differential YAMAHA GRIZZLY 660 2007 User Guide

5-3
5
EBU19540Fuel Make sure that there is sufficient fuel in the tank.
(See page 4-15.)
WARNING
EWB00520
Do not overfill the fuel tank. Fuel expands
when it heats up. If the fuel tank is overfilled,
fuel could spill out due to heat from the en-
gine or the sun.
Be careful not to spill fuel, especially on the
engine or exhaust pipe which can cause a
fire and severe injury. Wipe up any spilled
fuel immediately.
Do not refuel right after the engine has been
running and is still very hot.
Be sure the fuel tank cap is closed securely.EBU19560Engine oil Make sure that the engine oil is at the specified lev-
el. Add oil as necessary. (See page 8-17.)EBU19590Final gear oil Make sure that the final gear oil is at the specified
level. Add oil as necessary. (See page 8-21.)
EBU19600Differential gear oil Make sure that the differential gear oil is at the
specified level. Add oil as necessary. (See page
8-22.)EBU19630Coolant Make sure that the coolant is at the specified level.
Add coolant as necessary. (See page 8-24.)NOTE:The coolant level must be checked on a cold en-
gine since the level varies with engine tempera-ture.
WARNING
EWB00510Wait 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 pressureto escape before completely removing the cap.
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8-5
8
15*Shock absorber as-
sembliesCheck operation and correct if necessary.
Check for oil leakage and replace if necessary.√√√
16*Stabilizer bushesCheck for cracks or other damage, and replace if
necessary.√√√
17*Knuckle pivotsLubricate with lithium-soap-based grease.√√√
18*Steering systemCheck operation and repair or replace if damaged.
Check toe-in and adjust if necessary.√√√√√
19*Engine mountCheck for cracks or other damage, and replace if
necessary.√√√
20*Axle bootsCheck for cracks or other damage, and replace if
necessary.√√√√√
21*CarburetorCheck starter (choke) operation and correct if nec-
essary.
Check engine idling speed and adjust if neces-
sary.√√√√
22*Crankcase breather
systemCheck breather hose for cracks or other damage,
and replace if necessary.√√√
23 Engine oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√ √√√
24Engine oil filter car-
tridgeReplace.√√√
25 Differential gear oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√√ NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300U2C661E0.book Page 5 Thursday, March 16, 2006 10:45 AM

8-22
85. Add the specified amount of the recommend-
ed final gear oil.
CAUTION:ECB00420Be sure no foreign material enters the finalgear case.
6. Install the oil filler bolt, and then tighten it to the
specified torque.
7. Check the final gear case for oil leakage. If oil
is leaking, check for the cause.
EBU23421Differential gear oil The differential gear case must be checked for oil
leakage before each ride. If any leakage is found,
have a Yamaha dealer check and repair the ATV.
In addition, the differential gear oil level must be
checked and the oil changed as follows at the in-
tervals specified in the periodic maintenance and
lubrication chart.
To check the differential gear oil level
1. Place the ATV on a level surface.NOTE:The differential gear oil level must be checked ona cold engine.
2. Remove the differential gear oil filler bolt, and
then check the oil level in the differential gear
case. Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
Recommended final gear oil:
See page 10-1.
Oil quantity:
0.25 L (0.26 US qt) (0.22 Imp.qt)
Tightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
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8-23
8
NOTE:The oil level should be at the brim of the filler hole.
3. If the oil is below the brim of the filler hole, add
sufficient oil of the recommended type to raise
it to the correct level.
4. Install the oil filler bolt, and then tighten it to the
specified torque.To change the differential gear oil
1. Place the ATV on a level surface.
2. Place an oil pan under the differential gear
case to collect the used oil.
3. Remove the differential gear oil filler bolt and
the differential gear oil drain bolt to drain the
oil from the differential gear case.
4. Install the drain bolt, and then tighten it to the
specified torque.1. Differential gear oil
2. Differential gear oil filler bolt
3. Correct oil levelTightening torque:
Differential gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
1. Differential gear oil drain boltTightening torque:
Differential gear oil drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
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8-24
85. Add the recommended differential gear oil to
the brim of the filler hole as shown.
