brake pads YAMAHA GRIZZLY 660 2007 Owners Manual

OPERATION .................................................. 6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-3
Operating the drive select lever and
driving in reverse ...................................... 6-3
Engine break-in .......................................... 6-5
Parking ....................................................... 6-5
Parking on a slope ..................................... 6-6
Accessories and loading ............................ 6-6
RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV............... 7-2
RIDE WITH CARE AND GOOD
JUDGEMENT ............................................ 7-2
BE CAREFUL WHERE YOU RIDE ............. 7-9
TURNING YOUR ATV .............................. 7-13
CLIMBING UPHILL ................................... 7-14
RIDING DOWNHILL.................................. 7-17
CROSSING A SLOPE............................... 7-18
CROSSING THROUGH SHALLOW
WATER ................................................... 7-19
RIDING OVER ROUGH TERRAIN ........... 7-22
SLIDING AND SKIDDING ......................... 7-22
WHAT TO DO IF... .................................... 7-23
WHAT TO DO... ........................................ 7-23PERIODIC MAINTENANCE AND MINOR
REPAIR ..........................................................8-1
Owner’s manual and tool kit .......................8-1
Periodic maintenance and lubrication
chart ..........................................................8-3
Removing and installing panels ..................8-8
Checking the spark plug ...........................8-15
Engine oil and oil filter cartridge ................8-17
Changing the final gear oil ........................8-21
Differential gear oil ....................................8-22
Coolant .....................................................8-24
Cleaning the air filter element ...................8-28
Cleaning the spark arrester ......................8-32
V-belt cooling duct check hose .................8-33
V-belt case drain plug ...............................8-33
Adjusting the carburetor ............................8-34
Adjusting the engine idling speed .............8-34
Adjusting the throttle cable free play .........8-35
Valve clearance ........................................8-36
Adjusting the drive select lever safety
system cable ...........................................8-36
Checking the front and rear brake pads ...8-36
Checking the brake fluid level ...................8-37
Changing the brake fluid ...........................8-39
Checking the front brake lever
free play ..................................................8-39U2C661E0.book Page 2 Thursday, March 16, 2006 10:45 AM

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
5
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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5-4
5
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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8-3
8
EBU22401Periodic maintenance and lubrication chart NOTE:
For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-
vals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance
intervals should be followed.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,data and technical skills.NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300
1*Fuel lineCheck fuel hoses for cracks or other damage, and
replace if necessary.√√√
2 Spark plugCheck condition and clean, regap, or replace if
necessary.√√√√√
3*ValvesCheck valve clearance and adjust if necessary.√ √√√
4 Air filter elementClean and replace if necessary.Every 20–40 hours (more often in wet or
dusty areas)
5*Front brakeCheck operation and correct if necessary.
Check fluid level and ATV for fluid leakage, and
correct if necessary.√√√√√
Replace brake pads. Whenever worn to the limit
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8-4
8
6*Rear brakeCheck operation and correct if necessary.
Check brake lever free play and adjust if neces-
sary.
Check fluid level and ATV for fluid leakage, and
correct if necessary.√√√√√
Replace brake pads. Whenever worn to the limit
7*Brake hosesCheck for cracks or other damage, and replace if
necessary.√√√√
Replace. Every 4 years
8*WheelsCheck runout and for damage, and replace if nec-
essary.√ √√√
9*TiresCheck tread depth and for damage, and replace if
necessary.
Check air pressure and balance, and correct if
necessary.√ √√√
10*Wheel bearingsCheck for looseness or damage, and replace if
necessary.√ √√√
11*Upper and lower
arm pivotsLubricate with lithium-soap-based grease.√√√
12*V- b e l tCheck for wear, cracks or other damage, and re-
place if necessary.√ √√√
13*Drive shaft univer-
sal jointLubricate with lithium-soap-based grease.√√√
14*Chassis fastenersMake sure that all nuts, bolts, and screws are
properly tightened.√√√√√ 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 4 Thursday, March 16, 2006 10:45 AM

8-36
83. Tighten the locknut.
EBU24060Valve clearance The valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
EBU24070Adjusting the drive select lever safety
system cable The drive select lever safety system cable stretch-
es with use, which can result in improper function.
Therefore, the safety system cable should be
checked and adjusted at the intervals specified in
the periodic maintenance and lubrication chart.EBU24130Checking the front and rear brake pads The front and rear brake pads must be checked for
wear at the intervals specified in the periodic main-
tenance and lubrication chart.EBU24171Front brake pads
Check each front brake pad for damage and mea-
sure the lining thickness. If a brake pad is dam-
aged or if the lining thickness is less than 1.0 mm
(0.04 in), have a Yamaha dealer replace the brake
pads as a set.
1. Locknut
2. Throttle cable free play adjusting bolt
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8-37
8
NOTE:The wheels need to be removed to check thebrake pads. (See page 8-52.)EBU24221Rear brake pads
Check each rear brake pad for damage and mea-
sure the lining thickness. If a brake pad is dam-
aged or if the lining thickness is less than 1.5 mm
(0.06 in), have a Yamaha dealer replace the brake
pads as a set.
EBU24261Checking the brake fluid level Insufficient brake fluid may allow air to enter the
brake system, possibly causing it to become inef-
fective.
Before riding, check that the brake fluid is above
the minimum level mark and replenish if neces-
sary. A low brake fluid level may indicate worn
brake pads and/or brake system leakage. If the
brake fluid level is low, be sure to check the brake
pads for wear and the brake system for leakage.
1. Brake pad
2. Lining thickness
1. Brake pad
2. Lining thickness
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8-39
8

As the brake pads wear, it is normal for the brake
fluid level to gradually go down. However, if the
brake fluid level goes down suddenly, have a
Yamaha dealer check the cause.EBU24290Changing the brake fluid Have a Yamaha dealer change the brake fluid at
the intervals specified in the NOTE after the peri-
odic maintenance and lubrication chart. In addi-
tion, have the oil seals of the master cylinders and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are dam-
aged or leaking.
Oil seals: Replace every two years.
Brake hoses: Replace every four years.EBU24390Checking the front brake lever free play The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever should have a
free play of zero mm (zero in) as shown. If the free
play is incorrect, have a Yamaha dealer check the
brake system.
WARNING
EWB02070Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:
Make sure the brakes operate smoothly and
that the free play is correct.
Make sure the brakes do not drag.
Make sure the brakes are not spongy. All air
must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These proceduresshould be performed by a Yamaha dealer.1. Brake lever free play
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8-40
8
EBU27140Adjusting the rear brake lever free play
and checking the brake pedal position The brake lever free play must be adjusted and
brake pedal position must be checked and, if nec-
essary, adjusted at the intervals specified in the
periodic maintenance and lubrication chart.NOTE:
Always perform this maintenance completely in
the following order whenever adjusting the rear
brake.
Before adjusting the brake lever free play and
checking the brake pedal position, check therear brake pads for wear.
Adjusting the brake lever free play
The brake lever free play should measure 0.5–2.0
mm (0.02–0.08 in) as shown. If the free play is in-
correct, adjust it as follows.1. Loosen the locknut.
2. Turn the brake lever free play adjusting bolt in
direction (a) to increase the free play, and in
direction (b) to decrease it.
1. Brake lever free play
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