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YFM660FS Grizzly 4x4
Yamaha YFM660FS Grizzly 4x4 User Manual
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LIT-11616-17-14
5KM-28197-E2
YFM660FS
SUPPLEMENTARY
SERVICE MANUAL
2
Table of Contents
Table of Contents
6
Important Information
3
General Information
7
Features
7
Override Switch (Deactivating the Speed Limiter When the Differential Is Locked)
7
Specifications
9
General Specifications
9
Maintenance Specifications
10
Engine
10
Chassis
11
Electrical
11
Chassis
12
Steering System
12
Installing the Rear Brake Lever
12
Electrical
13
Checking the Switch
13
Checking the Switch Continuity
13
Signal System
15
Circuit Diagram
15
Yfm660Fs Wiring Diagram
18
Front Constant Velocity Joints/Differential Gear
55
Cooling System
76
Chassis
76
Table of Contents
77
Default Chapter
78
General Information
78
Specifications
78
Engine
80
Cooling System
83
Carburetion
84
Drive Train
84
Chassis
85
Troubleshooting
88
Chapter 1. General Information
90
Gen Info
90
Machine Identification
90
Vehicle Identification Number
90
Model Label
90
Features
91
Front Differential
91
Transmission
98
Important Information
99
Preparation for Removal Procedures
99
Replacement Parts
99
Gaskets, Oil Seals and O-Rings
99
Lock Washers/Plates and Cotter Pins
100
Bearings and Oil Seals
100
Circlips
100
Checking of Connections
101
Special Tools
102
Chapter 2. Specifications
107
General Specifications
107
Maintenance Specifications
110
Engine
110
Chassis
120
Electrical
124
General Torque Specifications
126
How to Use the Conversion Table
126
Lubrication Points and Lubricant Types
127
Engine
127
Coolant Flow Diagrams
128
Oil Flow Diagrams
130
Cable Routing
133
Chapter 3. Periodic Checks and Adjustments
148
Introduction
148
Periodic Maintenance/Lubrication Intervals
148
Seat, Carriers, Fenders and Fuel Tank
150
Seat and Side Panels
150
Front Carrier, Front Bumper and Front Grill
151
Handlebar Cover, Fuel Tank Cover and Front Fender
152
Rear Carrier and Rear Fender
154
Engine Skid Plate (Center) and Engine Skid Plate (Rear)
156
Fuel Tank
157
Footrest Boards
159
Engine
160
Adjusting the Valve Clearance
160
Adjusting the Timing Chain
163
Adjusting the Idling Speed
164
Adjusting the Throttle Lever Free Play
164
Adjusting the Speed Limiter
166
Adjusting the Starter Cable
168
Checking the Spark Plug
168
Checking the Ignition Timing
169
Measuring the Compression Pressure
171
Checking the Engine Oil Level
173
Changing the Engine Oil
174
Cleaning the Air Filter
177
Checking the Coolant Level
178
Changing the Coolant
179
Checking the Coolant Temperature Warning Light
183
Checking the V-Belt
184
Cleaning the Spark Arrester
184
Chassis
186
Adjusting the Rear Brake
186
Checking the Brake Fluid Level
188
Checking the Front Brake Pad
190
Checking the Rear Brake Pad
190
Checking the Brake Hose
191
Bleeding the Hydraulic Brake System
191
Adjusting the Select Lever Control Cable and Shift Rod
193
Adjusting the Rear Brake Light Switch
194
Checking the Final Gear Oil Level
195
Changing the Final Gear Oil
195
Checking the Differential Gear Oil
196
Changing the Differential Gear Oil
197
Checking the Constant Velocity Joint Dust Boot
198
Checking the Steering System
198
Adjusting the Toe-In
199
Adjusting the Front Shock Absorber
200
Adjusting the Rear Shock Absorber
201
Checking the Tire
201
Checking the Wheel
203
Checking and Lubricating the Cable
204
Lubricating the Levers, Pedal, Etc
204
Electrical
205
Checking the Battery
205
Checking the Fuse
211
Adjusting the Headlight Beam
212
Changing the Headlight Bulb
213
Chapter 4. Engine
214
Engine Removal
214
Air Ducts, Muffler and Exhaust Pipe
214
Select Lever Unit and Coolant Reservoir
216
Hoses and Leads
217
Engine Mounting Bolts
218
Installing the Engine
220
Cylinder Head Cover
221
Removing the Cylinder Head Cover
223
Checking the Cylinder Head Cover
223
Checking the Tappet Cover
224
Installing the Cylinder Head Cover
224
Rocker Arms
225
Removing the Rocker Arm
227
Checking the Rocker Arm
227
Installing the Rocker Arm
228
Camshaft and Cylinder Head
229
Removing the Camshaft and Cylinder Head
