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 YFM550DF YFM550PF/YFM550PHF 2LB-F8199-61...
Page 2 Original instructions Notice originale Manual original PRINTED IN USA 2014.03-0.5×1 CR (E,F,S)
Page 3 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM550DF YFM550PF/YFM550PHF WARNING This ATV should not be ridden by anyone under 16 years of age. 2LB-F8199-61-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 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM550FWAD (YFM550PF) (5Y4AJ53W0E0503461–) (YFM550PHF) (5Y4AJ54W0E0500861–)
Page 5 EC Declaration of Conformity conforming to Directive 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM550FWA (YFM550DF) (5Y4AJ39W0E0502081–) (Make, model) to which this declaration applies, conforms to the essential health and safety requirements of Directive 2006/42/EC...
Page 6 Congratulations on your purchase of the Yamaha YFM550DF/YFM550PF/YFM550PHF. This ATV repre- sents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace- setting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
Page 7 EBU17331 IMPORTANT MANUAL INFORMATION EBU17343 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. EBU17411 YFM550DF/YFM550PF/YFM550PHF OWNER’S MANUAL ©2014 by Yamaha Motor Co., Ltd. 1st edition, February 2014 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
Page 9: Table Of Contents
EBU17421 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........
Page 10 Parking ............6-5 Removing and installing panels....8-10 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 ....7-2 Differential gear oil........
Page 11 Checking the wheel hub bearings..... 8-54 Checking the stabilizer bushes ....8-54 Lubricating the rear knuckle pivots... 8-55 Lubricating the steering shaft ....8-55 Battery............8-55 Replacing a fuse ........8-59 Replacing a headlight bulb ....... 8-61 Adjusting a headlight beam ...... 8-63 Replacing the tail/brake light 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 re- placement label from your Yamaha dealer. For Europe...
Page 13 45 kg 1322 lbf < 147 N < 15 kgf ( 99 lbs) < 33 lbf 37S-F817S-00 1HP-F817R-00 1HP-F2259-21 YAMAHA 1P0-F816P-20 < 85 kg ( 187 lbs) 1HP-F817R-10 35.0 kPa 30.0 kPa 0.35 kgf/cm² 0.30 kgf/cm² 5.0 psi 4.4 psi...
Page 14 7 YFM550DF YFM550FWA 2014 27.5 kW YAMAHA MOTOR CO., LTD. 294 kg 2500 SHINGAI, IWATA, JAPAN 1NP-F155A-20 7 YFM550PF/YFM550PHF YFM550FWAD 2014 27.5 kW YAMAHA MOTOR CO., LTD. 294 kg 2500 SHINGAI, IWATA, JAPAN 2LB-F155A-10 YAMAHA 1HP-F811R-00 < 0.5 kg ( 1 lb )
Page 15 37S-F816S-00 YAMAHA 1P0-F816R-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 use on paved roads. ALWAYS use an approved helmet and NEVER carry passengers. protective gear.
Page 17 This unit contains high-pressure nitrogen Turning 4WD-LOCK gas. (“DIFF.LOCK”) takes more effort. Operate at a slow speed and allow extra Mishandling can cause an explosion. Do not incinerate, puncture or open. time and distance for maneuvers to avoid loss of control. This pictogram shows the loading limits and/or maximum load capacity for this ATV.
Page 18 Year of construction Model Name ****** **** *** kW YAMAHA MOTOR CO., LTD. Max. Power *** kg 2500 SHINGAI, IWATA, JAPAN Mass In Running Order...
Page 19 For Oceania...
Page 20 LOAD LIMIT PULLING LOAD: 5880 N (600 kgf) 1322 lbf 45 kg (99 lbs) TONGUE WEIGHT: 147 N ( 15 kgf) 33 lbf YAMAHA 1HP-F4877-A0 37S-F151K-00 WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE 1HP-F2259-21 INJURY or DEATH.
Page 21 Maximum Vehicle Load : 220 kg, (485 lbs) Includes weight of operator, cargo and accessories UNDER (and if applicable, trailer tongue weight). YAMAHA 1HP-F816M-00 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.
Page 22 • use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns. • avoid paved surfaces-pavement may seriously affect handling and control. LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. YAMAHA 4XE-F1568-10 1-11...
