The Grizzly 660, model code YFM660FP, produced between 2001 and 2002, is a formidable All-Terrain Vehicle (ATV) designed for demanding off-road use. This high-performance utility ATV boasts a torquey 660cc liquid-cooled, four-stroke engine, renowned Ultramatic automatic transmission with selectable 2WD/4WD and a locked front differential, and independent front and rear suspension for superior comfort and terrain handling. Its sealed hydraulic disc brakes on all four wheels provide reliable stopping power. The Grizzly 660 was engineered for recreational riders, hunters, farmers, and utility users, earning a strong reputation for its power, reliability, and robust build in challenging conditions. This comprehensive Service Repair Manual provides detailed guidance for the maintenance and repair of the Grizzly 660 ATV. It covers a wide array of systems, including the engine, transmission, drivetrain, suspension, brakes, and electrical components, offering professional-level diagnostic and repair procedures. The manual includes essential information on routine maintenance, troubleshooting common issues, engine and transmission overhauls, brake service, electrical diagnostics, and suspension repairs. With step-by-step instructions, torque specifications, and high-resolution illustrations, this manual is an indispensable resource for owners and technicians seeking to ensure the optimal performance and longevity of their Grizzly 660. 🏷️ Basic Information Identification Make: Yamaha Model: Grizzly 660 Model Code: YFM660FP Year: 2001-2002 Codes Atv Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Category: High-performance utility ATV Target Audience: Recreational riders, hunters, farmers, and utility users requiring robust off-road capability. Competitive Analysis Competitors Early 2000S: Polaris Sportsman, Can-Am Outlander, Suzuki King Quad, Honda Foreman/Rancher. Key Features Engine: Torquey 660cc liquid-cooled, four-stroke SOHC engine. Drivetrain: Yamaha's Ultramatic automatic transmission with 2WD/4WD selection and locked front differential. Suspension: Independent front and rear suspension for improved comfort and terrain handling. Braking: Sealed hydraulic disc brakes on all four wheels. 📋 Manual Details Coverage Areas Scope: Comprehensive service and repair Page Count Estimated Pages: Varies by specific edition, typically 300-500+ pages for a full service manual Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed breakdown of the 660cc engine, including lubrication, cooling, fuel, ignition, and emissions systems. Transmission: Coverage of the automatic transmission (CVT), including belt inspection, clutch operation, and gearbox maintenance. Drivetrain: In-depth information on the 4x4 system, differentials (front and rear), driveshafts, and wheel hubs. Suspension: Front and rear suspension components, including shock absorbers, springs, A-arms, steering knuckles, and bushings. Brakes: Disc brake systems (front and rear), including hydraulic lines, calipers, master cylinders, and rotor specifications. Electrical: Wiring diagrams, electrical component testing, battery, starter, charging system, lighting, and electronic control units (ECU). Chassis: Frame, body panels, seats, handlebars, footrests, and storage components. Cooling System: Radiator, fan, hoses, coolant specifications, and flushing procedures. Fuel System: Carburetor (Mikuni BSR42), fuel pump, fuel lines, and fuel tank. Steering: Steering column, tie rods, ball joints, and related components. Wheels And Tires: Wheel specifications, tire pressure recommendations, and replacement procedures. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain adjustment (if applicable), lubrication points. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting for common issues. Engine Repair: Top-end and bottom-end engine rebuilds, piston and cylinder inspection, valve clearance adjustment, camshaft installation. Transmission Overhaul: CVT belt replacement, clutch component inspection and replacement, gearbox dis assembly and reassembly. Brake Service: Brake pad replacement, caliper service, master cylinder overhaul, brake bleeding procedures. Electrical Diagnostics: Testing of ignition system, charging system, starter motor, lighting circuits, and ECU diagnostics. Suspension Repair: Shock absorber replacement, bushing replacement, ball joint inspection and replacement, steering component service. Carburetor Tuning: Carburetor cleaning, adjustment, and synchronization. Drivetrain Maintenance: CVT drive belt inspection and replacement, differential oil changes, driveshaft inspection. Technical Depth Level: Professional-level diagnostic and repair procedures, suitable for mechanics and experienced DIY enthusiasts. Detail: Includes torque specifications, clearances, diagnostic values, and step-by-step instructions with accompanying illustrations. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content allows for quick location of specific information. Print Quality Image Resolution: High-resolution illustrations and diagrams for clarity. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, SOHC, single-cylinder Displacement: 660 cc Bore X Stroke: 100 mm x 84 mm Compression Ratio: 9.1:1 Valve Train: SOHC, 4 valves per cylinder Performance Horsepower Est: Approximately 45-50 HP (estimated, factory figures not always published) Torque Est: Approximately 38-42 lb-ft (estimated) Fuel System Carburetor: Mikuni BSR42, single, with throttle position sensor (TPS) Fuel Capacity: 5.1 gallons (19.3 L) Recommended Fuel: Unleaded gasoline, 87 octane or higher Lubrication Oil Capacity: 2.3 US qt (2.2 L) with filter change Engine Oil Type: Yamaha Motorcycle Oil SAE 10W-40 (API SG or higher) or equivalent 🔧 Transmission Standard Type: Yamaha Ultramatic V-belt automatic transmission with engine braking Drive Modes: 2WD / 4WD with locking front differential Optional Gear Reduction: High and Low range Features Belt Type:...