coolant level 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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5-3
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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8-6
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

8-24
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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8-25
8
NOTE:The coolant should be between the minimum andmaximum level marks.
3. If the coolant is at or below the minimum level
mark, remove panel D. (See page 8-8.)
4. Remove the reservoir cap, add coolant or dis-
tilled water to the maximum level mark, install
the reservoir cap, and then install the panel.
CAUTION:ECB00400
If coolant is not available, use distilled water
or soft tap water instead. Do not use hard wa-
ter or salt water since it is harmful to the en-
gine.
If water has been used instead of coolant, re-
place it with coolant as soon as possible,
otherwise the engine may not be sufficiently
cooled and the cooling system will not be
protected against frost and corrosion.
If water has been added to the coolant, have
a Yamaha dealer check the antifreeze con-
tent of the coolant as soon as possible, oth-
erwise the effectiveness of the coolant willbe reduced.
NOTE:
The radiator fan is automatically switched on or
off according to the coolant temperature in the
radiator.
1. Coolant reservoir cap
2. Maximum level mark
3. Minimum level mark
Coolant reservoir capacity (up to the maximum
level mark):
0.30 L (0.32 US qt) (0.26 Imp.qt)
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8-26
8

If the engine overheats, see page 8-55 for fur-ther instructions.EBU23601To change the coolant
WARNING
EWB01890Wait 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 place a thick rag over the cap
when opening. Allow any remaining pressureto escape before completely removing the cap.
1. Place the ATV on a level surface.
2. Remove panels E and F. (See page 8-8.)
3. Place a container under the engine, and then
remove the coolant drain bolt. (Use a trough
or a similar object as shown to prevent coolant
from spilling on the footrest.)
4. Remove the front carrier and panel C. (See
page 8-8.)
1. Coolant drain bolt
1. Trough
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8-27
8 5. Remove the radiator cap.
6. Remove panel D. (See page 8-8.)
7. Remove the coolant reservoir cap.
8. Disconnect the hose on the coolant reservoir
side, and then drain the coolant from the cool-
ant reservoir.9. After draining the coolant, thoroughly flush the
cooling system with clean tap water.
10. Replace the coolant drain bolt washer if it is
damaged, install the coolant drain bolt, and
then tighten it to the specified torque.
11. Connect the coolant reservoir hose.
12. Pour the recommended coolant into the reser-
voir to the maximum level mark, and then in-
stall the reservoir cap.
1. Radiator cap
1. Coolant reservoir hoseTightening torque:
Coolant drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
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8-28
813. Pour the recommended coolant into the radia-
tor until it is full.
CAUTION:ECB00400
If coolant is not available, use distilled water
or soft tap water instead. Do not use hard wa-
ter or salt water since it is harmful to the en-
gine.
If water has been used instead of coolant, re-
place it with coolant as soon as possible,
otherwise the engine may not be sufficiently
cooled and the cooling system will not be
protected against frost and corrosion.

If water has been added to the coolant, have
a Yamaha dealer check the antifreeze con-
tent of the coolant as soon as possible, oth-
erwise the effectiveness of the coolant willbe reduced.
14. Install the radiator cap, start the engine, let it
idle for several minutes, and then turn it off.
15. Remove the radiator cap to check the coolant
level in the radiator. If it is low, add sufficient
coolant until it reaches the top of the radiator,
and then install the radiator cap.
16. Start the engine, and then check for coolant
leakage.
NOTE:If any leakage is found, have a Yamaha dealercheck the cooling system.
17. Install the panels and the front carrier.EBU23660Cleaning the air filter element The air filter element should be cleaned at the in-
tervals specified in the periodic maintenance and
lubrication chart. Clean the air filter element more
frequently if you are riding in unusually wet or dusty
areas. Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol antifreeze con-
taining corrosion inhibitors for aluminum en-
gines
Coolant quantity:
Radiator capacity (including all routes):
1.80 L (1.90 US qt) (1.58 Imp.qt)
Coolant reservoir capacity (up to the maxi-
mum level mark):
0.30 L (0.32 US qt) (0.26 Imp.qt)
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8-56
8Engine overheating
WARNING
EWB02290Wait 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 pressure to escape before completely removing the cap.NOTE:If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the rec-ommended coolant as soon as possible.Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer check
and repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
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