Page 23: Safety Information
EBU17432 SAFETY INFORMATION SAFETY INFORMATION  Never allow a child under age 16 to operate an EBU27254 ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
Page 24  Never operate at speeds too fast for your skills  Never operate the ATV on hills too steep for the or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills.
Page 25  Never operate an ATV in fast flowing water or in technique described in this manual on level ground. Avoid crossing the side of a steep hill if water deeper than that recommended in this possible. manual. Remember that wet brakes may have ...
Page 26  Never maintain an ATV without proper knowl- vehicle. If the vehicle is in safe operating con- edge. Contact an authorized ATV dealer to in- dition and you can safely operate it, restart it form you on basic ATV maintenance. Certain and ride gently back to camp or other known maintenance can only be carried out by certified location where you can receive medical at-...
Page 27 While you may find aftermarket products similar in therefore, such accessories are not recom- design and quality to genuine Yamaha accesso- mended. ries, recognize that some aftermarket accessories  Use caution when adding electrical accesso- or modifications are not suitable because of po- ries.
Page 28  Do not run engine outdoors where engine EWB00073 WARNING exhaust can be drawn into a building through openings such as windows and doors. Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nau- sea, confusion, and eventually death.
Page 29: Description
EBU17681 DESCRIPTION EBU17691 EBU17701 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 30: Controls And Instruments
EBU17713 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. Multi-function display 7.
Page 31: Instrument And Control Functions
EBU17735 INSTRUMENT AND CONTROL FUNCTIONS EBU29912 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 be started. The key cannot be removed.
Page 32: Indicator Lights And Warning Lights
EBU26696 EBU17991 Low-range indicator light “ ” Indicator lights and warning lights This indicator light comes on when the transmis- sion is in the low-range position. EBU17981 High-range indicator light “ ” This indicator light comes on when the transmis- sion is in the high-range position.
Page 33 “ ” (on), or if the warning 4-7 for an explanation of the self-diagnosis de- light remains on, have a Yamaha dealer check the vice.) electrical circuit. The electrical circuit of the warning light can be ECB00892 checked by turning the key to “...
Page 34 “ ” (on). If the switch is set to the “LOCK” position. warning light does not come on, have a Yamaha dealer check the electrical circuit.  Due to the synchronizing mechanism in the dif- ferential gear case, the four-wheel-drive indica- ...
Page 35: Multi-Function Display
 an hour meter (which shows the total time the EBU30494 Multi-function display engine has been running)  a fuel meter  a self-diagnosis device Odometer and tripmeter modes Pushing the “SELECT” button switches the dis- play between the odometer mode “ODO” and the tripmeter modes “TRIP A”...
Page 36 CLOCK → HOUR → CLOCK warning indicator will start flashing. If this occurs, have a Yamaha dealer check the electrical circuit. To set the clock 1. Set the display to the clock mode.
Page 37: Handlebar Switches
If the multi-function display indicates an error co- 1. Light switch “ /OFF” de, note the code number, and then have a 2. Start switch “ ” Yamaha dealer check the vehicle. 3. Engine stop switch “ ” 4. Override switch “OVERRIDE” 5. Horn switch “ ”...
Page 38 recharge it. (See page 8-55.) EBU18081 Engine stop switch “ ” Set this switch to “ ” before starting the engine. EBU18171 The engine stop switch controls the ignition and Horn switch “ ” stops the engine when it is running. Use this Press the switch to sound the horn.
Page 39 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 40 This ATV is equipped with a switch to change from two-wheel drive to four-wheel drive and vice ver- sa. Select the appropriate drive according to the terrain and the conditions.  “2WD” (two-wheel drive): Power is supplied to the rear wheels. ...
Page 41  “LOCK” (four-wheel drive with the differential expectedly. This could distract the operator and increase the risk of losing control and gear locked): Power is supplied to the rear and causing an accident. front wheels and the differential gear is locked. Unlike in four-wheel drive, all wheels turn at the EWB00141 same speed.
Page 42 LOCK 1. Differential gear lock lever 1. On-Command differential gear lock switch “4WD”/“LOCK” 2. On-Command four-wheel-drive switch “2WD”/“4WD” To unlock the differential gear, stop the ATV and Stop the ATV, move the differential gear lock lever push the switch to the “4WD” position. to position (a), and then push the differential gear lock switch in to the “LOCK”...
