check engine YAMAHA GRIZZLY 660 2003 User Guide

8-8
* It is recommended that these items be serviced by a Yamaha dealer.
** Lithium-soap-based greaseNOTE:Recommended brake fluid: DOT 4
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check
the brake fluid level and add fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.Wheels*•Check balance/damage/runout.
•Repair if necessary.Wheel bearing*•Check bearing assemblies for looseness/damage.
•Replace if damaged.Front and rear
suspension*•Check operation.
•Correct if necessary.Steering system*•Check operation/Replace if damaged.
•Check toe-in/Adjust if necessary.Rear upper and lower
knuckle pivots*•Lubricate.**Drive shaft universal
joint*•Lubricate.**Engine mount*
•Check for cracks or damage.Front and rear axle boots*•Check operation.
•Replace if damaged.Stabilizer bushes*
•Check for cracks or damage.Fittings and Fasteners*•Check all chassis fittings and fasteners.
•Correct if necessary.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
km 320 1,200 2,400 2,400 4,800
hours 20 75 150 150 300
U5KM60.book Page 8 Thursday, June 21, 2001 2:40 PM

8-33 1. Engine oil dipstick
1. Jauge d’huile
1. Varilla de medición del aceite de motor
1. Maximum level mark 2. Minimum level mark
1. Repère de niveau maximum 2. Repère de niveau minimum
1. Marca de nivel máximo 2. Marca de nivel mínimo
EBU00847
Engine oil
Oil level inspection
1. Remove panel F. (See page 8-31 for panel
removal and installation procedures.)
2. Place the ATV on a level place and warm up
the engine for several minutes.
3. Stop the engine.
4. Remove the dipstick and wipe it off with a
clean rag. Insert the dipstick in the filler hole
without screwing it in.NOTE:_ Wait a few minutes until the oil level settles before
checking. _5. The oil level should be between the maxi-
mum and minimum marks. If the level is low,
fill the engine with sufficient oil to reach the
specified level.
U5KM60.book Page 33 Thursday, June 21, 2001 2:40 PM

8-43
‘1. Final gear oil drain bolt
1. Boulon de vidange de l’huile de couple conique arrière
1. Perno de drenaje de aceite de la transmisión final
10. Start the engine and warm it up for several
minutes. While warming up, check for oil
leakage. If oil leakage is found, stop the en-
gine immediately and check for the cause.
11. Install the panels.
EBU00880
Final gear oil
The final gear case must be checked for oil leak-
age before each ride. If any leakage is found, have
a Yamaha dealer check and repair the ATV.
Final gear oil replacement
1. Place the machine on a level place.
2. Place a container under the final gear case to
collect the used oil.
3. Remove the oil filler bolt and the drain bolt to
drain the oil.
U5KM60.book Page 43 Thursday, June 21, 2001 2:40 PM

8-55 1. Coolant reservoir tank cap
2. Maximum level mark
3. Minimum level mark
1. Bouchon du vase d’expansion
2. Repère de niveau maximum
3. Repère de niveau minimum
1. Tapa del depósito de refrigerante
2. Marca de nivel máximo
3. Marca de nivel mínimo
EBU00771
Cooling system
1. Check the coolant level in the coolant reser-
voir when the engine is cold as the coolant
level will vary with engine temperature. The
coolant level should be between the maxi-
mum and minimum marks.
2. If the level is low, remove panel D. (See pag-
es 8-17 ~ 8-19 for panel removal and installa-
tion procedures.)
U5KM60.book Page 55 Thursday, June 21, 2001 2:40 PM

8-65
12. Install the radiator cap.
13. Start the engine and let it idle for several min-
utes. Stop the engine, and then check the
coolant level in the radiator. If it is low, add
more coolant until it reaches the top of the ra-
diator.
14. Fill the coolant reservoir with coolant up to
the maximum level.
15. Install the coolant reservoir cap and check for
coolant leakage.NOTE:_ If any leakage is found, ask a Yamaha dealer to in-
spect the cooling system. _16. Install the panels and the front carrier.
U5KM60.book Page 65 Thursday, June 21, 2001 2:40 PM

