Yamaha Grizzly 550 Owners Manual

The Yamaha Grizzly 550 is a powerful and reliable all-terrain vehicle (ATV) designed for work and recreation. This manual covers essential information for safe operation, routine maintenance, specifications, and troubleshooting of your ATV. Below are key sections covering safety, features, operation, maintenance, and technical details.

1. Features at a Glance 2. Safety Information 3. Controls and Instruments 4. Operation Instructions 5. Specifications 6. Routine Maintenance 7. Fuel and Lubrication 8. Tire and Wheel Care 9. Storage Guidelines 10. Troubleshooting 11. Warranty Information

Features at a Glance

Key components: 550cc liquid-cooled engine, Ultramatic automatic transmission with engine braking, On-Command 2WD/4WD with differential lock, independent double-wishbone front suspension, IRS rear suspension, disc brakes, and durable cargo racks.

Feature	Description
Engine	550cc, 4-stroke, SOHC, liquid-cooled
Transmission	Ultramatic automatic V-belt with all-wheel engine braking
Drive System	On-Command 2WD/4WD with diff lock
Suspension	Independent double-wishbone front / IRS rear
Brakes	Dual hydraulic disc front / sealed hydraulic disc rear
Fuel Capacity	4.8 gallons (18.2 liters)
Cargo Capacity	Front: 88 lbs (40 kg), Rear: 187 lbs (85 kg)
Towing Capacity	Up to 1,212 lbs (550 kg)
Electric Start	Primary with auxiliary pull start
Instrumentation	Speedometer, odometer, trip meter, fuel gauge, gear indicator

Safety Information

Always wear an approved helmet, eye protection, gloves, boots, and protective clothing. Never operate under the influence of alcohol or drugs.

Pre-ride inspection: Check tires, controls, lights, oil, fuel, and brakes before each ride.
Riding terrain: Operate only on designated trails; avoid paved roads.
Passengers: This ATV is designed for one operator only. Do not carry passengers.
Loading: Do not exceed cargo and towing capacities; secure all loads.

WARNING! ATVs can be hazardous to operate. Always follow safe riding practices. This vehicle is for operators 16 years and older.

Controls and Instruments

Familiarize yourself with all controls before operation.

Left Handlebar: Headlight dimmer switch, horn button, 2WD/4WD switch, differential lock switch, rear brake lever.

Right Handlebar: Electric start button, engine stop switch, throttle lever, front brake lever.

Instrument Panel: Speedometer, odometer, dual trip meters, fuel gauge, gear position indicator, 4WD indicator, diff lock indicator, warning lights (oil, temp, battery).

Other Controls: Fuel valve, choke knob, parking brake lever, shift lever (F-N-R), ignition key switch.

Operation Instructions

Starting and riding your Grizzly 550.

Pre-start: Sit on vehicle, apply parking brake, shift to Neutral (N).
Starting: Turn fuel valve ON, pull choke (if cold), turn key ON, press brake lever, press start button.
Driving: Release parking brake, select Forward (F) or Reverse (R), apply throttle smoothly.
4WD/Diff Lock: Use switches to engage 4WD or differential lock for difficult terrain.
Stopping: Release throttle, apply brakes evenly, shift to Neutral, apply parking brake.

CAUTION! Avoid sudden throttle or brake applications. Practice in a safe, open area before challenging terrain.

Specifications

Model: Yamaha Grizzly 550 (YFM55FPA/G).
Engine Type: 4-stroke, SOHC, liquid-cooled, 4-valve.
Displacement: 558cc.
Bore x Stroke: 92.0mm x 84.0mm.
Compression Ratio: 9.5:1.
Fuel System: Mikuni BSR36 carburetor.
Ignition: DC-CDI.
Starting System: Electric and auxiliary recoil.
Transmission: Ultramatic automatic V-belt with H, L, N, R, P.
Final Drive: Shaft drive.
Suspension Travel: Front 7.1 in (180mm), Rear 9.5 in (241mm).
Brakes: Hydraulic disc front and rear.
Tires: AT25 x 8-12 front, AT25 x 10-12 rear.
Dimensions (LxWxH): 81.5 x 46.1 x 48.4 in (2070 x 1170 x 1230mm).
Dry Weight: 600 lbs (272 kg).

