2007-2008 Yamaha Grizzly 400, YFM4FG ATV repair manual

Product Information

Table of Contents

GENERAL INFORMATION Machine Identification

• Vehicle Identification Number
• Model Label Important Information
• Preparation for Removal Procedures
• Replacement Parts
• Gaskets, Oil Seals, and O-Rings
• Lock Washers/Plates and Cotter Pins
• Bearings and Oil Seals
• Circlips Checking of Connections Special Tools

SPECIFICATIONS General Specifications Maintenance Specifications

• Engine
• Chassis
• Electrical How to Use the Conversion Table General Torque Specifications Lubrication Points and Lubricant Types
• Engine Coolant Flow Diagrams Oil Flow Diagrams Cable Routing

PERIODIC CHECKS AND ADJUSTMENTS Introduction Periodic Maintenance/Lubrication Seat, Carriers, Fenders, and Fuel Tank

• Seat and Side Panels
• Front Carrier, Front Bumper, and Front Fender
• Rear Carrier and Rear Fender
• Fuel Tank Footrest Boards Engine
• Adjusting the Valve Clearance
• Adjusting the Idling Speed
• Adjusting the Throttle Lever Free Play
• Adjusting the Speed Limiter
• Adjusting the Starter Cable
• Checking the Spark Plug
• Checking the Ignition Timing
• Measuring the Compression Pressure
• Checking the Engine Oil Level
• Changing the Engine Oil
• Cleaning the Air Filter
• Checking the Coolant Level
• Changing the Coolant
• Checking the Coolant Temperature Warning Light
• Checking the V-Belt
• Cleaning the Spark Arrester Chassis
• Adjusting the Rear Brake
• Checking the Front Brake Fluid Level
• Checking the Front Brake Pads
• Checking the Rear Brake Shoes
• Checking the Brake Hoses
• Bleeding the Hydraulic Brake System
• Adjusting the Select Lever Control Cable and Shift Rod
• Adjusting the Rear Brake Light Switch
• Checking the Final Gear Oil Level
• Changing the Final Gear Oil
• Changing the Differential Gear Oil
• Checking the Constant Velocity Joint Dust Boots
• Checking the Steering System
• Adjusting the Toe-In
• Adjusting the Front Shock Absorbers
• Adjusting the Rear Shock Absorber
• Checking the Tires
• Checking the Wheels
• Checking and Lubricating the Cables
• Lubricating the Levers, Pedal, etc. Electrical
• Checking the Battery
• Checking the Fuses
• Adjusting the Headlight Beams
• Changing the Headlight Bulb

ENGINE Engine Removal

• Air Ducts, Muffler, and Exhaust Pipe
• Select Lever Unit and Coolant Reservoir
• Hoses and Leads
• Engine Mounting Bolts
• Installing the Engine Cylinder Head
• Removing the Cylinder Head
• Checking the Tappet Covers
• Checking the Timing Chain Tensioner
• Checking the Camshaft Sprocket
• Checking the Cylinder Head
• Installing the Cylinder Head Camshaft, Rocker Arms, and Valves
• Removing the Camshaft and Rocker Arms
• Removing the Valves and Valve Springs
• Checking the Camshaft
• Checking the Rocker Arms and Camshaft
• Checking the Valves and Valve Springs
• Installing the Valves and Valve Springs
• Installing the Camshaft and Rocker Arms Cylinder and Piston
• Removing the Piston
• Checking the Timing Chain Guide
• Checking the Cylinder and Piston
• Checking the Piston Rings
• Checking the Piston Pin
• Installing the Piston
• Installing the Cylinder Recoil Starter and A.C. Magneto
• Removing the A.C. Magneto
• Disassembling the Recoil Starter
• Checking the A.C. Magneto
• Checking the Starter Clutch
• Checking the Starter Pulley
• Checking the Recoil Starter
• Assembling the Recoil Starter
• Installing the A.C. Magneto Primary and Secondary Sheaves
• Primary Sliding Sheave
• Secondary Sheave
• Removing the Primary and Secondary Sheaves
• Disassembling the Secondary Sheave
• Checking the Primary Sheave
• Checking the Secondary Sheave
• Assembling the Primary Sheave
• Assembling the Secondary Sheave
• Installing the Primary and Secondary Sheaves Clutch
• Removing the Clutch
• Checking the Clutch
• Installing the Clutch Crankcase
• Starter Motor, Timing Chain, and Oil Filter
• Crankcase
• Crankcase Bearings
• Removing the Oil Pump Drive Gear
• Separating the Crankcase
• Checking the Timing Chain and Guide
• Checking the Oil Strainer and Oil Delivery Pipe
• Checking the Crankcase
• Checking the Bearings
• Assembling the Crankcase
• Installing the Shift Lever
• Installing the Oil Pump Drive Gear

COOLING SYSTEM Cooling System Inspection

• Coolant Replacement
• Checking the Radiator Cap
• Checking the Radiator
• Checking the Water Pump
• Checking the Thermostat
• Checking the Coolant Temperature Sensor Cooling System Testing

CARBURETION Carburetor Disassembly and Assembly

• Carburetor Cleaning
• Float Height Adjustment
• Jet Needle Adjustment
• Pilot Screw Adjustment
• Throttle Valve Adjustment Carburetor Inspection and Testing

DRIVE TRAIN Drive Shaft Inspection and Replacement CV Joint Inspection Differential Inspection and Replacement Drive Belt Inspection and Replacement

CHASSIS Frame Inspection and Repair Subframe Inspection Frame Bolt Torque Specifications Footpeg and Handlebar Inspection

ELECTRICAL Battery Inspection and Replacement Charging System Check Starter Motor Inspection Ignition System Inspection Lighting System Inspection Electrical Component Testing and Replacement Wiring Diagram

TROUBLESHOOTING Engine Troubleshooting Chassis Troubleshooting Electrical Troubleshooting Drive Train Troubleshooting

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