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Yamaha GRIZZLY 550 2013 Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YFM550DE/YFM550DHE
YFM550PE/YFM550PHE
WARNING
This ATV should not be ridden by anyone under 16 years of age.
LIT-11626-27-22
2LB-F8199-10

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Summary of Contents for Yamaha GRIZZLY 550 2013

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM550DE/YFM550DHE YFM550PE/YFM550PHE WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-27-22 2LB-F8199-10...
  • Page 2 EBU17092 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold.
  • Page 3 Congratulations on your purchase of the Yamaha YFM550DE/YFM550DHE/YFM550PE/YFM550PHE. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, tour- ing, and pace-setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
  • Page 4 EBU17330 IMPORTANT MANUAL INFORMATION EBU17342 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
  • Page 5 Please check your local riding laws and regulations before operating this ATV. EBU17402 YFM550DE/YFM550DHE YFM550PE/YFM550PHE OWNER’S MANUAL ©2013 by Yamaha Motor Corporation, U.S.A. 1st edition, March 2013 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

  • Page 6: Table Of Contents

    Speed limiter ..........4-13 EWB00011 WARNING Front brake lever ........4-14 Indicates a hazardous situation which, if not Brake pedal and rear brake lever .....4-14 avoided, could result in death or serious injury. Drive select lever ........4-15 Fuel tank cap ..........4-15 Fuel ............4-16 Seat ............4-18 EBU17420 Storage compartments ......4-19...
  • Page 7 OPERATION ..........6-1 PERIODIC MAINTENANCE AND Starting the engine ........6-1 ADJUSTMENT..........8-1 Operating the drive select lever and driving Owner’s manual and tool kit .......8-2 in reverse ..........6-2 Periodic maintenance chart for the Engine break-in .......... 6-4 emission control system ......8-3 Parking ............
  • Page 8 ........8-53 Noise regulation ........11-4 Checking and lubricating the brake Maintenance record ........11-5 pedal ............8-54 YAMAHA MOTOR CORPORATION, Checking the wheel hub bearings .... 8-54 U.S.A. ATV LIMITED WARRANTY ..11-6 Checking the stabilizer bushes ....8-54 YAMAHA EXTENDED SERVICE Lubricating the rear knuckle pivots ...

  • Page 9: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 10 Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your Yamaha dealer. Overloading this ATV or carrying cargo improperly can change handling, stability and braking performance and can lead to an accident.
  • Page 11 WARNING WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN This unit contains high pressure nitrogen gas. CAUSE LOSS OF CONTROL. Mishandling can cause explosion. LOSS OF CONTROL CAN RESULT IN SEVERE Read owner's manual for instructions. INJURY OR DEATH. Do not incinerate, puncture or open. OPERATING TIRE PRESSURE: Set with tires cold •...
  • Page 12 WARNING UNDER Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 1P0-F816L-00 4XE-F1568-00...
  • Page 13 Certification of Compliance This ATV complies with applicable provisions of ANSI/SVIA 1-2010 and is subject to an approved ATV action plan submitted by YAMAHA and on file with the U.S. Consumer Product Safety Commission. YAMAHA MOTOR CORPORATION U.S.A. 6555 Katella Avenue, Cypress, California 90630-5101, U.S.A.

  • Page 14: Safety Information

    EBU17431 SAFETY INFORMATION ● EBU27234 Never allow a child under age 16 to operate an ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
  • Page 15 ● Always inspect your ATV each time you use it to ● Always follow proper procedures for climbing make sure it is in safe operating condition. Al- hills as described in this manual. Check the ter- ways follow the inspection and maintenance rain carefully before you start up any hill.
  • Page 16 steady speed when climbing a hill. If you stall or ● Always be sure there are no obstacles or people roll backwards, follow the special procedure for behind you when you operate in reverse. When braking described in this manual. Dismount on it is safe to proceed in reverse, go slowly.
  • Page 17 In the event of an accident tion. If necessary, contact your riding party or 1. If serious injuries are incurred, you may be local authorities to let them know where you safer staying next to your vehicle; it may are and what has happened. shield you from oncoming riders.
  • Page 18 This im- While you may find aftermarket products similar in proper position limits the freedom of movement design and quality to genuine Yamaha accesso- of the operator and may limit control ability, ries, recognize that some aftermarket accessories...
  • Page 19 ● Do not run engine outdoors where engine EWB00072 WARNING exhaust can be drawn into a building through openings such as windows and Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, doors. a deadly gas. Breathing carbon monoxide can FOR MORE INFORMATION ABOUT ATV SAFE- cause headaches, dizziness, drowsiness, nau- TY, call the Consumer Products Safety Commis-...

  • Page 20: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Rear shock absorber assembly spring preload adjusting 1. Radiator cap ring 2. Battery 2. Rear storage compartment and tool kit 3. Fuses 3. Fuel tank cap cover 4. Air filter case 4.

