2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 Owners Manual
2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 Manual
2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 manual content summary:
- 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 1
READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER'S MANUAL YFM660FP WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-15-01 5KM-28199-10 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 2
EBU00776 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 3
- 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 4
- 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 5
of your ATV, please consult a Yamaha dealer. AN IMPORTANT SAFETY MESSAGE: G READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. G PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV. G NEVER - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 6
INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 7
manufacture. Please check your local riding laws and regulations before operating this machine. EBU00711 AFFIX DEALER LABEL HERE YFM660FP OWNER'S MANUAL © 2001 by Yamaha Motor Corporation, U.S.A. 1st Edition, March 2001 All rights reserved. Any reprinting or unauthorized use without the written - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 8
EBU00014 WARNING Indicates a potential hazard that could result in serious injury or death. 4 CONTENTS 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS...1-1 SAFETY INFORMATION...2-1 DESCRIPTION AND MACHINE IDENTIFICATION ...3-1 Identification number records...3-2 Key identification number - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 9
5 PRE-OPERATION CHECKS ...5-1 Front and rear brakes ...5-2 Fuel ...5-4 Engine oil ...5-6 Final gear oil...5-7 Differential gear oil ...5-7 Coolant...5-7 Throttle lever ...5-9 Fittings and Fasteners ...5-9 Lights...5-9 Switches...5-9 Tires ...5-10 How to measure tire pressure...5-12 Tire wear limit - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 10
8 PERIODIC MAINTENANCE AND ADJUSTMENT...8-1 Owner's manual and tool kit...8-1 Periodic maintenance/lubrication ...8-3 Panel removal and installation ...8-5 Engine ...8-51 Headlight beam adjustment...8-52 Tail/brake light bulb replacement...8-53 Troubleshooting ...8-54 Troubleshooting charts ...8-55 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 11
9 CLEANING AND STORAGE...9-1 A. Cleaning...9-1 B. Storage ...9-3 SPECIFICATIONS...10-1 NOISE REGULATION...11-1 MAINTENANCE RECORD ...12-1 ATV LIMITED WARRANTY ...13-1 YAMAHA EXTENDED SERVICE (Y.E.S.) ...14-1 10 11 12 13 14 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 12
EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1-1 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 13
Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. 1 2 WARNING - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 14
5 6 7 1-3 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 15
8 9 WARNING UNDER Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 5FE-21697-01 0 WARNING Turning the ATV in 4WD-LOCK("DIFF. LOCK") takes more effort. Operate at a slow speed and allow extra time - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 16
riding on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: G Read this manual and all labels carefully and follow the operating procedures described. G Never operate an ATV without proper training or - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 17
time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation. Always go slowly and be extra careful - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 18
sharply to one side. Go straight down the hill where possible. Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 19
. Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 20
WARNING POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 21
WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation. 2-6 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 22
Throttle lever Front brake lever Auxiliary DC jack NOTE: The machine you have purchased may differ slightly from those shown in the figures of this manual. 3-1 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 23
EBU00600 EBU00035 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 24
EBU00036 EBU00787 Vehicle identification number The vehicle identification number is stamped into the frame. Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 25
EBU00039 CONTROL FUNCTIONS 1 WARNING Indicates a potential hazard that could result in serious injury or death. EBU00041 2 3 4 5 6 1. Main switch Main switch Functions of the respective switch positions are as follows: ON: Engine can be started only at this position and the headlight and - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 26
EBU00802 EBU00839 Indicator and warning lights Differential gear lock indicator light "DIFF. LOCK" This indicator light comes on along with the differential gear lock indicator in the display when the differential gear lock switch is set to the "4WD-LOCK" position. EBU00838 Low-range indicator - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 27
EBU00867* EBU00884* Reverse indicator light "R" This indicator light comes on when the drive select lever is in the "R" reverse position. NOTE: If the indicator light flashes or the speedometer does not show the speed while riding, have a Yamaha dealer check the speed sensor circuit. _ _ Four- - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 28
EBU00860 Coolant temperature warning light " " When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 29
EBU00844* Speedometer unit G G a clock an hour meter (which shows the total time the key has been turned to "ON") 1. 3. 5. 6. Speedometer 2. Odometer/Tripmeter A/Tripmeter B Clock/Hour meter 4. TRIP/ODO button Clock/Hour " "/" " button "H" button 7. "M" button The speedometer unit is equipped - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 30
