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 YFM5FGZ YFM5FGPZ/YFM5FGPHZ YFM550FAZ/YFM550FAPZ 28P-28199-61...
Page 2 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN IMPRIMÉ SUR PAPIER RECYCLÉ 2009.03-0.3×1 CR IMPRESO EN PAPEL RECICLADO (E,F,S)
Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM5FGZ YFM5FGPZ/YFM5FGPHZ YFM550FAZ/YFM550FAPZ 28P-28199-61-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, 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM550FWA (YFM5FG) (JY4AJ39W090000051–)
Page 5 EC Declaration of Conformity conforming to Directive 98/37/EC, 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM550FWAD (YFM5FGP) (JY4AJ41W090003150–) (YFM5FGPH) (Make, model) to which this declaration applies, conforms to the essential health...
Page 6 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. This manual will provide you with a good basic understanding of the features and operation of this ATV.
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 Please check your local riding laws and regulations before operating this ATV. EBU17390 YFM5FGZ/YFM5FGPZ/YFM5FGPHZ YFM550FAZ/YFM550FAPZ OWNER’S MANUAL ©2009 by Yamaha Motor Co., Ltd. 1st edition, March 2009 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
Page 9: Table Of Contents
EBU17420 TABLE OF CONTENTS LOCATION OF THE WARNING AND Storage compartments ......4-18 SPECIFICATION LABELS ......1-1 Front carrier ..........4-21 Rear carrier ..........4-21 SAFETY INFORMATION ......2-1 Adjusting the front and rear shock absorber assemblies .......4-21 DESCRIPTION ..........3-1 Auxiliary DC jack ........4-23 Left view ............
Page 10 Parking ............6-5 Removing and installing panels ....8-8 Parking on a slope ........6-5 Removing the radiator grills ......8-19 Accessories and loading ......6-6 Checking the spark plug ......8-20 Engine oil and oil filter cartridge ....8-22 RIDING YOUR ATV ........7-1 Final gear oil ..........8-26 GETTING TO KNOW YOUR ATV....
Page 11 Checking and lubricating the brake pedal ............8-51 Checking the wheel hub bearings .... 8-52 Checking the stabilizer bushes ....8-52 Lubricating the rear knuckle pivots ... 8-52 Lubricating the steering shaft ....8-52 Battery ............8-53 Replacing a fuse ........8-56 Replacing a headlight bulb .......
Page 12: Location Of The Warning And Specification Labels
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...
Page 13 < 5880 N < 600 kgf < < 45 kg 1322 lbf < 147 N < 15 kgf ( 99 lbs) < 33 lbf 43P-2817S-00 43P-2817R-00 35.0 kPa 30.0 kPa 43P-2816P-00 0.35 kgf/cm² 0.30 kgf/cm² 5.0 psi 4.4 psi 28P-2816M-M0 <...
Page 14 YEAR OF CONSTRUCTION : 2009 YAMAHA MOTOR CO., LTD. 2500 SHINGAI, IWATA, JAPAN 5PG-2817L-10 < 0.5 kg ( 1 lb ) 4D3-2816L-20 43P-2816N-00 MODEL : YFM550FWA MAX.POWER : 27.5 kW MASS IN RUNNING ORDER : 294 kg 28P-2156A-00...
Page 15 43P-2816S-00 43P-2816R-00...
Page 16 Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the Owner’s manual. NEVER permit children under age 12 to operate this ATV. Operation of this ATV by children under the age of 12 increases the risk of severe injury or death.
Page 17 NEVER use with drugs or alcohol. Adjust tire pressure. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or death. **.* kPa **.* kPa *.** kgf/cm² *.** kgf/cm² *.* psi *.* psi NEVER store fuel or flammable liquids. Turning 4WD-LOCK (“DIFF.LOCK”) takes more effort.
Page 18 This pictogram shows trailer Hitch Tow weight limit. (Combined weight of the trailer and all cargo in the trailer.) Overloading can cause loss of control. Loss of control can result in severe injury or death. This pictogram shows trailer Hitch Tongue weight limit.
Page 19 For Oceania...
Page 20 MAXIMUM LOADING LIMIT LOAD LIMIT PULLING LOAD: 5880 N (600 kgf) 1322 lbf 45 kg{99 lbs} TONGUE WEIGHT: 147 N ( 15 kgf) 33 lbf 3GC-24877-A0 43P-2151K-00 WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.
Page 21 1-10...
Page 22 1-11...
Page 23: Safety Information
EBU17431 SAFETY INFORMATION EBU27251 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 24 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 25 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 26 and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in en- closed or poorly ventilated areas. If you experi- ence any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT.
