Yamaha Grizzly550 Manuals

Manuals and User Guides for Yamaha Grizzly550. We have 1 Yamaha Grizzly550 manual available for free PDF download: User Manual

Yamaha Grizzly550 User Manual

Yamaha Grizzly550 User Manual (443 pages)

ATV

Brand: Yamaha | Category: Offroad Vehicle | Size: 14.37 MB

Table of Contents

Table of Contents

5
- General Information
  7
Specifications

29
- General Specifications
  30
- Engine Specifications
  31
- Chassis Specifications
  39
- Electrical Specifications
  42
- Tightening Torques
  45
- Lubrication Points and Lubricant Types
  53
  - Engine
    53
- Lubrication System Chart and Diagrams
  56
  - Lubrication Diagrams
    56
- Cooling System Diagrams
  60
- Cable Routing
  62
Periodic Checks and Adjustments

77
- Periodic Maintenance
  
  80
- Engine
  
  83
  - Adjusting the Valve Clearance
    83
  - Adjusting the Throttle Lever Free Play
    85
  - Adjusting the Speed Limiter
    85
  - Checking the Spark Plug
    86
  - Checking the Ignition Timing
    87
  - Measuring the Compression Pressure
    87
  - Checking the Engine Oil Level
    88
  - Changing the Engine Oil
    89
  - Cleaning the Air Filter Element
    91
  - Checking the V-Belt
    92
  - Replacing the V-Belt
    92
  - Checking the Throttle Body Joint
    93
  - Checking the Fuel Line
    93
  - Checking the Breather Hoses
    93
  - Checking the Exhaust System
    94
  - Cleaning the Spark Arrester
    94
  - Checking the Coolant Level
    95
  - Checking the Cooling System
    95
  - Changing the Coolant
    96
- Chassis
  
  99
  - Adjusting the Front Disc Brake
    99
    
    Adjusting the Rear Disc Brake
    99
    
    Checking the Brake Fluid Level
    100
    
    Checking the Front Brake Pads
    100
    
    Checking the Rear Brake Pads
    101
    
    Checking the Front Brake Hoses
    101
    
    Checking the Rear Brake Hoses
    101
    
    Checking the Rear Brake Hose Protectors
    102
    
    Bleeding the Hydraulic Brake System
    102
    
    Adjusting the Drive Select Lever Control Cable and Shift Rod
    103
    
    Checking the Final Gear Oil Level
    104
    
    Changing the Final Gear Oil
    105
    
    Checking the Differential Gear Oil Level
    105
    
    Changing the Differential Gear Oil
    106
    
    Checking the Constant Velocity Shaft Assembly Dust Boots
    106
    
    Checking the Steering System
    107
    
    Adjusting the Toe-In
    108
    
    Checking the Front Shock Absorber Assemblies
    109
    
    Adjusting the Front Shock Absorber Assemblies
    110
    
    Checking the Rear Shock Absorber Assemblies
    110
    
    Adjusting the Rear Shock Absorber Assemblies
    111
    
    Checking the Tires
    111
    
    Checking the Wheels
    113
    
    Checking and Lubricating the Cables
    113
    
    Lubricating the Levers
    113
    
    Lubricating the Pedal
    113
- Electrical System
  
  114
  - Checking and Charging the Battery
    114
  - Checking the Fuses
    114
  - Replacing the Headlight Bulbs
    114
  - Adjusting the Headlight Beams
    114
Chassis

117
- General Chassis
  
  120
  - Installing the Rear Fender
    125
  - Installing the Footrest Boards
    131
- Front Wheels
  
  133
  - Removing the Front Wheels
    134
  - Checking the Front Wheels
    134
  - Checking the Front Wheel Hubs
    134
  - Installing the Front Brake Discs
    135
  - Installing the Front Wheel Hubs
    135
  - Installing the Front Wheels
    135
- Rear Wheels
  
  137
  - Removing the Rear Wheels
    138
  - Checking the Rear Wheels
    138
  - Checking the Rear Wheel Hubs
    138
  - Installing the Rear Brake Discs
    138
  - Installing the Rear Wheel Hubs
    138
  - Installing the Rear Wheels
    139
- Front Brake
  
