Factory Service & Shop Manual: Yamaha Grizzly 660 YFM660FP (2001) ATV

Ultimate 2001 Yamaha Grizzly 660 YFM660FP Service & Repair Manual

Master your machine with the definitive professional-grade service manual for the 2001 Yamaha Grizzly 660. This first-edition guide, originally released in May 2001 by Yamaha Motor Corporation U.S.A., provides the specialized technical knowledge required to maintain and repair one of the most powerful ATVs of its era. Whether you are performing a simple oil change or a complete engine overhaul, this manual delivers factory-spec precision for every task related to the Grizzly 660 series.

Covered Models and Identification

This manual is specifically engineered for the following models:

• Yamaha Grizzly 660 YFM660FP (2001)
• Yamaha Grizzly 660 YFM660F (2001)

To ensure you are using the correct data for your specific vehicle, refer to the identification numbers located on your machine. This manual covers units starting with the following serial number ranges:

• Primary ID: 5KM-000101 and higher
• Engine Serial Number: 5KM-000101 and higher

Comprehensive Technical Coverage

This guide goes far beyond basic maintenance. It features 5KM-specific data and detailed schematics across several critical systems of the Grizzly 660:

• Liquid-Cooled 660cc Engine: Full teardown and assembly instructions for the 4-stroke, single-cylinder power plant. Includes precise valve clearance adjustments, decompressor system timing, and cylinder head torque sequences.
• On-Command 4WD System: Specialized troubleshooting and repair procedures for the famous Yamaha On-Command 4WD and differential gear lock systems, including gear motor testing and relay configurations.
• Drivetrain & Ultramatic Transmission: Detailed service steps for the Ultramatic V-belt transmission, centrifugal clutch, and the sophisticated constant-mesh 5-speed gearbox (including high, low, and reverse ranges).
• Chassis & Suspension: Complete specs for the double-wishbone front suspension and the swingarm (monocross) rear suspension. Includes shock absorber adjustment and front/rear hydraulic disc brake maintenance.
• Electrical & Troubleshooting: Deep-dive into the CDI ignition system, electric starter, and the cooling fan circuit (including thermo switch 1 and 2 testing).

Professional Features for DIY Success

• Detailed Specifications: Gain access to exact tightening torques, wear limits, and fluid capacities (including the 2.3-liter engine oil capacity and 1.2-liter coolant system).
• Wiring Diagrams: Full-color coded electrical schematics help you trace circuits for headlights, signaling systems, and the auxiliary DC jack.
• Step-by-Step Instructions: Organized by system (General, Engine, Carburetion, Chassis, Electrical) with clear, exploded diagrams that show how every nut and bolt fits together.
• Optimized for Use: Designed with logical section headers and clear indexing to help you find the exact repair procedure you need in seconds.

Investing in this manual provides the technical clarity needed to extend the lifespan of your Yamaha Grizzly 660, ensuring peak performance on the trail and reliability in the most demanding conditions.