Yamaha YFM660 Grizzly 2002-2007 ATV Service Repair Manual

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Art.-Nr: 86195

Stichworte: 2002 2003 2004 2005 2006 2007 ATV Grizzly Models Powersports Yamaha YFM660 Grizzly

Produktvarianten

Beschreibung

This manual covers the YFM660 Grizzly All-Terrain Vehicle (ATV), specifically the first generation models produced between 2002 and 2007, identified by model codes YFM660F and YFM660FG. Renowned for its powerful 660cc liquid-cooled engine, automatic Ultramatic® transmission with engine braking, and true 4WD system with differential lock, the YFM660 Grizzly established itself as a benchmark in the utility ATV segment. Its robust construction, comfortable ride, and significant towing capacity make it a capable machine for a wide range of off-road applications. The legacy in ATV innovation is evident in the key features of this model, including its substantial horsepower and torque, and its durable design for demanding terrains. This comprehensive service repair manual in English provides essential information for owners, DIY mechanics, and professional technicians. It details routine maintenance procedures, such as oil changes, filter replacements, and valve adjustments, alongside in-depth repair instructions for all major systems. Coverage includes the engine, fuel, drivetrain, electrical, suspension, braking, and steering systems, with specific guidance on troubleshooting common issues and understanding technical specifications. With approximately 300-400 pages of illustrated step-by-step instructions and detailed diagrams, this manual is designed to facilitate efficient maintenance and repair, ensuring the optimal performance and longevity of your YFM660 Grizzly.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

YFM660 Grizzly

Vehicle Type:

All-Terrain Vehicle (ATV)

Generation

Generation:

First Generation

Codes

Model Codes Covered:

YFM660F, YFM660FG

👋 Introduction

Market Position

Target User:

Owners, DIY mechanics, and professional service technicians seeking detailed repair and maintenance information for the Yamaha YFM660 Grizzly.

Competitive Analysis

Value Proposition:

Provides essential, manufacturer-level technical data, enabling cost-effective maintenance and repair compared to dealership services. Crucial for maintaining optimal performance and longevity.

Key Features

Manual Features:

Illustrated step-by-step instructions, detailed diagrams, troubleshooting flowcharts, and comprehensive technical specifications.

📋 Manual Details

Coverage Areas

Model Years Covered:

2002, 2003, 2004, 2005, 2006, 2007

Page Count

Estimated Page Count:

Approx. 300-400 pages (typical for comprehensive service manuals of this era)

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine disassembly, assembly, troubleshooting, lubrication, cooling, valve adjustments, piston/cylinder inspection, camshaft timing, carburetor overhaul and adjustment, decompression system.

Fuel System:

Fuel tank, fuel pump, fuel lines, carburetor (Mikuni BSR42), fuel filter, fuel shut-off valve.

Drivetrain System:

Automatic transmission (V-belt type), clutch (drive and driven), gear shift mechanism, drive shafts, differentials (front and rear), wheel hubs.

Electrical System:

Ignition system (CDI), starter motor, charging system (stator, rectifier/regulator), battery, lighting (headlights, taillights, brake lights), wiring diagrams, switches, fuses, diagnostics.

Suspension System:

Front and rear suspension components, shock absorbers, springs, A-arms, bushings, bearings, alignment procedures.

Braking System:

Front and rear hydraulic disc brakes, brake calipers, master cylinders, brake lines, brake pads, brake fluid specifications and bleeding procedures.

Steering System:

Handlebar, steering shaft, tie rods, ball joints, knuckle assembly, steering system troubleshooting.

Frame And Body:

Frame inspection, body panels (fenders, plastics), seat, racks, storage compartments, mounting hardware.

Cooling System:

Radiator, cooling fan, coolant types and capacities, thermostat, hoses, water pump.

Procedures Included

Maintenance Procedures:

Regular service checks, oil changes, filter replacements, lubrication points, spark plug replacement, air filter cleaning/replacement, valve clearance checks, brake pad inspection/replacement, chain adjustment (if applicable on specific models).

Repair Procedures:

Complete engine rebuild, transmission overhaul, carburetor tuning and repair, suspension component replacement, brake system bleeding and repair, electrical component testing and replacement, starter motor repair, carburetor jetting.

Troubleshooting Guides:

Step-by-step diagnostic charts for common problems related to starting, running, electrical issues, braking, and drivetrain performance.

Technical Specifications Charts:

Detailed torque specifications, clearances, fluid capacities, electrical resistance values, and engine timing parameters.