  • Page 21: Controls And Instruments

    EBU17712 Controls and instruments The ATV you have purchased may differ slightly from the figures shown in this manual. 1. Drive select lever 2. Rear brake lever 3. Handlebar switches 4. Rear brake fluid reservoir 5. Multi-function display 6. Front brake fluid reservoir 7.

  • Page 22: Instrument And Control Functions

    EBU17726 INSTRUMENT AND CONTROL FUNCTIONS EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU29911 Main switch The positions of the main switch are as follows: “ ” (on) All electrical systems are supplied with power. The headlights and taillight come on when the light 1.

  • Page 23: Indicator Lights And Warning Lights

    EBU26695 EBU17990 Low-range indicator light “ ” Indicator lights and warning lights This indicator light comes on when the transmis- sion is in the low-range position. EBU17980 High-range indicator light “ ” This indicator light comes on when the transmis- sion is in the high-range position.
  • Page 24 “ ” (on), or if the warning light 4-7 for an explanation of the self-diagnosis device.) remains on, have a Yamaha dealer check the elec- The electrical circuit of the warning light can be trical circuit.
  • Page 25 “ ” (on). If the switch is set to the “LOCK” position. warning light does not come on, have a Yamaha dealer check the electrical circuit. ● Due to the synchronizing mechanism in the dif- ferential gear case, the four-wheel-drive indica- ●...

  • Page 26: Multi-Function Display

    ● an hour meter (which shows the total time the EBU30493 Multi-function display engine has been running) ● a fuel meter ● a self-diagnosis device Odometer and tripmeter modes Pushing the “SELECT” button switches the display between the odometer mode “ODO” and the trip- meter modes “TRIP A”...
  • Page 27 CLOCK → HOUR → CLOCK ing indicator will start flashing. If this occurs, have a Yamaha dealer check the electrical circuit. To set the clock 1. Set the display to the clock mode.

  • Page 28: Handlebar Switches

    EBU18080 If the multi-function display indicates an error code, Engine stop switch “ ” note the code number, and then have a Yamaha Set this switch to “ ” before starting the engine. dealer check the vehicle. The engine stop switch controls the ignition and ECB00811 stops the engine when it is running.
  • Page 29 EBU18101 EBU18190 Start switch “ ” Override switch “OVERRIDE” Push this switch to crank the engine with the start- er. See the starting instructions on page 6-1 prior to starting the engine. EBU18154 Light switch “ /OFF” Set this switch to “ ”...
  • Page 30 In moving may cause the ATV to unexpectedly this case, take the ATV to a Yamaha dealer at the handle differently. This could distract the oper- first opportunity.
  • Page 31 ● “4WD” (four-wheel drive): Power is supplied to EBU30461 On-Command differential gear lock switch the rear and front wheels. “4WD”/“LOCK” To change from two-wheel drive to four-wheel EWB00131 drive, stop the ATV and push the switch in to the WARNING “4WD”...
  • Page 32 EWB00140 WARNING Always ride at a slow speed when the ATV is in differential gear lock, and allow extra time and distance for maneuvers. All wheels turn at the same speed when the dif- ferential gear is locked, so it takes more effort to turn the ATV.
  • Page 33 LOCK 1. Differential gear lock lever 1. On-Command differential gear lock switch “4WD”/“LOCK” 2. On-Command four-wheel-drive switch “2WD”/“4WD” To unlock the differential gear, stop the ATV and Stop the ATV, move the differential gear lock lever push the switch to the “4WD” position. to position (a), and then push the differential gear lock switch in to the “LOCK”...

  • Page 34: Throttle Lever

    ● Riding before the differential gear is properly en- gaged or disengaged (e.g., when the indicator and indicator light are flashing) will cause the ve- hicle speed to be limited until the differential gear is completely engaged or disengaged. ● When the ATV is in four-wheel-drive differential gear lock, the maximum traveling speed is limit- ed to 35 km/h (22 mi/h).

  • Page 35: Front Brake Lever

    crease the maximum engine power available EBU18391 Front brake lever and the maximum speed of the ATV, turn the The front brake lever is located on the right handle- adjusting screw in direction (b). Do not turn bar. To apply the front brake, pull the brake lever the adjusting screw out more than 12 mm toward the handlebar grip.

  • Page 36: Drive Select Lever

    EBU18611 Drive select lever The drive select lever is used to shift your ATV into the low-range, high-range, neutral, reverse and park positions. See the “Operating the drive select lever and driving in reverse” section on page 6-2 for the drive select lever operation. 1.

  • Page 37: Fuel

    To install the fuel tank cap Install the fuel tank cap by turning it clockwise until a click is heard, and then close the fuel tank cap cover. EBU18731 Fuel Make sure there is sufficient gasoline in the tank. EWB02521 WARNING Gasoline and gasoline vapors are extremely flammable.
  • Page 38 expands when it heats up, heat from the en- 3. Wipe up any spilled fuel immediately. gine or the sun can cause fuel to spill out of NOTICE: Immediately wipe off spilled fuel the fuel tank. with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts.

