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Yamaha GRIZZLY 550 FI YFM5FGY Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
LIRE ATTENTIVEMENT CE MANUEL!
Il comprend d'importantes informations de sécurité.
¡LEA ESTE MANUAL ATENTAMENTE!
Contiene indicaciones importantes acerca de la seguridad.
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
YFM5FGY/YFM5FGPY
OWNER'S MANUAL
28P-28199-60

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Summary of Contents for Yamaha GRIZZLY 550 FI YFM5FGY

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. LIRE ATTENTIVEMENT CE MANUEL! Il comprend d’importantes informations de sécurité. ¡LEA ESTE MANUAL ATENTAMENTE! Contiene indicaciones importantes acerca de la seguridad. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM5FGY/YFM5FGPY 28P-28199-60...
  • Page 2 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIMÉ SUR PAPIER RECYCLÉ 2008.04-1.1×1 CR IMPRESO EN PAPEL RECICLADO (E,F,S)
  • Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM5FGY/YFM5FGPY 28P-28199-60-E0...
  • Page 4 Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. EC Declaration of Conformity conforming to Directive 98 / 37 /EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM550FWA (YFM5FG) (JY4AJ39W080000001~)
  • Page 5 EC Declaration of Conformity conforming to Directive 98 / 37 /EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM550FWA (YFM5FGP) (JY4AJ41W080000001~) ( Make, model ) to which this declaration applies, conforms to the essential health...
  • Page 6 Congratulations on your purchase of the Yamaha YFM5FGY/YFM5FGPY. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing ma- chines. 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 7 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 8 IMPORTANT NOTICE EBU17370 Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for use on UNPAVED surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway.
  • Page 9: Table Of Contents

    EBU17420 TABLE OF CONTENTS SAFETY INFORMATION ......1-1 Storage compartments ......4-18 Front carrier ..........4-21 LOCATION OF THE WARNING AND Rear carrier ..........4-21 SPECIFICATION LABELS ......2-1 Adjusting the front and rear shock absorber assemblies .......4-21 DESCRIPTION ..........3-1 Auxiliary DC jack ........4-22 Left view ............
  • Page 10 Operating the drive select lever and Periodic maintenance chart for driving in reverse ........6-2 the emission control system .....8-3 Engine break-in .......... 6-4 General maintenance and lubrication Parking ............6-5 chart ............8-4 Parking on a slope ........6-5 Removing and installing panels ....8-8 Accessories and loading ......
  • Page 11 Checking and lubricating the cables ..8-52 Checking and lubricating the front and rear brake levers ........8-52 Checking and lubricating the brake pedal ............8-53 Checking the wheel hub bearings .... 8-53 Checking the stabilizer bushes ....8-53 Lubricating the rear knuckle pivots ... 8-54 Lubricating the steering shaft ....
  • Page 12: Safety Information

    EBU17430 SAFETY INFORMATION EBU27250 Never carry a passenger on an ATV. Always avoid operating an ATV on any paved AN ATV IS NOT A TOY AND CAN BE HAZARD- surfaces, including sidewalks, driveways, park- OUS TO OPERATE. ing lots and paved streets. An ATV handles differently from other vehicles, in- Never operate an ATV on any paved street, cluding motorcycles and cars.
  • Page 13 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 14 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 15 nition such as the pilot lights of water heat- ers and clothes dryers. Gasoline can catch fire and you could be burned. When transporting the ATV in another vehi- cle, be sure it is kept upright. Otherwise, fuel may leak out of the fuel tank. Gasoline is poisonous.
  • Page 16: Location Of The Warning And Specification Labels

    EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 17 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. 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. For Europe and Oceania...
  • Page 18 For Europe...
  • Page 19 For Europe...
  • Page 20 For Europe...
  • Page 21 For Oceania...
  • Page 22 For Oceania...
  • Page 23: Description

    EBU17680 DESCRIPTION EBU17690 EBU17700 Left view Right view 1. Radiator cap 1. Rear shock absorber assembly spring preload adjusting ring 2. Battery 2. Rear storage compartment and tool kit 3. Fuses 3. Fuel tank cap cover 4. Air filter case 4.
  • Page 24: 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. Horn switch 5. Rear brake fluid reservoir 6. Multifunction display 7.
  • Page 25: Instrument And Control Functions

    EBU17732 INSTRUMENT AND CONTROL FUNCTIONS EBU17760 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.
  • Page 26: Indicator Lights And Warning Lights

