2003 YAMAHA GRIZZLY 660 engine

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

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

2-1
EBU00661
SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BEHAZARDOUS TO OPERATE.
An ATV handles
differently from other vehicles including
motorcycles and cars. A collision or rollover can
occur quickly, even during routine maneuvers
such as turning and riding on hills or over
obstacles, if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do
not follow these instructions:


Read this manual and all labels carefully and
follow the operating procedures described.


Never operate an ATV without proper instruc-
tion.


Always follow the age recommendation:
– A child under 16 years old should never oper-
ate an ATV with engine size greater than 90cc.


Never allow a child under age 16 to operate an
ATV without adult supervision, and never allow
continued use of an ATV by a child if he or she
does not have the abilities to operate it safely.
U5KM60.book Page 1 Thursday, June 21, 2001 2:40 PM

2-15
WARNING


Always turn off the engine when refueling.


Do not refuel right after the engine has
been running and is still very hot.


Do not spill gasoline on the engine or ex-
haust pipe/muffler when refueling. Never
refuel while smoking, or while in the vicini-
ty of sparks, open flames, or other sources
of ignition such as the pilot lights of water
heaters and clothes dryers. Gasoline can
catch fire and you could be burned.


When transporting the machine in another
vehicle, be sure it is kept upright and that
the fuel cock is in the “OFF” position. Oth-
erwise, fuel may leak out of the carburetor
or fuel tank.


Gasoline is poisonous. If you should swal-
low some gasoline or inhale a lot of gaso-
line vapor, or get some gasoline in your
eyes, see your doctor immediately. If gaso-
line spills on your skin, wash with soap
and water. If gasoline spills on your cloth-
ing, change your clothes.
U5KM60.book Page 15 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

4-1 1. Main switch
1. Contacteur à clé
1. Interruptor principal
EBU00040
CONTROL FUNCTIONS
EBU00041
Main switch
Functions of the respective switch positions are as
follows:
ON:
Engine can be started only at this position and the
headlight and taillight come on when the light
switch is on.
OFF:
All electrical circuits are switched off. The key can
be removed in this position.
U5KM60.book Page 1 Thursday, June 21, 2001 2:40 PM

4-7
EBU00860
Coolant temperature warning light “”
When the coolant temperature reaches a specified
level, this light comes on to warn that the coolant
temperature is too hot. If the light comes on during
operation, stop the engine as soon as it is safe to
do so and allow the engine to cool down for about
10 minutes.CAUTION:_

The engine may overheat if the ATV is
overloaded. If this happens, reduce the
load to specification.


After restarting, make sure that the light is
out. Continuous use while the light is on
may cause damage to the engine.
_
U5KM60.book Page 7 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