Yamaha YFM660FS Grizzly 2002-2005 Workshop Service Manual

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Art.-Nr: 76094

Stichworte: 2002 2003 2004 2005 ATV Grizzly Models Powersports Yamaha YFM660FS Grizzly

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Beschreibung

The Yamaha YFM660FS Grizzly, a first-generation model produced from 2002 to 2005, stands as a formidable All-Terrain Vehicle (ATV) engineered for demanding off-road conditions. Featuring a powerful 660cc, 5-valve SOHC liquid-cooled engine paired with its renowned automatic transmission and 2WD/4WD system, this ATV delivers exceptional performance and terrain adaptability. Its independent front and rear suspension, coupled with sealed hydraulic disc brakes, ensures a comfortable and controlled ride across varied landscapes, making it a reliable choice for outdoor enthusiasts, hunters, and farmers. This comprehensive workshop service manual is designed to provide detailed guidance for the maintenance, repair, and overhaul of the Yamaha YFM660FS Grizzly from 2002 to 2005. Covering all essential systems including the engine, transmission, chassis, suspension, brakes, and electrical components, this manual offers step-by-step instructions, diagnostic procedures, and technical specifications. It serves as an indispensable resource for owners and technicians to ensure the optimal performance, longevity, and safety of the vehicle through accurate and thorough information.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

YFM660FS Grizzly

Model Designation:

FS (Four-Stroke, SOHC)

Generation

Generation Designation:

First Generation Grizzly 660

Codes

Chassis Code:

YFM660FS

👋 Introduction

Market Position

Category:

High-performance All-Terrain Vehicle (ATV)

Target Audience:

Outdoor enthusiasts, hunters, farmers, recreational riders requiring a robust and capable off-road machine.

Competitive Analysis

Competitors:

Honda Foreman, Suzuki King Quad, Polaris Sportsman, Kawasaki Prairie.

Key Features

Engine Type:

Liquid-cooled, 4-stroke, SOHC, 5-valve, single-cylinder

Drive System:

Ultramatic automatic transmission with On-Command 2WD/4WD and differential lock.

Suspension:

Independent front and rear suspension for superior ride comfort and terrain handling.

Braking:

Sealed hydraulic disc brakes front and rear.

📋 Manual Details

Coverage Areas

Years Covered:

2002, 2003, 2004, 2005

Page Count

Total Pages:

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, maintenance, diagnostics, cooling system, lubrication system, fuel system, ignition system, exhaust system, carburetor adjustment and overhaul, internal engine components (piston, rings, crankshaft, cylinder head, valves).

Transmission:

Automatic transmission (CVT), clutch operation, belt inspection and replacement, gearbox maintenance, final drive system, differential.

Chassis And Suspension:

Frame inspection, front and rear suspension systems (shocks, springs, A-arms), steering system (handlebars, tie rods, rack and pinion), wheel bearings, lubrication points.

Brakes:

Hydraulic brake system, front and rear brake calipers, brake discs, brake pads, brake fluid specifications and bleeding procedures, parking brake system.

Electrical System:

Wiring diagrams, battery maintenance, starter motor, charging system (stator, regulator/rectifier), lighting system (headlights, taillights, indicators), ignition system components, switches, sensors, fuses, troubleshooting electrical faults.

Bodywork And Controls:

Body panel removal and installation, seat, fenders, racks, controls (throttle, brake levers, shifter), cable adjustments, fluid reservoirs.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil and filter changes, air filter cleaning/replacement, spark plug replacement, valve clearance adjustment, drive belt inspection, lubrication.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, fault codes (if applicable), diagnostic flowcharts.

Repair:

Detailed step-by-step instructions for disassembly, repair, and reassembly of all major components and systems.

Overhaul:

Comprehensive guidance for complete engine, transmission, and major component rebuilds.

Technical Depth

Depth:

Comprehensive, covering everything from basic rider maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, clearances, and diagnostic procedures.

📊 Manual Specifications

File Format

File Format Detail:

Searchable PDF for efficient information retrieval, printable pages.

Print Quality

Image Resolution:

High resolution for clear diagrams and text.

