2003 YAMAHA GRIZZLY 660 brake light

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
1234
Recoil starter ..................................... 4-37
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
5
U5KM60.book Page 1 Thursday, June 21, 2001 2:40 PM

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

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
BrakesCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-7 ~ 5-9,
8-91 ~ 8-105
FuelCheck fuel level.
Fill with fuel if necessary.5-11 ~ 5-13
Engine oilCheck oil level.
Fill with oil if necessary.5-15 ~ 5-17,
8-33 ~ 8-43
Coolant reservoirCheck coolant level.
Fill with coolant if necessary.8-55 ~ 8-65
Final gear oil/
Differential gear oilCheck for leakage.5-19 ~ 5-21,
8-43 ~ 8-53
ThrottleCheck for proper throttle cable operation. 5-23, 8-89
Wheels and tiresCheck tire pressure, wear and damage.5-27 ~ 5-33,
8-113 ~ 8-115
Fittings and FastenersCheck all fittings and fasteners. 5-23
LightsCheck for proper operation. 5-25, 8-127 ~ 133
Axle bootsCheck for damage. 8-67
U5KM60.book Page 1 Thursday, June 21, 2001 2:40 PM

5-25
EBU00803
Lights
Check the headlight and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
EBU00912
Switches
Check the operation of the light switch, engine
stop switch and any other switches. Repair as nec-
essary for proper operation.
U5KM60.book Page 25 Thursday, June 21, 2001 2:40 PM

6-5 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:

When the drive select lever is in the neutral or
park position, if either indicator light does not
come on, ask a Yamaha dealer to inspect its
electric circuit.


The engine can be started in any gear if the
rear brake lever is applied. However, it is rec-
ommended to shift into neutral or park before
starting the engine.
5. Use the starter (choke) in reference to the fig-
ure:
Position
1 : Cold engine start-
ambient temperature below 5 °C.
Position
2 : Cold engine start-
ambient temperature at 0 °C ~ 30 °C
and warming up position.
Position
3 : Cold engine start-
ambient temperature above 25 °C
and warm engine start position.
6. Completely close the throttle lever and start
the engine by pushing the start switch.
U5KM60.book Page 5 Thursday, June 21, 2001 2:40 PM

6-13 1. Drive select lever
a. L (Low)
b. H (High)
c. N (Neutral)
d. R (Reverse)
e. P (Park)
1. Levier de présélection
a. L (rapport inférieur)
b. H (rapport supérieur)
c. N (point mort)
d. R (marche arrière)
e. P (stationnement)
1. Palanca de selección de marcha
a. L (baja)
b. H (alta)
c. N (punto muerto)
d. R (marcha atrás)
e. P (estacionamiento)
Shifting: Neutral to Reverse and Reverse to
ParkNOTE:The drive select lever cannot be shifted into or
from reverse or park without applying the rear
brake. 1. Bring the machine to a complete stop and re-
turn the throttle lever to the closed position.
2. Apply the rear brake pedal.
3. Shift from neutral to reverse or from reverse
to park and vice versa by moving the drive
select lever along the shift guide.NOTE:

When in reverse, the reverse indicator light
should be on. If the light does not come on,
ask a Yamaha dealer to inspect the reverse in-
dicator light electrical circuit.


Due to the synchronizing mechanism in the
engine, the light may not come on until the
ATV starts moving.
U5KM60.book Page 13 Thursday, June 21, 2001 2:40 PM

8-105 1. Rear brake light switch
2. Adjusting nut
1. Contacteur de feu stop
2.Écrou de réglage
1. Interruptor de la luz del freno trasero
2. Tuerca de ajuste
EBU00834
Adjusting the rear brake light switch
The rear brake light switch, which is activated by
the brake pedal and brake levers, is properly ad-
justed when the brake light comes on just before
braking takes effect. If necessary, adjust the brake
light switch as follows.
Turn the adjusting nut while holding the rear brake
light switch in place. To make the brake light come
on earlier, turn the adjusting nut in direction
a. To
make the brake light come on later, turn the adjust-
ing nut in direction
b.
U5KM60.book Page 105 Thursday, June 21, 2001 2:40 PM