2001-2005 Yamaha YFM 660 Raptor Service & Repair Manual

YFM660RN YFM660RNC SERVICEMANUAL LIT-11616-14-21 5LP-28197-E0

EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use. Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig- nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice. IMPORTANT INFORMATION 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 injury or death to the machine operator, a bystander or a person inspecting or repairing the machine. A CAUTION indicates special precautions that must be taken to avoid dam- age to the machine. A NOTE provides key information to make procedures easier or clearer. WARNING CAUTION: NOTE:

EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page. 3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa- nied by corresponding illustrations. EXPLODED DIAGRAMS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs. 2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6. The meanings of the symbol marks are given on the next page. 4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart.

EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Carburetion 8 Electrical 9 Troubleshooting Illustrated symbols 0 to G are used to identify the specifications appearing in the text. 0 Can be serviced with engine mounted A Filling fluid B Lubricant C Special tool D Torque E Wear limit, clearance F Engine speed G Ω, V, A Illustrated symbols H to N in the exploded diagrams indicate the types of lubricants and lubrication points. H Apply engine oil I Apply gear oil J Apply molybdenum disulfide oil K Apply wheel bearing grease L Apply lightweight lithium soap base grease M Apply molybdenum disulfide grease N Apply silicon grease Illustrated symbols O to P in the exploded diagrams indicate where to apply a locking agent O and when to install a new part P. O Apply the locking agent (LOCTITE  ) P Replace 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K O P GEN INFO SPEC CHK ADJ CHAS ENG COOL CARB – + ELEC TRBL SHTG T R . . E G M B LS M S L M N LT New

TABLE OF CONTENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS CHAS 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 CARBURETION CARB 7 ELECTRICAL ELEC 8 TROUBLESHOOTING TRBL SHTG 9 – +

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 ENGINE ................................................................................................. 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 ENGINE ............................................................................................... 2-21 COOLANT FLOW DIAGRAMS ................................................................... 2-22 OIL FLOW DIAGRAMS .............................................................................. 2-23 CABLE ROUTING ....................................................................................... 2-27

GEN INFO 1 SPEC 2 CHK ADJ 3 CHAS 4 ENG 5 COOL 6 CARB 7 ELEC 8 TRBL SHTG 9 – + 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

GEN INFO 1 SPEC 2 CHK ADJ 3 CHAS 4 ENG 5 COOL 6 CARB 7 ELEC 8 TRBL SHTG 9 – + 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

2001-2005 Yamaha YFM 660 Raptor Service & Repair Manual

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