2011 YAMAHA GRIZZLY 550 check engine

8-43
8 4. Check the gasket for damage, and replace it if
necessary.
5. Install the gasket, and then insert the tailpipe
into the muffler and align the bolt holes.
6. Install the bolts and tighten them to the speci-
fied torque.
7. Remove the purging bolt and its gasket.8. Start the engine and rev it up approximately
twenty times while momentarily creating ex-
haust system back pressure by blocking the
end of the muffler with a shop towel.
9. Stop the engine and allow the exhaust pipe to
cool.
10. Check the gasket for damage, and replace it if
necessary.
11. Install the purging bolt and its gasket, and
then tighten the bolt to the specified torque.
1. Tailpipe
2. Spark arrester
3. GasketTightening torque:
Tailpipe bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1. Purging bolt
2. Gasket
2
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8-44
8
WARNING
EWB02380Never run the engine in an enclosed area when
purging the spark arrester, otherwise it could
cause injury to the eyes, burns, carbon monox-
ide poisoning, possibly leading to death, and
start a fire.
Always let the exhaust system cool prior to
touching exhaust components.
Always wear eye protection, and make sure
no one is behind the ATV.
Make sure there are no combustible materi-
als in the area.EBU23930V-belt case drain plug After riding in water deep enough to allow it to en-
ter the V-belt case, remove this plug to drain the
water from the case.
TIPIf water drains from the V-belt case after removing
the plug, have a Yamaha dealer check the ATV as
the water may affect other engine parts.EBU29700Adjusting the throttle cable free play The throttle cable free play should be checked
and, if necessary, adjusted at the intervals speci-
fied in the periodic maintenance and lubrication
chart. Tightening torque:
Purging bolt:
27 Nm (2.7 m·kgf, 20 ft·lbf)1. V-belt case drain plug
U28P62E0.book Page 44 Thursday, March 11, 2010 3:25 PM

8-45
8 The throttle cable free play should measure 3.0–
5.0 mm (0.12–0.20 in) at the throttle lever. Period-
ically check the throttle cable free play and, if nec-
essary, adjust it as follows.
1. Slide the rubber cover back.
2. Loosen the locknut.
3. To increase the throttle cable free play, turn
the throttle cable free play adjusting bolt in di-
rection (a). To decrease the throttle cable free
play, turn the adjusting bolt in direction (b).
4. Tighten the locknut.5. Slide the rubber cover to its original position.
EBU24060Valve clearance The valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.EBU24071Adjusting the drive select lever safety
system cable The drive select lever safety system cable stretch-
es with use, which can result in improper function.
Therefore, the safety system cable should be
checked and adjusted by a Yamaha dealer at the
intervals specified in the periodic maintenance and
lubrication chart.EBU29601Brakes Replacement of brake components requires pro-
fessional knowledge. Brake service should be per-
formed by a Yamaha dealer.
1. Rubber cover
2. Throttle cable free play adjusting bolt
3. Locknut
4. Throttle cable free play
2WD
4WD
3
2
1
4 (b)
(a)
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8-52
8
EBU24230Axle boots The axle boots must be checked for damage at the
intervals specified in the periodic maintenance and
lubrication chart. Check the axle boots for tears or
damage. If any damage is found, have them re-
placed by a Yamaha dealer.
EBU24901Checking and lubricating the cables The operation and the condition of all control ca-
bles should be checked before each ride, and the
cables and cable ends should be lubricated if nec-
essary. If a cable is damaged or does not move
smoothly, have a Yamaha dealer check or replace
it.
1. Front axle boot (each side)
1 1
1. Rear axle boot (each side)Recommended lubricant:
Engine oil
1
1
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8-66
8
EBU27691Troubleshooting charts Starting problems or poor engine performance
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the ATV.
Remove the spark plug
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the ATV.
The engine does not start.
Have a Yamaha dealer
check the ATV.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Operate the electric starter.
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8-67
8 Engine overheating
WARNING
EWB02290Wait for the engine and radiator to cool before removing the radiator cap. You could be burned by
hot fluid and steam blown out under pressure. Always put a thick rag over the cap when opening.
Allow any remaining pressure to escape before completely removing the cap.TIPIf coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec-
ommended coolant as soon as possible.Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer check
and repair the cooling system.Add coolant. (See TIP.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
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9-2
9
EBU27261Storage Short-term
Always store your ATV in a cool, dry place and, if
necessary, protect it against dust with a porous
cover. NOTICE: Storing the ATV in a poorly ven-
tilated room or covering it with a tarp while it is
still wet, will allow water and humidity to seep
in and cause rust. To prevent corrosion, avoid
damp cellars, stables (because of the presence
of ammonia) and areas where strong chemi-
cals are stored.
[ECB00721]
Long-term
Before storing your ATV for several months:
1. Follow all the instructions in the “Cleaning”
section of this chapter.
2. Fill up the fuel tank and add fuel stabilizer (if
available) to prevent the fuel from deteriorat-
ing.3. Perform the following steps to protect the cyl-
inder, piston rings, etc. from corrosion.
a. Remove the spark plug cap and spark
plug.
b. Pour a teaspoonful of engine oil into the
spark plug bore.
c. Install the spark plug cap onto the spark
plug, and then place the spark plug on the
cylinder head so that the electrodes are
grounded. (This will limit sparking during
the next step.)
d. Turn the engine over several times with the
starter. (This will coat the cylinder wall with
oil.)
e. Remove the spark plug cap from the spark
plug, and then install the spark plug and
the spark plug cap.
4. Lubricate all control cables and the pivoting
points of all levers and pedals.
5. Check and, if necessary, correct the tire air
pressure, and then block up the ATV so that
all of its wheels are off the ground. Alternative-
ly, turn the wheels a little every month in order
to prevent the tires from becoming degraded
in one spot. Specified amount:
7.5 ml of stabilizer to each liter of fuel (or 1
oz of stabilizer to each gallon of fuel)U28P62E0.book Page 2 Thursday, March 11, 2010 3:25 PM

