|
Introduction
|
|
Market Position
|
|
Positioning:
|
The Yamaha Grizzly 660 and Raptor 660 were high-performance ATVs positioned for serious recreational riders, utility work (Grizzly), and sport riding (Raptor). They offered class-leading power and capabilities for their respective segments.
|
|
Competitive Analysis
|
|
Competitors:
|
Competed against models from Honda (e.g., Foreman, TRX450/400EX), Polaris (e.g., Sportsman, Predator), Kawasaki (e.g., Prairie, KFX700), and Suzuki (e.g., King Quad, LT-Z400/LT-R450).
|
|
Key Features
|
|
Engine:
|
Powerful 660cc liquid-cooled, SOHC, four-valve, single-cylinder engine (derived from Yamaha's Snowmobile and Utility ATV lines).
|
|
Transmission Grizzly:
|
Ultramatic automatic transmission with engine-braking and an Occupant Neutral Position for reduced fatigue.
|
|
Transmission Raptor:
|
5-speed manual transmission with reverse, delivering direct rider control.
|
|
Suspension Grizzly:
|
Independent front and rear suspension for superior ride quality and terrain capability.
|
|
Suspension Raptor:
|
Long-travel, independent front and rear suspension optimized for sport riding and handling.
|
|
Drivetrain Grizzly:
|
On-Command push-button 2WD/4WD with locking front differential and shaft drive.
|
|
Brakes Grizzly:
|
Sealed hydraulic disc brakes front and rear for reliable stopping power in all conditions.
|
|
Brakes Raptor:
|
Hydraulic disc brakes front and rear with wave-style rotors for enhanced performance and heat dissipation.
|
|
Utility Features:
|
Front and rear steel racks, tow hitch (Grizzly) for hauling capability.
|
|
Manual Coverage
|
|
Systems Covered
|
|
Engine Mechanical:
|
Complete disassembly, inspection, overhaul, and assembly of the 660cc engine (cylinder head, piston, crankshaft, connecting rod, valve train, lubrication system, cooling system).
|
|
Fuel System:
|
Carburetor (Mikuni BSR42) tuning, cleaning, overhaul, fuel pump, fuel lines, fuel tank.
|
|
Ignition System:
|
CDI, ignition coils, spark plugs, troubleshooting.
|
|
Drivetrain:
|
Final drive (bevel gear case), driveshafts, CV joints, differential (Grizzly), wheel hubs.
|
|
Transmission:
|
Automatic Continuously Variable Transmission (CVT) system (sheaves, belt, clutch, torque converter), gearshift mechanism, reverse gear operation.
|
|
Suspension:
|
Front and rear suspension systems, shock absorbers, springs, control arms, bushings, wheel alignment, settings.
|
|
Brakes:
|
Front and rear hydraulic disc brake systems, brake calipers, master cylinders, brake lines, pads, rotors, bleeding procedures.
|
|
Electrical System:
|
Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, lighting system, switches, indicators, fault finding.
|
|
Cooling System:
|
Radiator, cooling fan, water pump, coolant hoses, thermostat, capacity and fluid specifications.
|
|
Steering:
|
Handlebar assembly, steering stem, tie rods, steering knuckle, steering column.
|
|
Frame And Bodywork:
|
Frame inspection, plastic body panels, fenders, racks, seat, decals, removal and installation.
|
|
Procedures Included
|
|
Routine Maintenance:
|
Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, lubrication points, tire pressure checks, brake adjustments.
|
|
Troubleshooting:
|
Systematic diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides, electrical fault diagnosis.
|
|
Engine Rebuild:
|
Detailed step-by-step instructions for complete engine disassembly, parts inspection, measurement of critical components (e.g., piston ring gap, cylinder bore, valve clearance), and reassembly with torque specifications.
|
|
Transmission Overhaul:
|
CVT sheave alignment, roller inspection, clutch spring replacement, torque converter servicing.
|
|
Brake System Service:
|
Master cylinder rebuild, caliper servicing, pad replacement, rotor inspection and replacement, brake fluid bleeding techniques.
|
|
Electrical Diagnostics:
|
Reading wiring diagrams, testing components with multimeters, identifying short circuits and open circuits, troubleshooting charging system issues.
|
|
Suspension Adjustment And Repair:
|
Adjusting preload, shock absorber rebuilding, bushing replacement.
|
|
Torque Specifications:
|
Comprehensive list of all critical torque values for engine, chassis, and suspension fasteners.
|
|
Technical Depth
|
|
Depth:
|
Comprehensive coverage from basic owner maintenance to advanced mechanical and electrical repairs, including full engine and transmission rebuilds. Suitable for both amateur mechanics and professional technicians.
|
|
Transmission
|
|
Standard
|
|
Grizzly:
|
Constant-mesh, automatic, Ultramatic® transmission with centrifugal clutch and helical gear reduction.
|
|
Raptor:
|
Constant-mesh, 5-speed manual with wet, multi-plate clutch and constant-mesh, 2-speed reduction gear with reverse.
|
|
Optional
|
|
Optional Types:
|
N/A (Manual transmission for Raptor, Automatic for Grizzly)
|
|
Features
|
|
Grizzly Features:
|
Engine braking, high/low range, neutral, reverse.
|
|
Raptor Features:
|
Wet clutch, engine braking via downshifting.
|
|
Fluid Specifications
|
|
Grizzly Fluid Type:
|
Yamaha Yamalube 4 (or equivalent) SAE 10W-40 API SG, SJ, SL
|
|
Grizzly Fluid Capacity:
|
2.00 L (2.11 US qt) / 1.70 L (1.80 US qt) without filter change
|
|
Raptor Fluid Type:
|
Yamaha Yamalube 4 (or equivalent) SAE 10W-40 API SG, SJ, SL
|
|
Raptor Fluid Capacity:
|
1.80 L (1.90 US qt) / 1.60 L (1.69 US qt) without filter change
|
|
Maintenance
|
|
Service Intervals
|
|
Engine Oil Change:
|
Every 100 hours or 6 months, whichever comes first.
|
|
Oil Filter Replacement:
|
Every 100 hours or 12 months (replace with oil change).
|
|
Air Filter Cleaning:
|
Every 20 hours or 3 months (clean more frequently in dusty conditions).
|
|
Spark Plug Check:
|
Every 100 hours or 12 months.
|
|
Valve Clearance Check:
|
Every 200 hours or 24 months.
|
|
Belt Inspection Grizzly:
|
Inspect every 100 hours or 6 months, replace as needed based on wear.
|
|
Brake Fluid Flush:
|
Every 12 months or as needed.
|
|
Fluid Specifications
|
|
Engine Oil Spec:
|
Yamaha Yamalube 4 (or equivalent) SAE 10W-40 API SG, SJ, SL.
|
|
Coolant Spec:
|
Permanent type antifreeze coolant (50% mixture with distilled water) based on SAE J1034 and ASTM D3306 standards.
|
|
Brake Fluid Spec:
|
DOT 3 or DOT 4 brake fluid.
|
|
Known Issues
|
|
Common Issues:
|
Some units experienced issues with starter motor reliability, occasional carburetor tuning needs due to atmospheric changes, and potential wear on CVT components with hard use. The manual provides troubleshooting for these and other common concerns.
|
|
Part Numbers
|
|
Oil Filter Part Number:
|
Examples: 5JX-13440-00-00, 3FV-13440-00-00 (cross-reference is often required).
|
|
Spark Plug Part Number:
|
Example: NGK CR7E or similar, depending on specific year/model. (Manual will specify exact recommended part).
|