Page 27: 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 28: 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 29: Instrument And Control Functions
EBU17733 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 30: Indicator Lights And Warning Lights
“ON”, or if the warning light re- indicator “ ”/“ ” mains on, have a Yamaha dealer check the electri- 8. Engine trouble warning light “ ” cal circuit. 9. Coolant temperature warning light “...
Page 31 If the warning light does not come on initially when NOTICE the key is turned to “ON”, or if the warning light re- mains on, have a Yamaha dealer check the electri- The engine may overheat if the ATV is over- cal circuit.
Page 32 If the steering load is too heavy (i.e., excessive the indicator light continue to flash, the differen- steering use when the ATV is traveling at a slow tial is not locked. In this case, start moving to al- speed), the power assist is reduced to protect low time for the differential to lock.
Page 33: Multi-Function Display
EBU27298 an hour meter (which shows the total time the 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 34 2. Push the “SELECT” button and “RESET” but- ing indicator will start flashing. If this occurs, have ton together for at least three seconds. a Yamaha dealer check the electrical circuit. 3. When the hour digits start flashing, push the “RESET” button to set the hours.
Page 35: Handlebar Switches
5. Horn switch “ ” If the multi-function display indicates an error code, EBU18080 note the code number, and then have a Yamaha Engine stop switch “ ” dealer check the vehicle. Set this switch to “...
Page 36 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. EBU18152 Light switch “ /OFF” Set this switch to “ ”...
Page 37 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 38 “4WD” (four-wheel drive): Power is supplied to EBU18255 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” position.
Page 39 control and have an accident if you cannot make a sharp enough turn for the speed you are traveling. 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.
Page 40 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 release the differential gear lock, stop the ATV Stop the ATV, move the differential gear lock lever and push the switch to the “4WD” position. to position (a), and then push the differential gear lock switch in to the “LOCK”...
Page 41: Throttle Lever
Riding before the differential gear lock is proper- ly engaged (e.g., when the indicator and indica- tor light are flashing) will cause the vehicle speed to be limited until engagement is com- plete. 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 42: 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 43: 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 44: 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. EBU18753 Fuel Make sure there is sufficient gasoline in the tank. EWB02521 WARNING Gasoline and gasoline vapors are extremely flammable.
Page 45 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 46: Seat
If knocking (or pinging) occurs, use a gasoline of a To install the seat different brand. Use of unleaded fuel will extend Insert the projections on the front of the seat into spark plug life and reduce maintenance costs. the seat holders and push down on the seat at the rear.
Page 47 ECB00830 NOTICE Do not store metal or sharply edged objects, like tools, in the storage compartments. If they must be stored, wrap them in appropriate cushion material to prevent damaging the stor- age compartments. The front storage compartment is located at the front right side of the ATV.
Page 48 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. Do not exceed the load limit of 0.5 kg (1 lb) for the front storage compartment or 2.0 kg (4 lb) for the rear storage compartment.
Page 49: Front Carrier
EBU18962 Front carrier Do not exceed the load limit of 45.0 kg (99 lb) for the front carrier. Do not exceed the maximum load of 220.0 kg (485 lb) for the ATV. EBU18972 Rear carrier Do not exceed the load limit of 85.0 kg (187 lb) for the rear carrier.
Page 50 1. Special wrench Spring preload setting: Minimum (soft): Standard: 1. Spring preload adjusting ring Maximum (hard): 2. Position indicator A special wrench can be obtained at a Yamaha dealer to make this adjustment. 4-22...
Page 51: Auxiliary Dc Jack
EBU19181 Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running.
Page 52 If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine start- ing may become difficult. Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged.
Page 53: 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 54 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, 8-43, 8-45, 8-46 • Check brake fluid level in reservoir, and add recommended brake fluid to specified level if necessary.
Page 55: 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- 8-28.) 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 56: Throttle Lever
(See page 8-43.) 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 57 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 58 Use of improper tires on this ATV may cause Size: loss of control, increasing your risk of an acci- AT25 x 10-12 dent. Type: Tubeless After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.
Page 59: Chassis Fasteners
Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. EBU19840 Chassis fasteners Make sure that all nuts, bolts and screws are prop-...
Page 60: 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 61: Operating The Drive Select Lever And Driving In Reverse
The rear brake lever or brake pedal is applied EBU20441 Operating the drive select lever and with the drive select lever in any position. How- driving in reverse ever, it is recommended to shift into the neutral or park position before starting the engine. ECB00170 NOTICE 3.