Page 43: Throttle Lever
 Riding before the differential gear is properly en- gaged or disengaged (e.g., when the indicator and indicator light are flashing) will cause the vehicle speed to be limited until the differential gear is completely engaged or disengaged.  When the ATV is in four-wheel-drive differential gear lock, the maximum traveling speed is limit- ed to 35 km/h (22 mi/h).
Page 44: Front Brake Lever
decrease the maximum engine power avail- 3. Tighten the locknut. able and the maximum speed of the ATV, turn EBU18392 the adjusting screw in direction (b). Do not Front brake lever turn the adjusting screw out more than 12 The front brake lever is located on the right han- mm (0.47 in) or the throttle cable could be dlebar.
Page 45: Drive Select Lever
EBU18612 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 46: 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. EBU18757 Fuel Make sure there is sufficient gasoline in the tank. EWB02522 WARNING Gasoline and gasoline vapors are extremely flammable.
Page 47 fuel expands when it heats up, heat from the 3. Wipe up any spilled fuel immediately. NOTICE: Immediately wipe off spilled fuel engine or the sun can cause fuel to spill out of the fuel tank. with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts.
Page 48: Seat
Your Yamaha engine has been designed to use To install the seat regular unleaded gasoline with a research octane Insert the projections on the front of the seat into number of 91 or higher (95 or higher for Europe). If...
Page 49 ECB00831 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 50 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 stor- age compartments. ...
Page 51: Front Carrier
EBU18963 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. EBU18973 Rear carrier  Do not exceed the load limit of 85.0 kg (187 lb) for the rear carrier.
Page 52 2. Position indicator EWB02731 WARNING The rear shock absorber assembly contains A special wrench can be obtained at a Yamaha highly pressurized nitrogen gas. If the shock dealer to make this adjustment. absorber assembly is damaged, it could ex- plode causing injury or property damage.
Page 53: Auxiliary Dc Jack
 Do not deform or damage the cylinder in any way.  Do not dispose of a damaged or worn out shock absorber assembly yourself. Take the shock absorber assembly to a Yamaha deal- 1. Auxiliary DC jack cap er for any service. EBU19184...
Page 54 Maximum rated capacity for the auxiliary DC jack: DC 12 V, 10 A (120 W) 5. Turn the accessory on. 6. When the auxiliary DC jack is not being used, cover it with the cap. ECB00121 NOTICE  Do not use accessories requiring more than the above maximum capacity.
Page 55: 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 56 ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-3, 8-46, 8-47, 8-49 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.
Page 57: Fuel
They should move smoothly and there specified level. Add oil as necessary. (See page should be a firm feeling when the brakes are ap- 8-29.) plied. If not, have a Yamaha dealer check the brake system. EBU19632 Coolant Brake fluid level Make sure that the coolant is at the specified level.
Page 58: Throttle Lever
(See page 8-46.) pressures to the following specifications: EBU19762 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 59 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 60 YFM550DF MAXXIS/MU20 dent. (EUR)(FRA)(GBR) YFM550PF CHENG SHIN/C828 After extensive tests, only the tires listed below (AUS)(NZL) have been approved for this model by Yamaha YFM550PF MAXXIS/MU20 Motor Manufacturing Corporation of America. (EUR)(FRA)(GBR) YFM550PHF MAXXIS/MU20...
Page 61: Chassis Fasteners
Size: AT25 x 10-12 Type: Tubeless 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.
Page 62: Operation
The corresponding indicator light should come on. If the indicator light does not come ECB00151 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 63: Operating The Drive Select Lever And Driving In Reverse
 The rear brake lever or brake pedal is applied EBU20442 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. ECB00171 NOTICE 3.
Page 64 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 65: Engine Break-In
320 km (200 mi) or should come on. If the indicator light does not 20 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 66: Parking
If any engine trouble should occur during the 1. Bring the ATV to a stop by applying the engine break-in period, immediately have a brakes. Yamaha dealer check the ATV. 2. Stop the engine. 3. With the brake pedal applied, shift the drive EBU27322 Parking select lever to the park position.
Page 67: Accessories And Loading
ATV. Yamaha vehicles. Yamaha is not in a position to  Do not mount an accessory where it could inter- test the products that these aftermarket compa- fere with your ability to control the ATV.