    3. High-range indicator light “H” checked by turning the key to “ON”. If the warning 4. Neutral indicator light “N” light does not come on, have a Yamaha dealer 5. Reverse indicator light “R” check the electrical circuit. 6. Park indicator light “P”...
  • Page 27 The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning EBU27280 light does not come on, have a Yamaha dealer Engine trouble warning light “ ” check the electrical circuit.
  • Page 28 EBU17961 EBU17980 On-Command four-wheel-drive/differential High-range indicator light “ ” gear lock indicator “ ”/“ ” This indicator light comes on when the transmis- The On-Command four-wheel-drive indicator “ ” sion is in the high-range position. comes on when the On-Command four-wheel- EBU17990 drive switch is set to the “4WD”...
  • Page 29: Multifunction Display

    EBU27293 a clock Multifunction display an hour meter (which shows the total time the 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 “A”...
  • Page 30 1. Set the display to the clock mode. display segments and fuel level warning indicator 2. Push the “SELECT” button and “RESET” but- will start flashing. If this occurs, have a Yamaha ton together for at least three seconds. dealer check the electrical circuit.
  • Page 31: Handlebar Switches

    If the multifunction display indicates such an error EBU18080 code, note the code number, and then have a Engine stop switch “ ” Yamaha dealer check the vehicle. Set this switch to “ ” before starting the engine. ECB00810 The engine stop switch controls the ignition and NOTICE stops the engine when it is running.
  • Page 32 EBU18100 EBU18190 Start switch “ ” Override switch “OVERRIDE” Push this switch to crank the engine with the start- ECB00050 NOTICE See the starting instructions on page 6-1 prior to starting the engine. EBU18151 Light switch “ /OFF” Set this switch to “ ”...
  • Page 33 In To change from two-wheel drive to four-wheel this case, take the ATV to a Yamaha dealer at the drive, stop the ATV and push the switch in to the first opportunity.
  • Page 34 EBU18254 On-Command differential gear lock switch “4WD”/“LOCK” This ATV is equipped with a switch allowing you to lock the differential gear when in four-wheel drive. Select the appropriate switch position according to the terrain and the conditions. “4WD” (four-wheel drive): Power is supplied to the rear and front wheels.
  • Page 35 To lock the differential gear in four-wheel drive, make sure the On-Command four-wheel-drive switch is pushed in to the “4WD” position. LOCK 1. On-Command differential gear lock switch “4WD”/“LOCK” To release the differential gear lock, stop the ATV and push the switch to the “4WD” position. 1.
  • Page 36: Throttle Lever

    pectedly. This could distract the operator and Riding before the differential gear lock is proper- increase the risk of losing control and causing ly engaged (e.g., when the indicator and indica- an accident. tor light are flashing) will cause the engine speed to be limited until engagement is complete.
  • Page 37: Speed Limiter

    If the throttle does not work smoothly, check for the cause. Correct the problem be- 1. Locknut fore riding the ATV or consult a Yamaha dealer. 2. Adjusting screw 3. No more than 12 mm (0.47 in) 4-13...
  • Page 38: Front Brake Lever

    3. Tighten the locknut. EWB00240 WARNING Improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation. You could lose control, have an accident or be injured. Do not turn the adjusting screw out more than 12 mm (0.47 in) or the throttle cable could be dam- aged.
  • Page 39: 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 40: 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. EBU18752 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.
  • Page 41: Seat

    Be careful not to spill fuel, especially on the Recommended fuel: engine or exhaust pipe which can cause a UNLEADED GASOLINE ONLY fire and severe injury. Wipe up any spilled For Europe: Regular unleaded gasoline only fuel immediately. with a research octane number of 91 or high- Do not refuel right after the engine has been running and is still very hot.
  • Page 42: Storage Compartments

    To install the seat The front storage compartment is located at the Insert the projections on the front of the seat into front right side of the ATV. To access the storage the seat holders and push down on the seat at the compartment, remove the storage compartment rear.
  • Page 43 1. Front storage compartment 1. Rear storage compartment cover The rear storage compartment is located under the seat. (See page 4-17.) To access the storage com- partment, remove the storage compartment cover. 1. Rear storage compartment 4-19...
  • Page 44 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. ECB00830 NOTICE Do not store metal or sharply edged objects,...
  • Page 45: Front Carrier

