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Yamaha GRIZZLY 550 2010, Owner'S Manual

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Yamaha GRIZZLY 550 2010 Owner'S Manual Download Page 8

Checking the front and rear brake lever 

free play  ................................................. 8-49

Adjusting the brake pedal free play  .......... 8-50
Axle boots  ................................................ 8-52
Checking and lubricating the cables  ........ 8-53
Checking and lubricating the front and 

rear brake levers  .................................... 8-53

Checking and lubricating the brake 

pedal ...................................................... 8-54

Checking the wheel hub bearings  ............ 8-55
Checking the stabilizer bushes  ................ 8-55
Lubricating the rear knuckle pivots ........... 8-55
Lubricating the steering shaft  ................... 8-56
Battery ...................................................... 8-56
Replacing a fuse  ...................................... 8-59
Replacing a headlight bulb  ....................... 8-61
Adjusting a headlight beam  ...................... 8-63
Replacing the tail/brake light bulb  ............ 8-63
Removing a wheel .................................... 8-64
Installing a wheel ...................................... 8-65
Troubleshooting ....................................... 8-66
Troubleshooting charts ............................. 8-67

CLEANING AND STORAGE.......................... 9-1

Cleaning ..................................................... 9-1
Storage ....................................................... 9-2

SPECIFICATIONS .......................................10-1

CONSUMER INFORMATION.......................11-1

Identification numbers ...............................11-1
Noise regulation ........................................11-4
Maintenance record  ..................................11-5
YAMAHA MOTOR CORPORATION, 

U.S.A. ATV LIMITED WARRANTY .........11-6

YAMAHA EXTENDED SERVICE 

(Y.E.S.) ...................................................11-8

U28P12E0.book  Page 3  Thursday, March 11, 2010  10:13 AM

Summary of Contents for GRIZZLY 550 2010

Page 1: ...ld not be ridden by anyone under 16 years of age WARNING OWNER S MANUAL 28P 28199 12 LIT 11626 24 12 YFM5FGA YFM5FGHA YFM5FGPA YFM5FGPHA READ THIS MANUAL CAREFULLY It contains important safety informa...

Page 2: ...EBU17092 Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if it is sold U28P12E0 book Page 1 Thursday March 11 2010 10 13 AM...

Page 3: ...provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or m...

Page 4: ...fety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous situ...

Page 5: ...in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17382 YFM5FGA YFM5FGHA YFM5FGPA YFM5FGPHA OWNER S MANUAL 2010 by Yamaha Motor Cor...

Page 6: ...5 Handlebar switches 4 7 Throttle lever 4 13 Speed limiter 4 13 Front brake lever 4 14 Brake pedal and rear brake lever 4 14 Drive select lever 4 15 Fuel tank cap 4 15 Fuel 4 16 Seat 4 18 Storage comp...

Page 7: ...and tool kit 8 2 Periodic maintenance chart for the emission control system 8 3 General maintenance and lubrication chart 8 5 Removing and installing panels 8 10 Removing the radiator grills 8 22 Chec...

Page 8: ...cating the steering shaft 8 56 Battery 8 56 Replacing a fuse 8 59 Replacing a headlight bulb 8 61 Adjusting a headlight beam 8 63 Replacing the tail brake light bulb 8 63 Removing a wheel 8 64 Install...

Page 9: ...1 1 1 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 2 3 4 5 6 9 8 7 10 11 U28P12E0 book Page 1 Thursday March 11 2010 10 13 AM...

Page 10: ...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 99 lbs 45 kg 3B4 24875 U0 187 lbs 85 kg 3B...

Page 11: ...TRAILER TOWING Cargo or a trailer can affect stability and handling Read owner s manual before loading or towing When loading with cargo or towing a trailer Reduce speed and allow more room to stop A...

Page 12: ...ject to an approved ATV action plan submitted by YAMAHA and on file with the U S Consumer Product safety Commission Certification of Compliance YAMAHA MOTOR CORPORATION U S A 6555 Katella Avenue Cypre...

Page 13: ...ld never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or sh...

Page 14: ...ing hills as described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the...

Page 15: ...duce the chance of skidding or sliding out of con trol Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stop...

Page 16: ...rly ventilated areas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to venti...

Page 17: ...l dipstick 7 Oil filter cartridge 8 Coolant reservoir 5 1 Rear shock absorber assembly spring preload adjusting ring 2 Rear storage compartment and tool kit 3 Fuel tank cap cover 4 Front shock absorbe...

