Segment:
Performance-oriented utility ATV segment
Key Competitors:
Honda Foreman, Suzuki King Quad, Polaris Sportsman
Grizzly Identity:
Known for its powerful engine, robust build, and independent rear suspension (IRS), offering superior comfort and handling
Manual Value Proposition:
Provides comprehensive DIY repair and maintenance capabilities, saving owners significant costs associated with dealership service.
Years Covered:
2001, 2002, 2003, 2004, 2005, 2006
Estimated Pages:
Estimated 300-500 pages (typical for comprehensive service manuals)
Manual Classification:
Full Service & Repair Manual
File Format:
PDF Download
Powertrain:
Engine, transmission, drivetrain, clutch, cooling system, fuel system, exhaust system
Chassis And Suspension:
Frame, suspension (front and rear), steering system, wheels, tires
Brakes:
Front and rear braking systems (hydraulic, discs, calipers, master cylinders)
Electrical:
Ignition system, starting system, charging system, lighting, instrumentation, wiring diagrams
Bodywork And Trim:
Body panels, fenders, plastics, seating, handlebars, guards
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication, valve adjustments, carburetor tuning
Troubleshooting:
Diagnostic procedures, common problem identification, symptom-based troubleshooting guides
Repair:
Engine rebuild, transmission overhaul, suspension repair, brake service, electrical system repairs, component replacement
Disassembly And Assembly:
Step-by-step instructions for component removal and installation
Suspension Setup:
Front and rear suspension adjustment procedures, including spring preload and damping settings (if applicable).
Wheel Alignment:
Specifications and procedures for checking and adjusting front wheel alignment.
Cooling System Service:
Radiator flushing, coolant replacement, thermostat replacement, and fan operation checks.
Drive Shaft And Ujoints:
Inspection, lubrication, and replacement procedures for drive shafts and universal joints.
Diagnostic Level:
Advanced diagnostics, including electrical troubleshooting with wiring diagrams and component testing
Rebuild Level:
Complete engine and transmission rebuild procedures with detailed specifications and torque values
Diagnostic Tools:
Information on required special tools and general tools for service and repair
Searchability:
Typically searchable text within the PDF for quick access to information
Image Clarity:
High-resolution diagrams, illustrations, and photographs for clarity
Digital Binding:
PDF format allows for digital navigation via bookmarks and hyperlinks
Digital Paper Type:
N/A (Digital Format)
Engine Type:
4-stroke, SOHC, liquid-cooled, 5-valve, single-cylinder
Bore X Stroke:
100.0 mm x 84.0 mm
Horsepower Estimated:
Approx. 45-50 HP (varies slightly by year and region)
Torque Estimated:
Approx. 40-45 lb-ft (varies slightly by year and region)
Fuel Delivery:
Mikuni 41mm BSR carburetor (CV type)
Fuel Type:
Unleaded gasoline (87 octane recommended)
Fuel Tank Capacity:
4.0 US gal (15 L)
Oil Type:
Yamalube 4 (or equivalent) SAE 10W-30 API SG or higher
Oil Capacity:
2.5 US qt (2.4 L) with filter change
Cooling Type:
Liquid-cooled
Coolant Type:
Yamahaitrile/ethylene glycol based coolant (50/50 mix) (Yamalube Super Coolant recommended)
Transmission Type:
Automatic, V-belt, variable ratio with engine braking
Optional Transmission:
N/A
Drive System:
2WD/4WD, shaft drive
Differential:
Differential lock (on-command)
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R), Park (P)
Transmission Fluid Type:
Yamaha Belt Drive Gear Oil (or equivalent SAE 80 hypoid gear oil)
Length:
Approx. 81.5 inches (2070 mm)
Width:
Approx. 43.7 inches (1108 mm)
Height:
Approx. 45.1 inches (1145 mm)
Wheelbase:
Approx. 50.4 inches (1280 mm)
Dry Weight:
Approx. 606 lbs (275 kg)
Ground Clearance:
Approx. 10.8 inches (275 mm)
Front Rack Capacity:
45 kg (99 lbs)
Rear Rack Capacity:
85 kg (187 lbs)
Towing Capacity:
N/A (refer to owner's manual for specific towing recommendations/limitations)
Atv Safety Standards:
Complies with ANSI/SVIA standards
Braking System:
Hydraulic disc brakes front and rear for strong stopping power
Engine Braking:
Integral engine braking system for controlled descents
4Wd Engagement:
On-command 2WD/4WD system for enhanced traction
Lighting:
Dual 30W halogen multi-reflector headlights, 8W incandescent taillight/stoplight
Ergonomics:
Comfortable seating position and intuitive controls for rider fatigue reduction
Instrument Cluster:
Digital LCD meter with speedometer, odometer, trip meter, clock, fuel gauge, 4WD indicator, and transmission gear indicator.
Throttle Limiter:
N/A (basic design for its era)
Power Outlets:
12V DC accessory outlet for charging devices (availability may vary by specific trim/year).
Engine Oil Change:
Every 1000 km (600 miles) or 6 months, whichever comes first
Air Filter Cleaning:
Every 400 km (250 miles) or when dirty
Spark Plug Replacement:
Every 3000 km (1800 miles) or 1 year
Valve Clearance Check:
Every 2000 km (1200 miles) or 1 year
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Coolant Capacity:
Approx. 2.14 US qt (2.03 L)
Carburetor Tuning:
Carburetor may require periodic adjustment or cleaning due to sensitivity to altitude or fuel quality.
Starter Clutch:
Some models may experience wear on the starter clutch mechanism; manual provides inspection and replacement procedures.
Belt Wear:
CVT belt requires regular inspection for wear and proper tension; manual details inspection and replacement.
Yamaha Motors:
Yamaha Motor Company is renowned for its engineering prowess in motorcycles, marine engines, and ATVs, built on a legacy of innovation and performance.
Yfm660 Grizzly Development:
The YFM660 Grizzly represented a significant advancement in Yamaha's ATV lineup, introducing features like IRS and a powerful 5-valve engine to compete in the premium utility segment.
Manufacturing Location:
Primarily manufactured in Japan by Yamaha Motor Company.
