2016 YAMAHA GRIZZLY 450 check engine

EBU17421
TABLE OF CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS .............................. 1-1
SAFETY INFORMATION ................................ 2-1
DESCRIPTION................................................ 3-1Left view ...................................................... 3-1
Right view.................................................... 3-1
Controls and instruments............................ 3-2
INSTRUMENT AND CONTROL
FUNCTIONS ................................................... 4-1 Main switch ................................................. 4-1
Indicator lights and warning lights .............. 4-2
Multi-function display.................................. 4-5
Fuel gauge .................................................. 4-6
Handlebar switches .................................... 4-7
Throttle lever ............................................. 4-12
Speed limiter ............................................. 4-13
Front brake lever ....................................... 4-14
Brake pedal and rear brake lever .............. 4-14
Drive select lever ....................................... 4-15
Fuel tank cap ............................................ 4-15
Fuel ........................................................... 4-15 Fuel cock .................................................. 4-17
Starter (choke) ......................................... 4-18
Seat .......................................................... 4-19
Storage compartments ............................. 4-20
Front carrier .............................................. 4-22
Rear carrier ............................................... 4-22
Adjusting the front and rear shock
absorber assemblies ............................. 4-22
Auxiliary DC jack....................................... 4-24
PRE-OPERATION CHECKS .......................... 5-1 Fuel ............................................................. 5-3
Engine oil .................................................... 5-3
Final gear oil ............................................... 5-3
Differential gear oil ...................................... 5-3
Coolant ....................................................... 5-3
Front and rear brakes ................................. 5-3
Throttle lever ............................................... 5-4
Tires ............................................................ 5-4
Chassis fasteners ....................................... 5-7
Instruments, lights and switches ................ 5-7
OPERATION .................................................. 6-1 Starting a cold engine................................. 6-1U2LC62E0.book Page 1 Monday, May 11, 2015 2:28 PM

Starting a warm engine ............................... 6-3
Operating the drive select lever and driving in reverse ....................................... 6-3
Engine break-in ........................................... 6-5
Parking ........................................................ 6-5
Parking on a slope ...................................... 6-6
Accessories and loading ............................. 6-6
RIDING YOUR ATV ........................................ 7-1 GETTING TO KNOW YOUR ATV ................ 7-2
RIDE WITH CARE AND GOOD JUDGMENT .............................................. 7-2
BE CAREFUL WHERE YOU RIDE ............... 7-9
TURNING YOUR ATV................................ 7-12
CLIMBING UPHILL ................................... 7-13
RIDING DOWNHILL .................................. 7-16
CROSSING A SLOPE................................ 7-17
CROSSING THROUGH SHALLOW WATER .................................................... 7-18
RIDING OVER ROUGH TERRAIN ............. 7-21
SLIDING AND SKIDDING .......................... 7-21
WHAT TO DO IF... ..................................... 7-22
WHAT TO DO... ......................................... 7-23
PERIODIC MAINTENANCE AND
ADJUSTMENT................................................ 8-1 Owner’s manual and tool kit ....................... 8-2 Periodic maintenance chart for the
emission control system ........................... 8-3
General maintenance and lubrication chart.......................................................... 8-5
Removing and installing panels ................ 8-10
Checking the spark plug........................... 8-14
Engine oil and oil filter cartridge ............... 8-16
Final gear oil ............................................. 8-21
Differential gear oil .................................... 8-24
Coolant ..................................................... 8-26
Cleaning the air filter element ................... 8-30
Cleaning the spark arrester ...................... 8-33
V-belt cooling duct check hose ................ 8-34
V-belt case drain plug............................... 8-35
Adjusting the carburetor ........................... 8-35
Adjusting the engine idling speed ............ 8-35
Adjusting the throttle lever free play ......... 8-37
Valve clearance......................................... 8-37
Adjusting the drive select lever safety system cable .......................................... 8-38
Brakes....................................................... 8-38
Checking the front brake pads and rear brake friction plates ................................ 8-38
Checking the brake fluid level .................. 8-39
Changing the brake fluid .......................... 8-40
Checking the front brake lever free play... 8-40
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2-4
2
Never maintain an ATV without proper knowl-
edge. Contact an authorized ATV dealer to in-
form you on basic ATV maintenance. Certain
maintenance can only be carried out by certified
staff.
