Yamaha Raptor 660 User Manual
Have a problem? Instant download 2001-2005 Yamaha ATV Raptor 660 YFM660RN YFM660RNC Workshop Manual, Fix it! Keep Your All-Terrain Vehicle Running Smoothly. 2001-2005 Yamaha ATV Raptor 660 YFM660RN YFM660RNC Service Repair Workshop Manual This is the Complete Official Workshop Service and Repair Manual for the Yamaha ATV Raptor 660 YFM660RN YFM660RNC. Modles: Raptor 660 YFM660RN YFM660RNC Production model years: 2001 2002 2003 2004 2005.
TABLE OF CONTENTS: ——————————— CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION 1-1 VEHICLE IDENTIFICATION NUMBER. 1-1 MODEL LABEL.
1-1 IMPORTANT INFORMATION. 1-2 PREPARATION FOR REMOVAL PROCEDURES.
1-2 REPLACEMENT PARTS. 1-2 GASKETS, OIL SEALS AND O-RINGS 1-2 LOCK WASHERS/PLATES AND COTTER PINS 1-3 BEARINGS AND OIL SEALS. 1-3 CIRCLIPS.
1-3 CHECKING OF CONNECTIONS 1-4 SPECIAL TOOLS 1-5 CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS. 2-1 MAINTENANCE SPECIFICATIONS. 2-4 CHASSIS 2-14 ELECTRICAL. 2-18 HOW TO USE THE CONVERSION TABLE. 2-20 GENERAL TORQUE SPECIFICATIONS 2-20 LUBRICATION POINTS AND LUBRICANT TYPES.
2-21 COOLANT FLOW DIAGRAMS. 2-22 OIL FLOW DIAGRAMS 2-23 CABLE ROUTING 2-27 CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION. 3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS.
3-1 SEAT, FENDERS AND FUEL TANK 3-3 SEAT, FRONT PANEL, FOOTREST GUARDS AND ENGINE SKID PLATE 3-3 HEADLIGHTS AND FRONT FENDER. 3-4 REAR FENDER. 3-5 FUEL TANK. 3-6 ENGINE 3-8 ADJUSTING THE VALVE CLEARANCE. 3-8 ADJUSTING THE TIMING CHAIN 3-11 ADJUSTING THE IDLING SPEED 3-11 ADJUSTING THE THROTTLE LEVER FREE PLAY.
3-12 ADJUSTING THE SPEED LIMITER. 3-14 ADJUSTING THE STARTER CABLE.
3-15 CHECKING THE SPARK PLUG 3-16 CHECKING THE IGNITION TIMING 3-17 MEASURING THE COMPRESSION PRESSURE 3-18 CHECKING THE ENGINE OIL LEVEL 3-19 CHANGING THE ENGINE OIL. 3-20 ADJUSTING THE CLUTCH CABLE. 3-23 CLEANING THE AIR FILTER. 3-24 CHECKING THE COOLANT LEVEL 3-27 CHANGING THE COOLANT 3-27 CHECKING THE COOLANT TEMPERATURE WARNING LIGHT.
3-31 CLEANING THE SPARK ARRESTER 3-31 CHASSIS. 3-33 ADJUSTING THE FRONT BRAKE. 3-33 ADJUSTING THE REAR BRAKE. 3-33 ADJUSTING THE PARKING BRAKE.
3-34 CHECKING THE BRAKE FLUID LEVEL 3-35 CHECKING THE FRONT BRAKE PAD. 3-36 CHECKING THE REAR BRAKE PAD. 3-36 ADJUSTING THE REAR BRAKE LIGHT SWITCH. 3-36 CHECKING THE BRAKE HOSE 3-37 BLEEDING THE HYDRAULIC BRAKE SYSTEM. 3-38 ADJUSTING THE SHIFT PEDAL. 3-39 ADJUSTING THE REVERSE CONTROL CABLE 3-40 ADJUSTING THE DRIVE CHAIN SLACK.
3-40 CHECKING THE STEERING SYSTEM. 3-42 ADJUSTING THE TOE-IN. 3-42 ADJUSTING THE FRONT SHOCK ABSORBER.
3-44 ADJUSTING THE REAR SHOCK ABSORBER. 3-45 CHECKING THE TIRE 3-47 CHECKING THE WHEEL. 3-49 CHECKING AND LUBRICATING THE CABLE. 3-49 LUBRICATING THE LEVERS AND PEDAL.
3-50 ELECTRICAL. 3-51 CHECKING THE BATTERY. 3-51 CHECKING THE FUSE. 3-56 ADJUSTING THE HEADLIGHT BEAM. 3-58 REPLACING THE HEADLIGHT BULB 3-58 CHAPTER 4. CHASSIS FRONT WHEELS 4-1 FRONT WHEELS.
4-1 CHECKING THE WHEEL. 4-3 CHECKING THE WHEEL HUB. 4-3 CHECKING THE BRAKE DISC. 4-4 INSTALLING WHEEL HUB. 4-5 INSTALLING THE WHEEL. 4-5 REAR WHEELS, WHEEL AXLE AND HUB.
4-6 REAR WHEELS 4-6 WHEEL AXLE AND HUB. 4-7 REMOVING THE REAR AXLE. 4-9 CHECKING THE WHEEL.
4-10 CHECKING THE WHEEL HUB. 4-10 CHECKING THE REAR AXLE 4-10 CHECKING THE HUB. 4-11 CHECKING THE BRAKE DISC.
4-11 INSTALLING THE NUTS (REAR AXLE) 4-11 INSTALLING THE WHEEL HUB 4-12 INSTALLING THE WHEEL 4-12 FRONT AND REAR BRAKES. 4-13 FRONT BRAKE PADS 4-13 REAR BRAKE PADS 4-14 REPLACING THE FRONT BRAKE PAD 4-15 REPLACING THE REAR BRAKE PAD. 4-17 FRONT BRAKE MASTER CYLINDER 4-19 REAR BRAKE MASTER CYLINDER. 4-21 CHECKING THE MASTER CYLINDER.
4-24 ASSEMBLING THE FRONT AND REAR BRAKE MASTER CYLINDER. 4-25 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4-25 INSTALLING THE REAR BRAKE MASTER CYLINDER. 4-27 FRONT BRAKE CALIPERS. 4-29 REAR BRAKE CALIPER 4-31 DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER. 4-34 CHECKING THE FRONT AND REAR BRAKE CALIPER. 4-34 ASSEMBLING THE FRONT BRAKE CALIPER. 4-35 ASSEMBLING THE REAR BRAKE CALIPER 4-36 INSTALLING THE FRONT BRAKE CALIPER 4-37 INSTALLING THE REAR BRAKE CALIPER 4-38 STEERING SYSTEM.