Page 62 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 63: 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 64: 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 65: 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 66 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 67 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 the maximum ATV load limit. Load cargo on the carriers as close to the center of the ATV as possible.
Page 68: Riding Your Atv
EBU21141 RIDING YOUR ATV...
Page 69: Getting To Know Your Atv
EBU27417 RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01381 This ATV is mainly for utility use, but may also be WARNING used for recreation. This section, Riding your ATV, Do not operate this ATV or allow anyone else provides general ATV riding instructions for recre- to operate it without proper instruction.
Page 70 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. Take the time to learn the basic techniques well before attempting more difficult maneuvers.
Page 71 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 72 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 73 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 box in this section or ve- the maximum engine power available and de- hicle labeling).
Page 74 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 75 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 76: 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 use on unpaved surfaces children are not likely to touch it. only. WARNING! Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control.
Page 77 know your country’s laws and regulations before ful when operating on unfamiliar terrain. Al- you ride on unpaved public streets or roads. Do not ways be alert to changing terrain conditions ride on any paved public street, road or motorway. when operating the ATV.
Page 78 loose terrain could cause loss of traction or ATV control, which could result in an accident, including an overturn. [EWB01541] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting per- mission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.
Page 79: Turning Your Atv
Select a large, flat, unpaved area to become famil- ECB00251 NOTICE iar 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 80: 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 81 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. Never climb hills with excessively slippery or loose surfaces.
Page 82 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 83: Riding Downhill
uphill. Turn the ATV around and remount, following Always check the terrain carefully before the procedure described in the 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 84: 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 85: 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 86 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 87 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 88: 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 89: 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 90: 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 91: Periodic Maintenance And Adjustment
If you are not fa- EBU27111 miliar with vehicle service, have a Yamaha Owner’s manual and tool kit dealer perform the service. Be sure to put this owner’s manual in the plastic bag and to always carry it as well as the owner’s...
Page 92 However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.
Page 93: 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 94: 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 95 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 96 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 97 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 98: 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 99 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 100 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 101 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 102: 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 4-18.) 1. Panel C 2.
Page 103 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 104 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 105 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 106 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 107 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 4-18.) 8-17...
Page 108: 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 109: 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 110: Checking The Spark Plug
EBU23211 2. Remove the spark plug as shown, with the 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 111: Tightening Torque
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 112: Engine Oil And Oil Filter Cartridge
3. Remove panel F. (See page 8-8.) 4. Remove the engine oil dipstick, and then wipe If a torque wrench is not available when installing it off with a clean rag. a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight.
Page 113 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. Place an oil pan under the engine to collect the used oil. 4.
Page 114 Make sure that the O-ring is properly seated. 8. Install the new oil filter cartridge with an oil fil- ter wrench, and then tighten it to the specified An oil filter wrench is available at a nearby Yamaha torque with a torque wrench. dealer.
Page 115 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 116: Final Gear Oil
If any leakage is found, have 1. Final gear oil a Yamaha dealer check and repair the ATV. In ad- 2. Final gear oil level check bolt dition, the final gear oil level must be checked and 3.
Page 117 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 filler bolt 4. Install the oil level check bolt and oil filler bolt, and then tighten them to the specified torques.
Page 118: 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 checked and the oil changed as follows at the in- tervals specified in the periodic maintenance and lubrication chart.
Page 119 2. Place an oil pan under the differential gear case to collect the used oil. 3. Remove the differential gear oil filler bolt and the differential gear oil drain bolt to drain the oil from the differential gear case. 1. Differential gear oil 2.
Page 120: Coolant
5. Refill with the recommended differential gear Tightening torque: oil to the brim of the filler hole as shown. Differential gear oil filler bolt: NOTICE: Be sure no foreign material en- 23 Nm (2.3 m·kgf, 17 ft·lbf) ters the differential gear case. [ECB00411] 7.
Page 121 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.
Page 122 3. Place a container under the engine, and then Coolant reservoir capacity (up to the maximum remove the coolant drain bolt. (Use a trough level mark): or a similar object as shown to prevent coolant 0.24 L (0.25 US qt, 0.21 Imp.qt) from spilling on the engine guard.) The radiator fan is automatically switched on or off according to the coolant temperature in the...
Page 123 6. Remove the coolant reservoir cap. 7. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the cool- ant reservoir. 1. Trough 4. Remove panel B. (See page 8-8.) 5. Remove the radiator cap. 1. Coolant reservoir hose 8.
Page 124 10. Connect the coolant reservoir hose. 13. Loosen the water pump air bleed bolt, without 11. Pour the recommended coolant into the radia- removing it, to allow all of the air to escape tor until it is full. from the air bleed bolt hole. 12.
