differential YAMAHA GRIZZLY 550 2012 User Guide

4-13
4

Riding before the differential gear is properly en-
gaged or disengaged (e.g., when the indicator
and indicator light are flashing) will cause the ve-
hicle 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). However, if conditions
require full engine power to be available, push
and hold the override switch to disable the differ-
ential gear lock speed limiter. (See page 4-8 for
a detailed explanation of this switch.)EBU18282Throttle lever Once the engine is running, pushing the throttle le-
ver will 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 the throttle lever is re-
leased.Before starting the engine, check the throttle to be
sure it is operating smoothly. Make sure it returns
to the idle position as soon as the lever is released.
EBU18323Speed limiter Your ATV is equipped with an adjustable speed
limiter. The speed limiter keeps the throttle from
fully opening, even when the throttle lever is
pushed to the maximum.
1. Loosen the locknut.
2. To increase the maximum engine power avail- able and the maximum speed of the ATV, turn
the adjusting screw in direction (a). To de-1. Throttle lever
2WD
4WD
1
U1HS60E0.book Page 13 Tuesday, April 26, 2011 7:53 PM

5-1
5
EBU19201
PRE-OPERATION CHECKS
EBU19224Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always
follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWB00481Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equip-
ment damage. 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:
ITEM ROUTINE PAGE
Fuel 
Check fuel level in fuel tank, and add recommended fuel if neces-
sary.
 Check fuel line for leakage. Correct if necessary. 4-16, 5-3
Engine oil 
Check oil level in engine, and add recommended oil to specified lev-
el if necessary.
 Check ATV for oil leakage. Correct if necessary. 5-3, 8-22
Final gear oil Check ATV for oil leakage. Correct if necessary. 5-3, 8-27
Differential gear oil Check ATV for oil leakage. Correct if necessary. 5-3, 8-29
Coolant 
Check coolant level in reservoir, and add recommended coolant to
specified level if necessary.
 Check cooling system for leakage. Correct if necessary. 5-3, 8-32
U1HS60E0.book Page 1 Tuesday, April 26, 2011 7:53 PM

5-3
5
EBU19541Fuel Make sure that there is sufficient fuel in the tank.
(See page 4-16.)EBU19560Engine oil Make sure that the engine oil is at the specified lev-
el. Add oil as necessary. (See page 8-22.)EBU19590Final gear oil Make sure that the final gear oil is at the specified
level. Add oil as necessary. (See page 8-27.)EBU19600Differential gear oil Make sure that the differential gear oil is at the
specified level. Add oil as necessary. (See page
8-29.)EBU19631Coolant Make sure that the coolant is at the specified level.
Add coolant as necessary. (See page 8-32.)
TIPThe coolant level must be checked on a cold en-
gine since the level varies with engine tempera-
ture.EBU29082Front and rear brakes Brake levers and brake pedal
Check that there is no free play in the front and
rear brake levers. If there is free play, have a
Yamaha dealer check the brake system.
Check for correct free play in the brake pedal. If
the free play is incorrect, adjust it. (See page
8-50.)
Check the operation of the brake levers and
pedal. They should move smoothly and there
should be a firm feeling when the brakes are ap-
plied. If not, have a Yamaha dealer check the
brake system.
Brake fluid level
Check the brake fluid level. Add fluid if necessary.
(See page 8-48.)
U1HS60E0.book Page 3 Tuesday, April 26, 2011 7:53 PM

8-8
8
20 Differential gear oil
Change.
 Check ATV for oil leakage, and correct if neces-
sary. √√
21 Final gear oil 
Change.
 Check ATV for oil leakage, and correct if neces-
sary. √√
22 Cooling system 
Check coolant level and ATV for coolant leakage,
and correct if necessary. √√√√√
 Replace coolant. Every 2 years
23 *Moving parts and
cables

Lubricate. √√√√
24 *Drive select lever
safety system cable 
Check operation and adjust or replace if neces-
sary. √√√
25 *Throttle lever 
Check operation.
 Check throttle lever free play, and adjust if neces-
sary.
 Lubricate cable and lever housing. √√√√√
26 *Front and rear brake
switches

