2003 YAMAHA GRIZZLY 660 oil

5-21
EBU00678
Differential gear oil
Make sure the differential gear oil is at the speci-
fied level. Add oil as necessary. (See pages 8-49 ~
8-53 for details.)
EBU00497*
Coolant
Check the coolant level in the reservoir tank when
the engine is cold. (The coolant level will vary with
engine temperature.) The coolant level is satisfac-
tory if it is between the “FULL” and “LOW” marks
on the tank. If the coolant level is at or below the
“LOW” level, add tap water (soft water) to bring the
level up to “FULL”. Change the coolant every two
years. (See pages 8-55 ~ 8-65 for details.)CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use distilled water if you can’t
get soft water. _
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
U5KM60.book Page 21 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

8-7
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.U5KM60.book Page 7 Thursday, June 21, 2001 2:40 PM

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
U5KM60.book Page 8 Thursday, June 21, 2001 2:40 PM

8-33 1. Engine oil dipstick
1. Jauge d’huile
1. Varilla de medición del aceite de motor
1. Maximum level mark 2. Minimum level mark
1. Repère de niveau maximum 2. Repère de niveau minimum
1. Marca de nivel máximo 2. Marca de nivel mínimo
EBU00847
Engine oil
Oil level inspection
1. Remove panel F. (See page 8-31 for panel
removal and installation procedures.)
2. Place the ATV on a level place and warm up
the engine for several minutes.
3. Stop the engine.
4. Remove the dipstick and wipe it off with a
clean rag. Insert the dipstick in the filler hole
without screwing it in.NOTE:_ Wait a few minutes until the oil level settles before
checking. _5. The oil level should be between the maxi-
mum and minimum marks. If the level is low,
fill the engine with sufficient oil to reach the
specified level.
U5KM60.book Page 33 Thursday, June 21, 2001 2:40 PM

8-35 1. Engine oil drain bolt
1. Boulon de vidange de l’huile
1. Perno de drenaje del aceite de motor
Engine oil and oil filter cartridge replacement
1. Remove panels E and F. (See pages 8-29 ~
8-31 for panel removal and installation proce-
dures.)
2. Warm up the engine for several minutes.
3. Stop the engine. Place an oil pan under the
engine and remove the dipstick.
4. Remove the drain bolt and drain the oil.
U5KM60.book Page 35 Thursday, June 21, 2001 2:40 PM

8-37 1. Engine oil filter cartridge
2. Oil filter wrench
1. Cartouche du filtre à huile moteur
2. Clé pour filtre à huile
1. Cartucho del filtro de aceite de motor
2. Llave para filtros de aceite
5. Remove the oil filter by using an oil filter
wrench.NOTE:_ An oil filter wrench is available at a nearby
Yamaha dealer. _6. Install the drain bolt and tighten it to the spec-
ified torque.
Tightening torque:
Drain bolt:
30 Nm (3.0 m·kgf)
U5KM60.book Page 37 Thursday, June 21, 2001 2:40 PM

8-39 1. Torque wrench
1. Clé dynamométrique
1. Llave de apriete
7. Apply a light coat of engine oil to the O-ring of
the new oil filter.NOTE:_ Make sure the O-ring is seated properly. _8. Install the oil filter and tighten it to the speci-
fied torque with a torque wrench.
Tightening torque:
Oil filter:
17 Nm (1.7 m·kgf)
U5KM60.book Page 39 Thursday, June 21, 2001 2:40 PM