Yamaha YFM660 01 User Manual

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CHASSTEERING SYSTEM
Order Job name/Part name Q’ty Remarks
9 Bearing retainer 1 Refer to “REMOVING/INSTALLING THE 
BEARING RETAINER”.
10 Bearing 1
For installation, reverse the removal pro-
cedure.  

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CHASSTEERING SYSTEM
REMOVING THE BEARING RETAINER
1.Remove:

Bearing retainer (steering stem)
Damper rod holder:
P/N. YM-01327, 90890-01327
CHECKING THE STEERING STEM
1.Check:

Steering stem 1
 
Bends →
 Replace.
WARNING
Do not attempt to straighten a bent stem;
this may dangerously weaken the stem.
2.Check: 

Oil seals 1
 

Steering stem bushings 2
 
Wear/damage →
 Replace.
New
INSTALLING THE BEARING RETAINER
1.Install:

Bearing retainer (steering stem) 
Damper rod holder:
P/N. YM-01327,...

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CHASSTEERING SYSTEM
TIE-ROD AND STEERING KNUCKLE
Order Job name/Part name Q’ty Remarks
Removing the tie-rod and steering 
knuckleRemove the parts in the order below.
Front wheel/brake disc Refer to “FRONT WHEELS”.
1 Tie-rod 2 Refer to “INSTALLING THE TIE-ROD”.
2 Pitman arm 1
3 Brake disc guard (inner) 1
4 Front bumper 1
5 Front arm (lower) 1
6 Front arm (upper) 1
7 Steering knuckle 1 Refer to “REMOVING THE STEERING 
KNUCKLE”.
For installation, reverse the removal pro-
cedure.  

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CHASSTEERING SYSTEM
REMOVING THE STEERING KNUCKLE
1.Remove:

Steering knuckle 1
 
NOTE:
Use a general puller to separate the ball joint
2
 and steering knuckle.
CHECKING THE TIE-ROD
1.Check:

Tie-rod free play and movement
Free play →
 Replace the tie-rod end.
Turns roughly →
 Replace the tie-rod end.
2.Check:

Tie-rod

Bends/damage →
 Replace.
CHECKING THE STEERING KNUCKLE
1.Check:

Steering knuckle
Damage/pitting →
 Replace.
INSTALLING THE TIE-ROD
1.Install:

Tie-rods (left and right) 
NOTE:
The...

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CHASFRONT ARMS AND FRONT SHOCK ABSORBERS
FRONT ARMS AND FRONT SHOCK ABSORBERS
Order Job name/Part name Q’ty Remarks
Removing the front arm and front 
shock absorberRemove the parts in the order below.
Front wheel/brake disc Refer to “FRONT WHEELS”.
1 Front bumper 1
2 Brake disc guard (inner) 1
3Nut 1
4 Tie-rod 1 Disconnect.
5Nut 1
6Nut 1
7 Nut/bolt 1/1
8 Nut/bolt 2/2
Refer to “REMOVING/INSTALLING THE 
FRONT ARMS”.  9 Front arm (lower) 1
10 Nut/bolt 1/1
11 Front arm (upper) 1 

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CHASFRONT ARMS AND FRONT SHOCK ABSORBERS
Order Job name/Part name Q’ty Remarks
12 Nut/bolt 1/1
13 Front shock absorber/collar 1/1
14 Steering knuckle 1
15 Dust cover 6
16 Collar 1
17 Collar 2
18 Bushing 6
19 Circlip 1
20 Rubber boot 1
21 Ball joint 1
For installation, reverse the removal pro-
cedure.  

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CHASFRONT ARMS AND FRONT SHOCK ABSORBERS
REMOVING THE FRONT ARM
1.Check:

Front arm free play
***********************************************
Checking steps:

Check the front arm side play È
 by moving it
from side to side.
If side play is noticeable, check the bushings.

Check the front arm vertical movement É
 by
moving it up and down.
If the vertical movement is tight or rough, or if
there is binding, check the bushings.
***********************************************
2.Remove:

Front arms...

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CHASFRONT ARMS AND FRONT SHOCK ABSORBERS
CHECKING THE BALL JOINT
1.Check:

Ball joint (front arm-upper)
Damage/pitting →
 Replace the front arm 
(upper).
Free play →
 Replace the front arm.
Turns roughly →
 Replace the front arm 
(upper).
2.Check: 

Ball joint (front arm-lower)
Damage/pitting →
 Replace the ball joint.
Free play →
 Replace the ball joint.
Turns roughly →
 Replace the ball joint.
***********************************************
Ball joint replacement steps:

Clean the outside of the...

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CHAS

Attach the assembled ball joint remover/
installer, new ball joint A
, installer spacer 7
and installer washer 8
 to the front lower arm
0
.
NOTE:

Do not tap or damage the top of the ball joint.

Installer spacer 7
 must be aligned with the
projection on the head of the ball joint A
.

Remove the ball joint remover/installer.

Apply lithium-soap base grease to the new
ball joint A
.

Install a new rubber boot and new circlip.
NOTE:
Always use a new ball joint set....

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CHASREAR SHOCK ABSORBER AND RELAY ARM
REAR SHOCK ABSORBER AND RELAY ARM
Order Job name/Part name Q’ty Remarks
Removing the rear shock absorber 
and relay armRemove the parts in the order below.
Rear wheels and hub Refer to “REAR WHEELS, WHEEL AXLE
AND HUB”.
1 Metal screw clamp 2
2 Self-locking nut/bolt 1/1
Refer to “REMOVING THE REAR 
SHOCK ABSORBER”.
3 Self-locking nut/bolt 1/1
4 Self-locking nut/bolt 1/1
5 Self-locking nut/bolt 1/1
6 Rear shock absorber 1
7 Collar/oil seal 2/2
8 Collar/oil seal...