Yamaha GRIZZLY 400 Manual

READ THIS MANUAL CAREFULLY!

It contains important safety information.

OWNER’S MANUAL

YFM4FGW

WARNING

This ATV should not be ridden by anyone under 16 years of age.

LIT-11626-20-33

1P1-F8199-13

EBU17091

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INTRODUCTION

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Congratulations on your purchase of the Yamaha YFM4FGW. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.

This manual will provide you with a good basic understanding of the features and operation of this ATV.

This manual includes important safety information. It provides information about special techniques and skills necessary to ride the ATV. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer.

AN IMPORTANT SAFETY MESSAGE:

●READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.

●PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.

●NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMATION.

●THIS ATV, AND ANY OTHER ATV OVER 90 cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE.

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IMPORTANT MANUAL INFORMATION

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FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

				Failure to follow WARNING instructions could result in severe injury
	WARNING			or death to the ATV operator, a bystander, or a person inspecting or
				repairing the ATV.
				A CAUTION indicates special precautions that must be taken to avoid
	CAUTION:
				damage to the ATV.
	NOTE:			A NOTE provides key information to make procedures easier or clearer.

* Product and specifications are subject to change without notice.

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IMPORTANT NOTICE

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Welcome to the Yamaha world of motor sports!

This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway.

This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.

Please check your local riding laws and regulations before operating this ATV.

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		YFM4FGW
		OWNER’S MANUAL
		©2006 by Yamaha Motor Corporation, U.S.A.
		1st edition, May 2006
AFFIX DEALER		All rights reserved.
		Any reprinting or unauthorized use
LABEL HERE		without the written permission of
		Yamaha Motor Corporation, U.S.A.
		is expressly prohibited.
		Printed in U.S.A.
		P/N LIT-11626-20-33

EWB00010

WARNING

Indicates a potential hazard that could result in serious injury or death.

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TABLE OF CONTENTS

SAFETY INFORMATION ..............................	1-1
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................	2-1
DESCRIPTION ..............................................	3-1
Left 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 light ................	4-2
Speedometer ..............................................	4-3
Fuel gauge .................................................	4-3
Handlebar switches ....................................	4-4

Throttle lever ...............................................	4-6
Speed limiter ...............................................	4-7
Front brake lever .........................................	4-8
Brake pedal and rear brake lever ...............	4-9
Drive select lever ........................................	4-9
Recoil starter .............................................	4-10
Fuel tank cap ............................................	4-11
Fuel ...........................................................	4-11
Fuel cock ..................................................	4-12
Starter (choke) ..........................................	4-14
Seat ..........................................................	4-14
Storage compartment ...............................	4-15
Front carrier ..............................................	4-16
Rear carrier ...............................................	4-17
Adjusting the front and rear shock
absorber assemblies ...............................	4-17
Auxiliary DC jack .......................................	4-18
PRE-OPERATION CHECKS ..........................	5-1
Pre-operation check list ..............................	5-1
Fuel .............................................................	5-4
Engine oil ....................................................	5-4
Final gear oil ...............................................	5-4
Differential gear oil ......................................	5-4
Coolant .......................................................	5-4
Front and rear brakes .................................	5-5
Throttle lever ...............................................	5-6

Tires ...........................................................	5-6
Measuring the tire pressure .......................	5-7
Tire wear limit .............................................	5-8
Chassis fasteners .......................................	5-9
Instruments, lights and switches ................	5-9
OPERATION ..................................................	6-1
Starting a cold engine ................................	6-1
Starting a warm engine ..............................	6-3
Operating the drive select lever and
driving in reverse ......................................	6-3
Engine break-in ..........................................	6-5
Parking .......................................................	6-6
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
JUDGEMENT............................................	7-3
BE CAREFUL WHERE YOU RIDE...........	7-13
TURNING YOUR ATV ..............................	7-17
CLIMBING UPHILL ...................................	7-19
RIDING DOWNHILL..................................	7-23
CROSSING A SLOPE...............................	7-25
CROSSING THROUGH SHALLOW
WATER ...................................................	7-27

