brake light YAMAHA GRIZZLY 660 2005 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 ............................... 4-11
Handlebar switches ............................ 4-19
Throttle lever ...................................... 4-37
Speed limiter ...................................... 4-39
Front brake lever ................................ 4-41
Brake pedal and rear brake lever ....... 4-43
Drive select lever ................................ 4-45
Recoil starter ...................................... 4-45
Fuel tank cap ...................................... 4-47
1234
Fuel cock............................................ 4-49
Starter (choke) ................................... 4-51
Seat.................................................... 4-53
Storage compartment ........................ 4-55
Front carrier ....................................... 4-55
Rear carrier ........................................ 4-55
Front and rear shock absorber
adjustment ....................................... 4-57
Auxiliary DC jack ................................ 4-61
PRE-OPERATION CHECKS ................... 5-1
Front and rear brakes .......................... 5-7
Fuel .................................................... 5-11
Engine oil ........................................... 5-15
Final gear oil ...................................... 5-17
Differential gear oil ............................. 5-19
Coolant............................................... 5-19
Throttle lever ...................................... 5-21
Fittings and fasteners......................... 5-21
Lights ................................................. 5-23
Switches............................................. 5-23
Tires ................................................... 5-25
How to measure tire pressure ............ 5-29
Tire wear limit..................................... 5-31
5
U5KM63.book Page 1 Monday, March 15, 2004 11:44 AM

Adjusting the rear brake lever and
brake pedal .................................... 8-111
Adjusting the rear brake light
switch ............................................. 8-115
Cable inspection and lubrication ...... 8-117
Brake lever and brake pedal
lubrication ....................................... 8-119
Rear knuckle upper and lower pivot
lubrication ....................................... 8-121
Wheel removal ................................. 8-123
Wheel installation ............................. 8-125
Battery .............................................. 8-127
Battery maintenance ........................ 8-131
Fuse replacement............................. 8-133
Replacing a headlight bulb ............... 8-137
Headlight beam adjustment.............. 8-141
Tail/brake light bulb replacement ..... 8-141
Troubleshooting................................ 8-145
Troubleshooting chart....................... 8-147
CLEANING AND STORAGE ................... 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................. 10-1
910
CONVERSION TABLE .......................... 11-1
11
U5KM63.book Page 3 Monday, March 15, 2004 11:44 AM

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 fluid reservoir
5. Front shock absorber spring
preload adjusting ring
6. Rear brake fluid reservoir
7. Brake pedal
8. V-belt case drain plug
9. Radiator cap
10. Drive select lever
11. Fuel tank cap
12. Fuel cock
13. Battery
14. Fuses15. Engine oil dipstick
16. Recoil starter
17. Coolant reservoir
18. Drive select lever box check
hose
19. V-belt cooling duct check hose
20. Rear brake lever
21. Left handlebar switches
22. Horn switch
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.
U5KM63.book Page 1 Monday, March 15, 2004 11:44 AM

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,
8-101–8-115
FuelCheck fuel level.
Fill with fuel if necessary.5-11–5-13
Engine oilCheck oil level.
Fill with oil if necessary.5-15,
8-39–8-51
Coolant reservoirCheck coolant level in reservoir.
Fill with coolant if necessary.5-19–5-21,
8-63–8-73
Final gear oil/
Differential gear oilCheck for leakage.5-17–5-19,
8-53–8-61
ThrottleCheck for proper throttle cable operation and free play. 5-21, 8-99
Wheels and tiresCheck tire pressure, wear and damage.5-25–5-31,
8-123–8-125
Fittings and fastenersCheck all fittings and fasteners. 5-21
Lights and switchesCheck for proper operation. 5-23, 8-137–8-143
Axle bootsCheck for damage. 8-75
U5KM63.book Page 1 Monday, March 15, 2004 11:44 AM

5-23
EBU01003
Lights
Check the headlights and tail/brake light to make
sure they are in working condition. Repair as nec-
essary for proper operation.
EBU01170
Switches
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper op-
eration.
U5KM63.book Page 23 Monday, March 15, 2004 11:44 AM

6-5 a. Starter (choke)
1. Fully open
2. Half open
3. Closed
a. Starter (enrichisseur)
1. Complètement ouvert
2. Mi-ouvert
3. Fermé
a. Starter (choke)
1. Abre completamente
2. Semiabierto
3. Cerrado
NOTE:_

When the drive select lever is in the neutral or
park position, if either indicator light does not
come on, ask a Yamaha dealer to inspect the
respective electric circuit.


