Yamaha Grizzly 660 YFM660FP 2001-2002 ATV Service Repair Manual

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Tipo: Atv

Proveedor:

SKU: 86194

Etiquetas: 2001 2002 ATV Grizzly 660 YFM660FP Grizzly Models Powersports Yamaha

Variantes de producto

Descripción

The Grizzly 660, model code YFM660FP, produced between 2001 and 2002, is a formidable All-Terrain Vehicle (ATV) designed for demanding off-road use. This high-performance utility ATV boasts a torquey 660cc liquid-cooled, four-stroke engine, renowned Ultramatic automatic transmission with selectable 2WD/4WD and a locked front differential, and independent front and rear suspension for superior comfort and terrain handling. Its sealed hydraulic disc brakes on all four wheels provide reliable stopping power. The Grizzly 660 was engineered for recreational riders, hunters, farmers, and utility users, earning a strong reputation for its power, reliability, and robust build in challenging conditions. This comprehensive Service Repair Manual provides detailed guidance for the maintenance and repair of the Grizzly 660 ATV. It covers a wide array of systems, including the engine, transmission, drivetrain, suspension, brakes, and electrical components, offering professional-level diagnostic and repair procedures. The manual includes essential information on routine maintenance, troubleshooting common issues, engine and transmission overhauls, brake service, electrical diagnostics, and suspension repairs. With step-by-step instructions, torque specifications, and high-resolution illustrations, this manual is an indispensable resource for owners and technicians seeking to ensure the optimal performance and longevity of their Grizzly 660.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

Grizzly 660

Model Code:

YFM660FP

Year:

2001-2002

Codes

Atv Type:

All-Terrain Vehicle (ATV)

👋 Introduction

Market Position

Category:

High-performance utility ATV

Target Audience:

Recreational riders, hunters, farmers, and utility users requiring robust off-road capability.

Competitive Analysis

Competitors Early 2000S:

Polaris Sportsman, Can-Am Outlander, Suzuki King Quad, Honda Foreman/Rancher.

Key Features

Engine:

Torquey 660cc liquid-cooled, four-stroke SOHC engine.

Drivetrain:

Yamaha's Ultramatic automatic transmission with 2WD/4WD selection and locked front differential.

Suspension:

Independent front and rear suspension for improved comfort and terrain handling.

Braking:

Sealed hydraulic disc brakes on all four wheels.

📋 Manual Details

Coverage Areas

Scope:

Comprehensive service and repair

Page Count

Estimated Pages:

Varies by specific edition, typically 300-500+ pages for a full service manual

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Detailed breakdown of the 660cc engine, including lubrication, cooling, fuel, ignition, and emissions systems.

Transmission:

Coverage of the automatic transmission (CVT), including belt inspection, clutch operation, and gearbox maintenance.

Drivetrain:

In-depth information on the 4x4 system, differentials (front and rear), driveshafts, and wheel hubs.

Suspension:

Front and rear suspension components, including shock absorbers, springs, A-arms, steering knuckles, and bushings.

Brakes:

Disc brake systems (front and rear), including hydraulic lines, calipers, master cylinders, and rotor specifications.

Electrical:

Wiring diagrams, electrical component testing, battery, starter, charging system, lighting, and electronic control units (ECU).

Chassis:

Frame, body panels, seats, handlebars, footrests, and storage components.

Cooling System:

Radiator, fan, hoses, coolant specifications, and flushing procedures.

Fuel System:

Carburetor (Mikuni BSR42), fuel pump, fuel lines, and fuel tank.

Steering:

Steering column, tie rods, ball joints, and related components.

Wheels And Tires:

Wheel specifications, tire pressure recommendations, and replacement procedures.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain adjustment (if applicable), lubrication points.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting for common issues.

Engine Repair:

Top-end and bottom-end engine rebuilds, piston and cylinder inspection, valve clearance adjustment, camshaft installation.

Transmission Overhaul:

CVT belt replacement, clutch component inspection and replacement, gearbox dis assembly and reassembly.

Brake Service:

Brake pad replacement, caliper service, master cylinder overhaul, brake bleeding procedures.

Electrical Diagnostics:

Testing of ignition system, charging system, starter motor, lighting circuits, and ECU diagnostics.

Suspension Repair:

Shock absorber replacement, bushing replacement, ball joint inspection and replacement, steering component service.

Carburetor Tuning:

Carburetor cleaning, adjustment, and synchronization.

Drivetrain Maintenance:

CVT drive belt inspection and replacement, differential oil changes, driveshaft inspection.

Technical Depth

Level:

Professional-level diagnostic and repair procedures, suitable for mechanics and experienced DIY enthusiasts.

Detail:

Includes torque specifications, clearances, diagnostic values, and step-by-step instructions with accompanying illustrations.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text content allows for quick location of specific information.

Print Quality

Image Resolution:

High-resolution illustrations and diagrams for clarity.