INDEX
AAccessories and loading ................................................ 6-6
Accessories, auxiliary jack ........................................... 4-23
Air filter element, cleaning ............................................ 8-38
Axle boots .................................................................... 8-52BBattery .......................................................................... 8-55
Brake fluid, changing .................................................... 8-49
Brake fluid level, checking ............................................ 8-47
Brake hose protectors, checking the rear .................... 8-47
Brake lever, front .......................................................... 4-14
Brake levers, checking and lubricating ......................... 8-53
Brake pads, checking the front and rear ...................... 8-46
Brake pedal and rear brake lever ................................. 4-14
Brake pedal, checking and lubricating ......................... 8-54
Brake pedal free play, adjusting ................................... 8-50
Brakes .......................................................................... 8-45
Brakes, front and rear .................................................... 5-3CCables, checking and lubricating ................................. 8-52
Carrier, front ................................................................. 4-21
Carrier, rear .................................................................. 4-21
Chassis fasteners ........................................................... 5-7
Cleaning ......................................................................... 9-1
Coolant .................................................................. 5-3, 8-33
Coolant temperature warning light ................................. 4-3DDifferential gear oil ................................................ 5-3, 8-30Drive select lever .......................................................... 4-15
Drive select lever and driving in reverse ........................ 6-2
Drive select lever safety system cable, adjusting ......... 8-45
EEngine break-in .............................................................. 6-4
Engine oil ....................................................................... 5-3
Engine oil and oil filter cartridge ................................... 8-24
Engine stop switch ......................................................... 4-7
Engine trouble warning light ........................................... 4-3
EPS warning light (for EPS model) ................................ 4-3FFinal gear oil .......................................................... 5-3, 8-28
Four-wheel-drive/differential gear lock indicator ............ 4-4
Front and rear brake lever free play, checking ............. 8-49
Fuel ....................................................................... 4-16, 5-3
Fuel tank cap ................................................................ 4-15
Fuses, replacing ........................................................... 8-59HHandlebar switches ........................................................ 4-7
Headlight beam, adjusting ............................................ 8-62
Headlight bulb, replacing .............................................. 8-61
High-range indicator light ............................................... 4-2
Horn switch .................................................................... 4-8IIdentification numbers .................................................. 11-1
Indicator lights and warning lights .................................. 4-2
Instruments, lights and switches .................................... 5-7
U28P62E0.book Page 1 Thursday, March 11, 2010 3:25 PM