EBU00843 Clock mode Pushing the " "/" " button switches the display between the clock mode "CLOCK" and the hour meter mode "HOUR" in the following order. CLOCK→HOUR→CLOCK To set the clock 1. Push the " "/" " button for at least two seconds and the clock will start flashing. 2. Set the hours by - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 31
EBU00053 Handlebar switches CAUTION: Do not use the headlight with the engine turned off for more than thirty minutes. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. EBU00606 1. Light switch 2. - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 32
EBU00607 Start switch " " The starter motor cranks the engine when this switch is pushed. CAUTION: See starting instructions prior to starting the engine. (See page 6-1 for details.) 1. On-command four-wheel drive switch "2WD"/"4WD" 2. Differential gear lock switch "4WD"/"LOCK" EBU00842* On- - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 33
G G Four-wheel drive (4WD): Power is supplied to the rear and front wheels. Four-wheel drive with the differential gear locked (4WD-LOCK): Power is supplied to the rear and front wheels when the differential gear is locked ("DIFF.LOCK"). Unlike the 4WD mode, all wheels turn at the same speed. - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 34
1. Lever 2. On-command four-wheel drive switch "2WD"/"4WD" 1. Differential gear lock switch "4WD"/"LOCK" 2. Lever On-command four-wheel drive switch "2WD"/"4WD" To change from 2WD to 4WD, stop the ATV, and then set the switch to "4WD". When the ATV is in 4WD, the 4WD indicator " " will come on in - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 35
WARNING POTENTIAL HAZARD Riding too fast while the ATV is in 4WDLOCK. WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked, so it takes more effort to turn the ATV. The amount of effort is more the faster you go. You may lose control and have an accident if you cannot - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 36
HAZARD Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you can't find or solve the - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 37
EBU00066 Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV. WARNING POTENTIAL HAZARD Improper adjustment of the - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 38
EBU00070 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. 1. Rear brake pedal 1. Front brake lever EBU00073 Rear brake pedal and lever The brake pedal is located on the right side of the machine and the brake lever - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 39
EBU00608 Drive select lever The drive select lever is used to shift your machine into the low, high, neutral, reverse and park positions. (Refer to page 6-4 for the drive select lever operation.) 1. Drive select lever 4-15 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 40
EBU00855 Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out. WARNING POTENTIAL HAZARD Starting the engine without setting the drive select lever to the park position "P". WHAT CAN HAPPEN - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 41
EBU00092 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 1. Fuel tank cap 4-17 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 42
EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 43
EBU00095 RES Position 1. Arrow mark Starter (choke) " " Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to "Starting a cold - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 44
EBU00567 Seat 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. Seat 2. Seat - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 45
Storage compartment The storage compartment is located under the seat. (See page 4-20 for seat removal and installation procedures.) When storing the owner's manual or other documents in the storage compartment, be sure to wrap them in a plastic bag so that they will not get wet. When washing - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 46
EBU00856 Front and rear shock absorber adjustment The spring preload can be adjusted to suit the rider's weight and riding conditions. NOTE: When adjusting the rear shock absorbers, the rear wheels need to be removed. (See page 8-45 for removal and installation procedures.) _ _ Adjust the spring - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 47
WARNING POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting. 1. Special wrench - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 48
EBU00748 Auxiliary 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 can only be used when the main switch is in the "ON" position. 1. Auxiliary DC jack Maximum rated capacity - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 49
4. When the auxiliary DC jack is not being used, cover it with the cap. CAUTION: G G G 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 headlight turned - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 50
PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM Brakes Fuel Engine oil Coolant reservoir tank Final gear oil/ Differential gear oil Throttle Wheels and tires Fittings and Fasteners Lights Axle boots ROUTINE • Check operation, free play, fluid level and fluid leakage. - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 51
use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. Front and rear brakes 1. Brake levers and brake pedal Check for correct free play in the rear brake lever and that there is no free - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 52
accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have the ATV inspected by a Yamaha dealer. 5-3 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 53
content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems. CAUTION: _ Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 54
WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun. HOW TO AVOID THE HAZARD Do not overfill the - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 55
