2008 YAMAHA GRIZZLY 660 check oil

EBU17420
TABLE OF CONTENTS
SAFETY INFORMATION .............................. 1-1
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 2-1
DESCRIPTION .............................................. 3-1
Left view ...................................................... 3-1
Right view.................................................... 3-1
Controls and instruments ............................ 3-2
INSTRUMENT AND
CONTROL FUNCTIONS ................................ 4-1
Main switch ................................................ 4-1
Indicator lights and warning light ................ 4-2
Multifunction display ................................... 4-4
Handlebar switches .................................... 4-6
Throttle lever ............................................ 4-11
Speed limiter ............................................ 4-12
Front brake lever ...................................... 4-12
Brake pedal and rear brake lever ............. 4-13
Drive select lever ...................................... 4-14
Recoil starter ............................................ 4-14
Fuel tank cap ............................................ 4-14
Fuel .......................................................... 4-15Fuel cock ..................................................4-16
Starter (choke) ..........................................4-17
Seat ..........................................................4-18
Storage compartment ...............................4-19
Front carrier ..............................................4-20
Rear carrier ...............................................4-20
Adjusting the front and
rear shock absorber assemblies .............4-20
Auxiliary DC jack .......................................4-21
PRE-OPERATION CHECKS ..........................5-1
Pre-operation check list ..............................5-1
Fuel .............................................................5-3
Engine oil ....................................................5-3
Final gear oil ...............................................5-3
Differential gear oil ......................................5-3
Coolant .......................................................5-3
Front and rear brakes .................................5-4
Throttle lever ...............................................5-5
Tires ............................................................5-5
Measuring the tire pressure ........................5-6
Tire wear limit .............................................5-7
Chassis fasteners .......................................5-7
Instruments, lights and switches .................5-7U23D60E0.book Page 1 Thursday, March 15, 2007 7:59 PM

OPERATION .................................................. 6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-3
Operating the drive select lever and
driving in reverse ...................................... 6-3
Engine break-in .......................................... 6-5
Parking ....................................................... 6-6
Parking on a slope ..................................... 6-6
Accessories and loading ............................ 6-6
RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV............... 7-2
RIDE WITH CARE AND
GOOD JUDGEMENT ................................ 7-2
BE CAREFUL WHERE YOU RIDE ............. 7-9
TURNING YOUR ATV .............................. 7-13
CLIMBING UPHILL ................................... 7-14
RIDING DOWNHILL.................................. 7-17
CROSSING A SLOPE............................... 7-18
CROSSING THROUGH
SHALLOW WATER................................. 7-19
RIDING OVER ROUGH TERRAIN ........... 7-22
SLIDING AND SKIDDING ......................... 7-22
WHAT TO DO IF... .................................... 7-23
WHAT TO DO... ........................................ 7-23PERIODIC MAINTENANCE AND
MINOR REPAIR .............................................8-1
Owner’s manual and tool kit .......................8-1
Periodic maintenance chart for
the emission control system .....................8-3
General maintenance and
lubrication chart ........................................8-5
Removing and installing panels ..................8-9
Checking the spark plug ...........................8-16
Engine oil and oil filter cartridge ................8-18
Final gear oil .............................................8-22
Differential gear oil ....................................8-24
Coolant .....................................................8-26
Cleaning the air filter element ...................8-30
Cleaning the spark arrester ......................8-34
V-belt cooling duct check hose .................8-35
V-belt case drain plug ...............................8-35
Adjusting the carburetor ............................8-36
Adjusting the engine idling speed .............8-36
Adjusting the throttle cable free play .........8-37
Valve clearance ........................................8-38
Adjusting the drive select lever
safety system cable ................................8-38
Checking the front and rear brake pads ...8-38
Checking the brake fluid level ...................8-39
Changing the brake fluid ...........................8-41
Checking the front brake lever free play ...8-41U23D60E0.book Page 2 Thursday, March 15, 2007 7:59 PM

3-1
3
EBU17680
DESCRIPTION
EBU17690Left view
EBU17700Right view
1. Radiator cap
2. Fuel tank cap
3. Fuel cock
4. Oil filter cartridge
5. Throttle stop screw
6. Fuses
7. Engine oil filler cap
8. Recoil starter
9. Coolant reservoir
10.Drive select lever box check hose
11.V-belt cooling duct check hose
1. Rear shock absorber assembly spring preload adjusting
ring
2. Spark arrester
3. Storage compartment and tool kit
4. Battery
5. Air filter case
6. Spark plug
7. Front brake fluid reservoir
8. Front shock absorber assembly spring preload adjusting
ring
9. Rear brake fluid reservoir
10.Brake pedal
11.V-belt case drain plug
U23D60E0.book Page 1 Thursday, March 15, 2007 7:59 PM

