2005 YAMAHA GRIZZLY 660 oil filter

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............ 8-17
Engine oil and oil filter cartridge ......... 8-39
Final gear oil ....................................... 8-53
Differential gear oil.............................. 8-57
Cooling system ................................... 8-63
Changing the coolant.......................... 8-67
Axle boots ........................................... 8-75
Spark plug inspection ......................... 8-77
Air filter element cleaning ................... 8-83
V-belt cooling duct check hose ........... 8-91
V-belt case drain plug ......................... 8-91
Carburetor adjustment ........................ 8-93
Idle speed adjustment ........................ 8-95
Valve clearance adjustment ............... 8-97
Select lever safety system cable
adjustment ........................................ 8-97
Throttle lever adjustment .................... 8-99
Front brake pad check ...................... 8-101
Checking the rear brake pads .......... 8-101
Checking the brake fluid level........... 8-103
Brake fluid replacement .................... 8-107
Front brake lever free play................ 8-109
8
U5KM63.book Page 2 Monday, March 15, 2004 11:44 AM

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. Brake pedal
8. V-belt case drain plug
9. Radiator cap
10. Drive select lever
11. Fuel tank cap
12. Fuel cock
13. Battery
14. Fuses15. 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 switch
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.
U5KM63.book Page 1 Monday, March 15, 2004 11:44 AM

8-7
EBU02621
PERIODIC MAINTENANCE/LUBRICATION
NOTE:_

For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.


For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance in-
tervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month mainte-
nance intervals should be followed.
_
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
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).U5KM63.book Page 7 Monday, March 15, 2004 11:44 AM

8-8
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 8-9.
Correct if necessary.Rear brake*Check operation/fluid leakage/see NOTE page 8-9.
Correct if necessary.Select lever safety system
cable*Check operation.
Adjust if necessary.V-belt*Check operation.
Check for cracks or damage.Wheels*Check balance/damage/runout.
Repair if necessary.Wheel bearing*Check bearing assemblies for looseness/damage.
Replace if damaged.Front and rear
suspension*Check operation.
Correct if necessary.Steering system*Check operation/Replace if damaged.
Check toe-in/Adjust if necessary.Rear upper and lower
knuckle pivots*Lubricate with lithium-soap-based grease.Drive shaft universal
joint*Lubricate with lithium-soap-based grease.Engine mount*
Check for cracks or damage.Front and rear axle boots*Check operation.
Replace if damaged.Stabilizer bushes*
Check for cracks or damage.Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
U5KM63.book Page 8 Monday, March 15, 2004 11:44 AM

8-39 1. Engine oil filler cap
2. Dipstick
1. Bouchon de remplissage d’huile de moteur
2. Jauge
1. Tapa de relleno de aceite de motor
2. Varilla
EBU10992
Engine oil and oil filter cartridge
The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter cartridge replaced at the intervals
specified in the periodic maintenance and lubrica-
tion chart.
To check the engine oil level
1. Remove panel F. (See page 8-33 for panel
removal and installation procedures.)
2. Place the ATV on a level surface.
3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Wait a few minutes until the oil settles.
5. Remove the engine oil filler cap and wipe off
the dipstick with a clean rag.
U5KM63.book Page 39 Monday, March 15, 2004 11:44 AM

8-45 1. Engine oil filter cartridge
2. Oil filter wrench
1. Cartouche du filtre à huile de moteur
2. Clé pour filtre à huile
1. Cartucho del filtro de aceite de motor
2. Llave para filtros de aceite
NOTE:_ Skip steps 5–9 if the oil filter cartridge is not being
replaced. _5. Remove panels D and E. (See pages 8-19–
8-21 and 8-31 for panel removal and installa-
tion procedures.)
6. Remove the oil filter cartridge with an oil filter
wrench.
U5KM63.book Page 45 Monday, March 15, 2004 11:44 AM

8-47 1. O-ring
1. Joint torique
1. Junta tórica
1. Torque wrench
1. Clé dynamométrique
1. Llave de apriete
NOTE:_ An oil filter wrench is available at a nearby
Yamaha dealer. _7. Apply a light coat of engine oil to the O-ring of
the new oil filter cartridge.NOTE:_ Make sure the O-ring is seated properly. _8. Install the new oil filter cartridge with an oil fil-
ter wrench, and then tighten it to the specified
torque with a torque wrench.
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
U5KM63.book Page 47 Monday, March 15, 2004 11:44 AM

8-49
9. Install panels D and E.
10. Install the engine oil drain bolt, and then tight-
en it to the specified torque.
11. Add the specified amount of recommended
engine oil, and then install the engine oil filler
cap and tighten it. Tightening torque:
Engine oil drain bolt:
30 Nm (3.0 m·kgf)
Recommended engine oil:
See page 10-2.
Oil quantity:
Without oil filter cartridge replacement:
1.9 L
With oil filter cartridge replacement:
2.0 L
U5KM63.book Page 49 Monday, March 15, 2004 11:44 AM