maintenance YAMAHA GRIZZLY 660 2003 Owners Manual

EBU00946
1-INTRODUCTION
Congratulations on your purchase of the Yamaha
YFM660FP. It represents the result of many years
of Yamaha experience in the production of fine
sporting, touring, and pacesetting racing ma-
chines. With the purchase of this Yamaha, you can
now appreciate the high degree of craftsmanship
and reliability that have made Yamaha a leader in
these fields. This manual will provide you with a
good basic understanding of the features and op-
eration of this ATV.
This manual includes impor-
tant safety information. It provides information
about special techniques and skills necessary
to ride your ATV. It also includes basic mainte-
nance and inspection procedures. If you have any
questions regarding the operation or maintenance
of your ATV, please consult a Yamaha dealer.
U5KM60.book Page 4 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

Rear brake adjustment .................... 8-101
Adjusting the rear brake light
switch ............................................. 8-105
Cable inspection and lubrication ..... 8-107
Brake lever and brake pedal
lubrication ...................................... 8-109
Rear knuckle upper and lower pivot
lubrication ....................................... 8-111
Wheel removal ................................ 8-113
Wheel installation ............................ 8-115
Battery ............................................. 8-117
Battery maintenance ....................... 8-121
Fuse replacement ............................ 8-123
Replacing the headlight bulb ........... 8-127
Headlight beam adjustment ............. 8-131
Tail/brake light bulb replacement ..... 8-133
Troubleshooting ............................... 8-135
Troubleshooting chart ...................... 8-137CLEANING AND STORAGE .................. 9-1
A. Cleaning ......................................... 9-1
B. Storage ........................................... 9-7
SPECIFICATIONS................................. 10-1
HOW TO USE THE CONVERSION
TABLE .................................................. 11-1
91011
U5KM60.book Page 3 Thursday, June 21, 2001 2:40 PM

2-5

Always inspect your ATV each time you use it
to make sure it is in safe operating condition.
Always follow the inspection and maintenance
procedures and schedules described in this
manual.


Always keep both hands on the handlebars
and both feet on the footboards of the ATV dur-
ing operation.


Always go slowly and be extra careful when op-
erating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the
ATV.


Never operate on excessively rough, slippery
or loose terrain until you have learned and
practiced the skills necessary to control the
ATV on such terrain. Always be especially cau-
tious on these kinds of terrain.


Always follow proper procedures for turning as
described in this manual. Practice turning at
low speeds before attempting to turn at faster
speeds. Do not turn at excessive speed.
U5KM60.book Page 5 Thursday, June 21, 2001 2:40 PM

5-2
5
WARNING
Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Own-
er’s Manual. Failure to inspect increases the possibility of an accident or equipment damage.U5KM60.book Page 2 Thursday, June 21, 2001 2:40 PM

8-1
EBU00516
PERIODIC MAINTENANCE AND
ADJUSTMENTPeriodic inspection, adjustment and lubrication will
keep your machine in the safest and most efficient
condition possible. Safety is an obligation of the
machine owner. The most important points of ma-
chine inspection, adjustment and lubrication are
explained on the following pages.
WARNING
Never service an engine while it is running.
Moving parts can catch clothing or parts of the
body, causing injury. Electrical components
can cause shocks or can start fires. Turn off
the engine when performing maintenance un-
less otherwise specified. Have a Yamaha deal-
er perform service if you are not familiar with
machine service.
U5KM60.book Page 1 Thursday, June 21, 2001 2:40 PM

8-3 1. Owner’s manual
2. Owner’s tool kit
3. Low-pressure tire gauge
1. Manuel du propriétaire
2. Manuel du trousse à outils
3. Manomètre basse pression pour pneus
1. Manual del propietario
2. Manual del juego de herramientas
3. Manómetro de baja presión
EBU00563
Owner’s manual and tool kit
You are recommended to put this owner’s manual
in the vinyl bag and always carry it in the storage
box. Put the owner’s tool kit and low-pressure tire
gauge in the space beside the battery.
The service information included in this manual is
intended to provide you, the owner, with the nec-
essary information for completing your own pre-
ventive maintenance and minor repairs. The tools
provided in the Owner’s tool kit are sufficient for
this purpose, except that a torque wrench is also
necessary to properly tighten nuts and bolts.NOTE:_ If you do not have a torque wrench available dur-
ing a service operation requiring one, take your
machine to a Yamaha dealer to check the torque
settings and adjust them as necessary. _
U5KM60.book Page 3 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

8-15 1. Panel A 2. Panel C 3. Panel B
1. Cache A 2. Cache C 3. Cache B
1. Panel A 2. Panel C 3. Panel B
4. Panel D 5. Panel E 6. Panel F
4. Cache D 5. Cache E 6. Cache F
4. Panel D 5. Panel E 6. Panel F
EBU00614
Panel removal and installation
The panels illustrated need to be removed to per-
form some of the maintenance described in this
chapter.
Refer to this section each time a panel has to be
removed or reinstalled.
U5KM60.book Page 15 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