Page 125 1. V-belt cooling duct 1. Cylinder head air bleed bolt 2. Clamp screw 18. When coolant begins to flow out of the bolt 17. Loosen the cylinder head air bleed bolt, with- hole, tighten the cylinder head air bleed bolt to out removing it, to allow all of the air to escape the specified torque.
Page 126: 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 127 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 128 2. Air filter mesh damaged. 5. Clean the mesh with solvent, and then wipe 9. Apply Yamaha foam air filter oil or other qual- the solvent off. ity foam air filter oil to the sponge material. 6. Wash the sponge material gently, but thor- oughly, in solvent.
Page 129 engine damage. Additionally, operation without the air filter element will affect the fuel injection system with subsequent poor performance and possible engine overheating. [ECB00761] 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.
Page 130: Cleaning The Spark Arrester
EBU27810 Cleaning the spark arrester Select a well-ventilated area free of combustible materials and make sure the exhaust and muffler are cool. 1. Remove the bolts. 1. Tailpipe 2. Spark arrester 3. Gasket 4. Install the gasket, and then insert the tailpipe into the muffler and align the bolt holes.
Page 131: V-Belt Case Drain Plug
9. Install the purging bolt and tighten it to the specified torque. If water drains from the V-belt case after removing Tightening torque: the plug, have a Yamaha dealer check the ATV as Purging bolt: the water may affect other engine parts. 27 Nm (2.7 m·kgf, 19 ft·lbf)
Page 132: Adjusting The Throttle Cable Free Play
3. To increase the throttle cable free play, turn the throttle cable free play adjusting bolt in di- rection (a). To decrease the throttle cable free play, turn the adjusting bolt in direction (b). 1. V-belt case drain plug EBU29700 Adjusting the throttle cable free play The throttle cable free play should be checked 1.
Page 133: Valve Clearance
Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- EBU27470 brication chart.
Page 134: Checking The Rear Brake Hose Protectors
Each brake 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. The wheels need to be removed to check the 1.
Page 135: Checking The Brake Fluid Level
Front brake 1. Rear brake hose protector 1. Minimum level mark 2. Wear indicator 3. Protector is normal. Rear brake 4. Protector is worn. EBU24251 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become inef- fective.
Page 136: Changing The Brake Fluid
EBU24291 Changing the brake fluid When checking the fluid level, make sure that Have a Yamaha dealer change the brake fluid at the top of the brake fluid reservoir is level. the intervals specified in the TIP after the periodic Use only the recommended quality brake fluid, maintenance and lubrication chart.
Page 137: Adjusting The Brake Pedal Free Play
Front brake 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 138 1. Brake pedal free play 1. Locknut 2. Brake pedal free play adjusting nut 1. Remove panel H. (See page 8-8.) 4. Tighten the locknut. 2. Loosen the locknut. 5. After adjusting, there should be slight play at 3. Turn the brake pedal free play adjusting nut in the brake pedal cable joint as shown.
Page 139: Axle Boots
Check the axle boots for tears or damage. If any damage is found, have them re- placed by a Yamaha dealer. 1. Brake pedal cable joint 2. Slight play 6. Install the panel.
Page 140: Checking And Lubricating The Cables
If a cable is damaged or does not move The operation of the front and rear brake levers smoothly, have a Yamaha dealer check or replace should be checked before each ride, and the lever pivots should be lubricated if necessary.
Page 141: Checking And Lubricating The Brake Pedal
Front brake lever EBU28832 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary. To access the brake pedal pivot, remove panel H. (See page 8-8.) Recommended lubricant: Lithium-soap-based grease...
Page 142: Checking The Wheel Hub Bearings
If there is play in a wheel hub or if a wheel does not turn smoothly, have a Yamaha dealer check the wheel hub bear- ings. EBU25021 Checking the stabilizer bushes The stabilizer bushes must be checked for cracks 1.
Page 143: Battery
EBU29046 Batteries produce explosive gases. Keep Battery sparks, flame, cigarettes or other sources of ig- This model is equipped with a VRLA (Valve Regu- nition away. Ventilate when charging or using lated Lead Acid) battery. There is no need to check in an enclosed space.
Page 144 NOTICE: When removing the bat- To charge the battery tery, the main switch must be off, and the Have a Yamaha dealer charge the battery as soon negative lead must be disconnected be- as possible if it seems to have discharged. Keep in fore the positive lead.
Page 145 If you do 2. Connect the positive battery lead first, then not have access to a constant-voltage battery connect the negative battery lead by installing charger, have a Yamaha dealer charge your their bolt. battery. To store the battery...