qt) YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 -20° -10° 0° 10° 20° 30° 40° 50°C Recommended engine oil classification: API Service SE, SF, SG type or higher 5-6 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 56
EBU00493 EBU00678 Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-16 ~ 8-17 for details.) Recommended oil: SAE 80 API GL-4 Hypoid gear oil If desired, an SAE 80W90 hypoid gear oil may be used for all conditions. NOTE: GL-4 is a quality and - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 57
CAUTION: _ WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always use a thick rag - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 58
and Fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. EBU00803 Lights Check the headlight and tail/brake light to make sure they are in working condition. Repair as - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 59
EBU00157 Tires WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of accident. - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 60
4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst. 5-11 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 61
EBU00159 How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set pressure - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 62
EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. 3 mm (0.12 in) 5-13 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 63
familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner's Manual carefully. If there is a control or function you do not understand, ask your Yamaha dealer. 6-1 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 64
NOTE: G When the drive select lever is in the neutral or park position, if either indicator light does not come on, ask a Yamaha dealer to inspect its electric circuit. G The engine can be started in any gear if the rear brake lever is applied. However, it is recommended to shift into neutral or - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 65
NOTE: G If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. G If the battery is - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 66
stop and return the throttle lever to the closed position. 2. Apply the brakes, then shift by moving the drive select lever along the shift guide. NOTE: Make sure that the drive select lever is completely shifted into position. _ _ 1. Drive select lever 3. Open the throttle lever gradually - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 67
rear brake pedal. 3. Shift from neutral to reverse or from reverse to park and vice versa by moving the drive select lever along the shift guide. 1. Drive select lever NOTE: G When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 68
5. Open the throttle lever gradually and continue to watch to the rear while backing. WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 69
EBU00210 Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 70
EBU00612 2. 10 ~ 20 hours: Avoid prolonged operation above 3/4 throttle. Rev the machine freely but do not use full throttle at any time. 3. After break-in: Avoid prolonged full throttle operation. Vary speeds occasionally. Parking When parking, stop the engine and shift the drive select lever - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 71
EBU00615 Parking on a slope WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the machine - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 72
EBU00221 Accessories and loading EBU00222 G Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. G Choose only accessories designed for your ATV. Your Yamaha dealer has a - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 73
EBU00231* Loading Cargo or a trailer can change the stability and handling of an ATV. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: G Never exceed the weight limits shown. An overloaded ATV can be unstable. MAXIMUM LOADING - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 74
G G G G Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Although conditions vary, it is good practice not to exceed low range whenever you are carrying heavier loads or when towing a trailer. Allow more braking distance. A heavier vehicle takes - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 75
EBU00956 WARNING _ Indicates a potential hazard that could result in serious injury or death. 6-13 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 76
Riding Your ATV 7 7-1 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 77
7-2 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 78
recreation. This section, Riding your ATV, provides general ATV riding instructions for recreational riding. The skills and techniques described in this begin to 7-3 ride, be sure you have read this Owner's Manual completely and understand the operation of the controls. Pay particular attention to - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 79
the course and the operating techniques described in this Owner's Manual. For more information about the training course, contact an authorized more difficult maneuvers. WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 80
Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 81
This machine is designed to carry operator and cargo only - passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/ or your passenger. HOW - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 82
Apparel WARNING Apparel POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 83
Do not operate after consuming alcohol or drugs. Operator's performance capability is reduced by the influence of alcohol or drugs. WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 84
. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner's Manual for this vehicle on pages . Always maintain proper tire pressure as described in the Owner's Manual on page 5-10. WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 85
