The Yamaha Grizzly 450 is a rugged, all-terrain vehicle (ATV) designed for utility and recreational use. This parts manual provides comprehensive information on genuine Yamaha replacement parts, assemblies, and components for the Grizzly 450 model. It is intended for use by technicians, service personnel, and owners to ensure proper identification, ordering, and installation of parts to maintain optimal performance and safety. Below are key sections covering parts identification, diagrams, ordering information, maintenance schedules, and troubleshooting.
Key components are illustrated in exploded-view diagrams with corresponding part numbers for accurate identification.
| Diagram Section | Description |
|---|---|
| Overall Vehicle Layout | Complete ATV assembly with major component groups |
| Engine Assembly | Cylinder, piston, crankshaft, camshaft, valves |
| Transmission & Drive | Gear sets, shafts, clutch, drive belt, differential |
| Front & Rear Suspension | A-arms, shocks, springs, swingarm, linkages |
| Wheels & Brakes | Hubs, rims, tires, brake discs, calipers, pads |
| Fuel & Exhaust System | Fuel tank, pump, carburetor, air filter, muffler |
| Electrical Harness | Wiring, connectors, switches, relays, fuses |
| Control Assembly | Handlebar, levers, throttle, cables, footpegs |
| Body Panels | Fenders, racks, seat, skid plates, covers |
| Lighting & Instruments | Headlight, taillight, gauge cluster, indicators |
Detailed listing of internal and external engine components and power transmission parts.
WARNING! Use only Yamaha Genuine Parts for engine repairs to ensure reliability and avoid voiding warranty.
Components related to frame, steering, suspension, and wheels.
CAUTION! Inspect suspension components regularly for wear or damage; replace in pairs if needed.
Parts for operator controls, cables, and instrument panel.
Handlebar Controls: Throttle lever assembly, brake levers, clutch lever, switch housings.
Cables: Throttle cable, choke cable, brake cables, speedometer cable.
Instruments: Speedometer unit, indicator lights, fuel gauge, mounting bracket.
Foot Controls: Brake pedal, shift lever, footpegs, rubber grips.
External body panels, protective components, and optional accessories.
Tip: Use Yamaha-approved accessories to ensure proper fit and maintain vehicle balance.
Recommended part replacement intervals based on hours of operation or mileage.
WARNING! Adhere to maintenance intervals. Failure to replace parts as recommended can lead to premature wear or failure.
How to identify and order correct Yamaha parts.
Part Number Format: Typically a combination of letters and numbers (e.g., 5GH-12345-00-00). Always verify the full part number from the diagram.
Ordering: Contact an authorized Yamaha dealer with the part number, model (Grizzly 450), and model year.
Warranty: Yamaha Genuine Parts are covered by a limited warranty. Keep your sales receipt.
Critical torque values for major fasteners. Use a calibrated torque wrench.
| Component | Fastener | Torque (ft-lb / Nm) |
|---|---|---|
| Cylinder Head | Head Bolts | 20 ft-lb / 27 Nm |
| Wheel Hub | Axle Nut | 65 ft-lb / 88 Nm |
| Spark Plug | Spark Plug | 13 ft-lb / 18 Nm |
| Oil Drain Plug | Drain Bolt | 20 ft-lb / 27 Nm |
| Swingarm Pivot | Pivot Bolt | 58 ft-lb / 79 Nm |
CAUTION! Overtightening can strip threads; undertightening can cause parts to loosen. Always follow specified sequence for multi-bolt assemblies.
This vehicle complies with applicable safety and emissions standards. Use of non-genuine parts may affect compliance. Always wear appropriate safety gear when servicing. Dispose of used parts (e.g., oil, filters, batteries) according to local environmental regulations.
| Symptom | Possible Failed Part | Corrective Action |
|---|---|---|
| Engine won't start | Spark plug, fuel pump, starter relay | Check for spark; listen for fuel pump; test relay. |
| Loss of power/overheating | Clutch belt, air filter, cooling fins | Inspect belt for wear; clean air filter; clear debris from fins. |
| Excessive vibration | Wheel balance, axle bearings, U-joints | Check tire balance; inspect bearings and U-joints for play. |
| Brakes dragging/pulling | Brake pads, caliper pins, brake fluid | Inspect pad wear; lubricate caliper pins; check fluid level. |
| Electrical issues (no lights) | Bulbs, switches, wiring harness, fuse | Test bulbs; check switch continuity; inspect harness for damage; replace fuse. |
Service Support: For technical assistance or to locate an authorized dealer, visit www.yamahamotorsports.com or contact Yamaha Customer Relations.