Yamaha ATV Grizzly 660 Manual

The Yamaha ATV Grizzly 660 is a high-performance all-terrain vehicle featuring a 660cc liquid-cooled, 4-stroke, SOHC engine, Ultramatic automatic transmission with engine braking, On-Command 2WD/4WD with differential lock, independent double wishbone front suspension, IRS rear suspension, disc brakes, electric start, and a comprehensive instrument panel. Below are key sections for safety, features, operation, maintenance, specifications, and troubleshooting.

Features at a Glance

Key components: 660cc engine, Ultramatic transmission, On-Command 4WD system, independent suspension, digital instrument display, front and rear cargo racks.

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 (Front: 3.9 psi / 27 kPa, Rear: 3.4 psi / 24 kPa).
3. Check all fluid levels: engine oil, coolant, and brake fluid.
4. Test brakes and throttle for smooth operation.
5. Ensure lights, indicators, and horn are functioning.
6. Check for loose bolts, nuts, or any visible damage.

WARNING! Never operate the ATV if any component is damaged or malfunctioning. Always wear appropriate safety gear.

Controls and Instrument Panel

Familiarize yourself with all controls before operation.

Handlebar Controls (Left): Headlight dimmer switch, turn signal switch, horn button, 2WD/4WD/Diff Lock switch, auxiliary light switch (if equipped).

Handlebar Controls (Right): Electric start button, engine stop switch, throttle lever, front brake lever, parking brake lever.

Instrument Panel: Digital display shows speed, odometer, tripmeter, hour meter, fuel level, gear position (H, L, N, R, P), 4WD and differential lock indicators, warning lights (oil pressure, coolant temp, battery).

Foot Controls: Rear brake pedal (right), gear shift pedal (left: Forward/Neutral/Reverse/Low/High/Park).

Specifications

• Engine Type: 660cc liquid-cooled, 4-stroke, SOHC, 4-valve.
• Bore x Stroke: 102.0mm x 80.5mm.
• Compression Ratio: 9.2:1.
• Fuel System: Mikuni BSR40 carburetor.
• Ignition System: DC-CDI.
• Transmission: Ultramatic automatic V-belt with all-wheel engine braking.
• Drive System: Yamaha On-Command 2WD/4WD with differential lock.
• Suspension Front/Rear: Independent double wishbone / Independent rear suspension (IRS).
• Brakes Front/Rear: Dual hydraulic disc / Sealed hydraulic disc.
• Tires Front/Rear: AT25 x 8-12 / AT25 x 10-12.
• Dimensions (LxWxH): 83.1" x 46.5" x 49.4" (2110 x 1180 x 1255 mm).
• Ground Clearance: 11.0" (280 mm).
• Dry Weight: 600 lbs (272 kg).

Operation Procedures

Starting, riding, and stopping the ATV.

1. Starting: Sit on the ATV. Insert key, turn to ON. Ensure transmission is in Neutral (N). Pull choke if cold. Press brake lever, then press START button. Release choke as engine warms.
2. Driving: With engine running, press brake lever, select gear (H for High, L for Low, R for Reverse). Release brake and apply throttle gradually.
3. 4WD Operation: Use On-Command switch to select 2WD or 4WD. Engage differential lock only when needed for extreme traction and at low speeds.
4. Stopping: Release throttle, apply brakes evenly. Come to complete stop. Shift to Park (P) or Neutral (N). Engage parking brake on inclines.
5. Shut Down: Turn key to OFF. Remove key.

CAUTION! Always keep feet on footrests while moving. Avoid sudden throttle or brake applications.

Maintenance Schedule

Follow this schedule to maintain optimal performance and longevity. Refer to hour meter or odometer.

Basic Maintenance Tasks

Procedures for common maintenance items.

1. Engine Oil Change: Warm engine. Place drain pan under drain plug. Remove plug and drain oil. Replace filter. Reinstall plug. Refill with recommended oil (approx. 3.7 qts / 3.5 L). Check level with dipstick.
2. Air Filter Service: Remove seat and side panel. Remove air filter cover. Clean foam filter with solvent, dry, and re-oil. Replace paper element if damaged.
3. Spark Plug: Remove spark plug cap. Clean area. Use plug wrench to remove. Check gap (0.028-0.031 in / 0.7-0.8 mm). Install and torque to 13 ft-lb (18 Nm).
4. Tire Pressure: Check when cold. Adjust to specified pressures.

WARNING! Allow engine to cool before servicing. Use proper tools and Yamaha Genuine Parts.

Storage Guidelines

Proper storage prevents damage during periods of non-use.

1. Change engine oil and filter.
2. Fill fuel tank and add fuel stabilizer. Run engine for 5 minutes.
3. Remove spark plug, add a teaspoon of oil into cylinder, crank engine, reinstall plug.
4. Clean entire ATV thoroughly. Apply protectant to plastic and rubber.
5. Inflate tires to recommended pressure. Place on stands to relieve weight.
6. Disconnect battery negative terminal. Store battery in a cool, dry place and charge monthly.
7. Store in a cool, dry place, covered with a breathable cover.

Safety Information

Always follow these safety rules.

• Always wear an approved helmet, eye protection, gloves, long sleeves, long pants, and over-the-ankle boots.
• Never carry passengers. This ATV is designed for one operator only.
• Never operate on public roads or paved surfaces (unless crossing).
• Avoid excessive speed and be especially careful on difficult terrain.
• Never operate under the influence of alcohol or drugs.
• Complete a training course. Supervise riders under 16. This is an adult ATV.
• Read and understand the owner's manual completely before operation.

DANGER! Failure to follow instructions can result in severe injury or death. Ride responsibly.

Warranty & Support

Yamaha Motor Corporation, U.S.A. provides a limited warranty. See your dealer for details. For technical support, parts, or service, contact an authorized Yamaha ATV dealer. You can also visit www.yamahamotorsports.com or call Yamaha Customer Relations at 1-800-962-7926.

Troubleshooting

Note: For complex repairs, consult an authorized Yamaha service technician.

Service: 1-800-962-7926; www.yamahamotorsports.com