2003 yamaha grizzly 660 repair manual free download. DOWNLOAD Yamaha Grizzly Repair Manual 350 400 450 550 600 660

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YAMAHA YFMFS GRIZZLY 4X4 SUPPLEMENTARY SERVICE MANUAL Pdf Download | ManualsLib

 

Fuel System 5. Body, Steering, Suspension 6. PVT System 7. Final Drive 8. Transmission Service 9. Brakes Electrical Troubleshooting Wiring Diagrams. The first section of the manual contains general information. General knowledge is considered to be the main features or elements of the Yamaha Grizzly ATV such as model identification, serial number locations, machine dimensions and critical specifications.

Other information might include standard torque specifications, conversion tables and glossary of terms. All Yamaha repair manuals contain a maintenance section. The maintenance section contains more than just a periodic maintenance chart, it contains a step-by-step guide on how to perform each maintenance procedure. Maintenance may consist of carburetor of fuel injection maintenance, battery maintenance, electrical maintenance or engine maintenance. Each Grizzly repair manual also contains a troubleshooting guide.

A troubleshooting guide provides information to help the mechanic make an informed decision or calculation on how to fix the machine. The most important section of the Yamaha Grizzly handbook is the repair information. The book gives information such as facts on service and repair; e. Remove: Front wheels 2. NOTE: Hold the machine in an upright position and apply the front or rear brake. Add the proper brake fluid to the reservoir. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow.

Connect the clear plastic hose 1 tightly to the caliper bleed screw 2. If the operation of the select lever is incor- rect, adjust the select lever control cable 3 with the adjuster 4. Place the machine on a level place. Do not remove the bolt, otherwise the gear oil may come out.

Fill: Final gear case Periodic oil change: 0. Place a receptacle under the differential gear case. Remove: Oil filler bolt Drain plug 1 4. Drain: Differential gear oil 5. Install: Drain plug 10 Nm 1. Mark both front tire tread centers. Face the handlebar straight ahead. This reference point will be needed during adjustment. Loosen the locknuts tie-rod end 1 of both tie-rods. The same number of turns should be given to both the right and left tie-rods 2 until the specified toe-in is obtained.

The tires listed below have been approved by Yamaha Motor Co. Recommended lubricant: Yamaha chain and cable lube or Engine oil NOTE: Hold the cable end up and apply several drops of lubricant to the cable.

Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals. Always follow these preventive measures: Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames e. Connect a charger and ammeter to the battery and start charging. NOTE: After cleaning the terminals, apply a light coat of grease.

Install: Battery 7. YU, If the tester indicates o, replace the fuse. Install a new fuse of the proper amperage. Turn on switches to verify operation of the related electrical devices. Adjust: Headlight beam vertically Turn the adjuster 1 in or out. Turning in Headlight beam raised. Turning out Headlight beam lowered. Do not touch the bulb until it cools down. Page Chapter 4. Shift arm Select lever shift rod Select lever unit Coolant reservoir breather hose Spark plug lead Crankcase breather hose Thermo switch lead Dowel pin For installation, reverse the removal procedure.

ACC Yamaha bond No. Install: Cylinder head cover Washers 1 Bolts 10 Nm 1. Rocker arm shaft outside diameter: Loosen: Camshaft sprocket bolts 1 2. Loosen: Timing chain tensioner cap bolt 3. Remove: Timing chain tensioner Timing chain guide exhaust Decompressor cam guide plates Camshaft sprocket Camshaft NOTE: Fasten a safety wire to the timing chain to prevent it from falling into the crankcase.

Measure: Cam lobes length a and b. Camshaft lobe limit: Intake: a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. Cylinder head warpage: Less than 0. Use a feeler gauge to measure the warpage. If the warpage is out of specification, resur- face the cylinder head. Camshaft sprocket bolt: 20 Nm 2. Clearance stem to guide : Intake: 0. Margin thickness: Intake: 0. Valve seat width: Intake: 0.

Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound. NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood.

Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4. Then, find the average of the measurements. Standard Wear limit Measure: Ring side clearance Use a feeler gauge. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance Standard Limit If out of specification, replace the piston pin.

Outside diameter piston pin : Position: Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown. Engine oil Drain. Coolant Drain. Starter wheel gear Washer Starter idle gear shaft Spring Sheave drum Rope Coil spring For assembly, reverse the disassembly YU, 2. After installing the rotor, check that the rotor rotates smoothly. If not, reinstall the key and rotor. Straighten the lock washer tabs. Loosen: Balancer driven gear nut 1 NOTE: Place an aluminum plate 2 between the teeth of the balancer drive gear 3 and balancer driven gear 4.