  140
- Rear Brake
  
  151
  - Introduction
    157
  - Checking the Rear Brake Discs
    157
  - Replacing the Rear Brake Pads
    157
  - Rear Brake
    157
  - Removing the Rear Brake Master Cylinder
    158
  - Disassembling the Rear Brake Calipers
    158
  - Checking the Rear Brake Calipers
    159
  - Assembling the Rear Brake Calipers
    159
  - Installing the Rear Brake Calipers
    159
  - Checking the Rear Brake Master Cylinder
    160
  - Assembling the Rear Brake Master Cylinder
    160
  - Installing the Rear Brake Master Cylinder
    160
- Handlebar
  
  165
  - Removing the Handlebar
    165
  - Checking the Handlebar
    165
  - Installing the Handlebar
    165
- Steering Stem
  
  167
- Tie-Rods and Steering Knuckles
  
  175
- Front Arms and Front Shock Absorber Assemblies
  
  178
- Rear Knuckles and Stabilizer
  
  183
- Rear Arms and Rear Shock Absorber Assemblies
  
  187
Engine

189
- Engine Removal
  
  192
  - Installing the Muffler
    193
  - Installing the V-Belt Cooling Ducts
    193
  - Installing the Drive Select Lever Unit
    196
  - Installing the Engine
    200
- Cylinder Head
  
  201
- Rocker Arms and Camshaft
  
  208
- Valves and Valve Springs
  
  213
  - Removing the Valves
    213
  - Checking the Valves and Valve Guides
    213
  - Checking the Valve Seats
    215
  - Checking the Valve Springs
    216
  - Installing the Valves
    217
- Cylinder and Piston
  
  219
  - Removing the Piston
    220
  - Checking the Cylinder and Piston
    220
  - Checking the Piston Rings
    221
  - Checking the Piston Pin
    222
  - Installing the Piston and Cylinder
    223
- Ac Magneto and Starter Clutch
  
  225
  - Removing the Ac Magneto Rotor
    227
  - Removing the Starter Clutch
    227
  - Checking the Stator Coil and Crankshaft Position Sensor
    228
  - Checking the Starter Clutch
    228
  - Checking the Torque Limiter
    228
  - Installing the Starter Clutch
    228
  - Installing the Ac Magneto
    229
- Electric Starter
  
  231
- Primary and Secondary Sheaves
  
  238
  - Removing the Primary and Secondary Sheaves
    241
  - Disassembling the Secondary Sheave
    241
  - Checking the V-Belt
    241
  - Checking the Primary Sheave
    242
  - Checking the Primary Sheave Weights
    242
  - Checking the Primary Sheave Sliders
    242
  - Checking the Secondary Sheave
    242
  - Assembling the Primary Sheave
    243
  - Assembling the Secondary Sheave
    243
  - Installing the Primary and Secondary Sheaves
    245
- Clutch
  
  247
  - Removing the Clutch
    249
  - Checking the Clutch
    249
  - Checking the Clutch Shoe
    249
  - Assembling the Clutch Housing
    250
  - Installing the Clutch
    250
- Crankcase
  
  252
  - Separating the Crankcase
    256
  - Checking the Timing Chain and Timing Chain Guide
    256
  - Checking the Relief Valve
    256
  - Checking the Bearings
    256
  - Checking the Crankcase
    257
  - Assembling the Crankcase
    257
  - Installing the Shift Lever
    258
- Crankshaft and Oil Pump
  
  259
  - Removing the Crankshaft
    261
  - Checking the Oil Pump
    261
  - Checking the Oil Strainer
    262
  - Checking the Crankshaft
    262
  - Assembling the Oil Pump
    262
  - Installing the Crankshaft
    263
- Transmission
  
  264
  - Removing the Transmission
    267
  - Checking the Shift Forks
    267
  - Checking the Shift Drum
    267
  - Checking the Transmission
    267
  - Checking the Secondary Shaft
    268
  - Checking the Stopper Lever and Stopper Wheel
    268
  - Assembling the Shift Fork Assembly
    268
  - Installing the Shift Forks and Shift Drum
    268
- Middle Gear
  
  270
  - Removing the Middle Drive Shaft
    273
  - Removing the Middle Driven Shaft
    273
  - Checking the Pinion Gears
    274
  - Installing the Bearing and Oil Seals
    275
  - Installing the Middle Driven Shaft
    275
  - Installing the Middle Drive Shaft
    276
  - Measuring the Middle Gear Backlash
    277
  - Aligning the Middle Gear
    278
Cooling System