Page 68  Never exceed the weight limits shown. An over- bulky object attached to the handlebars which 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 69 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 70: Riding Your Atv
EBU21142 RIDING YOUR ATV...
Page 71: Getting To Know Your Atv
RIDE WITH CARE AND GOOD JUDGMENT EBU27419 Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01382 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 72 the time to learn the basic techniques well before This ATV is designed to carry the operator and attempting more difficult maneuvers. Become fa- cargo only – passengers prohibited. miliar with this ATV at slow speeds first, even if you The long seat is to allow the operator to shift posi- are an experienced operator.
Page 73 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 74 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 mainte- Do not operate after or while consuming alco- nance procedures and schedules described in the hol or drugs.
Page 75  Do not exceed the maximum loading limits fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting for the vehicle (see “MAXIMUM LOADING screw limits the maximum engine power available LIMIT” in this section or vehicle labeling). ...
Page 76 During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during ATV loading limit (total weight of cargo, rid- operation; otherwise, they may contact the rear er, accessories, and tongue): wheels. WARNING! Removing even one hand or 220.0 kg (485 lb) foot can reduce your ability to control the ATV Front carrier: or could cause you to lose your balance and...
Page 77 ATV should during operation or after leaving the ATV, do not be genuine Yamaha or equivalent components let brush, grass and other materials collect under designed for use on this ATV and should be in- the vehicle, near the muffler or exhaust pipe, or stalled and used according to instructions.
Page 78: 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 79 know your country’s laws and regulations before ful when operating on unfamiliar terrain. Al- you ride on unpaved public streets or roads. Do ways be alert to changing terrain conditions not ride on any paved public street, road or motor- when operating the ATV.
Page 80 terrain could cause loss of traction or ATV con- trol, which could result in an accident, includ- ing an overturn. [EWB01542] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.
Page 81: Turning Your Atv
Select a large, flat, unpaved area to become famil- ECB00252 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 82: 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 turn, come to a stop and then practice the proce- you do so, put your weight on the footboard to the dure again.
Page 83  Never operate the ATV on hills too steep for the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills.  Always check the terrain carefully before you start up any hill.
Page 84 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 85: Riding Downhill
 Always check the terrain carefully before you straight uphill. Turn the ATV around and remount, following the procedure described in the Owner’s start down any hill.  Never operate the ATV on hills too steep for Manual. WARNING! Stalling, rolling backwards or improperly dismounting while climbing a hill the ATV or for your abilities.
Page 86: 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 87: 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 88 The ATV can be used to cross slow moving, shal- braking ability. WARNING! Wet brakes may have low water of up to a maximum of 35 cm (14 in) in reduced stopping ability, which could cause depth. Before entering the water, choose your loss of control.
Page 89 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 90: Riding Over Rough Terrain
accident. 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 result. SLIDING AND SKIDDING EWB01663 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.
Page 91: What To Do If
To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help. With practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting If the rear wheels of your ATV start to slide side- such maneuvers, since both stability and control...
Page 92: What To Do
 If your ATV is traversing a sloping surface: WHAT TO DO...  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 93: Periodic Maintenance And Adjustment
The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.
Page 94: Owner's Manual And Tool Kit
If you do not have the tools or experience required spective compartments under the seat. for a particular job, have a Yamaha dealer perform it for you. 1. Owner’s manual 2.
Page 95: 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 still be followed.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 96 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours √ √ √ Spark arrester • Clean.
Page 97: General Maintenance And Lubrication Chart
However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should still be followed.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 98 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check operation and correct if necessary. • Check brake pedal free play and adjust if neces- √...
Page 99 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours Shock absorber as- • Check operation and correct if necessary. √ √ √ semblies • Check for oil leakage and replace if necessary. •...
Page 100 INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Change. √ √ Final gear oil • Check ATV for oil leakage, and correct if neces- sary.
Page 101 EBU23072  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 102: Removing And Installing Panels
EBU23091 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 103 Panel B To remove the panel 1. Remove panel A. 2. Remove the front carrier by removing the bolts. 1. Panel A To install the panel Place the panel in the original position. 1. Carrier bolt (under the fenders) 8-11...
Page 104 3. Remove the quick fasteners, and then pull the panel upward to remove it. 1. Front carrier 2. Carrier bolt (upper) 1. Panel B 2. Quick fastener To install the panel 1. Place the panel in the original position, and then install the quick fasteners.