Routine Maintenance

Regular maintenance ensures longevity and safety. Refer to the maintenance schedule in your manual.

Item	Interval	Action
Engine Oil	Every 100 hrs or 6 months	Check level; change oil and filter.
Air Filter	Every 50 hrs or 3 months	Clean foam element; replace if damaged.
Spark Plug	Every 100 hrs or 6 months	Check gap; clean or replace.
Drive Shaft Oil	Every 200 hrs or 12 months	Check and change.
Differential Oil	Every 200 hrs or 12 months	Check and change (front & rear).
Brake Fluid	Every 2 years	Inspect level and condition; replace.
Brake Pads	As needed	Inspect wear; replace if worn.
Throttle & Brake	Before each ride	Check free play and operation.

Fuel and Lubrication

Use unleaded gasoline with a minimum octane rating of 87 (R+M)/2. Do not use gasoline containing more than 10% ethanol.

Engine Oil: Use Yamalube 4 (10W-30) or equivalent 4-stroke motorcycle oil meeting API service classification SG or higher. Capacity: approx. 2.6 qt (2.5 L) with filter change.
Final Drive Oil: Use SAE 80 API GL-4 Hypoid gear oil. Front diff: 0.26 qt (0.25 L). Rear diff: 0.42 qt (0.40 L).
Grease Points: Lubricate suspension pivots, steering stem, and brake lever pivots periodically.

WARNING! Do not overfill. Wipe up spills immediately. Gasoline is highly flammable.

Tire and Wheel Care

Maintain correct tire pressure for optimal handling and tire life.

Recommended Pressure: Front: 3.6 psi (25 kPa), Rear: 3.6 psi (25 kPa) for standard loads. Adjust for heavy loads or specific terrain.
Inspection: Check for cuts, embedded objects, and wear before each ride.
Tire Replacement: Use specified tire sizes. Have tires mounted by a qualified technician.
Wheel Nuts: Check torque periodically: 65 Nm (47 ft-lb).

Storage Guidelines

If storing the ATV for more than one month:

Clean entire vehicle thoroughly.
Change engine oil and filter.
Fill fuel tank and add fuel stabilizer. Run engine for 5 minutes.
Remove spark plug, add a teaspoon of oil, crank engine, reinstall plug.
Inflate tires to recommended pressure; lift vehicle to take weight off tires.
Store in a cool, dry place, away from sunlight. Cover with a breathable cover.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine does not start	Fuel valve off, dead battery, clogged fuel line	Check fuel valve, battery charge, and fuel flow.
Engine starts but dies	Choke not adjusted, dirty air filter	Adjust choke for temperature; clean air filter.
Loss of power	Dirty air filter, clogged fuel filter, worn drive belt	Service air/fuel filters; inspect drive belt.
Poor handling	Low tire pressure, worn tires, loose wheel nuts	Inflate tires; inspect for wear; tighten nuts.
Brakes feel spongy	Air in brake lines, low brake fluid	Bleed brake system; top up brake fluid.
Overheating	Low coolant, clogged radiator, low oil	Check coolant and oil levels; clean radiator fins.
Electrical issues	Blown fuse, loose connection	Check main fuse (30A) and wiring connections.

Note: For complex issues, consult an authorized Yamaha dealer.

Warranty Information

Your Yamaha Grizzly 550 is covered by a limited warranty. Please see your Yamaha dealer for complete warranty details and registration.

Warranty Period: 6 months (Limited Factory Warranty). An extended Y.E.S. (Yamaha Extended Service) plan is available.

Owner Responsibility: Perform required maintenance as outlined in this manual. Keep records of service.

Contact: For warranty service, locate an authorized Yamaha ATV dealer. For customer support, visit www.yamahamotorsports.com or call 1-800-962-7926.