YAMAHA GRIZZLY 660 2007 Service Manual

4-18
4 Move the starter (choke) in direction (b) to turn off
the starter (choke).
See the “Starting a cold engine” section on page
6-1 for proper operation.
EBU18880Seat To remove the seat
Pull the seat lock lever upward and pull up the seat
at the rear.To install the seat
Insert the projections on the front of the seat into
the seat holders and push down on the seat at the
rear.
NOTE:Make sure that the seat is securely fitted.
1. Starter (choke) “”
1. Seat
2. Seat lock lever
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4-19
4
EBU27090Storage compartment The storage compartment is located under the
seat. (See page 4-18.)
When storing the owner’s manual or other docu-
ments in the storage compartment, be sure to wrap
them in a plastic bag so that they will not get wet.
When washing the ATV, be careful not to let any
water enter the storage compartment.
CAUTION:ECB00130Do not store metal or sharply edged objects,
like tools, in the storage compartment. If they
must be stored, wrap them in appropriate
cushion material to prevent damaging the stor-age compartment.
Do not exceed the load limit of 2.0 kg (4 lb)
for the storage compartment.
Do not exceed the maximum load of 220.0 kg
(485 lb) for the ATV.
1. Projection
2. Seat holder
1. Storage compartment
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4-20
4
EBU18960Front carrier
Do not exceed the load limit of 45.0 kg (99 lb) for
the front carrier.
Do not exceed the maximum load of 220.0 kg
(485 lb) for the ATV.EBU18970Rear carrier
Do not exceed the load limit of 85.0 kg (187 lb)
for the rear carrier.
Do not exceed the maximum load of 220.0 kg
(485 lb) for the ATV.EBU19160Adjusting the front and rear shock ab-
sorber assemblies The spring preload can be adjusted to suit the rid-
er’s weight and the riding conditions.NOTE:The rear wheels need to be removed to adjust therear shock absorber assemblies. (See page 8-52.)
Adjust the spring preload as follows.Turn the adjusting ring in direction (a) to increase
the spring preload and thereby harden the suspen-
sion, and in direction (b) to decrease the spring
preload and thereby soften the suspension.
NOTE:A special wrench can be obtained at a Yamahadealer to make this adjustment.1. Spring preload adjusting ring
2. Position indicator
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4-21
4
WARNING
EWB00400Always adjust the shock absorber assemblies
on the left and right side to the same setting.
Uneven adjustment can cause poor handling
and loss of stability, which could lead to an ac-cident.EBU19180Auxiliary DC jack The auxiliary DC jack is located at the front right
side of the ATV. The auxiliary DC jack can be used
for suitable work lights, radios, etc. The auxiliary
DC jack should only be used when the engine is
running.
1. Set the light switch to “OFF”.
2. Start the engine. (See page 6-1.)
3. Open the auxiliary DC jack cap, and then in-
sert the accessory power plug into the jack.
1. Special wrenchSpring preload setting:
Minimum (soft):
1
Standard:
2
Maximum (hard):
5
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4-22
4 4. When the auxiliary DC jack is not being used,
cover it with the cap.
CAUTION:ECB00120
Do not use accessories requiring more than
the above maximum capacity. This may
overload the circuit and cause the fuse to
blow.
If accessories are used without the engine
running or with the headlights turned on, the
battery will lose its charge and engine start-
ing may become difficult.
Do not use an automotive cigarette lighter or
other accessories with a plug that gets hotbecause the jack can be damaged.
1. Auxiliary DC jack cap
1. Auxiliary DC jack
Maximum rated capacity for the auxiliary DC
jack:
DC 12 V, 120 W (10 A)
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5-1
5
EBU19200
PRE-OPERATION CHECKS
EBU19220Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table.NOTE:The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic
maintenance and lubrication chart” on page 8-3 to determine which service should be performed by aYamaha dealer.
ITEM ROUTINE PAGE
FuelCheck fuel level in fuel tank, and add recommended fuel if neces-
sary.
Check fuel line for leakage. Correct if necessary.4-15, 5-3
Engine oilCheck oil level in engine, and add recommended oil to specified lev-
el if necessary.
Check ATV for oil leakage. Correct if necessary.5-3, 8-17
Final gear oilCheck ATV for oil leakage. Correct if necessary. 5-3, 8-21
Differential gear oilCheck ATV for oil leakage. Correct if necessary. 5-3, 8-22
CoolantCheck coolant level in reservoir, and add recommended coolant to
specified level if necessary.
