1998–2008 Yamaha Grizzly 600, 660 ATV Service Manual Set (P/N 5KM-28197-E0)

This Yamaha Grizzly 600 and 660 ATV service manual set combines two base manuals with supplements covering revised specifications, drivetrain components, chassis details, and electrical systems. The Grizzly 660 base manual is identified as Manual No. 5KM-28197-E0. Supplements work with the corresponding base manual for procedures they do not repeat.

• Engine repair: Engine removal, cylinder-head and valve work, piston inspection, crankcase separation, and crankshaft and balancer installation.

• CVT and transmission: V-belt inspection, primary and secondary sheave disassembly, centrifugal-clutch checks, and internal transmission inspection and assembly.

• Shaft drive: Constant velocity joint repair, differential and final-drive inspection, gear-lash measurement, shim selection, and universal-joint service.

• Fuel and cooling: Mikuni carburetor inspection and fuel-level adjustment, plus Grizzly 660 radiator, thermostat, and water-pump service.

• Brakes and chassis: Hydraulic brake bleeding, master-cylinder and caliper service, Grizzly 600 rear drum-brake repair, and steering and suspension inspection.

• Electrical diagnosis: Circuit diagrams and troubleshooting charts for ignition, starting, charging, lighting, cooling-fan operation, and the 2WD/4WD selecting system.

This set is suited to mechanics with ATV repair experience and access to the measuring equipment and special tools used in the inspection and assembly procedures.

Engine Inspection, Valve Timing, and CVT Repair

Engine inspection covers valve guides and seats, camshaft lobes, piston rings, crankshaft runout, and oil-pump clearances. Exploded assembly views and job tables accompany the removal and assembly work, with component-specific tolerances, wear limits, and tightening specifications.

Camshaft installation addresses timing-mark alignment and decompressor positioning. The clutch sections specify the inward-facing flange on the one-way clutch bearing and matched replacement of the one-way clutch assembly and clutch housing.

Primary and secondary sheave service includes spring compression, inspection of sliding components, and reassembly. The transmission chapters cover shift forks, gears, shafts, and the related operating checks.

Shaft-Drive Setup and Differential Service Limits

Shim-selection charts and dial-gauge methods support gear setup after bearing, housing, or gear replacement. The tool listings identify the gear-lash measurement tool YM-01467 / 90890-01467, connecting the inspection procedures with the equipment needed for the work.

The base manuals warn against opening the internal differential unit assembled at the factory. Grizzly 660 supplement procedures revise the coupling-gear and front-drive-shaft work; the gear motor remains a unit that must not be internally disassembled.

Middle-gear service flags a left-hand-threaded bearing retainer and warns that pressing directly on the shaft end can damage its threads.

Carburetor Inspection and Cooling-System Tests

Carburetor procedures cover the diaphragm, needle valve, float mechanism, and fuel-level measurement. The Grizzly 600 supplements distinguish regional carburetor specifications, including California settings.

Grizzly 660 cooling-system work includes radiator-cap pressure testing, thermostat testing, and water-pump disassembly and seal installation. Coolant Flow Diagrams and Oil Flow Diagrams trace the passages associated with those systems.

Brake, Steering, and Suspension Work

The chassis chapters distinguish the Grizzly 600 rear drum brake and swingarm from the Grizzly 660 rear disc brake and independent rear suspension. Steering-knuckle and bearing inspections are supported by toe-in, steering-geometry, and suspension-spring specifications.

Use appropriate protective equipment and follow the manual’s precautions for fuel handling, hot coolant, brake work, and spring-loaded sheave assemblies.

Electrical Fault Isolation and Wiring References

Ignition troubleshooting links spark, coil, switch, and wiring checks to the applicable test specifications. These charts help narrow a no-spark complaint to the affected circuit or component before replacement parts are selected.

The YFM660FP and YFM660FS Wiring Diagrams provide connector and wire-color references alongside the Ignition System circuit diagrams. Cable Routing drawings identify harness, hose, and control-cable placement during reassembly.

The YFM660FS supplement adds override-switch operation, continuity checks, and the associated signal-system circuitry.

A Preview of Valve Clearances and Engine Service Data

Cold intake-valve clearance is 0.05–0.10 mm in the Grizzly 600 material, compared with 0.10–0.15 mm in the Grizzly 660 base manual.

The Grizzly 600 cylinder-head installation section lists 29 Nm for its M8 bolts within a sequenced, two-stage tightening procedure. Other cylinder-head fasteners have separate specifications.

Both base manuals specify 1.9 L for a periodic engine-oil change, with separate capacities listed for filter replacement and total filling.

PDF Search Coverage and Wiring Detail

Navigation and legibility: Embedded bookmarks link chapters and supplements, although document-start links open on divider pages. Text search covers most of the Grizzly 660 base manual and the YFM660FS supplement; it does not cover the Grizzly 600 publications or the 5KM8/5KMA supplement. Enlarged 660 wiring labels are legible, while dark backgrounds obscure some small labels in the 600 circuit diagrams.

A single printable, English-language PDF contains 807 pages:

Five additional divider pages are already included in the total.