. Tighten the locknut at the brake lever.
TIPWhen adjusting the rear brake lever free play:
Be sure not to step on the brake pedal.
Make sure the brake pedal does not move.
Checking the brake pedal position
The top of the brake pedal should be positioned
75.0–85.0 mm (2.95–3.35 in) above the footboard.
If the brake pedal position is incorrect, have a
Yamaha dealer adjust it.
1. Brake lever free play adjusting nut
2. Brake camshaft lever
3. Gap “B”
1. Locknut
2. Brake lever free play adjusting bolt
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8
WARNING
EWB02080Operating 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.
Replacement of brake components requires
professional knowledge. These proceduresshould be performed by a Yamaha dealer.
EBU24230Axle boots The axle boots must be checked for damage at the
intervals specified in the periodic maintenance and
lubrication chart. Check the axle boots for tears or
damage. If any damage is found, have them re-
placed by a Yamaha dealer.
1. Distance between brake pedal and footboard
1. Front axle boot (each side)
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EBU24752Brake light switches The operation of the brake light switches must be
checked and, if necessary, adjusted at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
The brake light switch for the brake pedal can be
adjusted as follows, but the other brake light
switches should be adjusted by a Yamaha dealer.
1. Remove panel B. (See page 8-9.)
TIPThe brake light switch is properly adjusted when
the brake light comes on just before braking takeseffect.
2. Turn the brake light switch adjusting nut while
holding the brake light switch in place. To
make the brake light come on earlier, turn the
adjusting nut in direction (a). To make the
brake light come on later, turn the adjusting
nut in direction (b).
3. Install the panel.
1. Rear axle boot (each side)
1. Brake light switch
2. Brake light switch adjusting nut
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EBU24900Checking and lubricating the cables The operation and the condition of all control ca-
bles should be checked before each ride, and the
cables and cable ends should be lubricated if nec-
essary. If a cable is damaged or does not move
smoothly, have a Yamaha dealer check or replace
it.
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.EBU28711Checking 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.
EBU28832Checking and lubricating the brake
pedal The operation of the brake pedal should be
checked before each ride, and the pedal pivot
should be lubricated if necessary. Recommended lubricant:
Engine oilRecommended lubricants:
Front brake lever:
Silicone grease
Rear brake lever:
Lithium-soap-based grease
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8
TIPTo access the brake pedal pivot, remove panel B.(See page 8-9.)EBU24962Checking the wheel hub bearings The front and rear wheel hub bearings must be
checked at the intervals specified in the periodic
maintenance and lubrication chart. If there is playin a wheel hub or if a wheel does not turn smoothly,
have a Yamaha dealer check the wheel hub bear-
ings.
EBU24970Lubricating the drive shaft universal
joint The drive shaft universal joint must be lubricated at
the intervals specified in the periodic maintenance
and lubrication chart.
Lubricate the universal joint using a grease gun.EBU25021Checking the stabilizer bushes The stabilizer bushes must be checked for cracks
or damage at the intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer replace the stabilizer bush-
es if necessary. Recommended lubricant:
Lithium-soap-based greaseRecommended lubricant:
Lithium-soap-based grease
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