2002–2008 Yamaha Grizzly 660 ATV Service Manual Set (P/N 5KM-28197-E0)

This Yamaha service manual set for the 2002–2008 Grizzly 660 (YFM660F) combines the base manual, Manual No. 5KM-28197-E0, with two model-specific supplements. The supplements provide revised specifications and procedures to use with the base chapters.

• Engine repair: Engine removal, cylinder-head and valve service, timing-chain installation, crankcase separation, and crankshaft and oil-pump inspection.

• Belt drive and transmission: V-belt replacement, primary and secondary sheave overhaul, centrifugal-clutch inspection, shift-fork checks, and parking-position mechanism coverage.

• Cooling and carburetion: Radiator pressure testing, thermostat checks, water-pump service, and Mikuni BSR42 carburetor disassembly, inspection, and fuel-level adjustment.

• Shaft drive and differential: CV-joint service, drive-pinion and ring-gear shim selection, backlash measurement, and differential gear-motor testing.

• Brakes and chassis: Hydraulic brake bleeding, master-cylinder and caliper repair, wheel-bearing replacement, steering-knuckle service, and suspension inspection.

• Electrical troubleshooting: Ignition, electric-starting, charging, lighting, and cooling-fan tests, plus 2WD/4WD circuit diagnosis and wiring diagrams.

• Workshop reference: Engine and chassis torque tables, wear limits, lubrication points, exploded assembly diagrams, and illustrated job instruction charts.

This set is suited to technicians and experienced owners who can use electrical test equipment and the special tools required for internal engine and driveline work.

Engine Internals and Belt-Drive Service

Internal repair coverage includes rocker-arm and camshaft checks, valve-seat inspection, piston-to-cylinder measurements, and decompression-system checks. The recoil starter, starter clutch, and AC magneto have their own removal and inspection sections.

Transmission illustrations explain the compact three-shaft layout, chain-driven reverse, and shift-cam-operated park mechanism. Sheave service extends to roller weights, torque-cam grooves, guide pins, and spring inspection; the tool references include sheave spring compressor YM-04134 / 90890-04134.

Changes Documented in the Supplements

The 5KM8/5KMA supplement updates oil-pump inspection limits, starter-clutch details, middle-driven-shaft work, and front differential service. Revised chassis pages cover wheel hubs, steering knuckles, and rear suspension.

The 5KMH/5KMM/5KMN/5KMP supplement supplies different reduction and low/high-range ratios, revised carburetor and suspension data, and updated ignition and charging specifications. It also explains the differential-lock override switch and its speedometer display, with corresponding switch checks and signal-system circuitry.

Shaft-Drive Fault Tracing and Service Limits

Noise and symptom charts help distinguish wheel-bearing trouble from gear-lash or gear-tooth faults before teardown. Middle-gear and final-drive sections include calculations based on component markings, shim selection, and separate adjustment checks.

The middle-driven-shaft procedures flag left-hand bearing-retainer threads, where an incorrect turning direction can damage the threads. Differential assembly instructions address gear-motor indexing: a displaced sliding gear can leave the indicator display out of step with the actual drive mode and prevent engagement.

The base manual's front differential coverage includes case service and backlash adjustment; the factory-assembled internal gear unit is not to be disassembled.

Follow the manual's safety procedures when supporting the ATV, servicing brakes, or handling spring-loaded driveline components.

Cooling, Carburetor, and Wiring References

Coolant flow diagrams and oil flow diagrams show the circulation paths, while cable-routing views identify hose and harness placement. Carburetor inspection distinguishes the float valve, vacuum diaphragm, coasting enricher, jets, and starter plunger.

Electrical fault charts connect test results to specific components and wiring checks. The 2WD/4WD selecting-system circuit diagram supports relay and gear-motor diagnosis; separate YFM660FP and YFM660FS wiring diagrams include connector layouts and wire-color legends.

A Look at Head-Fastener, Coolant, and Gear-Lash Data

These figures are a small sample of the service specifications in the manual.

For cylinder-head installation, the base manual lists 38 Nm for the M9 head bolts, together with a tightening sequence and staged tightening requirements. Cooling-system data lists 1.8 L for the radiator and circulation routes.

The front differential gear-lash specification is 0.05–0.25 mm. Its measurement and shim-selection sections distinguish this setting from middle-gear and rear final-drive adjustments.

PDF Search, Bookmarks, and Included Publications

Search and diagram detail: PDF pages 1–417 contain searchable text; pages 418–466 do not. Chapter and subsection bookmarks are present, but one supplement heading has no working jump target. The full-page wiring diagrams require zooming to read the small labels.

The set is supplied as one printable, 466-page PDF. The publication sections are combined in this order:

The total already includes 22 pages of usage notes, symbol explanations, and contents across these sections.