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Yamaha YFM660 01 User Manual

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Page 1

YFM660RN
YFM660RNC
SERVICE MANUAL
LIT-11616-14-21 5LP-28197-E0 

Page 2

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...

Page 3

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...

Page 4

EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1
 to 9
 are printed on the
top right of each page and indicate the subject
of each chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Cooling system
7Carburetion
8Electrical
9Troubleshooting
Illustrated symbols 0
 to G
 are used to identify
the specifications appearing in the text.
0Can be serviced with engine mounted
AFilling fluid
BLubricant
CSpecial tool
DTorque
EWear limit, clearance
FEngine speed
G
Ω, V,...

Page 5

TABLE OF CONTENTS
GENERAL INFORMATIONGEN 
INFO
1
SPECIFICATIONS
SPEC2
PERIODIC CHECKS AND 
ADJUSTMENTS
CHK 
ADJ
3
CHASSIS
CHAS4
ENGINE
ENG5
COOLING SYSTEM
COOL6
CARBURETION
CARB7
ELECTRICAL
ELEC8
TROUBLESHOOTINGTRBL
SHTG
9
–+ 

Page 6

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...

Page 7

GEN 
INFO
1
SPEC2
CHK 
ADJ
3
CHAS4
ENG5
COOL6
CARB7
ELEC8
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...

Page 8

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...

Page 9

GEN 
INFO
1
SPEC2
CHK 
ADJ
3
CHAS4
ENG5
COOL6
CARB7
ELEC8
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...

Page 10

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...
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