2003 YAMAHA GRIZZLY 660 wheel

Rear brake adjustment .................... 8-101
Adjusting the rear brake light
switch ............................................. 8-105
Cable inspection and lubrication ..... 8-107
Brake lever and brake pedal
lubrication ...................................... 8-109
Rear knuckle upper and lower pivot
lubrication ....................................... 8-111
Wheel removal ................................ 8-113
Wheel installation ............................ 8-115
Battery ............................................. 8-117
Battery maintenance ....................... 8-121
Fuse replacement ............................ 8-123
Replacing the headlight bulb ........... 8-127
Headlight beam adjustment ............. 8-131
Tail/brake light bulb replacement ..... 8-133
Troubleshooting ............................... 8-135
Troubleshooting chart ...................... 8-137CLEANING AND STORAGE .................. 9-1
A. Cleaning ......................................... 9-1
B. Storage ........................................... 9-7
SPECIFICATIONS................................. 10-1
HOW TO USE THE CONVERSION
TABLE .................................................. 11-1
91011
U5KM60.book Page 3 Thursday, June 21, 2001 2:40 PM

2-3

Never carry passenger on an ATV.


Always avoid operating an ATV on any paved
surfaces, including sidewalks, driveways, park-
ing lots and streets.


Never operate an ATV on any public street,
road or highway, even a dirt or gravel one.


Never operate an ATV without wearing an ap-
proved motorcycle helmet that fits properly.
You should also wear eye protection (goggles
or face shield), gloves, boots, long-sleeved
shirt or jacket, and long pants.


Never consume alcohol or drugs before or
while operating this ATV.


Never operate at speeds too fast for your skills
or the conditions. Always go at a speed that is
proper for the terrain, visibility and operating
conditions, and your experience.


Never attempt wheelies, jumps, or other stunts.
U5KM60.book Page 3 Thursday, June 21, 2001 2:40 PM

4-3
1. Differential gear lock indicator light “DIFF. LOCK”
2. Low-range indicator light “L”
3. High-range indicator light “H”
4. Neutral indicator light “N”
5. Reverse indicator light “R”
6. Park indicator light “P”
7. Four-wheel-drive indicator “”/“”
8. Coolant temperature warning light “”
1. Témoin de blocage du différentiel “DIFF. LOCK”
2. Témoin du rapport inférieur “L”
3. Témoin du rapport supérieur “H”
4. Témoin de point mort “N”
5. Témoin de marche arrière “R”
6. Témoin de stationnement “P”
7. Indicateur 4x4 “”/“”
8. Témoin d’avertissement de la température du liquide de
refroidissement “”
1. Luz indicadora de bloqueo del diferencial “DIFF.LOCK”
2. Luz indicadora de margen bajo “L”
3. Luz indicadora de margen alto “H”
4. Luz de control de punto muerto “N”
5. Luz indicadora de marcha atrás “R”
6. Luz indicadora de estacionamiento “P”
7. Indicador del modo de tracción en las cuatro ruedas “”/“”
8. Luz de aviso de la temperatura del refrigerante “”
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
EBU00802
Indicator and warning lights
EBU00839
Differential gear lock indicator light “DIFF.
LOCK”
This indicator light comes on along with the differ-
ential gear lock indicator in the display when the
differential gear lock switch is set to the “4WD-
LOCK” position.
EBU00838*
Low-range indicator light “L”
This indicator light comes on when the drive select
lever is in the “L” position.
EBU00836*
High-range indicator light “H”
This indicator light comes on when the drive select
lever is in the “H” position.
EBU00603*
Neutral indicator light “N”
This indicator light comes on when the drive select
lever is in the “N” position.
U5KM60.book Page 3 Thursday, June 21, 2001 2:40 PM

4-5
1. Differential gear lock indicator light “DIFF. LOCK”
2. Low-range indicator light “L”
3. High-range indicator light “H”
4. Neutral indicator light “N”
5. Reverse indicator light “R”
6. Park indicator light “P”
7. Four-wheel-drive indicator “”/“”
8. Coolant temperature warning light “”
1. Témoin de blocage du différentiel “DIFF. LOCK”
2. Témoin du rapport inférieur “L”
3. Témoin du rapport supérieur “H”
4. Témoin de point mort “N”
5. Témoin de marche arrière “R”
6. Témoin de stationnement “P”
7. Indicateur 4x4 “”/“”
8. Témoin d’avertissement de la température du liquide de
refroidissement “”
1. Luz indicadora de bloqueo del diferencial “DIFF.LOCK”
2. Luz indicadora de margen bajo “L”
3. Luz indicadora de margen alto “H”
4. Luz de control de punto muerto “N”
5. Luz indicadora de marcha atrás “R”
6. Luz indicadora de estacionamiento “P”
7. Indicador del modo de tracción en las cuatro ruedas “”/“”
8. Luz de aviso de la temperatura del refrigerante “”
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
EBU00867*
Reverse indicator light “R”
This indicator light comes on when the drive select
lever is in the “R” reverse position.NOTE:_ If the indicator light flashes or the speedometer
does not show the speed while riding, have a
Yamaha dealer check the speed sensor circuit. _
EBU00609
Park indicator light “P”
This indicator light comes on when the drive select
lever is in the “P” (park) position.
EBU00884*
Four-wheel-drive indicator “”/“”
This indicator comes on when the “2WD”/“4WD”
switch is set to the “4WD” position. The differential
lock indicator “DIFF.LOCK” in the four-wheel-drive
indicator also comes on when the “4WD”/“LOCK”
switch is set to the “4WD-LOCK” position.NOTE:_ Due to the synchronizing mechanism in the differ-
ential gear case, the four-wheel drive indicator
may not come on until the ATV starts moving. _
DIFF.
LOCK
U5KM60.book Page 5 Thursday, June 21, 2001 2:40 PM