Page 105 Panel C To remove the panel 1. Remove the seat. (See page 4-18.) 2. Remove the quick fastener screws, and then pull the panel upward to remove it. 2. Install the front carrier by installing the bolts and tightening them to the specified torques. Tightening torques: Carrier bolt (upper): 34 Nm (3.4 m·kgf, 25 ft·lbf)
Page 106 1. Panel D 2. Install the seat. 2. Quick fastener screw Panels D and E To remove a panel 1. Remove panels A and C. 2. Remove the quick fastener screw and bolt, and then pull the panel upward to remove it. To ease removal of panel D, shift the drive select lever into the reverse position.
Page 107 To install a panel 1. Place the panel in the original position, and then install the bolt and quick fastener screw. 1. Panel E 2. Quick fastener screw 1. Bolt 2. Install panels A and C. 8-15...
Page 108 Panels F and G To remove a panel 1. Remove the panel bolts, footboard bolt, and footboard nut. 2. Pull the panel downward while pushing the projection. 1. Panel G 2. Footboard nut 3. Footboard bolt 4. Panel bolt 5. Projection To install a panel 1.
Page 109 Tightening torques: Panel bolt: 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Footboard nut: 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Panel H To remove the panel 1. Remove the seat. (See page 4-18.) 2. Remove the rear carrier by removing the bolts. 2.
Page 110 3. Remove the quick fasteners, and then push inward on the areas shown. 1. Rear carrier 2. Carrier bolt (upper) 1. Panel H 2. Quick fastener To install the panel 1. Place the panel in the original position, and then install the quick fasteners. 1.
Page 111: Removing The Radiator Grills
EBU28672 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 112: Checking The Spark Plug
2. Remove the spark plug as shown, with the EBU23214 Checking the spark plug spark plug wrench included in the owner’s The spark plug is an important engine component, tool 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 ac- cordance with the periodic maintenance and lubri-...
Page 113 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 114: Engine Oil And Oil Filter Cartridge
Tightening torque: Spark plug: If the engine was started before checking the oil 13 Nm (1.3 m·kgf, 9.4 ft·lbf) level, be sure to warm up the engine sufficiently, and then wait at least 10 minutes until the oil set- tles for an accurate reading. If a torque wrench is not available when installing 3.
Page 115 1. Engine oil dipstick 1. Maximum level mark 2. Minimum level mark 5. Insert the dipstick completely into the oil filler 6. If the engine oil is at or below the minimum hole, and then remove it again to check the oil level mark, add sufficient oil of the recom- level.
Page 116 1. Oil filter cartridge 2. Oil filter wrench 1. Engine oil drain bolt 2. Gasket An oil filter wrench is available at a nearby Yamaha dealer. 7. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge.
Page 117 1. O-ring 1. Torque wrench Tightening torque: Oil filter cartridge: Make sure that the O-ring is properly seated. 17 Nm (1.7 m·kgf, 12 ft·lbf) 8. Install the new oil filter cartridge with an oil fil- 9. Install panel F. ter wrench, and then tighten it to the specified 10.
Page 118: Final Gear Oil
The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have ECB00301 a Yamaha dealer check and repair the ATV. In ad- NOTICE dition, the final gear oil level must be checked and ...
Page 119 2. Remove the final gear oil level check bolt and its gasket, and then check the oil level in the final gear case. The oil level should be at the brim of the check hole. 1. Final gear oil filler bolt 2.
Page 120 To change the final gear oil Tightening torque: 1. Place the ATV on a level surface. Final gear oil drain bolt: 2. Place an oil pan under the final gear case to 23 Nm (2.3 m·kgf, 17 ft·lbf) collect the used oil. 3.
Page 121: Differential Gear Oil
2. Gasket leakage before each ride. If any leakage is found, 3. Differential gear oil have a Yamaha dealer check and repair the ATV. 4. Correct oil level In addition, the differential gear oil level must be 3. If the oil is below the brim of the filler hole, add...
Page 122 5. Install the oil filler bolt and its gasket, and then 4. Install the drain bolt and its new gasket, and tighten the bolt to the specified torque. then tighten the bolt to the specified torque. Tightening torque: Tightening torque: Differential gear oil filler bolt: Differential gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf)
Page 123: Coolant
Recommended differential gear oil: See page 10-1. The coolant level must be checked on a cold en- gine since the level varies with engine tempera- 6. Check the oil filler bolt gasket for damage, ture. and replace it if necessary. 7.