  • Page 39: Seat

    Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research oc- tane number of 91 or higher. If knocking (or ping- ing) occurs, use a gasoline of a different brand.

  • Page 40: Storage Compartments

    The front storage compartment is located at the front right side of the ATV. To access the storage compartment, remove the storage compartment cover by turning it counterclockwise. 1. Projection 2. Seat holder EBU27362 Storage compartments 1. Front storage compartment cover This ATV is equipped with two storage compart- ments.
  • Page 41 1. Front storage compartment 1. Rear storage compartment cover The rear storage compartment is located under the seat. (See page 4-18.) To access the storage com- partment, remove the storage compartment cover. 1. Rear storage compartment 4-20...
  • Page 42 When storing any documents in the storage com- partments, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartments. ●...

  • Page 43: Front Carrier

    Uneven adjustment can cause poor handling A special wrench can be obtained at a Yamaha and loss of stability, which could lead to an ac- dealer to make this adjustment.

  • Page 44: Auxiliary Dc Jack

    ● Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the 1. Special wrench shock absorber assembly to a Yamaha deal- er for any service. Spring preload setting: Minimum (soft): EBU19183 Auxiliary DC jack...
  • Page 45 Maximum rated capacity for the auxiliary DC jack: DC 12 V, 10 A (120 W) 5. Turn the accessory on. 6. When the auxiliary DC jack is not being used, cover it with the cap. ECB00120 NOTICE ● Do not use accessories requiring more than the above maximum capacity.
  • Page 46 EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 4-25...

  • Page 47: Pre-Operation Checks

    Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
  • Page 48 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-3, 8-46, 8-47, 8-49 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.

  • Page 49: Fuel

    They should move smoothly and there specified level. Add oil as necessary. (See page should be a firm feeling when the brakes are ap- 8-29.) plied. If not, have a Yamaha dealer check the brake system. EBU19631 Coolant Brake fluid level Make sure that the coolant is at the specified level.

  • Page 50: Throttle Lever

    (See page 8-46.) pressures to the following specifications: EBU19761 Throttle lever Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have a Yamaha dealer correct if necessary.
  • Page 51 Recommended tire pressure: Front 35.0 kPa (0.350 kgf/cm², 5.0 psi) Rear 30.0 kPa (0.300 kgf/cm², 4.4 psi) Minimum tire pressure: Front 32.0 kPa (0.320 kgf/cm², 4.6 psi) Rear 27.0 kPa (0.270 kgf/cm², 4.0 psi) Maximum tire seating pressure: 1. Low-pressure tire gauge Front 250 kPa (2.5 kgf/cm², 36 psi) Tire wear limit...

  • Page 52: Chassis Fasteners

    After extensive tests, only the tires listed below EBU19840 have been approved for this model by Yamaha Chassis fasteners Motor Manufacturing Corporation of America. Make sure that all nuts, bolts and screws are prop-...

  • Page 53: Instruments, Lights And Switches

    EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly. Correct if necessary.

  • Page 54: Operation

    The corresponding indicator light should come on. If the indicator light does not come ECB00150 NOTICE on, have a Yamaha dealer check the electrical circuit. See the “Engine break-in” section on page 6-4 prior to operating the engine for the first time.

  • Page 55: Operating The Drive Select Lever And Driving In Reverse

    ECB00163 NOTICE This model is equipped with an ignition circuit cut- For maximum engine life, never accelerate off system. The engine can be started under the hard when the engine is cold! following conditions: ● The drive select lever is in the neutral or park po- EBU20441 sition.
  • Page 56 reverse, make sure there are no people or ob- stacles behind you. When it is safe to proceed, go slowly. 1. Bring the ATV to a complete stop. 2. Apply the brake pedal. The drive select lever cannot be shifted into or from reverse or park without applying the brake pedal.

  • Page 57: Engine Break-In

    320 km (200 mi) or 20 should come on. If the indicator light does not hours. The various parts in the engine wear and come on, have a Yamaha dealer check the elec- polish themselves to the correct operating clear- trical circuit.

  • Page 58: Parking

    If any engine trouble should occur during the steep you could not walk up them easily. engine break-in period, immediately have a 1. Bring the ATV to a stop by applying the Yamaha dealer check the ATV. brakes. 2. Stop the engine. EBU27321 Parking 3.

  • Page 59: Accessories And Loading

    Yamaha ability to control the ATV. vehicles. Yamaha is not in a position to test the ● Do not mount an accessory where it could inter- products that these aftermarket companies pro- fere with your ability to control the ATV.
  • Page 60 bulky object attached to the handlebars which ● Never exceed the weight limits shown. An over- could make steering difficult, an accessory that loaded ATV can be unstable. limits your ability to move around on the seat, or MAXIMUM LOADING LIMIT one that limits your view.
  • Page 61 just the load in the trailer, if necessary, to reduce the weight on the hitch. If you are carrying cargo and towing a trailer, include the tongue weight in EWB00011 the maximum ATV load limit. WARNING ● Load cargo on the carriers as close to the center Indicates a hazardous situation which, if not of the ATV as possible.