    (485 lb) for the ATV. 2. Position indicator EBU19142 Adjusting the front and rear shock ab- A special wrench can be obtained at a Yamaha sorber assemblies dealer to make this adjustment. The spring preload can be adjusted to suit the rid- er’s weight and the riding conditions.
  • Page 46: Auxiliary Dc Jack

    EWB00400 WARNING Always adjust the shock absorber assemblies on the left and right side to the same setting. Uneven adjustment can cause poor handling and loss of stability, which could lead to an ac- cident. EBU19181 Auxiliary DC jack The auxiliary DC jack is located at the front right 1.
  • Page 47 Maximum rated capacity for the auxiliary DC jack: DC 12 V, 10 A (120 W) 4. 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. This may overload the circuit and cause the fuse to 1.
  • Page 48: Pre-Operation Checks

    Manual. Failure to inspect increases the possibility of an accident or equipment damage. The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
  • Page 49 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 5-4, 8-44, 8-46, 8-48 • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.
  • Page 50: Fuel

    EBU19540 EBU19600 Fuel Differential gear oil Make sure that there is sufficient fuel in the tank. Make sure that the differential gear oil is at the (See page 4-16.) specified level. Add oil as necessary. (See page EWB00520 8-29.) WARNING EBU19630 Do not overfill the fuel tank.
  • Page 51: Front And Rear Brakes

    Do not ride the ATV if you find any prob- plied. If not, have a Yamaha dealer check the lem with the brakes or you could lose braking brake system.
  • Page 52: Tires

    Pay attention to the following. Size: The tires listed below have been approved AT25 x 10-12 by Yamaha Motor Co., Ltd. for this model. Type: Other tire combinations are not recommend- Tubeless The tires should be set to the recommended...
  • Page 53: Measuring The Tire Pressure

    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) • Use no more than the following pressures when seating the tire beads. Maximum tire seating pressure: Front: 250 kPa (2.5 kgf/cm², 36 psi) Rear: 250 kPa (2.5 kgf/cm², 36 psi) 1.
  • Page 54: Tire Wear Limit

    EBU19830 Tire wear limit Replace the tire when the tire groove decreases to 3 mm (0.12 in). 1. Tire wear limit EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. EBU19850 Instruments, lights and switches Check that all instruments, lights and switches are working properly.
  • Page 55: Operation

    The coolant temperature warning light and en- accident or injury. If there is a control or func- gine trouble warning light should come on, tion you do not understand, ask your Yamaha then go off. dealer. The EPS warning light should come on, then go off when the engine is started.
  • Page 56: Operating The Drive Select Lever And Driving In Reverse

    ECB00160 NOTICE This model is equipped with an ignition circuit cut- For maximum engine life, always warm the en- off system. The engine can be started under the gine up before starting off. Never accelerate following conditions: hard when the engine is cold! The drive select lever is in the neutral or park po- sition.
  • Page 57 The drive select lever cannot be shifted into or from should come on. If the indicator light does not reverse or park without applying the brake pedal. come on, have a Yamaha dealer check the elec- trical circuit. 1. Bring the ATV to a complete stop.
  • Page 58: Engine Break-In

    Due to the synchronizing mechanism in the en- There is never a more important period in the life of gine, the indicator light may not come on until the your engine than the first 320 km (200 mi) or 20 ATV starts moving.
  • Page 59: Parking

    2. Stop the engine. If any engine trouble should occur during the 3. With the brake pedal applied, shift the drive engine break-in period, immediately have a Yamaha dealer check the ATV. select lever to the park position. EBU27321 Parking When parking the ATV, stop the engine, and shift the drive select lever into the park position.
  • Page 60 However, You must use common sense and good judgment it is not possible for Yamaha to test all non- when carrying cargo or towing a trailer. Keep the Yamaha accessories, nor control over their qual- following points in mind: ity or suitability.
  • Page 61 the weight on the hitch. If you are carrying cargo MAXIMUM LOADING LIMIT and towing a trailer, include the tongue weight in ATV loading limit (total weight of rider, cargo, the maximum ATV load limit. accessories, and tongue): Load cargo on the carriers as close to the center 220.0 kg (485 lb) of the ATV as possible.
  • Page 62 EWB00820 WARNING Never exceed the stated load capacity for this ATV. Overloading this ATV or carrying or tow- ing cargo improperly could cause changes in ATV handling which could lead to an accident. Cargo should be properly distributed and se- curely attached.
  • Page 63: Riding Your Atv

