maintenance YAMAHA GRIZZLY 550 2012 User Guide

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EBU21865General maintenance and lubrication chart TIP
For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-
vals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance
intervals should be followed.
Items marked with 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 month136612
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320
1 Air filter element Clean and replace if necessary. Every 20
–40 hours (more often in wet or
dusty areas)
2 *Front brake 
Check operation and correct if necessary.
 Check fluid level and ATV for fluid leakage, and
correct if necessary. √√√√√
 Replace brake pads. Whenever worn to the limit
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3*Rear brake 
Check operation and correct if necessary.
 Check brake pedal free play and adjust if neces-
sary.
 Check fluid level and ATV for fluid leakage, and
correct if necessary. √√√√√
 Replace brake pads. Whenever worn to the limit
4 *Brake hoses 
Check for cracks or other damage, and replace if
necessary. √√√√
 Replace. Every 4 years
5 *Rear brake hose
protectors 
Check for wear, cracks or other damage, 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 correct if
necessary. √ √√√
8 *Wheel hub bearings 
Check for looseness or damage, and replace if
necessary. √ √√√
9 *V- b e l t 
Check for wear, cracks or other damage, and re-
place if necessary. √ √√√
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 80 160 160 320
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10*Chassis fasteners 
Make sure that all nuts, bolts, and screws are
properly tightened. √√√√√
11 *Shock absorber as-
semblies 
Check operation and correct if necessary.
 Check for oil leakage and replace if necessary. √√√
12 *Stabilizer bushes 
Check for cracks or other damage, and replace if
necessary. √√√
13 *Rear knuckle pivots Lubricate with lithium-soap-based grease. √√√
14 *Steering shaft Lubricate with lithium-soap-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 *Axle boots 
Check for cracks or other damage, and replace if
necessary. √√√√√
18 Engine oil 
Change.
 Check ATV for oil leakage, and correct if neces-
sary. √ √√√
19 Engine oil filter car-
tridge 
Replace. √√√
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 7 Tuesday, April 26, 2011 7:53 PM

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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

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EBU23071TIP
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.
 Replace the brake hoses every four years and if cracked or damaged.
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EBU23090Removing 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.
EBU27385Panel A
To remove the panelPull upward on the areas shown.
1. Panel A
2. Panel B
3. Panel C
4. Panel D
5. Panel F
1
2
3
5
4
1. Panel E
2. Panel G
3. Panel H
1
3
2
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EBU28671Removing 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.
To install a radiator grill
Place the radiator grill in its original position, and
then install the quick fastener.
EBU23213Checking 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 should be removed and checked in accor-
dance with the periodic maintenance and lubrica-
tion chart. In addition, the condition of the spark
plug can reveal the condition of the engine.
To remove the spark plug1. Remove the spark plug cap.
1. Radiator grill
2. Quick fastener
21
1. Spark plug cap1
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To install the spark plug
1. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any
grime from the spark plug threads.
2. Install the spark plug with the spark plug wrench, and then tighten it to the specified
torque.
TIPIf a torque wrench is not available when installing
the spark plug, a good estimate of the correct
torque is 1/4 –1/2 turn past finger tight. However,
the spark plug should be tightened to the specified
torque as soon as possible.3. Install the spark plug cap.EBU27467Engine oil and oil filter cartridge The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter cartridge replaced at the intervals spec-
ified in the periodic maintenance and lubrication
chart.
To check the engine oil level 1. Place the ATV on a level surface.
2. Check the engine oil level on a cold engine.
1. Spark plug gapSpark plug gap: 0.8 –0.9 mm (0.031– 0.035 in)
Tightening torque:
Spark plug:13 Nm (1.3 m ·kgf, 9.4 ft· lbf)
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Make sure that no foreign material enters the
crankcase.12. Start the engine, and then let it idle for severalminutes while checking it for oil leakage. If oil
is leaking, immediately turn the engine off and
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 the access cover by turning it clock- wise.EBU27306Final gear oil The final gear case must be checked for oil leak-
age before each ride. If any leakage is found, have
a Yamaha dealer check and repair the ATV. In ad-
dition, the final gear oil level must be checked and
the oil changed as follows at the intervals specified
in the periodic maintenance and lubrication chart.
To check the final gear oil level1. Place the ATV on a level surface. 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.
3. If the oil is below the brim of the check hole, remove the final gear oil filler bolt and its gas-
ket, and then add sufficient oil of the recom-
mended type to raise it to the correct level.
1. Final gear oil
2. Gasket
3. Final gear oil level check bolt
4. Correct oil level
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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.
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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)
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