Grizzly 660 Parts Manual

The Grizzly 660 Parts Manual provides comprehensive information on components, part numbers, assembly diagrams, and maintenance specifications for the Yamaha Grizzly 660 ATV. This manual is essential for owners, technicians, and service personnel for identification, ordering, and replacement of genuine Yamaha parts. Below are key sections covering parts identification, diagrams, ordering information, maintenance schedules, and troubleshooting.

Parts Identification Guide

Key components: Engine assembly, chassis frame, suspension system, electrical harness, drive train components.

Component Group	Description
Engine Assembly	Complete engine block with internal components
Chassis Frame	Main structural frame including subframes
Suspension System	Front and rear shocks, A-arms, swingarm
Electrical Harness	Main wiring harness with connectors
Drive Train	CVT components, drive shaft, differential
Fuel System	Tank, pump, injectors, lines
Exhaust System	Header, muffler, heat shields
Braking System	Calipers, rotors, master cylinders
Body Panels	Fenders, seat, storage compartments
Controls	Handlebar controls, cables, levers

Engine Components

Detailed breakdown of engine parts and assemblies.

1. Cylinder Head Assembly: Includes valves, springs, camshaft.
2. Crankcase & Crankshaft: Main engine case with bearings.
3. Piston & Connecting Rod: Piston rings, wrist pin, rod.
4. Timing System: Cam chain, tensioner, sprockets.
5. Lubrication System: Oil pump, filter, cooler lines.

WARNING! Engine components are precision parts; handle with care to avoid damage. Use proper tools for disassembly.

Chassis & Suspension

Frame and suspension component identification.

1. Main Frame: Steel construction with mounting points.
2. Front Suspension: Double A-arms, shocks, tie rods.
3. Rear Suspension: Swingarm, monoshock, linkage.
4. Steering Components: Stem, bearings, handlebar clamp.
5. Wheels & Hubs: Aluminum wheels, hub assemblies.

CAUTION! Inspect suspension components regularly for wear or damage. Replace worn parts immediately.

Electrical System

• Battery: 12V maintenance-free type.
• Starter Motor: Electric start system.
• Alternator: AC magneto charging system.
• Ignition System: CDI unit, coil, spark plug.
• Lighting: Headlights, taillights, indicators.
• Switches: Handlebar controls, kill switch.
• Wiring Harness: Color-coded with connectors.
• Fuses: Main and accessory circuit protection.

Drive System

CVT transmission and final drive components.

Primary Drive: CVT belt, driven/pulley assemblies, weights.

Final Drive: Drive shaft, U-joints, differential assembly.

Axles: Front and rear axle assemblies with CV joints.

Bearings & Seals: Wheel bearings, differential seals.

Maintenance: Regular belt inspection, lubrication of U-joints.

Fuel & Exhaust

Fuel delivery and exhaust system parts.

1. Fuel Tank: Plastic reservoir with cap and vent.
2. Fuel Pump: Electric in-tank type.
3. Injectors: Electronic fuel injection system.
4. Throttle Body: With TPS and idle control.
5. Exhaust Header: Stainless steel construction.
6. Muffler: Spark arrestor equipped.

Tip: Always use genuine Yamaha fuel system components for proper performance.

Body & Accessories

Plastic body panels and optional accessories.

1. Front Fenders: Molded plastic with mounting hardware.
2. Rear Fenders: Integrated with taillight assembly.
3. Seat: Vinyl cover with foam padding.
4. Storage Box: Under-seat compartment.
5. Winch Mount: Front receiver for accessory winch.
6. Rack Systems: Front and rear cargo racks.
7. Light Guards: Protective grilles for headlights.
8. Skid Plates: Underbody protection.

WARNING! Ensure all body fasteners are properly tightened to prevent vibration damage.

Maintenance Parts

Common replacement parts for routine maintenance.

Filters: Oil filter, air filter element, fuel filter.

Fluids: Engine oil, differential oil, brake fluid.

Brake Pads: Front and rear friction material.

Drive Belt: CVT replacement belt.

Spark Plug: Standard and iridium options.

Ordering Information

How to order genuine Yamaha parts.

1. Use the part number from diagrams in this manual.
2. Contact authorized Yamaha dealer with VIN.
3. Verify compatibility with model year (2002-2007).
4. Check availability of superseded parts.

CAUTION! Using non-genuine parts may void warranty and affect performance.

Safety Precautions

Always disconnect battery before electrical work. Use jack stands when working underneath. Wear safety glasses. Follow torque specifications. Dispose of fluids properly.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel delivery, spark plug, compression test.
Poor performance	Clogged filter, worn belt	Replace air filter, inspect CVT belt.
Electrical issues	Battery, connections	Test battery voltage, check ground connections.
Noise from drivetrain	Worn U-joints, bearings	Inspect U-joints, replace worn bearings.
Oil leakage	Seals, gaskets	Replace crank seals, valve cover gasket.

Service Intervals: Refer to maintenance schedule for part replacement timing.

Support: Contact Yamaha dealer or visit Yamaha-Motor.com