    EBU21141 RIDING YOUR ATV...
  • Page 64: Getting To Know Your Atv

    EBU27413 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV Beginners should get training from a certified in- This ATV is mainly for utility use, but may also be structor. used for recreation. This section, Riding your ATV, Become familiar with this ATV at slow speeds first, provides general ATV riding instructions for recre- even if you are an experienced operator.
  • Page 65 Not recommended for children under 16 years This ATV is designed to carry operator and car- of age. go only – passengers prohibited. EWB01390 EWB01400 WARNING WARNING A child under 16 should never operate an ATV Never carry a passenger. The long seat is to al- with engine size greater than 90 cc.
  • Page 66 Apparel Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants 1. Protective clothing 2. Goggles 3. Gloves 4. Boots 5. Helmet...
  • Page 67 EWB01410 WARNING Never operate this ATV without wearing an ap- proved motorcycle helmet, eye protection and protective clothing. Operating without an ap- proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and in- creases your chances of a severe injury in the event of an accident.
  • Page 68 in the Owner’s Manual. Failure to inspect the Speed limiter ATV before operating or failure to properly For riders less experienced with this model, the maintain the ATV increases the possibility of throttle lever housing is equipped with a speed lim- an accident or equipment damage.
  • Page 69 Loading and accessories EWB01460 WARNING Use extra caution when riding the ATV with addi- tional loads, such as accessories or cargo. The Never exceed the stated load capacity for ATV’s handling may be adversely affected. Re- this ATV. duce your speed when adding additional loads. Cargo should be properly distributed and se- curely attached.
  • Page 70 All parts and tact with the rear wheels, which could injure accessories added to this ATV should be gen- you or cause an accident. uine Yamaha or equivalent components de- signed for use on this ATV and should be...
  • Page 71: Be Careful Where You Ride

    installed and used according to instructions. Improper installation of accessories or modifi- cation of this ATV may cause changes in han- dling which in some situations could lead to an accident. If you have questions, consult an au- thorized ATV dealer. Exhaust system The exhaust system on the ATV is very hot during and following operation.
  • Page 72 EWB01520 WARNING Never operate this ATV on any paved street, paved road or motorway. You can collide with another vehicle. In many areas, it is illegal to operate ATVs on public streets, roads and highways. While riding on unpaved public streets or roads may be legal in your area, such operation can in- crease the risk of collision with other vehicles.
  • Page 73 EWB01530 ATV on such terrain. Failure to use extra care WARNING when operating on excessively rough, slippery or loose terrain could cause loss of traction or Go slowly and be extra careful when operating ATV control, which could result in an accident, on unfamiliar terrain.
  • Page 74 Select a large, flat, unpaved area to become famil- iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice EWB01550 control of the throttle, brakes, shifting procedures, WARNING and turning techniques in this area before trying Always mount a caution flag on the ATV to more difficult terrain.
  • Page 75: Turning Your Atv

    With the engine idling, shift the drive select lever wheels also turn together at the same speed. into the low-range position or the high-range posi- Therefore, unless the wheel on the inside of the tion. Apply the throttle slowly and smoothly. The turn is allowed to slip or lose some traction, the centrifugal clutch will engage and you will start to ATV will resist turning.
  • Page 76: Climbing Uphill

    Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body move- ments, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside.
  • Page 77 EWB01580 Never go over the top of any hill at high WARNING speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side Never operate the ATV on hills too steep for the of the hill. ATV or for your abilities.
  • Page 78 EWB01600 WARNING 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. Avoid crossing the side of a steep hill if possible.
  • Page 79: Riding Downhill

    could come off the ground. The ATV could easily tip over backwards. Apply both the front and rear brakes gradually, or dismount the ATV immediate- ly on the uphill side. EWB01801 WARNING Use the proper gear and maintain a steady speed when climbing a hill.
  • Page 80: Crossing A Slope

    When this ATV is in 4WD or 4WD-LOCK, all Avoid going down a hill at an angle that wheels (front and rear) are interconnected by the would cause the ATV to lean sharply to one drive train. This means that applying either the side.
  • Page 81: Crossing Through Shallow Water

    to cross a sloping surface. Avoid slopes with slip- Shift your weight to the uphill side of the pery surfaces or rough terrain that may upset your ATV. balance. As you travel across a slope, lean your body in the uphill direction.
  • Page 82 EWB01640 Test your brakes after leaving the water. Do not WARNING continue to ride your ATV without verifying that you have regained proper braking ability. Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual.
  • Page 83 1. Air filter case check hose 1. Storage compartment drain plug 1. Air filter case check hose 1. Storage compartment drain plug 7-21...
  • Page 84: Riding Over Rough Terrain

    you go over obstacles, always follow proper procedures as described in the Owner’s Manu- SLIDING AND SKIDDING Care should be used when riding on loose or slip- pery surfaces since the ATV may slide. If unex- pected and uncorrected, sliding could lead to an accident.
  • Page 85: What To Do If