In the event of an accident 1. If serious injuries are incurred, you may be safer staying next to your vehicle; it may
shield you from oncoming riders. Depending
on your injuries and position in the trail; you
must make a judgment call as to whether you
should move to a position off the trail. If you
have sustained head, neck, or back injuries,
or cannot feel your limbs, you should not
move. Keep your helmet on and remain mo-
tionless. Lie down next to your vehicle and
wait for help.
2. If less serious injuries are incurred and you can walk, then move to a position off the trail.
Check yourself for injuries and apply first aid
as needed.
3. If your injuries are light, when safe to do so, move your vehicle off the trail to avoid colli-
sions with oncoming riders. Check for injuries
and apply first aid as necessary. If you can
physically operate your vehicle, inspect your vehicle. If the vehicle is in safe operating con-
dition and you can safely operate it, restart it
and ride gently back to camp or other known
location where you can receive medical at-
tention. If necessary, contact your riding party
or local authorities to let them know where
you are and what has happened.
In the event of a breakdown 1. If your vehicle will not restart or is not in safe operating condition, turn off the main switch
and engine stop switch. If the breakdown oc-
curs at twilight or night, leave the main switch
on so that your lights may warn other riders of
your stopped vehicle.
2. Get out of danger. Check for oncoming vehi- cles and when safe, push your vehicle to the
side of the trail or even off the main trail to
avoid any possible collisions with oncoming
riders. If you cannot move your vehicle by
yourself, when safe, walk to the nearest van-
tage point and signal an oncoming rider to
help you push your vehicle to a safe place off
the trail.
3. Inspect your vehicle for any immediate haz- ardous conditions. The most obvious hazard-
ous conditions are leaking fuel and
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2-5
2
ungrounded or broken wiring. Visually check
for broken wiring and leaking fuel. Leaking
fuel can be confirmed by the odor of gasoline.
4. Once immediate safety hazards are con- firmed not to exist, you may remove your hel-
met to more closely inspect your vehicle.
Check for external signs of wear, broken
parts, fluid leaks, cracks in the frame, sus-
pension damage, wheel damage, and so on.
Fuel, oil, and coolant usually give off a notice-
able odor.
5. If your vehicle will not restart or if it is unsafe to ride, then turn off all vehicle systems (en-
gine stop switch, main switch, and fuel cock),
and then signal or go for help.
Aftermarket Parts, Accessories, and Modifica-
tions
While you may find aftermarket products similar in
design and quality to genuine Yamaha accesso-
ries, recognize that some aftermarket accessories
or modifications are not suitable because of po-
tential safety hazards to you or others. Installing
aftermarket products or having other modifica-
tions performed to your vehicle that change any of
the vehicle’s design or operation characteristics
can put you and others at greater risk of serious injury or death. You are responsible for injuries re-
lated to changes in the vehicle. Keep the following
guidelines in mind, as well as those provided un-
der “Loading” when mounting accessories.

Never install accessories that would impair the
performance of your ATV. Carefully inspect the
accessory before using it to make sure that it
does not in any way reduce ground clearance,
limit suspension travel, steering travel or control
operation.
 Accessories fitted to the ATV can create insta-
bility due to improper weight distribution.
 Bulky or large accessories may seriously affect
the stability of the ATV.
 Certain accessories can displace the operator
from his or her normal riding position. This im-
proper position limits the freedom of movement
of the operator and may limit control ability,
therefore, such accessories are not recom-
mended.
 Use caution when adding electrical accesso-
ries. If electrical accessories exceed the capac-
ity of the ATV’s electrical system, an electric
failure could result, which could cause a dan-
gerous loss of lights or engine power.