Page 146: Replacing A Fuse
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) 5. Install the panel. EBU27751 Replacing a fuse 1. Ignition fuse 2. Headlight fuse 3. Four-wheel-drive motor fuse 4.
Page 147 YFM5FGPHZ 40.0 A YFM5FGPZ 40.0 A 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 8-57...
Page 148: Replacing A Headlight Bulb
EBU27443 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the cover at the rear of the headlight by pulling it off. 1. Headlight bulb cover 3. Disconnect the headlight coupler. 1. Cover at the rear of the headlight 2.
Page 149: Adjusting A Headlight Beam
ECB00690 versely affected. Thoroughly clean off any NOTICE dirt and fingerprints on the headlight bulb It is advisable to have a Yamaha dealer make using a cloth moistened with alcohol or this adjustment. thinner. [ECB00651]...
Page 150: Replacing The Tail/Brake Light Bulb
To raise a headlight beam, turn the headlight beam adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b). 1. Tail/brake light bulb holder 3. Remove the burnt-out bulb by pushing it in and turning it counterclockwise.
Page 151: Removing A Wheel
4. Insert a new bulb into the bulb holder, push it EBU25701 Installing a wheel in, and then turn it clockwise until it stops. 1. Place the ATV on a level surface. 5. Install the bulb holder (together with the bulb) 2.
Page 152: Troubleshooting
The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself. However, should your ATV re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, expe- 1. Tapered nut rience, and know-how to service the ATV properly.
Page 153: 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 154 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 155: Cleaning And Storage
EBU25860 CLEANING AND STORAGE EBU25881 tion of wheel bearings, brakes, transmis- 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 156: Storage
EBU27261 3. Perform the following steps to protect the cyl- 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 157 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 158: Specifications
EBU25960 SPECIFICATIONS Dimensions: Vibration on handlebar (EN1032, ISO5008): YFM5FGPHZ Will not exceed 2.5 m/s² Overall length: YFM5FGPZ Will not exceed 2.5 m/s² 2065 mm (81.3 in) YFM5FGZ Will not exceed 2.5 m/s² Overall width: Engine: 1180 mm (46.5 in) Overall height: Engine type: 1240 mm (48.8 in) Liquid cooled 4-stroke, SOHC...
Page 159 Type: Differential gear oil: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- Type: SAE 80 API GL-4 Hypoid gear oil Quantity: 0.22 L (0.23 US qt, 0.19 Imp.qt) 50 ˚C Cooling system: Coolant reservoir capacity (up to the maximum level mark): SAE 5W-30 0.24 L (0.25 US qt, 0.21 Imp.qt) SAE 10W-30...
Page 160 Spark plug gap: Front tire: 0.8–0.9 mm (0.031–0.035 in) Type: Clutch: Tubeless Clutch type: Size: Wet, centrifugal automatic AT25 x 8-12 Transmission: Manufacturer/model: YFM550FAPZ CHENG SHIN/C828-4P Primary reduction system: YFM550FAZ CHENG SHIN/C828-4P V-belt YFM5FGPHZ DUNLOP/KT421 Secondary reduction system: YFM5FGPZ DUNLOP/KT421 Shaft drive YFM5FGZ DUNLOP/KT421 Secondary reduction ratio:...
Page 161 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 162 Tail/brake light: EPS fuse: 12 V, 5.0/21.0 W × 1 YFM550FAPZ 40.0 A Meter lighting: YFM5FGPHZ 40.0 A YFM5FGPZ 40.0 A Neutral indicator light: Headlight fuse: 15.0 A Reverse indicator light: Signaling system fuse: 5.0 A Coolant temperature warning light: Ignition fuse: 15.0 A Engine trouble warning light:...
Page 163: Consumer Information
Yamaha dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
Page 164 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 165 1. Model label 11-3...
Page 166 INDEX Drive select lever ............4-15 Drive select lever and driving in reverse ......6-2 Accessories and loading ..........6-6 Drive select lever safety system cable, adjusting ..8-43 Accessories, auxiliary jack ........... 4-23 Air filter element, cleaning ..........8-36 Axle boots ..............
Page 167 Key identification number ..........11-1 Safety information ............2-1 Seat ................4-18 Shock absorber assemblies, adjusting the front and Label locations ............... 1-1 rear ................4-21 Light switch ..............4-8 Spark arrester, cleaning ..........8-40 Low-range indicator light ..........4-4 Spark plug, checking ...........
Page 168 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2009.03-0.3×1 CR...

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Yamaha GRIZZLY 550 FI Owner's Manual

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