4-21 1. On-command four-wheel drive switch “2WD”/“4WD”
2. Differential gear lock switch “4WD”/“LOCK”
1. Contacteur de commande du mode de traction “2WD”/“4WD”
2. Contacteur de blocage du différentiel “4WD”/“LOCK”
1. Selector de tracción en las cuatro ruedas “2WD”/“4WD”
2. Selector de bloqueo del diferencial “4WD”/“LOCK”
EBU00974
On-command four-wheel drive and differential
gear lock switches
This ATV is equipped with an on-command four-
wheel drive switch “2WD”/“4WD” and a differential
gear lock switch “4WD”/“LOCK”. Select the appro-
priate drive according to terrain and the conditions.

Two-wheel drive (2WD): Power is supplied to
the rear wheels only.


Four-wheel drive (4WD): Power is supplied to
the rear and front wheels.


Four-wheel drive with the differential gear
locked (4WD-LOCK): Power is supplied to the
rear and front wheels when the differential gear
is locked (“DIFF.LOCK”). Unlike the 4WD
mode, all wheels turn at the same speed.WARNING
_ Always stop the ATV before changing from 2WD
to 4WD, or from 4WD to 4WD-LOCK, or vice-ver-
sa.
The ATV handles differently in 2WD than in 4WD
and in 4WD-LOCK in some circumstances.
Changing from 2WD to 4WD, or from 4WD to
4WD-LOCK, or vice-versa while moving may
cause the ATV to unexpectedly handle different-
ly. This could distract the operator and increase
the risk of losing control and an accident. _
U5KM60.book Page 21 Thursday, June 21, 2001 2:40 PM

4-23 1. Lever
2. On-command four-wheel drive switch “2WD”/“4WD”
1. Levier
2. Contacteur de commande du mode de traction “2WD”/“4WD”
1. Palanca
2. Selector de tracción en las cuatro ruedas “2WD”/“4WD”
On-command four-wheel drive switch
“2WD”/“4WD”
To change from 2WD to 4WD, stop the ATV, and
then set the switch to “4WD”. When the ATV is in
4WD, the 4WD indicator “” will come on in the
speedometer unit display. To change from 4WD to
2WD, stop the ATV, be sure the lever is set to po-
sition
a, and then set the switch to “2WD”.
U5KM60.book Page 23 Thursday, June 21, 2001 2:40 PM

4-25 1. Differential gear lock switch “4WD”/“LOCK”
2. Lever
1. Contacteur de blocage du différentiel “4WD”/“LOCK”
2. Levier
1. Selector de bloqueo del diferencial “4WD”/“LOCK”
2. Palanca
Differential gear lock switch “4WD”/“LOCK”
To lock the differential gear in 4WD, make sure the
on-command four-wheel-drive switch is set to
“4WD”, stop the ATV, move the lever to
position
b, and then set the switch to “LOCK”.
When the differential gear is locked, the differential
gear lock indicator light (“DIFF.LOCK”) will come
on along with the indicator “” in the speedometer
unit display. To release the differential gear lock,
stop the ATV and set the switch to “4WD”.
DIFF.
LOCK
U5KM60.book Page 25 Thursday, June 21, 2001 2:40 PM

4-27
WARNING
_ Always ride at a slow speed when the ATV is in
4WD-LOCK, and allow extra time and distance
for maneuvers.
All wheels turn at the same speed when the dif-
ferential is locked, so it takes more effort to
turn the ATV. The amount of effort is more the
faster you go. You may lose control and have
an accident if you cannot make a sharp
enough turn for the speed you are traveling. _ NOTE:_

When the switch is set to “LOCK”, the differ-
ential gear lock indicator light will flash until
the differential gear is locked.


When the indicator light is flashing, turning
the handlebar back and forth will help the dif-
ferential gear lock to engage.


Riding before the differential gear lock is
properly engaged (e.g., when the indicator
light is flashing) will cause the engine speed
to be limited until engagement is complete.


When the ATV is in 4WD-LOCK, the maxi-
mum traveling speed is limited to 35 km/h.
_
U5KM60.book Page 27 Thursday, June 21, 2001 2:40 PM