2006 Yamaha Grizzly 660 Manual

The 2006 Yamaha Grizzly 660 is a 4x4 all-terrain vehicle (ATV) featuring a 660cc liquid-cooled, 4-stroke, SOHC engine with 5 valves, Ultramatic automatic transmission with On-Command 2WD/4WD and differential lock, independent double wishbone front suspension, IRS rear suspension, disc brakes, electric start, and a towing capacity of 850 lbs. Below are key sections for safety, features, operation, maintenance, specifications, and troubleshooting.

1. Features at a Glance 2. Pre-Ride Inspection 3. Operation Instructions 4. Specifications 5. Controls and Indicators 6. Maintenance Schedule 7. Basic Maintenance Procedures 8. Storage Guidelines 10. Troubleshooting

Features at a Glance

Key components: 660cc engine, Ultramatic transmission, On-Command 2WD/4WD system, independent rear suspension, front and rear disc brakes, digital instrument panel.

FeatureDescription
Engine660cc liquid-cooled, 4-stroke, SOHC, 5-valve
TransmissionUltramatic automatic with engine braking
Drive SystemOn-Command 2WD/4WD with differential lock
Suspension FrontIndependent double wishbone, 7.1" travel
Suspension RearIndependent rear suspension (IRS), 9.5" travel
BrakesHydraulic disc front and rear
Fuel Capacity4.8 gallons
Towing Capacity850 lbs
InstrumentationDigital display with speedometer, odometer, tripmeter, hour meter, gear indicator, fuel gauge, 4WD indicator
Starting SystemElectric start with auxiliary recoil

Pre-Ride Inspection

Before each ride, perform a thorough inspection to ensure safe operation.

  1. Check fuel level and add fuel if necessary.
  2. Inspect tires for proper pressure and damage.
  3. Check all fluid levels (engine oil, coolant, brake fluid).
  4. Test brakes and throttle for proper operation.
  5. Ensure lights and indicators are functioning.
  6. Check for loose bolts or damaged components.

WARNING! Never operate an ATV without proper inspection. Failure to do so may result in accident or injury.

Operation Instructions

Starting and operating your Grizzly 660 safely.

  1. Starting: Sit on vehicle, apply parking brake, shift to Neutral (N), turn key ON, pull choke if cold, press start button.
  2. Driving: Release parking brake, select Drive (D) or Reverse (R) using shift lever, apply throttle gradually.
  3. On-Command System: Use switch to select 2WD, 4WD, or 4WD with differential lock. Do not engage differential lock on hard surfaces.
  4. Stopping: Release throttle, apply brakes evenly, shift to Neutral, apply parking brake, turn key OFF.

CAUTION! Always wear appropriate safety gear including helmet, eye protection, gloves, and boots. Never carry passengers.

Specifications

Controls and Indicators

Main controls located on handlebars and dashboard.

Left Handlebar: Headlight dimmer switch, turn signal switch, horn button, 2WD/4WD switch, differential lock switch.

Right Handlebar: Electric start button, engine stop switch, throttle lever, front brake lever.

Dashboard: Key switch, speedometer, odometer, tripmeter, fuel gauge, gear position indicator, 4WD indicator, differential lock indicator, warning lights (oil, coolant, battery).

Center Console: Shift lever (P-R-N-D-L), parking brake lever, choke knob, rear brake pedal.

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

ItemEvery 20 hrs/100 miEvery 100 hrs/500 miEvery 200 hrs/1000 mi
Engine oilCheckChangeChange
Oil filter-ReplaceReplace
Air filterCleanClean/ReplaceReplace
Spark plugCheckClean/ReplaceReplace
Brake fluidCheckChangeChange
Drive shaft oilCheckChangeChange
Wheel nuts/boltsTightenTightenTighten

Basic Maintenance Procedures

Essential maintenance tasks for the Grizzly 660 owner.

  1. Engine Oil Change: Warm engine, remove drain plug and filler cap, drain oil, replace filter, refill with 3.2 quarts of SAE 10W-30 Yamalube or equivalent.
  2. Air Filter Service: Remove seat, open airbox, clean foam filter with solvent, apply filter oil, reinstall.
  3. Spark Plug: Remove with spark plug wrench, check gap (0.028-0.031 in), clean or replace with NGK CR8E.
  4. Tire Pressure: Maintain 3.6 psi front, 3.6 psi rear for standard riding conditions.
  5. Battery: Check terminals for corrosion, maintain charge with battery tender during storage.

Tip: Always use genuine Yamaha parts or equivalents meeting Yamaha specifications.

Storage Guidelines

Proper storage prevents damage during periods of non-use.

  1. Clean ATV thoroughly, especially underside.
  2. Change engine oil and filter.
  3. Add fuel stabilizer to full tank, run engine for 5 minutes.
  4. Remove spark plug, add teaspoon of oil, crank engine, reinstall plug.
  5. Disconnect battery, store in cool dry place, maintain charge.
  6. Elevate ATV to keep tires off ground, cover with breathable cover.

CAUTION! Store in well-ventilated area away from open flames or sparks. Gasoline vapors are explosive.

Troubleshooting

SymptomPossible CauseCorrective Action
Engine won't startFuel, spark, batteryCheck fuel level and petcock; inspect spark plug; test battery voltage; ensure in Neutral.
Poor performanceAir filter, carburetorClean/replace air filter; check for clogged fuel filter; clean carburetor jets.
OverheatingCoolant, radiatorCheck coolant level; clean radiator fins; ensure water pump functioning.
Transmission slippingBelt wearInspect drive belt for wear/cracks; adjust belt tension if applicable.
Electrical issuesFuses, connectionsCheck all fuses; inspect wiring harness for damage; clean battery terminals.
Brakes weak/spongyAir in lines, pad wearBleed brake system; inspect brake pads for wear; replace if necessary.

Service: For complex issues, consult authorized Yamaha dealer. Use genuine Yamaha parts.

Support: Yamaha Customer Relations: 1-800-962-7926 or www.yamaha-motor.com

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