Join Date: Apr 2010
Location: Near Austin, TX
Thanked 440 Times in 314 Posts
I think Jack gave you excellent suggestions for the cooling issue. Also, does the Grizzly have the heat kit installed? There are several components to this kit but the two biggies are a foam rubber insulation mat glued to the bottom of the gas tank (easily seen if you remove the tank cover plastic) and the "sharks gills" side panels. If either or both of these items is missing, it is worth getting them. The panels can be gotten new or from eBay (sometimes there available...sometimes you have to watch for a while). The insulation mat can either be purchased with a used gas tank or gotten new.
Since you don't know the complete history of this bike (you were already surprised by the oil), I'd do a careful once-over on the whole quad. Here are some suggested things to check / look for:
Any overly rusted pieces
Missing bolts, straps, and clamps
Check all the CV boots, ball joint boots and tie-rod boots. Also do some jerking on all of those to make sure they are not worn out or improperly tightened (the tie rod ends are known to get loose...best to pull the cotter pin, and verify torque then replace pin)
Oil leaks around all seals (front diff axle and drive shaft seals, rear drive axles and drive shaft, the seals where the middle drive shaft (inside the engine) comes out of the front and rear of the engine to connect with the drive shafts, seal on the shaft under the pull starter (just remove plastic cover then the pull starter / cover...you will probably find that needs cleaning inside as well)
Also, some maintenance items commonly overlooked:
Grease the front drive shaft. The U-joints need to be greased and the splined connectors also need grease. If you jack the front of the quad up, you can then remove the bolts that hold the front differential in place...pull the diff up a little and away from the engine. This should allow you to get the drive shaft out. Once out, it is a LOT easier to get to the zerk fittings on the U-joints and you can clean and grease the splined ends of the shaft as well as the connectors on the diff and engine that they mate with.
Same thing on the rear drive shaft...same procedure just no U-joints.
The OEM air filter sux! If it still has it, consider an upgrade...check my garage for a custom adapter to use a really nice clamp-on K&N that solves the possible leaking seal issue with the OEM design.
Clean & disconnect (in that order) every electrical connection you can find and, before putting it back together, put a glob of dielectric grease on every connection and also on the rubber seal.
Check the wheel bearings for looseness.
CVT cleaning and re-greasing...people are really bad about not doing this one and it's a good idea to verify everything in your CVT is OK (like the belt). Speaking of which, I strongly suggest using only genuine Yamaha belts.
Gotta make the drive to the casa but, if I think of anything else (likely), I'll post it up.
You got yourself an excellent machine...I love the hell out of my '02 660 and I am sure you will love yours too. Congrats on a great quad!
Mine: '02 660 now in custom Hammered Copper paint
Mods: Custom air box mod for big-o' clamp-on K&N, Dial-A-Jet, 26" BH 2.0's on ITP SS 106's, SuperTrapp IDSX exhaust, Maier fender flares, black Ricochet skids. Remote res. Works A-T Steelers shocks on all 4.
Hers: '04 660 LE (Ruby red)
Mods: same A/F mod, 1.5" billet spacers with BH 2.0's on stock wheels, Yami aluminum skids.
That which doesn't kill you, leaves scars to remind you not to do it again