2004 YAMAHA GRIZZLY 660 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 ...................................... 4-35
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
EE.book Page 1 Tuesday, April 1, 2003 12:23 PM

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

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 a headlight bulb ............... 8-127
Headlight beam adjustment.............. 8-131
Tail/brake light bulb replacement ..... 8-131
Troubleshooting................................ 8-133
Troubleshooting chart....................... 8-135
CLEANING AND STORAGE ................... 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................. 10-1
CONVERSION TABLE .......................... 11-1
91011EE.book Page 3 Tuesday, April 1, 2003 12:23 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 vicin-
ity of sparks, open flames, or other sourc-
es of ignition such as the pilot lights of
water heaters and clothes dryers. Gaso-
line can catch fire and you could be
burned.


When transporting the machine in anoth-
er vehicle, be sure it is kept upright and
that the fuel cock is in the “OFF” position.
Otherwise, fuel may leak out of the carbu-
retor or fuel tank.


Gasoline is poisonous. If you should
swallow some gasoline or inhale a lot of
gasoline vapor, or get some gasoline in
your eyes, see your doctor immediately. If
gasoline spills on your skin, wash with
soap and water. If gasoline spills on your
clothing, change your clothes.
EE.book Page 15 Tuesday, April 1, 2003 12:23 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 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.
EE.book Page 1 Tuesday, April 1, 2003 12:23 PM

4-1 1. Main switch
1. Contacteur à clé
1. Interruptor principal
EBU00040
CONTROL FUNCTIONS
EBU00942
Main switch
Functions of the respective switch positions are as
follows:
ON:
The engine can be started only at this position and
the headlights 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.
EE.book Page 1 Tuesday, April 1, 2003 12:23 PM

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
EBU00802
Indicator and warning lights
EBU01130
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.
EBU01122
Low-range indicator light “L”
This indicator light comes on when the drive select
lever is in the “L” position.
EBU01064
High-range indicator light “H”
This indicator light comes on when the drive select
lever is in the “H” position.
EBU00972
Neutral indicator light “N”
This indicator light comes on when the drive select
lever is in the “N” position.
EE.book Page 3 Tuesday, April 1, 2003 12:23 PM

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. _
EBU00609
Park indicator light “P”
This indicator light comes on when the drive select
lever is in the “P” (park) position.
EBU01131
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
EE.book Page 5 Tuesday, April 1, 2003 12:23 PM