2003 YAMAHA GRIZZLY 660 battery

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

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 master cylinder
5. Front shock absorber spring
preload adjusting ring
6. Rear brake master cylinder
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 case 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.
U5KM60.book Page 1 Thursday, June 21, 2001 2:40 PM

4-17 1. Lights switch
2. Engine stop switch
3. Start switch “”
4. Horn switch “”
1. Contacteur d’éclairage
2. Coupe-circuit du moteur
3. Contacteur du démarreur “”
4. Contacteur de l’avertisseur “”
1. Interruptor de luces
2. Interruptor de paro del motor
3. Interruptor de arranque “”
4. Interruptor de la bocina “”
EBU00053
Handlebar switches
EBU00735
Light switch
Turn the switch to the “” position to switch on
the low beam and the taillight.
Turn the switch to the “” position to switch on
the high beam and the taillight.
Turn the switch to the “OFF” position to switch off
the headlight and the taillight.CAUTION:
Do not use the headlight with the engine
turned off for more than thirty minutes. The
battery may discharge to the point that the
starter motor will not operate properly. If this
should happen, remove the battery and re-
charge it.
EBU00606
Engine stop switch
Make sure that the engine stop switch is in the
“” position. The engine stop switch controls ig-
nition and can be used at all times to stop the en-
gine, especially in an emergency. The engine will
not start or run when the engine stop switch is
turned to “”.
U5KM60.book Page 17 Thursday, June 21, 2001 2:40 PM

4-55
CAUTION:

Do not use accessories requiring more
than the above maximum capacity. This
may overload the circuit and cause the
fuse to blow.


If accessories are used without the engine
running or with the headlight turned on,
the battery will lose its charge and engine
starting may become difficult.


Do not use an automotive cigarette lighter
or other accessories with a plug that gets
hot because the jack can be damaged.
U5KM60.book Page 55 Thursday, June 21, 2001 2:40 PM

6-7 a. Starter (choke) lever
1. Fully open
2. Half open
3. Closed
a. Starter (enrichisseur)
1. Complètement ouvert
2. Mi-ouvert
3. Fermé
a. Starter (choke)
1. Abre completamente
2. Semiabierto
3. Cerrado
NOTE:

If the engine fails to start, release the start
switch, then push the start switch again.
Pause a few seconds before the next attempt.
Each cranking should be as short as possible
to preserve battery energy. Do not crank the
engine more than 10 seconds on each at-
tempt.


If the battery is discharged, pull the recoil
starter to start the engine.
7. If the engine is started with the starter (choke)
in position
1, the starter (choke) should be
returned to position
2 to warm up the en-
gine. If the engine is started with the starter
(choke) in position
2, keep the starter
(choke) in this position to warm up the en-
gine.
8. Continue warming up the engine until it idles
smoothly and return the starter (choke) to po-
sition
3 before riding.CAUTION:
See the “Engine break-in” section prior to op-
erating the engine for the first time.
U5KM60.book Page 7 Thursday, June 21, 2001 2:40 PM

8-3 1. Owner’s manual
2. Owner’s tool kit
3. Low-pressure tire gauge
1. Manuel du propriétaire
2. Manuel du trousse à outils
3. Manomètre basse pression pour pneus
1. Manual del propietario
2. Manual del juego de herramientas
3. Manómetro de baja presión
EBU00563
Owner’s manual and tool kit
You are recommended to put this owner’s manual
in the vinyl bag and always carry it in the storage
box. Put the owner’s tool kit and low-pressure tire
gauge in the space beside the battery.
The service information included in this manual is
intended to provide you, the owner, with the nec-
essary information for completing your own pre-
ventive maintenance and minor repairs. The tools
provided in the Owner’s tool kit are sufficient for
this purpose, except that a torque wrench is also
necessary to properly tighten nuts and bolts.NOTE:_ If you do not have a torque wrench available dur-
ing a service operation requiring one, take your
machine to a Yamaha dealer to check the torque
settings and adjust them as necessary. _
U5KM60.book Page 3 Thursday, June 21, 2001 2:40 PM

8-117
EBU00381
Battery
This machine is equipped with a sealed-type bat-
tery. Therefore it is not necessary to check the
electrolyte or add distilled water in the battery. If
the battery seems to have discharged, consult a
Yamaha dealer.CAUTION:
Do not try to remove the sealing caps of the
battery cells. You may damage the battery.
U5KM60.book Page 117 Thursday, June 21, 2001 2:40 PM

8-119
WARNING
Battery electrolyte is poisonous and danger-
ous, causing severe burns, etc. It contains sul-
furic acid. Avoid contact with skin, eyes or
clothing.
Antidote:

EXTERNAL: Flush with water.


lNTERNAL: Drink large quantities of water
or milk. Follow with milk of magnesia, beat-
en egg or vegetable oil. Call a physician
immediately.


EYES: Flush with water for 15 minutes and
get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes or other sources of
ignition away. Ventilate when charging or us-
ing in an enclosed space. Always shield your
eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
U5KM60.book Page 119 Thursday, June 21, 2001 2:40 PM