CAUTION:ECB00410Be sure no foreign material enters the differen-tial gear case.
6. Install the oil filler bolt, and then tighten it to the
specified torque.7. Check the differential gear case for oil leak-
age. If oil is leaking, check for the cause.
EBU23470Coolant The coolant level should be checked before each
ride. In addition, the coolant must be changed at
the intervals specified in the periodic maintenance
and lubrication chart.EBU27120To check the coolant level
1. Place the ATV on a level surface.NOTE:The coolant level must be checked on a cold en-
gine since the level varies with engine tempera-ture.
2. Check the coolant level in the coolant reser-
voir.
1. Differential gear oil
2. Differential gear oil filler bolt
3. Correct oil levelRecommended differential gear oil:
See page 10-1.
Tightening torque:
Differential gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
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10-2
10
Engine oil:Type:
SAE5W30 or SAE10W30 or SAE10W40 or SAE15W40
or SAE20W40 or SAE20W50
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Without oil filter cartridge replacement:
1.90 L (2.01 US qt) (1.67 Imp.qt)
With oil filter cartridge replacement:
2.00 L (2.11 US qt) (1.76 Imp.qt)Final gear oil:Type:
SAE80 API GL-4 Hypoid gear oil
Quantity:
0.25 L (0.26 US qt) (0.22 Imp.qt)
Differential gear oil:Type:
SAE80 API GL-4 Hypoid gear oil
Quantity:
0.28 L (0.30 US qt) (0.25 Imp.qt)Cooling system:Coolant reservoir capacity (up to the maximum level mark):
0.30 L (0.32 US qt) (0.26 Imp.qt)
Radiator capacity (including all routes):
1.80 L (1.90 US qt) (1.58 Imp.qt)Air filter:Air filter element:
Wet elementFuel:Recommended fuel:
Regular unleaded gasoline only (EUR)
Unleaded gasoline only (AUS)(NZL)
Fuel tank capacity:
20.0 L (5.28 US gal) (4.40 Imp.gal)
Fuel reserve amount:
3.5 L (0.92 US gal) (0.77 Imp.gal)Carburetor:Manufacturer:
MIKUNI
Type x quantity:
BSR42 x 1Spark plug (s):Manufacturer/model:
NGK/DPR8EA-9
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
-20˚ -10˚ 0˚
10˚20˚ 30˚40˚50˚C
10W/30
15W/4020W/4020W/50
10W/40
5W/30
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10-5
10
Coolant temperature warning light:
LED
Park indicator light:
LED
On-Command four-wheel-drive/differential gear lock
indicator:
LCD
High-range indicator light:
LED
Low-range indicator light:
LED
Differential gear lock indicator light:
LEDFuses:Main fuse:
30.0 A
Headlight fuse:
15.0 A
Signaling system fuse:
10.0 A
Ignition fuse:
10.0 A
Auxiliary DC jack fuse:
10.0 A
Backup fuse:
10.0 A
Four-wheel-drive motor fuse:
3.0 A
U2C661E0.book Page 5 Thursday, March 16, 2006 10:45 AM

INDEX
AAccessories and loading ................................................ 6-6
Accessories, auxiliary jack ........................................... 4-21
Air filter element, cleaning ............................................ 8-28
Axle boots .................................................................... 8-42BBattery .......................................................................... 8-46
Brake fluid, changing .................................................... 8-39
Brake fluid level, checking ............................................ 8-37
Brake lever free play and brake pedal position (rear),
adjusting and checking .............................................. 8-40
Brake lever free play, checking the front ...................... 8-39
Brake lever, front .......................................................... 4-12
Brake levers, checking and lubricating ......................... 8-43
Brake light switches ..................................................... 8-42
Brake pads, checking the front and rear ...................... 8-36
Brake pedal and rear brake lever ................................. 4-13
Brake pedal, checking and lubricating ......................... 8-44
Brakes, front and rear .................................................... 5-4CCables, checking and lubricating ................................. 8-43
Carburetor, adjusting .................................................... 8-34
Carrier, front ................................................................. 4-20
Carrier, rear .................................................................. 4-20
Chassis fasteners ........................................................... 5-7
Cleaning ......................................................................... 9-1
Coolant .................................................................. 5-3, 8-24
Coolant temperature warning light ................................. 4-2
DDifferential gear lock indicator light ................................ 4-3
Differential gear oil ................................................ 5-3, 8-22
Drive select lever .......................................................... 4-14
Drive select lever and driving in reverse ........................ 6-3
Drive select lever safety system cable, adjusting ......... 8-36
Drive shaft universal joint, lubricating ........................... 8-45EEngine break-in .............................................................. 6-5
Engine, cold start ........................................................... 6-1
Engine idling speed ...................................................... 8-34
Engine oil ....................................................................... 5-3