RIDING OVER ROUGH TERRAIN............	7-29
SLIDING AND SKIDDING .........................	7-31
WHAT TO DO IF........................................	7-32
WHAT TO DO............................................	7-32
PERIODIC MAINTENANCE AND
MINOR REPAIR .............................................	8-1
Owner’s manual and tool kit .......................	8-1
Periodic maintenance chart for the
emission control system ...........................	8-3
General maintenance and
lubrication chart ........................................	8-5
Removing and installing panels ..................	8-9
Checking the spark plug ...........................	8-14
Engine oil and oil filter cartridge ................	8-16
Final gear oil .............................................	8-21
Changing the differential gear oil ..............	8-23
Coolant .....................................................	8-25
Cleaning the air filter element ...................	8-29
Cleaning the spark arrester ......................	8-33
V-belt cooling duct check hose .................	8-34
V-belt case drain plug ...............................	8-34
Adjusting the carburetor ............................	8-35
Adjusting the engine idling speed .............	8-35
Adjusting the throttle cable free play .........	8-36
Valve clearance ........................................	8-37

Adjusting the drive select lever safety
system cable ..........................................	8-37
Checking the front and rear brake pads ...	8-37
Checking the brake fluid level ..................	8-38
Changing the brake fluid ..........................	8-40
Checking the front brake lever
free play .................................................	8-40
Adjusting the rear brake lever free play
and checking the brake pedal position ...	8-41
Axle boots ................................................	8-43
Brake light switches .................................	8-44
Checking and lubricating the cables ........	8-44
Checking and lubricating the front and
rear brake levers ....................................	8-45
Checking and lubricating the brake
pedal ......................................................	8-45
Checking the wheel bearings ...................	8-46
Lubricating the drive shaft universal
joint .........................................................	8-46
Checking the stabilizer bushes ................	8-46
Lubricating the upper and lower
arm pivots ...............................................	8-46
Lubricating the knuckle pivots ..................	8-46
Lubricating the knuckle shafts ..................	8-47
Lubricating the steering shaft ...................	8-47
Battery ......................................................	8-47
Replacing a fuse ......................................	8-49

Replacing a headlight bulb .......................	8-51
Adjusting a headlight beam ......................	8-53
Replacing the tail/brake light bulb .............	8-54
Removing a wheel ....................................	8-55
Installing a wheel ......................................	8-56
Troubleshooting ........................................	8-58
Troubleshooting charts .............................	8-59
CLEANING AND STORAGE ..........................	9-1
Cleaning ......................................................	9-1
Storage .......................................................	9-2
SPECIFICATIONS .......................................	10-1
CONSUMER INFORMATION.......................	11-1
Identification numbers ...............................	11-1
Noise regulation ........................................	11-3
Maintenance record ..................................	11-4
YAMAHA MOTOR
CORPORATION, U.S.A.
ATV LIMITED WARRANTY ....................	11-5
YAMAHA EXTENDED SERVICE
(Y.E.S.) ...................................................	11-7

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SAFETY INFORMATION
		1

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AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.

An ATV handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions.

SEVERE INJURY OR DEATH can result if you do not follow these instructions:

●Read this manual and all labels carefully and follow the operating procedures described.

●Never operate an ATV without proper training or instruction. Take a Training Course. Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call 1- 800-887-2887 to find out about the training courses nearest you.

●Always follow the age recommendation:

– A child under 16 years old should never operate an ATV with engine size greater than 90 cc.

1-1

●Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely.

●Never carry a passenger on an ATV.

●Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.

●Never operate an ATV on any public street, road or highway, even a dirt or gravel one.

●Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or a jacket, and long pants.

●Never consume alcohol or drugs before or while operating this ATV.

●Never operate at speeds too fast for your skills or the riding conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience.

●Never attempt wheelies, jumps, or other stunts.

●Always inspect your ATV each time you use it to make sure it is in safe operating condition. Al-

1ways follow the inspection and maintenance procedures and schedules described in this manual.

●Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation.

●Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

●Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

●Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds and never turn at excessive speeds.

●Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

●Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high speed.

●Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

●Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

●Always use proper procedures if you stall or roll backwards when climbing a hill. Maintain a steady speed when climbing a hill. If you stall or

1-2

roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual.

●Always check for obstacles before operating in a new area.

●Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

●Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

●Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.

● Always be sure there are no obstacles or people
behind you when you operate in reverse. When	1
it is safe to proceed in reverse, go slowly.

●Always use the size and type of tires specified in this manual.

●Always maintain proper tire pressure as described in this manual.

●Never modify an ATV through improper installation or use of accessories.

●Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or

pulling a trailer. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.

1-3

EWB00021

WARNING

1POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN

Gasoline can catch fire and you could be burned.

