Yamaha Grizzly 550/550FI 2012 ATV Owner’s & Service Manual Set (P/N LIT-11616-25-06)

The owner’s volume covers operation and routine care; the service volume supplies workshop repair and diagnosis. Within the 550 range, P/PH models use EPS, while base/H models use conventional steering. Separate steering-stem and pitman-arm procedures help match the work to the correct configuration.

PDF Search, Bookmarks and Wiring Detail

Search and diagram detail: Both manuals have searchable main text and embedded PDF bookmarks. Text search does not cover the owner’s manual’s two appended warranty-card pages. Small labels in the service manual’s dense circuit diagrams are readable with zooming.

The ZIP contains two printable English PDFs totaling 626 pages, including covers, blank and separator pages, three promotional pages, and two warranty-card pages. The service PDF’s two color wiring sheets are also included in that total.

ATV Operation, Engine Repair and Drive-System Diagnosis

The following is a selection of the included material, rather than a complete contents list. Other topics include cleaning, storage, and starter-motor inspection and assembly.

• Operation and owner maintenance: Controls, pre-ride checks, riding procedures, loading, On-Command 2WD/4WD and differential-lock operation, and scheduled maintenance.

• Engine repair: Engine removal, cylinder-head and valvetrain service, piston and cylinder inspection, crankcase separation, crankshaft installation, and oil-pump checks.

• CVT and transmission: V-belt replacement, primary/secondary sheave service, centrifugal clutch inspection, transmission disassembly, and middle-gear setup.

• Shaft drive: Front and rear CV-shaft disassembly, boot-band installation, differential and final-drive repair, shim selection, and backlash adjustment.

• Brakes and chassis: Hydraulic bleeding, caliper and master-cylinder service, pad replacement, wheels and hubs, tie-rods, knuckles, ball joints, suspension arms, shock inspection, and toe-in adjustment.

• Cooling and fuel systems: Radiator-cap pressure testing, thermostat checks, water-pump disassembly and seal installation, fuel-tank and pump removal, injector inspection, fuel-pressure testing, and throttle-position-sensor adjustment.

• Electrical troubleshooting: Ignition, starting, charging, lighting, signaling, radiator-fan, fuel-injection, fuel-pump, 2WD/4WD, and EPS diagnosis, supported by circuit diagrams and electrical test specifications.

The service volume is written primarily for Yamaha dealers and qualified mechanics; repair work assumes mechanical knowledge and the appropriate tools.

Controls and Routine Maintenance

The owner’s volume maps warning and specification labels, controls, service points, and storage locations. It explains the multi-function display, drive selector, speed limiter, differential-lock indicators, override function, brake controls, shock-preload adjustment, carriers, and auxiliary DC jack.

Pre-ride checks address engine and gear oils, coolant, brakes, throttle, tires, chassis fasteners, lights, and switches. Maintenance charts organize work by mileage, operating hours, and calendar time.

Engine-care coverage includes valve-clearance inspection, spark-plug checks, air-filter cleaning, oil changes, cooling-system checks, spark-arrester cleaning, and V-belt inspection. Chassis and electrical maintenance covers axle boots, brake pads and hoses, wheel bearings, steering lubrication, battery care, fuses, and lighting.

Reference tables identify MAXXIS MU19/MU20 tires and supply tire-pressure data, cooling and lubricant capacities, fuse ratings, and accessory-jack limits.

Internal Engine and Transmission Work

Step-by-step repair procedures pair exploded assembly views and removal-order charts with inspection criteria, installation notes, and component-specific tightening data.

Cylinder-head work extends to cam timing, decompression-system checks, rocker arms, valve-guide replacement, and valve-seat contact checks. Internal engine sections address piston rings, the AC magneto and starter clutch, and crankcase sealing.

Transmission inspection covers shift forks, the shift drum, shafts, gears, and engagement. Middle-gear alignment includes shim calculations for replacement crankcases, gears, and bearing housings.

Driveline Setup and Component Limits

Shaft-drive troubleshooting distinguishes bearing rumble, gear whine, and other symptoms before component inspection. The service manual warns that insufficient backlash can severely damage gear teeth.

The differential ring gear and differential gear are factory-matched; separating that assembly can cause malfunction. Differential-motor installation also includes indexing precautions because incorrect positioning can leave the indicators out of step with the selected drive mode.

Fuel-system procedures cover throttle-body removal, inspection, and associated sensor and injector work; the throttle body itself is not to be internally disassembled.

Fault Codes, Circuit Diagrams and Workshop References

FI diagnostic tables connect fault codes with probable causes, sensor and actuator checks, and ECU reinstatement criteria. EPS diagnosis distinguishes present and stored faults and explains warning-light signaling. The EPS unit must not be disassembled because this can damage it.

A separate symptom-based chapter addresses starting failures, incorrect idle, poor medium- and high-speed performance, shifting and clutch faults, overheating, poor braking, unstable handling, and lighting or signaling problems.

Drawings include the EPS block diagram, lubrication-system diagrams, cooling-system diagrams, cable-routing views, the fuel-injection circuit diagram, and the 2WD/4WD selecting-system circuit diagram.

The special-tool index identifies the sheave spring compressor 90890-04134/YM-04134 and crankcase separating tool 90890-01135/YU-01135-B. Fuel-pressure adapter 90890-03176/YM-03176 and gear-lash measurement tool 90890-01475/YM-01475 are listed alongside their applicable procedures. Specification sections provide torque tables, lubrication data, clearances, wear limits, capacities, and electrical test values.

Brake hydraulic work, fuel-pressure testing, engine removal, and driveline setup require secure vehicle support, proper fire precautions, and qualified mechanical judgment before the ATV is returned to service.

Valve-Clearance and V-Belt Specification Samples

For the covered 550 engines, valve-clearance specifications are 0.09–0.13 mm intake and 0.16–0.20 mm exhaust, measured with the engine cold at room temperature.

The CVT inspection section lists a V-belt width of 33.3 mm and a wear limit of 30.0 mm. Related inspection material addresses belt damage, sheave condition, weights, sliders, and the secondary-sheave spring.