2007 YAMAHA GRIZZLY 660 maintenance

8-4
8
6*Rear brakeCheck operation and correct if necessary.
Check brake lever free play and adjust if neces-
sary.
Check fluid level and ATV for fluid leakage, and
correct if necessary.√√√√√
Replace brake pads. Whenever worn to the limit
7*Brake hosesCheck for cracks or other damage, and replace if
necessary.√√√√
Replace. Every 4 years
8*WheelsCheck runout and for damage, and replace if nec-
essary.√ √√√
9*TiresCheck tread depth and for damage, and replace if
necessary.
Check air pressure and balance, and correct if
necessary.√ √√√
10*Wheel bearingsCheck for looseness or damage, and replace if
necessary.√ √√√
11*Upper and lower
arm pivotsLubricate with lithium-soap-based grease.√√√
12*V- b e l tCheck for wear, cracks or other damage, and re-
place if necessary.√ √√√
13*Drive shaft univer-
sal jointLubricate with lithium-soap-based grease.√√√
14*Chassis fastenersMake sure that all nuts, bolts, and screws are
properly tightened.√√√√√ NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300U2C661E0.book Page 4 Thursday, March 16, 2006 10:45 AM

8-5
8
15*Shock absorber as-
sembliesCheck operation and correct if necessary.
Check for oil leakage and replace if necessary.√√√
16*Stabilizer bushesCheck for cracks or other damage, and replace if
necessary.√√√
17*Knuckle pivotsLubricate with lithium-soap-based grease.√√√
18*Steering systemCheck operation and repair or replace if damaged.
Check toe-in and adjust if necessary.√√√√√
19*Engine mountCheck for cracks or other damage, and replace if
necessary.√√√
20*Axle bootsCheck for cracks or other damage, and replace if
necessary.√√√√√
21*CarburetorCheck starter (choke) operation and correct if nec-
essary.
Check engine idling speed and adjust if neces-
sary.√√√√
22*Crankcase breather
systemCheck breather hose for cracks or other damage,
and replace if necessary.√√√
23 Engine oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√ √√√
24Engine oil filter car-
tridgeReplace.√√√
25 Differential gear oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√√ NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300U2C661E0.book Page 5 Thursday, March 16, 2006 10:45 AM

8-6
8
26 Final gear oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√√
27 Cooling systemCheck coolant level and ATV for coolant leakage,
and correct if necessary.√√√√√
Replace coolant. Every 2 years
28*Moving parts and
cablesLubricate.√√√√
29*Drive select lever
safety system cableCheck operation and adjust or replace if neces-
sary.√√√
30*Throttle lever hous-
ing and cableCheck operation and correct if necessary.
Check throttle cable free play and adjust if neces-
sary.
Lubricate throttle lever housing and cable.√√√√√
31*Exhaust systemCheck for leakage and replace gasket(s) if neces-
sary.
Check for looseness and tighten all screw clamps
and joints if necessary.√√√
32 Spark arresterClean.√√√
33*Front and rear brake
switchesCheck operation and correct if necessary.√√√√√
34*Lights and switchesCheck operation and correct if necessary.
Adjust headlight beams.√√√√√ NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300U2C661E0.book Page 6 Thursday, March 16, 2006 10:45 AM

8-8
8
EBU23090Removing and installing panels The panels shown need to be removed to perform
some of the maintenance jobs described in this
chapter. Refer to this section each time a panel
needs to be removed and installed.
EBU27051Panels A and D
To remove one of the panels1. Remove the seat. (See page 4-18.)
2. Pull outward on the area shown, and then pull
upward as shown.
1. Panel A
2. Panel B
3. Panel C
1. Panel D
2. Panel E
3. Panel F
4. Panel G
U2C661E0.book Page 8 Thursday, March 16, 2006 10:45 AM

8-15
8
EBU23221Checking the spark plug The spark plug is an important engine component,
which is easy to check. Since heat and deposits
will cause any spark plug to slowly erode, the spark
plug should be removed and checked in accor-
dance with the periodic maintenance and lubrica-
tion chart. In addition, the condition of the spark
plug can reveal the condition of the engine.
To remove the spark plug
1. Remove panel A. (See page 8-8.)
2. Remove the spark plug cap.3. Remove the spark plug as shown, with the
spark plug wrench included in the owner’s tool
kit.
To check the spark plug
1. Check that the porcelain insulator around the
center electrode of the spark plug is a medi-
um-to-light tan (the ideal color when the ATV
is ridden normally).
NOTE:If the spark plug shows a distinctly different color,
the engine could be operating improperly. Do not
attempt to diagnose such problems yourself. In-stead, have a Yamaha dealer check the ATV.
1. Spark plug cap
1. Spark plug wrench
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8-17
8
NOTE:If a torque wrench is not available when installing
a spark plug, a good estimate of the correct torque
is 1/4–1/2 turn past finger tight. However, the spark
plug should be tightened to the specified torque assoon as possible.
4. Install the spark plug cap.
5. Install the panel.EBU23321Engine 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 spec-
ified in the periodic maintenance and lubrication
chart.
To check the engine oil level
1. Remove panel F. (See page 8-8.)
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 before
checking.
5. Remove the engine oil filler cap, and then
wipe the dipstick off with a clean rag.6. Insert the dipstick into the filler hole (without
screwing it in), and then remove it again to
check the oil level.
1. Engine oil filler cap
2. Dipstick
U2C661E0.book Page 17 Thursday, March 16, 2006 10:45 AM

8-22
85. Add the specified amount of the recommend-
ed final gear oil.
CAUTION:ECB00420Be sure no foreign material enters the finalgear case.
6. Install the oil filler bolt, and then tighten it to the
specified torque.
7. Check the final gear case for oil leakage. If oil
is leaking, check for the cause.
EBU23421Differential gear oil The differential gear case must be checked for oil
leakage before each ride. If any leakage is found,
have a Yamaha dealer check and repair the ATV.
In addition, the differential gear oil level must be
checked and the oil changed as follows at the in-
tervals specified in the periodic maintenance and
lubrication chart.
To check the differential gear oil level
1. Place the ATV on a level surface.NOTE:The differential gear oil level must be checked ona cold engine.
2. Remove the differential gear oil filler bolt, and
then check the oil level in the differential gear
case. Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
Recommended final gear oil:
See page 10-1.
Oil quantity:
0.25 L (0.26 US qt) (0.22 Imp.qt)
Tightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
U2C661E0.book Page 22 Thursday, March 16, 2006 10:45 AM

8-24
85. Add the recommended differential gear oil to
the brim of the filler hole as shown.
CAUTION:ECB00410Be sure no foreign material enters the differen-tial gear case.
6. Install the oil filler bolt, and then tighten it to the
specified torque.7. Check the differential gear case for oil leak-
age. If oil is leaking, check for the cause.
EBU23470Coolant The coolant level should be checked before each
ride. In addition, the coolant must be changed at
the intervals specified in the periodic maintenance
and lubrication chart.EBU27120To check the coolant level
1. Place the ATV on a level surface.NOTE:The coolant level must be checked on a cold en-
gine since the level varies with engine tempera-ture.
2. Check the coolant level in the coolant reser-
voir.
1. Differential gear oil
2. Differential gear oil filler bolt
3. Correct oil levelRecommended differential gear oil:
See page 10-1.
Tightening torque:
Differential gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
U2C661E0.book Page 24 Thursday, March 16, 2006 10:45 AM