HOW TO AVOID THE HAZARD

Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot.

Do not spill gasoline on the engine or exhaust pipe/muffler when refueling.

Never refuel while smoking, or in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers.

When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank.

WHAT CAN HAPPEN

Gasoline is poisonous and can cause injuries.

HOW TO AVOID THE HAZARD

If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, seek medical help immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

EWB00030

WARNING

POTENTIAL HAZARD

Starting or running the engine in a closed area.

1-4

WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death			1
within a short time.
HOW TO AVOID THE HAZARD
Always operate your ATV in an area with ad-
equate ventilation.

1-5

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LOCATION OF THE WARNING AND SPECIFICATION LABELS

2

2-1

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Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation.

Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- 2 ment label from your Yamaha dealer.

2-2

2

2-3

2

2-4

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Left view

3

1.Radiator cap

2.Fuel cock

3.Recoil starter

4.Throttle stop screw

5.Air filter case

6.Battery

7.Fuses

8.Tail/brake light

9.Engine oil filler cap 10.Oil filter cartridge 11.Coolant reservoir

12.V-belt cooling duct check hose

DESCRIPTION

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Right view

1.Rear shock absorber assembly spring preload adjusting ring

2.Spark arrester

3.Storage compartment and tool kit

4.Spark plug

5.Rear brake fluid reservoir

6.Front shock absorber assembly spring preload adjusting ring

7.Brake light switch

8.Brake pedal

9.V-belt case drain plug

3-1

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Controls and instruments	NOTE:
	The ATV you have purchased may differ slightly
	from the figures shown in this manual.

3

1.Rear brake lever

2.Handlebar switches

3.Starter (choke)

4.Drive select lever

5.Speedometer

6.Main switch

7.Fuel tank cap

8.Auxiliary DC jack

9.On-Command four-wheel-drive switch 10.Throttle lever

11.Front brake lever

3-2

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INSTRUMENT AND CONTROL FUNCTIONS

EWB00010

WARNING

Indicates a potential hazard that could result in serious injury or death.

4 EBU17770

Main switch

The positions of the main switch are as follows:

ON

All electrical systems are supplied with power. The headlights, meter lighting and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.

OFF

All electrical systems are off. The key can be removed.

1. Main switch

4-1

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Indicator lights and warning light

1.Neutral indicator light “N”

2.Reverse indicator light “R”

3.Coolant temperature warning light “ ”

4.Park indicator light “P”

5.On-Command four-wheel-drive indicator light “ ”

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Reverse indicator light “”

This indicator light comes on when the transmission is in the reverse position.

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Neutral indicator light “”

This indicator light comes on when the transmission is in the neutral position.

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Coolant 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.

The electrical circuit of the warning light can be checked according to the following procedure.

1. Set the engine stop switch to “ ” and turn the 4 key to “ON”.

2.Shift the drive select lever into the neutral position or park position.

3.Push the start switch. If the warning light does not come on while the start switch is pushed, have a Yamaha dealer check the electrical cir-

cuit.

ECB00010

CAUTION:

●The engine may overheat if the ATV is overloaded. In this case, reduce the load to specification.

●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.

4-2

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On-Command four-wheel-drive indicator light

“ ”

This indicator light comes on when the On-Com- mand four-wheel-drive switch is set to the “4WD” position.

NOTE:

4

Due to the synchronizing mechanism in the differential gear case, the light may not come on until the ATV starts moving.

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Park indicator light “ ”

This indicator light comes on when the transmission is in the park position.

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Speedometer

The speedometer shows the riding speed. This speedometer is equipped with a tripmeter. The tripmeter can be reset to “0” with the reset knob. Use the tripmeter to estimate how far you can ride on a tank of fuel before going to reserve. This information will enable you to plan fuel stops in the future.

1.Speedometer

2.Tripmeter

3.Reset knob

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Fuel gauge

The fuel gauge indicates the amount of fuel in the fuel tank. When the needle reaches the red line, refill the tank at the first opportunity.

4-3

1.Fuel gauge

2.Red line

NOTE:

If the ATV runs out of fuel, move the fuel cock lever to the “RES” position. Approximately 4.5 L (1.19 US gal) (0.99 Imp.gal) of fuel will be remaining in the tank.

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Handlebar switches

4

1.	Light switch “	/	/OFF”
2.	Engine stop switch “		/	”
3.	Start switch “	”
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Engine stop switch “				/ ”

Set this switch to “ ” before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation. The engine will not start or run when this switch is set to “ ”.