  • Page 62: Riding Your Atv

    EBU21132 RIDING YOUR ATV...

  • Page 63: Getting To Know Your Atv

    Beginning and inexperienced operators should have read this Owner’s Manual completely and un- complete the certified training course offered by derstand the operation of the controls. Pay partic- Yamaha. They should then regularly practice the skills learned in the course and the operating tech-...
  • Page 64 niques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. Riding your ATV requires skills acquired through practice over a period of time. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV’s handling and performance characteristics.
  • Page 65 Apparel Always wear the following to reduce risk of injury in an accident: ● Approved motorcycle helmet that fits properly ● Eye protection (goggles, helmet face shield, or protective eyewear) ● Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
  • Page 66 1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots 5. Helmet Perform the pre-operation checks listed on page 5-1. Always follow the inspection and maintenance Do not operate after or while consuming alco- procedures and schedules described in the Own- hol or drugs.
  • Page 67 opening, even when the throttle lever is pushed to ● Do not exceed the maximum loading limits the maximum. Turning in the adjusting screw limits for the vehicle (see “MAXIMUM LOADING the maximum engine power available and de- LIMIT” in this section or vehicle labeling). ●...
  • Page 68 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during op- ATV loading limit (total weight of cargo, rider, eration; otherwise, they may contact the rear accessories, and tongue): wheels. WARNING! Removing even one hand 220.0 kg (485 lb) or foot can reduce your ability to control the Front carrier: ATV or could cause you to lose your balance...
  • Page 69 ATV should be during operation or after leaving the ATV, do not let genuine Yamaha or equivalent components de- brush, grass and other materials collect under the signed for use on this ATV and should be installed vehicle, near the muffler or exhaust pipe, or next to and used according to instructions.

  • Page 70: Be Careful Where You Ride

    To prevent burns, avoid touching the exhaust sys- BE CAREFUL WHERE YOU RIDE tem. Park the ATV in a place where pedestrians or This ATV is designed for off-road use only. children are not likely to touch it. WARNING! Paved surfaces may seriously af- fect handling and control of the ATV, and may cause the ATV to go out of control.
  • Page 71 WARNING! Never operate this ATV on any pub- lic street, road or highway, even a dirt or gravel one. You could collide with another vehicle. [EWB01031] Do not operate on rough, slippery, or loose terrain Know the terrain where you ride. Ride cautiously in until you have learned and practiced the skills nec- unfamiliar areas.
  • Page 72 When riding in an area where you might not easily Do not ride in areas posted “no trespassing”. be seen, such as desert terrain, mount a caution Do not ride on private property without getting per- flag on the ATV. DO NOT use the flag pole bracket mission.

  • Page 73: Turning Your Atv

    Select a large, flat area off-road to become familiar ECB00251 NOTICE with your ATV. Make sure that this area is free of obstacles and other riders. You should practice Do not shift from low-range to high-range or control of the throttle, brakes, shifting procedures, vice versa without coming to a complete stop.

  • Page 74: Climbing Uphill

    As you approach a curve, slow down and begin to may continue to go straight. If the ATV doesn’t turn the handlebars in the desired direction. As you turn, come to a stop and then practice the proce- do so, put your weight on the footboard to the out- dure again.
  • Page 75 ● Never operate the ATV on hills too steep for the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills. ● Always check the terrain carefully before you start up any hill.
  • Page 76 Do not attempt to climb hills until you have mas- If you are climbing a hill and you find that you have tered basic maneuvers on flat ground. Always not properly judged your ability to make it to the check the terrain carefully before attempting any top, you should turn the ATV around while you still hill.

  • Page 77: Riding Downhill

    the ATV around and remount, following the proce- ● Always check the terrain carefully before dure described Owner’s Manual. you start down any hill. WARNING! Stalling, rolling backwards or im- ● Never operate the ATV on hills too steep for properly dismounting while climbing a hill the ATV or for your abilities.

  • Page 78: Crossing A Slope

    Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. When this ATV is in “4WD”, all wheels (front and rear) are interconnected by the drive train.

  • Page 79: Crossing Through Shallow Water

    ● Shift your weight to the uphill side of the ATV. ● Never attempt to turn the ATV around on any hill until you have mastered the turning tech- nique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill.
  • Page 80 The ATV can be used to cross slow moving, shal- ability. WARNING! Wet brakes may have re- low water of up to a maximum of 35 cm (14 in) in duced stopping ability, which could cause loss depth. Before entering the water, choose your path of control.
  • Page 81 1. Air filter case check hose 1. Storage compartment drain plug 1. Air filter case check hose 1. Storage compartment drain plug 7-20...

  • Page 82: Riding Over Rough Terrain

    cident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may re- sult. SLIDING AND SKIDDING EWB01662 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.

  • Page 83: What To Do If

    If the rear wheels of your ATV start to slide side- ways, control can usually be regained (if there is With practice, over a period of time, skill at con- room to do so) by steering in the direction of the trolled sliding can be developed.