WARNING _ Indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions. WHAT CAN HAPPEN Increases your chances of - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 86
ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking. Always follow the instructions in your Owner's Manual for carrying cargo or pulling a trailer. 7-11 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 87
During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 88
Avoid wheelies and jumping. You may lose control of the machine or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 89
added to this vehicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized ATV dealer. 7-14 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 90
Exhaust system The exhaust system on the machine is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the machine in a place where pedestrians or children are not likely to touch it. Do not touch the hot exhaust system. Do not park the machine in a - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 91
BE CAREFUL WHERE YOU RIDE This machine is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 92
Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 93
Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the machine to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 94
WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 95
When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the machine. DO NOT use the flag pole bracket as a trailer hitch. WHAT CAN HAPPEN You could be in a collision. You could be injured. HOW TO AVOID THE HAZARD Always mount a caution flag on the - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 96
is designed for off-road use only, and handling maneuvers are more difficult to perform on pavement. Shift to the parking position "P" and follow the instruction on page 6-1 to start the engine. Once it has warmed up you are ready to begin riding your ATV. Remember that the engine and exhaust - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 97
that this skill be learned first at low speed. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner's Manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the conditions - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 98
Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 99
CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 100
of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner's Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 101
AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner's Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. 7-26 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 102
When crossing the side of a hill: Always follow proper procedures as described in the Owner's Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. 7-27 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 103
If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 104
position "P". Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner's Manual. 7-29 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 105
RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you. For maximum engine compression braking effect, select low range - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 106
HAPPEN Could cause loss of control or cause the ATV to overturn. Always follow proper procedures for going down hills as described in this Owner's Manual. Note: a special technique is required when braking as you go down a hill. HOW TO AVOID THE HAZARD Always check the terrain carefully before you - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 107
AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner's Manual on level ground. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. When crossing the side of - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 108
7-33 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 109
an accident. HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner's Manual. 7-34 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 110
Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. CAUTION: _ After 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 and the check - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 111
1. V-belt cooling duct check hose (Left side) 1. Drive select lever box check hose 1. V-belt case drain plug 7-36 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 112
ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner's Manual. 7-37 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 113
SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 114
With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 115
WHAT TO DO IF ...This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. WHAT TO DO ...G If your ATV doesn't turn when you want it to: Bring - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 116
G G If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 117
dealer perform service if you are not familiar with machine service. EBU00562 WARNING POTENTIAL HAZARD Servicing an engine while performing maintenance unless otherwise specified. 8-1 Owner's manual and tool kit You are recommended to put this owner's manual in the vinyl bag and always carry it - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 118
The service information included in this manual is intended to provide you, the owner, with the necessary information designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an authorized Yamaha ATV dealer. 1 2 3 4 5 6 7 8 9 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 119
EBU00261 PERIODIC MAINTENANCE/LUBRICATION ITEM ROUTINE Whichever comes first mile (km) hours 200 (320) 20 INITIAL 750 (1,200) 75 1,500 (2,400) 150 EVERY 1,500 3,000 (2,400) (4,800) 150 300 Valves* Cooling system Spark plug Air filter Carburetor* Crankcase breather system* Exhaust system* Sparks - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 120
