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I picked up a fairly clean 04 660 Rhino today that had a rod bust the cases. I have a small salvage yard and have 2 complete 660 Grizzly motors that at least have good cases. I've read a little about what needs to be done and doesn't seem to be a big deal. I noticed that the transmission gears were said to be different and so I checked a schematic to see how much. The 02-03 Grizzly have different transmissions than the 04+ Grizzly. I know one of the bikes I have is an 02 and I'll have to check on the other. I'm hoping its 04+ so that I would have whichever I feel is the best. Here is the schematic for the transmission on the 02 grizzly and 04 Rhino. Yamaha ATV Parts 2004 RHINO 660 HARDWOODS CAMO HUNTER EDITION (Realtree Hardwoods Camo) - YXR66FAHS TRANSMISSION Diagram Yamaha ATV Parts 2002 GRIZZLY 660 - YFM660FP TRANSMISSION Diagram As you can see the gears are different. I don't have a problem opening up one of the bottom ends I have and putting whatever gears need to be put in from the Rhino, but I was wondering if it would be possible to interchange gears from both bikes? I would want the lowest for low range and highest for high, best of both worlds I guess. Has anyone any eperience with anything like this and from looking at the schematic what would be my best gear set combination?

Thread moved to Engine and Transmission forum by okbear
 

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This is the first I have heard the transmission gears are different. Even though the part numbers are different, I am doubtful there is a gearing change. If there was, everyone would know about it because the mud riding crowd would of been all over it years ago.

As far as I know, the only difference between the Grizzly and Rhino engines was the Park gear. The Rhino does not have Park position in the transmission.....but the again.....I could be 100% wrong.
 

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Discussion Starter #3
This is the first I have heard the transmission gears are different. Even though the part numbers are different, I am doubtful there is a gearing change. If there was, everyone would know about it because the mud riding crowd would of been all over it years ago.

As far as I know, the only difference between the Grizzly and Rhino engines was the Park gear. The Rhino does not have Park position in the transmission.....but the again.....I could be 100% wrong.

If you will look at the schematics it lists the # of teeth on each gear. So while I agree the different part #s don't necessarily mean different ratios the difference in the teeth do. I've done a little research on the Rhino forums and the consensus is that the Rhino gearing is lower. Some that have done the swap didn't swap the gears and just went with the Grizzly gearing others swapped the internals from the Rhino to the Grizzly motor. There are a few minor things that have to be done but not much. I think if you swap the Rhino gears there was something in the grizzly cases that had to be bored slightly but I'll have to get more info on that. The Rhino also has an oil cooler and the Grizzly doesn't. Not that big of a deal until you ell and someone asks why isn't this hooked up :) I just figured there would have been more knowledge on here than the Rhino forums. They aren't the latest and greatest any more so the feedback isn't great. DEEZ I know you're pretty knowledgeable on some of this so you can go ahead and research those gear setups and see what would be best for me :)

By the way I realized I put this in the general discussion area so if someone wants to move it to the Grizzly section thats fine.
 

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I am definitely going to look into this. I never heard about it before....but I have never asked or looked either. Now I am interested.
 
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If you need any pics or measurements I don't mind while I have stuff apart. The rhino motor was completly apart and bagged up. I got the gears out last night and checked them out. I've taken 100's of bikes apart but never messed with or really looked into building transmissions or different gear ratios. But from what I can see you can either switch the whole gear setup out or you can do some swapping on the middle drive gears. I plan to have the engine from the Grizzly pulled this week. and maybe split by next week. I'm assuming you wouldn't be able to just switch individual low and high gears because of gear size. I wouldn't think that a gear with a different amount of teeth would be the same size to just swap it alone and still fit properly. The secondary shaft that meshes with the hi and low gears is a one piece gear so I'm guessing you couldn't interchange gears from different bikes but you could swap out the entire gear setup. The middle drive setup is different though. Both gears for it are removeable so if the measurements for both gear sets are equal you could do just a swap on them for ratio changes.
 
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