Engine oil and oil filter cartridge ................................... 8-17
Engine, starting a warm ................................................. 6-3
Engine stop switch ......................................................... 4-6FFinal gear oil ................................................................... 5-3
Final gear oil, changing ................................................ 8-21
Four-wheel-drive/differential gear lock indicator ............ 4-3
Fuel ....................................................................... 4-15, 5-3
Fuel cock ...................................................................... 4-16
Fuel tank cap ................................................................ 4-14
Fuses, replacing ........................................................... 8-48HHandlebar switches ........................................................ 4-6
Headlight beam, adjusting ............................................ 8-51
Headlight bulb, replacing .............................................. 8-49
High-range indicator light ............................................... 4-3
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Horn switch .................................................................... 4-6IIdentification numbers .................................................. 11-1
Indicator lights and warning light .................................... 4-2
Instruments, lights and switches .................................... 5-7KKey identification number ............................................. 11-1
Knuckle pivots, lubricating ........................................... 8-45LLabel locations ............................................................... 2-1
Light switch .................................................................... 4-6
Low-range indicator light ................................................ 4-3MMain switch .................................................................... 4-1
Model label ................................................................... 11-2
Multifunction display ....................................................... 4-4NNeutral indicator light ..................................................... 4-2OOn-Command differential gear lock switch .................... 4-9
On-Command four-wheel-drive switch ........................... 4-8
Override switch .............................................................. 4-7
Owner’s manual and tool kit ........................................... 8-1PPanels, removing and installing ..................................... 8-8
Park indicator light ......................................................... 4-3
Parking ........................................................................... 6-5
Parking on a slope ......................................................... 6-6
Part locations ................................................................. 3-1
Periodic maintenance and lubrication chart ................... 8-3
Pre-operation check list ................................................. 5-1
RRecoil starter ................................................................ 4-14
Reverse indicator light ................................................... 4-2
Riding your ATV ............................................................. 7-1SSafety information .......................................................... 1-1
Seat ............................................................................. 4-18
Shock absorber assemblies, adjusting the front
and rear ..................................................................... 4-20
Spark arrester, cleaning ............................................... 8-32
Spark plug, checking ................................................... 8-15
Specifications ............................................................... 10-1
Speed limiter ................................................................ 4-12
Stabilizer bushes, checking ......................................... 8-45
Starter (choke) ............................................................. 4-17
Start switch .................................................................... 4-6
Storage .......................................................................... 9-2
Storage compartment .................................................. 4-19
Suspension, lubricating the upper and lower
arm pivots .................................................................. 8-45TTail/brake light bulb, replacing ..................................... 8-51
Throttle cable free play, adjusting ................................ 8-35
Throttle lever ......................................................... 4-11, 5-5
Tire pressure, measuring ............................................... 5-6
Tires ............................................................................... 5-5
Tire wear limit ................................................................ 5-7
Troubleshooting ........................................................... 8-54
Troubleshooting charts ................................................ 8-55VValve clearance ........................................................... 8-36
V-belt case drain plug .................................................. 8-33
U2C661E0.book Page 2 Thursday, March 16, 2006 10:45 AM