Page 124 If water has been added to the coolant, have Coolant reservoir capacity (up to the maxi- a Yamaha dealer check the antifreeze con- mum level mark): tent of the coolant as soon as possible, 0.24 L (0.25 US qt, 0.21 Imp.qt) otherwise the effectiveness of the coolant will be reduced.
Page 125 EBU27769 To change the coolant EWB01891 WARNING Wait for the engine and radiator to cool before removing the radiator cap. You could be burned by hot fluid and steam blown out under pressure. Always place a thick rag over the cap when opening.
Page 126 6. Remove the radiator cap. 1. Coolant drain bolt 2. Gasket 1. Radiator cap 7. Remove the coolant reservoir cap. 8. Disconnect the coolant reservoir hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir. 1.
Page 127 13. Pour the recommended coolant into the res- ervoir to the maximum level mark, and then install the reservoir cap. NOTICE: Mix anti- freeze with distilled water only. However, if distilled water is not available, soft water may be used for refilling. Do not use hard water or salt water since they are harmful to the engine.
Page 128 1. Water pump air bleed bolt 1. V-belt cooling duct 2. Clamp screw 15. When coolant begins to flow out of the bolt 18. Loosen the cylinder head air bleed bolt, with- hole, tighten the water pump air bleed bolt to out removing it, to allow all of the air to es- the specified torque.
Page 129 24. Start the engine, and then check for coolant leakage. If any leakage is found, have a Yamaha dealer check the cooling system. 1. Cylinder head air bleed bolt 25. Install the V-belt cooling duct, and then tight- en the clamp screw.
Page 130 1. Footboard nut Tightening torques: 2. Footboard bolt A Footboard nut: 3. Footboard bolt B 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Footboard bolt A: 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Tighten footboard bolts B in the order shown. Footboard bolt B: 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 27.
Page 131: Cleaning The Air Filter Element
EBU27807 Cleaning the air filter element The air filter element should be cleaned at the in- tervals specified in the periodic maintenance and lubrication chart. Clean or, if necessary, replace the air filter element more frequently if you are rid- ing in unusually wet or dusty areas.
Page 132 3. Remove the air filter case cover by unhooking the holders. 1. Air filter case cover holder 2. Air filter case cover 4. Remove the sponge material and the air filter mesh from the air filter case. 1. Sponge material 2.
Page 133 8. Check the sponge material and replace it if damaged. 9. Apply Yamaha foam air filter oil or other qual- ity foam air filter oil to the sponge material. 8-41...
Page 134: Cleaning The Spark Arrester
13. Install the panel. The air filter element should be cleaned every 20– 40 hours. It should be cleaned and lubricated more often if the ATV is operated in extremely dusty areas. Each time the air filter element main- tenance is performed, check the air inlet of the air filter case for obstructions.
Page 135 1. Tailpipe bolt 1. Tailpipe 2. Spark arrester 2. Remove the tailpipe by pulling it out of the 3. Gasket muffler, and then remove the gasket. 4. Check the gasket for damage, and replace it 3. Tap the tailpipe lightly, and then use a wire if necessary.
Page 136: V-Belt Case Drain Plug
Tightening torque: Purging bolt: 27 Nm (2.7 m·kgf, 20 ft·lbf) EWB02381 WARNING Never run the engine in an enclosed area when purging the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monox- ide poisoning, possibly leading to death, and start a fire.
Page 137: Adjusting The Throttle Lever Free Play
If water drains from the V-belt case after removing 3. To increase the throttle lever free play, turn the plug, have a Yamaha dealer check the ATV as the throttle lever free play adjusting bolt in di- the water may affect other engine parts.
Page 138: Valve Clearance
Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- EBU27471 brication chart.
Page 139: Checking The Brake Fluid Level
Front brake EBU29843 Checking the brake fluid level Before riding, check that the brake fluid is above the minimum level mark. Check the brake fluid lev- el with the top of the reservoir level. Replenish the brake fluid if necessary. Front brake 1.
Page 140 If the brake fluid level goes down sud- mance. denly, have a Yamaha dealer check the cause be-  Clean the filler cap before removing. Use fore further riding. only DOT 4 brake fluid from a sealed contain-...
