2003 YAMAHA GRIZZLY 660 air filter

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

7-65
1. Air filter case check hose
1. Flexible de contrôle du boîtier de filtre à air
1. Manguera de comprobación de la caja del filtro de aire
Test your brakes after leaving the water. Do not
continue to ride your ATV without verifying that
you have regained proper braking ability.CAUTION:_ After riding your ATV in water, be sure to drain
the trapped water by removing the check hose
at the bottom of the air filter case and the
check hose on the V-belt cooling duct. Wash
the ATV in fresh water if it has been operated in
salt water or muddy conditions. _
U5KM61.book Page 65 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

8-77 1. Air filter case check hose
1. Flexible de contrôle du boîtier de filtre à air
1. Manguera de comprobación de la caja del filtro de aire
1. Holder (× 5) 2. Air filter case cover
1. Support (× 5) 2. Couvercle du boîtier de filtre à air
1. Soporte (× 5) 2. Cubierta de la caja del filtro de aire
EBU01212
Air filter element cleaningNOTE:_ There is a check hose at the bottom of the air filter
case. If dust or water collects in this hose, empty
the hose and clean the air filter element and air fil-
ter case. _1. Remove the seat. (See page 4-45 for seat re-
moval and installation procedures.)
2. Remove the air filter case cover by unhook-
ing the holders.
U5KM61.book Page 77 Friday, July 26, 2002 11:13 AM

8-79 1. Air filter element
1.Élément de filtre à air
1. Elemento del filtro de aire
1. Air filter element frame
1. Armature d’élément de filtre à air
1. Bastidor del elemento del filtro de aire
3. Remove the air filter element.
4. Remove the air filter element from its frame.
5. Wash the air filter element gently but thor-
oughly in solvent.
WARNING
_ Always use parts cleaning solvent to clean the
air filter element. Never use low flash point sol-
vents or gasoline to clean the air filter element
because the engine could catch fire or ex-
plode. _6. Squeeze the excess solvent out of the air fil-
ter element and let it dry.CAUTION:_ Do not twist the air filter element when squeez-
ing it. _7. Inspect the air filter element and replace it if
damaged.
8. Apply foam air filter oil to the air filter element.
If foam air filter oil is not available, engine oil
may be used.NOTE:_ The air filter element should be wet but not drip-
ping. _
U5KM61.book Page 79 Friday, July 26, 2002 11:13 AM

8-81 1. Breather hose
1. Reniflard
1. Manguera del respiradero
9. Pull the air filter element over its frame.
10. Install the air filter element.
11. Install the air filter case cover and be sure to
connect the hose.
12. Install the seat.NOTE:_ The air filter element should be cleaned every 20–
40 hours. It should be cleaned and lubricated more
often if the machine is operated in extremely dusty
areas. Each time air filter element maintenance is
performed, check the air inlet to the air filter case
for obstructions. Check the air filter element rubber
joint to the carburetor and manifold fittings for an
airtight seal. Tighten all fittings securely to avoid
the possibility of unfiltered air entering the engine. _CAUTION:_ Never operate the engine with the air filter ele-
ment removed. This will allow unfiltered air to
enter, causing rapid engine wear and possible
engine damage. Additionally, operation with-
out the air filter element will affect carburetor
jetting with subsequent poor performance and
possible engine overheating. _
U5KM61.book Page 81 Friday, July 26, 2002 11:13 AM

10-3
Engine oil:
Quantity:
Periodic oil change 1.9 L
With oil filter replacement 2.0 L
Total amount 2.2 L
Final gear case oil:
Type SAE80 API “GL-4” Hypoid gear oil
Quantity:
Periodic oil change 0.25 L
Total amount 0.30 L
Differential gear case oil:
Type SAE80 API “GL-4” Hypoid gear oil
Quantity:
Periodic oil change 0.28 L
Total amount 0.33 L
Air filter: Wet type element
Fuel:
Type For Europe
REGULAR UNLEADED GASOLINE ONLY
For Oceania
UNLEADED GASOLINE ONLY
Fuel tank capacity 20 L
Fuel reserve amount 3.5 LModel YFM660F
U5KM61.book Page 3 Friday, July 26, 2002 11:13 AM