Check cooling system for leakage. Correct if necessary.5-3, 8-24
Front brakeCheck operation. If soft or spongy, have Yamaha dealer bleed hy-
draulic system.
Check brake pads for wear, and replace if necessary.
Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.
Check hydraulic system for leakage. Correct if necessary.5-4, 8-36, 8-37, 8-39
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5-2
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WARNING
EWB00480Always 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 the Owner’sManual. Failure to inspect increases the possibility of an accident or equipment damage.Rear brakeCheck operation. If soft or spongy, have Yamaha dealer bleed hy-
draulic system.
Check lever free play, and adjust if necessary.
Check brake pads for wear, and replace if necessary.
Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.
Check hydraulic system for leakage. Correct if necessary.5-4, 8-36, 8-37, 8-40
Throttle leverMake sure that operation is smooth. Lubricate cable and lever hous-
ing if necessary.
Check cable free play, and adjust if necessary.5-5, 8-35
Control cablesMake sure that operation is smooth. Lubricate if necessary. 8-43
Wheels and tiresCheck wheel condition, and replace if damaged.
Check tire condition and tread depth. Replace if necessary.
Check air pressure. Correct if necessary.5-5, 5-6, 5-7
Brake pedal Make sure that operation is smooth. Lubricate pedal pivoting point if
necessary.8-44
Brake leversMake sure that operation is smooth. Lubricate lever pivoting points if
necessary.8-43
Axle bootsCheck for cracks or damage, and replace if necessary. 8-42
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened. 5-7
Instruments, lights and
switchesCheck operation, and correct if necessary. 5-7 ITEM ROUTINE PAGE
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5-3
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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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5-4
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EBU19730Front and rear brakes Brake levers and brake pedal
Check that there is no free play in the front brake
lever. If there is free play, have a Yamaha dealer
adjust it.
Check for correct free play in the rear brake le-
ver. If the free play is incorrect, adjust it. (See
page 8-40.)
Check for correct brake pedal height. If the pedal
height is incorrect, have a Yamaha dealer adjust
it.
Check the operation of the brake levers and
pedal. They should move smoothly and there
should be a firm feeling when the brakes are ap-
plied. If not, have a Yamaha dealer check the
brake system.
Brake fluid level
Check the brake fluid level. Add fluid if necessary.
(See page 8-37.)Brake fluid leakage
Check to see if any brake fluid is leaking out of the
pipe joints or brake fluid reservoirs. Apply the
brakes firmly for one minute. If a lever moves slow-
ly inward, there may be a leak in the brake system.
If there is any leakage, the brake system should be
checked by a Yamaha dealer.
Brake operation
Test the brakes at slow speed after starting out to
make sure they are working properly. If the brakes
do not provide proper braking performance, check
the brake pads for wear. (See page 8-36.)
WARNING
EWB00580Always check the brakes at the start of every
ride. Do not ride the ATV if you find any prob-
lem with the brakes or you could lose braking
ability, which could lead to an accident. If a
problem cannot be corrected by the adjust-
ment procedures provided in this manual, havea Yamaha dealer check for the cause.
Recommended brake fluid:
DOT 4
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5-5
5
EBU19761Throttle lever Check the operation of the throttle lever. It must
open smoothly and spring back to the idle position
when released. Have a Yamaha dealer correct if
necessary.EBU19791Tires
WARNING
EWB00601Use of improper tires on this ATV, or operation
of this ATV with improper or uneven tire pres-
sure, may cause loss of control, increasing
your risk of accident.
Pay attention to the following.
The tires listed below have been approved
by Yamaha Motor Co., Ltd. for this model.
Other tire combinations are not recommend-
ed.
Front:
Manufacturer/model:
CHENG SHIN/C828-4P (AUS)(NZL)
DUNLOP/KT131 (EUR)
Size:
AT25 x 8-12Type:
Tubeless
Rear:
Manufacturer/model:
CHENG SHIN/C828-4P (AUS)(NZL)
DUNLOP/KT135 (EUR)
Size:
AT25 x 10-12
Type:
Tubeless

The tires should be set to the recommended
pressure:
Recommended tire pressure:
Front:
35 kPa (5.0 psi) (0.35 kgf/cm²)
Rear:
30 kPa (4.3 psi) (0.30 kgf/cm²)
Check and adjust tire pressures when the
tires are cold.
Tire pressures must be equal on both
sides.
Tire pressure below the minimum speci-
fied could cause the tire to dislodge from
the rim under severe riding conditions.
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