  • Page 84: What To Do

    WHAT TO DO... ● If your ATV is traversing a sloping surface: ● If your ATV doesn’t turn when you want it to: Be sure to ride with your weight positioned to- Bring the ATV to a stop and practice the turning wards the uphill side of the ATV to maintain maneuvers again.

  • Page 85: Periodic Maintenance And Adjustment

    The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.

  • Page 86: Owner's Manual And Tool Kit

    If you do not have the tools or experience required spective compartments under the seat. for a particular job, have a Yamaha dealer perform it for you. 1. Owner’s manual 2.

  • Page 87: Periodic Maintenance Chart For The Emission Control System

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. INITIAL...
  • Page 88 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours √ √ √ Spark arrester • Clean.

  • Page 89: General Maintenance And Lubrication Chart

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. INITIAL...
  • Page 90 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check operation and correct if necessary. • Check brake pedal free play and adjust if neces- √ √...
  • Page 91 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Shock absorber as- • Check operation and correct if necessary. √ √ √ 11 * semblies • Check for oil leakage and replace if necessary. •...
  • Page 92 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Change. √ √ Final gear oil • Check ATV for oil leakage, and correct if neces- sary. •...
  • Page 93 EBU23071 ● Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. ● Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.

  • Page 94: Removing And Installing Panels

    EWB00011 WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. EBU23090 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed.
  • Page 95 Panel B To remove the panel 1. Remove panel A. 2. Remove the front carrier by removing the bolts. 1. Panel A To install the panel Place the panel in the original position. 1. Carrier bolt (under the fenders) 8-11...
  • Page 96 3. Remove the quick fasteners, and then pull the panel upward to remove it. 1. Front carrier 2. Carrier bolt (upper) 1. Panel B 2. Quick fastener To install the panel 1. Place the panel in the original position, and then install the quick fasteners.
  • Page 97 Panel C To remove the panel 1. Remove the seat. (See page 4-18.) 2. Remove the quick fastener screws, and then pull the panel upward to remove it. 2. Install the front carrier by installing the bolts and tightening them to the specified torques. Tightening torques: Carrier bolt (upper): 34 Nm (3.4 m·kgf, 25 ft·lbf)
  • Page 98 1. Panel D 2. Install the seat. 2. Quick fastener screw Panels D and E To remove a panel 1. Remove panels A and C. 2. Remove the quick fastener screw and bolt, and then pull the panel upward to remove it. To ease removal of panel D, shift the drive select lever into the reverse position.
  • Page 99 To install a panel 1. Place the panel in the original position, and then install the bolt and quick fastener screw. 1. Panel E 2. Quick fastener screw 1. Bolt 2. Install panels A and C. 8-15...
  • Page 100 Panels F and G To remove a panel 1. Remove the panel bolts, footboard bolt, and footboard nut. 2. Pull the panel downward while pushing the projection. 1. Panel G 2. Footboard nut 3. Footboard bolt 4. Panel bolt 5. Projection To install a panel 1.
  • Page 101 Tightening torques: Panel bolt: 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Footboard nut: 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Panel H To remove the panel 1. Remove the seat. (See page 4-18.) 2. Remove the rear carrier by removing the bolts. 2.
  • Page 102 3. Remove the quick fasteners, and then push inward on the areas shown. 1. Rear carrier 2. Carrier bolt (upper) 1. Panel H 2. Quick fastener To install the panel 1. Place the panel in the original position, and then install the quick fasteners. 1.

  • Page 103: Removing The Radiator Grills

    EBU28671 Removing the radiator grills The radiator grills can be removed to access the radiator for cleaning. To remove a radiator grill Remove the quick fastener, pull the radiator grill outward at the top, and then pull it upward. 2. Install the rear carrier by installing the bolts and tightening them to the specified torques.

  • Page 104: Checking The Spark Plug

    2. Remove the spark plug as shown, with the EBU23213 Checking the spark plug spark plug wrench included in the owner’s tool The spark plug is an important engine component, kit. which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accor- dance with the periodic maintenance and lubrica-...
  • Page 105 If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.

  • Page 106: Engine Oil And Oil Filter Cartridge

    Tightening torque: Spark plug: If the engine was started before checking the oil 13 Nm (1.3 m·kgf, 9.4 ft·lbf) level, be sure to warm up the engine sufficiently, and then wait at least 10 minutes until the oil settles for an accurate reading. If a torque wrench is not available when installing 3.
  • Page 107 1. Engine oil dipstick 1. Maximum level mark 2. Minimum level mark 5. Insert the dipstick completely into the oil filler 6. If the engine oil is at or below the minimum hole, and then remove it again to check the oil level mark, add sufficient oil of the recom- level.
  • Page 108 1. Oil filter cartridge 2. Oil filter wrench 1. Engine oil drain bolt 2. Gasket An oil filter wrench is available at a nearby Yamaha dealer. 7. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.
  • Page 109 1. O-ring 1. Torque wrench Tightening torque: Oil filter cartridge: Make sure that the O-ring is properly seated. 17 Nm (1.7 m·kgf, 12 ft·lbf) 8. Install the new oil filter cartridge with an oil fil- 9. Install panel F. ter wrench, and then tighten it to the specified 10.