Technical Depth

Depth Of Coverage:

Comprehensive from basic routine maintenance and adjustments to complete engine and transmission overhauls, including electrical system diagnostics and component-level repair.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Print Quality

Image Resolution:

High-resolution scans suitable for clear viewing and printing of diagrams and text.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Searchability

Text Searchability:

Likely text-searchable within the PDF for quick information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, 5-valve, liquid-cooled

Displacement:

660 cc

Bore X Stroke:

95.0 mm x 93.2 mm

Compression Ratio:

8.1:1

Carburetor:

Mikuni BSR42 (Constant Velocity)

Ignition:

CDI (Capacitor Discharge Ignition)

Oil Type:

Yamalube 4 (or equivalent SAE 10W-40 API SG or higher)

Oil Capacity:

Approx. 2.2 L (with oil filter change)

Performance

Horsepower Approx:

Approx. 40-45 HP (Figures vary slightly by region and specific model year tuning)

Torque Approx:

Approx. 50-55 Nm (Figures vary slightly by region and specific model year tuning)

Fuel System

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Fuel Tank Capacity:

15.0 L (including reserve)

🔧 Transmission

Standard

Transmission Type:

Automatic (Yamaha Ultramatic® Transmission - CVT)

Drive System:

Shaft drive, 4WD with differential lock

Gear Reduction:

High, Low, Neutral, Reverse, Park

Features

Belt Type:

V-belt

Clutch Type:

Centrifugal automatic clutch

Transmission Fluid:

Yamalube Gear Oil SAE 80 (or equivalent API GL-4)

Transmission Fluid Capacity:

Approx. 0.2 L

📐 Dimensions

Exterior

Overall Length:

2,065 mm (81.3 in)

Overall Width:

1,120 mm (44.1 in)

Overall Height:

1,170 mm (46.1 in)

Wheelbase:

1,280 mm (50.4 in)

Ground Clearance:

260 mm (10.2 in)

Weights

Dry Weight:

262 kg (578 lbs)

Curb Weight:

N/A (Typically published as dry weight)

Front Rack Capacity:

40 kg (88 lbs)

Rear Rack Capacity:

80 kg (176 lbs)

Towing Capacity:

500 kg (1102 lbs)

Trailer Tongue Weight:

50 kg (110 lbs)

🛡️ Safety Features

Ratings

Atv Safety Considerations:

While no formal crash ratings like cars exist, the manual emphasizes safe operating practices, proper protective gear, and adherence to load capacities.

Active Features

Active Safety Features:

Engine braking, durable 4WD system with differential lock for enhanced traction, responsive hydraulic disc brakes.

Passive Features

Passive Safety Features:

Robust frame construction, hand guards, comfortable seating position for rider control, integrated lighting system.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic utility ATV with focus on performance and functionality, not infotainment features).

Driver Assistance

Driver Assistance Features:

N/A (No electronic driver assistance systems common in modern vehicles).

Connectivity

Connectivity Features:

Engine Management

Ignition System Technology:

CDI (Capacitor Discharge Ignition) system for reliable spark timing.

Transmission Technology:

Yamaha's Ultramatic® CVT (Continuously Variable Transmission) with engine braking system for consistent power delivery and downhill control.

🔧 Maintenance

Service Intervals

Engine Oil Change Interval:

Every 1,000 km (600 miles) or 6 months, whichever comes first. (Refer to manual for exact initial intervals).

Air Filter Cleaning Interval:

Every 500 km (300 miles) or 3 months, or more frequently in dusty conditions. (Replace if damaged).

Spark Plug Replacement Interval:

Every 5,000 km (3,000 miles) or 2 years. (Check gap at 1,000 km).

Valve Clearance Check Interval:

Every 5,000 km (3,000 miles) or 2 years.

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Coolant Type:

Yamaha Super Coolant (or equivalent permanent type antifreeze, ethylene glycol based, 50/50 mixture with distilled water)

Grease Type:

Lithium-soap base, multi-purpose grease

Known Issues

Common Wear Items:

CVT belt wear, carburetor jetting issues due to ethanol fuels, suspension bushings, starter motor brushes.

Potential Maintenance Challenges:

Carburetor cleaning and synchronization can be complex. CVT belt inspection and replacement require specific procedures. Access to some engine components can be tight.

📚 Vehicle History

Brand Heritage

Yamaha Atv Legacy:

Yamaha has a long-standing reputation for innovation and reliability in the ATV market, with models like the 'Warrior' and 'Raptor' setting benchmarks. The Grizzly line built upon this heritage, emphasizing utility and comfort.

Model Evolution

Grizzly 660 Introduction:

The YFM660 Grizzly was introduced for the 2002 model year, featuring a significant upgrade in engine size and performance over its predecessors. It quickly became a benchmark in the utility ATV segment.

Key Innovations Of 660 Grizzly:

The 660cc engine, true 4WD with a push-button differential lock, and Yamaha's Ultramatic transmission were key selling points that set it apart from many competitors.

Production

Manufacturing Location:

Primarily manufactured in Japan by Yamaha Motor Corporation.

Model Lifespan:

The 660cc engine platform was produced from 2002 until its replacement by the fuel-injected 700cc model in 2008.

🏆 Awards & Recognition

Recognitions

Industry Reputation:

The YFM660 Grizzly was widely praised upon release for its powerful engine, comfortable ride, and robust 4WD system, establishing itself as a leader in the utility ATV market.

Ratings

Consumer Reviews Summary:

Generally high consumer satisfaction ratings for its durability, off-road capability, and utility features. Often cited for its comfortable long-distance ride and strong towing capacity.

Certifications

Atv Certification:

N/A (ATVs are typically designed to meet specific safety standards rather than formal automotive certifications like crash test ratings).