2009 Yamaha Grizzly 450 4WD ATV Service Manual Set (P/N LIT-11616-KD-48)

This Yamaha service manual set for the 2009 Grizzly 450 4WD, publication LIT-11616-KD-48, combines the YFM450FAR base manual with four supplementary service manuals through YFM45FGY. It brings together the underlying repair procedures and the later updates needed for the covered configuration.

The YFM45FGY supplement is intended to be used with the base manual and the three earlier supplements listed above.

Repair and Diagnostic Coverage

• Engine and transmission: Engine removal, cylinder-head and valve service, piston inspection, crankcase separation, crankshaft installation, and internal transmission checks.

• Ultramatic drive: Primary and secondary sheave disassembly, V-belt inspection, centrifugal-clutch repair, and one-way clutch bearing checks.

• Fuel system: Mikuni BSR33 carburetor disassembly, diaphragm and needle-valve inspection, float-height checks, and fuel-level adjustment.

• Cooling system: Radiator and cap testing, thermostat inspection, water-pump disassembly, seal installation, and coolant replacement.

• Shaft drive: Front and rear constant velocity joint service, differential gear-motor testing, middle-gear shim selection, and final-drive backlash adjustment.

• Brakes and chassis: Hydraulic front-brake service and bleeding, wet rear-brake inspection, steering-knuckle repair, and rear-arm and stabilizer service.

• Electrical diagnosis: Ignition, starting, charging, lighting, cooling-fan, and 2WD/4WD troubleshooting, supported by circuit diagrams and wiring sheets.

Written primarily for Yamaha dealers and qualified mechanics, these manuals assume a basic understanding of mechanical principles and vehicle repair procedures.

Using the Base Manual and Supplements

The YFM45FGY supplement adds revised specifications, cable routing, front-bodywork removal information, and middle-driven-shaft details.

The later supplements document independent rear suspension and the wet multiple-plate rear brake. Matching those updates to the ATV helps prevent earlier rear-axle and brake procedures from being applied to the wrong hardware.

Engine, Ultramatic and Carburetor Repair

Internal engine coverage extends to valve-guide replacement, valve-seat inspection, cylinder and piston measurements, oil-pump checks, and crankshaft and balancer installation. Component-specific torque tables, wear limits, and assembly illustrations support those procedures.

The Ultramatic material explains sheave inspection, clutch-shoe wear, and the one-way bearing’s orientation and directional operation. Exploded views and job instruction charts identify the parts involved in removal and reassembly.

Carburetor coverage goes beyond cleaning: it addresses the piston-valve diaphragm, coasting enricher, needle valve and seat, float height, and measured fuel level.

Cooling-System Inspection and Water-Pump Service

Radiator-cap pressure checks and thermostat testing support cooling-system diagnosis. The water-pump section identifies the impeller, rubber damper, mechanical seal, oil seal, and bearing, with installation-tool references for seal replacement.

Shaft Drive, Rear Brakes and Chassis

Middle-gear and final-drive sections explain shim selection, backlash measurement, bearing inspection, and universal-joint service. The tool references include gear-lash measurement tool YM-01467 and universal-joint holder YM-04062.

The middle-gear procedure warns that pressing directly on the driven-shaft end can damage its threads. Shaft-drive troubleshooting also explains how insufficient gear lash can damage gear teeth.

Wet rear-brake coverage includes friction plates, brake-plate warpage, springs, the pressure plate, and ring-gear dogs. Steering-knuckle bearing work, ball-joint replacement, rear knuckles, suspension arms, and stabilizer components are also addressed. Chassis work requires secure vehicle support and the manual’s brake-service precautions.

Electrical Fault Isolation and Diagram References

The front-differential explanation distinguishes travel-related standby and incomplete spline engagement from completed differential locking. Together with the relay, switch, and gear-motor checks, this helps separate an engagement condition from an electrical fault.

Reference material includes Coolant Flow Diagrams, Oil Flow Diagrams, and Cable Routing drawings. The 2WD/4WD Selecting System circuit diagram supports drive-selection diagnosis, while the YFM45FGY 2009 Wiring Diagram provides the complete wiring layout with connector views and wire-color codes.

Valve-Clearance and Rear-Brake Inspection Preview

For cold valve checks, the manual specifies intake clearance of 0.06–0.10 mm and exhaust clearance of 0.16–0.20 mm. These figures accompany the valve-clearance inspection and adjustment procedures.

Wet rear-brake friction plates have a specified thickness range of 2.37–2.53 mm, with a wear limit of 2.22 mm. The inspection section distinguishes the normal range from the replacement limit.

PDF Chapter Access and Wiring Detail

Search, bookmarks and wiring: Text search is unavailable in the manual pages. Embedded bookmarks cover the base manual and supplements, but the wiring-diagram bookmarks open the legends; the complete 2009 wiring sheet is on PDF p. 373. Small wiring and connector labels require zooming.

Supplied as one printable, English-language PDF with 561 pages in total. The total also includes one compilation cover and five additional wiring-diagram pages.