4-40 HANDLEBAR 4-40 REMOVING THE FRONT BRAKE SWITCH, PARK SWITCH AND CLUTCH SWITCH 4-42 REMOVING THE HANDLEBAR GRIP 4-42 CHECKING THE HANDLEBAR. 4-42 INSTALLING THE HANDLEBAR. 4-43 INSTALLING THE HANDLEBAR GRIP. 4-43 INSTALLING THE CLUTCH LEVER 4-43 INSTALLING THE BRAKE MASTER CYLINDER. 4-44 STEERING STEM. 4-45 REMOVING THE BEARING RETAINER.
4-47 CHECKING THE STEERING STEM 4-47 INSTALLING THE BEARING RETAINER. 4-47 INSTALLING THE LOCK WASHER. 4-47 TIE-ROD AND STEERING KNUCKLE 4-48 REMOVING THE STEERING KNUCKLE. 4-49 CHECKING THE TIE-ROD 4-49 CHECKING THE STEERING KNUCKLE. 4-49 INSTALLING THE TIE-ROD. 4-49 FRONT ARMS AND FRONT SHOCK ABSORBERS.
4-50 REMOVING THE FRONT ARM. 4-52 CHECKING THE FRONT ARM. 4-52 CHECKING THE FRONT SHOCK ABSORBER 4-52 CHECKING THE BALL JOINT 4-53 INSTALLING THE FRONT ARM 4-54 REAR SHOCK ABSORBER AND RELAY ARM. 4-55 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER 4-57 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 4-57 REMOVING THE REAR SHOCK ABSORBER. 4-58 CHECKING THE REAR SHOCK ABSORBER 4-58 CHECKING THE RELAY ARM AND CONNECTING ARM. 4-58 INSTALLING THE RELAY ARM AND CONNECTING ARM 4-59 INSTALLING THE REAR SHOCK ABSORBER. 4-59 SWINGARM AND DRIVE CHAIN 4-60 REMOVING THE SWINGARM 4-62 CHECKING THE SWINGARM 4-62 CHECKING THE DRIVE CHAIN 4-63 INSTALLING THE SWINGARM.
4-65 INSTALLING THE DRIVE SPROCKET. 4-65 CHAPTER 5. ENGINE ENGINE REMOVAL. 5-1 MUFFLER AND EXHAUST PIPES. 5-1 LEFT FOOTREST 5-2 LEADS, CABLES AND HOSES 5-3 ENGINE MOUNTING BOLTS 5-5 INSTALLING THE ENGINE.
5-7 CYLINDER HEAD COVER 5-8 REMOVING THE CYLINDER HEAD COVER. 5-10 CHECKING THE CYLINDER HEAD COVER. 5-10 CHECKING THE TAPPET COVER. 5-11 INSTALLING THE CYLINDER HEAD COVER. 5-11 ROCKER ARMS. 5-12 REMOVING THE ROCKER ARM. 5-14 CHECKING THE ROCKER ARM.
5-14 INSTALLING THE ROCKER ARM 5-15 CAMSHAFT AND CYLINDER HEAD 5-16 REMOVING THE CAMSHAFT AND CYLINDER HEAD 5-18 CHECKING THE CAMSHAFT. 5-19 CHECKING THE CAMSHAFT SPROCKET. 5-19 CHECKING THE DECOMPRESSION SYSTEM 5-19 CHECKING THE TIMING CHAIN GUIDE. 5-20 CHECKING THE TIMING CHAIN TENSIONER. 5-20 CHECKING THE CYLINDER HEAD 5-20 INSTALLING THE CAMSHAFT AND CYLINDER HEAD. 5-21 VALVES AND VALVE SPRINGS 5-24 REMOVING THE VALVE AND VALVE SPRING. 5-25 CHECKING THE VALVE AND VALVE SPRING 5-26 INSTALLING THE VALVE AND VALVE SPRING.
5-30 CYLINDER AND PISTON 5-32 REMOVING THE PISTON 5-33 CHECKING THE CYLINDER AND PISTON 5-33 CHECKING THE PISTON RING 5-35 CHECKING THE PISTON PIN INSPECTION. 5-36 INSTALLING THE PISTON.
5-36 INSTALLING THE CYLINDER 5-37 AC MAGNETO. 5-38 REMOVING THE AC MAGNETO ROTOR 5-40 CHECKING THE COIL 5-40 CHECKING THE STARTER CLUTCH 5-41 INSTALLING THE AC MAGNETO ROTOR. 5-42 CLUTCH 5-43 REMOVING THE CLUTCH. 5-47 REMOVING THE PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR 5-47 CHECKING THE FRICTION PLATE 5-48 CHECKING THE CLUTCH PLATE.
5-48 CHECKING THE CLUTCH SPRING 5-49 CHECKING THE CLUTCH HOUSING 5-49 CHECKING THE CLUTCH BOSS. 5-49 CHECKING THE PRESSURE PLATE 5-49 CHECKING THE PULL LEVER SHAFT AND PULL ROD 5-50 CHECKING THE PRIMARY DRIVE. 5-50 CHECKING THE BALANCER DRIVE.
5-50 INSTALLING THE PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR 5-51 INSTALLING THE CLUTCH. 5-52 OIL PUMP 5-54 CHECKING THE OIL PUMP 5-56 ASSEMBLING THE OIL PUMP 5-56 SHIFT SHAFT 5-57 CHECKING THE SHIFT SHAFT 5-59 CHECKING THE STOPPER LEVER.
5-59 CHECKING THE SHIFT GUIDE AND SHIFT LEVER. 5-59 CHECKING THE SEGMENT 5-59 INSTALLING THE SHIFT LEVER. 5-59 INSTALLING THE STOPPER LEVER 5-60 INSTALLING THE SHIFT SHAFT. 5-61 CRANKCASE. 5-62 TIMING CHAIN AND SPEED SENSOR ROTOR. 5-62 CRANKCASE. 5-64 CRANKCASE BEARING 5-65 SEPARATING THE CRANKCASE.
5-66 CHECKING THE TIMING CHAIN AND GUIDE. 5-66 CHECKING THE OIL STRAINER. 5-66 CHECKING THE CRANKCASE.
5-67 CHECKING THE BEARINGS. 5-67 ASSEMBLING THE CRANKCASE 5-67 CRANKSHAFT AND BALANCER.
