2003 YAMAHA GRIZZLY 660 check engine

EBU00015
1-CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ....................... 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION AND MACHINE
IDENTIFICATION .................................... 3-1
Identification number records ............... 3-3
Key identification number ..................... 3-5
Vehicle identification number ............... 3-7
Model label ........................................... 3-9
CONTROL FUNCTIONS ......................... 4-1
Main switch........................................... 4-1
Indicator and warning lights.................. 4-3
Speedometer unit ................................. 4-9
Fuel gauge ......................................... 4-15
Handlebar switches ............................ 4-17
Throttle lever ...................................... 4-29
Speed limiter ...................................... 4-31
Front brake lever ................................ 4-33
Rear brake pedal and lever ................ 4-35
Drive select lever ................................ 4-37
Recoil starter ...................................... 4-37
1234
Fuel tank cap ..................................... 4-39
Fuel cock............................................ 4-41
Starter (choke) ................................... 4-43
Seat.................................................... 4-45
Storage compartment ........................ 4-47
Front carrier ....................................... 4-47
Rear carrier ........................................ 4-47
Front and rear shock absorber
adjustment ....................................... 4-49
Auxiliary DC jack ................................ 4-53
PRE-OPERATION CHECKS ................... 5-1
Front and rear brakes .......................... 5-7
Fuel .................................................... 5-11
Engine oil ........................................... 5-15
Final gear oil ...................................... 5-19
Differential gear oil ............................. 5-21
Coolant............................................... 5-21
Throttle lever ...................................... 5-23
Fittings and fasteners......................... 5-23
Lights ................................................. 5-25
Switches............................................. 5-25
Tires ................................................... 5-27
How to measure tire pressure ............ 5-31
5
U5KM61.book Page 1 Friday, July 26, 2002 11:13 AM

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
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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

4-29 1. Throttle lever
1. Levier d’accélération
1. Palanca de aceleración
EBU00063
Throttle lever
Once the engine is running, movement of the
throttle lever will increase the engine speed.
Regulate the speed of the machine by varying the
throttle position. Because the throttle is spring-
loaded, the machine will decelerate, and the en-
gine will return to an idle any time the hand is re-
moved from the throttle lever.
Before starting the engine, check the throttle to be
sure it is operating smoothly. Make sure it returns
to the idle position as soon as the lever is released.
WARNING
Malfunction of the throttle could make it diffi-
cult to speed up or slow down when you need
to. This could cause an accident. Check the
operation of the throttle lever before you start
the engine. If the throttle does not work
smoothly, check for the cause. Correct the
problem before riding the ATV or consult a
Yamaha dealer.
U5KM61.book Page 29 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
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5-21
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Differential gear oil
Make sure the differential gear oil is at the speci-
fied level. Add oil as necessary. (See pages 8-51–
8-55 for details.)
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Coolant
Check the coolant level in the coolant reservoir
when the engine is cold. (The coolant level will
vary with engine temperature.) The coolant level is
satisfactory if it is between the upper and lower
level marks on the coolant reservoir. If the coolant
level is at or below the lower level mark, add tap
water (soft water) to bring the level up to the upper
level mark. Change the coolant every two years.
(See pages 8-57–8-67 for details.)CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use distilled water if you cannot
get soft water. _
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
U5KM61.book Page 21 Friday, July 26, 2002 11:13 AM

5-23
WARNING
_ Wait 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. _
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Throttle lever
Check to see that the throttle lever operates cor-
rectly. It must open smoothly and spring back to
the idle position when released. Have a Yamaha
dealer repair as necessary for proper operation.
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Fittings and fasteners
Always check the tightness of chassis fittings and
fasteners before a ride. Take the machine to a
Yamaha dealer or refer to the Service Manual for
correct tightening torque.Coolant reservoir capacity:
0.3 L
U5KM61.book Page 23 Friday, July 26, 2002 11:13 AM

6-9
EBU00180
Starting a warm engine
To start a warm engine, refer to the “Starting a cold
engine” section. The starter (choke) should not be
used. The throttle should be opened slightly.
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Warming up
To get maximum engine life, always warm up the
engine before starting off. Never accelerate hard
with a cold engine! To see whether or not the en-
gine is warm, check if it responds to the throttle
normally with the starter (choke) turned off.
U5KM61.book Page 9 Friday, July 26, 2002 11:13 AM