2016 YAMAHA GRIZZLY 450 Owners Manual

8-37
8
EBU24048Adjusting the throttle lever free playThe throttle lever free play should be checked and,
if necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.
The throttle lever free play should measure 3.0–5.0
mm (0.12–0.20 in) as shown. Periodically check
the throttle lever free play and, if necessary, adjust
it as follows.TIPThe engine idling speed must be checked, and
adjusted if necessary, before adjusting the throttle
lever free play. 1. Slide the rubber cover back.
2. Loosen the locknut.
3. To increase the throttle lever free play, turnthe throttle lever free play adjusting bolt in di-
rection (a). To decrease the throttle lever free
play, turn the adjusting bolt in direction (b). 4. Tighten the locknut.
5. Slide the rubber cover to its original position.
EBU24061Valve clearanceThe valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.1. Rubber cover
2. Throttle lever free play adjusting bolt
3. Locknut
4. Throttle lever free play
U2LC62E0.book Page 37 Monday, May 11, 2015 2:28 PM

8-38
8
EBU24072Adjusting the drive select lever safety
system cableThe 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.EBU29602BrakesReplacement of brake components requires pro-
fessional knowledge. Brake service should be
performed by a Yamaha dealer.
WARNING
EWB02572Operating with improperly serviced or adjust-
ed brakes could lead to a loss in braking ability
and an accident.
EBU28414Checking the front brake pads and rear
brake friction platesThe 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
gear case. EBU24172Front 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.
U2LC62E0.book Page 38 Monday, May 11, 2015 2:28 PM

8-39
8
TIPThe wheels need to be removed to check the
brake pads. (See page 8-61.) EBU30321Rear brake friction plates
The rear brake friction plates must be checked
and, if necessary, replaced by a Yamaha dealer at
the intervals specified in the periodic maintenance
and lubrication chart.
EBU29843Checking the brake fluid levelBefore 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
EWB02721Improper maintenance can result in loss of
braking ability. Observe these precautions:
1. Lining thickness
1. Minimum level markSpecified brake fluid:DOT 4
1
U2LC62E0.book Page 39 Monday, May 11, 2015 2:28 PM

8-40
8
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 flu-
id and may result in vapor lock.
NOTICEECB01161Brake 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 brake pads for wear and the brake system for
leakage. If the brake fluid level goes down sud-
denly, have a Yamaha dealer check the cause be-
fore further riding.
EBU24283Changing the brake fluidHave a Yamaha dealer change the brake fluid at
the intervals specified in 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 damaged or leaking.

Oil seals: Replace every two years.
 Brake hoses: Replace every four years.EBU24395Checking the front brake lever free
playThe 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.
U2LC62E0.book Page 40 Monday, May 11, 2015 2:28 PM

8-41
8
EBU30345Adjusting the rear brake lever and
brake pedal free play, and the brake
pedal heightThe 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. Loosen the locknut at the brake lever.1. No brake lever free play
1. Brake lever free play
U2LC62E0.book Page 41 Monday, May 11, 2015 2:28 PM

8-42
82. To increase the brake lever free play, turn the
brake 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.
[ECB01143]
TIPIf the specified brake lever free play could be ob-
tained as described above, skip steps 3-8. 3. Fully turn the adjusting bolt in direction (a) to loosen the brake cable.
4. Slide the rubber cover back.
5. Loosen the brake cable adjuster locknut.
6. To increase the brake lever free play, turn the brake lever free play adjusting nut in direction
(a). To decrease the brake lever free play, turn
1. Locknut
2. Distance A
3. Brake lever free play adjusting bolt
12
3
(a)
(b)
1. Rubber cover
2. Distance B
3. Brake cable adjuster locknut
4. Brake lever free play adjusting nut
1
2
3
4
(b)(a)
U2LC62E0.book Page 42 Monday, May 11, 2015 2:28 PM

8-43
8
the adjusting nut in direction (b).
NOTICE:
Make sure that distance B measures 22
mm (0.87 in) or less. If distance B reaches
22 mm (0.87 in), adjust the brake lever free
play at the brake lever again. If distance A
exceeds 12.7 mm (0.50 in), have a Yamaha
dealer check the vehicle.
[ECB01153]
7. Tighten the brake cable adjuster locknut.
8. Slide the rubber cover to its original position.
9. 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. Remove the footboard by removing the bolts
and nuts.
1. Distance between brake pedal and footboard bracket1
U2LC62E0.book Page 43 Monday, May 11, 2015 2:28 PM

8-44
82. 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 speci-
fied torques.
1. Footboard
2. Bolt and nut
3. Bolt22
31
1. Locknut
2. Adjusting boltTightening torque:Locknut:7 Nm (0.7 m·kgf, 5.1 ft·lbf)
21
U2LC62E0.book Page 44 Monday, May 11, 2015 2:28 PM