Page 18: ...lever 2 Rear brake lever 3 Handlebar switches 4 Rear brake fluid reservoir 5 Multi function display 6 Front brake fluid reservoir 7 On Command four wheel drive differential gear lock switch 8 Front br...

Page 19: ...7760 Main switch The positions of the main switch are as follows ON All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can b...

Page 20: ...This indicator light comes on when the transmis sion is in the reverse position EBU17970 Park indicator light This indicator light comes on when the transmis sion is in the park position 1 On Command...

Page 21: ...ccess the radiator Start the engine after making sure that the warning light is out Continuous use while the warning light is on may cause damage to the engine EBU27284 Engine trouble warning light Th...

Page 22: ...or On Command differential gear lock indicator and indicator light DIFF LOCK The On Command four wheel drive indicator comes on when the On Command four wheel drive switch is set to the 4WD position T...

Page 23: ...tripmeter select it by pushing the SE LECT button and then push the RESET button for at least three seconds The tripmeters can be used to estimate the distance that can be traveled with a full tank o...

Page 24: ...meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear from F full towards E empty as the fuel level decreases When the E segment disap pears and the fuel...

Page 25: ...display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage EBU18061 Handlebar switches EBU18080 Engine stop switch Set this switch to before sta...

Page 26: ...rge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it See page 8 56 for battery charging information EBU18190 Override switch OVERR...

Page 27: ...ough turn for the speed you are trav eling EBU26606 On Command four wheel drive switch 2WD 4WD WARNING EWB00163 Always stop the ATV before changing from two wheel drive to four wheel drive and vice ve...

Page 28: ...ATV handles differently in four wheel drive than in differential gear lock in some circum stances Changing from four wheel drive to dif ferential gear lock or vice versa while moving may cause the ATV...

Page 29: ...ied to the rear and front wheels LOCK four wheel drive with the differential gear locked Power is supplied to the rear and front wheels and the differential gear is locked Unlike in four wheel drive a...

Page 30: ...k stop the ATV and push the switch to the 4WD position TIP When the switch is set to LOCK the differential gear lock indicator and indicator light will flash until the differential gear is locked When...

Page 31: ...increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decelerate and the engine will return to an idle any time t...

Page 32: ...eration You could lose control resulting in an accident EWB00241 3 Tighten the locknut EBU18391 Front brake lever The front brake lever is located on the right handle bar To apply the front brake pull...

Page 33: ...ating the drive select lever and driving in reverse section on page 6 2 for the drive select lever operation EBU27350 Fuel tank cap To remove the fuel tank cap Open the fuel tank cap cover and then re...

Page 34: ...l low these instructions 1 Before refueling turn off the engine and be sure that no one is sitting on the vehicle Nev er refuel while smoking or while in the vicinity of sparks open flames or other so...

Page 35: ...y mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If...

Page 36: ...containing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 E10 Gasohol contain ing methanol is not recommended by Yamaha because it can cause damage to the f...

Page 37: ...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 To access the storage...

Page 38: ...d under the seat See page 4 18 To access the storage com partment remove the storage compartment cover 1 Front storage compartment 1 Rear storage compartment cover 1 Rear storage compartment U28P12E0...

Page 39: ...lb for the front storage compartment or 2 0 kg 4 lb for the rear storage compartment Do not exceed the maximum load of 220 0 kg 485 lb for the ATV TIP A drain plug is fitted at the bottom of each sto...

Page 40: ...iding conditions WARNING EWB00400 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...

Page 41: ...should only be used when the engine is running and the light switch is set to OFF 1 Set the light switch to OFF 2 Start the engine See page 6 1 3 Open the auxiliary DC jack cap and then in sert the a...

Page 42: ...h 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...

Page 43: ...Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if n...

Page 44: ...hrottle lever Make sure that operation is smooth Lubricate cable and lever hous ing if necessary Check cable free play and adjust if necessary 5 4 8 45 Control cables Make sure that operation is smoot...

Page 45: ...ry See page 8 33 TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture EBU29081 Front and rear brakes Brake levers and brake pedal Check that there is...

Page 46: ...t open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary EBU19794 Tires Check tire pressure regularly to make sure it is at the recommended specific...

Page 47: ...the tire groove decreases to 3 mm 0 12 in due to wear replace the tire Recommended tire pressure Front 35 0 kPa 0 350 kgf cm 5 0 psi Rear 30 0 kPa 0 300 kgf cm 4 4 psi Minimum tire pressure Front 32 0...

Page 48: ...he 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 combination...