Check for cracks or damage. Check all chassis fittings and fasteners. Correct if necessary. * It is recommended that these items be serviced by a Yamaha dealer. ** Lithium-soap-based grease NOTE: • Recommended brake fluid: DOT 4 • Brake fluid replacement: 1. When disassembling the master cylinder - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 121
EBU00614 Panel removal and installation The panels illustrated need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a panel has to be removed or reinstalled. 4. Panel D 6. Panel F 5. Panel E 1. Panel A 3. Panel B 2. Panel C 8-5 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 122
EBU00879 Panels A and D To remove 1. Remove the seat. (See page 4-20 for seat removal and installation procedures.) 2. Pull outward on the area shown, and then pull upward as shown. 1. Panel D 1. Panel A 8-6 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 123
To install 1. Insert the panel projections in the numerical order shown in the illustration, and then push inward on the area shown. 2. Install the seat. 1. Panel D 1. Panel A 8-7 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 124
EBU00962 Panel B To remove Remove the bolts. To install Place the panel in the original position and install the bolts. CAUTION: _ When installing the panel, be sure not to pinch the cables or wires. _ 1. Panel B 2. Bolt (× 2) 8-8 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 125
EBU00873 Panel C To remove 1. Remove the front carrier by removing its stay covers at the rear, then by removing the bolts. 2. Remove the quick fasteners and pull the panel upward. 1. Bolt (× 2) 1. Front carrier stay cover (× 2) 1. Bolt (× 2) 8-9 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 126
To install 1. Place the panel in the original position and install the quick fasteners. 2. Install the front carrier by installing its bolts and tightening them to the specified torques, and then by installing the stay covers. Tightening torques: Carrier bolt: 19 Nm (1.9 m·kgf, 13 ft·lb) 1. Bolt ( - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 127
EBU00616 EBU00638 Panel E To remove Remove the bolts. To install Place the panel in the original position and install the bolts. Panel F To remove Pull outward on the areas shown. 1. Panel F 1. Panel E 2. Bolt (× 6) 8-11 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 128
EBU00847 To install Place the panel in its original position. Engine oil Oil level inspection 1. Remove panel F. (See page 8-11 for panel removal and installation procedures.) 2. Place the ATV on a level place and warm up the engine for several minutes. 3. Stop the engine. 4. Remove the dipstick - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 129
NOTE: Wait a few minutes until the oil level settles before checking. _ _ 5. The oil level should be between the maximum and minimum marks. If the level is low, fill the engine with sufficient oil to reach the specified level. Engine oil and oil filter cartridge replacement 1. Remove panels E and - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 130
5. Remove the oil filter by using an oil filter wrench. NOTE: An oil filter wrench is available at a nearby Yamaha dealer. _ _ 6. Install the drain bolt and tighten it to the specified torque. Tightening torque: Drain bolt: 30 Nm (3.0 m.kgf, 22 ft.lb) 1. Engine oil filter cartridge 2. Oil filter - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 131
9. Fill the engine with sufficient oil to reach the specified level. Install the dipstick and tighten it. Recommended oil: See page 10-2. Oil quantity: Total amount: 2.2 L (1.94 Imp qt, 2.33 US qt) Periodic oil change: 1.9 L (1.67 Imp qt, 2.01 US qt) With oil filter replacement: 2.0 L (1.76 Imp qt, - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 132
10. Start the engine and warm it up for several minutes. While warming up, check for oil leakage. If oil leakage is found, stop the engine immediately and check for the cause. 11. Install the panels. EBU00880 Final gear oil replacement Final gear oil The final gear case must be checked for oil - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 133
4. Install the drain bolt and tighten it to the specified torque. Tightening torque: Drain bolt (final gear case): 23 Nm (2.3 m·kgf, 16 ft·lb) 5. Fill the final gear case with oil. Recommended oil: See page 10-3. Oil quantity: Periodic oil change: 0.25 L (0.22 Imp qt, 0.26 US qt) Total amount: 0.30 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 134
EBU00706* Differential gear oil Differential gear oil measurement 1. Place the machine on a level place. 2. Remove the oil filler bolt and check the oil level. It should be up to the brim of the hole. If the level is low, add sufficient oil to raise it to the specified level. 3. Install the oil - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 135
4. Install the drain bolt and tighten it to the specified torque. Tightening torque: Drain bolt: 10 Nm (1.0 m·kgf, 7 ft·lb) 5. Fill the differential gear case with oil. Recommended oil: SAE 80 API "GL-4" Hypoid gear oil Oil quantity: Periodic oil change: 0.28 L (0.25 Imp qt, 0.3 US qt) Total amount: - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 136
EBU00771 Cooling system 1. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature. The coolant level should be between the maximum and minimum marks. _ 3. Remove the coolant reservoir cap, and then add coolant or distilled - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 137
EBU00887 NOTE: G If water is added, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible. G The radiator fan operation is completely automatic. It is switched on or off according to the coolant temperature in the radiator. _ _ Changing the coolant WARNING POTENTIAL - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 138
1. Place the ATV on a level surface. 2. Remove panels E and F. (See page 8-11 for panel removal and installation procedures.) 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.) - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 139
