2004 YAMAHA GRIZZLY 660 coolant level

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
EE.book Page 2 Tuesday, April 1, 2003 12:23 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.
_
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
EE.book Page 7 Tuesday, April 1, 2003 12:23 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,
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
EE.book Page 1 Tuesday, April 1, 2003 12:23 PM

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.)
EBU13160
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

5-21
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. _
EBU01083
Throttle lever
Check to see that the throttle lever operates cor-
rectly. It must open smoothly and spring back to
the idle position when released. Have a Yamaha
dealer repair as necessary for proper operation.
EBU01162
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.Coolant reservoir capacity
(up to the maximum level mark):
0.3 L
EE.book Page 21 Tuesday, April 1, 2003 12:23 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 systemCheck coolant leakage.
Repair if necessary.
Replace coolant every 24 months.Spark plugCheck condition.
Adjust gap and clean.
Replace if necessary.Air filter elementClean.
Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*Check starter (choke) operation.
Adjust engine idling speed.Crankcase breather
system*Check breather hose for cracks or damage.
Replace if necessary.Exhaust system*Check for leakage.
Tighten 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.Wheels*Check balance/damage/runout.
Repair if necessary.EE.book Page 7 Tuesday, April 1, 2003 12:23 PM

8-57 1. Coolant reservoir tank cap
2. Maximum level mark
3. Minimum level mark
1. Bouchon du vase d’expansion
2. Repère de niveau maximum
3. Repère de niveau minimum
1. Tapa del depósito de refrigerante
2. Marca de nivel máximo
3. Marca de nivel mínimo
EBU13210
Cooling system
1. Place the ATV on a level surface.
2. Check the coolant level in the coolant reser-
voir when the engine is cold as the coolant
level will vary with engine temperature.NOTE:_ The coolant level should be between the minimum
and maximum level marks. _
EE.book Page 57 Tuesday, April 1, 2003 12:23 PM

8-59
3. If the coolant is at or below the minimum level
mark, remove panel D. (See pages 8-17–
8-19 for panel removal and installation proce-
dures.)
4. Remove the reservoir cap, add coolant to the
maximum level mark, install the reservoir
cap, and then install the panel.CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use soft water if you cannot 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 8-140 for details. Coolant reservoir capacity
(up to the maximum level mark):
0.3 L
EE.book Page 59 Tuesday, April 1, 2003 12:23 PM