Page 141: Changing The Brake Fluid
Front brake EBU24293 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking.
Page 142: Adjusting The Brake Pedal Free Play
EBU29074 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 143 5. After adjusting, there should be slight play at If the correct free play cannot be obtained, have a the brake pedal cable joint as shown. If there Yamaha dealer adjust it. is no play, repeat steps 2 to 4. When adjusting the brake pedal free play: ...
Page 144: Axle Boots
If a cable is damaged or does not move 1. Front axle boot (each side) smoothly, have a Yamaha dealer check or replace Recommended lubricant: Yamaha cable lubricant or other suitable...
Page 145: Checking And Lubricating The Front And Rear Brake Levers
Front brake lever EWB02582 WARNING  Inspect cables frequently and replace if damaged. Corrosion can result when the ca- ble sheaths become damaged, and cables can also become frayed or kinked, which could restrict the operation of controls and lead to an accident or injury. ...
Page 146: Checking And Lubricating The Brake Pedal
Yamaha dealer check the wheel hub bearings. To access the brake pedal pivot, remove panel G.
Page 147: Lubricating The Rear Knuckle Pivots
The rear knuckle pivots must be lubricated at the The steering shaft must be lubricated by a intervals specified in the periodic maintenance Yamaha dealer at the intervals specified in the pe- and lubrication chart. riodic maintenance and lubrication chart.
Page 148 To remove the battery EWB02161 WARNING 1. Remove panel A. (See page 8-10.) 2. Remove the front carrier by removing the Battery electrolyte is poisonous and danger- bolts. ous, as it contains sulfuric acid, which can cau- se severe burns. Avoid contact with skin, eyes or clothing.
Page 149 3. Remove the battery holding plate by remov- ing the nuts. 4. Disconnect the negative battery lead first, then the positive battery lead by removing their bolt. NOTICE: When removing the bat- tery, the main switch must be off, and the negative lead must be disconnected be- fore the positive lead.
Page 150 To charge the battery To install the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep Be sure the battery is fully charged. in mind that the battery tends to discharge more quickly if the ATV is equipped with optional elec- 1.
Page 151: Replacing A Fuse
4. Install the front carrier by installing the bolts EBU30521 Replacing a fuse and tightening them to the specified torques. Tightening torques: Carrier bolt (upper): 34 Nm (3.4 m·kgf, 25 ft·lbf) Carrier bolt (lower): 34 Nm (3.4 m·kgf, 25 ft·lbf) Carrier bolt (under the fenders): 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 5.
Page 152 ECB00641 NOTICE To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. WARNING! Always use a fuse of the spec- ified rating, and never use a substitute ob- ject in place of the proper fuse.
Page 153: Replacing A Headlight Bulb
YFM550PHF 40.0 A 3. Turn the key to “ ” (on) and turn on the elec- trical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 8-61...
Page 154 4. Unhook the headlight bulb holder, and then remove the burnt-out bulb. 1. Headlight bulb cover 3. Disconnect the headlight coupler. 1. Headlight bulb holder 2. Headlight bulb 5. Place a new headlight bulb into position, and then secure it with the bulb holder. NOTICE: Do not touch the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the luminos-...
Page 155: Adjusting A Headlight Beam
Adjusting a headlight beam 1. Remove panel H. (See page 8-10.) ECB00691 2. Remove the tail/brake light bulb holder (to- NOTICE gether with the bulb) by turning it counter- It is advisable to have a Yamaha dealer make clockwise. this adjustment. 8-63...
Page 156: Removing A Wheel
4. Insert a new bulb into the bulb holder, push it in, and then turn it clockwise until it stops. 5. Install the bulb holder (together with the bulb) by turning it clockwise. 6. Install the panel. EBU25652 Removing a wheel 1.
Page 157: Installing A Wheel
EBU25702 Installing a wheel 1. Place the ATV on a level surface. 2. Install the wheel and the nuts.  The arrow mark on the tire must point to- ward the rotating direction of the wheel.  Tapered nuts are used for both the front and rear wheels.
Page 158: Troubleshooting
The following troubleshooting charts represent quick and easy procedures for checking these vi- tal systems yourself. However, should your ATV require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the ATV properly.
