2003 YAMAHA GRIZZLY 660 check oil

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
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

5-21
EBU00678
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.)
EBU01244
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

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

8-33 1. Engine oil filler cap
2. Engine oil dipstick
1. Bouchon de remplissage d’huile de moteur
2. Jauge d’huile
1. Tapa de relleno de aceite de motor
2. Varilla de medición del aceite de motor
EBU01099
Engine oil
Engine oil level measurement
1. Remove panel F. (See page 8-31 for panel
removal and installation procedures.)
2. Place the ATV on a level surface and warm
up the engine for several minutes.
3. Stop the engine.
4. Remove the engine oil filler cap and wipe off
the dipstick with a clean rag.
5. Insert the dipstick in the filler hole without
screwing it in.NOTE:_ Wait a few minutes until the oil level settles before
checking. _
U5KM61.book Page 33 Friday, July 26, 2002 11:13 AM