check oil YAMAHA GRIZZLY 660 2007 Owners Manual

EBU17420
TABLE OF CONTENTS
SAFETY INFORMATION .............................. 1-1
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 2-1
DESCRIPTION .............................................. 3-1
Left view ...................................................... 3-1
Right view.................................................... 3-1
Controls and instruments ............................ 3-2
INSTRUMENT AND CONTROL
FUNCTIONS .................................................. 4-1
Main switch ................................................ 4-1
Indicator lights and warning light ................ 4-2
Multifunction display ................................... 4-4
Handlebar switches .................................... 4-6
Throttle lever ............................................ 4-11
Speed limiter ............................................ 4-12
Front brake lever ...................................... 4-12
Brake pedal and rear brake lever ............. 4-13
Drive select lever ...................................... 4-14
Recoil starter ............................................ 4-14
Fuel tank cap ............................................ 4-14
Fuel .......................................................... 4-15Fuel cock ..................................................4-16
Starter (choke) ..........................................4-17
Seat ..........................................................4-18
Storage compartment ...............................4-19
Front carrier ..............................................4-20
Rear carrier ...............................................4-20
Adjusting the front and rear shock
absorber assemblies ...............................4-20
Auxiliary DC jack .......................................4-21
PRE-OPERATION CHECKS ..........................5-1
Pre-operation check list ..............................5-1
Fuel .............................................................5-3
Engine oil ....................................................5-3
Final gear oil ...............................................5-3
Differential gear oil ......................................5-3
Coolant .......................................................5-3
Front and rear brakes .................................5-4
Throttle lever ...............................................5-5
Tires ............................................................5-5
Measuring the tire pressure ........................5-6
Tire wear limit .............................................5-7
Chassis fasteners .......................................5-7
Instruments, lights and switches .................5-7U2C661E0.book Page 1 Thursday, March 16, 2006 10:45 AM

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

3-1
3
EBU17680
DESCRIPTION
EBU17690Left view
EBU17700Right view
1. Radiator cap
2. Fuel tank cap
3. Fuel cock
4. Oil filter cartridge
5. Throttle stop screw
6. Fuses
7. Engine oil dipstick
8. Recoil starter
9. Coolant reservoir
10.Drive select lever box check hose
11.V-belt cooling duct check hose
1. Rear shock absorber assembly spring preload adjusting
ring
2. Spark arrester
3. Storage compartment and tool kit
4. Battery
5. Air filter case
6. Spark plug
7. Front brake fluid reservoir
8. Front shock absorber assembly spring preload adjusting
ring
9. Rear brake fluid reservoir
10.Brake pedal
11.V-belt case drain plug
U2C661E0.book Page 1 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
U2C661E0.book Page 1 Thursday, March 16, 2006 10:45 AM

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.
U2C661E0.book Page 3 Thursday, March 16, 2006 10:45 AM

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

8-6
8
26 Final gear oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√√
27 Cooling systemCheck coolant level and ATV for coolant leakage,
and correct if necessary.√√√√√
Replace coolant. Every 2 years
28*Moving parts and
cablesLubricate.√√√√
29*Drive select lever
safety system cableCheck operation and adjust or replace if neces-
sary.√√√
30*Throttle lever hous-
ing and cableCheck operation and correct if necessary.
Check throttle cable free play and adjust if neces-
sary.
Lubricate throttle lever housing and cable.√√√√√
31*Exhaust systemCheck for leakage and replace gasket(s) if neces-
sary.
Check for looseness and tighten all screw clamps
and joints if necessary.√√√
32 Spark arresterClean.√√√
33*Front and rear brake
switchesCheck operation and correct if necessary.√√√√√
34*Lights and switchesCheck operation and correct if necessary.
Adjust headlight beams.√√√√√ 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 6 Thursday, March 16, 2006 10:45 AM

8-17
8
NOTE:If a torque wrench is not available when installing
a spark plug, a good estimate of the correct torque
is 1/4–1/2 turn past finger tight. However, the spark
plug should be tightened to the specified torque assoon as possible.
4. Install the spark plug cap.
5. Install the panel.EBU23321Engine oil and oil filter cartridge The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter cartridge replaced at the intervals spec-
ified in the periodic maintenance and lubrication
chart.
To check the engine oil level
1. Remove panel F. (See page 8-8.)
2. Place the ATV on a level surface.
3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Wait a few minutes until the oil settles before
checking.
5. Remove the engine oil filler cap, and then
wipe the dipstick off with a clean rag.6. Insert the dipstick into the filler hole (without
screwing it in), and then remove it again to
check the oil level.
1. Engine oil filler cap
2. Dipstick
U2C661E0.book Page 17 Thursday, March 16, 2006 10:45 AM

8-21
8 13. Start the engine, and then let it idle for several
minutes while checking it for oil leakage. If oil
is leaking, immediately turn the engine off and
check for the cause.
14. Turn the engine off, and then check the oil lev-
el and correct it if necessary.
15. Install panel F.
EBU23410Changing the final gear oil The final gear case must be checked for oil leak-
age before each ride. If any leakage is found, have
a Yamaha dealer check and repair the ATV. In ad-
dition, the final gear oil must be changed as follows
at the intervals specified in the periodic mainte-
nance and lubrication chart.
1. Place the ATV on a level surface.
2. Place an oil pan under the final gear case to
collect the used oil.
3. Remove the final gear oil filler bolt and the fi-
nal gear oil drain bolt to drain the oil from the
final gear case.
4. Install the drain bolt, and then tighten it to the
specified torque.
1. Final gear oil filler bolt
1. Final gear oil drain bolt
U2C661E0.book Page 21 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)
U2C661E0.book Page 22 Thursday, March 16, 2006 10:45 AM