  • Page 110: Final Gear Oil

    The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have ECB00300 a Yamaha dealer check and repair the ATV. In ad- NOTICE dition, the final gear oil level must be checked and ●...
  • Page 111 2. Remove the final gear oil level check bolt and its gasket, and then check the oil level in the final gear case. The oil level should be at the brim of the check hole. 1. Final gear oil filler bolt 2.
  • Page 112 To change the final gear oil Tightening torque: 1. Place the ATV on a level surface. Final gear oil drain bolt: 2. Place an oil pan under the final gear case to 23 Nm (2.3 m·kgf, 17 ft·lbf) collect the used oil. 3.

  • Page 113: Differential Gear Oil

    2. Gasket leakage before each ride. If any leakage is found, 3. Differential gear oil have a Yamaha dealer check and repair the ATV. 4. Correct oil level In addition, the differential gear oil level must be 3. If the oil is below the brim of the filler hole, add...
  • Page 114 5. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) To change the differential gear oil 1. Place the ATV on a level surface. 2.

  • Page 115: Coolant

    8. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause. EBU23470 Coolant The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 116 If water has been added to the coolant, have a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. [ECB01011] 1. Maximum level mark 2.
  • Page 117 ● The radiator fan is automatically switched on or off according to the coolant temperature in the radiator. ● If the engine overheats, see page 8-68 for fur- ther instructions. EBU27767 To change the coolant EWB01890 WARNING 1. Footboard Wait for the engine and radiator to cool before 2.
  • Page 118 6. Remove the radiator cap. 1. Coolant drain bolt 2. Gasket 1. Radiator cap 7. Remove the coolant reservoir cap. 8. Disconnect the coolant reservoir hose on the coolant reservoir side, and then drain the cool- ant from the coolant reservoir. 1.
  • Page 119 13. Pour the recommended coolant into the reser- voir to the maximum level mark, and then in- stall the reservoir cap. NOTICE: antifreeze with distilled water only. Howev- er, if distilled water is not available, soft water may be used for refilling. Do not use hard water or salt water since they are harmful to the engine.
  • Page 120 1. Water pump air bleed bolt 1. V-belt cooling duct 2. Clamp screw 15. When coolant begins to flow out of the bolt 18. Loosen the cylinder head air bleed bolt, with- hole, tighten the water pump air bleed bolt to out removing it, to allow all of the air to escape the specified torque.
  • Page 121 24. Start the engine, and then check for coolant leakage. If any leakage is found, have a Yamaha dealer check the cooling system. 1. Cylinder head air bleed bolt 25. Install the V-belt cooling duct, and then tighten the clamp screw.
  • Page 122 1. Footboard nut Tightening torques: 2. Footboard bolt A 3. Footboard bolt B Footboard nut: 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Footboard bolt A: Tighten footboard bolts B in the order shown. 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Footboard bolt B: 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 27.

  • Page 123: Cleaning The Air Filter Element

    EBU27806 Cleaning the air filter element The air filter element should be cleaned at the in- tervals specified in the periodic maintenance and lubrication chart. Clean or, if necessary, replace the air filter element more frequently if you are riding in unusually wet or dusty areas. There are two check hoses at the bottom of the air filter case, which are located behind panels D and E.
  • Page 124 3. Remove the air filter case cover by unhooking the holders. 1. Air filter case cover holder 2. Air filter case cover 4. Remove the sponge material and the air filter mesh from the air filter case. 1. Sponge material 2.
  • Page 125 8. Check the sponge material and replace it if damaged. 9. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material. 8-41...

  • Page 126: Cleaning The Spark Arrester

    13. Install the panel. The air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar- eas. Each time the air filter element maintenance is performed, check the air inlet of the air filter case for obstructions.
  • Page 127 1. Tailpipe bolt 1. Tailpipe 2. Spark arrester 2. Remove the tailpipe by pulling it out of the 3. Gasket muffler, and then remove the gasket. 4. Check the gasket for damage, and replace it if 3. Tap the tailpipe lightly, and then use a wire necessary.

  • Page 128: V-Belt Case Drain Plug

    Tightening torque: Purging bolt: 27 Nm (2.7 m·kgf, 20 ft·lbf) EWB02380 WARNING Never run the engine in an enclosed area when purging the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monox- ide poisoning, possibly leading to death, and start a fire.

  • Page 129: Adjusting The Throttle Lever Free Play

    If water drains from the V-belt case after removing 3. To increase the throttle lever free play, turn the plug, have a Yamaha dealer check the ATV as the throttle lever free play adjusting bolt in di- the water may affect other engine parts.

  • Page 130: Valve Clearance

    Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- EBU27470 brication chart.

