Yamaha YFM660 01 User Manual

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CHASREAR WHEELS, WHEEL AXLE AND HUB
REAR WHEELS, WHEEL AXLE AND HUB
REAR WHEELS
Order Job name/Part name Q’ty Remarks
Removing the rear wheel
Remove the parts in the order below.
Place the machine on a level surface.
WARNING
Securely support the machine so there
is no danger of it falling over.
1 Rear wheel 2 Refer to “INSTALLING THE WHEEL”.
2 Cotter pin 2
Refer to “INSTALLING THE WHEEL 
HUB”.
3 Axle nut 2
4 Wheel hub 2
For installation, reverse the removal pro-
cedure.  
						

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CHASREAR WHEELS, WHEEL AXLE AND HUB
WHEEL AXLE AND HUB
Order Job name/Part name Q’ty Remarks
Removing the wheel axle and hub
Remove the parts in the order below.
1 Nut 2 Refer to “INSTALLING THE NUTS 
(REAR AXLE)”.
2 Locknut 2 Refer to “REMOVING THE REAR AXLE”.
3 Adjusting bolt 2
4 Rear axle 1
5 Brake caliper 1
NOTE:
Do not apply the brake pedal and do not
use the parking brake when the brake
caliper is off of the brake disc as the
brake pad will be force shut. 
						

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CHASREAR WHEELS, WHEEL AXLE AND HUB
Order Job name/Part name Q’ty Remarks
6 Brake disc 1
7 Driven sprocket 1
8 Brake caliper bracket 1
9Hub 1
For installation, reverse the removal pro-
cedure.  
						

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CHASREAR WHEELS, WHEEL AXLE AND HUB
REMOVING THE REAR AXLE
1.Place the machine on a level surface.
2.Loosen:

Nuts (rear axle) 1
 
NOTE:

Apply the brake pedal so that the rear axle
does not turn, when loosening the nuts.

Use a axle nut wrench (50 mm) 2
.
Axle nut wrench (50 mm):
P/N. YM-37132, 90890-01419
3.Elevate the rear wheels by placing the suit-
able stand under the frame.
4.Remove:

Rear wheels

Wheel hubs

Nuts (rear axle)
5.Loosen:

Hub nuts 1
 
6.Loosen:

Locknuts 1
 

Adjusting bolts 2
  
						

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CHASREAR WHEELS, WHEEL AXLE AND HUB
7.Remove:

Rear axle 1
 
CAUTION:

Never directly tap the axle end with a
hammer, since this will result in damage
to the axle thread and spline.

Attach a suitable socket 2 on the axle
end and tap it with a soft hammer. Pull out
the rear axle to the right.
CHECKING THE WHEEL
Refer to “FRONT WHEELS”.
CHECKING THE WHEEL HUB
1.Check:

Wheel hub 1
 
Cracks/damage →
 Replace.

Splines (wheel hub) 2
 
Wear/damage →
 Replace the wheel hub.
CHECKING THE REAR AXLE
1.Check:

Rear axle runout a
 
Out of specification →
 Replace.
WARNING
Do not attempt to straighten a bent axle.
Rear axle runout limit:
1.5 mm (0.06 in) 
						

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CHASREAR WHEELS, WHEEL AXLE AND HUB
CHECKING THE HUB
1.Check:

Hub bearings
Refer to “FRONT WHEELS-WHEEL HUB
INSPECTION”.
CHECKING THE BRAKE DISC
Refer to “FRONT WHEELS”.
INSTALLING THE NUTS (REAR AXLE)
1.Tighten:
Nuts (rear axle) 1
, 2
 
***********************************************
Nuts tightening steps:
NOTE:
Before tightening the nuts, apply the LOC-
TITE® to the thread portion of the rear axle.

Finger tighten the inside nut 1
 while check-
ing the ring gear engagement.

Tighten the inside nut with rear axle nut
wrench to specification while holding the rear
axle. 

Hold the inside nut 1
 and tighten the outside
nut 2
 with rear axle nut wrench to specifica-
tion.

Draw the line a
 on inside and outside nut.

Hold the outside nut 2
 and tighten back the
inside nut 1
 with rear axle nut wrench to
specification.

Measure the distance b
 between lines. If
distance b
 is less than 15 mm (0.59 in),
retighten back the inside nut.
***********************************************
Axle nut wrench (50 mm):
P/N. YM-37132, 90890-01419
T R..
Inside nut (first tightening):
55 Nm (5.5 m  kg, 40 ft  lb)
T R..
Outside nut:
190 Nm (19.0 m  kg, 140 ft  lb)
T R..
Inside nut (final tightening):
240 Nm (24.0 m  kg, 170 ft  lb) 
						

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CHASREAR WHEELS, WHEEL AXLE AND HUB
INSTALLING THE WHEEL HUB
Refer to “FRONT WHEELS”.
INSTALLING THE WHEEL
1.Install:

Wheel
NOTE:
The wording on the tire “SIDE FACING OUT-
WARDS” 1
 must be facing outwards. 
						

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CHASFRONT AND REAR BRAKES
FRONT AND REAR BRAKES
FRONT BRAKE PADS
Order Job name/Part name Q’ty Remarks
Removing the front brake pad
Remove the parts in the order below.
Front wheel/wheel hub Refer to “FRONT WHEELS”.
1 Brake pad holding bolt 2
Refer to “REPLACING THE FRONT 
BRAKE PAD”. 2 Brake pad/pad shim 2/1
3 Brake pad spring 1
For installation, reverse the removal pro-
cedure.  
						

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CHASFRONT AND REAR BRAKES
REAR BRAKE PADS
Order Job name/Part name Q’ty Remarks
Removing rear brake pad
Remove the parts in the order below.
1 Brake caliper mounting bolt 1
Refer to “REPLACING THE REAR 
BRAKE PAD”. 2 Brake caliper mounting bolt 1
3 Brake pad holding bolt 2
4 Lock washer 1
5 Brake pad/pad shim 2/1
6 Brake pad spring 1
For installation, reverse the removal pro-
cedure.  
						

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CHASFRONT AND REAR BRAKES
CAUTION:
Disc brake components rarely require dis-
assembly. DO NOT:

disassemble components unless abso-
lutely necessary;

use solvents on internal brake compo-
nents;

use spent brake fluid for cleaning; (use
only clean brake fluid)

allow brake fluid to come in contact with
the eyes, as this may cause eye injury;

splash brake fluid onto painted surfaces or
plastic parts, as this may cause damage;

disconnect any hydraulic connection, as
this would require the entire brake sys-
tem to be disassembled, drained,
cleaned, properly filled and bled after
reassembly.
REPLACING THE FRONT BRAKE PAD
NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1.Remove:

Brake pads
aWear limit
NOTE:
Replace the brake pads as a set if either is
found to be worn to the wear limit.
2.Install:

Brake pads

Brake pad spring
NOTE:
Always install new brake pads, brake pad shim
and brake pad spring as a set.