coolant YAMAHA GRIZZLY 660 2003 Owners Manual

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 ................................ 4-9
Fuel gauge ........................................ 4-15
Handlebar switches ........................... 4-17
Throttle lever ..................................... 4-29
Speed limiter ..................................... 4-31
Front brake lever ............................... 4-33
Rear brake pedal and lever ............... 4-35
Drive select lever ............................... 4-37
1234
Recoil starter ..................................... 4-37
Fuel tank cap .................................... 4-39
Fuel cock ........................................... 4-41
Starter (choke) “” .......................... 4-43
Seat ................................................... 4-45
Storage compartment ....................... 4-47
Front carrier ...................................... 4-47
Rear carrier ....................................... 4-47
Front and rear shock absorber
adjustment ...................................... 4-49
Auxiliary DC jack ............................... 4-53
PRE-OPERATION CHECKS .................. 5-1
Front and rear brakes ......................... 5-7
Fuel ................................................... 5-11
Engine oil .......................................... 5-15
Final gear oil ..................................... 5-19
Differential gear oil ............................ 5-21
Coolant .............................................. 5-21
Throttle lever ..................................... 5-23
Fittings and Fasteners ...................... 5-23
Lights ................................................ 5-25
Switches ............................................ 5-25
5
U5KM60.book Page 1 Thursday, June 21, 2001 2:40 PM

Tires ...................................................5-27
How to measure tire pressure ............5-31
Tire wear limit .....................................5-33
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
67
What to do if ... ................................... 7-75
What to do ... ...................................... 7-75
PERIODIC MAINTENANCE AND
ADJUSTMENT ........................................ 8-1
Owner’s manual and tool kit ................. 8-3
Periodic maintenance/lubrication ......... 8-7
Panel removal and installation ........... 8-15
Engine oil ............................................ 8-33
Final gear oil ....................................... 8-43
Differential gear oil ............................. 8-49
Cooling system ................................... 8-55
Changing the coolant.......................... 8-59
Axle boots ........................................... 8-67
Spark plug inspection ......................... 8-69
Air filter element cleaning ................... 8-75
V-belt cooling duct check hose ........... 8-81
Carburetor adjustment ....................... 8-83
Idle speed adjustment ....................... 8-85
Valve clearance adjustment .............. 8-87
Throttle lever adjustment ................... 8-89
Front brake pad inspection ................ 8-91
Rear brake pad inspection.................. 8-91
Inspecting the brake fluid level ........... 8-93
Brake fluid replacement ...................... 8-97
Front brake adjustment ...................... 8-99
8
U5KM60.book Page 2 Thursday, June 21, 2001 2:40 PM

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 master cylinder
5. Front shock absorber spring
preload adjusting ring
6. Rear brake master cylinder
7. Rear brake pedal
8. V-belt case drain plug
9. Radiator cap
10. Drive select lever
11. Fuel tank cap
12. Fuel cock
13. Fuses14. Battery
15. Engine oil dipstick
16. Recoil starter
17. Coolant reservoir
18. Drive select lever case check
hose
19. V-belt cooling duct check hose
20. Rear brake lever
21. Left handlebar switches
22. Horn
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.
U5KM60.book Page 1 Thursday, June 21, 2001 2:40 PM

4-3
1. Differential gear lock indicator light “DIFF. LOCK”
2. Low-range indicator light “L”
3. High-range indicator light “H”
4. Neutral indicator light “N”
5. Reverse indicator light “R”
6. Park indicator light “P”
7. Four-wheel-drive indicator “”/“”
8. Coolant temperature warning light “”
1. Témoin de blocage du différentiel “DIFF. LOCK”
2. Témoin du rapport inférieur “L”
3. Témoin du rapport supérieur “H”
4. Témoin de point mort “N”
5. Témoin de marche arrière “R”
6. Témoin de stationnement “P”
7. Indicateur 4x4 “”/“”
8. Témoin d’avertissement de la température du liquide de
refroidissement “”
1. Luz indicadora de bloqueo del diferencial “DIFF.LOCK”
2. Luz indicadora de margen bajo “L”
3. Luz indicadora de margen alto “H”
4. Luz de control de punto muerto “N”
5. Luz indicadora de marcha atrás “R”
6. Luz indicadora de estacionamiento “P”
7. Indicador del modo de tracción en las cuatro ruedas “”/“”
8. Luz de aviso de la temperatura del refrigerante “”
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
EBU00802
Indicator and warning lights
EBU00839
Differential gear lock indicator light “DIFF.
LOCK”
This indicator light comes on along with the differ-
ential gear lock indicator in the display when the
differential gear lock switch is set to the “4WD-
LOCK” position.
EBU00838*
Low-range indicator light “L”
This indicator light comes on when the drive select
lever is in the “L” position.
EBU00836*
High-range indicator light “H”
This indicator light comes on when the drive select
lever is in the “H” position.
EBU00603*
Neutral indicator light “N”
This indicator light comes on when the drive select
lever is in the “N” position.
U5KM60.book Page 3 Thursday, June 21, 2001 2:40 PM