  • Page 131: Checking The Brake Fluid Level

    Front brake EBU29841 Checking the brake fluid level Before riding, check that the brake fluid is above the minimum level mark. Check the brake fluid lev- el with the top of the reservoir level. Replenish the brake fluid if necessary. Front brake 1.
  • Page 132 If the brake fluid level goes down suddenly, mance. have a Yamaha dealer check the cause before fur- ● Clean the filler cap before removing. Use ther riding.

  • Page 133: Changing The Brake Fluid

    Front brake EBU24292 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking.

  • Page 134: Adjusting The Brake Pedal Free Play

    EBU29072 Adjusting the brake pedal free play The brake pedal free play must be adjusted at the intervals specified in the periodic maintenance and lubrication chart. ● Always perform this maintenance completely in the following order whenever adjusting the rear brake.
  • Page 135 5. After adjusting, there should be slight play at If the correct free play cannot be obtained, have a the brake pedal cable joint as shown. If there Yamaha dealer adjust it. is no play, repeat steps 2 to 4. When adjusting the rear brake pedal free play: ●...

  • Page 136: Axle Boots

    If a cable is damaged or does not move 1. Front axle boot (each side) smoothly, have a Yamaha dealer check or replace Recommended lubricant: Yamaha cable lubricant or other suitable ca-...

  • Page 137: Checking And Lubricating The Front And Rear Brake Levers

    Front brake lever EWB02581 WARNING ● Inspect cables frequently and replace if dam- aged. Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could restrict the operation of controls and lead to an accident or injury.

  • Page 138: Checking And Lubricating The Brake Pedal

    Yamaha dealer check the wheel hub bear- ings. To access the brake pedal pivot, remove panel G.

  • Page 139: Lubricating The Rear Knuckle Pivots

    Lubricating the rear knuckle pivots Lubricating the steering shaft The rear knuckle pivots must be lubricated at the The steering shaft must be lubricated by a Yamaha intervals specified in the periodic maintenance and dealer at the intervals specified in the periodic lubrication chart.
  • Page 140 To remove the battery EWB02160 WARNING 1. Remove panel A. (See page 8-10.) 2. Remove the front carrier by removing the Battery electrolyte is poisonous and danger- ous, as it contains sulfuric acid, which can bolts. cause severe burns. Avoid contact with skin, eyes or clothing.
  • Page 141 3. Remove the battery holding plate by removing the nuts. 4. Disconnect the negative battery lead first, then the positive battery lead by removing their bolt. NOTICE: When removing the bat- tery, the main switch must be off, and the negative lead must be disconnected be- fore the positive lead.
  • Page 142 To charge the battery To install the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in Be sure the battery is fully charged. mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- 1.

  • Page 143: Replacing A Fuse

    4. Install the front carrier by installing the bolts EBU30520 Replacing a fuse and tightening them to the specified torques. Tightening torques: Carrier bolt (upper): 34 Nm (3.4 m·kgf, 25 ft·lbf) Carrier bolt (lower): 34 Nm (3.4 m·kgf, 25 ft·lbf) Carrier bolt (under the fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 5.
  • Page 144 ECB00640 NOTICE To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. WARNING! Always use a fuse of the spec- ified rating, and never use a substitute ob- ject in place of the proper fuse.

  • Page 145: Replacing A Headlight Bulb

    YFM550PHE 40.0 A 3. Turn the key to “ ” (on) and turn on the elec- trical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 8-61...
  • Page 146 4. Unhook the headlight bulb holder, and then remove the burnt-out bulb. 1. Headlight bulb cover 3. Disconnect the headlight coupler. 1. Headlight bulb holder 2. Headlight bulb 5. Place a new headlight bulb into position, and then secure it with the bulb holder. NOTICE: Do not touch the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the luminos-...

  • Page 147: Adjusting A Headlight Beam

    Adjusting a headlight beam 1. Remove panel H. (See page 8-10.) ECB00690 2. Remove the tail/brake light bulb holder (to- NOTICE gether with the bulb) by turning it counter- It is advisable to have a Yamaha dealer make clockwise. this adjustment. 8-63...

  • Page 148: Removing A Wheel

    4. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 5. Install the bulb holder (together with the bulb) by turning it clockwise. 6. Install the panel. EBU25651 Removing a wheel 1.

  • Page 149: Installing A Wheel

    EBU25701 Installing a wheel 1. Place the ATV on a level surface. 2. Install the wheel and the nuts. ● The arrow mark on the tire must point toward the rotating direction of the wheel. ● Tapered nuts are used for both the front and rear wheels.

  • Page 150: Troubleshooting

    However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.

  • Page 151: Troubleshooting Charts

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the compression. 4. Compression The engine does not start. There is compression.
  • Page 152 Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec- ommended coolant as soon as possible.

  • Page 153: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE tion of wheel bearings, brakes, transmis- EBU25881 Cleaning sion seals and electrical devices. Many Frequent, thorough cleaning of your ATV will not expensive repair bills have resulted from only enhance its appearance but will improve its improper high-pressure detergent applica- general performance and extend the useful life of tions such as those available in coin-oper-...