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3-1
3
EBU17681
DESCRIPTION
EBU17691Left view
EBU17701Right view
1. Radiator cap
2. Fuel cock
3. Throttle stop screw
4. Air filter case
5. Battery
6. Fuses
7. Tail/brake light
8. Engine oil filler cap
9. Oil filter cartridge
10.Coolant reservoir
11.V-belt cooling duct check hose
1 2 3 4 5,6 78
91011
1. Rear shock absorber assembly spring preload adjusting
ring
2. Spark arrester
3. Rear storage compartment and tool kit
4. Spark plug
5. Fuel tank cap
6. Front shock absorber assembly spring preload adjusting ring
7. Rear brake light switch
8. Brake pedal
9. V-belt case drain plug1
2
3
4
6
7
8
5
9
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4-3
4
EBU17843Reverse indicator light “ ”
This indicator light comes on when the transmis-
sion is in the reverse position.
Furthermore, this indicator light flashes when the
engine is being raced for 10 seconds or more.TIPIf the indicator light flashes under any other cir-
cumstances or the speedometer does not show
the speed while riding, have a Yamaha dealer
check the speed sensor circuit. EBU17971Park indicator light “ ”
This indicator light comes on when the transmis-
sion is in the park position.EBU17921Coolant temperature warning light “ ”
This warning light comes on when the engine
overheats. When this occurs during operation,
stop the engine as soon as it is safe to do so and
allow it to cool down for about 10 minutes.
NOTICEECB00011The engine may overheat if the ATV is over-
loaded. In this case, reduce the load to spec-
ification.
 Start the engine after making sure that the
warning light is out. Continuous use while
the warning light is on may cause damage to
the engine. EBU29062Electric Power Steering warning light “EPS”
(for EPS model)
This warning light comes on when the key is
turned to “ON”, and then goes off once the engine
is started. If the warning light remains on or comes
on after the engine is started, the EPS system may
not be working correctly. When this occurs, have
a Yamaha dealer check the EPS system.
The electrical circuit of the warning light can be
checked by turning the key to “ON”. If the warning
light does not come on, have a Yamaha dealer
check the electrical circuit.
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4-13
4
Before starting the engine, check the throttle to be
sure it is operating smoothly. Make sure it returns
to the idle position as soon as the lever is released.
EBU18324Speed limiterYour ATV is equipped with an adjustable speed
limiter. The speed limiter keeps the throttle from
fully opening, even when the throttle lever is
pushed to the maximum. 1. Loosen the locknut.
2. To increase the maximum engine power available and the maximum speed of the ATV,
turn the adjusting screw in direction (a). To decrease the maximum engine power avail-
able and the maximum speed of the ATV, turn
the adjusting screw in direction (b). Do not
turn the adjusting screw out more than 12
mm (0.47 in) or the throttle cable could be
damaged. Always make sure the throttle lever
free play is adjusted to 3.0–5.0 mm (0.12–
0.20 in). (See page 8-37.)
WARNING! Im-
proper adjustment of the speed limiter and
throttle could cause throttle cable damage
or improper throttle operation. You could
lose control, resulting in an accident.
[EWB00242]
1. Throttle lever
1. Locknut
2. Adjusting screw
3. No more than 12 mm (0.47 in)
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5-1
5
EBU19203
PRE-OPERATION CHECKS
EBU19226Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always
follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWB00482Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equip-
ment damage. Do not operate the vehicle if you find any problem. If a problem cannot be corrected
by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:
ITEMROUTINE PAGE
Fuel • Check fuel level in fuel tank,
and add recommended fuel if neces-
sary.
• Check fuel line for leakage. Correct if necessary. 4-15, 5-3
Engine oil • Check oil level in engine, and add recommended oil to specified
level if necessary.
• Check ATV for oil leakage. Correct if necessary. 5-3, 8-16
Final gear oil • Check ATV for oil leakage. Correct if necessary. 5-3, 8-21
Differential gear oil • Check ATV for oil leakage. Correct if necessary. 5-3, 8-24
Coolant • Check coolant level in reservoir, and add recommended coolant to
specified level if necessary.
• Check cooling system for leakage. Correct if necessary. 5-3, 8-26
U2LC62E0.book Page 1 Monday, May 11, 2015 2:28 PM