Yamaha 660 Grizzly 02 & Up

XTY660

 

 

Read these instructions carefully. Care should be taken to follow all standard safety procedures. If you are not sure of the correct safety measures please consult a professional mechanic.

 

A thorough inspection of the suspension should be made prior to performing the installation. Any worn, bent or broken parts should be replaced. After installation another inspection should be made, checking for loose components, missing hardware, binding or contact between moving parts of any kind. Inspect, again after eight hours of operation.

 

To begin, check to make sure all components and necessary tools are on hand.

 

Components:

The kit consists of brackets for the front and brackets for the rear. Each bag is numbered 1-4.

#1 goes to the left front as you are sitting on the bike. #2 goes to the right front,

#3 goes to the left rear #4 goes to the right rear.

 

Disassembly / Installation Procedure

 

FRONT

1.)Begin by loosening the lug nuts on both front tires. Raise the unit, using a suitable lifting device or procedure, until the front tires are off the ground. If using a floor jack with stands, chock the rear wheels to prevent the unit from rolling. If using jack stands, make sure the stands are placed under the frame and not the body. Make sure the unit is stable and secure.

 

2.)Remove the tires / wheels.

 

NOTE: Now is a good time to check the threads on the lug studs. Check for rust, pulled threads or other deterioration that could cause a stud/thread failure.

 

3.)With the suspension hanging, remove the top shock bolt. Loosen the bottom bolt and rotate the shock out of the way.

 

4.)Assemble the brackets as shown in figure #1. Do not tighten the two 5/16 bolts at this time.

 

5.)Take one of the 55mm bolts and insert it through the rear bracket and while holding the ¾ inch diameter spacer in the factory shock mount insert the bolt, do not go completely through.

 

6.)With the bolt inserted into the spacer place the other bracket between the spacer and the factory mount, finish inserting the bolt. Install the 10mm nut and tighten finger tight.

NOTE: If you are in doubt as to how the brackets are placed check fig.#1.

 

7.)Take a 1” ID u-bolts and install it in the bottom position, tighten the bolts finger tight. Install the other 1” ID u-bolt in the front position and tighten the nuts finger tight. Complete this by installing the 1 ¼” ID u-bolt and nuts.

 

8.)Install the top of the shock in the new mounting position and insert the 55mm bolt and nut. Now tighten the shock first and then all the other bolts. Torque the 10mm bolts to 45 ft lbs. and the ¼” nuts to 12 ft. lbs.

 

9.)Proceed to the other side and duplicate the steps 3-8.

 

 

 

 

THE FENDERS ARE REMOVED IN THESE PICTURES, BUT IT IS NOT NECESSARY

 

This view is passenger side, rear to front. This view is passenger side, front to rear.

 

 

 

 

REAR

1.)Begin by loosening the lug nuts on both rear tires. Raise the unit, using a suitable lifting device or procedure, until the rear tires are off the ground. If using a floor jack with stands, chock the front wheels to prevent the unit from rolling. If using jack stands, make sure the stands are placed under the frame and not the body. Make sure the unit is stable and secure.

 

2.)Remove the tires / wheels.

 

NOTE: Now is a good time to check the threads on the lug studs. Check for rust, pulled threads or other deterioration that could cause a stud/thread failure.

 

NOTE: START WITH THE LEFT REAR.

 

3.)With the suspension hanging, remove the shock bolts. Remove the shock and place it out of the way.

 

4.)Take a 10mm bolt and insert it through one side of the bracket.

 

5.)Place the ¾” dia. sleeve between the factory bracket and the other side of the bracket. Insert the bolt and install the nut finger tight.

 

6).Install the 1” ID u-bolt and tighten finger tight.

 

7).Install the shock with the top in its new position. Tighten all bolts. Torque the 10mm bolts to 45 ft. lbs. and the ¼” nuts to 12 ft. lbs.

 

8). Repeat steps 3-7 for the opposite side.

 

NOTE: The U-bolt for the RIGHT REAR MUST be installed before installing the first 10mm bolt. If you do not do this, you will have to start over on this side.

 

 

BE SURE YOU HAVE THE BRACKETS ON THE REAR INSTALLED AS SHOWN IN FIGURE #2.

 

 

THE FENDERS ARE REMOVED IN THESE PICTURES, BUT IT IS NOT NECESSARY

 

 

This view is passenger side, rear to front. This view is driver side, rear to front.

 

 

 

WARRANTY: This kit will be warranted against defects in workmanship and materials ONLY. Problems from misuse, improper installation or abuse are not covered in the warranty. This warranty is good for one year (12 months) from date of purchase. All warranty claims MUST be accompanied by the original receipt or suitable proof of purchase date. Call us at 1-888-283-0977 with any questions regarding installation or warranty issues.