5-69 REMOVING THE CRANKSHAFT. 5-70 CHECKING THE CRANKSHAFT. 5-70 INSTALLING THE CRANKSHAFT 5-71 TRANSMISSION. 5-72 MAIN AXLE. 5-74 DRIVE AXLE 5-75 CHECKING THE SHIFT FORK. 5-77 CHECKING THE SHIFT DRUM.
5-77 CHECKING THE TRANSMISSION. 5-77 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE. 5-78 INSTALLING THE TRANSMISSION 5-79 CHAPTER 6. COOLING SYSTEM RADIATOR. 6-1 CHECKING THE RADIATOR. 6-3 INSTALLING THE RADIATOR.
6-4 THERMOSTAT. 6-5 CHECKING THE THERMOSTAT. 6-7 ASSEMBLING THE THERMOSTAT.
6-7 WATER PUMP. 6-8 DISASSEMBLING THE WATER PUMP. 6-11 CHECKING THE WATER PUMP.
6-11 ASSEMBLING THE WATER PUMP. 6-12 CHAPTER 7.
CARBURETION CARBURETORS. 7-1 DISASSEMBLING THE CARBURETOR. 7-5 CHECKING THE CARBURETOR 7-5 ASSEMBLING THE CARBURETOR. 7-7 ADJUSTING THE FUEL LEVEL 7-8 CHAPTER 8. ELECTRICAL ELECTRICAL COMPONENTS 8-1 CHECKING THE SWITCH.
8-2 CHECKING THE SWITCH. 8-2 CHECKING A SWITCH SHOWN IN THE MANUAL. 8-2 CHECKING THE SWITCH CONTINUITY 8-3 IGNITION SYSTEM 8-5 CIRCUIT DIAGRAM 8-5 TROUBLESHOOTING. 8-6 ELECTRIC STARTING SYSTEM 8-11 CIRCUIT DIAGRAM.
8-11 STARTING CIRCUIT OPERATION. 8-12 TROUBLESHOOTING 8-13 STARTER MOTOR. 8-16 CHECKING THE STARTER MOTOR. 8-17 ASSEMBLING THE STARTER MOTOR 8-18 CHARGING SYSTEM 8-19 CIRCUIT DIAGRAM. 8-19 TROUBLESHOOTING 8-20 LIGHTING SYSTEM 8-22 CIRCUIT DIAGRAM. 8-22 TROUBLESHOOTING 8-23 CHECKING THE LIGHTING SYSTEM 8-25 SIGNAL SYSTEM 8-27 CIRCUIT DIAGRAM.
8-27 TROUBLESHOOTING 8-28 CHECKING THE SIGNAL SYSTEM 8-30 COOLING SYSTEM 8-36 CIRCUIT DIAGRAM. 8-36 TROUBLESHOOTING. 8-37 CHAPTER 9. TROUBLESHOOTING STARTING FAILURE/HARD STARTING. 9-1 FUEL SYSTEM.
9-1 ELECTRICAL SYSTEM. 9-1 COMPRESSION SYSTEM. 9-2 POOR IDLE SPEED PERFORMANCE. 9-2 POOR IDLE SPEED PERFORMANCE.
9-2 POOR MEDIUM AND HIGH-SPEED PERFORMANCE. 9-2 POOR MEDIUM AND HIGH-SPEED PERFORMANCE. 9-2 FAULTY GEAR SHIFTING 9-3 HARD SHIFTING. 9-3 SHIFT PEDAL DOES NOT MOVE.
9-3 JUMP-OUT GEAR 9-3 CLUTCH SLIPPING/DRAGGING. 9-3 CLUTCH SLIPPING 9-3 CLUTCH DRAGGING 9-3 OVERHEATING.
9-4 OVERHEATING 9-4 OVER COOLING. 9-4 COOLING SYSTEM 9-4 FAULTY BRAKE. 9-4 POOR BRAKING EFFECT. 9-4 SHOCK ABSORBER MALFUNCTION 9-5 MALFUNCTION. 9-5 UNSTABLE HANDLING. 9-5 UNSTABLE HANDLING 9-5 LIGHTING SYSTEM. 9-5 HEADLIGHT DARK.
9-5 BULB BURNT OUT. 9-5 File Format: PDF Language: English Yamaha Raptor 660,Yamaha YFM660RN,Yamaha YFM660RNC, ATV, All-Terrain Vehicle, service manual, repair manual, workshop manual, factory manual, fsm, download.
. READ THIS MANUAL CAREFULLY!
It contains important safety information. OWNER’S MANUAL YFM660RP WARNING This ATV should not be ridden by anyone under 16 years of age. LIT-11626-15-31 5LP-28199-11. Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines.
With the purchase of this Yamaha, you can now appreciate the high degree of crafts- manship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this machine. EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe in- WARNING. Please check your local riding laws and regulations before operating this machine. EBU00981 YFM660RP OWNER’S MANUAL ©2001 by Yamaha Motor Corporation, AFFIX DEALER U.S.A. 1st edition, July 2001 LABEL HERE All rights reserved.
EBU00014 CONTROL FUNCTIONS.4-1 WARNING Main switch.4-1 Indicates a potential hazard that could Indicator and warning lights.4-2 result in serious injury or death. Handlebar switches.4-4 Throttle lever.4-6 Speed limiter.4-7 CONTENTS Clutch lever.4-8 Brake lever.4-8 Brake pedal.4-9 LOCATION OF THE WARNING Parking brake.4-10 AND SPECIFICATION LABELS. PRE-OPERATION CHECKS. 5-1 Engine break-in.
6-9 Front and rear brakes. 5-3 Parking.
6-10 Fuel.5-4 Parking on a slope.6-11 Engine oil.5-6 Accessories and loading.6-12 Coolant.5-7 Chain.5-8 RIDING YOUR ATV.7-1 Throttle lever. PERIODIC MAINTENANCE AND Parking brake adjustment.8-29 ADJUSTMENT.8-1 Adjusting the rear brake light Owner’s manual and tool kit.
8-1 switch.8-31 Periodic maintenance/ Clutch lever free play lubrication.8-3 adjustment.8-31 Panel removal and installation.8-5 Drive chain slack check.8-33 Engine oil and oil filter cartridge. Troubleshooting.8-49 Troubleshooting charts.8-50 CLEANING AND STORAGE. Cleaning.9-1 B. Storage.9-3 SPECIFICATIONS.10-1 NOISE REGULATION.11-1 MAINTENANCE RECORD. 12-1 ATV LIMITED WARRANTY. 13-1 YAMAHA EXTENDED SERVICE (Y.E.S.).
EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. WARNING UNDER Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. EBU00924 SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars.
A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions. Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, park- ● ing lots and streets. ● Never operate an ATV on any public street, road or highway, even a dirt or gravel one. ● Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.
● Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds.
Do not turn at excessive speed. Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller ●. Always use proper procedures if you stall or roll backwards when climbing a hill.
To avoid stall- ● ing, use proper gear and maintain a steady speed when climbing a hill. If you stall or roll back- wards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. ● Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual.
● Never modify an ATV through improper installation or use of accessories. ● ● Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. WARNING When transporting the ATV in another vehicle, be sure it is kept upright and POTENTIAL HAZARD that the fuel cock is in the “OFF” posi- Improper handling of gasoline. Otherwise, fuel may leak out of the WHAT CAN HAPPEN carburetor or fuel tank. WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.
HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation. EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1. Spark arrester 10. Tail/brake light 2.
Shift pedal 3. Fuel tank cap 12.
Clutch lever 4. Engine oil tank 13. Handlebar switches 5. Brake pedal 14.
Parking brake 6. Headlight 15. Main switch 7.
This number can be used for ordering a new when ordering spare parts from a Yamaha key. Dealer or for reference in case the vehicle is stolen. Record the information on this la- bel in the space provided. This information will be needed to order spare parts from your Yamaha dealer. Vehicle identification number NOTE: The vehicle identification number is used to 1.
EBU00039 CONTROL FUNCTIONS WARNING Indicates a potential hazard that could result in serious injury or death. EBU00942 Main switch Functions of the respective switch positions are as follows: The engine can be started only at this position and the headlights and taillight come on when the light switch is on. EBU00802 EBU00713 Indicator and warning lights Coolant temperature warning light “ ” When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the en- gine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.
Coolant temperature Coolant temperature warning light comes on warning light does not momentarily. Coolant temperature and electrical circuit are OK. Go Ask a Yamaha dealer to ahead with riding. Inspect the electrical circuit. EBU00053 Handlebar switches CAUTION: Do not use the headlights with the engine turned off for more than thirty minutes.
The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. EBU00849 Engine stop switch “. EBU00607 Start switch “ ” The starter motor cranks the engine when this switch is pushed. CAUTION: See starting instructions prior to starting the engine.
(See page 6-1 for details.). Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you 1.
Throttle lever can’t find or solve the problem yourself. EBU00066 Speed limiter WARNING The speed limiter keeps the throttle from fully POTENTIAL HAZARD opening, even when the throttle lever is Improper adjustment of the speed limit- pushed to the maximum.
Screwing in the ad- er and throttle. Juster limits the maximum engine power avail- WHAT CAN HAPPEN able and decreases the maximum speed of The throttle cable could be damaged. EBU00069 EBU00988 Clutch lever Brake lever The clutch lever is located on the left handle- The brake lever is located on the right handle- bar and the ignition circuit cut-off system is in- bar. Pull it toward the handlebar to apply the corporated in the clutch lever holder. EBU00989 Brake pedal The brake pedal is located on the right side of the machine.
Push down on the pedal to apply the rear brake. EBU00080 Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Squeeze the clutch lever while push- ing the button, then push in the lock plate to apply the parking brake. Squeeze the clutch lever to release the parking brake. EBU00788 Shift pedal WARNING This machine is equipped with a constant- POTENTIAL HAZARD mesh 5-speed forward and 1-speed reverse Improper use of the parking brake. The shift pedal is located on the WHAT CAN HAPPEN left side of the engine and is used in combina- The ATV could start moving unexpect- tion with the clutch when shifting. EBU00747.
EBU00092 Reverse knob “REV” Fuel tank cap The reverse knob is used to shift into reverse Remove the fuel tank cap by turning it coun- gear. Refer to the “Reverse knob operation and re- verse driving” section (page 6-5) before oper- ating this machine in reverse gear. EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor.
The fuel cock has three positions. OFF: With the lever in this position, fuel will not flow.
Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. EBU00095 EBU01010 Starter (choke) “ ” Seat Starting a cold engine requires a richer air-fuel To remove the seat, insert your hand between mixture.
A separate starter circuit supplies this the rear of the seat and the rear fender, pull mixture. To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. NOTE: Make sure that the seat is securely fitted. Projection (× 2) 2.
Seat holder (× 2) 4-15. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set- ting. Adjusting ring NOTE: A special wrench can be obtained at a Yamaha dealer. Yamaha dealer. Do not deform or damage the cylinder ● in any way.
● Do not dispose of a damaged or worn out shock absorber yourself. Take the unit to a Yamaha dealer.
The length of the spring (installed) 4. Tighten the locknut to the specified changes 1.5 mm (0.06 in) per turn of the torque. Adjusting nut.
Tightening torque: Measurement A: 42 Nm (4.2 mkgf, 30 ftlb) Installed length: CAUTION: Minimum (hard): 232 mm (9.1 in) Always tighten the locknut against the Standard. Adjust the rebound damping force as follows. Adjust the compression damping force as fol- Turn the rebound damping force adjusting lows. Screw in direction a to increase the rebound Turn the compression damping force adjust- damping force and in direction b to decrease ing screw in direction a to increase the com- pression damping force and in direction b to the rebound damping force. CAUTION: WARNING Never turn an adjusting mechanism be- POTENTIAL HAZARD yond the minimum and maximum settings.
Suspension components become hot during operation. NOTE: WHAT CAN HAPPEN Although the total number of clicks of a damp- You could be burned. Ing force adjusting mechanism may not exact- HOW TO AVOID THE HAZARD ly match the above specifications due to small Never touch the compression damping. PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE.
Check operation, free play, fluid level and fluid leakage. 5-3 5-4, Front brake. Fill with DOT 4 brake fluid if necessary. 8-24 8-27. WARNING POTENTIAL HAZARD Failure to inspect the ATV before oper- ating. Failure to properly maintain the ATV.
WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe op- erating condition. ● Check that there is no free play in the brake the brakes firmly for one minute.
If there is lever. If there is free play, have a Yamaha any leaking, have the machine inspected dealer adjust it. By a Yamaha dealer. Yamaha dealer.
Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number (R+M/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Fuel can spill, which can cause a fire hol containing methanol is not recommended and severe injury. By Yamaha because it may cause fuel system Fuel expands when it heats up. If the damage or vehicle performance problems. Fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun.
EBU00914 Engine oil CAUTION: Make sure the engine oil is at the specified Be sure to use motor oils that do not con- level. Add oil as necessary.
2002 Yamaha Raptor 660 Manual
(See page 8-6.) tain anti-friction modifiers. Passenger car motor oils (often labeled “ENERGY Recommended oil: CONSERVING II”) contain anti-friction ad. EBU00496 Coolant WARNING Check the coolant level in the reservoir tank POTENTIAL HAZARD when the engine is cold. (The coolant level will Removing the radiator cap when the en- vary with engine temperature.) The coolant gine and radiator are still hot. Level is satisfactory if it is between the “FULL”. Repair as necessary for proper operation.
