Yamaha YFM660 2001-2006 Workshop Service Manual Repair

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类型: Atv

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标签: 2001 2002 2003 2004 2005 2006 Atv Misc Motorcycles Yamaha YFM660

产品多属性

Description

Welcome to the comprehensive guide for the Yamaha YFM660 Grizzly, a high-performance utility All-Terrain Vehicle produced between 2001 and 2006. Renowned for its powerful 660cc engine, automatic transmission with selectable 4WD, and independent front suspension, the Grizzly 660 was designed for off-road enthusiasts, hunters, farmers, and recreational riders seeking capability and reliability. Its robust chassis, substantial cargo rack capacity, and comfortable ride made it a benchmark in its segment, comparable to leading models from other manufacturers. This workshop service manual provides detailed information essential for the maintenance, repair, and troubleshooting of your Yamaha YFM660 Grizzly. Covering all major systems including the powertrain, chassis, and electrical components, this manual offers step-by-step procedures for everything from routine maintenance, such as oil changes and filter replacements, to complex overhauls of the engine and transmission. It includes vital technical specifications, diagnostic guidance, and safety instructions, empowering owners and technicians to ensure the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

YFM660

Model Designation:

Grizzly 660

Codes

Production Years:

2001, 2002, 2003, 2004, 2005, 2006

👋 Introduction

Market Position

Segment:

High-performance Utility ATV (All-Terrain Vehicle)

Target Audience:

Off-road enthusiasts, hunters, farmers, recreational riders.

Competitive Analysis

Competitors:

Honda Foreman/Rancher, Polaris Sportsman, Suzuki King Quad, Arctic Cat 500/650.

Key Features

Features Of Vehicle:

Powerful 660cc engine, automatic transmission with selectable 4WD/2WD, independent front suspension, robust chassis, large cargo racks.

📋 Manual Details

Coverage Areas

Applicable Models:

Yamaha YFM660 Grizzly 660

Applicable Years:

2001-2006

Page Count

Estimated Pages:

Manual Type

Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Transmission, Drivetrain, Clutch, Carburetor/Fuel Injection

Chassis:

Suspension (Front & Rear), Steering, Brakes, Wheels, Tires

Electrical:

Ignition System, Lighting System, Starting System, Charging System, Wiring Diagrams, ECU/ECM

Bodywork And Frame:

Frame, Body Panels, Fenders, Racks, Seat

Procedures Included

Maintenance:

Scheduled Maintenance, Oil Changes, Filter Replacements, Lubrication Points

Troubleshooting:

Diagnostic Procedures, Fault Finding Charts, Symptom-Based Diagnosis

Repair And Rebuild:

Engine Overhaul, Transmission Reassembly, Brake System Repair, Suspension Component Replacement

Adjustments:

Carburetor/Fuel Injection Tuning, Valve Clearances, Brake Adjustments

Technical Depth

Depth:

Comprehensive: From basic checks and fluid changes to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications.

📊 Manual Specifications

File Format

File Type:

Searchable:

Yes (typically, depending on PDF source)

Print Quality

Quality:

High-resolution, suitable for printing

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Type:

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

Displacement:

660 cc (40.3 cu. in.)

Bore X Stroke:

100.0 mm x 84.0 mm (3.94 in x 3.31 in)

Compression Ratio:

9.1:1

Performance

Horsepower Estimated:

~40 HP @ 5500 RPM (Manufacturer specifications vary by region and tuning)

Torque Estimated:

~45 lb-ft @ 4500 RPM (Manufacturer specifications vary by region and tuning)

Fuel System

Fuel Delivery:

Mikuni BSR42 diaphragm-type carburetor (specific model may vary)

Fuel Tank Capacity:

4.0 US gal (15.0 L) with 0.7 US gal (2.7 L) reserve

Fuel Type:

Unleaded gasoline, 87 octane or higher

🔧 Transmission

Standard

Type:

Automatic (Yamaha Constant Velocity Transmission - YCVT)

Drive Modes:

Shaft drive; 2-wheel drive / 4-wheel drive (selectable)

Gear Selection:

Forward, Neutral, Reverse

Features

Engine Braking:

Provides significant engine braking in lower gear ranges.

Belt Material:

Reinforced rubber composite V-belt.

📐 Dimensions

Exterior

Length:

81.7 in (2075 mm)

Width:

44.5 in (1130 mm)

Height:

45.1 in (1145 mm)

Wheelbase:

50.8 in (1290 mm)

Ground Clearance:

10.8 in (275 mm)

Cargo

Front Rack Capacity:

99 lbs (45 kg)

Rear Rack Capacity:

187 lbs (85 kg)

Weights

Dry Weight:

562 lbs (255 kg)

Wet Weight:

591 lbs (268 kg)

Towing Capacity:

1102 lbs (500 kg)

Front Tire Size:

AT25x8-12

Rear Tire Size:

AT25x10-12

Wheel Bolt Pattern:

4x110 mm

🛡️ Safety Features

Ratings

Atv Safety Standards:

Complies with ANSI standards for recreational ATVs.

Active Features

Brakes Front:

Dual hydraulic disc

Brakes Rear:

Dual hydraulic disc (inboard mounted)

Parking Brake:

Mechanical drum brake on rear drive shaft

Passive Features

Lighting:

Dual 30W halogen headlights, 15W incandescent tail/brake light

Hand Grips:

High-density foam grips for reduced vibration.

Seat:

Comfortable, contoured seat for extended riding.

💡 Technology Features

Infotainment

Features:

Basic instrumentation cluster (speedometer, odometer, trip meter, fuel gauge, 4WD indicator, etc.). No advanced infotainment features typical of modern vehicles.

Driver Assistance

Features:

None (focus is on mechanical capability and driver control).

Connectivity

Features:

None.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1,000 km (600 miles) or 6 months, whichever comes first. Check oil level weekly.

Air Filter Cleaning:

Clean every 3 months or 1,000 km (600 miles). Replace as needed.

Spark Plug Replacement:

Replace every 12 months or 3,000 km (1,800 miles).

Valve Clearance Check:

Check every 6 months or 2,000 km (1,200 miles).

Fluid Specifications

Engine Oil Type:

Yamalube 4 (SAE 10W-30) or equivalent API SG, JASO MA certified oil.

Engine Oil Capacity:

2.20 L (2.3 US qt) without filter change; 2.40 L (2.5 US qt) with filter change.

Coolant Type:

Permanent antifreeze (ethylene glycol based) with high-purity water, 50/50 mix.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Transmission Fluid Type:

Yamaha Idemitsu CVT Fluid or equivalent (specific viscosity and type).

Known Issues

Common Problems:

CVT belt wear/failure, carburetor issues (clogging, tuning), starter motor issues, occasional electrical gremlins, front drive shaft U-joint wear.

Preventative Measures:

Regular CVT belt inspection and replacement at recommended intervals, proper carburetor cleaning and maintenance, keeping electrical connections clean and protected.

📚 Vehicle History

Brand Heritage

Heritage:

Yamaha has a long-standing reputation for producing reliable and high-performance powersports vehicles, including a strong legacy in ATVs.

Model Evolution

Model Lineage:

The YFM660 Grizzly was Yamaha's flagship utility ATV for its generation, succeeding the successful YFM400 Kodiak and establishing a benchmark for power and capability in the utility class.

Production

Manufacturing Location:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

The YFM660 Grizzly was widely praised in its time for its powerful engine, comfortable ride, and robust utility capabilities, earning positive reviews from ATV publications and consumers.