This manual covers the YFM660 Grizzly All-Terrain Vehicle (ATV), specifically the first generation models produced between 2002 and 2007, identified by model codes YFM660F and YFM660FG. Renowned for its powerful 660cc liquid-cooled engine, automatic Ultramatic® transmission with engine braking, and true 4WD system with differential lock, the YFM660 Grizzly established itself as a benchmark in the utility ATV segment. Its robust construction, comfortable ride, and significant towing capacity make it a capable machine for a wide range of off-road applications. The legacy in ATV innovation is evident in the key features of this model, including its substantial horsepower and torque, and its durable design for demanding terrains. This comprehensive service repair manual in English provides essential information for owners, DIY mechanics, and professional technicians. It details routine maintenance procedures, such as oil changes, filter replacements, and valve adjustments, alongside in-depth repair instructions for all major systems. Coverage includes the engine, fuel, drivetrain, electrical, suspension, braking, and steering systems, with specific guidance on troubleshooting common issues and understanding technical specifications. With approximately 300-400 pages of illustrated step-by-step instructions and detailed diagrams, this manual is designed to facilitate efficient maintenance and repair, ensuring the optimal performance and longevity of your YFM660 Grizzly. 🏷️ Basic Information Identification Make: Yamaha Model: YFM660 Grizzly Vehicle Type: All-Terrain Vehicle (ATV) Generation Generation: First Generation Codes Model Codes Covered: YFM660F, YFM660FG 👋 Introduction Market Position Target User: Owners, DIY mechanics, and professional service technicians seeking detailed repair and maintenance information for the Yamaha YFM660 Grizzly. Competitive Analysis Value Proposition: Provides essential, manufacturer-level technical data, enabling cost-effective maintenance and repair compared to dealership services. Crucial for maintaining optimal performance and longevity. Key Features Manual Features: Illustrated step-by-step instructions, detailed diagrams, troubleshooting flowcharts, and comprehensive technical specifications. 📋 Manual Details Coverage Areas Model Years Covered: 2002, 2003, 2004, 2005, 2006, 2007 Page Count Estimated Page Count: Approx. 300-400 pages (typical for comprehensive service manuals of this era) Manual Type Manual Type: Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, troubleshooting, lubrication, cooling, valve adjustments, piston/cylinder inspection, camshaft timing, carburetor overhaul and adjustment, decompression system. Fuel System: Fuel tank, fuel pump, fuel lines, carburetor (Mikuni BSR42), fuel filter, fuel shut-off valve. Drivetrain System: Automatic transmission (V-belt type), clutch (drive and driven), gear shift mechanism, drive shafts, differentials (front and rear), wheel hubs. Electrical System: Ignition system (CDI), starter motor, charging system (stator, rectifier/regulator), battery, lighting (headlights, taillights, brake lights), wiring diagrams, switches, fuses, diagnostics. Suspension System: Front and rear suspension components, shock absorbers, springs, A-arms, bushings, bearings, alignment procedures. Braking System: Front and rear hydraulic disc brakes, brake calipers, master cylinders, brake lines, brake pads, brake fluid specifications and bleeding procedures. Steering System: Handlebar, steering shaft, tie rods, ball joints, knuckle assembly, steering system troubleshooting. Frame And Body: Frame inspection, body panels (fenders, plastics), seat, racks, storage compartments, mounting hardware. Cooling System: Radiator, cooling fan, coolant types and capacities, thermostat, hoses, water pump. Procedures Included Maintenance Procedures: Regular service checks, oil changes, filter replacements, lubrication points, spark plug replacement, air filter cleaning/replacement, valve clearance checks, brake pad inspection/replacement, chain adjustment (if applicable on specific models). Repair Procedures: Complete engine rebuild, transmission overhaul, carburetor tuning and repair, suspension component replacement, brake system bleeding and repair, electrical component testing and replacement, starter motor repair, carburetor jetting. Troubleshooting Guides: Step-by-step diagnostic charts for common problems related to starting, running, electrical issues, braking, and drivetrain performance. Technical Specifications Charts: Detailed torque specifications, clearances, fluid capacities, electrical resistance values, and engine timing parameters. Technical Depth Depth Of Coverage: Comprehensive from basic routine maintenance and adjustments to complete engine and transmission overhauls, including electrical system diagnostics and component-level repair. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Image Resolution: High-resolution scans suitable for clear viewing and printing of diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Text Searchability: Likely text-searchable within the PDF for quick information retrieval. ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 5-valve, liquid-cooled Displacement: 660 cc Bore X Stroke: 95.0 mm x 93.2 mm Compression Ratio: 8.1:1 Carburetor: Mikuni BSR42 (Constant Velocity) Ignition: CDI (Capacitor Discharge Ignition) Oil Type: Yamalube 4 (or equivalent SAE 10W-40 API SG or higher) Oil Capacity: Approx. 2.2 L (with oil filter change) Performance Horsepower Approx: Approx. 40-45 HP (Figures vary slightly by region and specific model year tuning) Torque Approx: Approx. 50-55 Nm (Figures vary slightly by region and specific model year tuning) Fuel System Fuel Type: Unleaded gasoline, 87 octane (minimum) Fuel Tank Capacity: 15.0 L (including reserve) 🔧 Transmission Standard Transmission Type: Automatic (Yamaha Ultramatic® Transmission - CVT) Drive System: Shaft drive, 4WD with differential lock Gear Reduction: High, Low, Neutral, Reverse, Park Features Belt Type:...