EBU00152 Fittings and Fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. The following are minimums: 1. The tires listed below have been ap- Front 24.5 kPa (0.245 kgf/cm, 3.5 psi) proved by Yamaha Motor Co., Ltd. Rear 24.5 kPa (0.245 kgf/cm, 3.5 psi) for this model. Other tire combina- tions are not recommended. Set pressure with tires cold.
Use no more than the following Set tire pressures to the following specifica- pressures when seating the tire tions: beads. Front 250 kPa (2.5 kgf/cm, 36 psi) Recommended Minimum Maximum pressure Rear 250 kPa (2.5 kgf/cm, 36 psi) Higher pressures may cause the 27.5 kPa. EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. 3 mm (0.12 in) 5-11. Turn the fuel cock to “ON”.
There is a control or function you do not 3. Turn the main switch to “ON” and the en- understand, ask your Yamaha dealer. Gine stop switch to “ ”. Shift the transmission into neutral. When the transmission is in neutral.
The neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it.
When the clutch is disengaged with the ● transmission in any position. However, it is recommended to shift into neutral be- fore starting the engine. NOTE: CAUTION: If the engine fails to start, release the start See the “Engine break-in” section prior to switch, then push it again.
Pause a few sec- operating engine for the first time. Onds before the next attempt. Each cranking should be as short as possible to preserve battery energy. EBU00180 Starting a warm engine To start a warm engine, refer to the “Starting a cold engine” section. The starter (choke) should not be used. The throttle should be opened slightly. EBU00538 Warming up To get maximum engine life, always warm up the engine before starting off.
If the light does not come on, 2. While applying the rear brake pedal, turn ask a Yamaha dealer to inspect the machine. The reverse knob clockwise with your right hand. Check behind you for people or obsta- 3. EBU00199 Shifting WARNING This model has a 5-speed forward and 1-speed POTENTIAL HAZARD reverse transmission. The transmission allows Improperly operating in reverse. You to control the amount of power you have WHAT CAN HAPPEN available at a given speed or for starting, accel- You could hit an obstacle or person be- erating, climbing hills, etc.
EBU00203 To start out and accelerate: CAUTION: 1. Release the throttle lever.
● Do not coast for long periods with the engine off, and do not tow the ma- CAUTION: chine a long distance. Even in neutral Always close the throttle while shifting position, the transmission is only gears. EBU00207 8. Follow the same procedure when shifting To decelerate: to the next higher gear.
When slowing down or stopping, release the throttle and apply the brakes smoothly and WARNING evenly. As you slow down, shift to a lower POTENTIAL HAZARD gear.
Because the engine is If any abnormality is noticed during this peri- brand new, you must not put an excessive od, consult a Yamaha dealer. Load on it for the first several hours of running. 0 10 hours. EBU00211 Parking When parking, stop the engine and shift into neutral. Turn the fuel cock to “OFF” and apply the parking brake. Locked position 1.
Lock plate 6-10. EBU00992 Parking on a slope 1. Bring the machine to a stop by applying the brakes in low gear.
Stop the engine and release the clutch POTENTIAL HAZARD lever. Parking on a hill or other incline. With the front and rear brakes applied, WHAT CAN HAPPEN apply the parking brake and slowly re- The ATV could roll out of control, in.
Choose only accessories designed for your ● Use extra caution when riding an ATV with ATV. Your Yamaha dealer has a variety of accessories. The ATV may handle differ- genuine Yamaha accessories. Other ac- ently than it does without accessories. EBU00584 Loading ● Tie down cargo securely to the carriers. As originally equipped, this ATV is not de- Make sure cargo in the trailer cannot move signed to carry cargo or tow a trailer. If you around.
A shifting load can cause an acci- choose to add accessories so that you can dent. WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow- ing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle han- dling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. EBU00929 WARNING Indicates a potential hazard that could result in serious injury or death.
R iding Your. WARNING Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV the operation of the controls. Pay particular at- This ATV is intended for recreational use by tention to the safety information on pages 2-1 experienced operators only. JUDGEMENT Beginning and inexperienced operators should complete the certified training Get training if you are inexperienced. Course offered by Yamaha.
They should Beginners should get training from a certified then regularly practice the skills learned instructor. In the course and the operating tech- Become familiar with this ATV at slow speeds niques described in this Owner’s Manu. Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommenda- tions for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not rec- ommended for their age can lead to se- vere injury or death of the child.
This ATV is designed to carry operator only - passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/ or your passenger. Apparel Operating without protective clothing WARNING increases your chances of severe injury in the event of an accident. POTENTIAL HAZARD HOW TO AVOID THE HAZARD Operating this ATV without wearing an Always wear an approved motorcycle approved motorcycle helmet, eye pro- helmet that fits properly.
Do not operate after consuming alcohol or WARNING drugs. POTENTIAL HAZARD Operator’s performance capability is reduced Operating this ATV after consuming al- by the influence of alcohol or drugs. Cohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment.
Could cause you to react more slowly. Pre-operation checks WARNING Always perform the pre-operation checks list- POTENTIAL HAZARD ed on page 5-1 before riding for safety and Operating this ATV with improper tires, proper care of the ATV. Or with improper or uneven tire pres- WARNING sure. POTENTIAL HAZARD WHAT CAN HAPPEN Failure to inspect the ATV before oper. Speed limiter WARNING For riders inexperienced with this model, this Indicates a potential hazard that could model is equipped with a speed limiter in the result in serious injury or death. Throttle lever housing.
The speed limiter limits the power and top speed of the ATV. Turning Do not operate at speeds too fast for your the screw in decreases top speed, and turning skills or the conditions. Loading and accessories WARNING Use extra caution when riding the ATV with POTENTIAL HAZARD additional loads, such as accessories or car- Overloading this ATV or carrying or tow- go. The ATV’s handling may be adversely af- ing cargo improperly. Reduce your speed when adding WHAT CAN HAPPEN additional loads. During operation WARNING Always keep your feet on the footboards dur- POTENTIAL HAZARD ing operation. Otherwise your feet may con- Removing hands from handlebars or tact the rear wheels.
Feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can re- duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. Avoid wheelies and jumping. You may lose control of the ATV or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts.
WHAT CAN HAPPEN Increases the chance of an accident, in- cluding an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Never modify this ATV through improp- er installation or use of accessories. All parts and accessories added to this ve- hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions.