Page 49: ...5 7 5 EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary U28P12E0 book Page 7 Thursday March 11 2010 10 13 AM...

Page 50: ...r the first time 1 Turn the key to ON and the engine stop switch to The following warning lights should come on for a few seconds then go off Coolant temperature warning light Engine trouble warning l...

Page 51: ...when the engine is cold ECB00162 TIP If the engine fails to start release the start switch then push it again Pause a few seconds before the next attempt Each cranking should be as short as possible...

Page 52: ...ople 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 with...

Page 53: ...n in hours For ATVs not equipped with an odometer or hour meter follow the figures given in hours There is never a more important period in the life of your engine than the first 320 km 200 mi or 20 h...

Page 54: ...ngine and shift the drive select lever into the park position EBU29900 Parking on a slope WARNING EWB00860 Avoid parking on hills or other inclines Park ing on a hill or other incline could cause the...

Page 55: ...ftermarket products similar in design and quality to genuine Yamaha Accesso ries recognize that some aftermarket accessories or modifications are not suitable because of poten tial safety hazards to y...

Page 56: ...ailer can change the stability and han dling of an ATV You must use common sense and good judgment when carrying cargo or towing a trailer Keep the following points in mind Never exceed the weight lim...

Page 57: ...s not interfere with con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it...

Page 58: ...7 1 7 EBU21132 RIDING YOUR ATV U28P12E0 book Page 1 Thursday March 11 2010 10 13 AM...

Page 59: ...ve read this Owner s Manual completely and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 2 1 2 4 Also read all warning and notice labels on you...

Page 60: ...ator Not recommended for children under 16 years of age WARNING EWB01390 A child under 16 should never operate an ATV with engine size greater than 90 cc Use by chil dren of ATVs that are not recommen...

Page 61: ...Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01411 Wear eye protection when operating your ATV to reduce the...

Page 62: ...h time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 5 1 Always follow the inspection and maintenance procedures and schedules describe...

Page 63: ...e to side and as low as possible Be sure cargo is se cured a loose load could change handling unexpectedly Make sure the load does not interfere with your control or ability to see where you are going...

Page 64: ...off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident EWB01471 Avoid wheelies and jumping WARNIN...

Page 65: ...e engine area could catch fire Do not operate idle or park the ATV in dry grass or other dry ground cov er Keep the engine area free of dry grass brush or other combustible material Someone touching t...

Page 66: ...eriously af fect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets EWB01511 Do not ride on a...

Page 67: ...bumps or holes Go slowly and be extra care ful when operating on unfamiliar terrain Al ways be alert to changing terrain conditions when operating the ATV EWB01531 Do not operate on rough slippery or...

Page 68: ...WARNING You could collide with another vehicle if operating in off road ar eas where you cannot easily be seen Mount a caution flag on the ATV to make you more vis ible Watch carefully for other vehi...

Page 69: ...se the throt tle and apply the brakes smoothly and evenly Im proper use of the brakes can cause the tires to lose traction reducing control and increasing the possi bility of an accident NOTICE ECB002...

Page 70: ...your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures s...

Page 71: ...denly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Never attempt to tu...

Page 72: ...limbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to do so...

Page 73: ...n extremely steep hills than on level surfaces or small hills Shift your weight backward and to the up side of the hill Never go down a hill at high speed Avoid going down a hill at an angle that woul...

Page 74: ...er the front or rear brake be cause the wheels on the uphill side could come off the ground Apply both the front and rear brakes gradually Whenever possible ride your ATV straight down hill Avoid shar...

Page 75: ...may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If your...

Page 76: ...V with out verifying that you have regained proper braking ability WARNING Wet brakes may have re duced stopping ability which could cause loss of control EWB02621 After riding your ATV in water be su...

Page 77: ...7 20 7 1 Air filter case check hose 1 Air filter case check hose 1 Storage compartment drain plug 1 Storage compartment drain plug U28P12E0 book Page 20 Thursday March 11 2010 10 13 AM...

Page 78: ...e ATV may re sult SLIDING AND SKIDDING WARNING EWB01662 Skidding or sliding improperly may cause you to lose control of this ATV You may also re gain traction unexpectedly which may cause the ATV to o...

Page 79: ...ime skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are re duced Bear in mind that sliding maneuv...

Page 80: ...physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE IF THE ATV IS IN 2WD the ATV may tip over on top of you Dismount the ATV on the uphill side See page 7 13 I...

Page 81: ...e engine when performing mainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fires Running...

