Yamaha Grizzly 660 Manual Set – 2005 Owner’s Manual + Workshop Manuals (P/N LIT-11626-18-03)

Yamaha directs technicians to use the FR supplement with the FP base manual and the FS supplement with both earlier publications.

Model coverage. For the 2005 YFM660FAT, this set provides owner-level operating, maintenance, and troubleshooting information. Workshop coverage applies to the YFM660FP, YFM660FR, and YFM660FS.

PDF Bookmarks, Search, and Wiring Detail

Navigation and diagram detail. Both PDFs have chapter and section bookmarks. Text search covers the main owner’s chapters and the FP and FS service material. The FR supplement opens through bookmarks and is read page by page. Some owner’s back matter, including the safety card, is also outside text search. Zoom in to read the smaller connector labels and wire color codes on the FP and FS wiring diagrams.

The ZIP contains two printable English PDFs totaling 676 pages. One contains the owner’s manual and the other combines the three workshop publications. Covers, introductory pages, the owner’s warranty and supplemental pages, and the two-page safety card are included in that total.

Engine, Drivetrain, and Electrical Service

This selection of workshop topics sits alongside owner’s manual material on cold starting and shock absorber preload adjustment.

• Engine repair: Engine removal and installation, cylinder head and valve service, camshaft timing, piston and cylinder inspection, and crankshaft inspection and replacement.
• V-belt drive and transmission: Primary and secondary sheave disassembly, centrifugal clutch inspection, shift fork and reverse-drive chain service, and select-lever cable and shift rod adjustment.
• Shaft drive: Front and rear CV joints, middle gears, and rear final drive service, with shim selection, gear backlash measurement, and front differential gear motor alignment.
• MIKUNI BSR42 carburetor: Teardown, diaphragm and needle valve inspection, and float height and fuel level adjustment.
• Cooling system: Radiator cap pressure testing, thermostat checks, and water pump disassembly, inspection, and reassembly.
• Brakes and chassis: Hydraulic master cylinder and caliper service, pad replacement, bleeding, and work on wheel bearings, steering knuckles, tie rods, suspension arms, and the rear stabilizer.
• Electrical diagnosis: Ignition, starting, charging, cooling fan, and four-wheel-drive fault tracing, with circuit diagrams, switch continuity charts, and component tests.

The owner’s manual is for Grizzly riders handling pre-ride checks and routine upkeep. Yamaha wrote the workshop publications for dealers and qualified mechanics.

YFM660FAT Controls, Riding, and Upkeep

The owner’s manual explains On-Command four-wheel drive, differential lock, the override switch, and the auxiliary DC jack. Pre-ride checks address fluids, brakes, throttle operation, tire pressure, and axle boots. The riding section covers climbing, descending, crossing slopes, and shifting rider weight. It distinguishes carrier loads, trailer pulling load, tongue weight, and total vehicle loading.

Maintenance covers panel removal, engine oil and filter replacement, gear oil and coolant changes, and air filter and spark arrester cleaning. It also explains the V-belt cooling duct check hose and case drain after water exposure. Yamaha refers valve clearance and select-lever safety cable adjustments to a dealer. Illustrated pages locate warning labels, the VIN, and the model label. Troubleshooting charts address starting problems, poor performance, and overheating.

FR and FS Service Updates

The FR supplement revises cable routing and procedures for the starter clutch, middle driven shaft, front differential, and wheel hub hardware. It also covers steering and rear knuckle bearings, the stabilizer, and rear suspension removal.

The FS supplement explains how the differential lock override appears on the speedometer and updates the switch continuity checks and signal circuit. It also documents revised carburetor, suspension, ignition, and transmission ratio specifications.

Wiring, Special Tools, and Repair Limits

Coolant and oil flow diagrams trace fluid paths. The electric starting circuit diagram shows the starter interlock, and the 2WD/4WD selecting circuit diagram and its relay, switch, and gear motor tests help isolate an electrical selection fault. Full FP and FS wiring diagrams identify components and wire colors.

Exploded views accompany removal and disassembly procedures. Torque tables, wear limits, clearances, fuel and fluid capacities, compression test data, and electrical specifications support inspection and reassembly. Special tools include the YM-04134 secondary sheave spring compressor and the FR supplement’s YM-01486 coupling gear holding tool.

The FP manual directs technicians to keep the factory-assembled differential gear unit intact. The FR supplement gives a revised differential case procedure, and both publications direct technicians to leave the gear motor assembled. The FP manual warns that direct press loading can damage the middle driven shaft threads and that insufficient backlash can damage gear teeth. Brake-system repair and drivetrain reassembly require a qualified technical background because errors can compromise vehicle control.

Sample FP Valve Clearances and Belt Wear Limit

For the YFM660FP, the valve adjustment section specifies cold clearances of 0.10–0.15 mm at the intake and 0.15–0.20 mm at the exhaust. The V-belt inspection gives a minimum belt width of 29.9 mm (1.18 in) as the replacement limit.