2003 YAMAHA GRIZZLY 660 radiator

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

5-23
WARNING
_ Wait for the engine and radiator to cool before
removing the radiator cap. You could be
burned by hot fluid and steam blown out under
pressure. Always put a thick rag over the cap
when opening. Allow any remaining pressure
to escape before completely removing the cap. _
EBU00151
Throttle lever
Check to see that the throttle lever operates cor-
rectly. It must open smoothly and spring back to
idle position when released. Repair as necessary
for proper operation.
EBU00152
Fittings and Fasteners
Always check the tightness of chassis fittings and
fasteners before a ride. Take the machine to a
Yamaha dealer or refer to the Service Manual for
correct tightening torque.Reservoir tank capacity:
0.3 L
U5KM60.book Page 23 Thursday, June 21, 2001 2:40 PM

8-57
3. Remove the coolant reservoir cap, and then
add coolant or distilled water to raise it to the
specified level.
4. Install the panel.CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use soft water if you can’t get
distilled water. _NOTE:_

If water is added, have a Yamaha dealer
check the antifreeze content of the coolant as
soon as possible.


The radiator fan operation is completely auto-
matic. It is switched on or off according to the
coolant temperature in the radiator.
_If your ATV overheats, see page 8-138 for details. Coolant reservoir capacity:
0.30 L
U5KM60.book Page 57 Thursday, June 21, 2001 2:40 PM

8-59 1. Coolant drain bolt
1. Boulon de vidange du liquide de refroidissement
1. Perno de drenaje del refrigerante
1. Trough
1. Feuille de papier repliée en forme de conduit
1. Pasante
EBU00977
Changing the coolant
WARNING
_ Wait for the engine and radiator to cool before
removing the radiator cap. You could be
burned by hot fluid and steam blown out under
pressure. Always put a thick rag over the cap
when opening. Allow any remaining pressure
to escape before completely removing the cap. _1. Place the ATV on a level surface.
2. Remove panels E and F. (See pages 8-29 ~
8-31 for removal and installation procedures.)
3. Place a container under the engine, and then
remove the coolant drain bolt. (Use a trough
or a similar object as shown to prevent cool-
ant from spilling on the footrest.)
4. Remove the front carrier and panel C. (See
pages 8-23 and 8-27 for removal and installa-
tion procedures.)
U5KM60.book Page 59 Thursday, June 21, 2001 2:40 PM

8-61 1. Radiator cap
1. Bouchon du radiateur
1. Tapa del radiador
1. Coolant reservoir drain hose
1. Boulon de vidange du liquide de refroidissement
1. Manguera de drenaje del depósito de refrigerante
5. Remove the radiator cap.
6. Remove the coolant reservoir cap.
7. Disconnect the hose on the coolant reservoir
side, and then drain the coolant from the
coolant reservoir.
8. After draining the coolant, thoroughly flush
the cooling system with clean tap water.
9. Replace the coolant drain bolt washer if it is
damaged, and then tighten the coolant drain
bolt to the specified torque.
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf)
U5KM60.book Page 61 Thursday, June 21, 2001 2:40 PM

8-65
12. Install the radiator cap.
13. Start the engine and let it idle for several min-
utes. Stop the engine, and then check the
coolant level in the radiator. If it is low, add
more coolant until it reaches the top of the ra-
diator.
14. Fill the coolant reservoir with coolant up to
the maximum level.
15. Install the coolant reservoir cap and check for
coolant leakage.NOTE:_ If any leakage is found, ask a Yamaha dealer to in-
spect the cooling system. _16. Install the panels and the front carrier.
U5KM60.book Page 65 Thursday, June 21, 2001 2:40 PM

8-138
Engine overheatingNOTE:If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is
changed to the recommended coolant as soon as possible.
WARNING
Wait for the engine and radiator to cool before removing the radiator cap. You could be burned by
hot fluid and steam blown out under pressure. Always put a thick rag over the cap when opening.
Allow any remaining pressure to escape before completely removing the cap. Wait until the
engine has cooled.
Check the coolant level in the
reservoir tank and/or radiator.
Level is OK.Level is low, check the
cooling system for leakage.
No
leakage.Leakage.
Ask a Yamaha dealer to inspect
and repair the cooling system.Add coolant. (See NOTE.)
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and/or repair the cooling system.
U5KM60.book Page 138 Thursday, June 21, 2001 2:40 PM