Yamaha YF660FP ATV 2002-2008 OEM Service Manual (P/N LIT-11616-15-01)

This official PDF service publication (P/N LIT-11616-15-01, Form 5KM-28197-E0) serves as the primary technical reference for keeping the 2002–2008 YFM660FP Grizzly series in peak operating condition. It details all periodic maintenance schedules, engine overhauls, and electrical troubleshooting necessary for professional shop work or serious DIY repair.

• Covers liquid-cooled 660cc 4-stroke engines and V-belt automatic transmissions
• Contains 407 pages of raw technical data, including detailed torque tables, wiring schematics, and fluid-capacity charts
• Features step-by-step procedures for the carburetor, water pump, constant velocity joints, AC magneto, recoil starter, middle gear, and steering knuckles
• Includes exploded diagrams, circuit diagrams, coolant flow diagrams, oil flow diagrams, cable routing views, job instruction charts, and troubleshooting charts

Component and System Documentation

The manual organizes information into ten dedicated chapters, stripping down every major system. Need to rebuild the top end? The engine section extensively covers the cylinder head, camshaft, valves, pistons, and both the primary and secondary sheaves. Drivetrain documentation explains the intricate operation of the front differential—specifically the 4WD and Diff-Lock modes—alongside rear final drive assemblies. Chassis tear-downs cover front and rear brake disc procedures, steering system alignments, and precise suspension settings. By outlining comprehensive step-by-step instructions for labor-intensive tasks like bleeding the hydraulic brake system, adjusting valve clearances, and measuring differential gear lash, this manual allows you to perform complex maintenance in-house, effectively bypassing expensive trips to the dealership.

Technical Specification Preview

Factory reference values ensure precise clearances and tolerances, significantly reducing bench time and preventing costly drivetrain comebacks. The publication provides exact figures for the entire machine. For instance, cylinder head bolt torque is strictly documented at 38 Nm, while spark plugs require a snug 18 Nm. Engine idle speed sits comfortably at 1,450–1,550 r/min. If you are flushing the system, note the 1.8-liter total cooling capacity across all routes. Electrical diagnostics are just as precise, listing the ignition coil secondary winding resistance at 6.32–9.48 k-ohms at 68 degrees Fahrenheit (20 degrees Celsius). Working on high-torque ATV drivetrains and suspension systems carries inherent physical risks. Always verify your tools and environment, and consider bringing in certified professionals for complex electrical or high-pressure hydraulic work.