231
Checking the Camshaft
232
Checking the Camshaft Sprocket
232
Checking the Decompression System
232
Checking the Timing Chain Guide
233
Checking the Timing Chain Tensioner
233
Checking the Cylinder Head
233
Installing the Camshaft and Cylinder Head
234
Valves and Valve Springs
237
Removing the Valve and Valve Spring
238
Checking the Valve and Valve Spring
239
Installing the Valve and Valve Spring
243
Cylinder and Piston
245
Removing the Piston
246
Checking the Cylinder and Piston
246
Checking the Piston Ring
248
Checking the Piston Pin
249
Installing the Piston
249
Installing the Cylinder
250
Recoil Starter and Ac Magneto
251
Removing the Ac Magneto
254
Disassembling the Recoil Starter
254
Checking the Ac Magneto
254
Checking the Starter Clutch
255
Checking the Starter Pulley
256
Checking the Recoil Starter
256
Assembleing the Recoil Starter
256
Installing the Ac Magneto
257
Balancer Gears and Oil Pump Gears
260
Removing the Balancer Drive Gear and Balancer Driven Gear
261
Removing the Balancer Drive Gear and Buffer Boss
261
Checking the Oil Pump Drive
261
Checking the Balancer Drive
262
Installing the Balancer Drive Gear and Balancer Driven Gear
262
Primary and Secondary Sheaves
264
Primary Sheave
266
Secondary Sheave
267
Removing the Primary and Secondary Sheaves
268
Disassembling the Secondary Sheave
268
Cheking the Primary Sheave
269
Checking the Secondary Sheave
269
Assembling the Primary Sheave
270
Assembling the Secondary Sheave
270
Installing the Primary and Secondary Sheaves
272
Clutch
273
Removing the Clutch
275
Checking the Clutch
275
Installing the Clutch
276
Crankcase
278
Starter Motor, Timing Chain and Oil Filter
278
Crankcase
279
Crankcase Bearing
281
Separating the Crankcase
282
Checking the Timing Chain and Guide
282
Checking the Oil Delivery Pipe
282
Checking the Crankcase
283
Checking the Bearings
283
Assembling the Crankcase
283
Installating the Shift Lever
284
Crankshaft and Oil Pump
285
Oil Pump
286
Removing the Crankshaft
287
Checking the Oil Pump
287
Checking the Relief Valve
288
Checking the Oil Strainer
288
Assembling the Oil Pump
288
Checking the Crankshaft
289
Installing the Crankshaft and Balancer
290
Transmission
291
Removing the Transmission
294
Checking the Shift Fork
294
Checking the Shift Cam
295
Checking the Drive Axle
295
Checking the High Wheel Gear and Middle Drive Gear
295
Checking the Secondary Shaft and Driven Sprocket
296
Checking the Chain
296
Checking the Stopper Lever and Stopper Wheel
296
Assembling the Shift Fork Assembly
297
Installing the Transmission
297
Middle Gear
298
Middle Drive Shaft
298
Middle Driven Shaft
299
Removing the Middle Drive Shaft
301
Removing the Middle Driven Shaft
301
Checking the Pinion Gear
304
Middle Drive and Driven Gear Shim Selection
304
Installing the Middle Driven Shaft
307
Installing the Middle Drive Shaft
309
Measuring the Middle Gear Backlash
310
Chapter 5. Cooling System
311
Radiator
311
Checking the Radiator
313
Installing the Radiator
314
Thermostat
315
Checking the Thermostat
316
Installing the Thermostat
316
Water Pump
317
Disassembling the Water Pump
319
Checking the Water Pump
319
Assembling the Water Pump
320
Chapter 6. Carburetion
322
Carburetor
323
Disassembling the Carburetor
325
Checking the Carburetor
325
Assembling the Carburetor
327
Adjusting the Fuel Level
328
Chapter 7. Drive Train
329
Troubleshooting
329
Front Constant Velocity Joints and Differential Gear
332
Disassembling the Universal Joint
337
Removing the Ring Gear
338
Checking the Constant Velocity Joint
338
Checking the Differential Gear
338
Checking the Gear Motor
339
Assembling the Front Constant Velocity Joint
339
Assembling the Differential Gear
340
Installing the Universal Joint
342
Measuring and Adjusting the Differential Gear Lash
343
Checking the Differential Gear Operation
345
Rear Constant Velocity Joint/Final Drive Gear and Drive Shaft
346
Assembling the Rear Constant Velocity Joint
350
Removing and Disassembling the Final Drive Roller Bearing
351
Positioning the Final Drive Pinion Gear and Ring Gear
352
Checking the Drive Shaft
357
Checking the Final Drive Gear