Page 82: ...nd the tools provided in the owner s tool kit are in tended to assist you in the performance of preven tive maintenance and minor repairs However additional tools such as a torque wrench may be necess...

Page 83: ...ols data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel...

Page 84: ...Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 U28P12E0 book Page 4 Thursday...

Page 85: ...h an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km m...

Page 86: ...amage and re place if necessary 6 Wheels Check runout and for damage and replace if nec essary 7 Tires Check tread depth and for damage and replace if necessary Check air pressure and balance and corr...

Page 87: ...p based grease 15 Steering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 16 Engine mount Check for cracks or other damage and replace if necessary 17 Axl...

Page 88: ...adjust or replace if neces sary 25 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjust if neces sary Lubricate throttle lever housing a...

Page 89: ...ull 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 chang...

Page 90: ...oving 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 instal...

Page 91: ...nel A To remove the panel Pull upward on the areas shown To install the panel Place the panel in the original position 1 Panel E 2 Panel H 3 Panel I 1 3 2 1 Panel A U28P12E0 book Page 11 Thursday Marc...

Page 92: ...ve panel A 2 Remove the front carrier by removing the bolts 3 Remove the front carrier stays by removing the bolts 1 Carrier bolt under the fenders 1 Carrier bolt top 1 Front carrier stay U28P12E0 boo...

Page 93: ...pull the panel upward to remove it To install the panel 1 Place the panel in the original position and then install the quick fasteners 1 Front carrier stay bolt 1 Panel B 2 Quick fastener U28P12E0 b...

Page 94: ...stall panel A Panel C To remove the panel 1 Remove the seat See page 4 18 2 Remove panel A 3 Remove the quick fastener screws and then pull the panel upward to remove it Tightening torque Front carrie...

Page 95: ...nstall 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 TIP To ease removal of panel D shift...

Page 96: ...8 16 8 1 Panel D 2 Quick fastener screw 1 Bolt 1 Panel E 2 Quick fastener screw 1 Bolt U28P12E0 book Page 16 Thursday March 11 2010 10 13 AM...

Page 97: ...al position and then install the bolt and quick fastener screw 2 Install panel C Panel F To remove the panel Pull outward on the areas shown To install the panel Place the panel in the original positi...

Page 98: ...G and H To remove one of the panels Remove the nut and bolts and then pull the panel downward while pushing the projection 1 Panel G 2 Nut 3 Bolt 4 Projection U28P12E0 book Page 18 Thursday March 11...

Page 99: ...nels Place the panel in the original position and then in stall the bolts and nut Panel I To remove the panel 1 Remove the seat See page 4 18 1 Panel H 2 Nut 3 Bolt 4 Projection U28P12E0 book Page 19...

Page 100: ...arrier by removing the bolts 3 Remove the quick fasteners and then push inward on the areas shown 1 Carrier bolt under the fenders 1 Carrier bolt upper 1 Carrier bolt lower U28P12E0 book Page 20 Thurs...

Page 101: ...installing the bolts and tightening them to the specified torques 3 Install the seat 1 Panel I 2 Quick fastener 2 1 Tightening torques Carrier bolt upper 53 Nm 5 3 m kgf 38 ft lbf Carrier bolt lower...

Page 102: ...fastener EBU23213 Checking the spark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug shoul...

Page 103: ...ug 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...

Page 104: ...uld be tightened to the specified torque as soon as possible 3 Install the spark plug cap EBU27466 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In additi...

Page 105: ...and then remove it again to check the oil level TIP The engine oil should be between the minimum and maximum level marks 6 If the engine oil is at or below the minimum level mark add sufficient oil of...

Page 106: ...gasket to drain the oil from the crankcase TIP Skip steps 5 9 if the oil filter cartridge is not being replaced 5 Remove panel G See page 8 10 6 Remove the oil filter cartridge with an oil filter wren...

Page 107: ...rque with a torque wrench 9 Install panel G 10 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the speci fied torque 1 O ring 1 Torque wrench Tightening torque Oil fi...

Page 108: ...check for the cause 13 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary 14 Install panel F EBU27306 Final gear oil The final gear case must be che...

Page 109: ...ecessary 5 Install the oil level check bolt the oil filler bolt and their gasket and then tighten the bolts to the specified torques 1 Final gear oil 2 Gasket 3 Final gear oil level check bolt 4 Corre...

Page 110: ...bolt and its new gasket and then tighten the bolt to the specified torque 5 Refill with the recommended final gear oil to the brim of the check hole as shown NOTICE Be sure no foreign material enters...

