2004 YAMAHA GRIZZLY 660 coolant

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 ...................................... 4-35
Speed limiter ...................................... 4-37
Front brake lever ................................ 4-39
Rear brake pedal and lever ................ 4-41
Drive select lever ................................ 4-43
Recoil starter ...................................... 4-43
1234
Fuel tank cap ..................................... 4-45
Fuel cock............................................ 4-47
Starter (choke) ................................... 4-49
Seat.................................................... 4-51
Storage compartment ........................ 4-53
Front carrier ....................................... 4-53
Rear carrier ........................................ 4-53
Front and rear shock absorber
adjustment ....................................... 4-55
Auxiliary DC jack ................................ 4-59
PRE-OPERATION CHECKS ................... 5-1
Front and rear brakes .......................... 5-7
Fuel .................................................... 5-11
Engine oil ........................................... 5-15
Final gear oil ...................................... 5-17
Differential gear oil ............................. 5-19
Coolant............................................... 5-19
Throttle lever ...................................... 5-21
Fittings and fasteners......................... 5-21
Lights ................................................. 5-23
Switches............................................. 5-23
Tires ................................................... 5-25
How to measure tire pressure ............ 5-29
5
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Tire wear limit......................................5-31
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
What to do if ........................................7-75
What to do...........................................7-75
67
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 and oil filter cartridge ......... 8-33
Final gear oil ....................................... 8-47
Differential gear oil.............................. 8-51
Cooling system ................................... 8-57
Changing the coolant.......................... 8-61
Axle boots ........................................... 8-69
Spark plug inspection ......................... 8-71
Air filter element cleaning ................... 8-77
Carburetor adjustment ........................ 8-85
Idle speed adjustment ........................ 8-87
Valve clearance adjustment ............... 8-89
Throttle lever adjustment .................... 8-89
Front brake pad check ........................ 8-91
Rear brake pad inspection.................. 8-91
Inspecting the brake fluid level ........... 8-93
Brake fluid replacement ...................... 8-97
Front brake lever free play.................. 8-99
Rear brake lever and pedal
adjustment ...................................... 8-101
Adjusting the rear brake light
switch ............................................. 8-105
Cable inspection and lubrication....... 8-107
8
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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 fluid reservoir
5. Front shock absorber spring
preload adjusting ring
6. Rear brake fluid reservoir
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 box 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.
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4-3
1. Differential gear lock indicator light “DIFF. LOCK”
2. Low-range indicator light “L”
3. High-range indicator light “H”
4. Neutral indicator light “N”
5. Reverse indicator light “R”
6. Park indicator light “P”
7. Four-wheel-drive indicator “”/“”
8. Coolant temperature warning light “”
1. Témoin de blocage du différentiel “DIFF. LOCK”
2. Témoin du rapport inférieur “L”
3. Témoin du rapport supérieur “H”
4. Témoin de point mort “N”
5. Témoin de marche arrière “R”
6. Témoin de stationnement “P”
7. Indicateur 4x4 “”/“”
8. Témoin d’avertissement de la température du liquide de
refroidissement “”
1. Luz indicadora de bloqueo del diferencial “DIFF.LOCK”
2. Luz indicadora de margen bajo “L”
3. Luz indicadora de margen alto “H”
4. Luz de control de punto muerto “N”
5. Luz indicadora de marcha atrás “R”
6. Luz indicadora de estacionamiento “P”
7. Indicador del modo de tracción en las cuatro ruedas “”/“”
8. Luz de aviso de la temperatura del refrigerante “”
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
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Indicator and warning lights
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Differential gear lock indicator light
“DIFF. LOCK”
This indicator light comes on along with the differ-
ential gear lock indicator in the display when the
differential gear lock switch is set to the “LOCK-
4WD” position.
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Low-range indicator light “L”
This indicator light comes on when the drive select
lever is in the “L” position.
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High-range indicator light “H”
This indicator light comes on when the drive select
lever is in the “H” position.
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Neutral indicator light “N”
This indicator light comes on when the drive select
lever is in the “N” position.
