2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 Owners Manual
2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 Manual
2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 manual content summary:
- 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 1
READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER'S MANUAL YFM660FS WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-17-14 5KM-28199-12 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 2
EBU00776 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 3
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 4
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 5
of manufacture. Please check your local riding laws and regulations before operating this machine. EBU00981 AFFIX DEALER LABEL HERE YFM660FS OWNER'S MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. 1st edition, March 2003 All rights reserved. Any reprinting or unauthorized use without the written - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 6
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 7
5 PRE-OPERATION CHECKS ...5-1 Front and rear brakes ...5-3 Fuel ...5-5 Engine oil ...5-7 Final gear oil...5-7 Differential gear oil ...5-8 Coolant...5-9 Throttle lever ...5-10 Fittings and fasteners...5-10 Lights...5-10 Switches...5-10 Tires ...5-11 How to measure tire pressure...5-13 Tire wear - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 8
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 ...8-51 Headlight beam adjustment...8-52 Tail/brake light bulb replacement ...8-53 Troubleshooting ...8-53 Troubleshooting charts ...8-55 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 9
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 10
EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1-1 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 11
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 12
5 6 7 1-3 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 13
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 14
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 15
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 16
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 17
. 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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 18
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 19
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 20
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 21
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 22
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 23
EBU00039 CONTROL FUNCTIONS 1 WARNING Indicates a potential hazard that could result in serious injury or death. EBU00942 2 3 4 5 6 1. Main switch Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights and - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 24
EBU00802 EBU01130 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 "LOCK-4WD" position. EBU01122 Low-range indicator - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 25
EBU00867 EBU01131 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-wheel- - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 26
EBU00860 EBU01132 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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 27
G G a clock an hour meter (which shows the total time the key has been turned to "ON") Odometer and tripmeter modes Pushing the "TRIP/ODO" button switches the display between the odometer mode "ODO" and the tripmeter modes "A" and "B" in the following order: ODO→TRIP A→TRIP B→ODO To reset a - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 28
EBU00843 EBU00053 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank. The display segments of the fuel gauge disappear towards "E" (Empty) as the fuel level decreases. When the "E" segment disappears and the fuel level warning indicator flashes, set the fuel cock to reserve - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 29
when the engine stop switch is set to " ". 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.) 4-7 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 30
1. Override switch "OVERRIDE" EBU13781 Override switch "OVERRIDE" Top speed is normally limited when operating in 4WD-LOCK. If conditions require more engine power when riding forward, push and hold this switch to override the 4WD-LOCK speed limiting function. (See page 4-11 for a detailed - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 31
WARNING POTENTIAL HAZARD Riding too fast while the ATV is in 4WD-LOCK. 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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 32
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. - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 33
1. Lever 2. On-command four-wheel drive switch "2WD"/"4WD" 1. Differential gear lock switch "LOCK"/"4WD" 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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 34
WARNING POTENTIAL HAZARD Riding too fast while the ATV is in 4WD-LOCK. 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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 35
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 36
EBU11590 Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. WARNING POTENTIAL HAZARD Improper adjustment - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 37
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 38
EBU00608 EBU00855 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.) Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt. Then - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 39
EBU00092 WARNING POTENTIAL HAZARD Starting the engine without setting the drive select lever to the park position "P". WHAT CAN HAPPEN The ATV could start to move unexpectedly, which could cause an accident. HOW TO AVOID THE HAZARD Set the drive select lever to the park position before starting the - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 40
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 41
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 42
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 43
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 44
EBU01124 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 pages 8-46-8-47 for removal and installation procedures.) _ _ Adjust the - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 45
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 46
EBU01002 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 should only be used when the engine is running. 1. Auxiliary DC jack Maximum rated capacity for the - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 47
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 headlights - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 48
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 and switches Axle boots ROUTINE • Check operation, free play, fluid level and - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 49
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. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 5-2 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 50
EBU00854 Front and rear brakes Brake levers and brake pedal Check for correct free play in the brake levers and brake pedal. If the free play is incorrect, adjust it. (See pages 8-41-8-42.) Check the operation of the brake levers and brake pedal. They should move smoothly and there should be a firm - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 51
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. 5-4 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 52
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 internal engine parts, such as the valves and - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 53
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 54
EBU10842 EBU00493 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See page 8-12.) CAUTION: _ Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-17- 8-18 for details.) Recommended oil: SAE 80 API GL-4 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 55
EBU00678 Differential gear oil Make sure the differential gear oil is at the specified level. Add oil as necessary. (See pages 8-19-8-20 for details.) Recommended oil: SAE 80 API GL-4 Hypoid gear oil 5-8 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 56
