2008 YAMAHA GRIZZLY 660 engine 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

4-14
4
EBU18611Drive select lever The drive select lever is used to shift your ATV into
the low-range, high-range, neutral, reverse and
park positions. See the “Operating the drive select
lever and driving in reverse” section on page 6-3
for the drive select lever operation.EBU18690Recoil starter Firmly grasp the handle and pull slightly until en-
gagement can be felt. Then pull forcefully, being
careful not to pull the rope all the way out.
WARNING
EWB00330Always shift the drive select lever to park posi-
tion before starting the engine, otherwise the
ATV could start to move unexpectedly, whichcould cause an accident.EBU18720Fuel tank cap Remove the fuel tank cap by turning it counter-
clockwise.
1. Drive select lever
1. Recoil starter
U23D60E0.book Page 14 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.
U23D60E0.book Page 3 Thursday, March 15, 2007 7:59 PM

6-2
64. Use the starter (choke) in reference to the fig-
ure:
Position (1):
Cold engine start with ambient temperature
below 5 °C (40 °F).
Position (2):
Cold engine start with ambient temperature
between 0 °C (30 °F) and 30 °C (90 °F).
Position (3):
Cold engine start with ambient temperature
above 25 °C (80 °F).
Ambient temp./starter (choke) position5. Apply the rear brake lever.
6. Completely close the throttle lever and start
the engine by pushing the start switch.
NOTE:
If the engine fails to start, release the start
switch, then push it again. Pause a few seconds
before the next attempt. Each cranking should
be as short as possible to preserve battery ener-
gy. Do not crank the engine more than 10 sec-
onds on each attempt.
If the battery is discharged, pull the recoil starterto start the engine.
7. If the engine is started with the starter (choke)
in position (1), the starter (choke) should be
returned to position (2) to warm up the engine.
If the engine is started with the starter (choke)
in position (2), keep the starter (choke) in this
position to warm up the engine.CAUTION:ECB00160For maximum engine life, always warm the en-
gine up before starting off. Never acceleratehard when the engine is cold!
1. Fully open
2. Half open
3. Closed
4. Starter (choke)U23D60E0.book Page 2 Thursday, March 15, 2007 7:59 PM

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