Category Archives: Grizzly Chassis & Body

08 660 pinion help!

I have assembeled the pinion as shown below. When I snug the 4 bolts holding the cover, the gear is unable to spin. All bearings are new. The diff was taken apart with 2 spacers instead of 3. I doubt that is my problem tho. Do I have to assemble the rest of the diff and then the pinion?

Front Brake Master Cylinder Rebuild

2001 Grizzly 600

I am rebuilding the front brake master cylinder. This is a machine that my hunting club bought for $500. It had been sitting and not running for several years. After about $260 in parts, including and battery, it runs great.

In the bottom of the reservoir there is a round rubber seal with a small "X" cut into it. It covers the two holes where the brake fluid goes in and out. The holes are small but one is considerably larger than the other. One is about 1 millimeter and the other is probably 3 millimeters in diameter.

The rebuild kit did not contain a new seal to cover the ports. Automotive master cylinders do not have this rubber seal. I am wondering if it is even needed. Can anyone give me input?

I attached a picture. One is without the rubber seal installed and the other it is installed.

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Front Drive Delete

HI All….
I was recently given an 05 Grizzly 660. I’m in the process of rebuilding the motor. Its in bad shape and that’s why it was given to me. Other than that the bike is in pretty good shape. I have a Polaris Sportsman already and really have no need for another utility quad. My plan is to trim the plastics, ditch the front and rear racks, and remove the front diff along with the axles and front drive shaft to reduce as much weight as possible.
Does anyone see any concerns with converting it to two wheel drive? I don’t mud and my Sportsman is set up to plow snow. I’m just looking to set it up more of a sport quad. I know there are some that will think its a dumb idea or some that will say to fix it then sell it and get a sport quad but I kinda like the idea of doing something a little different.
Thanks….Mike