If you have questions, consult an autho- rized ATV dealer. Exhaust system The exhaust system on the ATV is very hot during and following operation.
To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it.
WARNING POTENTIAL HAZARD Hot exhaust system. BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only.
Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of con. Do not ride on any public road, street, or high- way. Riding on public roads can result in colli- sions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways.
WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt. Know the terrain where you ride. Ride cau- tiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and oth- er hidden hazards which may cause the ATV to upset.
WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an acci- dent, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills neces. When riding in an area where you might not WHAT CAN HAPPEN easily be seen, such as desert terrain, mount You could be in a collision. You could a caution flag on the ATV.
DO NOT use the be injured. Flag pole bracket as a trailer hitch. Select a large, flat area off-road to become fa- With the engine idling, pull the clutch lever to miliar with your ATV. Make sure that this area disengage the clutch and shift into 1st gear, is free of obstacles and other riders. You and then release the parking brake. When slowing down or stopping, release the WARNING throttle and apply the brakes smoothly and POTENTIAL HAZARD evenly.
As you slow down, shift to a lower Opening the throttle abruptly or releas- gear. Be sure that the engine has sufficiently ing the clutch lever to quickly. TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off- Always follow proper procedures for road, the two rear wheels are mounted solidly turning as described in this Owner’s on one axle and turn together at the same Manual. Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. CLIMBING UPHILL HOW TO AVOID THE HAZARD Use proper riding techniques to avoid vehicle Never operate the ATV on hills too steep overturns on hills. Be sure that you can ma- for the ATV or for your abilities.
Neuver your ATV well on flat ground before at- Practice on smaller hills before attempt- tempting any incline and then practice riding ing large hills. WARNING An obstacle, a sharp drop, or another vehicle or person could be on the other POTENTIAL HAZARD side of the hill. Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Own- er’s Manual.
If you are climbing a hill and you find that you When crossing the side of a hill: have not properly judged your ability to make Always follow proper procedures as de- it to the top, you should turn the ATV around scribed in the Owner’s Manual. If your ATV has stalled or stopped and you WARNING believe you can continue up the hill, restart POTENTIAL HAZARD carefully to make sure you do not lift the front Stalling, rolling backwards or improper- wheels which could cause you to lose control. Ly dismounting while climbing a hill. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the pro- cedure described in the Owner’s Manual.
RIDING DOWNHILL WARNING When riding your ATV downhill, shift your POTENTIAL HAZARD weight as far to the rear and uphill side of the Going down a hill improperly. ATV as possible. Move back on the seat and WHAT CAN HAPPEN sit with your arms straight. CROSSING A SLOPE WARNING Traversing a sloping surface on your ATV re- POTENTIAL HAZARD quires you to properly position your weight to Improperly crossing hills or turning on maintain proper balance. Be sure that you hills. Have learned the basic riding skills on flat WHAT CAN HAPPEN ground before attempting to cross a sloping Could cause loss of control or cause the.
Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. CROSSING THROUGH SHALLOW WATER Remember that wet brakes may have re- The ATV can be used to cross slow moving, duced stopping ability. Test your brakes shallow water of up to a maximum of 35 cm after leaving water. If necessary, apply (14 inches) in depth. Test your brakes after leaving the water.
2003 Yamaha Raptor 660 Manual
Do CAUTION: not continue to ride your ATV without verifying After riding your ATV in water, be sure to that you have regained proper braking ability. Drain the trapped water by removing the check hose at the bottom of the air filter case. RIDING OVER ROUGH TERRAIN WARNING Riding over rough terrain should be done with POTENTIAL HAZARD caution. Look out for obstacles which could Improperly operating over obstacles. Cause damage to the ATV or could lead to an WHAT CAN HAPPEN upset or accident. Be sure to keep your feet Could cause loss of control or a colli- firmly mounted on the footboards at all times. SLIDING AND SKIDDING If the rear wheels of your ATV start to slide Care should be used when riding on loose or sideways, control can usually be regained (if slippery surfaces since the ATV may slide.
If there is room to do so) by steering in the direc- unexpected and uncorrected, sliding could tion of the slide. With practice, over a period of time, skill at WARNING controlled sliding can be developed.
The ter- POTENTIAL HAZARD rain should be chosen carefully before at- Skidding or sliding improperly. Tempting such maneuvers, since both stability WHAT CAN HAPPEN and control are reduced.
Bear in mind that You may lose control of this ATV. WHAT TO DO IF. ● If your ATV starts to slide sideways: This section is designed to be a reference Steer in the direction of the slide if you have guide only. Be sure to read each section on the room.
If your ATV is traversing a sloping surface: ● Be sure to ride with your weight positioned towards the uphill side of the ATV to main- tain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.
EBU00515 PERIODIC MAINTENANCE AND Have a Yamaha dealer perform service if ADJUSTMENT you are not familiar with machine ser- vice. Periodic inspection, adjustment and lubrica- tion will keep your machine in the safest and most efficient condition possible. Safety is an EBU00257 obligation of the machine owner.
HOW TO AVOID THE HAZARD during a service operation requiring one, take Never modify this ATV through improp- your machine to a Yamaha dealer to check er installation or use of accessories. All the torque settings and adjust them as neces- parts and accessories added to this ve- sary. EBU00261 PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY ITEM ROUTINE month months months months year. Check valve clearance. Valves. Adjust if necessary. Check coolant leakage.
Cooling system. Repair if necessary. Replace coolant every 24 months. Check condition. Spark plug. Lubricate every 6 months. Check all chassis fittings and fasteners.
Fittings and fasteners. Correct if necessary. It is recommended that these items be serviced by a Yamaha dealer.
Lithium-soap-based grease NOTE:. Recommended brake fluid: DOT4. EBU00807 EBU01013 Panel removal and installation Panel A 1. Bolt (× 2) The panel illustrated needs to be removed to To remove perform some of the maintenance described Remove the bolts, and then take the panel off. In this chapter. EBU01014 Engine oil and oil filter cartridge 3. Wait a few minutes until the oil settles, re- The engine oil level should be checked before move the engine oil tank filler cap, wipe each ride.
In addition, the oil must be changed the dipstick clean with a clean rag, insert and the oil filter cartridge replaced at the inter- it back into the filler hole (without screw. If the engine oil is below the minimum To change the engine oil (with or without level mark, add sufficient oil of the recom- oil filter cartridge replacement) mended type to raise it to the correct lev- NOTE: When adding oil, be careful not to overfill the engine oil tank. Remove the crankcase engine oil drain bolt. Engine oil tank drain bolt 5. Remove the engine oil tank filler cap and the oil tank drain bolt. Crankcase engine oil drain bolt 6.