The engine can be started in any gear if the
rear brake lever or brake pedal is applied.
However, it is recommended to shift into neu-
tral or park before starting the engine.
_5. Use the starter (choke) in reference to the fig-
ure:
Position
1: Cold engine start-
ambient temperature below 5°C.
Position
2: Cold engine start-
ambient temperature at 0°C–30°C
and warming up position.
Position
2: Cold engine start-
ambient temperature above 25°C
and warm engine start position.
6. Completely close the throttle lever and start
the engine by pushing the start switch.
U5KM63.book Page 5 Monday, March 15, 2004 11:44 AM

6-13 1. Drive select lever
a. L (Low)
b. H (High)
c. N (Neutral)
d. R (Reverse)
e. P (Park)
1. Levier de présélection
a. L (rapport inférieur)
b. H (rapport supérieur)
c. N (point mort)
d. R (marche arrière)
e. P (stationnement)
1. Palanca de selección de marcha
a. L (baja)
b. H (alta)
c. N (punto muerto)
d. R (marcha atrás)
e. P (estacionamiento)
Shifting: Neutral to Reverse and Reverse to
ParkNOTE:_ The drive select lever cannot be shifted into or
from reverse or park without applying the rear
brake. _1. Bring the ATV to a complete stop and return
the throttle lever to the closed position.
2. Apply the brake pedal.
3. Shift from neutral to reverse or from reverse
to park and vice versa by moving the drive
select lever along the shift guide.NOTE:_

When in reverse, the reverse indicator light
should be on. If the light does not come on,
ask a Yamaha dealer to inspect the electrical
circuit.


Due to the synchronizing mechanism in the
engine, the light may not come on until the
ATV starts moving.
_
U5KM63.book Page 13 Monday, March 15, 2004 11:44 AM

8-9
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
When disassembling the master cylinders or caliper cylinders, replace the brake fluid. Normally
check the brake fluid level and add fluid as required.
On the inner parts of the master cylinders and caliper cylinders, replace the oil seals every two
years.
Replace the brake hoses every four years, or if cracked or damaged.
Lights and switches*Check operation.
Adjust headlight beams.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
U5KM63.book Page 9 Monday, March 15, 2004 11:44 AM

8-115 1. Rear brake light switch
2. Adjusting nut
1. Contacteur de feu stop
2.Écrou de réglage
1. Interruptor de la luz del freno trasero
2. Tuerca de ajuste
EBU12590
Adjusting the rear brake light switch
The rear brake light switch, which is activated by
the brake pedal and rear brake lever, is properly
adjusted when the brake light comes on just be-
fore braking takes effect. If necessary, adjust the
brake light switch as follows.
1. Remove panel B. (See page 8-23 for panel
removal and installation procedures.)
2. Turn the adjusting nut while holding the rear
brake light switch in place. To make the brake
light come on earlier, turn the adjusting nut in
direction
a. To make the brake light come on
later, turn the adjusting nut in direction
b.
3. Install the panel.
U5KM63.book Page 115 Monday, March 15, 2004 11:44 AM

8-141 1. Headlight beam adjusting screw
1. Vis de réglage du faisceau de phare
1. Tornillo de ajuste de la luz del faro
1. Tail/brake light bulb holder
1. Fixation d’ampoule de feu arrière/stop
1. Portalámparas de la luz de freno/piloto trasero
EBU01089
Headlight beam adjustmentCAUTION:_ It is advisable to have a Yamaha dealer make
this adjustment. _To raise the beam, turn the adjusting screw in di-
rection
a.
To lower the beam, turn the adjusting screw in di-
rection
b.
EBU15050
Tail/brake light bulb replacement
1. Remove panel G. (See pages 8-35–8-37 for
removal and installation procedures.)
2. Remove the bulb holder (together with the
bulb) by turning it counterclockwise.
3. Remove the defective bulb from the bulb
holder by pushing it inward and turning it
counterclockwise.
U5KM63.book Page 141 Monday, March 15, 2004 11:44 AM