2006 YAMAHA GRIZZLY 660 brake

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 ............................... 4-11
Handlebar switches ............................ 4-19
Throttle lever ...................................... 4-37
Speed limiter ...................................... 4-39
Front brake lever ................................ 4-41
Brake pedal and rear brake lever ....... 4-43
Drive select lever ................................ 4-45
Recoil starter ...................................... 4-45
Fuel tank cap ...................................... 4-47
1234
Fuel cock............................................ 4-49
Starter (choke) ................................... 4-51
Seat.................................................... 4-53
Storage compartment ........................ 4-55
Front carrier ....................................... 4-55
Rear carrier ........................................ 4-55
Front and rear shock absorber
adjustment ....................................... 4-57
Auxiliary DC jack ................................ 4-61
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
Tire wear limit..................................... 5-31
5
U2C660.book Page 1 Monday, April 11, 2005 10:29 AM

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
U2C660.book Page 2 Monday, April 11, 2005 10:29 AM

Adjusting the rear brake lever and
brake pedal .................................... 8-111
Adjusting the rear brake light
switch ............................................. 8-115
Cable inspection and lubrication ...... 8-117
Lubricating the brake levers and
brake pedal .................................... 8-119
Rear knuckle upper and lower pivot
lubrication ....................................... 8-121
Wheel removal ................................. 8-123
Wheel installation ............................. 8-125
Battery .............................................. 8-127
Battery maintenance ........................ 8-131
Fuse replacement............................. 8-133
Replacing a headlight bulb ............... 8-137
Headlight beam adjustment.............. 8-141
Tail/brake light bulb replacement ..... 8-141
Troubleshooting................................ 8-145
Troubleshooting chart....................... 8-147
CLEANING AND STORAGE ................... 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................. 10-1
910
CONVERSION TABLE .......................... 11-1
11
U2C660.book Page 3 Monday, April 11, 2005 10:29 AM

2-11

Always check for obstacles before operating in
a new area. Never attempt to operate over
large obstacles, such as large rocks or fallen
trees. Always follow proper procedures when
operating over obstacles as described in this
manual.


Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth
terrain. On extremely slippery surfaces, such
as ice, go slowly and be very cautious in order
to reduce the chance of skidding or sliding out
of control.


Never operate an ATV in fast flowing water or
in water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.
U2C660.book Page 11 Monday, April 11, 2005 10:29 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.
U2C660.book Page 1 Monday, April 11, 2005 10:29 AM

4-41 1. Front brake lever
1. Levier de frein avant
1. Palanca del freno delantero
EBU00070
Front brake lever
The front brake lever is located on the right handle-
bar. Pull it toward the handlebar to apply the front
brake.
U2C660.book Page 41 Monday, April 11, 2005 10:29 AM

4-43 1. Brake pedal
1. Pédale de frein
1. Pedal del freno
1. Rear brake lever
1. Levier de frein arrière
1. Palanca del freno trasero
EBU00732
Brake pedal and rear brake lever
The brake pedal is located on the right side of the
ATV and the rear brake lever is located on the left
handlebar. Push down on the pedal or pull the le-
ver toward the handlebar to apply the rear brake.
U2C660.book Page 43 Monday, April 11, 2005 10:29 AM

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,
8-101–8-115
FuelCheck fuel level.
Fill with fuel if necessary.5-11–5-13
Engine oilCheck oil level.
Fill with oil if necessary.5-15,
8-39–8-51
Coolant reservoirCheck coolant level in reservoir.
Fill with coolant if necessary.5-19–5-21,
8-63–8-73
Final gear oil/
Differential gear oilCheck for leakage.5-17–5-19,
8-53–8-61
ThrottleCheck for proper throttle cable operation and free play. 5-21, 8-99
Wheels and tiresCheck tire pressure, wear and damage.5-25–5-31,
8-123–8-125
Fittings and fastenersCheck all fittings and fasteners. 5-21
Lights and switchesCheck for proper operation. 5-23, 8-137–8-143
Axle bootsCheck for damage. 8-75
U2C660.book Page 1 Monday, April 11, 2005 10:29 AM