Front diff YAMAHA GRIZZLY 660 2006 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
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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
What to do if ........................................7-75
What to do...........................................7-75
67
PERIODIC MAINTENANCE AND
ADJUSTMENT ......................................... 8-1
Owner’s manual and tool kit ................. 8-3
Periodic maintenance/lubrication.......... 8-7
Panel removal and installation............ 8-17
Engine oil and oil filter cartridge ......... 8-39
Final gear oil ....................................... 8-53
Differential gear oil.............................. 8-57
Cooling system ................................... 8-63
Changing the coolant.......................... 8-67
Axle boots ........................................... 8-75
Spark plug inspection ......................... 8-77
Air filter element cleaning ................... 8-83
V-belt cooling duct check hose ........... 8-91
V-belt case drain plug ......................... 8-91
Carburetor adjustment ........................ 8-93
Idle speed adjustment ........................ 8-95
Valve clearance adjustment ............... 8-97
Select lever safety system cable
adjustment ........................................ 8-97
Throttle lever adjustment .................... 8-99
Front brake pad check ...................... 8-101
Checking the rear brake pads .......... 8-101
Checking the brake fluid level........... 8-103
Brake fluid replacement .................... 8-107
Front brake lever free play................ 8-109
8
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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.
U2C660.book Page 1 Monday, April 11, 2005 10:29 AM

4-27 1. On-Command four-wheel drive switch “2WD”/“4WD”
2. Differential gear lock switch “LOCK”/“4WD”
1. Contacteur de commande du mode de traction “2WD”/“4WD”
2. Contacteur de blocage du différentiel “LOCK”/“4WD”
1. Selector de tracción en las cuatro ruedas “2WD”/“4WD”
2. Selector de bloqueo del diferencial “LOCK”/“4WD”
EBU13803
On-Command four-wheel drive and differential
gear lock switches
This ATV is equipped with an On-Command four-
wheel drive switch “2WD”/“4WD” and a differential
gear lock switch “LOCK”/“4WD”. Select the appro-
priate drive according to terrain and the conditions.

Two-wheel drive (2WD): Power is supplied to
the rear wheels only.


Four-wheel drive (4WD): Power is supplied to
the rear and front wheels.


Four-wheel drive with the differential gear
locked (4WD-LOCK): Power is supplied to the
rear and front wheels when the differential gear
is locked (“DIFF.LOCK”). Unlike the 4WD
mode, all wheels turn at the same speed.
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7-39
TURNING YOUR ATV
To achieve maximum traction on unpaved surfac-
es in 2WD or 4WD, the two rear wheels turn to-
gether at the same speed. Furthermore, when
riding in 4WD-LOCK (“DIFF.LOCK”), the front
wheels also turn together at the same speed.
Therefore, unless the wheel on the inside of the
turn is allowed to slip or lose some traction, the
ATV will resist turning. A special turning technique
must be used to allow the ATV to make turns
quickly and easily. It is essential that this skill be
learned first at low speed.
WARNING
_ Always follow proper procedures for turning
as described in this Owner’s Manual. Practice
turning at low speeds before attempting to turn
at faster speeds. Do not turn at speeds too fast
for your skills or the conditions. Operate at a
slow speed and allow extra time and distance
for maneuvers when in 4WD-LOCK
(“DIFF.LOCK”). _
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8-8
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 8-9.
Correct if necessary.Rear brake*Check operation/fluid leakage/see NOTE page 8-9.
Correct if necessary.Select lever safety system
cable*Check operation.
Adjust if necessary.V-belt*Check operation.
Check for cracks or damage.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 with lithium-soap-based grease.Drive shaft universal
joint*Lubricate with lithium-soap-based grease.Engine mount*
Check for cracks or damage.Front and rear axle boots*Check operation.
Replace if damaged.Stabilizer bushes*
Check for cracks or damage.
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
U2C660.book Page 8 Monday, April 11, 2005 10:29 AM