EBU12530 Coolant Check the coolant level in the coolant reservoir when the engine is cold. (The coolant level will vary with engine temperature.) The coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir. If the coolant level is at or below the - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 57
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. EBU10030 Lights Check the headlights and tail/brake light to make sure they are in working condition. Repair as - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 58
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. - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 59
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. 5-12 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 60
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 61
EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. Tire wear limit 5-14 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 62
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 63
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 64
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 65
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 66
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 67
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 68
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 69
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 into - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 70
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 71
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 72
EBU00960 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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 73
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 74
EBU00956 WARNING _ Indicates a potential hazard that could result in serious injury or death. 6-13 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 75
Riding Your ATV 7 7-1 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 76
7-2 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 77
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 78
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 79
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 80
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 81
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. - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 82
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 83
. 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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 84
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 85
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 86
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 87
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. - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 88
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 89
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 90
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 91
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 92
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 93
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, - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 94
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 95
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 96
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 97
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 98
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 99
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 100
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 101
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 102
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 103
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 104
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 105
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 106
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 107
7-33 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 108
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 109
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 110
1. V-belt cooling duct check hose (Left side) 1. Drive select lever box check hose 1. V-belt case drain plug 7-36 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 111
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 112
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 113
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 114
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 115
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 116
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 117
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 118
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 element Carburetor* Crankcase breather system* Exhaust system* - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 119
fasteners* • Correct if necessary. • Check operation. Lights and switches* • Adjust headlight beam. * 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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 120
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 121
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 122
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 123
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 124
EBU01141 Panel C To remove 1. Remove the front carrier by removing the stay covers at the rear, then by removing the bolts. 2. Remove the quick fasteners and pull the panel upward. 1. Bolt (× 2) (TOP) 1. Front carrier stay cover (× 2) 1. Bolt (× 2) (TOP) 8-9 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 125
To install 1. Place the panel in the original position and install the quick fasteners. 2. Install the front carrier by installing the bolts and tightening them to the specified torques. Tightening torques: Carrier bolt (top): 26 Nm (2.6 m·kgf, 19 ft·lbf) Carrier bolt (under fenders): 7 Nm (0.7 m· - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 126
EBU01013 EBU00638 Panel E To remove Remove the bolts, and then take the panel off. To install Place the panel in the original position, and then install the bolts. Panel F To remove Pull outward on the areas shown. 1. Panel F 1. Panel E 2. Bolt (× 6) 8-11 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 127
EBU10991 To install Place the panel in its original position. Engine 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 specified in the periodic maintenance and - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 128
5. Remove the engine oil filler cap and wipe off the dipstick with a clean rag. 6. Insert the dipstick in the oil filler hole (without screwing it in), and then remove it again to check the oil level. NOTE: The engine oil should be between the minimum and maximum level marks. _ _ 1. Engine oil - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 129
7. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. 8. Insert the dipstick into the oil filler hole, and then tighten the oil filler cap. 9. Install the panel. To change the engine oil (with or without oil filter - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 130
NOTE: Skip steps 5-9 if the oil filter cartridge is not being replaced. _ _ 7. Apply a light coat of engine oil to the O-ring of the new oil filter cartridge. NOTE: Make sure the O-ring is seated properly. _ _ 5. Remove panel D. (See pages 8-6-8-7 for panel removal and installation procedures.) 6. - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 131
8. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. 9. Install panel D. 10. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 30 Nm (3.0 m·kgf, 22 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 132
EBU00880 CAUTION: _ G G _ In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of "CD" or oils of a higher quality than specified. In addition, do not use oils labeled "ENERGY - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 133
