2003 YAMAHA GRIZZLY 660 Oil filter

Tires ...................................................5-27
How to measure tire pressure ............5-31
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
67
What to do if ... ................................... 7-75
What to do ... ...................................... 7-75
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 ....................................... 8-43
Differential gear oil ............................. 8-49
Cooling system ................................... 8-55
Changing the coolant.......................... 8-59
Axle boots ........................................... 8-67
Spark plug inspection ......................... 8-69
Air filter element cleaning ................... 8-75
V-belt cooling duct check hose ........... 8-81
Carburetor adjustment ....................... 8-83
Idle speed adjustment ....................... 8-85
Valve clearance adjustment .............. 8-87
Throttle lever adjustment ................... 8-89
Front brake pad inspection ................ 8-91
Rear brake pad inspection.................. 8-91
Inspecting the brake fluid level ........... 8-93
Brake fluid replacement ...................... 8-97
Front brake adjustment ...................... 8-99
8
U5KM60.book Page 2 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

5-17
CAUTION:_ Be sure to use motor oils that do not contain
anti-friction modifiers. Passenger car motor
oils (often labeled “ENERGY CONSERVING II”)
contain anti-friction additives which will cause
clutch and/or starter clutch slippage, resulting
in reduced component life and poor engine
performance.
Oil quantity:
Total amount:
2.2 L
Periodic oil change:
1.9 L
With oil filter replacement:
2.0 L
U5KM60.book Page 17 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

8-35 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

8-41
9. Fill the engine with sufficient oil to reach the
specified level. Install the dipstick and tighten
it.CAUTION:_

Do not put in any chemical additives. En-
gine oil also lubricates the clutch and addi-
tives could cause clutch slippage.


Be sure no foreign material enters the
crankcase.
_
Recommended oil:
See page 10-2.
Oil quantity:
Total amount:
2.2 L
Periodic oil change:
1.9 L
With oil filter replacement:
2.0 L
U5KM60.book Page 41 Thursday, June 21, 2001 2:40 PM