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Yamaha 550 GRIZZLY Digital Workshop Repair Manual 2009-2010

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The Grizzly 550, model designation YFM550, represents a robust and capable all-terrain vehicle (ATV) produced for the 2009 and 2010 model years. Known for its single-cylinder, liquid-cooled, 535cc SOHC engine...
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Yamaha 550 GRIZZLY Digital Workshop Repair Manual 2009-2010
The Grizzly 550, model designation YFM550, represents a robust and capable all-terrain vehicle (ATV) produced for the 2009 and 2010 model years. Known for its single-cylinder, liquid-cooled, 535cc SOHC engine featuring Mikuni 44mm throttle body fuel injection, this ATV is engineered for reliable performance in demanding off-road conditions. Its design emphasizes durability, comfort, and exceptional handling, making it a popular choice for utility work, trail riding, and recreational adventures. Key features include the automatic transmission with engine braking, On-Command® 2WD/4WD with an electronically locking front differential, and substantial cargo capacity. This comprehensive digital workshop repair manual is designed for Grizzly 550 owners, mechanics, and technicians. It provides detailed instructions for repair, maintenance, rebuilding, refurbishing, and restoration, covering all major systems from the engine and fuel system to the drivetrain, suspension, brakes, and electrical components. The manual includes step-by-step procedures, diagnostic charts, troubleshooting guidance, and technical specifications, enabling users to effectively maintain and repair their ATV. With high-quality visuals and professional-level detail, this resource aims to facilitate efficient servicing and ensure the longevity of the vehicle.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Grizzly 550
Model Designation:
YFM550
Product Type:
Digital Workshop Repair Manual
Codes
Model Year Coverage:
2009, 2010
👋 Introduction
Market Position
Target Audience:
Yamaha Grizzly 550 owners, DIY mechanics, ATV enthusiasts, and professional repair shops.
Competitive Analysis
Value Proposition:
Provides professional-level repair and maintenance information, enabling significant cost savings on servicing.
Key Features
Content Quality:
Detailed diagnostic and repair procedures, high-quality visuals.
Usability:
Easy to navigate and print, designed for users of all technical skill levels.
📋 Manual Details
Coverage Areas
Scope:
Comprehensive repair, maintenance, rebuilding, refurbishing, and restoration.
Detail Level:
Professional technician and mechanic level.
Page Count
Estimated Pages:
Likely 500+ pages based on typical workshop manuals for ATVs of this caliber.
Manual Type
Type:
Workshop Repair Manual / Service Manual
Language
Language:
English (assumed, standard for most technical manuals of this nature unless specified otherwise).
Format
Format:
Digital (PDF or similar, viewable and printable).
📖 Manual Coverage
Systems Covered
Engine:
Complete engine assembly, disassembly, inspection, repair, and tuning.
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, pressure regulator, fuel tank.
Ignition System:
CDI unit, ignition coils, spark plugs, wiring.
Transmission:
Ultramatic automatic transmission, drive belts, clutches, gear selection.
Drivetrain:
Shaft drive, front differential, rear differential, CV joints, driveshafts.
Suspension:
Front and rear suspension systems, shock absorbers, control arms, bearings.
Brakes:
Hydraulic brake system, calipers, master cylinders, brake lines, pads, discs.
Steering:
Handlebar assembly, steering column, tie rods, steering knuckle.
Electrical System:
Wiring diagrams, battery, charging system, lighting, starter motor, ECU.
Cooling System:
Radiator, fan, coolant hoses, thermostat, water pump.
Exhaust System:
Exhaust pipes, muffler, heat shields.
Frame And Chassis:
Frame inspection, alignment, repair, mounting points.
Bodywork:
Plastic body panels, fenders, racks, seat.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault codes.
Repair:
Step-by-step repair instructions for all major components and systems.
Rebuilds:
Complete engine and transmission rebuild procedures.
Diagnostics:
Diagnostic charts, wiring schematics, testing procedures for electrical components.
Technical Depth
Depth:
From basic fluid checks and adjustments to complete engine and transmission overhauls.
📊 Manual Specifications
File Format
Digital Format:
Likely PDF; searchable text, bookmark navigation, high-resolution images.
Print Quality
Image Resolution:
High-quality photos, illustrations, and diagrams for clarity.
