Yamaha Grizzly 450 4WD 2011 ATV Manual Set – EPS & Non-EPS (P/N LIT-11616-KD-49)

Yamaha pairs the 2011 supplement with the base manual and the four earlier supplements for workshop service. For the 2011 models, the supplement provides the updated rear axle and wet rear brake procedures.

The Owner’s Manual applies to a different model pair. It covers operating controls, pre-ride checks, cargo and towing limits, routine maintenance, starting and overheating troubleshooting, and storage. Yamaha also calls for the separate Tips for the ATV Rider booklet before operation.

PDF Search, Bookmarks and Wiring Detail

Search and navigation: Both PDFs have searchable body text and embedded bookmarks. Some service bookmarks open the wrong section, and small wiring labels are readable at higher zoom. The two safety card pages in the Owner’s Manual sit outside text search.

The ZIP contains 851 pages across two printable PDFs. The 685-page service PDF includes the compilation cover and its blank reverse, plus 10 blank pages within the individual publications. The 166-page Owner’s Manual includes its back cover, three supplemental pages, and a two-page safety reply card.

EPS Diagnosis, Final Drive and Brake Service

These are selected workshop topics. The earlier references also cover differential-lock speed limiter operation and headlight aiming.

• Electric power steering diagnosis: Read current and stored warning-light fault codes, check the torque sensor, and test the EPS motor for continuity and shorts to its housing.

• Steering stem and EPS unit: Remove and install the steering stem and EPS assembly, index the pitman arm, and check and adjust steering tension.

• Rear final gear case: Replace the pinion bearing, select shims, and check gear backlash, ring gear thrust clearance, and ring gear stopper adjustment.

• Wet multiple-disc rear brake: Inspect the internal friction plates and brake plates, and adjust the rear brake lever and pedal.

• Engine and transmission: Remove and reinstall the engine, service the cylinder head and valves, inspect the piston and cylinder, split the crankcase, and disassemble the transmission.

• Belt and shaft drive: Service the primary and secondary sheaves, inspect the centrifugal clutch, and adjust the middle gear.

Yamaha wrote the service material primarily for dealer technicians and qualified mechanics. The separate Owner’s Manual guides riders through operation, inspection, and basic maintenance for its listed models.

EPS Circuit and Electrical Troubleshooting

The EPS system block diagram shows how steering torque and vehicle speed affect assist. The diagnostic section distinguishes heat-related assist reduction from a fault and covers code clearing and post-repair checks.

The EPS circuit diagram and separate 2011 wiring diagrams for EPS and non-EPS models let you trace connectors and harness faults against the matching electrical layout. Cable-routing drawings identify EPS motor and torque-sensor leads, grounds, relay wiring, and breather-hose paths.

The EPS unit is serviced as an assembly. Yamaha warns that opening the unit can damage it. Electrical reference tables distinguish the magneto, CDI, charging-system, and regulator specifications for EPS and non-EPS models. The base manual also covers no-spark diagnosis, starter motor inspection, and charging-system tests.

Fuel, Cooling and Chassis Service

Engine maintenance includes valve-clearance and compression checks. The Mikuni BSR33 carburetor section covers float and fuel-level adjustment, diaphragm inspection, and needle-valve service.

Cooling procedures include radiator-cap pressure testing, thermostat checks, and water-pump seal and bearing service. Coolant flow diagrams map the cooling circuit, and oil flow diagrams trace engine lubrication.

Chassis procedures cover front brake master-cylinder and caliper repair, hydraulic bleeding, and suspension-arm and ball-joint service. Drivetrain procedures include front differential gear-motor testing and installation, plus drive-select cable and shift-rod adjustment.

Workshop Tables and Special Tools

The service tables give fastener torques for components including the pitman arm and steering stem, along with wear limits, fluid capacities, lubricants, and brake pedal height. Separate charts list emissions-control maintenance and general lubrication intervals.

Special tools include the shim setting tool 90890-01562 and gear lash measurement tool 90890-01467 / YM-01467. The EPS steering-tension check calls for 90890-03170 / YM-03170, listed as a belt tension gauge.

Steering and drivetrain work carries safety risks. Verify the OEM specifications for the applicable model before starting repairs or adjustments.

Sample Final Gear Clearances and Rear Brake Wear Limit

The 2011 supplement specifies rear final gear backlash of 0.10–0.15 mm (0.004–0.006 in) at the four check positions and ring gear thrust clearance of 0–0.10 mm (0–0.004 in). The shim selection tables help set those clearances after reassembly, when insufficient backlash can damage the gear teeth.

The wet rear brake section lists a friction plate thickness service limit of 3.26 mm (0.128 in).