Page 159: Troubleshooting Charts
Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the ATV. Check the compression. 4. Compression The engine does not start. There is compression.
Page 160 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 recommended coolant as soon as possible.
Page 161: Cleaning And Storage
EBU25861 CLEANING AND STORAGE and deterioration of wheel bearings, EBU25882 Cleaning brakes, transmission seals and electrical Frequent, thorough cleaning of your ATV will not devices. Many expensive repair bills have only enhance its appearance but will improve its resulted from improper high-pressure de- general performance and extend the useful life of tergent applications such as those avail- many components.
Page 162: Storage
3. Perform the following steps to protect the cyl- EBU27262 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 163 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 164: Specifications
EBU25962 SPECIFICATIONS Dimensions: Vibration on handle (EN1032, ISO5008): YFM550DF Will not exceed 2.5 m/s² (EUR)(FRA)(GBR) Overall length: YFM550PF Will not exceed 2.5 m/s² (EUR)(FRA)(GBR) 2065 mm (81.3 in) YFM550PHF Will not exceed 2.5 m/s² Overall width: Engine: 1180 mm (46.5 in) Overall height: Engine type: 1240 mm (48.8 in)
Page 165 Type: Quantity: SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W- 0.22 L (0.23 US qt, 0.19 Imp.qt) Cooling system: Coolant reservoir capacity (up to the maximum level mark): 130 ˚F 0.24 L (0.25 US qt, 0.21 Imp.qt) Radiator capacity (including all routes): SAE 5W-30 1.99 L (2.10 US qt, 1.75 Imp.qt) Air filter:...
Page 166 Transmission: Manufacturer/model: YFM550DF CHENG SHIN/C828 (AUS)(NZL) Primary reduction system: YFM550DF MAXXIS/MU19 (EUR)(FRA)(GBR) V-belt YFM550PF CHENG SHIN/C828 (AUS)(NZL) Secondary reduction system: YFM550PF MAXXIS/MU19 (EUR)(FRA)(GBR) Shaft drive YFM550PHF MAXXIS/MU19 Secondary reduction ratio: 41/21 × 24/18 × 33/9 (9.544) Rear tire: Transmission type: Type: V-belt automatic Tubeless...
Page 167 Front wheel: Rear suspension: Wheel type: Type: Panel wheel Double wishbone Rim size: Spring/shock absorber type: 12 x 6.0AT Coil spring/gas-oil damper Rear wheel: Wheel travel: 230 mm (9.1 in) Wheel type: Electrical system: Panel wheel Rim size: Ignition system: 12 x 7.5AT Front brake: Charging system:...
Page 168 Coolant temperature warning light: Auxiliary DC jack fuse: 10.0 A EPS warning light: Four-wheel-drive motor fuse: YFM550PF LED 10.0 A YFM550PHF LED Radiator fan motor fuse: Park indicator light: 20.0 A On-Command four-wheel-drive/differential gear lock EBU30402 indicator: For Europe only Engine trouble warning light: The figures quoted are emission levels and are not necessarily safe working levels.
Page 169: Consumer Information
Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number (front left side)
Page 170 1. Model label 11-2...
Page 171: Index
INDEX Drive select lever safety system cable, adjusting ..8-46 Accessories and loading ..........6-6 Accessories, auxiliary jack ........... 4-23 Engine break-in .............. 6-4 Air filter element, cleaning ........... 8-39 Engine oil ............... 5-3 Axle boots ..............8-52 Engine oil and oil filter cartridge ........8-22 Engine stop switch ............
Page 172 Specifications .............. 10-1 Speed limiter ..............4-13 Main switch ..............4-1 Stabilizer bushes, checking ......... 8-54 Maintenance and lubrication chart ........8-5 Starting the engine ............6-1 Maintenance chart, emission control system ....8-3 Start switch ..............4-8 Model label ..............11-1 Steering shaft, lubricating ..........8-55 Multi-function display .............4-5 Storage ................
Page 174 EBU26173 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. NEVER USE ALWAYS USE NEVER USE NEVER CARRY AN APPROVED PASSENGERS WITH DRUGS ON PAVED HELMET AND OR ALCOHOL ROADS PROTECTIVE GEAR NEVER ALWAYS operate: • without proper training or instruction. •...

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Yamaha GRIZZLY 550 2015 Owner's Manual

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