Check operation and correct if necessary. √√√√√
27 *Lights and switches 
Check operation and correct if necessary.
 Adjust headlight beams. √√√√√
NO. ITEM
CHECK OR MAINTENANCE
JOB INITIAL EVERY
Whichev- er comes first month136612
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320U1HS60E0.book Page 8 Tuesday, April 26, 2011 7:53 PM

8-29
85. Refill with the recommended final gear oil to
the brim of the check hole as shown. NOTICE:
Be sure no foreign material enters the final
gear case.
[ECB00421]
6. Check the oil level check bolt gasket and the oil filler bolt gasket for damage, and replace
them if necessary.
7. Install the oil level check bolt, the oil filler bolt and their gasket, and then tighten the bolts to
the specified torques.
8. Check the final gear case for oil leakage. If oil is leaking, check for the cause.EBU23426Differential gear oil The differential gear case must be checked for oil
leakage before each ride. If any leakage is found,
have a Yamaha dealer check and repair the ATV.
In addition, the differential gear oil level must be
checked and the oil changed as follows at the in-
tervals specified in the periodic maintenance and
lubrication chart.
Tightening torque:
Final gear oil drain bolt:23 Nm (2.3 m ·kgf, 17 ft· lbf)
1. Final gear oil
2. Gasket
3. Final gear oil level check bolt
4. Correct oil levelRecommended final gear oil:
See page 10-1.
1
243
Tightening torques:Final gear oil level check bolt:10 Nm (1.0 m ·kgf, 7.2 ft ·lbf)
Final gear oil filler bolt: 23 Nm (2.3 m ·kgf, 17 ft· lbf)
U1HS60E0.book Page 29 Tuesday, April 26, 2011 7:53 PM

8-30
8
To check the differential gear oil level
1. Place the ATV on a level surface.
2. Remove the differential gear oil filler bolt and its gasket, and then check the oil level in the
differential gear case. The oil level should be
at the brim of the filler hole.
3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise
it to the correct level.
4. Check the gasket for damage, and replace it if necessary. 5. Install the oil filler bolt and its gasket, and then
tighten the bolt to the specified torque.
To change the differential gear oil 1. Place the ATV on a level surface.
2. Place an oil pan under the differential gear case to collect the used oil.
3. Remove the differential gear oil filler bolt, the differential gear oil drain bolt and their gasket
to drain the oil from the differential gear case.
1. Differential gear oil filler bolt
2. Gasket
3. Differential gear oil
4. Correct oil level
1
2
3
4
Tightening torque: Differential gear oil filler bolt:23 Nm (2.3 m ·kgf, 17 ft ·lbf)
U1HS60E0.book Page 30 Tuesday, April 26, 2011 7:53 PM

8-31
84. 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 the filler hole as shown.
NOTICE: Be sure no foreign material en-
ters the differential gear case.
[ECB00411]
6. Check the oil filler bolt gasket for damage, and replace it if necessary.
7. Install the oil filler bolt and its gasket, and then tighten the bolt to the specified torque.
1. Differential gear oil drain bolt
2. GasketTightening torque:Differential gear oil drain bolt:9.8 Nm (0.98 m ·kgf, 7.1 ft· lbf)
12
1. Differential gear oil filler bolt
2. Gasket
3. Differential gear oil
4. Correct oil levelRecommended differential gear oil:
See page 10-1.
Tightening torque: Differential gear oil filler bolt:23 Nm (2.3 m ·kgf, 17 ft· lbf)
1
2
3
4
U1HS60E0.book Page 31 Tuesday, April 26, 2011 7:53 PM

