2009 YAMAHA GRIZZLY 450 brake

7-25
7 BRAKES FOR PROPER OPERATION when
you come out of the water. Do not continue to
ride your ATV until you have regained adequate
braking ability. (See page 7-19.)
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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 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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8-7
8
EBU28390TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.22 Final gear oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√√√
23 Cooling systemCheck coolant level and ATV for coolant leakage,
and correct if necessary.√√√√√
Replace coolant. Every 2 years
24*Moving parts and
cablesLubricate.√√√√
25*Drive select lever
safety system cableCheck operation and adjust or replace if neces-
sary.√√√
26*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.√√√√√
27*Front and rear brake
switchesCheck operation and correct if necessary.√√√√√
28*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 320U37S60E0.book Page 7 Thursday, June 5, 2008 6:51 PM

8-8
8

Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinder and calipers, and change
the brake fluid.Replace the brake hoses every four years and if cracked or damaged.
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8
TIPIf the recommended oil is not available, SAE80W-
90 API GL-5 Hypoid gear oil may be used instead.
However, when using this oil, noise from the final
gear case may occur when applying the rearbrake.
NOTICEECB00420Be sure no foreign material enters the finalgear case.
7. Install the oil filler bolt, and then tighten it to the
specified torque.
8. Check the final gear case for oil leakage. If oil
is leaking, check for the cause.
9. Install the engine guard and the final gear
case guard by installing the bolts, and then
tightening them to the specified torques.
1. Final gear oil filler bolt
2. Correct oil level
3. Final gear oilRecommended final gear oil:
See page 10-1.
Tightening torque:
Final gear oil filler bolt:
24 Nm (2.4 m·kgf, 17 ft·lbf)
Tightening torques:
Engine guard bolt:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Final gear case guard bolt:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
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8
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.EBU28413Checking the front brake pads and rear
brake friction plates The front brake pads and the rear brake friction
plates must be checked for wear at the intervals
specified in the periodic maintenance and lubrica-
tion chart.TIPThis ATV is equipped with a wet, multiple-disc type
rear brake, which is located inside of the final gearcase.
EBU24171Front brake pads
Check each front brake pad for damage and mea-
sure the lining thickness. If a brake pad is dam-
aged or if the lining thickness is less than 1.0 mm
(0.04 in), have a Yamaha dealer replace the brake
pads as a set.TIPThe wheels need to be removed to check thebrake pads. (See page 8-58.)1. Lining thickness
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8
EBU28421Rear brake friction plates
The rear brake is provided with a wear indicator,
which allows you to check the brake friction plate
wear without having to disassemble the brake. To
check the brake friction plate wear, check the posi-
tion of the wear indicator while applying the brake.
If a brake friction plate has worn to the point that
the wear indicator reaches the wear limit mark,
have a Yamaha dealer replace the brake friction
plates as a set.
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.
Observe these precautions:
When checking the fluid level, make sure that
the top of the brake fluid reservoir is level.
1. Wear indicator
2. Wear limit mark
1. Minimum level mark
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8

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.EBU24281Changing 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 brake master cylinder and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are dam-
aged or leaking.

Oil seals: Replace every two years.
Brake hoses: Replace every four years.EBU24393Checking the front brake lever free play The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever should have no
free play as shown. If there is free play, have a
Yamaha dealer check the brake system. Recommended brake fluid:
DOT 41. Brake lever free play
U37S60E0.book Page 41 Thursday, June 5, 2008 6:51 PM