2006 YAMAHA GRIZZLY 660 Front drive

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

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

4-27 1. On-Command four-wheel drive switch “2WD”/“4WD”
2. Differential gear lock switch “LOCK”/“4WD”
1. Contacteur de commande du mode de traction “2WD”/“4WD”
2. Contacteur de blocage du différentiel “LOCK”/“4WD”
1. Selector de tracción en las cuatro ruedas “2WD”/“4WD”
2. Selector de bloqueo del diferencial “LOCK”/“4WD”
EBU13803
On-Command four-wheel drive and differential
gear lock switches
This ATV is equipped with an On-Command four-
wheel drive switch “2WD”/“4WD” and a differential
gear lock switch “LOCK”/“4WD”. Select the appro-
priate drive according to terrain and the conditions.

Two-wheel drive (2WD): Power is supplied to
the rear wheels only.


Four-wheel drive (4WD): Power is supplied to
the rear and front wheels.


Four-wheel drive with the differential gear
locked (4WD-LOCK): Power is supplied to the
rear and front wheels when the differential gear
is locked (“DIFF.LOCK”). Unlike the 4WD
mode, all wheels turn at the same speed.
U2C660.book Page 27 Monday, April 11, 2005 10:29 AM

6-21
EBU06761
Parking on a slope
WARNING
_ Avoid parking on hills or other inclines. Park-
ing on a hill or other incline could cause the
ATV to roll out of control, increasing the
chance of an accident. If you must park on an
incline, place the machine transversely across
the incline, apply the parking brake, and block
the front and rear wheels with rocks or other
objects.
Do not park the ATV at all on hills that are so
steep you could not walk up them easily. _1. Bring the machine to a stop by applying the
brakes.
2. Stop the engine.
3. With the brake pedal applied, shift the drive
select lever to the park position “P”.
U2C660.book Page 21 Monday, April 11, 2005 10:29 AM

7-37
With the engine idling, shift the drive select lever to
the low position “L” or the high position “H”. Apply
the throttle slowly and smoothly. The centrifugal
clutch will engage and you will start to accelerate.
If the throttle is applied too abruptly, the front
wheels may lift off the ground resulting in a loss of
directional control. Avoid higher speeds until you
are thoroughly familiar with the operation of your
ATV.
When slowing down or stopping, release the throt-
tle and apply the brakes smoothly and evenly. Im-
proper use of the brakes can cause the tires to
lose traction, reducing control and increasing the
possibility of an accident.CAUTION:_ Do not shift from drive position low “L” to high
“H” or vice versa without coming to a com-
plete stop. Damage to the engine or drive train
may occur. _
U2C660.book Page 37 Monday, April 11, 2005 10:29 AM

7-51
If your ATV has stalled or stopped and you believe
you can continue up the hill, restart carefully to
make sure you do not lift the front wheels which
could cause you to lose control. If you are unable
to continue up the hill, dismount the ATV on the
uphill side. Physically turn the ATV around and
then descend the hill.
If you start to roll backwards, DO NOT apply either
brake abruptly. If you are in 2WD, apply only the
front brake. When this ATV is in 4WD or 4WD-
LOCK, all wheels (front and rear) are interconnect-
ed by the drive train. This means that applying ei-
ther the front brake or the rear brake will brake all
wheels. When descending hills, using either brake
lever or the brake pedal will brake the wheels on
the downhill side. Avoid sudden application of ei-
ther the front or rear brake because the wheels on
the uphill side could come off the ground. The ATV
could easily tip over backwards. Apply both the
front and rear brakes gradually, or dismount the
ATV immediately on the uphill side.
U2C660.book Page 51 Monday, April 11, 2005 10:29 AM

7-55
RIDING DOWNHILL
When riding your ATV downhill, shift your weight
as far to the rear and uphill side of the ATV as pos-
sible. Move back on the seat and sit with your
arms straight. Engine compression will do most of
the braking for you. For maximum engine com-
pression braking effect, select low range “L” and
change to 4WD or 4WD-LOCK before beginning
to descend the hill. Improper braking may cause a
loss of traction. Use caution while descending a hill
with loose or slippery surfaces. Braking ability and
traction may be adversely affected by these sur-
faces. Improper braking may also cause a loss of
traction.
When this ATV is in 4WD or 4WD-LOCK, all
wheels (front and rear) are interconnected by the
drive train. This means that applying either the
front brake or the rear brake will brake all wheels.
When descending hills, using either brake lever or
the brake pedal will brake the wheels on the down-
hill side. Avoid sudden application of either the
front or rear brake because the wheels on the up-
hill side could come off the ground. Apply both the
front and rear brakes gradually.
U2C660.book Page 55 Monday, April 11, 2005 10:29 AM