8-32
8
8. Check the differential gear case for oil leak-
age. If oil is leaking, check for the cause.
EBU23470Coolant The coolant level should be checked before each
ride. In addition, the coolant must be changed at
the intervals specified in the periodic maintenance
and lubrication chart.EBU27126To check the coolant level1. Place the ATV on a level surface.TIPThe coolant level must be checked on a cold en-
gine since the level varies with engine tempera-
ture.2. Check the coolant level in the coolant reser- voir.TIPThe coolant should be between the minimum and
maximum level marks.
3. If the coolant is at or below the minimum levelmark, remove panel D to access the coolant
reservoir. (See page 8-10.)
4. Remove the coolant reservoir cap, add cool- ant or distilled water to the maximum level
mark, install the reservoir cap, and then install
the panel. NOTICE: If coolant is not avail-
able, use distilled water or soft tap water
instead. Do not use hard water or salt wa-
ter since they are harmful to the engine. If
water has been used instead of coolant, re-
place it with coolant as soon as possible,
otherwise the cooling system will not be1. Maximum level mark
2. Minimum level mark
U1HS60E0.book Page 32 Tuesday, April 26, 2011 7:53 PM

10-2
10
Type:SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W-
50
Recommended engine oil grade: API service SG type or higher, JASO standard MA
Engine oil quantity: Without oil filter cartridge replacement:
2.00 L (2.11 US qt, 1.76 Imp.qt)
With oil filter cartridge replacement: 2.10 L (2.22 US qt, 1.85 Imp.qt)Final gear oil:Type:
SAE 80 API GL-4 Hypoid gear oil
Quantity: 0.20 L (0.21 US qt, 0.18 Imp.qt)
Differential gear oil:Type:SAE 80 API GL-4 Hypoid gear oil
Quantity:
0.22 L (0.23 US qt, 0.19 Imp.qt)Cooling system:Coolant reservoir capacity (up to the maximum level mark):0.24 L (0.25 US qt, 0.21 Imp.qt)
Radiator capacity (including all routes):
1.99 L (2.10 US qt, 1.75 Imp.qt)Air filter:Air filter element:Wet elementFuel:Recommended fuel:YFM550FAB Unleaded gasoline only
YFM550FADB Unleaded gasoline only
YFM5FGPB Regular unleaded gasoline only
YFM5FGPHB Regular 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 Imp.gal)Fuel injection:Throttle body:ID mark: 28P7 10Spark plug (s):Manufacturer/model:
NGK/LMAR6A-9
0 10 30 50 70 90 110 130 ˚F
–20 –10 0 10 20 30 40 50 ˚CSAE 5W-30
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-40SAE 20W-50
U1HS60E0.book Page 2 Tuesday, April 26, 2011 7:53 PM

10-5
10
Tail/brake light:12 V, 5.0/21.0 W × 1
Meter lighting: EL (Electroluminescent)
Neutral indicator light:
LED
Reverse indicator light: LED
Coolant temperature warning light: LED
Engine trouble warning light:
LED
EPS warning light: YFM550FADB LED
YFM5FGPB LED
YFM5FGPHB LED
Park indicator light:
LED
On-Command four-wheel-drive/differential gear lock
indicator:
LCD
High-range indicator light: LED
Low-range indicator light: LED
Differential gear lock indicator light:
LEDFuses:Main fuse:40.0 A
Fuel injection system fuse:
15.0 A EPS fuse:
YFM550FADB 40.0 A
YFM5FGPB 40.0 A
YFM5FGPHB 40.0 A
Headlight fuse:
10.0 A
Signaling system fuse: 5.0 A
Ignition fuse: 10.0 A
Auxiliary DC jack fuse:
10.0 A
Four-wheel-drive motor fuse: 10.0 A
Radiator fan fuse: 20.0 A
EBU30400For EUR only
The figures quoted are emission levels and are not
necessarily safe working levels. Whilst there is a
correlation between the emission and exposure
levels, this cannot be used reliably to determine
whether or not further precautions are required.
Factors that influence the actual level of exposure
of work-force include the characteristics of the
work room, the other sources of noise, etc. i.e. the
number of machines and other adjacent process-
U1HS60E0.book Page 5 Tuesday, April 26, 2011 7:53 PM