This workshop service manual covers the model, produced for the years 2002 through 2005. The Grizzly is renowned for its robust 660cc, liquid-cooled, single-cylinder engine, automatic CVT transmission, and selectable 4WD system with a locking front differential, making it a capable machine for off-road exploration and demanding tasks. With a focus on durability and performance, the Grizzly has been engineered to offer reliable power and handling across various terrains, supported by its substantial ground clearance and towing capacity. This comprehensive 508-page English manual provides detailed instructions for the complete repair and overhaul of all major systems, including the engine, transmission, fuel, ignition, electrical, body, frame, suspension, brakes, cooling, and drive systems. It covers routine maintenance, tune-ups, removal and installation procedures, disassembly and assembly, and troubleshooting for common issues. The manual is designed to empower owners and technicians with the knowledge to perform dealership-level service, ensuring the longevity and optimal performance of the Grizzly. 🏷️ Basic Information Identification Make: Yamaha Model: Grizzly Model Code: YFM660FR Model Years Covered: 2002, 2003, 2004, 2005 Codes Chassis Code: YFM660FR 👋 Introduction Market Position Target Audience: Owners and technicians seeking comprehensive repair and maintenance information Competitive Analysis Value Proposition: Provides dealership-level service information for DIY maintenance and repair, saving time and money Key Features Completeness: Complete Service Manual containing all necessary instructions for any repair Accuracy: Endeavors to ensure accuracy of information, providing reliable repair guidance Usability: Aids users in understanding component functions and judging overall vehicle performance 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive repair and overhaul Page Count Page Count: 508 Manual Type Manual Type: Workshop Service Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Full engine disassembly, repair, and overhaul Transmission: Full transmission disassembly, repair, and overhaul Fuel System: Carburetor tuning, cleaning, and overhaul; fuel pump and lines Ignition System: Ignition coil testing, spark plug specifications, CDI unit troubleshooting Lubrication System: Oil pump operation, oil filter replacement, lubrication points Exhaust System: Muffler inspection and repair, exhaust pipe mounting Electrical System: Wiring diagrams, component testing, lighting, battery, charging system Body And Frame: Panel removal and installation, frame inspection, seat and handle bar assembly Suspension: Front and rear suspension component inspection, adjustment, and replacement Brakes: Brake caliper overhaul, brake pad replacement, hydraulic system bleeding Cooling System: Radiator service, coolant specifications, fan operation Drive System: CVT system maintenance and repair, drive shaft inspection Procedures Included Tune Ups: Detailed procedures for engine tuning and carburetor adjustments Maintenance: Routine maintenance tasks, lubrication, fluid changes, filter replacements Removal Installation: Step-by-step instructions for removing and installing all major components Disassembly Assembly: Detailed instructions for component and sub-assembly breakdown and reassembly Troubleshooting: Diagnostic procedures for identifying and resolving common and uncommon issues Overhaul: Complete overhaul procedures for engine, transmission, and other key components Technical Depth Depth: Extensive, covering basic maintenance to complete engine rebuilds Proprietary Components: Includes instructions for proprietary Yamaha components and guidance for third-party components 📊 Manual Specifications File Format File Format: PDF Digital Delivery: Fast and Free Electronic Delivery via Email Print Quality Printable: Yes Binding Type Binding Type: Digital Download (PDF) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 5-valve, Liquid-cooled, Single Cylinder Displacement: 660cc Bore X Stroke: 100.0 mm x 85.0 mm (Actual specs may vary, consult manual for exact figures) Compression Ratio: 9.2:1 (Typical for this engine family, consult manual for exact figure) Performance Horsepower: Approx. 40-45 HP (Varies by region and tuning, consult manual for exact specs) Torque: Approx. 40-45 lb-ft (Varies by region and tuning, consult manual for exact specs) Fuel System Fuel Delivery: Mikuni BSR33 carburetor (likely, specific model covered in manual) Fuel Type: Unleaded gasoline Fuel Tank Capacity: Approx. 4.2 US gallons (Consult manual for exact capacity) Lubrication Oil Type: Yamalube 4 (or equivalent high-quality ATV 4-stroke engine oil, consult manual for specific viscosity and API classification) Oil Capacity: Approx. 2.2 US quarts (Consult manual for exact capacity without filter change/with filter change) 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Drive System: Shaft drive, selectable 4WD with locking front differential Features Transmission Fluid: Yamalube 4 10W-40 (or equivalent, consult manual for precise specification) Gear Reduction: High/Low range with Reverse 📐 Dimensions Exterior Overall Length: Approx. 76.8 in (1950 mm) Overall Width: Approx. 43.7 in (1110 mm) Overall Height: Approx. 45.1 in (1145 mm) Weights Dry Weight: Approx. 591 lbs (268 kg) Ground Clearance: Approx. 10.0 in (254 mm) Towing Capacity: Approx. 1102 lbs (500 kg) (Consult manual for specific limitations) Rack Capacity Front: Approx. 99 lbs (45 kg) Rack Capacity Rear: Approx. 187 lbs (85 kg) 🛡️ Safety Features Ratings Safety Features Standard: All-wheel drive, selectable differential lock, powerful braking system Active Features Active Safety: Engine braking, reliable suspension for stability Passive Features Passive Safety: Sturdy frame construction, comfortable seating position 💡...