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, four-stroke, SOHC, single-cylinder

Displacement:

660 cc

Bore X Stroke:

100 mm x 84 mm

Compression Ratio:

9.1:1

Valve Train:

SOHC, 4 valves per cylinder

Performance

Horsepower Est:

Approximately 45-50 HP (estimated, factory figures not always published)

Torque Est:

Approximately 38-42 lb-ft (estimated)

Fuel System

Carburetor:

Mikuni BSR42, single, with throttle position sensor (TPS)

Fuel Capacity:

5.1 gallons (19.3 L)

Recommended Fuel:

Unleaded gasoline, 87 octane or higher

Lubrication

Oil Capacity:

2.3 US qt (2.2 L) with filter change

Engine Oil Type:

Yamaha Motorcycle Oil SAE 10W-40 (API SG or higher) or equivalent

🔧 Transmission

Standard

Type:

Yamaha Ultramatic V-belt automatic transmission with engine braking

Drive Modes:

2WD / 4WD with locking front differential

Optional

Gear Reduction:

High and Low range

Features

Belt Type:

CVT Drive Belt (specific part number required for replacement, e.g., 4XF-16261-00-00)

Transmission Fluid Type:

Yamalube 4 (or equivalent) SAE 20W-40 API SG or higher

Final Drive:

Shaft drive (front and rear)

📐 Dimensions

Exterior

Length:

81.7 inches (2075 mm)

Width:

44.5 inches (1130 mm)

Height:

44.5 inches (1130 mm)

Wheelbase:

50.4 inches (1280 mm)

Ground Clearance:

10.8 inches (275 mm)

Weights

Dry Weight:

562 lbs (255 kg)

Curb Weight:

Approximately 597 lbs (271 kg) (with all necessary fluids)

Cargo

Front Rack Capacity:

99 lbs (45 kg)

Rear Rack Capacity:

187 lbs (85 kg)

Wheels And Tires

Front Tire Size:

AT25x8-12

Rear Tire Size:

AT25x10-12

Front Wheel Offset:

N/A (Typically stamped on wheel)

Rear Wheel Offset:

N/A (Typically stamped on wheel)

🛡️ Safety Features

Ratings

Safety Standard:

Designed to meet ANSI standards for recreational ATVs.

Active Features

Braking System:

Hydraulic disc brakes front and rear, sealed for protection.

Engine Braking:

Ultramatic transmission provides constant engine braking on descents.

Passive Features

Seat Belt:

N/A (ATVs are operated without seat belts; helmets are mandatory).

Roll Over Protection:

N/A (Riders must wear helmets and exercise caution).

Lighting:

Dual halogen headlights, LED taillight/brake light.

💡 Technology Features

Infotainment

Display:

Basic LCD instrument panel displaying speed, odometer, trip meter, 4WD indicator, and neutral/reverse indicators.

Driver Assistance

Engine Braking:

Yamaha's signature Ultramatic transmission provides excellent, consistent engine braking.

Differential Lock:

Manually selectable 2WD/4WD with a locking front differential for maximum traction.

Connectivity

Usb Port:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1,000 miles (1600 km) or 6 months, whichever comes first.

Air Filter Cleaning:

Every 6 months or as needed based on operating conditions.

Spark Plug Inspection:

Every 1,000 miles (1600 km) or 6 months.

Transmission Oil Change:

Every 1,000 miles (1600 km) or 6 months.

Cvt Belt Inspection:

Every 6 months (check for wear, cracks, and proper tension).

Fluid Specifications

Engine Oil:

Yamalube 4 SAE 10W-40 API SG or higher

Transmission Oil:

Yamalube 4 SAE 20W-40 API SG or higher

Coolant Type:

Yamaha,'s 50/50 mixture of engine coolant and distilled water, or equivalent ethylene glycol-based coolant.

Known Issues

Cvt Belt Wear:

The CVT belt can wear over time, leading to slippage and reduced performance. Regular inspection and replacement are crucial.

Carburetor Clogging:

Due to ethanol in fuel or debris, the carburetor can become clogged, affecting fuel delivery and engine performance.

Rear Axle Seal Leaks:

Some models have reported leaks from rear axle seals, requiring replacement.

Radiator Fan Failure:

Overheating can occur if the radiator fan malfunctions. Testing and replacement of the fan or its associated components are necessary.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Corporation is a Japanese multinational corporation known for its wide range of products, including motorcycles, marine products, and musical instruments.

Model Evolution

Predecessor:

The Grizzly 600 was the predecessor, with the 660cc model representing a significant power and torque upgrade.

Successor:

The Grizzly 700 FI (Fuel Injection) replaced the 660 model, introducing fuel injection and power steering.

Production

Manufacturing Location:

Primarily manufactured in Japan or through Yamaha's global production facilities.

Production Period:

The 660cc engine variant was produced for several years, with the YFM660FP covering the 2001-2002 model years.

🏆 Awards & Recognition

Recognitions

Popularity:

The Grizzly 660 was highly regarded for its power, reliability, and true 4x4 capability in its era, earning a strong reputation among ATV enthusiasts.

Ratings

Consumer Reviews:

Consistently received positive reviews for its robust build and performance in challenging terrain.