1. Radiator cap 1. Coolant reservoir drain hose 5. Remove the radiator cap. 6. Remove the coolant reservoir cap. 7. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir. 8. After draining the coolant, thoroughly flush the cooling system with - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 140
10. Install the coolant reservoir hose. 11. Pour the recommended coolant into the radiator until it is full. Recommended antifreeze: High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines. Antifreeze and water mixing ratio: 1:1 Total amount: 1.8 L (1.58 Imp qt, - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 141
EBU00862 Axle boots Check the protective boots for holes or tears. If any damage is found, have them replaced by a Yamaha dealer. 1. Rear axle boot (× 2 each side) 1. Front axle boot (× 2 each side) 8-25 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 142
EBU00864 Spark plug inspection Removal 1. Remove panel A. (See pages 8-6 ~ 8-7 for panel removal and installation procedures.) 2. Remove the spark plug cap. 1. Spark plug wrench 1. Spark plug cap 3. Use the spark plug wrench in the tool kit to remove the spark plug as shown. 8-26 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 143
insulator around the center electrode is a mediumto-light tan color for a ATV that is being ridden normally. Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 144
Tightening torque: Spark plug: 17.5 Nm (1.75 m·kgf, 12.5 ft·lb) NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible. _ _ - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 145
EBU00792 Air filter element cleaning NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. _ _ 1. Clip (× 5) 2. Air filter case cover 3. Remove the air filter element and - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 146
WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element. 5. Squeeze the excess solvent out - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 147
7. Apply Yamaha foam air filter oil or other quality foam air filter oil to the element. If foam air filter oil is not available, motor oil may be used. NOTE: The element should be wet but not dripping. _ _ 8. Pull the element over its frame. 9. Install the element assembly. NOTE: The air filter - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 148
EBU00455 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolt. 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, then use a wire brush to remove any carbon deposits from the spark arrester - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 149
EBU00874* WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 150
EBU00296 V-belt case drain plug After riding in water deep enough to allow it to enter the V-belt case, remove this plug to drain the water from the case. NOTE: If a lot of water drains from the V-belt case after removing the plug, have a Yamaha dealer inspect the ATV as the water may affect other - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 151
fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician. - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 152
EBU00307 EBU00312 Throttle lever adjustment NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play is 3 ~ 5 mm (0.12 ~ 0.20 in). 3. Tighten the locknut. Front brake pad inspection - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 153
EBU00878 EBU00875 Rear brake pad inspection Inspect the brake pads for damage and wear. If the thickness is less than the specified value, have a Yamaha dealer replace the pads. Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system, possibly causing the - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 154
FRONT Observe these precautions: 1. When checking the fluid level, make sure the top of the master cylinder reservoir is level by turning the handlebars. 2. Use only the designated quality brake fluid. Otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 155
. If not, ask a Yamaha dealer to adjust it. Brake fluid replacement 1. Complete fluid replacement should be done only by trained Yamaha service personnel. 2. Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking. G Replace all rubber - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 156
adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: G Make sure the brakes operate smoothly and that the free play is correct. G Make sure the brakes do not drag. G Make sure the brakes are - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 157
2. Turn the adjusting bolt in direction a to increase free play, and in direction b to decrease free play. 3. Tighten the locknut. If correct free play cannot be obtained, ask a Yamaha dealer to make that adjustment. NOTE: When adjusting the rear brake lever free play: G Be sure not to step on the - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 158
adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: sure the brakes operate G Make smoothly and that the free play is correct. G Make sure the brakes do not drag. G All air must be bled - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 159
EBU00356 EBU00717 Cable inspection and lubrication WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 160
EBU00877 Rear wheel upper and lower knuckle lubrication Lubricate the upper and lower wheel knuckles. 1. Upper knuckle 2. Lower knuckle Recommended lubricant: Lithium-soap-based grease 8-44 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 161
EBU00373 EBU00828* Wheel removal 1. Elevate the wheel by placing a suitable stand under the frame. 2. Remove the nuts from the wheel. 3. Remove the wheel assembly. Wheel installation When installing a wheel, reverse the removal procedure. NOTE: The arrow mark on the tire must point toward the - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 162
1. Tapered wheel nuts are used for both front and rear wheels. Install the nut with its tapered side towards the wheel. 1. Tapered nut 2. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 55 Nm (5.5 m·kgf, 40 ft·lb) Rear: 55 Nm (5.5 m·kgf, 40 ft·lb) 8-46 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 163