    If the rear wheels of your ATV start to slide side- EWB01661 WARNING ways, control can usually be regained (if there is room to do so) by steering in the direction of the Learn to safely control skidding or sliding by slide.
  • Page 86 If your ATV starts to slide sideways: BRAKES FOR PROPER OPERATION when Steer in the direction of the slide if you have the you come out of the water. Do not continue to room. Applying the brakes or accelerating is not ride your ATV until you have regained adequate recommended until you have corrected the braking ability.
  • Page 87: Periodic Maintenance And Minor Repair

    EBU28781 PERIODIC MAINTENANCE AND MINOR REPAIR EBU21670 otherwise specified. Have a Yamaha dealer perform the service if you are not familiar with Safety is an obligation of the owner. Periodic in- maintenance work. spection, adjustment and lubrication will keep your...
  • Page 88 If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EWB01850 WARNING...
  • Page 89: 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.
  • Page 90: General Maintenance And Lubrication Chart

    EBU21864 General maintenance and lubrication chart INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element • Clean and replace if necessary. dusty areas) •...
  • Page 91 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours • Check for looseness or damage, and replace if √ √ √ √ Wheel hub bearings necessary. • Check for wear, cracks or other damage, and re- √...
  • 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. √ √ Differential gear oil • Check ATV for oil leakage, and correct if neces- sary. •...
  • Page 93 EBU23070 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 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

    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. 1. Panel E 2.
  • 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)
  • Page 96 1. Carrier bolt (top) 1. Front carrier stay bolt 3. Remove the front carrier stays by removing 4. Remove the quick fasteners, and then pull the the bolts. panel upward to remove it. 1. Front carrier stay 8-10...
  • Page 97 1. Panel B 2. Install the front carrier stays by installing the 2. Quick fastener bolts and tightening them to the specified torque. To install the panel 1. Place the panel in the original position, and Tightening torque: then install the quick fasteners. Front carrier stay bolt: 34 Nm (3.4 m·kgf, 24 ft·lbf) 3.
  • Page 98: Panel B

    Tightening torques: Carrier bolt (top): 26 Nm (2.6 m·kgf, 19 ft·lbf) Carrier bolt (under the fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 4. Install panel A. Panel C To remove the panel 1. Remove the seat. (See page 4-17.) 1. Panel C 2.
  • Page 99 1. Panel D 2. Install panel A. 2. Quick fastener screw 3. Install the seat. Panels D and E To remove one of the panels 1. Remove panel 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 100 To install one of the panels 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 panel C. 8-14...
  • Page 101 Panel F To remove the panel Pull outward on the areas shown. Panels G and H To remove one of the panels Remove the nut and bolts, and then pull the panel 1. Panel F downward while pushing the projection. To install the panel Place the panel in the original position.
  • Page 102 1. Panel G 1. Panel H 2. Nut 2. Nut 3. Bolt 3. Bolt 4. Projection 4. Projection To install one of the panels Place the panel in the original position, and then in- stall the bolts and nut. 8-16...
  • Page 103 2. Remove the rear carrier by removing the bolts. 1. Carrier bolt (under the fenders) Panel I To remove the panel 1. Carrier bolt (upper) 1. Remove the seat. (See page 4-17.) 8-17...
  • Page 104: Quick Fastener

    1. Panel I 1. Carrier bolt (lower) 2. Quick fastener 3. Remove the quick fasteners, and then push inward on the areas shown. To install the panel 1. Place the panel in the original position, and then install the quick fasteners. 8-18...
  • Page 105: 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 106: Checking The Spark Plug

    If the spark plug shows a distinctly different color, 1. Spark plug cap the engine could be operating improperly. Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 8-20...
  • Page 107: Tightening Torque

    2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/LMAR6A-9 To install the spark plug 1. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap to specification.
  • Page 108: Engine Oil And Oil Filter Cartridge

