Yamaha Grizzly 660 Repair Manual 2002-2008

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Item # M285-2  ISBN: 9781599693057




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This repair and service manual covers Yamaha Grizzly 660 2002-2008 4-wheeler ATVs.

Table of Contents

Quick Reference Data

Chapter One: General Information
Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Tools | Measuring tools | Electrical system fundamentals | Service methods | Storage | Specifications

Chapter Two: Troubleshooting
Water damage | Starting the engine | Engine spark test | Electrical testing | Engine starting system | Engine performance | Engine noise | Frame noise | Leakdown test | Transmission | Axles, differential and final drive units | Drive shafts and middle gear unit | Brake system | Steering and handling

Chapter Three: Lubrication, Maintenance and Tune-Up
Pre-ride inspection | Engine break-in | Battery | Engine oil and filter | Final drive | Front differential | Air filter | Front drive shaft lubrication | Rear suspension pivot lubrication | Control cable lubrication | Fastener inspection | Speed limiter adjustment | Axle boot inspection | Drain inspection | Cooling system | Exhaust system | Fuel system | Drive belt inspection | Control cable adjustment | Brake system | Tire inspection | Tune-up | Valve clearance | Carburetor adjustment | Ignition timing | Compression test | Spark plug | Specifications

Chapter Four: Engine Top End
Exhaust system | Cylinder head cover | Camshaft and cam chain tensioner | Cylinder head | Valves | Cylinder | Piston and piston rings | Specifications

Chapter Five: Engine Lower End
Engine | Recoil starter | Balancer and oil pump gears | Cam chain and rear guide | Crankcase | Crankcase seal replacement | Crankcase bearing replacement | Engine balancer | Oil pump | Crankshaft | Middle gear assembly | Middle gear assembly shim and lash adjustment | Specifications

Chapter Six: Clutch and Sheaves
Drive belt cover | Outer bearing housing | Drive belt inspection and replacement | Primary and secondary sheaves | Right crankcase cover | Clutch | Specifications

Chapter Seven: Transmission and Shift Mechanisms
Select lever assembly | Select lever cable replacement | External shift mechanism | Transmission | Shift drum and forks | Specifications

Chapter Eight: Fuel System
Carburetor | Fuel valve | Throttle cable replacement | Specification

Chapter Nine: Electrical System
Electrical component replacement | Ignition and charging system operation | Alternator cover | Stator and pickup coil | Rotor, starter clutch and starter gears | Starter | Starting system switches | Ignition system | Charging system | Fan system | Coolant temperature warning system | Four-wheel drive relays and gear motor | Indicator circuits | Switches | Headlights | Taillight | Specifications

Chapter Ten: Cooling System
Cooling system safety | Radiator and fan | Fan sending unit | Coolant temperature sending unit | Thermostat | Water pump | Specifications

Chapter Eleven: Front Suspension and Steering
Front wheel | Front hub | Tie rods | Steering knuckle | Control arms | Shock absorbers | Steering shaft | Handlebar | Tires | Wheel runout | Specifications

Chapter Twelve: Front Axles and Differential
Front axles | Differential | Front drive shaft | Specifications

Chapter Thirteen: Rear Suspension


Rear wheel | Rear hub | Rear knuckle | Stabilizer | Control arms | Shock absorbers | Specifications

Chapter Fourteen: Rear Axles and Final Drive
Rear axles | Final drive unit | Specifications

Chapter Fifteen: Brakes
Brake operation | Brake services | Front brake pads | Front brake caliper | Front master cylinder | Rear brake pads | Rear brake caliper | Rear master cylinder | Left hand brake cable replacement | Brake system draining | Brake system bleeding | Brake disc | Specifications

Chapter Sixteen: Body
Body panel fasteners | Seat | Fuel tank side panels | Fuel tank cover and fuel tank | Engine side cover and side panel | Front carrier | Front fender hood | Front bumper and skid plate | Front grille and lights | Front fender assembly | Rear carrier and fender panel | Rear fender | Footrest panels | Center and rear skid plates

Color Wiring Diagrams

Clymer Yamaha ATV repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Yamaha Grizzly 660 Repair Manual 2002-2008