2003 YAMAHA GRIZZLY 660 brake fluid

Tire wear limit......................................5-33
OPERATION ............................................6-1
Starting a cold engine ...........................6-3
Starting a warm engine .........................6-9
Warming up...........................................6-9
Drive select lever operation and
reverse driving ..................................6-11
Engine break-in ...................................6-17
Parking ................................................6-19
Parking on a slope ..............................6-21
Accessories and loading .....................6-23
RIDING YOUR ATV..................................7-1
Getting to know your ATV .....................7-3
Ride with care and good judgement .....7-5
Be careful where you ride ...................7-27
Turning your ATV ................................7-39
Climbing uphill.....................................7-45
Riding downhill ....................................7-55
Crossing a slope .................................7-59
Crossing through shallow water ..........7-63
Riding over rough terrain ....................7-69
Sliding and skidding ............................7-71
What to do if ........................................7-75
What to do...........................................7-75
67
PERIODIC MAINTENANCE AND
ADJUSTMENT ......................................... 8-1
Owner’s manual and tool kit ................. 8-3
Periodic maintenance/lubrication.......... 8-7
Panel removal and installation............ 8-15
Engine oil ............................................ 8-33
Final gear oil ....................................... 8-45
Differential gear oil.............................. 8-51
Cooling system ................................... 8-57
Changing the coolant.......................... 8-61
Axle boots ........................................... 8-69
Spark plug inspection ......................... 8-71
Air filter element cleaning ................... 8-77
V-belt cooling duct check hose ........... 8-83
Carburetor adjustment ........................ 8-85
Idle speed adjustment ........................ 8-87
Valve clearance adjustment ............... 8-89
Throttle lever adjustment .................... 8-91
Front brake pad inspection ................. 8-93
Rear brake pad inspection.................. 8-93
Inspecting the brake fluid level ........... 8-95
Brake fluid replacement ...................... 8-99
Front brake lever free play................ 8-101
Rear brake lever and pedal
adjustment ...................................... 8-103
Adjusting the rear brake light
switch ............................................. 8-107
8
U5KM61.book Page 2 Friday, July 26, 2002 11:13 AM

3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear shock absorber spring
preload adjusting ring
2. Storage compartment and tool
kit
3. Air filter case
4. Front brake fluid reservoir
5. Front shock absorber spring
preload adjusting ring
6. Rear brake fluid reservoir
7. Rear brake pedal
8. V-belt case drain plug
9. Radiator cap
10. Drive select lever
11. Fuel tank cap
12. Fuel cock
13. Fuses14. Battery
15. Engine oil dipstick
16. Recoil starter
17. Coolant reservoir
18. Drive select lever box check
hose
19. V-belt cooling duct check hose
20. Rear brake lever
21. Left handlebar switches
22. Horn
23. Speedometer unit
24. Main switch
25. Right handlebar switches
26. Throttle lever
27. Front brake lever
28. Auxiliary DC jack
29. Starter (choke)NOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5KM61.book Page 1 Friday, July 26, 2002 11:13 AM

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Brakes• Check operation, free play, fluid level and fluid leakage.
 Fill with DOT 4 brake fluid if necessary.5-7–5-9,
8-93–8-107
Fuel Check fuel level.
 Fill with fuel if necessary.5-11–5-13
Engine oil Check oil level.
 Fill with oil if necessary.5-15–5-17,
8-33–8-45
Coolant reservoir Check coolant level.
 Fill with coolant if necessary.8-57–8-67
Final gear oil/
Differential gear oil Check for leakage.5-19–5-21,
8-45–8-55
Throttle Check for proper throttle cable operation. 5-23, 8-91
Wheels and tires Check tire pressure, wear and damage.5-27–5-33,
8-115–8-117
Fittings and Fasteners Check all fittings and fasteners. 5-23
Lights Check for proper operation. 5-25, 8-129–8-135
Axle boots Check for damage. 8-69
E-5.fm Page 1 Tuesday, July 30, 2002 11:19 AM