    4. Remove the dipstick, and then wipe it off with a clean rag. If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.
  • Page 109 ECB00850 NOTICE Be sure the engine oil is at the correct level, otherwise engine damage may result. To change the engine oil (with or without oil fil- ter cartridge replacement) 1. Place the ATV on a level surface. 2. Remove panel F. (See page 8-8.) 3.
  • Page 110 1. Oil filter cartridge 2. Oil filter wrench 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 111 11. Refill with the specified amount of the recom- mended engine oil, and then insert the dip- stick completely into the oil filler hole. Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.00 L (2.11 US qt, 1.76 Imp.qt) With oil filter cartridge replacement: 2.10 L (2.22 US qt, 1.85 Imp.qt) 1.
  • Page 112: Final Gear Oil

    The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In ad- dition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 113 1. Final gear oil 1. Final gear oil filler bolt 2. Final gear oil level check bolt 4. Install the oil level check bolt and oil filler bolt, 3. Correct oil level and then tighten them to the specified torques. 3.
  • Page 114 3. Remove the final gear oil filler bolt, final gear oil level check bolt, and the final gear oil drain bolt to drain the oil from the final gear case. 1. Final gear oil 2. Final gear oil level check bolt 3.
  • Page 115: Differential Gear Oil

    The differential gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the differential gear oil level must be 1. Differential gear oil checked and the oil changed as follows at the in- 2.
  • Page 116 Tightening torque: Tightening torque: Differential gear oil filler bolt: Differential gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 5. Refill with the recommended differential gear To change the differential gear oil oil to the brim of the filler hole as shown. 1.
  • Page 117: Coolant

    ECB00410 NOTICE The coolant level must be checked on a cold en- Be sure no foreign material enters the differen- gine since the level varies with engine tempera- tial gear case. ture. 6. Install the oil filler bolt, and then tighten it to the 2.
  • Page 118 If water has been added to the coolant, have a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, oth- erwise the effectiveness of the coolant will be reduced.
  • Page 119 EBU27761 To change the coolant EWB01890 WARNING Wait for the engine and radiator to cool before removing the radiator cap. You could be burned by hot fluid and steam blown out under pressure. Always place a thick rag over the cap when opening.
  • Page 120 1. Radiator cap 1. Coolant reservoir hose 6. Remove the coolant reservoir cap. 8. After draining the coolant, thoroughly flush the 7. Disconnect the hose on the coolant reservoir cooling system with clean tap water. side, and then drain the coolant from the cool- 9.
  • Page 121 12. Pour the recommended coolant into the reser- If water has been added to the coolant, have voir to the maximum level mark, and then in- a Yamaha dealer check the antifreeze con- stall the reservoir cap. tent of the coolant as soon as possible, oth-...
  • Page 122 Tightening torque: Water pump air bleed bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 15. Remove panel E. (See page 8-8.) 16. Loosen the clamp screw, and then remove the V-belt cooling duct. 1. Cylinder head air bleed bolt 18. When coolant begins to flow out of the bolt hole, tighten the cylinder head air bleed bolt to the specified torque.
  • Page 123: Cleaning The Air Filter Element

    23. Start the engine, and then check for coolant leakage. If any leakage is found, have a Yamaha dealer check the cooling system. 24. Install the V-belt cooling duct, and then tighten the clamp screw.
  • Page 124 1. Air filter case check hose 1. Air filter case cover holder 2. Air filter case cover 1. Place the ATV on a level surface. 4. Remove the sponge material and the mesh 2. Remove panel C. (See page 8-8.) from the air filter case.
  • Page 125 8. Check the sponge material and replace it if oughly, in solvent. damaged. EWB01940 9. Apply Yamaha foam air filter oil or other qual- WARNING ity foam air filter oil to the sponge material. Always use parts cleaning solvent to clean the sponge material.
  • Page 126 11. Insert the projections on the air filter case cov- er into the holders on the air filter case, and then install the air filter case cover by hooking the holders onto the cover. 1. Hose (for all models) 2. Hose (for EPS model only) 13.
  • Page 127: Cleaning The Spark Arrester

    ECB00760 NOTICE Make sure that the air filter element is prop- erly seated in the air filter case. Never operate the engine with the air filter el- ement removed. This will allow unfiltered air to enter the engine, causing rapid engine wear and possible engine damage.
  • Page 128 1. Tailpipe 1. Purging bolt 2. Spark arrester 7. Start the engine and rev it up approximately 3. Gasket twenty times while momentarily creating ex- 4. Install the gasket, and then insert the tailpipe haust system back pressure by blocking the into the muffler and align the bolt holes.
  • Page 129: V-Belt Case Drain Plug

