Market Position:
The Yamaha Grizzly 660 established itself as a premium, robust, and highly capable utility ATV, known for its comfort, power, and 4x4 capabilities in the early 2000s market.
Competitive Analysis:
Competed against other major manufacturers' flagship utility ATVs, such as the Polaris Sportsman, Honda Foreman/Rancher, and Suzuki King Quad, offering a strong balance of features and performance.
Key Features:
Key features of the 2002 Grizzly 660 included its powerful 660cc engine, Ultramatic automatic transmission with engine braking, On-Command 4WD system, independent front and rear suspension, and comfortable seating.
Manual Value Proposition:
This manual is invaluable for owners seeking to perform their own maintenance, diagnostics, and repairs, saving significant costs associated with dealership service and ensuring proper upkeep for longevity.
Engine:
Complete engine overhaul, internal components, cylinder head, piston, crankshaft, lubrication system, cooling system, ignition system, fuel system, carburetor tuning and repair
Transmission:
Automatic transmission (CVT), clutch operation, gear case maintenance and repair, drive shafts
Drivetrain:
4WD system operation, differential maintenance, CV joints, driveshafts, propeller shafts
Suspension:
Front and rear suspension components, shock absorbers, control arms, bearings, bushings, alignment
Brakes:
Front and rear brake systems, hydraulic lines, calipers, brake pads, master cylinders, parking brake
Electrical:
Wiring diagrams, ignition system, charging system (stator, regulator/rectifier), battery, starter motor, lighting system, instrumentation, fuses, relays
Fuel System:
Carburetor (Mikuni BSR42), fuel pump, fuel filter, fuel lines, fuel tank
Cooling System:
Radiator, fan, coolant hoses, thermostat, coolant specifications
Frame And Body:
Frame inspection and repair, body panels, fenders, seats, racks
Wheels And Tires:
Wheel specifications, tire pressure, tire replacement
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug service, air filter cleaning, chain adjustment (if applicable, though this model has shaft drive), lubrication points
Troubleshooting:
Diagnostic procedures for common issues, symptom-based troubleshooting guides
Repair:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation
Engine Rebuild:
Complete engine disassembly, inspection of internal parts, measurement of wear, and reassembly
Carburetor Rebuild:
Carburetor cleaning, jet replacement, float adjustment, and overall repair
Electrical Diagnostics:
Testing electrical components, troubleshooting wiring issues using diagrams
Suspension Adjustment:
Adjusting preload and damping where applicable
Brake System Service:
Bleeding brake lines, replacing brake pads and fluid
Technical Depth:
Comprehensive, covering all aspects from basic rider maintenance to in-depth mechanical repairs and diagnostics
Diagnostic Codes:
Includes diagnostic codes and procedures where applicable
Torque Specifications:
Detailed torque specifications for all critical fasteners
Clearances And Tolerances:
Specific measurements for component clearances and wear tolerances
Wiring Diagrams:
High-quality, detailed wiring diagrams for electrical system troubleshooting
Illustrations:
Illustrated with clear step-by-step instructions, including diagrams and exploded views
Transmission Type:
Yamaha Ultramatic® V-belt automatic transmission
Drive System:
Yamaha On-Command® pushbutton, electronically selectable 2WD/4WD with locking front differential
Engine Braking:
Yes, inherent in the Ultramatic system
Gear Reduction:
Constant variable transmission (CVT) with High, Low, Neutral, Reverse, Park
Transmission Fluid Type:
Yamalube 4 (or equivalent) SAE 10W-40 or SAE 20W-40 API SG type motor oil
Transmission Fluid Capacity:
1.20 US qt (1.13 L)
Initial Break In Service:
Recommended at 100 miles (160 km) or 20 hours of operation (oil change, filter inspection/replacement, general check).
Regular Oil Change:
Every 1,000 miles (1600 km) or 6 months, whichever comes first. Also recommended after severe use.
Air Filter Cleaning:
Inspect every 20 hours or 3 months. Clean/replace as needed, more frequently in dusty conditions.
Spark Plug Replacement:
Recommended every 2,000 miles (3200 km) or 12 months. Check gap annually.
Valve Clearance Check:
Every 1,000 miles (1600 km) or 6 months.
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 20W-40 API SG type motor oil
Engine Oil Capacity:
2.70 US qt (2.5 L) with filter change
Coolant Type:
Yamaha-approved All-Weather Antifreeze or equivalent (50/50 mix of ethylene glycol and deionized water)
Brake Fluid Type:
SAE J1703 or FMVSS No. 116 DOT 3
Known Issues:
Early models could experience carburetor icing in cold, damp conditions; potential for drive shaft U-joint wear; some reports of radiator fan issues under heavy load. The manual provides troubleshooting for these.
Brand Heritage:
Yamaha has a long and storied history in motorsports and powersports, known for innovation, reliability, and performance across motorcycles, snowmobiles, and ATVs since its inception.
Model Evolution:
The Grizzly 660 represented a significant step forward for Yamaha in the utility ATV segment, building on the success of previous models and introducing the larger, more powerful 660cc engine. It was a direct response to market demand for increased performance and capability.
Production Years:
The 660cc Grizzly was produced from 2002 through 2008, before being succeeded by the fuel-injected Grizzly 700.
Production Location:
Manufactured in Japan and/or USA by Yamaha Motor Corporation.
