2005 YAMAHA GRIZZLY 660 cooling

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

6-19
0–10 hours:
Avoid continuous operation above half throttle. Al-
low a cooling off period of five to ten minutes after
every hour of operation. Vary the speed of the ma-
chine from time to time. Do not operate it at one
set throttle position.
10–20 hours:
Avoid prolonged operation above 3/4 throttle. Rev
the machine freely but do not use full throttle at any
time.
After break-in:
Avoid prolonged full throttle operation. Vary
speeds occasionally.
EBU00612
Parking
When parking, stop the engine and shift the drive
select lever into the park position, then turn the fuel
cock to the “OFF” position.
U5KM63.book Page 19 Monday, March 15, 2004 11:44 AM

7-65
1. Air filter case check hose
1. Flexible de contrôle du boîtier de filtre à air
1. Manguera de comprobación de la caja del filtro de aire
Test your brakes after leaving the water. Do not
continue to ride your ATV without verifying that
you have regained proper braking ability.CAUTION:_ After riding your ATV in water, be sure to drain
the trapped water by removing the check hose
at the bottom of the air filter case, the V-belt
cooling duct check hose and the drive select
lever box check hose. Also, remove the V-belt
case drain plug to drain any water that may
have accumulated. Wash the ATV in fresh wa-
ter if it has been operated in salt water or mud-
dy conditions. _
U5KM63.book Page 65 Monday, March 15, 2004 11:44 AM

7-67 1. V-belt cooling duct check hose (left side)
1. Flexible de contrôle du conduit de refroidissement de la courroie
trapézoïdale (côté gauche)
1. Manguera de comprobación del conducto de enfriamiento de
la correa trapezoidal (Lado izquierdo)
1. Drive select lever box check hose
1. Flexible de contrôle du boîtier du levier de présélection
1. Manguera de comprobación de la caja de la palanca de selec-
ción de marcha
1. V-belt case drain plug
1. Boulon de vidange du carter de courroie trapézoïdale
1. Tapón de drenaje de la caja de la correa trapezoidal
U5KM63.book Page 67 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

8-63 1. Coolant reservoir 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. _
U5KM63.book Page 63 Monday, March 15, 2004 11:44 AM

8-69 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 panel D. (See pages 8-19–8-21 for
panel removal and installation procedures.)
7. Remove the coolant reservoir cap.
8. Disconnect the hose on the coolant reservoir
side, and then drain the coolant from the
coolant reservoir.
9. After draining the coolant, thoroughly flush
the cooling system with clean tap water.
10. Replace the coolant drain bolt washer if it is
damaged, install the coolant drain bolt, and
then tighten it to the specified torque.
Tightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf)
U5KM63.book Page 69 Monday, March 15, 2004 11:44 AM