5-7
EBU00671
Front and rear brakes
1. Brake levers and brake pedal
Check for correct free play in the rear brake
lever and that there is no free play in the front
brake lever. If the free play is incorrect, adjust
it. (See pages 8-101–8-105.)
Check the operation of the levers and pedal.
They should move smoothly and there
should be a firm feeling when the brakes are
applied. If not, have the machine inspected
by a Yamaha dealer.
2. Brake fluid level
Check the brake fluid level.
Add fluid if necessary. (See pages 8-95–
8-99.)
3. Brake fluid leakage
Check to see if any brake fluid is leaking out
of the pipe joints or master cylinder. Apply the
brakes firmly for one minute. If there is any
leaking, have the machine inspected by a
Yamaha dealer. Recommended brake fluid: DOT 4
U5KM61.book Page 7 Friday, July 26, 2002 11:13 AM

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
km 320 1,200 2,400 2,400 4,800
hours 20 75 150 150 300
Valves*•Check valve clearance.
•Adjust if necessary.
Cooling system•Check coolant leakage.
•Repair if necessary.
•Replace coolant every 24 months.Spark plug•Check condition.
•Adjust gap and clean.
•Replace if necessary.Air filter•Clean.
•Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*•Check and adjust idle speed/starter operation.
•Adjust if necessary.Crankcase breather
system*•Check breather hose for cracks or damage.
•Replace if necessary.Exhaust system*•Check for leakage.
•Retighten if necessary.
•Replace gasket(s) if necessary.Fuel line*•Check fuel hose for cracks or damage.
•Replace if necessary.Engine oil
•Replace (Warm engine before draining).Engine oil filter cartridge
•Replace.Final gear oil
•Check oil level/oil leakage.
•Replace.Differential gear oil
Front brake*•Check operation/fluid leakage/see NOTE page 8-8.
•Correct if necessary.Rear brake*•Check operation/fluid leakage/see NOTE page 8-8.
•Correct if necessary.V-belt*•Check operation.
•Check for cracks or damage.U5KM61.book Page 7 Friday, July 26, 2002 11:13 AM

8-8
* It is recommended that these items be serviced by a Yamaha dealer.
** Lithium-soap-based greaseNOTE:Recommended brake fluid: DOT 4
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.Wheels*•Check balance/damage/runout.
•Repair if necessary.Wheel bearing*•Check bearing assemblies for looseness/damage.
•Replace if damaged.Front and rear
suspension*•Check operation.
•Correct if necessary.Steering system*•Check operation/Replace if damaged.
•Check toe-in/Adjust if necessary.Rear upper and lower
knuckle pivots*•Lubricate.**Drive shaft universal
joint*•Lubricate.**Engine mount*
•Check for cracks or damage.Front and rear axle boots*•Check operation.
•Replace if damaged.Stabilizer bushes*
•Check for cracks or damage.Fittings and Fasteners*•Check all chassis fittings and fasteners.
•Correct if necessary.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
km 320 1,200 2,400 2,400 4,800
hours 20 75 150 150 300
U5KM61.book Page 8 Friday, July 26, 2002 11:13 AM

8-95 1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
FRONT
Avant
Delantero1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimoREAR
Arrière
Trasero
EBU00875
Inspecting the brake fluid level
Insufficient brake fluid may let air enter the brake
system, possibly causing the brakes to become in-
effective.
Before riding, check that the brake fluid is above
the lower level and replenish when necessary. The
rear brake fluid master cylinder reservoir is located
behind panel B. (See page 8-21 for panel removal
and installation procedures.)
Observe these precautions:
1. When checking the fluid level, make sure the
top of the master cylinder reservoir is level by
turning the handlebars.
2. Use only the designated quality brake fluid.
Otherwise, the rubber seals may deteriorate,
causing leakage and poor brake perfor-
mance.
Recommended brake fluid: DOT 4
U5KM61.book Page 95 Friday, July 26, 2002 11:13 AM

8-97
3. Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reac-
tion and lead to poor brake performance.
4. Be careful that water does not enter the mas-
ter cylinder reservoir when refilling. Water will
significantly lower the boiling point of the fluid
and may result in vapor lock.
5. Brake fluid may deteriorate painted surfaces
or plastic parts. Always clean up spilled fluid
immediately.
6. Have a Yamaha dealer check the cause if the
brake fluid level goes down.
U5KM61.book Page 97 Friday, July 26, 2002 11:13 AM