8-79 1. Breather hose
1. Reniflard
1. Manguera del respiradero
8. Pull the element over its frame.
9. Install the element assembly.
10. Install the air filter case cover and be sure to
connect the hose.NOTE:_ The air filter element should be cleaned every 20 ~
40 hours. It should be cleaned and lubricated more
often if the machine is operated in extremely dusty
areas. Each time the filter element maintenance is
performed, check the air inlet to the filter case for
obstructions. Check the air cleaner rubber joint to
the carburetor and manifold fittings for an airtight
seal. Tighten all fittings securely to avoid the pos-
sibility of unfiltered air entering the engine. _CAUTION:_ Never operate the engine with the air filter ele-
ment removed. This will allow unfiltered air to
enter, causing rapid engine wear and possible
engine damage. Additionally, operation with-
out the filter element will affect carburetor jet-
ting with subsequent poor performance and
possible engine overheating. _
U5KM60.book Page 79 Thursday, June 21, 2001 2:40 PM

8-81 1. V-belt cooling duct check hose (Left side)
1. Flexible de contrôle du conduit de refroidissement de la courroie
trapézoïdale (côté gauche)
1. Manguera de comprobación del conducto de enfriamiento de
la correa trapezoidal (Lado izquierdo)
1. V-belt case drain plug
1. Boulon de vidange du carter de la courroie
1. Tapón de drenaje de la caja de la correa trapezoidal
EBU00874*
V-belt cooling duct check hose
If dust or water collects in the V-belt cooling duct
check hose, remove the hose and clean it.
V-belt case drain plug
After riding in water deep enough to allow it to en-
ter the V-belt case, remove this plug to drain the
water from the case.NOTE:_ If a lot of water drains from the V-belt case after re-
moving the plug, have a Yamaha dealer inspect
the ATV as the water may affect other engine
parts. _
U5KM60.book Page 81 Thursday, June 21, 2001 2:40 PM

8-137
EBU00724Troubleshooting chart
Starting problems or poor engine performance1. Fuel
Check if there is fuel
in the fuel tank.There is fuel.Turn the fuel cock
lever to “OFF”.No fuel.Fuel cock is
clogged.
Clean the
fuel cock. Some fuel.Turn the fuel cock
lever to “RES”.Restart the engine.
No fuel.Supply fuel.
2. Compression
Use the electric
starter to see if
there is compression.There is compression.
Compression normal.
No compression.Ask a Yamaha dealer to
inspect.
3. Ignition
Remove the
spark plug and
check electrodes.WetWipe clean with dry cloth.
DryAttach spark plug cap and
ground to chassis.Use the
electric starter.Spark is good.Ignition system is
normal.
Spark is weak.
Adjust the spark plug gap
or replace the spark plug. No spark.
Ask a Yamaha dealer to
inspect. 4. Battery
Use the electric starter.Engine turns over
quickly.Battery is good.
Engine turns over
slowly.Check the connections.Check the
fuel flow.
Turn the fuel cock
lever to “ON”.
Remove the fuel hose
from the fuel cock.
U5KM60.book Page 137 Thursday, June 21, 2001 2:40 PM

8-138
Engine overheatingNOTE:If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is
changed to the recommended coolant as soon as possible.
WARNING
Wait 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 pressure to escape before completely removing the cap. Wait until the
engine has cooled.
Check the coolant level in the
reservoir tank and/or radiator.
Level is OK.Level is low, check the
cooling system for leakage.
No
leakage.Leakage.
Ask a Yamaha dealer to inspect
and repair the cooling system.Add coolant. (See NOTE.)
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and/or repair the cooling system.
U5KM60.book Page 138 Thursday, June 21, 2001 2:40 PM