Binding Type
Binding:
N/A (Digital format, no physical binding).
Paper Type
Paper Type:
N/A (Digital format, no physical paper).
Compatibility
Operating Systems:
Microsoft Windows (95, 98, 98SE, 2000, NT, ME, XP, Vista, Windows 7) and all Mac computers.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, liquid-cooled, SOHC, 4-stroke
Displacement:
535 cc (32.6 cubic inches)
Bore X Stroke:
95.0 mm x 74.2 mm (3.74 in x 2.92 in)
Compression Ratio:
9.2:1
Fuel Delivery:
Mikuni 44mm throttle body fuel injection
Performance
Estimated Horsepower:
Approx. 30-35 HP (Varies based on tuning and environmental factors)
Estimated Torque:
Approx. 30-35 lb-ft (Varies based on tuning and environmental factors)
Fuel System
Fuel Type:
Unleaded gasoline (87 octane recommended)
Fuel Tank Capacity:
4.2 US gal (16 L)
🔧 Transmission
Standard
Transmission Type:
Yamaha Ultramatic® V-belt automatic with centrifugal clutch, engine braking
Features
Drive System:
On-Command® 2WD/4WD with electronic front differential lock
Final Drive:
Shaft drive, sealed O-ring chain
📐 Dimensions
Exterior
Length:
80.3 in (2040 mm)
Width:
45.5 in (1155 mm)
Height:
48.4 in (1230 mm)
Wheelbase:
50.2 in (1275 mm)
Weights
Wet Weight:
648 lbs (294 kg) (approx., includes all necessary fluids and full fuel tank)
Ground Clearance:
11.2 in (285 mm)
Cargo
Front Rack Capacity:
99 lbs (45 kg)
Rear Rack Capacity:
187 lbs (85 kg)
Towing Capacity:
1322 lbs (600 kg)
Dimensions
Tires Front:
AT25x8-12
Tires Rear:
AT25x10-12
Wheels:
12-inch aluminum alloy
🛡️ Safety Features
Active Features
Braking System:
Hydraulic disc brakes, front and rear
Passive Features
Lighting:
Dual 30W Krypton headlights, 8W taillight/stoplight
Engine Braking:
Yamaha Ultramatic® transmission provides significant engine braking.
💡 Technology Features
Infotainment
Dashboard Display:
Digital LCD meter displaying speedometer, odometer, trip meter, fuel gauge, clock, 4WD indicator, reverse, parking brake, and transmission gear indicators.
Driver Assistance
Locking Differential:
Electronically locking front differential for enhanced traction in difficult terrain.
Connectivity
Ignition System Type:
Digital CDI (Capacitor Discharge Ignition).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 km or 6 months (refer to manual for specific interval).
Air Filter Cleaning:
Every 1,000 km or as needed in dusty conditions.
Spark Plug Replacement:
Every 10,000 km (refer to manual for exact interval and spark plug type).
Fluid Specifications
Engine Oil Type:
Yamalube 4 (API SG, SH, SJ) SAE 10W-40 or 20W-40 (check manual for precise specification).
Engine Oil Capacity:
Approx. 2.20 US qt (2.1 L) without filter change, 2.30 US qt (2.2 L) with filter change.
Transmission Oil Type:
Yamalube 4 (API SG, SH, SJ) SAE 10W-40 or 20W-40 (check manual for precise specification).
Transmission Oil Capacity:
Approx. 0.76 US qt (0.72 L)
Coolant Type:
Permanent antifreeze (ethylene glycol based) with deionized water, 50/50 mix.
Known Issues
Common Wear Items:
Drive belts (Ultramatic transmission), wheel bearings, CV joint boots, brake pads.
Potential Concerns:
EFI system sensors, starter motor reliability under extreme use.
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Corporation, known for its long history in motorcycles, marine products, and powersports.
Model Evolution
Grizzly Lineage:
The Grizzly line is Yamaha's flagship series of utility ATVs, recognized for their comfort, capability, and reliability.
Production
Manufacturing Origin:
Typically manufactured in Japan or North America by Yamaha.
🏆 Awards & Recognition
Recognitions
General Reputation:
The Yamaha Grizzly line is consistently well-regarded in industry reviews for its durability, rider comfort, and off-road capability.
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