2003 YAMAHA GRIZZLY 660 fuel

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

5-11
EBU00998
Fuel
Make sure there is sufficient gasoline in the tank.NOTE:_ (for Europe only)
If knocking or pinging occurs, use a different brand
of gasoline or higher octane grade. _CAUTION:_ Use only unleaded gasoline. The use of leaded
gasoline will cause severe damage to internal
engine parts, such as the valves and piston
rings, as well as to the exhaust system. _
Recommended fuel:
For Europe: Regular unleaded gasoline
only with a research octane number of 91
or higher
For Australia: Unleaded gasoline only
Fuel tank capacity:
Total: 20 L
Reserve: 3.5 L
U5KM61.book Page 11 Friday, July 26, 2002 11:13 AM

5-13 1. Fuel level 2. Filler tube
1. Niveau de carburant 2. Tube de remplissage
1. Nivel de combustible 2. Tubo del relleno
WARNING
_

Do not overfill the fuel tank. Fuel expands
when it heats up. If the fuel tank is over-
filled, fuel could spill out due to heat from
the engine or the sun.


Be careful not to spill fuel, especially on
the engine or exhaust pipe which can
cause a fire and severe injury. Wipe up
any spilled fuel immediately.


Do not refuel right after the engine has
been running and is still very hot.


Be sure the fuel tank cap is closed secure-
ly.
_
U5KM61.book Page 13 Friday, July 26, 2002 11:13 AM

6-3
EBU00673
Starting a cold engine
WARNING
Always make sure all control cables work
smoothly before you begin riding in cold
weather. If the control cables are frozen or do
not work smoothly, you could be unable to
control the ATV, which could lead to an acci-
dent or collision.1. Apply the rear brake lever.
2. Turn the fuel cock to “ON”.
3. Turn the main switch to “ON” and the engine
stop switch to “”.
4. Shift the drive select lever into the neutral or
park position.
U5KM61.book Page 3 Friday, July 26, 2002 11:13 AM

6-19
1. 0–10 hours:
Avoid continuous operation above half throt-
tle. Allow a cooling off period of five to ten
minutes after every hour of operation. Vary
the speed of the machine from time to time.
Do not operate it at one set throttle position.
2. 10–20 hours:
Avoid prolonged operation above 3/4 throttle.
Rev the machine freely but do not use full
throttle at any time.
3. After break-in:
Avoid prolonged full throttle operation. Vary
speeds occasionally.
EBU00612
Parking
When parking, stop the engine and shift the drive
select lever into the park position, then turn the fuel
cock to the “OFF” position.
U5KM61.book Page 19 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

8-89
EBU00303
Valve clearance adjustment
The correct valve clearance changes with use, re-
sulting in improper fuel/air supply or engine noise.
To prevent this, the valve clearance must be ad-
justed regularly. This adjustment however, should
be left to a professional Yamaha service techni-
cian.
U5KM61.book Page 89 Friday, July 26, 2002 11:13 AM

8-137
EBU00413
Troubleshooting
Although Yamaha machines receive a rigid in-
spection before shipment from the factory, trouble
may occur during operation.
Any problem in the fuel, compression, or ignition
systems can cause poor starting and loss of pow-
er. The troubleshooting chart describes a quick,
easy procedure for making checks. If your ma-
chine requires any repair, take it to a Yamaha
dealer.
The skilled technicians at a Yamaha dealership
have the tools, experience, and know-how to prop-
erly service your machine. Use only genuine
Yamaha parts on your machine. Imitation parts
may look like Yamaha parts, but they are often in-
ferior.
Consequently, they have a shorter service life and
can lead to expensive repair bills.
WARNING
Do not smoke when checking the fuel system.
Fuel can ignite or explode, causing severe in-
jury or property damage. Make sure there are
no open flames or sparks in the area, including
pilot lights from water heaters or furnaces.
U5KM61.book Page 137 Friday, July 26, 2002 11:13 AM