    If water drains from the V-belt case after removing ically check the throttle cable free play and, if nec- the plug, have a Yamaha dealer check the ATV as essary, adjust it as follows. the water may affect other engine parts.
  • Page 130: Valve Clearance

    To ble free play. prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- 1. Loosen the locknut. vals specified in the periodic maintenance and lu- 2. To increase the throttle cable free play, turn brication chart.
  • Page 131: Checking The Rear Brake Hose Protectors

    Each brake 1. Wear indicator groove hose protector is provided with a wear indicator. If a protector wears to the point that its indicator be- comes visible, have a Yamaha dealer replace the protector. 8-45...
  • Page 132: Checking The Brake Fluid Level

    Before riding, check that the brake fluid is above the minimum level mark and replenish if neces- The wheels need to be removed to check the sary. A low brake fluid level may indicate worn brake hose protectors. (See page 8-63.) brake pads and/or brake system leakage.
  • Page 133: Changing The Brake Fluid

    EBU24291 Changing the brake fluid Observe these precautions: Have a Yamaha dealer change the brake fluid at When checking the fluid level, make sure that the intervals specified in the TIP after the periodic the top of the brake fluid reservoir is level.
  • Page 134: Checking The Front And Rear Brake Lever Free Play

    The brake le- vers should have no free play as shown. If there is free play, have a Yamaha dealer check the brake system. Front brake 1. Brake lever free play...
  • Page 135: Adjusting The Brake Pedal Free Play

    Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. EBU29071 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.
  • Page 136 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: Be sure not to step on the brake pedal.
  • Page 137: Axle Boots

    Replacement of brake components requires 1. Front axle boot (each side) professional knowledge. These procedures should be performed by a Yamaha dealer. EBU24230 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 138: Checking And Lubricating The Cables

    Front brake lever cables and cable ends should be lubricated if nec- essary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace Recommended lubricant: Engine oil EWB02130...
  • Page 139: Checking And Lubricating The Brake Pedal

    Yamaha dealer check the wheel hub bear- ings. To access the brake pedal pivot, remove panel H.
  • Page 140: Lubricating The Rear Knuckle Pivots

    Have a Yamaha dealer replace the stabilizer bush- EBU25102 Lubricating the steering shaft es if necessary. The steering shaft must be lubricated at the inter- vals specified in the periodic maintenance and lu- EBU25051 Lubricating the rear knuckle pivots brication chart.
  • Page 141 EWB02160 WARNING Battery electrolyte is poisonous and danger- ous, as it contains sulfuric acid, which can cause severe burns. Avoid contact with skin, eyes or clothing. Always shield your eyes when working near batteries. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk.
  • Page 142 5. Pull the battery out of its compartment. To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electri- cal accessories.
  • Page 143: Replacing A Fuse

    If you do not have access to a constant-voltage battery charger, have a Yamaha dealer charge your battery. EBU27750 Replacing a fuse 1. Positive battery lead (red) 2. Negative battery lead (black) 3. Install the battery holding plate by installing the nuts.
  • 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. 1. Ignition fuse 2. Headlight fuse 3. Four-wheel-drive motor fuse 4.
  • Page 145: Replacing A Headlight Bulb

    15.0 A circuits to check if the devices operate. Signaling system fuse: 4. If the fuse immediately blows again, have a 5.0 A Yamaha dealer check the electrical system. Auxiliary DC jack fuse: EBU27440 15.0 A Replacing a headlight bulb Radiator fan fuse: If a headlight bulb burns out, replace it as follows.
  • Page 146 1. Cover at the rear of the headlight 1. Headlight coupler 2. Remove the headlight bulb cover. 4. Unhook the headlight bulb holder, and then remove the defective bulb. 1. Headlight bulb cover 3. Disconnect the headlight coupler. 8-60...
  • Page 147 1. Headlight bulb holder 1. Do not touch the glass part of the bulb. 2. Headlight bulb ECB00650 NOTICE EWB02220 WARNING Do not touch the glass part of the headlight A headlight bulb is hot when it is on and imme- bulb to keep it free from oil, otherwise the diately after it is turned off.
  • Page 148: Adjusting A Headlight Beam