281
- Radiator
  
  282
  - Checking the Radiator
    284
  - Installing the Radiator
    284
- Thermostat
  
  285
  - Checking the Thermostat
    286
  - Installing the Thermostat
    286
- Water Pump
  
  288
  - Disassembling the Water Pump
    290
  - Checking the Water Pump
    290
  - Assembling the Water Pump
    290
Fuel System

293
- Fuel Tank
  
  294
  - Checking the Fuel Pump Body
    295
  - Checking the Fuel Tank Breather Hose Joint
    295
  - Installing the Fuel Pump
    295
  - Removing the Fuel Pump
    295
  - Removing the Fuel Tank
    295
  - Installing the Fuel Tank
    296
- Throttle Body
  
  297
  - Removing the Throttle Body Assembly
    299
  - Checking the Injector
    299
  - Checking the Throttle Body
    299
  - Installing the Throttle Body Assembly
    299
  - Checking the Fuel Pressure
    300
Drive Train

303
Electrical System

335
- Ignition System
  
  338
  - Circuit Diagram
    338
  - Troubleshooting
    340
- Electric Starting System
  
  342
  - Circuit Diagram
    342
  - Starting Circuit Cut-Off System Operation
    344
  - Troubleshooting
    346
- Charging System
  
  348
  - Circuit Diagram
    348
  - Troubleshooting
    350
- Lighting System
  
  352
  - Circuit Diagram
    352
  - Troubleshooting
    354
- Signaling System
  
  356
  - Circuit Diagram
    356
  - Troubleshooting
    358
- Cooling System
  
  364
  - Circuit Diagram
    364
  - Troubleshooting
    366
- Fuel Injection System
  
  368
  - Circuit Diagram
    368
  - Ecu Self-Diagnostic Function
    370
  - Self-Diagnostic Function Table
    370
  - Troubleshooting Method
    372
  - Diagnostic Mode
    373
  - Troubleshooting Details
    378
- Fuel Pump System
  
  392
  - Circuit Diagram
    392
  - Troubleshooting
    394
- 2Wd/4Wd Selecting System
  
  396
  - Circuit Diagram
    396
  - Troubleshooting
    398
- EPS (ELECTRIC POWER STEERING) SYSTEM (for YFM5FGP/YFM7FGP)
  
  400
- Electrical Components
  
  412
  - Checking the Switches
    416
  - Checking the Bulbs and Bulb Sockets
    419
  - Checking the Fuses
    420
  - Checking and Charging the Battery
    421
  - Checking the Relays
    424
  - Checking the Diode
    426
  - Checking the Spark Plug Cap
    427
  - Checking the Ignition Coil
    427
  - Checking the Ignition Spark Gap
    428
  - Checking the Crankshaft Position Sensor
    428
  - Checking the Lean Angle Sensor
    429
  - Checking the Starter Motor Operation
    429
  - Checking the Stator Coil
    429
  - Checking the Rectifier/Regulator
    430
  - Checking the Fuel Sender
    430
  - Checking the Speed Sensor
    431
  - Checking the Radiator Fan Motor
    431
  - Checking the Radiator Fan Motor Circuit Breaker
    432
  - Checking the Throttle Position Sensor
    433
  - Checking the Intake Air Pressure Sensor
    433
  - Checking the Intake Air Temperature Sensor
    433
  - CHECKING the EPS MOTOR (for YFM5FGP/YFM7FGP)
    434
  - CHECKING the EPS TORQUE SENSOR (for YFM5FGP/YFM7FGP)
    434
Troubleshooting

437
- Troubleshooting
  438
  - General Information
    438
  - Incorrect Engine Idling Speed
    438
  - Starting Failures
    438
  - Faulty Drive Train
    439
  - Faulty Gear Shifting
    439
  - Jumps out of Gear
    439
  - Poor Medium-And-High-Speed Performance
    439
  - Shift Lever Does Not Move
    439
  - Faulty Clutch
    440
  - Overcooling
    440
  - Overheating
    440
  - Faulty Lighting or Signaling System
    441
    
    Wiring Diagram
    442
  - Faulty Shock Absorber Assembly
    441
  - Poor Braking Performance
    441
  - Unstable Handling
    441

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