Page 111: ...t the in tervals specified in the periodic maintenance and lubrication chart To check the differential gear oil level 1 Place the ATV on a level surface 2 Remove the differential gear oil filler bolt...

Page 112: ...e oil from the differential gear case 4 Install the drain bolt and its new gasket and then tighten the bolt to the specified torque 5 Refill with the recommended differential gear oil to the brim of t...

Page 113: ...iodic maintenance and lubrication chart EBU27125 To check the coolant level 1 Place the ATV on a level surface TIP The coolant level must be checked on a cold en gine since the level varies with engin...

Page 114: ...e engine If water has been used instead of coolant re place it with coolant as soon as possible otherwise the cooling system will not be protected against frost and corrosion If water has been added t...

Page 115: ...team blown out under pressure Always place a thick rag over the cap when opening Allow any remaining pressure to escape before completely removing the cap 1 Place the ATV on a level surface 2 Remove p...

Page 116: ...flush the cooling system with clean tap water 9 Install the coolant drain bolt and its new gas ket and then tighten the bolt to the specified torque 10 Connect the coolant reservoir hose 11 Pour the...

Page 117: ...egins to flow out of the bolt hole tighten the water pump air bleed bolt to the specified torque 15 Remove panel E See page 8 10 16 Loosen the clamp screw and then remove the V belt cooling duct Antif...

Page 118: ...cylinder head air bleed bolt to the specified torque 19 Start the engine and let it idle for ten minutes 20 Rev the engine five times 21 Pour the recommended coolant into the radia tor until it is fu...

Page 119: ...ing the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication chart Clean or if necessary replace the air filter element m...

Page 120: ...11 3 Remove the air filter case cover by unhooking the holders 4 Remove the sponge material and the mesh from the air filter case 1 Air filter case check hose 1 Air filter case cover holder 2 Air fil...

Page 121: ...terial when squeezing it ECB00441 8 Check the sponge material and replace it if damaged 9 Apply Yamaha foam air filter oil or other qual ity foam air filter oil to the sponge material TIP The sponge m...

Page 122: ...as shown 13 Install the panel TIP The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time t...

Page 123: ...any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 4 Check the gasket for damage and replace it if necessary 5 Install the gasket and then insert t...

Page 124: ...when purging the spark arrester otherwise it could cause injury to the eyes burns carbon monox ide poisoning possibly leading to death and start a fire Always let the exhaust system cool prior to tou...

Page 125: ...re 3 0 5 0 mm 0 12 0 20 in at the throttle lever Period ically check the throttle cable free play and if nec essary adjust it as follows 1 Slide the rubber cover back 2 Loosen the locknut 3 To increas...

Page 126: ...hart EBU29601 Brakes Replacement of brake components requires pro fessional knowledge Brake service should be per formed by a Yamaha dealer WARNING EWB02571 Operating with improperly serviced or adjus...

Page 127: ...nance and lubrication chart 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...

Page 128: ...nd replenish if neces sary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake syste...

Page 129: ...vel to gradually go down However if the brake fluid level goes down suddenly have a Yamaha dealer check the cause EBU24291 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the i...

Page 130: ...perform this maintenance completely in the following order whenever adjusting the rear brake Before adjusting the brake pedal free play check the rear brake pads for wear The brake pedal free play sh...

Page 131: ...rease the free play and in direction b to decrease it 4 Tighten the locknut 5 After adjusting there should be slight play at the brake pedal cable joint as shown If there is no play repeat steps 2 to...

Page 132: ...rake lever and brake pedal do not move EBU24230 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart Check the axle boots f...

Page 133: ...h could restrict the operation of controls and lead to an accident or injury Always make sure all control cables work smoothly before you begin riding in cold weather If the control cables are frozen...

Page 134: ...l The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricated if necessary TIP To access the brake pedal pivot remove panel H See page 8 10 Recommended...

Page 135: ...stabilizer bushes must be checked for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart Have a Yamaha dealer replace the stabilizer bush es if necessary EB...

Page 136: ...ectrolyte 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 EX...

Page 137: ...removing the bat tery the main switch must be off and the negative lead must be disconnected be fore the positive lead ECB01001 5 Pull the battery out of its compartment 1 Carrier bolt under the fend...

Page 138: ...dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary NOTICE ECB00940 Always keep the battery charged Storing a dis charged b...

Page 139: ...7751 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 1 Fuse box 2 Main EPS spare fuse 3 Main fuse 4 EPS fuse for...

