2009–2011 Yamaha Grizzly 550 FI ATV Owner's & Service Manuals (P/N LIT-11626-24-12; Service Manual LIT-11616-22-19)

This Yamaha Grizzly 550 FI set combines the Owner's Manual, P/N LIT-11626-24-12 (first edition February 2010), with the Service Manual, LIT-11616-22-19 (first edition May 2008). Owner coverage is YFM5FGA, YFM5FGHA, YFM5FGPA and YFM5FGPHA. The service volume covers YFM5FGY/YFM5FGPY and YFM7FGY/YFM7FGPY, with shared Grizzly 550/700 coverage and separate EPS and non-EPS information.

Text search and diagram detail: Both PDFs have searchable manual text and embedded bookmarks. The two safety-card pages appended to the Owner's Manual are not searchable. Small labels in the FI and EPS circuit diagrams and the full-color wiring sheet are readable when enlarged.

• Engine repair: Engine removal, cylinder-head and valve work, piston inspection, camshaft and timing-chain service, crankshaft installation, and oil-pump checks.

• CVT and driveline: V-belt inspection and replacement, primary and secondary sheave service, clutch inspection, transmission repair, and differential and final-drive backlash adjustment.

• Fuel injection: Fuel-pressure testing, injector and throttle-body checks, throttle-position-sensor adjustment, onboard diagnostic mode, and ECU fault-code troubleshooting.

• Steering and brakes: EPS diagnostics, steering-stem removal, tie-rod and ball-joint inspections, brake-caliper repair, master-cylinder service, and hydraulic bleeding.

• Cooling and electrical systems: Radiator pressure tests, thermostat and water-pump service, starting and charging tests, and system-specific circuit diagrams.

• Owner maintenance: Pre-operation checks, maintenance schedules, fluid changes, spark plug inspection, air filter cleaning, fuse replacement, and headlight bulb replacement.

The owner volume explains operation and basic upkeep; Yamaha wrote the service volume primarily for dealers and qualified mechanics who already understand vehicle repair.

Operation and Routine Maintenance Details

The owner volume details operation of the On-Command four-wheel-drive system and the differential gear lock. Drive select lever operation and engine break-in are covered alongside riding guidance for steep inclines, descents, and shallow water crossings.

Routine service addresses engine oil, final gear oil, differential fluid and coolant replacement, plus throttle cable adjustment. The maintenance charts separate emission-control work from general maintenance and lubrication.

The specifications distinguish recommended and minimum tire pressures and list fuel capacities and loading limits for both carriers and trailers. Electrical and suspension references include auxiliary DC jack ratings, lighting configurations, and shock absorber spring preload adjustments.

Engine, CVT and Driveline Repair

The shared engine chapter separates Grizzly 550 and 700 piston dimensions, ring clearances and inspection limits. Exploded assembly views carry torque, lubrication and replacement notes for internal engine work.

Sheave procedures identify spring compressor YM-04134. The clutch section flags the carrier nut's left-hand thread; incorrect loosening can damage the threads.

Driveline repair extends to middle-gear alignment, CV shaft disassembly, final-drive pinion preload and shim selection. The ring gear and differential unit is a factory-assembled component, with a specific restriction against internal disassembly.

Fuel Injection and EPS Fault Tracing

The FI diagnostic section connects fault codes with sensor and actuator tests, connector checks and ECU reinstatement procedures. Fuel-pressure testing identifies gauge YU-03153 and adapter YM-03176.

EPS troubleshooting distinguishes current and stored faults, with separate checks for torque-sensor, motor, battery and charging problems. That helps trace an EPS warning before replacing the steering unit.

EPS coverage includes assembly removal and electrical testing. Yamaha warns that disassembling the EPS unit can damage it.

Circuit Diagrams and Service Reference Data

Electrical references include the Fuel Injection System Circuit Diagram, 2WD/4WD Selecting System Circuit Diagram and Starting Circuit Cut-off System Operation diagram. The EPS System Block Diagram, Lubrication System Chart and Diagrams and Cooling System Diagrams show the related system layouts.

Component-specific torque tables, fluid capacities, wear limits, electrical test values and adjustment data accompany the service procedures. Chassis coverage also includes wheel bearings, suspension arms and toe-in adjustment.

For brake and steering repair, consult a qualified mechanic if the work is beyond your experience.

Two-Manual PDF Set and Page Breakdown

The ZIP contains two printable English PDFs totaling 619 pages: a 172-page Owner's Manual, including two safety-card pages, and a 447-page Service Manual, including the final full-color wiring diagram sheet. All covers, front matter and blank pages are already included in those counts.