357
Measurement and Adjusting the Final Gear Lash
358
Assembling the Final Drive Gear
360
Installing the Final Drive Gear
360
Chapter 8. Chassis
361
Front Wheels and Brake Discs
361
Checking the Front Wheel
363
Checking the Front Wheel Hub
363
Checking the Front Brake Disc
364
Installing the Front Wheel Hub
364
Installing the Front Wheel
364
Rear Wheels and Brake Disc
366
Rear Wheels
366
Rear Brake Disc
367
Checking the Rear Wheel
368
Checking the Rear Wheel Hub
368
Checking the Rear Brake Disc
368
Installing the Rear Wheel Hub
369
Installing the Rear Wheel
369
Front and Rear Brakes
370
Front Brake Pads
370
Rear Brake Pads
371
Replacing the Front Brake Pad
372
Replacing the Rear Brake Pad
374
Front Brake Master Cylinder
376
Rear Brake Master Cylinder
378
Checking the Master Cylinder
381
Assembling the Front Brake Master Cylinder
382
Assembling the Rear Brake Master Cylinder
382
Installing the Front Brake Master Cylinder
383
Installing the Rear Brake Master Cylinder
384
Front Brake Caliper
386
Rear Brake Caliper
388
Disassembling the Brake Caliper
390
Disassembling the Rear Brake Caliper
390
Checking the Front and Rear Brake Caliper
391
Assembling the Front Brake Caliper
392
Installing the Front Brake Caliper
392
Assembling the Rear Brake Caliper
394
Installing the Rear Brake Caliper
395
Handlebar
396
Steering System
396
Removing the Rear Brake Switch
397
Checking the Handlebar
397
Installing the Handlebar
397
Installing the Rear Brake Lever
397
Installing the Master Cylinder Assembly
398
Steering Stem
399
Removing the Bearing Retainer
401
Checking the Steering Stem
401
Installing the Bearing Retainer
401
Installing the Steering Stem
401
Installing the Cable Guide
402
Tie Rod and Steering Knuckle
403
Removing the Steering Knuckle
404
Checking the Tie Rod
404
Checking the Steering Knuckle
404
Checking the Ball Joint
405
Checking the Tie Rod
405
Front Arms and Front Shock Absorber
406
Removing the Front Arms
408
Checking the Front Arm
408
Checking the Front Shock Absorber
408
Installing the Front Arms and Front Shock Absorber
409
Rear Knuckle and Stabilizer
410
Checking the Rear Knuckle
411
Checking the Stabilizer
411
Rear Arms and Rear Shock Absorber
412
Checking the Rear Arm
413
Checking the Rear Shock Absorber
413
Checking the Rear Arms and Rear Shock Absorber
413
Chapter 9
415
Electrical
415
Electrical Components
415
Checking the Switch
416
Checking a Switch Shown in the Manual
416
Checking the Switch Continuity
418
Checking the Bulbs and Bulb Sockets
420
Types of Bulbs
420
Checking the Condition of the Bulbs
420
Checking the Condition of the Bulb Sockets
422
CHECKING the Leds
422
Ignition System
423
Circuit Diagram
423
Troubleshooting
424
Electric Starting System
429
Circuit Diagram
429
Starting Circuit Operation
430
Troubleshooting
431
Starter Motor
431
Checking the Starter Motor
436
Assembling the Starter Motor
437
Charging System
438
Circuit Diagram
438
Troubleshooting
439
Lighting System
441
Circuit Diagram
441
Troubleshooting
442
Checking the Lighting System
444
Signal System
446
Circuit Diagram
446
Troubleshooting
448
Checking the Signal System
450
Circuit Diagram
461
Troubleshooting
462
2Wd/4Wd Selecting System
466
Circuit Diagram
466
Troubleshooting
471
Starting Failure/Hard Starting
471
Chapter 10
471
Electrical System
471
Fuel System
471
Compression System
472
Poor Idle Speed Performance
472
Poor Medium and High-Speed Performance
472
Faulty Drive Train
473
Faulty Clutch Performance
474
Engine Operates but Machine will Not Move
474
Clutch Slipping
474
Poor Starting Performance
474
Poor Speed Performance
475
Faulty Gear Shifting
474
Hard Shifting
474
Shift Lever Does Not Move
474
Jumps out of Gear
474
Faulty Brake
475
Poor Braking Effect
475
Overheating
475
Shock Absorber Malfunction
476
Unstable Handling
476
Lighting System
476
Headlight Dark
476
Bulb Burnt out
476
5
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Yamaha YFM660FS Grizzly 4x4 Specifications
General
Brand
Yamaha
Model
YFM660FS Grizzly 4x4
Category
Offroad Vehicle
Language
English
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