Check the washers for damage, and re- place if necessary. Install a new oil filter cartridge and tighten NOTE: it to the specified torque with a torque An oil filter wrench is available at a nearby wrench.
Yamaha dealer. Tightening torque: Oil filter cartridge: 17 Nm (1.7 mkgf, 12 ftlb). 10. Install the crankcase engine oil drain bolt CAUTION: and the engine oil tank drain bolt, then ● In order to prevent clutch slippage tighten them to the specified torques. (since the engine oil also lubricates Tightening torques: the clutch), do not mix any chemical Crankcase engine oil drain bolt: additives with the oil or use oils of a 30 Nm (3.0 mkgf, 22 ftlb).
You may use soft water if you can’t marks. Get distilled water. NOTE: If water is added, have a Yamaha dealer ● check the antifreeze content of the cool- ant as soon as possible. EBU01016 Changing the coolant 1. Place the ATV on a level surface. Remove panel A.
(See page 8-5 for pan- WARNING el removal and installation procedures.) POTENTIAL HAZARD 3. Place a container under the engine, and Removing the radiator cap when the en- then remove the coolant drain bolt. Remove the radiator cap. Remove the coolant reservoir cap. Disconnect the hose on the coolant res- ervoir side, and then drain the coolant from the coolant reservoir. Radiator cap 1. Coolant reservoir cap 2.
After draining the coolant, thoroughly flush the cooling system with clean tap water. 1.3 L (1.14 Imp qt, 1.37 US qt) NOTE: Coolant reservoir capacity: If any leakage is found, have a Yamaha deal- 0.29 L (0.26 Imp qt, 0.31 US qt) er check the cooling system. Install the panel. ATV that is being ridden normally. Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer.
You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. Installation Tightening torque: 1. Measure the electrode gap with a wire Spark plug: thickness gauge and, if necessary, adjust 17.5 Nm (1.75 mkgf, 12.7 ftlb) the gap to specification. NOTE: Spark plug gap: If a torque wrench is not available when you 0.8 0.9 mm (0.03 0.04 in) are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger. EBU00792 Air filter element cleaning NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case.
WARNING POTENTIAL HAZARD Using low flash point solvents or gaso- line to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the 1. Apply Yamaha foam air filter oil or other NOTE: The air filter element should be cleaned every quality foam air filter oil to the element.
If foam air filter oil is not available, motor oil 20 40 hours. It should be cleaned and lubri- cated more often if the machine is operated in may be used. EBU00780 Spark arrester cleaning 2.
Remove the tailpipe by pulling it out of Be sure the exhaust pipe and muffler are cool the muffler. Before cleaning the spark arrester. Tap the tailpipe lightly, then use a wire 1. Remove the bolt. Brush to remove any carbon deposits from the spark arrester portion of the tailpipe. The carburetor is a vital part of the engine and POTENTIAL HAZARD requires very sophisticated adjustment.
Most Improper cleaning of the spark arrester. Adjusting should be left to a Yamaha dealer Hot exhaust system who has the professional knowledge and ex- WHAT CAN HAPPEN perience to do so. EBU00301 Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min.
Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the 1. This adjust- ment however, should be left to a professional 1.
Loosen the locknut. Yamaha service technician. Turn the adjusting bolt until the throttle le- ver free play is 3 5 mm (0.12 0.20 in). Apply the brake and inspect the wear indicators grooves.
If the pad is worn to the point that the wear indicator grooves are al- most in contact with the disc plate, ask a Yamaha dealer to replace the pads. Wear indicator groove Front EBU01017. Reservoir cover 2. Bolt (× 2) 1. Minimum level mark Observe these precautions: Front When checking the fluid level, make sure ● the top of the brake fluid reservoir is level. ● Use only the designated quality brake fluid. Otherwise, the rubber seals may deterio- rate, causing leakage and poor brake per- formance.
Always clean up spilled You could lose braking ability, which fluid immediately. Could lead to an accident.
● Have a Yamaha dealer check the cause if HOW TO AVOID THE HAZARD the brake fluid level goes down. After servicing: ●. The front brake lever should have a free play POTENTIAL HAZARD of 0 mm (0.0 in) at the lever end. If not, ask a Operating with improperly serviced or Yamaha dealer to adjust it. Adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. Operating with improperly serviced or tioned 4 mm (0.16 in) below the top of the adjusted brakes.
If not, ask a Yamaha dealer to adjust WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. If the cable cannot be adjusted to specifica- 1. Adjusting bolt tion, consult a Yamaha dealer.
Loosen the adjusting bolt locknut and the adjusting bolt on the rear brake caliper. Tighten the adjusting bolt locknut on the clutch lever. Screw in the adjusting bolt on the brake WARNING caliper by hand until it feels tight, then POTENTIAL HAZARD screw it out 1/8 turn. Tighten the adjust- Operating with improperly adjusted ing bolt locknut to the specified torque.
Tightening torque: WHAT CAN HAPPEN The brakes could malfunction, causing. EBU00833 EBU00741 Adjusting the rear brake light switch Clutch lever free play adjustment The rear brake light switch, which is activated The clutch lever free play should be adjusted by the brake pedal and brake lever, is proper- to 5 10 mm (0.20 0.39 in). Ly adjusted when the brake light comes on just 1. Loosen the locknut at the crankcase side. Turn the adjusting nut at the crankcase in direction a to increase the free play or in direction b to decrease the free play.
Tighten the locknut at the crankcase and the clutch lever. EBU00350 EBU00917 Drive chain slack check Drive chain slack adjustment Inspect the drive chain while all tires are 1.
Loosen the rear wheel hub upper and touching the ground. Check the slack at the lower nuts. Position shown in the figure.
The normal verti- cal deflection is approximately 27 37 mm (1.1 1.5 in). There are alignment marks on each side of Tightening torque: the swingarm and on the hub. Use them to Locknut: check for proper wheel axle alignment. 16 Nm (1.6 mkgf, 12 ftlb) Upper wheel hub nut: 90 Nm (9.0 mkgf, 65 ftlb) Lower wheel hub nut: 90 Nm (9.0 mkgf, 65 ftlb) 1. EBU00805 Lubricating the drive chain 1. Clean the drive chain with kerosene and The drive chain must be cleaned and lubricat- a small soft brush.
Ed at the intervals specified in the periodic CAUTION: maintenance and lubrication chart, otherwise To prevent damaging the O-rings, do not it will quickly wear out, especially when riding in dusty or wet areas. WARNING Yamaha dealer to replace them. POTENTIAL HAZARD Damaged control cables. Recommended lubricant: Yamaha chain and cable lube or WHAT CAN HAPPEN Corrosion can result when the outer SAE 10W30 motor oil covering of control cables becomes damaged. Cables can also become EBU00737 frayed or kinked.