Binding Type

Binding Type:

N/A (Digital PDF download)

Paper Type

Paper Type:

N/A (Digital PDF download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

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

Displacement:

660 cc

Bore X Stroke:

95.0 mm x 93.2 mm

Compression Ratio:

9.2:1

Performance

Horsepower Estimate:

Approximately 45-50 HP (varies by region and tuning)

Torque Estimate:

Approximately 40-45 ft-lbs (varies by region and tuning)

Fuel System

Carburetor:

Mikuni BSR42 (single)

Fuel Type:

Unleaded gasoline (minimum 87 octane)

Lubrication System

Oil Type:

Yamaha Genuine 4-stroke motor oil or equivalent SAE 10W-40 API SG or higher.

Oil Capacity:

2.40 L (2.54 US qt) without filter change, 2.50 L (2.64 US qt) with filter change.

Cooling System

Coolant Type:

Ethylene glycol based antifreeze mixed 50/50 with distilled water.

Coolant Capacity:

1.90 L (2.01 US qt)

🔧 Transmission

Standard

Transmission Type:

Yamaha Ultramatic V-belt automatic transmission

Drive Modes:

2WD, 4WD, 4WD with differential lock (On-Command system)

Optional

Optional Transmissions:

N/A (All models equipped with Ultramatic CVT)

Features

Features:

Engine braking control, automatic centrifugal clutch, durable V-belt system.

Maintenance

Drive Belt Inspection Interval:

Every 1,000 km or 6 months, whichever comes first.

Gear Oil Type:

Yamalube Gear Oil or equivalent SAE 80 API GL-4.

Gear Oil Capacity:

0.25 L (0.26 US qt)

📐 Dimensions

Exterior

Overall Length:

2,003 mm (78.9 in)

Overall Width:

1,079 mm (42.5 in)

Overall Height:

1,067 mm (42.0 in)

Wheelbase:

1,231 mm (48.5 in)

Ground Clearance:

260 mm (10.2 in)

Weights

Wet Weight:

272 kg (599.7 lbs)

Fuel Capacity:

17 L (4.5 US gal)

Cargo

Front Rack Capacity:

45 kg (99 lbs)

Rear Rack Capacity:

85 kg (187 lbs)

Wheels And Tires

Front Tire Size:

AT25x8-12

Rear Tire Size:

AT25x10-12

Front Wheel Size:

12 x M6.0

Rear Wheel Size:

12 x M8.0

Bolt Pattern:

4 x 110 mm

🛡️ Safety Features

Ratings

Atv Safety Classification:

Not Applicable (ATVs are not typically rated by NCAP or IIHS)

Active Features

Active Safety:

On-Command 4WD with differential lock for enhanced traction, engine braking from Ultramatic transmission.

Passive Features

Passive Safety:

Ergonomic design for rider control, sturdy frame construction, handlebar padding, integrated floorboards with traction pegs.

Braking System

Front Brake Type:

Dual sealed hydraulic disc

Rear Brake Type:

Sealed hydraulic disc

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic utility vehicle, no integrated infotainment system)

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Features:

Lighting

Headlights:

Dual 30W halogen bulbs

Taillight Brake Light:

15W/5W bulb

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1,000 km or 6 months, whichever comes first.

Air Filter Cleaning:

Every 500 km or 3 months, or more frequently in dusty conditions.

Spark Plug Replacement:

Every 5,000 km or 12 months.

Valve Clearance Check:

Every 5,000 km or 12 months.

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid.

Coolant:

Yamaha Yamalube Coolant or equivalent 50/50 mix of ethylene glycol antifreeze and distilled water.

Chassis Grease Points:

Refer to manual for specific lubrication points (e.g., suspension pivots, steering head).

Known Issues

Common Wear Items:

Drive belt (CVT), brake pads, wheel bearings, ball joints.

Potential Problems:

Carburetor jetting issues in varying altitudes, occasional charging system component failures (regulator/rectifier), CV joint wear with aggressive use.

📚 Vehicle History

Brand Heritage

Manufacturer Focus:

Yamaha Motor Company is renowned for its high-performance motorcycles, marine products, and powersports vehicles.

Model Evolution

Grizzly Lineage:

The YFM660F Grizzly marked Yamaha's entry into the powerful 600cc+ ATV segment, building on the success of its smaller Grizzly models. It was a significant player in the performance ATV market for its era.

Key Innovations:

Introduction of the 5-valve engine technology to the ATV lineup, along with the industry-leading Ultramatic transmission.

Production

Production Period:

2002-2005

Manufacturing Location:

Japan