5-1
5
EBU19200
PRE-OPERATION CHECKS
EBU19221Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table.NOTE:The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodicmaintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
ITEM ROUTINE PAGE
FuelCheck fuel level in fuel tank, and add recommended fuel if neces-
sary.
Check fuel line for leakage. Correct if necessary.4-15, 5-3
Engine oilCheck oil level in engine, and add recommended oil to specified lev-
el if necessary.
Check ATV for oil leakage. Correct if necessary.5-3, 8-18
Final gear oilCheck ATV for oil leakage. Correct if necessary. 5-3, 8-22
Differential gear oilCheck ATV for oil leakage. Correct if necessary. 5-3, 8-24
CoolantCheck coolant level in reservoir, and add recommended coolant to
specified level if necessary.
Check cooling system for leakage. Correct if necessary.5-3, 8-26
Front brakeCheck operation. If soft or spongy, have Yamaha dealer bleed hy-
draulic system.
Check brake pads for wear, and replace if necessary.
Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.
Check hydraulic system for leakage. Correct if necessary.5-4, 8-38, 8-39, 8-41
U23D60E0.book Page 1 Thursday, March 15, 2007 7:59 PM

5-3
5
EBU19540Fuel Make sure that there is sufficient fuel in the tank.
(See page 4-15.)
WARNING
EWB00520
Do not overfill the fuel tank. Fuel expands
when it heats up. If the fuel tank is overfilled,
fuel could spill out due to heat from the en-
gine or the sun.
Be careful not to spill fuel, especially on the
engine or exhaust pipe which can cause a
fire and severe injury. Wipe up any spilled
fuel immediately.
Do not refuel right after the engine has been
running and is still very hot.
Be sure the fuel tank cap is closed securely.EBU19560Engine oil Make sure that the engine oil is at the specified lev-
el. Add oil as necessary. (See page 8-18.)EBU19590Final gear oil Make sure that the final gear oil is at the specified
level. Add oil as necessary. (See page 8-22.)
EBU19600Differential gear oil Make sure that the differential gear oil is at the
specified level. Add oil as necessary. (See page
8-24.)EBU19630Coolant Make sure that the coolant is at the specified level.
Add coolant as necessary. (See page 8-26.)NOTE:The coolant level must be checked on a cold en-
gine since the level varies with engine tempera-ture.
WARNING
EWB00510Wait for the engine and radiator to cool before
removing the radiator cap. You could be
burned by hot fluid and steam blown out under
pressure. Always put a thick rag over the cap
when opening. Allow any remaining pressureto escape before completely removing the cap.
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8-6
8
8*V- b e l tCheck for wear, cracks or other damage, and re-
place if necessary.√ √√√
9*Chassis fastenersMake sure that all nuts, bolts, and screws are
properly tightened.√√√√√
10*Shock absorber as-
sembliesCheck operation and correct if necessary.
Check for oil leakage and replace if necessary.√√√
11*Stabilizer bushesCheck for cracks or other damage, and replace if
necessary.√√√
12*Rear knuckle pivotsLubricate with lithium-soap-based grease.√√√
13*Steering shaftLubricate with lithium-soap-based grease.√√√
14*Steering systemCheck operation and repair or replace if damaged.
Check toe-in and adjust if necessary.√√√√√
15*Engine mountCheck for cracks or other damage, and replace if
necessary.√√√
16*Axle bootsCheck for cracks or other damage, and replace if
necessary.√√√√√
17 Engine oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√ √√√
18Engine oil filter car-
tridgeReplace.√√√
19 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)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320U23D60E0.book Page 6 Thursday, March 15, 2007 7:59 PM

8-7
8
EBU23070NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.20 Final gear oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√√
21 Cooling systemCheck coolant level and ATV for coolant leakage,
and correct if necessary.√√√√√
Replace coolant. Every 2 years
22*Moving parts and
cablesLubricate.√√√√
23*Drive select lever
safety system cableCheck operation and adjust or replace if neces-
sary.√√√
24*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.√√√√√
25*Front and rear brake
switchesCheck operation and correct if necessary.√√√√√
26*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)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320U23D60E0.book Page 7 Thursday, March 15, 2007 7:59 PM

8-18
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.EBU23325Engine 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 8-9.)
2. Place the ATV on a level surface.
3. Check the engine oil level on a cold engine.
NOTE:If the engine was started before checking the oil
level, be sure to warm up the engine sufficiently,
and then wait at least ten minutes until the oil set-tles for an accurate reading.
4. Remove the engine oil filler cap, and then
wipe the dipstick off with a clean rag.
5. 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
U23D60E0.book Page 18 Thursday, March 15, 2007 7:59 PM