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4-5
1. Differential gear lock indicator light “DIFF. LOCK”
2. Low-range indicator light “L”
3. High-range indicator light “H”
4. Neutral indicator light “N”
5. Reverse indicator light “R”
6. Park indicator light “P”
7. Four-wheel-drive indicator “”/“”
8. Coolant temperature warning light “”
1. Témoin de blocage du différentiel “DIFF. LOCK”
2. Témoin du rapport inférieur “L”
3. Témoin du rapport supérieur “H”
4. Témoin de point mort “N”
5. Témoin de marche arrière “R”
6. Témoin de stationnement “P”
7. Indicateur 4x4 “”/“”
8. Témoin d’avertissement de la température du liquide de
refroidissement “”
1. Luz indicadora de bloqueo del diferencial “DIFF.LOCK”
2. Luz indicadora de margen bajo “L”
3. Luz indicadora de margen alto “H”
4. Luz de control de punto muerto “N”
5. Luz indicadora de marcha atrás “R”
6. Luz indicadora de estacionamiento “P”
7. Indicador del modo de tracción en las cuatro ruedas “”/“”
8. Luz de aviso de la temperatura del refrigerante “”
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
EBU00867
Reverse indicator light “R”
This indicator light comes on when the drive select
lever is in the “R” reverse position.NOTE:_ If the indicator light flashes or the speedometer
does not show the speed while riding, have a
Yamaha dealer check the speed sensor circuit. _
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Park indicator light “P”
This indicator light comes on when the drive select
lever is in the “P” (park) position.
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Four-wheel-drive indicator “”/“”
This indicator comes on when the “2WD”/“4WD”
switch is set to the “4WD” position. The differential
lock indicator “DIFF.LOCK” in the four-wheel-drive
indicator also comes on when the “LOCK”-“4WD”
switch is set to the “LOCK-4WD” position.NOTE:_ Due to the synchronizing mechanism in the differ-
ential gear case, the four-wheel drive indicator
may not come on until the ATV starts moving. _
DIFF.
LOCK
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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.
_
1. Differential gear lock indicator light “DIFF. LOCK”
2. Low-range indicator light “L”
3. High-range indicator light “H”
4. Neutral indicator light “N”
5. Reverse indicator light “R”
6. Park indicator light “P”
7. Four-wheel-drive indicator “”/“”
8. Coolant temperature warning light “”
1. Témoin de blocage du différentiel “DIFF. LOCK”
2. Témoin du rapport inférieur “L”
3. Témoin du rapport supérieur “H”
4. Témoin de point mort “N”
5. Témoin de marche arrière “R”
6. Témoin de stationnement “P”
7. Indicateur 4x4 “”/“”
8. Témoin d’avertissement de la température du liquide de
refroidissement “”
1. Luz indicadora de bloqueo del diferencial “DIFF.LOCK”
2. Luz indicadora de margen bajo “L”
3. Luz indicadora de margen alto “H”
4. Luz de control de punto muerto “N”
5. Luz indicadora de marcha atrás “R”
6. Luz indicadora de estacionamiento “P”
7. Indicador del modo de tracción en las cuatro ruedas “”/“”
8. Luz de aviso de la temperatura del refrigerante “”
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
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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,
8-33–8-45
Coolant reservoirCheck coolant level.
Fill with coolant if necessary.8-57–8-67
Final gear oil/
Differential gear oilCheck for leakage.5-17–5-19,
8-47–8-55
ThrottleCheck for proper throttle cable operation. 5-21, 8-89
Wheels and tiresCheck tire pressure, wear and damage.5-25–5-31,
8-113–8-115
Fittings and fastenersCheck all fittings and fasteners. 5-21
Lights and switchesCheck for proper operation. 5-23, 8-127–8-131
Axle bootsCheck for damage. 8-69
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5-19
EBU00678
Differential gear oil
Make sure the differential gear oil is at the speci-
fied level. Add oil as necessary. (See pages 8-53–
8-55 for details.)
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Coolant
Check the coolant level in the coolant reservoir
when the engine is cold. (The coolant level will
vary with engine temperature.) The coolant level is
satisfactory if it is between the minimum and max-
imum level marks on the coolant reservoir. If the
coolant level is at or below the minimum level
mark, add distilled water to bring the level up to the
maximum level mark. Change the coolant every
two years. (See pages 8-57–8-67 for details.)CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use soft water if you cannot get
distilled water. _
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
EE.book Page 19 Tuesday, April 1, 2003 12:23 PM