Install: Lock washer Balancer driven gear nut 1 Nm Guide pin Secondary sliding sheave O-ring Secondary fixed sheave Oil seal First, loosen the nut secondary sheave 2, then loosen the nut primary sheave 1. Weight outside diameter: 30 mm 1. Apply Yamaha Grizzly grease to the inner surface of the collar. Apply Yamaha Grizzly grease to the inner surface of the primary sliding sheave.

Install: Secondary sheave assembly V-belt Primary sheave assembly NOTE: Tightening the bolts 1 will push the second- ary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen.

One-way clutch bearing Clutch carrier assembly For installation, reverse the removal Remove them after all of them are loosened. Straighten: Punched portion of the nut 1. Clutch shoe thickness: 1. Install: Collar Clutch carrier assembly Nut 1 Nm Install: Dowel pins Gasket Clutch housing assembly 10 Nm 1. After tightening the bolts, check that the clutch housing assembly to counterclockwise rotates smoothly.

Loosen the bolts in stages, using a criss- cross pattern. Install: Dowel pin 2 3. Fit the left crankcase onto the right case. Tap lightly on the case with a soft hammer.

Apply: 4-stroke engine oil to the crank pin, bearing and oil delivery hole 6. Rotor cover Shaft Inner rotor Outer rotor Oil pump housing For assembly, reverse the disassembly procedure. Remove: Crankshaft Use a crankcase separating tool 1.

Measure: Tip clearance a between the inner rotor 1 and the outer rotor 2 Side clearance b between the outer rotor 2 and the pump Install: Inner rotor Crank width: Big end side clearance: 0. Low wheel gear Shift cam Shift fork assembly Short spring White painting. Push down on the drive shaft, and then slide the shift fork assembly to remove the shift fork cam followers. Measure: Axle runout Use a centering device and a dial gauge. Straighten: Punched portion of the nut middle drive pin- ion gear 2.

YM 3. Secure the bearing housing edge in the vise. Attach the bearing retainer wrench 2. In the example above, the calculated shim thickness is 0. The chart instructs you, however, to round off 4 to 5. Hundredths Round value 0, 1, 2 3, 4, 5, 6, 7 8, 9 Shims are supplied in the following thickness.

Attach the bearing retainer wrench 3. YM, Tighten the bearing retainer. Apply wheel bearing grease to the bearings.

Install the bearing 1 onto the yoke. The needles can eas- ily fall out of their races. Slide the yoke back and forth on the bearings; Measure: Gear lash Middle gear lash: 0. Wrap a rag 2 around a screwdriver 3, and then insert it into the installation hole 1 of the left crankcase speed sensor to hold the middle driven gear. Page Chapter 5. Radiator outlet hose Disconnect. Radiator Radiator fan Thermo switch For installation, reverse the removal procedure.

Apply compressed air to the rear of the radia- tor. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. Slowly heat the water. Place a thermometer in the water.

Remove: Rubber damper holder 1 Rubber damper 2 from the impeller, with a thin, flathead screwdriver NOTE: Do not scratch the impeller shaft. Install: Oil seal 1 into the water pump housing 2 NOTE: Before installing the oil seal, apply tap water or coolant onto its outer surface.

Install the oil seal with a socket 3 that matches its outside diameter. Page Chapter 6. Pilot jet Starter jet For assembly, reverse the disassembly procedure. Check: Jet needle 1 Main jet 2 Needle jet Insert the piston valve into the carburetor body, and check for free movement. If both are fine, adjust the float height by bending the float tang 1 on the float.

Recheck the float height. Fuel level: 4. Page Chapter 7. Bearing damage. Improper gear lash. This must not be confused with engine surging or transmission characteris- C. Gear tooth damage. If a test ride following reas- sembly indicates this condition, stop riding immediately to minimize gear damage. You can zoom in or out on this manual as much as needed the images and text will not blur!. Don't miss some of these details.

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The procedures in this manual are organized in a sequential, step-by-step format. After waiting a little while, it did finally a couple times after backfiring again. All of our manuals come as easy-to-use PDF files. Recommended maintenance schedules will allow you to keep your machine operating at its full potential.

This is the same Repair Service manual your local dealer will use when doing a repair. Here is what the manual suggest you check if the engine is overeating: Ignition System.

Posted on 15 Sep, This Yamaha Grizzly manual also includes part inspection, maintenance intervals, unit repair and Yamaha Grizzly factory specifications e.

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