    9. Adjust the headlight beam if necessary. EBU25551 Adjusting a headlight beam ECB00690 NOTICE It is advisable to have a Yamaha dealer make 1. Headlight beam adjusting screw this adjustment. EBU25640 Replacing the tail/brake light bulb To raise a headlight beam, turn the headlight beam adjusting screw in direction (a).
  • Page 149: 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 150: 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 151: 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 152: Troubleshooting Charts

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.
  • Page 153 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 154: Cleaning And Storage

    EBU25860 CLEANING AND STORAGE EBU25880 ed from improper high-pressure detergent Cleaning applications such as those available in coin- Frequent, thorough cleaning of your ATV will not operated car washers. only enhance its appearance but will improve its 4. Once most of the dirt has been hosed off, general performance and extend the useful life of wash all surfaces with warm water and mild, many components.
  • Page 155: Storage

    EWB02310 Long-term WARNING Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” Wet brakes may have reduced stopping ability, section of this chapter. increasing the chance of an accident. Test the brakes after washing. Apply the brakes several 2.
  • Page 156 e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. 4. Lubricate all control cables and the pivoting points of all levers and pedals. 5. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that all of its wheels are off the ground.
  • Page 157: Specifications

    EBU25960 SPECIFICATIONS Dimensions: Engine: Overall length: Engine type: 2065 mm (81.3 in) Liquid cooled 4-stroke, SOHC Overall width: Cylinder arrangement: 1180 mm (46.5 in) Forward-inclined single cylinder Overall height: Displacement: 1240 mm (48.8 in) 558.0 cm³ Bore × stroke: Seat height: 92.0 ×...
  • Page 158 Engine oil: Differential gear oil: Type: Type: SAE 5W-30 or SAE 10W-30 or SAE 10W-40 or SAE SAE 80 API GL-4 Hypoid gear oil 15W-40 or SAE 20W-40 or SAE 20W-50 Quantity: 0.22 L (0.23 US qt, 0.19 Imp.qt) Cooling system: 50 ˚C Coolant reservoir capacity (up to the maximum level mark): 0.24 L (0.25 US qt, 0.21 Imp.qt)
  • Page 159 Spark plug (s): Trail: 26.0 mm (1.02 in) Manufacturer/model: Front tire: NGK/LMAR6A-9 Spark plug gap: Type: 0.8–0.9 mm (0.031–0.035 in) Tubeless Clutch: Size: AT25 x 8-12 Clutch type: Manufacturer/model: Wet, centrifugal automatic YFM5FGPY CHENG SHIN/C828-4P (AUS)(NZL) Transmission: YFM5FGPY DUNLOP/KT421 (EUR) Primary reduction system: YFM5FGY CHENG SHIN/C828-4P (AUS)(NZL) V-belt...
  • Page 160 Rear: Front suspension: 30.0 kPa (0.300 kgf/cm², 4.4 psi) Type: Minimum: Double wishbone Front: Spring/shock absorber type: 32.0 kPa (0.320 kgf/cm², 4.6 psi) Coil spring/oil damper Rear: Wheel travel: 27.0 kPa (0.270 kgf/cm², 4.0 psi) 180 mm (7.1 in) Front wheel: Rear suspension: Wheel type: Type:...
  • Page 161 Tail/brake light: Headlight fuse: 12 V, 5.0/21.0 W 15.0 A Meter lighting: Signaling system fuse: 5.0 A Neutral indicator light: Ignition fuse: 15.0 A Reverse indicator light: Auxiliary DC jack fuse: 15.0 A Coolant temperature warning light: Four-wheel-drive motor fuse: 15.0 A Engine trouble warning light: Radiator fan fuse:...
  • Page 162: Consumer Information

    Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 163 EBU26050 Model label 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 164 1. Model label 11-3...
  • Page 165 INDEX Drive select lever ............4-15 Drive select lever and driving in reverse ......6-2 Accessories and loading ..........6-5 Drive select lever safety system cable, adjusting ..8-44 Accessories, auxiliary jack ........... 4-22 Air filter element, cleaning ..........8-37 Axle boots ..............
  • Page 166 Key identification number ..........11-1 Safety information ............1-1 Seat ................4-17 Shock absorber assemblies, adjusting the front and Label locations ............... 2-1 rear ................4-21 Light switch ..............4-8 Spark arrester, cleaning ..........8-41 Low-range indicator light ..........4-4 Spark plug, checking ............
  • Page 168 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2008.04-1.1×1 CR...

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