EBU00380 Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a Yamaha dealer. CAUTION: Do not try to remove the sealing caps of the battery cells. - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 164
EBU00385 Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. CAUTION: A special battery charger (constant voltage/ampere or constant voltage) is required for - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 165
EBU00876 Fuse replacement 1. The main fuse case and the fuse box are located under the seat. 2. If a fuse is blown, turn off the main switch and install a new fuse of the specified amperage. Then turn on the switches. If the fuse immediately blows again, consult a Yamaha dealer. 1. 3. 5. 7. 9. Main - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 166
WARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse. CAUTION: _ To prevent - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 167
EBU00961 Replacing the headlight bulb If the headlight bulb burns out, replace it as follows: 1. Remove the cover at the rear of the headlight. 1. Bulb holder cover 3. Remove the bulb holder by turning it counterclockwise. 1. Cover 2. Remove the bulb holder cover. 8-51 1. Bulb holder - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 168
EBU00409 4. Remove the defective bulb by pushing it in and turning it counter clockwise. Headlight beam adjustment WARNING POTENTIAL HAZARD The headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 169
EBU00861 Tail/brake light bulb replacement 1. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 1. Bulb holder 2. Bulb 1. Bulb holder 2. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 3. Install a new bulb in - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 170
trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting , but they are often inferior. Consequently, they have a shorter service life and can lead to expensive repair bills. WARNING POTENTIAL HAZARD - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 171
EBU00806 Troubleshooting charts Starting problems or poor engine performance Turn the fuel cock lever to "ON". There is fuel. 1. Fuel Check if there is fuel in the fuel tank. Some - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 172
Engine overheating WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always use a - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 173
EBU00419 CLEANING AND STORAGE ¯ CAUTION: Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 174
6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 175
EBU00530 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 176
7. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)). NOTE: Make any necessary repairs before storing the machine. 9-4 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 177
EBU00428 SPECIFICATIONS Model Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Starting system - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 178
20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 4 40° 50°C -20° -10° 0° 10° 20° 30° 5 6 7 8 9 10 11 12 Recommended engine oil classification API Service SE, SF, SG type or higher CAUTION: Be sure to use motor oils that do not contain antifriction modifiers. Passenger car motor oils (often - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 179
Model Final gear case oil: Type Quantity: Periodic oil change Total amount Differential gear case oil: Type Quantity: Periodic oil change Total amount Air filter: Fuel: Type Fuel tank capacity Fuel reserve amount Carburetor: Type / quantity Manufacturer YFM660FP SAE80 API "GL-4" Hypoid gear oil 0. - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 180
Model Spark plug: Type/manufacturer Spark plug gap Clutch type Transmission: Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Reverse gear Sub transmission ratio Chassis: Frame type Caster angle Trail Tire: Type Size YFM660FP DPR8EA-9 / NGK - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 181
Model Brake: Front brake Rear brake Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery capacity Headlight type: type operation type - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 182
Model Bulb voltage, wattage × quantity: Headlight Brake/tail light Indicator light: Neutral indicator light Reverse indicator light Coolant temperature warning light Park position indicator light High gear position indicator light Low gear position indicator light Differential gear lock indicator - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 183
EBU00430 1- NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 184
,200 km) or 1,200 hours 13,500 mi (21,600 km) or 1,350 hours 15,000 mi (24,000 km) or 1,500 hours DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS 5 6 7 8 9 10 11 12 13 14 12-1 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 185
EBU00432 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY 13-1 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 186
1 2 3 4 5 6 7 8 9 10 11 12 13 14 13-2 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 187
EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.) 14-1 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 188
1 2 3 4 5 6 7 8 9 10 11 12 13 EBU00436 14 WARNING _ Indicates a potential hazard that could result in serious injury or death. 14-2 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 189
EBU00437 - 2002 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 190
with a passenger-passengers affect balance and steering and increase risk of losing control. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. (For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 · 4 - 9.0 × 2 CR
5KM-28199-10
LIT-11626-15-01
READ THIS MANUAL CAREFULLY!
It contains important safety information.
This ATV should not be ridden by anyone under 16 years of age.
WARNING
YFM660FP
OWNER’S MANUAL