Yamaha Grizzly 660 Parts Manual

The Yamaha Grizzly 660 Parts Manual provides comprehensive information for the identification, ordering, and replacement of components for the Yamaha Grizzly 660 ATV. This manual covers the complete parts catalog, including engine assembly, chassis, electrical system, transmission, suspension, brakes, and body panels. Below are key sections for parts identification, diagrams, ordering information, maintenance schedules, and compatibility notes.

1. Parts Identification & Diagrams 2. Engine Assembly Parts 3. Chassis & Suspension Parts 4. Electrical System Parts 5. Transmission & Drivetrain Parts 6. Brake System Parts 7. Body & Accessory Parts 8. Maintenance Schedule 9. Parts Ordering Information 10. Safety & Handling 11. Troubleshooting & Compatibility

Parts Identification & Diagrams

Key components: Exploded-view diagrams with part numbers for all major assemblies.

Diagram Section	Description
Engine Assembly	Complete breakdown of cylinder, piston, crankshaft, valves
Chassis Frame	Main frame, subframe, brackets, and mounting points
Suspension System	A-arms, shocks, springs, bushings, and linkages
Electrical Harness	Wiring, connectors, switches, and sensors
Transmission Case	Gears, shafts, bearings, and seals
Brake Calipers	Pads, rotors, master cylinders, lines
Body Panels	Fenders, seat, fuel tank, skid plates
Drive System	CVT components, drive shaft, U-joints
Cooling System	Radiator, hoses, water pump, thermostat
Exhaust System	Header, muffler, heat shields, gaskets

Engine Assembly Parts

Complete parts list for the 660cc liquid-cooled, SOHC, 4-stroke engine.

Cylinder Head Assembly: Includes head gasket, camshaft, valve springs, rocker arms.
Piston & Cylinder: Piston rings, wrist pin, cylinder liner, base gasket.
Crankshaft & Connecting Rod: Main bearings, rod bearings, balance shaft.
Valve Train: Valves (intake/exhaust), guides, seals, keepers.
Oil System: Oil pump, filter, cooler, lines, and passages.

WARNING! Use only genuine Yamaha parts for engine assembly to ensure proper fit and performance.

Chassis & Suspension Parts

Parts for the steel frame and independent double-wishbone suspension.

Frame: Main frame part number, weld points, and reinforcement brackets.
Front A-Arms: Upper and lower arms, ball joints, bushings.
Rear Swingarm: Pivot bearings, carrier, and linkage.
Shock Absorbers: Front and rear shocks, springs, preload adjusters.
Steering Components: Stem, handlebar clamp, tie rods, ends.

CAUTION! Inspect all suspension parts for cracks or wear before installation.

Electrical System Parts

Ignition System: CDI unit, spark plug, coil, pulse generator.
Charging System: Stator, regulator/rectifier, battery.
Lighting: Headlight assembly, tail light, brake light, indicators.
Switches: Handlebar controls, ignition switch, kill switch.
Wiring Harness: Main harness, sub-harnesses, connectors, grommets.
Sensors: Oil pressure, temperature, throttle position.
Instruments: Speedometer, gauge cluster, warning lights.
Starting System: Starter motor, solenoid, relay.

Transmission & Drivetrain Parts

Parts for the Ultramatic automatic transmission and 4WD system.

Transmission: Primary & secondary sheaves, drive belt, weights, springs.

Drive Shaft: Front and rear shafts, U-joints, boots, seals.

Differential: Front differential assembly, gears, bearings, lock mechanism.

Axles: CV axles, boots, clamps, axle nuts.

Final Drive: Sprockets, chain, tensioner, guard.

Brake System Parts

Dual hydraulic disc brakes front and single disc rear.

Front Brakes: Calipers, pads, rotors, master cylinder, lines.
Rear Brakes: Caliper, pad, rotor, parking brake assembly.
Brake Fluid: DOT 4 specification.
Brake Lines: Steel braided lines, banjo bolts, washers.

Tip: Always replace brake pads in sets and bleed system after service.

Body & Accessory Parts

Plastic body panels and optional accessories.

Front Fenders: Left and right fender assemblies, mounting brackets.
Rear Fenders: Fender set, mud flaps, storage compartment.
Seat: Seat cover, foam, latch mechanism.
Fuel Tank: Tank assembly, cap, petcock, mounting straps.
Skid Plates: Front, engine, and swingarm skid plates.
Accessories: Winch mount, cargo racks, brush guards, light bars.

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

Maintenance Schedule

Recommended part replacement intervals for optimal performance.

Component	Interval	Part Numbers
Engine Oil & Filter	Every 100 hours/6 months	Oil Filter: 5GH-13440-00-00
Air Filter	Every 50 hours	Air Filter: 5GH-14451-00-00
Spark Plug	Every 200 hours	Spark Plug: CR9E (NGK)
Drive Belt	Every 500 hours	Belt: 5GH-17641-00-00
Brake Pads	As needed (check wear)	Front: 5GH-W0047-00-00
CVT Weights/Springs	Every 300 hours	Weights: 5GH-17651-00-00
Differential Fluid	Every 200 hours	Fluid: Yamaha Hypoid Gear Oil
Wheel Bearings	Every 400 hours	Bearing Kit: 5GH-11681-00-00

Parts Ordering Information

How to order genuine Yamaha parts using this manual.

Ordering: Provide dealer with part number, quantity, and description.

Dealer Locator: Use Yamaha's online dealer locator for authorized service centers.

Warranty: Genuine Yamaha parts come with a 12-month limited warranty.

Safety & Handling

Always follow safety procedures when handling ATV parts.

CAUTION! Wear appropriate PPE (gloves, eye protection) when servicing. Use proper lifting equipment for heavy components like engine or transmission. Dispose of fluids according to local regulations.

Troubleshooting & Compatibility

Symptom	Possible Cause	Parts to Check/Replace
Engine won't start	Ignition or fuel system	Spark plug, CDI, fuel pump, carburetor parts
Loss of power	CVT or air intake	Drive belt, weights, air filter, exhaust components
Noisy suspension	Worn bushings/bearings	A-arm bushings, shock mounts, wheel bearings
Brakes dragging	Stuck caliper or cable	Caliper pins, pads, parking brake cable
4WD not engaging	Differential or actuator	Diff lock actuator, front diff gears, switch
Electrical failure	Wiring or battery	Main harness, battery, ground connections

Compatibility: Parts are specific to Yamaha Grizzly 660 model years 2002-2007. Verify model year before ordering.

Technical Support: Contact Yamaha Customer Relations at 1-800-962-7926 or visit www.yamahamotorsports.com.