Yamaha Grizzly 450 4x4 2007–2008 Service & Owner’s Manual Set (P/N LIT-11616-21-46)

The owner’s manual covers riding, pre-ride checks, and routine maintenance. For workshop repairs, Yamaha pairs the YFM45FGX supplement with the included base service manual and the two earlier supplements. The YFM45FGX supplement supplies model-specific changes to the base procedures, including wet rear brake service.

For model fit, use the YFM45FGX designation and the supplement’s 17S-series codes for the applicable market and wheel configuration. Yamaha also directs riders to read the separate Tips for the ATV Rider booklet before operating the ATV.

PDF Search, Bookmarks, and Wiring Detail

Search and diagram labels: Both PDFs have searchable chapter text and bookmarks. In the owner’s PDF, some warning-label illustrations and the rider acknowledgment card have no searchable wording. In the workshop PDF, zooming in makes the small connector labels and wire-color codes legible on the wiring diagrams.

The ZIP contains two printable PDFs totaling 756 pages. The owner’s PDF has 182 pages, including two blank pages, three supplemental pages, and a two-page rider acknowledgment card. The workshop PDF has 574 pages, including two blank pages and the repeated 24-page supplement. Covers are included in both counts.

ATV Operation, Drivetrain Repair, and Electrical Diagnosis

This selection from the manuals focuses on riding, maintenance, and workshop repairs. Other topics include long-term storage and drive-select cable and shift-rod adjustment.

• Riding and controls: Multifunction display, warning lights, cold and warm starts, drive selection and reverse, terrain riding, and cargo and trailer limits.

• Routine maintenance: Pre-ride checks, emissions and lubrication schedules, oil and filter service, air-filter and spark-arrester cleaning, and carburetor idle and throttle adjustment.

• Engine and transmission: Step-by-step procedures for engine removal, cylinder-head and valve-train work, piston inspection, crankcase separation, and internal transmission service.

• Fuel and cooling: Mikuni BSR33 carburetor disassembly and float-chamber fuel-level checks, plus radiator service, thermostat testing, and water-pump repair.

• Drivetrain: Front differential and gear-motor service, front and rear CV-joint work, driveshaft and universal-joint service, and gear-lash measurement and shimming.

• Brakes and chassis: Wet rear brake inspection, front hydraulic brake service, wheel hubs, steering, suspension arms and shocks, and rear knuckles and stabilizer.

• Electrical troubleshooting: Ignition, starting, charging, lighting, signals, cooling-fan control, and On-Command 2WD/4WD diagnosis, with circuit diagrams and system-specific tests.

The owner’s manual is written for ATV riders doing basic checks and upkeep. Yamaha’s workshop material is written for dealers and qualified mechanics and assumes prior repair knowledge.

Owner Checks and Riding Limits

The operating chapters explain the fuel gauge, handlebar switches, speed limiter, differential lock, recoil starter, shock adjustment, and auxiliary DC jack. Riding guidance covers break-in, parking, hills, side slopes, shallow water, rough terrain, and recovery from stalls or slides.

Separate limits for the carriers, storage compartment, trailer pulling, and tongue weight help the rider distinguish individual loading limits from the combined ATV limit. Owner maintenance includes fluid levels, fasteners, spark plugs, valve clearance, V-belt cooling ducts, axle boots, bearings, batteries, fuses, lamps, and wheel removal. Troubleshooting charts cover starting problems and overheating.

Engine Assembly and Model-Specific Service

The engine chapters cover the liquid-cooled SOHC single-cylinder layout, including camshaft and rocker arms, the A.C. magneto, primary and secondary sheaves, centrifugal clutch, crankshaft, oil pump, and middle gear. Exploded views and numbered job charts tie assembly work to inspection limits and component-specific torque data. Crankcase assembly includes a check for binding in the crankshaft and transmission.

The YFM45FGX supplement distinguishes carburetor IDs for the U.S. and Canada (1D9M 10) and for Europe and Oceania (5ND6 00). The Coolant Flow Diagrams, Oil Flow Diagrams, and Cable Routing views show the related routing and service details.

Final Drive, Wet Rear Brake, and 4WD Faults

Final-drive procedures cover pinion and ring-gear positioning, bearing replacement, thrust-clearance checks, and final operation checks. Too little gear lash after reassembly can damage the gear teeth. The YFM45FGX supplement also covers rear brake pedal and lever adjustment and inspection of the friction plates, steel plates, and springs.

The 2WD/4WD Selecting System Circuit Diagram and test charts help separate relay or switch faults from a differential gear-motor problem. The Ignition System Circuit Diagram and YFM45FGX 2008 Wiring Diagram provide circuit and connector references. The general troubleshooting chapter also addresses shifting faults, clutch slip, unstable handling, and shaft-drive noise.

Yamaha identifies the crankcase separating tool YU-01135-A/90890-01135, fuel-level gauge YM-01312-A/90890-01312, sheave spring compressor YM-04134/90890-04134, gear-lash tool YM-01467/90890-01467, and universal-joint holder YM-04062/90890-04062. Follow the manual’s precautions for hot pressurized coolant, fuel, brake fluid, batteries, rotating parts, and raised-vehicle work.

Selected Gear-Lash and Rear Brake Limits

The YFM45FGX supplement specifies 0.05–0.25 mm for front differential gear lash and 0.1–0.2 mm for rear final-drive gear lash. Both checks call for readings at four shaft positions and have separate shim charts.

For the wet rear brake, the supplement gives a 2.22 mm wear limit for the friction plates and describes how to check the steel plates for warpage.