cooling YAMAHA GRIZZLY 660 2008 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 ....................................................... 6-6
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 chart for
the emission control system .....................8-3
General maintenance and
lubrication chart ........................................8-5
Removing and installing panels ..................8-9
Checking the spark plug ...........................8-16
Engine oil and oil filter cartridge ................8-18
Final gear oil .............................................8-22
Differential gear oil ....................................8-24
Coolant .....................................................8-26
Cleaning the air filter element ...................8-30
Cleaning the spark arrester ......................8-34
V-belt cooling duct check hose .................8-35
V-belt case drain plug ...............................8-35
Adjusting the carburetor ............................8-36
Adjusting the engine idling speed .............8-36
Adjusting the throttle cable free play .........8-37
Valve clearance ........................................8-38
Adjusting the drive select lever
safety system cable ................................8-38
Checking the front and rear brake pads ...8-38
Checking the brake fluid level ...................8-39
Changing the brake fluid ...........................8-41
Checking the front brake lever free play ...8-41U23D60E0.book Page 2 Thursday, March 15, 2007 7:59 PM

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 filler cap
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
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5-1
5
EBU19200
PRE-OPERATION CHECKS
EBU19221Pre-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 periodicmaintenance charts on page 8-3 to determine which service should be performed by a Yamaha 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, 8-18
Final gear oilCheck ATV for oil leakage. Correct if necessary. 5-3, 8-22
Differential gear oilCheck ATV for oil leakage. Correct if necessary. 5-3, 8-24
CoolantCheck coolant level in reservoir, and add recommended coolant to
specified level if necessary.
Check cooling system for leakage. Correct if necessary.5-3, 8-26
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, 8-38, 8-39, 8-41
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7-20
7
WARNING
EWB01640Never operate this ATV in fast flowing water or
in water deeper than that specified in your
Owner’s Manual. Remember that wet brakes
may have reduced stopping ability. Test your
brakes after leaving water. If necessary, apply
them several times to let friction dry out the lin-
ings. If the ATV is operated through deep or
fast flowing water, the tires may float, causing
loss of traction and loss of control, whichcould lead to an accident.Test your brakes after leaving the water. Do not
continue to ride your ATV without verifying that you
have regained proper braking ability.
CAUTION:ECB00270After riding your ATV in water, be sure to drain
the trapped water by removing the check hose
at the bottom of the air filter case, the V-belt
cooling duct check hose and the drive select
lever box check hose. Also, remove the V-belt
case drain plug to drain any water that may
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7-21
7 have accumulated. Wash the ATV in fresh wa-
ter if it has been operated in salt water or mud-
dy conditions.1. Air filter case check hose
1. V-belt cooling duct check hose (left front side of ATV)
1. Drive select lever box check hose
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8-7
8
EBU23070NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.20 Final gear oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√√
21 Cooling systemCheck coolant level and ATV for coolant leakage,
and correct if necessary.√√√√√
Replace coolant. Every 2 years
22*Moving parts and
cablesLubricate.√√√√
23*Drive select lever
safety system cableCheck operation and adjust or replace if neces-
sary.√√√
24*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.√√√√√
25*Front and rear brake
switchesCheck operation and correct if necessary.√√√√√
26*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)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320U23D60E0.book Page 7 Thursday, March 15, 2007 7:59 PM

8-27
8
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.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 8-9.)
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:ECB00401
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 cooling system will not be pro-
tected 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.
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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8-29
8 5. Remove the radiator cap.
6. Remove panel D. (See page 8-9.)
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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8-30
813. Pour the recommended coolant into the radia-
tor until it is full.
CAUTION:ECB00401
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 cooling system will not be pro-
tected 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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8-35
8 4. Insert the tailpipe into the muffler and align the
bolt holes.
5. Install and tighten the bolts.
WARNING
EWB02340Do not start the engine when cleaning the
spark arrester, otherwise it could cause injury
to the eyes, burns, carbon monoxide poison-
ing, possibly leading to death, and start a fire.
Always let the exhaust system cool prior totouching exhaust components.
EBU23920V-belt cooling duct check hose If dust or water collects in the V-belt cooling duct
check hose, remove the hose and clean it.EBU23930V-belt case drain plug After riding in water deep enough to allow it to en-
ter the V-belt case, remove this plug to drain the
water from the case.NOTE:If water drains from the V-belt case after removing
the plug, have a Yamaha dealer check the ATV asthe water may affect other engine parts.
1. Tailpipe
2. Spark arrester
1. V-belt cooling duct check hose (left front side of ATV)
U23D60E0.book Page 35 Thursday, March 15, 2007 7:59 PM