4-5
1. Differential gear lock indicator light “DIFF. LOCK”
2. Low-range indicator light “L”
3. High-range indicator light “H”
4. Neutral indicator light “N”
5. Reverse indicator light “R”
6. Park indicator light “P”
7. Four-wheel-drive indicator “”/“”
8. Coolant temperature warning light “”
1. Témoin de blocage du différentiel “DIFF. LOCK”
2. Témoin du rapport inférieur “L”
3. Témoin du rapport supérieur “H”
4. Témoin de point mort “N”
5. Témoin de marche arrière “R”
6. Témoin de stationnement “P”
7. Indicateur 4x4 “”/“”
8. Témoin d’avertissement de la température du liquide de
refroidissement “”
1. Luz indicadora de bloqueo del diferencial “DIFF.LOCK”
2. Luz indicadora de margen bajo “L”
3. Luz indicadora de margen alto “H”
4. Luz de control de punto muerto “N”
5. Luz indicadora de marcha atrás “R”
6. Luz indicadora de estacionamiento “P”
7. Indicador del modo de tracción en las cuatro ruedas “”/“”
8. Luz de aviso de la temperatura del refrigerante “”
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
EBU00867*
Reverse indicator light “R”
This indicator light comes on when the drive select
lever is in the “R” reverse position.NOTE:_ If the indicator light flashes or the speedometer
does not show the speed while riding, have a
Yamaha dealer check the speed sensor circuit. _
EBU00609
Park indicator light “P”
This indicator light comes on when the drive select
lever is in the “P” (park) position.
EBU00884*
Four-wheel-drive indicator “”/“”
This indicator comes on when the “2WD”/“4WD”
switch is set to the “4WD” position. The differential
lock indicator “DIFF.LOCK” in the four-wheel-drive
indicator also comes on when the “4WD”/“LOCK”
switch is set to the “4WD-LOCK” position.NOTE:_ Due to the synchronizing mechanism in the differ-
ential gear case, the four-wheel drive indicator
may not come on until the ATV starts moving. _
DIFF.
LOCK
U5KM60.book Page 5 Thursday, June 21, 2001 2:40 PM

4-7
EBU00860
Coolant temperature warning light “”
When the coolant temperature reaches a specified
level, this light comes on to warn that the coolant
temperature is too hot. If the light comes on during
operation, stop the engine as soon as it is safe to
do so and allow the engine to cool down for about
10 minutes.CAUTION:_

The engine may overheat if the ATV is
overloaded. If this happens, reduce the
load to specification.


After restarting, make sure that the light is
out. Continuous use while the light is on
may cause damage to the engine.
_
U5KM60.book Page 7 Thursday, June 21, 2001 2:40 PM

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
BrakesCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-7 ~ 5-9,
8-91 ~ 8-105
FuelCheck fuel level.
Fill with fuel if necessary.5-11 ~ 5-13
Engine oilCheck oil level.
Fill with oil if necessary.5-15 ~ 5-17,
8-33 ~ 8-43
Coolant reservoirCheck coolant level.
Fill with coolant if necessary.8-55 ~ 8-65
Final gear oil/
Differential gear oilCheck for leakage.5-19 ~ 5-21,
8-43 ~ 8-53
ThrottleCheck for proper throttle cable operation. 5-23, 8-89
Wheels and tiresCheck tire pressure, wear and damage.5-27 ~ 5-33,
8-113 ~ 8-115
Fittings and FastenersCheck all fittings and fasteners. 5-23
LightsCheck for proper operation. 5-25, 8-127 ~ 133
Axle bootsCheck for damage. 8-67
U5KM60.book Page 1 Thursday, June 21, 2001 2:40 PM

5-21
EBU00678
Differential gear oil
Make sure the differential gear oil is at the speci-
fied level. Add oil as necessary. (See pages 8-49 ~
8-53 for details.)
EBU00497*
Coolant
Check the coolant level in the reservoir tank when
the engine is cold. (The coolant level will vary with
engine temperature.) The coolant level is satisfac-
tory if it is between the “FULL” and “LOW” marks
on the tank. If the coolant level is at or below the
“LOW” level, add tap water (soft water) to bring the
level up to “FULL”. Change the coolant every two
years. (See pages 8-55 ~ 8-65 for details.)CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use distilled water if you can’t
get soft water. _
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
U5KM60.book Page 21 Thursday, June 21, 2001 2:40 PM

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
km 320 1,200 2,400 2,400 4,800
hours 20 75 150 150 300
Valves*•Check valve clearance.
•Adjust if necessary.
Cooling system•Check coolant leakage.
•Repair if necessary.
•Replace coolant every 24 months.Spark plug•Check condition.
•Adjust gap and clean.
•Replace if necessary.Air filter•Clean.
•Replace if necessary.Every 20~40 hours
(More often in wet or dusty areas.)
Carburetor*•Check and adjust idle speed/starter operation.
•Adjust if necessary.Crankcase breather
system*•Check breather hose for cracks or damage.
•Replace if necessary.Exhaust system*•Check for leakage.
•Retighten if necessary.
•Replace gasket(s) if necessary.Fuel line*•Check fuel hose for cracks or damage.
•Replace if necessary.Engine oil
•Replace (Warm engine before draining).Engine oil filter cartridge
•Replace.Final gear oil
•Check oil level/oil leakage.
•Replace.Differential gear oil
Front brake*•Check operation/fluid leakage/see NOTE page 8-8.
•Correct if necessary.Rear brake*•Check operation/fluid leakage/see NOTE page 8-8.
•Correct if necessary.V-belt*•Check operation.
•Check for cracks or damage.U5KM60.book Page 7 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