2001 Yamaha Grizzly 660 YFM660FP Service Manual

Diagnostic procedures and component service for Yamaha Grizzly 660 YFM660FP. Documents paper handling and control panel diagnostics. PN LIT-11616-15-01

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Document Details

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Document Number / Seller:
28252 / Kevin Stewart
File Size:
12.27 MB
File Type:
PDF
Language:
Pages:
408
Printable:
Yes
Category:
ATV
Last updated / verified
Dec 29, 2025

Models Covered & Key Technical Specifications

Complete Calibration Manual: Yamaha Grizzly 660 YFM660FP (2001) ATV Workshop-Compendium

Diagnostic procedures and component service for Yamaha Grizzly 660 YFM660FP. Documents paper handling and control panel diagnostics. PN LIT-11616-15-01 | Structured Compendium Package.

  • Factory Clearance Data: 0.05 ~ 0.07 mm (0.0020 ~ 0.0028 in) is the standard piston-to-cylinder clearance Range.
  • Essential End Play: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) requires measurement for intake valve stem-to-guide clearance Requirements.
  • Key Power Draw: 36.46 mm (1.44 in) delivers the free length of the exhaust valve spring Baseline.
  • Verified Precision Specs: The engine oil level between the maximum and minimum marks indicates the proper oil quantity Threshold.
  • Designated Holding Capacity: 1.9 L (1.7 lmp qt, 2.0 US qt) supports the periodic oil change amount Benchmarks.
  • Approved Piston Wear Data: For the piston pin outside diameter, 21.971 mm (0.8650 in) is the limit for continued operation Specifications.

Professional Workshop Service Manual & Technical Specifications

Complete Calibration Manual: Yamaha Grizzly 660 YFM660FP (2001) ATV Workshop-Compendium

Product-Line: Yamaha Grizzly 660 YFM660FP (2001) // Design-Core: ATV / 4WD Logic // Assembly-Group: Service & Shop Manual The documentation provides guidance on:

Engine

Cooling System

Carburetion

Drive Train

Chassis

The manual details procedures for engine operation, cooling system maintenance, carburetor adjustments, drive train service, and chassis inspection. It includes comprehensive technical data for all major systems.

Engine Mechanism

Procedures for engine disassembly and reassembly are detailed, including valve clearance adjustments, timing chain checks, and piston ring inspection. Specific torque values are provided for critical engine components to ensure proper fastener fatigue prevention.

Chassis and Drivetrain Systems

This section covers chassis maintenance, including suspension adjustments and brake system servicing. Drivetrain components such as the differential gears and drive shafts are explained, with information on lubrication and backlash measurements.

Electrical System

Details on the electrical system include checks for switches, bulbs, and the charging system. Troubleshooting guides for common electrical issues are also provided, facilitating efficient problem diagnosis.

Maintenance and Lubrication Schedules

The manual outlines periodic maintenance and lubrication intervals, ensuring optimal vehicle performance and longevity. It details specific checks for components like brakes, V-belts, and tires, along with recommended lubricants.

Troubleshooting Guide

Includes a troubleshooting section to help diagnose and resolve common issues with the engine, drive train, and electrical systems. The manual documents procedures to ensure proper operation and maintainability.

FAQ

Assess the **critical** calibration settings for the Yamaha Grizzly 660? keyboard_arrow_down

0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) is the standard valve clearance for the intake valve, and 0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in) for the exhaust valve.

What components have **required** clearance measurements for the Yamaha Grizzly 660? keyboard_arrow_down

0.05 ~ 0.07 mm (0.0020 ~ 0.0028 in) is the standard piston-to-cylinder clearance, with a limit of 0.15 mm (0.0059 in) for the Yamaha Grizzly 660.

Confirm the **specified** torque specifications for the Yamaha Grizzly 660. keyboard_arrow_down

14 Nm (1.4 m•kg, 10.1 ft•lb) is the specified torque for the recoil starter installation on the Yamaha Grizzly 660.

What tools are **essential** for safety precautions on the Yamaha Grizzly 660? keyboard_arrow_down

32 Nm (0.32 kg/cm², 4.6 psi) for the front tire pressure and 27 kPa (0.27 kg/cm², 3.9 psi) for the rear tire pressure are essential precautions to prevent tire dislodging.

Identify the **correct** lubrication requirements for the Yamaha Grizzly 660. keyboard_arrow_down

SAE 80 API “GL-4” Hypoid Gear Oil is the correct type for the final gear oil and differential gear oil on the Yamaha Grizzly 660.

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The download process was a breeze, and the manual is incredibly detailed. It helped me understand my ATV better!
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I had a few questions and reached out for support. They responded quickly and were very helpful! The manual covers everything I needed.