4-4

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Start switch “ ”

Push this switch to crank the engine with the starter.

ECB00050

CAUTION:

See the starting instructions on page 6-1 prior to starting the engine.

4

EBU18160
Light switch “	/	/OFF”
Set this switch to “		” to turn on the low beams,

the taillight and the meter lighting. Set the switch to “ ” to turn on the high beams, the taillight and the meter lighting. Set the switch to “OFF” to turn off all the lights.

ECB00040

CAUTION:

Do not use the headlights with the engine turned off for an extended period of time, otherwise the battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it.

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On-Command four-wheel-drive switch “2WD”/“4WD”

This ATV is equipped with a switch to change from two-wheel drive to four-wheel drive and vice-versa. Select the appropriate drive according to the terrain and the conditions.

●“2WD” (two-wheel drive): Power is supplied to the rear wheels.

●“4WD” (four-wheel drive): Power is supplied to

the rear and front wheels.

To change from two-wheel drive to four-wheel drive, stop the ATV and push the switch in to the “4WD” position.

To change from four-wheel drive to two-wheel drive, stop the ATV and push the switch in to the “2WD” position.

4-5

1. On-Command four-wheel-drive switch “2WD”/“4WD”

EWB00120

WARNING

POTENTIAL HAZARD

Changing from two-wheel drive to fourwheel drive or from four-wheel drive to twowheel drive while the ATV is moving.

WHAT CAN HAPPEN
The ATV handles differently in two-wheel
drive than in four-wheel drive in some cir-
cumstances. Changing from two-wheel drive
to four-wheel drive or from four-wheel drive
to two-wheel drive while moving may cause
the ATV to unexpectedly handle differently.
This could distract the operator and in-
			4
crease the risk of losing control and of caus-
ing an accident.
HOW TO AVOID THE HAZARD
Always stop the ATV before changing from
two-wheel drive to four-wheel drive or vice-
versa.

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Throttle lever

Once the engine is running, movement of the throttle lever will increase the engine speed.

Regulate the speed of the ATV by varying the throttle position. Because the throttle is springloaded, the ATV will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever.

4-6

4

1. Throttle lever

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.

EWB00200

WARNING

POTENTIAL HAZARD Malfunction of throttle. WHAT CAN HAPPEN

The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident.

HOW TO AVOID THE HAZARD

Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can’t find or solve the problem yourself.

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Speed limiter

Your ATV was delivered 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 available and the maximum speed of the ATV, turn the adjusting screw in direction (b).

4-7

1.Locknut

2.Adjusting screw

3.No more than 12 mm (0.47 in)

3.Tighten the locknut.

EWB00190

WARNING

POTENTIAL HAZARD

Improper adjustment of the speed limiter and throttle.

WHAT CAN HAPPEN

The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured.

HOW TO AVOID THE HAZARD

Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 3.0–5.0 mm (0.12–0.20 in). (See page 8-36.)

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Front brake lever

The front brake lever is located on the right handle- 4 bar. To apply the front brake, pull the brake lever toward the handlebar grip.

1. Front brake lever

4-8

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Brake pedal and rear brake lever

The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar. To apply the rear brake, push down on the brake pedal or pull the brake lever toward the handlebar grip.

4

1. Brake pedal

1. Rear brake lever

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Drive select lever

The drive select lever is used to shift your ATV into the forward, neutral, reverse and park positions. See the “Operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever operation.

4-9

1. Drive select lever

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Recoil starter

Firmly grasp the handle and pull slightly until engagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out.

4

1. Recoil starter

EWB00290

WARNING

POTENTIAL HAZARD

Starting the engine without setting the drive select lever to the park position.

WHAT CAN HAPPEN

The ATV could start to move unexpectedly, which could cause an accident.

HOW TO AVOID THE HAZARD

Set the drive select lever to the park position before starting the engine.

4-10

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Fuel tank cap

Remove the fuel tank cap by turning it counterclockwise.

4

1. Fuel tank cap

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Fuel

Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.

1.Fuel level

2.Fuel tank filler tube

Recommended fuel: UNLEADED GASOLINE ONLY

Fuel tank capacity:

15.0 L (3.96 US gal) (3.30 Imp.gal) Fuel reserve amount:

4.5 L (1.19 US gal) (0.99 Imp.gal)

4-11