2012 YAMAHA GRIZZLY 450 Owners Manual

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EBU29841Checking the brake fluid level Before riding, check that the brake fluid is above
the minimum level mark. Check the brake fluid lev-
el with the top of the reservoir level. Replenish the
brake fluid if necessary.
WARNING
EWB02720Improper maintenance can result in loss of
braking ability. Observe these precautions:

Insufficient brake fluid may allow air to enter
the brake system, reducing braking perfor-
mance.
Clean the filler cap before removing. Use
only DOT 4 brake fluid from a sealed contain-
er.
Use only the specified brake fluid; otherwise,
the rubber seals may deteriorate, causing
leakage.
Refill with the same type of brake fluid. Add-
ing a brake fluid other than DOT 4 may result
in a harmful chemical reaction.
Be careful that water does not enter the
brake fluid reservoir when refilling. Water
will significantly lower the boiling point of
the fluid and may result in vapor lock.NOTICEECB01160Brake fluid may damage painted surfaces or
plastic parts. Always clean up spilled fluid im-
mediately.As the brake pads wear, it is normal for the brake
fluid level to gradually go down. A low brake fluid
level may indicate worn brake pads and/or brake
system leakage; therefore, be sure to check the
1. Minimum level markSpecified brake fluid:DOT 4
1
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8brake pads for wear and the brake system for leak-
age. If the brake fluid level goes down suddenly,
have a Yamaha dealer check the cause before fur-
ther riding.
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.EBU24394Checking 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.
EBU30342Adjusting the rear brake lever and
brake pedal free play, and the brake
pedal height The rear brake lever and brake pedal free play,
and the brake pedal height must be checked and,
if necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.
Adjusting the brake lever free play
The brake lever free play should measure 10.0 mm
(0.39 in). If the free play is incorrect, adjust it as fol-
lows.1. No brake lever free play
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1. Loosen the locknut at the brake lever.
2. To increase the brake lever free play, turn thebrake lever free play adjusting bolt in direction
(a). To decrease the brake lever free play, turn
the adjusting bolt in direction (b). NOTICE:
Distance A must not measure more than
12.7 mm (0.50 in). If distance A exceeds
12.7 mm (0.50 in), the specified brake lever
free play cannot be obtained, therefore
proceed with the following steps.
[ECB01141]
1. Brake lever free play
1. Locknut
2. Distance A
3. Brake lever free play adjusting bolt
12
3
(a)
(b)
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TIPIf the specified brake lever free play could be ob-
tained as described above, skip steps 3-7.3. Slide the rubber cover back.
4. Loosen the brake cable adjuster locknut.
5. To increase the brake lever free play, turn thebrake lever free play adjusting nut in direction
(a). To decrease the brake lever free play, turn
the adjusting nut in direction (b). NOTICE:
Make sure that distance B measures 22 mm (0.87 in) or less. If the specified free
play cannot be obtained or if distance B
exceeds 22 mm (0.87 in), have a Yamaha
dealer check the vehicle.
[ECB01150]
6. Tighten the brake cable adjuster locknut.
7. Slide the rubber cover to its original position.
8. Tighten the locknut at the brake lever.
Adjusting the brake pedal height
The top of the brake pedal should be positioned
75.0– 85.0 mm (2.95 –3.35 in) above the footboard
bracket. If the brake pedal height is incorrect, ad-
just it as follows.
1. Rubber cover
2. Distance B
3. Brake cable adjuster locknut
4. Brake lever free play adjusting nut
1
2
3
4
(b)(a)
1. Distance between brake pedal and footboard bracket1
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1. Remove the footboard by removing the bolts
and nuts.
2. Loosen the locknut. 3. Turn the adjusting bolt in or out until the brake
pedal height is within the specified limits.
4. Tighten the locknut.
5. Install the footboard by installing the bolts and nuts, and then tighten them to the specified
torques.
1. Footboard
2. Bolt22
21
1. Locknut
2. Adjusting boltTightening torque:Locknut:7 Nm (0.7 m ·kgf, 5.1 ft ·lbf)
21
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8Adjusting the brake pedal free play
The brake pedal free play should measure 20.0
mm (0.79 in). If the free play is incorrect, adjust it
as follows.
TIPThe brake lever free play and brake pedal height
must be adjusted before adjusting the brake pedal
free play.1. Loosen the locknut.
1. Footboard bolt A
2. Footboard bolt BTightening torques:Footboard bolt A:4.0 Nm (0.40 m ·kgf, 2.9 ft· lbf)
Footboard bolt B: 7 Nm (0.7 m ·kgf, 5.1 ft ·lbf)11
2
1. Brake pedal free play
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2. To increase the brake pedal free play, turn the
brake pedal free play adjusting nut in direction
(a). To decrease the brake pedal free play,
turn the adjusting nut in direction (b).
3. Tighten the locknut.
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. Locknut
2. Brake pedal free play adjusting nut
21
(a)
(b)
1. Front axle boot (each side)
1. Rear axle boot (each side)
1
1
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EBU29881Brake light switches The brake light, which is activated by the brake
pedal and brake levers, should come on just be-
fore braking takes effect.
The rear 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.
Turn the rear 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).
EBU24902Checking 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
EWB02581
Inspect 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
restrict the operation of controls and lead to
an accident or injury.
Always make sure all control cables work
smoothly before you begin riding in cold
weather. If the control cables are frozen or do
not work smoothly, you could be unable to
control the ATV, which could lead to an acci-
dent or collision.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1
2(b)
(a)
Recommended lubricant:
Yamaha Chain and Cable Lube or engine oil
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