Page 140: ...lacing a fuse 2 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Always use a fuse of the spec ified rating and never use a substitute ob ject in place of the proper...

Page 141: ...lows 1 Remove the cover at the rear of the headlight by pulling it off 2 Remove the headlight bulb cover Specified fuses Main fuse 40 0 A Headlight fuse 15 0 A Ignition fuse 15 0 A Four wheel drive mo...

Page 142: ...t of the head light bulb to keep it free from oil otherwise the transparency of the glass the luminos ity of the bulb and the bulb life will be ad versely affected Thoroughly clean off any dirt and fi...

Page 143: ...dealer make this adjustment 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 EBU25642 Replacing the t...

Page 144: ...b holder together with the bulb by turning it clockwise 6 Install the panel EBU25651 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 3 Elevate the ATV and place a suitable...

Page 145: ...el Tapered nuts are used for both the front and rear wheels Install the nuts with their tapered side to wards the wheel 3 Lower the ATV to the ground 4 Tighten the wheel nuts to the specified torques...

Page 146: ...repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts ma...

Page 147: ...check the ATV Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the ATV The engin...

Page 148: ...an be temporarily used instead provided that it is changed to the rec ommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The co...

Page 149: ...dry out the linings EWB02311 NOTICE Excessive water pressure may cause water seepage and deteriora tion of wheel bearings brakes transmis sion seals and electrical devices Many expensive repair bills...

Page 150: ...e spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the spark plug and then place the spark plug on the cylinder head so that...

Page 151: ...t 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 For more in formation on storing the...

Page 152: ...SOHC Cylinder arrangement Forward inclined single cylinder Displacement 558 cm Bore stroke 92 0 84 0 mm 3 62 3 31 in Compression ratio 9 30 1 Starting system Electric starter Lubrication system Wet s...

Page 153: ...S qt 1 75 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 20 0 L 5 28 US gal 4 40 Imp gal Fuel reserve amount 4 5 L 1 19 US gal 0 99 Im...

Page 154: ...ure measured on cold tires Recommended Front 35 0 kPa 0 350 kgf cm 5 0 psi Rear 30 0 kPa 0 300 kgf cm 4 4 psi Minimum Front 32 0 kPa 0 320 kgf cm 4 6 psi Rear 27 0 kPa 0 270 kgf cm 4 0 psi Front wheel...

Page 155: ...lb Bulb voltage wattage quantity Headlight 12 V 35 35 W 2 Tail brake light 12 V 5 0 21 0 W 1 Meter lighting EL Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light...

Page 156: ...YFM5FGPHA 40 0 A Headlight fuse 15 0 A Signaling system fuse 5 0 A Ignition fuse 15 0 A Auxiliary DC jack fuse 15 0 A Four wheel drive motor fuse 15 0 A Radiator fan fuse 20 0 A U28P12E0 book Page 5...

Page 157: ...rence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key...

Page 158: ...be need ed when ordering spare parts from a Yamaha deal er EBU29662 Vehicle Emission Control Information label The Vehicle Emission Control Information label is affixed at the location in the illustra...

Page 159: ...11 3 11 1 Vehicle Emission Control Information label 1 U28P12E0 book Page 3 Thursday March 11 2010 10 13 AM...

Page 160: ...se of noise control prior to its sale or delivery to the ul timate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inope...

Page 161: ...he maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1...

Page 162: ...equent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and re...

Page 163: ...upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Q Is the warranty transferable to second owners A Yes The remainder of...

Page 164: ...o pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives...

Page 165: ...ithin the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be ha...

Page 166: ...11 10 11 EBU26132 U28P12E0 book Page 10 Thursday March 11 2010 10 13 AM...

Page 167: ...ture warning light 4 3 D Differential gear oil 5 3 8 31 Drive select lever 4 15 Drive select lever and driving in reverse 6 2 Drive select lever safety system cable adjusting 8 46 E Engine break in 6...

Page 168: ...light 4 2 Riding your ATV 7 1 S Safety information 2 1 Seat 4 18 Shock absorber assemblies adjusting the front and rear 4 22 Spark arrester cleaning 8 43 Spark plug checking 8 22 Specifications 10 1...

Page 169: ...U28P12E0 book Page 3 Thursday March 11 2010 10 13 AM...

Page 170: ...surfaces pavement may seriously affect handling and control Improper ATV use can result in SEVERE INJURY or DEATH NEVER operate without proper training or instruction at speeds too fast for your skill...

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