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 L (0.26 Imp qt, 0.32 US qt) CAUTION: 1. Final gear oil drain bolt _ 4. Install the drain bolt and tighten it to the specified torque. Tightening torque: Drain bolt (final gear - 2004 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 - 2004 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, 7.2 ft·lbf) 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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 136
EBU12560 Cooling system 1. Place the ATV on a level surface. 2. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature. NOTE: The coolant should be between the minimum and maximum level marks. _ _ 3. If the coolant is at or - 2004 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 - 2004 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 pages 8-11-8-12 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 - 2004 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 - 2004 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, - 2004 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) 8-26 - 2004 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. 8-27 - 2004 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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 144
Installation 1. Measure the electrode gap with a wire thickness gauge and, if necessary, adjust the gap to specification. Spark plug gap: 0.8-0.9 mm (0.031-0.035 in) _ Tightening torque: Spark plug: 17.5 Nm (1.75 m·kgf, 12.5 ft·lbf) NOTE: If a torque wrench is not available when you are installing - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 145
EBU12110 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. Holder (× 5) 2. Air filter case cover 3. Remove the air filter element. 1. - 2004 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. 6. Squeeze the excess solvent out - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 147
8. Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter element. If foam air filter oil is not available, engine oil may be used. NOTE: The air filter element should be wet but not dripping. _ _ 12. Install the seat. NOTE: The air filter element should be cleaned - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 148
EBU01066 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark - 2004 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: - 2004 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 water drains from the V-belt case after removing the plug, have a Yamaha dealer inspect the ATV as the water may affect other engine - 2004 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. - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 152
EBU00307 EBU13090 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 check Check the - 2004 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 - 2004 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. - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 155
the cause if the brake fluid level goes down. Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel. Have a Yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking. G Replace the oil seals - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 156
check the brake system. WARNING POTENTIAL HAZARD Operating with improperly serviced or 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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 157
EBU00963 Rear brake lever and pedal adjustment Rear brake lever free play adjustment The rear brake lever free play should be 0.5- 2 mm (0.02-0.08 in). 1. Loosen the locknut. 2. Turn the adjusting bolt in direction a to increase free play, and in direction b to decrease free play. 3. Tighten the - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 158
Rear brake pedal height adjustment NOTE: Adjust the rear brake before inspecting the rear brake pads. _ _ WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 159
EBU00834 EBU00356 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and brake levers, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. Turn the - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 160
EBU00717 Brake lever and brake pedal lubrication Lubricate the pivoting parts. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 8-45 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 161
EBU13110 EBU01112 Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun. Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. 1. Upper - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 162
EBU01121 Wheel installation 1. Install the wheel and the nuts. NOTE: G Tapered nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel. G The arrow mark on the tire must point toward the rotating direction of the wheel. _ _ 1. Tapered nut 2. Lower - 2004 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. - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 164
EBU00385 EBU00876 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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 165
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. 1. 3. 5. 7. 9. Main fuse - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 166
EBU01125 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the bulb holder cover at the rear of the headlight by pulling it off. 1. Bulb holder cover 2. Remove the headlight bulb holder by turning it counterclockwise. 1. Cover 8-51 1. Bulb holder - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 167
EBU01089 3. Remove the defective bulb by pushing it in and turning it counterclockwise. Headlight beam adjustment WARNING POTENTIAL HAZARD A 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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 168
the tail/brake light bulb burns out, have a Yamaha dealer replace it. Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 169
WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe injury or property damage. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system. Make sure there are no open flames or sparks in the area, - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 170
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 171
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 172
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 173
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 174
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 175
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 176
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 177
SAE 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: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 178
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 YFM660F SAE80 API "GL-4" Hypoid gear oil 0.25 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 179
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 YFM660F DPR8EA-9 / NGK - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 180
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 181
Model Bulb voltage, wattage × quantity: Headlight Tail/brake light Indicator light: Neutral indicator light Reverse indicator light Coolant temperature warning light Park indicator light High-range indicator light Low-range indicator light Differential gear lock indicator light Fuses: Main fuse - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 182
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 183
,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 12-1 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 184
EBU00432 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY 13-1 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 185
1 2 3 4 5 6 7 8 9 10 11 12 13 14 13-2 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 186
EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.) 14-1 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 187
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 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 188
EBU00437 - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 189
. 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) NEVER operate: YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN - 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 190
- 2004 Yamaha Motorsports Grizzly 660 Auto. 4x4 | Owners Manual - Page 191
5KM-28199-12
LIT-11626-17-14
READ THIS MANUAL CAREFULLY!
It contains important safety information.
This ATV should not be ridden by anyone under 16 years of age.
WARNING
YFM660FS
OWNER’S MANUAL