  • Page 154: Storage

    3. Perform the following steps to protect the cyl- EBU27261 Storage inder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark Short-term plug. Always store your ATV in a cool, dry place and, if b. Pour a teaspoonful of engine oil into the necessary, protect it against dust with a porous spark plug bore.
  • Page 155 6. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 7. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an exces- sively cold or warm place [less than 0 °C (30 °F) or more than 30 °C (90 °F)].

  • Page 156: Specifications

    EBU25961 SPECIFICATIONS Dimensions: Compression ratio: 9.30 : 1 Overall length: Starting system: 2065 mm (81.3 in) Electric starter Overall width: Lubrication system: 1180 mm (46.5 in) Wet sump Overall height: Engine oil: 1240 mm (48.8 in) Seat height: Recommended brand: 905 mm (35.6 in) YAMALUBE Wheelbase:...
  • Page 157 Engine oil quantity: Fuel injection: Without oil filter cartridge replacement: Throttle body: 2.00 L (2.11 US qt, 1.76 Imp.qt) ID mark: With oil filter cartridge replacement: 28P7 10 2.10 L (2.22 US qt, 1.85 Imp.qt) Spark plug (s): Final gear oil: Manufacturer/model: Type: NGK/LMAR6A-9...
  • Page 158 Chassis: Minimum: Front: Frame type: 32.0 kPa (0.320 kgf/cm², 4.6 psi) Steel tube frame Rear: Caster angle: 27.0 kPa (0.270 kgf/cm², 4.0 psi) 5.0 ° Front wheel: Trail: 26.0 mm (1.02 in) Wheel type: Front tire: Panel wheel Rim size: Type: 12 x 6.0AT Tubeless...
  • Page 159 Front suspension: Tail/brake light: 12 V, 5.0/21.0 W × 1 Type: Meter lighting: Double wishbone EL (Electroluminescent) Spring/shock absorber type: Neutral indicator light: Coil spring/oil damper Wheel travel: Reverse indicator light: 180 mm (7.1 in) Rear suspension: Coolant temperature warning light: Type: Double wishbone Engine trouble warning light:...
  • Page 160 EPS fuse: YFM550PE 40.0 A YFM550PHE 40.0 A Headlight fuse: 10.0 A Signaling system fuse: 5.0 A Ignition fuse: 10.0 A Auxiliary DC jack fuse: 10.0 A Four-wheel-drive motor fuse: 10.0 A Radiator fan fuse: 20.0 A 10-5...

  • Page 161: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 162 Model label ment Canada. The model label is affixed at the location in the il- lustration. Record the information on this label in the space provided. This information will be need- ed when ordering spare parts from a Yamaha deal- 11-2...
  • Page 163 1. Vehicle Emission Control Information label 11-3...

  • Page 164: Noise Regulation

    EBU26060 Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ul- timate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 165: Maintenance Record

    EBU26080 Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required.

  • Page 166: Yamaha Motor Corporation, U.s.a. Atv Limited Warranty

    (6) months from the date of purchase. appropriate owner’s manual; YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO 2. Give notice to an authorized Yamaha ATV dealer OTHER WARRANTY OF ANY KIND, EXPRESSED OR of any and all apparent defects within ten (10) days DURING THE PERIOD OF WARRANTY any authorized IMPLIED.
  • Page 167 Attention: Warranty Department 3. Each Yamaha ATV dealer is held responsible for his setup, service and war- ranty repair work. This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

  • Page 168: Yamaha Extended Service (Y.e.s.)

    Yamaha people who handle your warranty – and it Y.E.S. coverage is transferable to a new owner if you shows in the comprehensive coverage benefits. There sell or trade in your ATV. That can make your Yamaha are no mileage limitations. Coverage isn’t limited to much more valuable! “moving par ts”...
  • Page 169 Y.E.S. costs less within the first 90 days after you buy your Yamaha. See your dealer today! A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primar y ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
  • Page 170 INDEX Drive select lever and driving in reverse ......6-2 Drive select lever safety system cable, adjusting ..8-46 Accessories and loading ..........6-6 Accessories, auxiliary jack ........... 4-23 Air filter element, cleaning ..........8-39 Engine break-in .............. 6-4 Axle boots ..............8-52 Engine oil ...............
  • Page 171 Seat ................4-18 Shock absorber assemblies, adjusting the front and Label locations ............... 1-1 rear ................4-22 Light switch ..............4-8 Spark arrester, cleaning ..........8-42 Low-range indicator light ..........4-2 Spark plug, checking ........... 8-20 Specifications ............... 10-1 Main switch ..............4-1 Speed limiter ..............
  • Page 173 EBU30392 For your best ownership experience, think Genuine Yamaha! Genuine Yamaha Parts – Genuine Yamaha replacement parts are the exact same parts as the ones originally equipped on your vehicle, providing you with the performance and durability you have come to expect.
  • Page 174 EBU26152 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER ALWAYS operate: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough...

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