EBU01018 Front upper and lower arm pivot Right side lubrication Lubricate the upper and lower arm pivots. Recommended lubricant: Lithium-soap-based grease Left side 1. EBU01019 Rear arm pivot lubrication Lubricate the rear arm pivot.
Recommended lubricant: Lithium-soap-based grease 8-38. EBU00373 Wheel removal Rear 1. Elevate the wheel by placing a suitable stand under the frame. Remove the nuts from the wheel. Remove the wheel assembly.
Nut (× 4) 8-39. EBU00782 Wheel installation Rear When installing a wheel, reverse the removal procedure. NOTE: ● When installing a front wheel, the arrow mark on the tire must point toward the rotating direction of the wheel. When installing a rear wheel, the wording ●. Keep out of reach of chil- tery. If the battery seems to have discharged, dren.
Consult a Yamaha dealer. Antidote: EXTERNAL: Flush with water. CAUTION: INTERNAL: Drink large quantities of wa- Do not try to remove the sealing caps of ter or milk. Then turn on the switch- es. If the fuse immediately blows again, CAUTION: consult a Yamaha dealer.
A special battery charger (constant volt- Specified fuse: 20 A age/ampere or constant voltage) is re. EBU01020 Replacing a headlight bulb WARNING 1. Remove the headlight assembly by re- POTENTIAL HAZARD moving the bolts. Using an improper fuse.
WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rat- ing. Disconnect the headlight coupler. Remove the screw.
Headlight coupler 1. Remove the headlight cover from the headlight assembly. Remove the screw and pull the headlight Pull outward on the rear of the headlight unit, unit out from its case. And then pull outward on the front. Remove the headlight bulb holder cover.
Headlight bulb holder cover 1. Push the headlight bulb holder inward, WARNING turn it counterclockwise and remove the POTENTIAL HAZARD defective bulb.
A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flamma- ble. Connect the headlight coupler. Install the headlight assembly in the orig- inal position and tighten the bolts. Have a Yamaha dealer adjust the head- light beam if necessary. Headlight bulb 2.
Headlight bulb holder 9. EBU01021 Tail/brake light bulb replacement 1.
Remove the screws and the lens. Install a new bulb by pushing it inward and turning it clockwise. Screw (× 2) 4.
Install the lens and tighten the screws. EBU00412 Troubleshooting WARNING Although Yamaha machines receive a rigid in- POTENTIAL HAZARD spection before shipment from the factory, Checking the fuel system while smok- trouble may occur during operation. Any prob- ing or near an open flame.
Lem in the fuel, compression, or ignition sys. Compression There is compression.
Compression normal. Use the electric starter to see if there is compression. Ask a Yamaha dealer to No compression.
Ignition Wipe clean with dry cloth. Ignition system is Spark is good. Restart the engine. If the engine overheats again, ask a Level is OK. Yamaha dealer to inspect and/or repair the cooling system. NOTE: If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recommended coolant as soon as possible.
EBU00417 CLEANING AND STORAGE CAUTION: Excessive water pressure may cause wa- A. CLEANING ter seepage and deterioration of wheel Frequent, thorough cleaning of your machine bearings, brakes, transmission seals and will not only enhance its appearance but will electrical devices. Many expensive repair improve its general performance and extend bills have resulted from improper high the useful life of many components. Clean the seat with a vinyl upholstery WARNING cleaner to keep the cover pliable and POTENTIAL HAZARD glossy. Operation with wet brakes after wash- 8. Automotive type wax may be applied to ing.
All painted and chrome plated surfaces. WHAT CAN HAPPEN Avoid combination cleaner-waxes.
Do not apply oil to NOTE: any rubber parts or the seat cover. Use of fuel stabilizer and conditioner elimi- nates the need to drain the fuel system. Con- sult a Yamaha dealer if the fuel system needs to be drained instead.
Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an ex- cessively warm or cold place (less than 0°C (30°F) or more than 30°C (90°F)).
NOTE: Make any necessary repairs before storing the machine. EBU00428 SPECIFICATIONS MODEL YFM660R Dimension: Overall length 1,830 mm ( 72 in) Overall width 1,100 mm ( 43.3 in) Overall height 1,150 mm ( 45.3 in) Seat height 860 mm ( 33.9 in) Wheel base 1,245 mm ( 49 in) Ground clearance 265 mm ( 10.4 in) Minimum turning radius. MODEL YFM660R Engine oil: 0˚ 90˚ 110˚ 130˚F 10˚ 30˚ 50˚ 70˚ Type YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 -20˚ -10˚ 0˚ 20˚ 30˚ 40˚ 50˚C 10˚ Recommended engine oil classification: API Service SE, SF, SG type or higher CAUTION: Be sure to use motor oils that do not contain anti- friction modifiers.
MODEL YFM660R Radiator capacity (including all routes): 1.3 L (1.14 lmp qt, 1.37 US qt) Air filter: Wet type element Fuel: Type UNLEADED GASOLINE ONLY Tank capacity 12 L (2.64 Imp gal, 3.17 US gal) Reserve amount 2.6 L (0.57 Imp gal, 0.69 US gal) Carburetor: Type ×. MODEL YFM660R Gear ratio: 31/12 (2.583) 30/18 (1.667) 27/21 (1.286) 22/21 (1.047) 19/21 (0.904) 33/25 × 25/18 (1.833) Reverse Chassis: Frame type Steel tube ° Caster angle Trail 47 mm (1.85 in) Tire: Type Tubeless AT21 × 7 - 10 Size: Front AT20 ×. MODEL YFM660R Wheel travel: Front 230 mm (9.06 in) Rear 220 mm (8.66 in) Electrical: Ignition system DC-C.D.I. Generator system A.C. Magneto Battery type/voltage capacity YTX14-BS/12V, 12Ah Headlight type: Krypton bulb Bulb voltage, wattage × quantity: 12V, 30W/30W × 2 Headlight 12V, 5W/21W ×. EBU00430 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop- erative by any person other than for purposes of maintenance, repair, or replacement of any de- vice or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. EBU00431 MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to docu- ment maintenance done in accordance with the warranty.
The chart below is printed only as a re- minder to you that the maintenance work is required. It is not acceptable proof of maintenance work. EBU00432 YAMAHA MOTOR CORPORATION, U.S.A.
ATV LIMITED WARRANTY 13-1. EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.) 14-1. EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death. EBU00437 14-5. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
(For replacement manual, call 1-800-532-1558) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001. 7 - 6.0 × 1 CR.