Yamaha YFM660 01 User Manual

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CHASFRONT AND REAR BRAKES
ASSEMBLING THE REAR BRAKE CALIPER
WARNING

All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.

Replace the caliper piston seal whenever
a brake caliper is disassembled.
1.Install:

O-ring 1
 

Caliper piston seal 2
 

Dust seal 3
 
Recommended brake fluid:
DOT 4
New
New
New
2.Install:

Brake caliper piston 1
 
3.Install:

Lock washer 1
 

Brake pad holding bolts 2
 
4.Bend the lock washer tabs along a flat side
of the bolts.
New
T R..18 Nm (1.8 m  kg, 13 ft  lb)
5.Mesh the bearing race tab 1
 with parking
brake case slit. 
						

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CHASFRONT AND REAR BRAKES
INSTALLING THE FRONT BRAKE CALIPER 
1.Install:

Brake caliper assembly

Brake caliper mounting bolts 1
 

Brake hose 2
 

Copper washers 3

Union bolt 4
 
CAUTION:
When installing the brake hose on the
brake caliper, make sure that the brake
pipe touches the projection a on the brake
caliper.
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
2.Fill:

Brake reservoir
CAUTION:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING

Use only the designated quality brake
fluid: Other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.

Refill with the same type of brake fluid:
Mixing brake fluids may result in a harm-
ful chemical reaction and lead to poor
brake performance.

Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.
3.Air bleed

Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.
Recommended brake fluid:
DOT 4
T R..28 Nm (2.8 m  kg, 20 ft  lb)
New
T R..27 Nm (2.7 m  kg, 19 ft  lb) 
						

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CHAS
4.Check:

Brake fluid level
Brake fluid level is below the “LOWER” level
line →
 Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.
INSTALLING THE REAR BRAKE CALIPER
1.Install:

Brake caliper assembly

Brake caliper mounting bolts 1
 

Brake hose 2
 

Copper washers 3

Union bolt 4
 
CAUTION:
When installing the brake hose on the
brake caliper, make sure that the brake
pipe touches the projection a on the brake
caliper.
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
2.Fill:

Brake reservoir
CAUTION:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
Recommended brake fluid:
DOT 4
T R..28 Nm (2.8 m  kg, 20 ft  lb)
New
T R..30 Nm (3.0 m  kg, 22 ft  lb)
FRONT AND REAR BRAKES 
						

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CHAS
WARNING

Use only the designated quality brake
fluid: Other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.

Refill with the same type of brake fluid:
Mixing brake fluids may result in a harmful
chemical reaction and lead to poor brake
performance.

Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.
3.Air bleed

Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.
4.Check:

Brake fluid level
Brake fluid level is below the “LOWER” level
line →
 Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.
5.Adjust:

Parking brake cable end length
Refer to “ADJUSTING THE PARKING
BRAKE” in CHAPTER 3.
FRONT AND REAR BRAKES 
						

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CHASSTEERING SYSTEM
STEERING SYSTEM
HANDLEBAR
Order Job name/Part name Q’ty Remarks
Removing the handlebar
Remove the parts in the order below.
1 Handlebar cover 1
2Band 2
3 Front brake switch 1 Refer to “REMOVING THE FRONT 
BRAKE SWITCH, PARK SWITCH AND 
CLUTCH SWITCH”.
4 Brake master cylinder/bracket 1/1
Refer to “INSTALLING THE BRAKE 
MASTER CYLINDER”. 5 Throttle lever assembly/bracket 1/1
6 Collar 1
7 Park switch 1 Refer to “REMOVING THE FRONT 
BRAKE SWITCH, PARK SWITCH AND 
CLUTCH SWITCH”. 8 Clutch switch 1
9 Clutch lever/bracket 1/1
Refer to “INSTALLING THE CLUTCH 
LEVER”.
10 Handlebar switch 1 
						

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CHASSTEERING SYSTEM
Order Job name/Part name Q’ty Remarks
11 Handlebar grip 2 Refer to “REMOVING/INSTALLING THE 
HANDLEBAR GRIP”.
12 Handlebar cover bracket 2
Refer to “INSTALLING THE HANDLE-
BAR”. 13 Handlebar holder 2
14 Handlebar 1
For installation, reverse the removal pro-
cedure.  
						

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CHASSTEERING SYSTEM
REMOVING THE FRONT BRAKE SWITCH, 
PARK SWITCH AND CLUTCH SWITCH
1.Remove:

Front brake switch 1
 

Park switch

Clutch switch
NOTE:

Push the fastener when removing the front
brake switch out of the brake master cylin-
der.

Push the fastener when removing the park
switch and clutch switch out of the clutch
lever holder.
REMOVING THE HANDLEBAR GRIP
1.Remove:

Handlebar grips 1
 
NOTE:
Blow compressed air between the handlebar
and handlebar grip, and gradually push the
grip off the handlebar.
CHECKING THE HANDLEBAR
1.Check:

Handlebar 1
 
Bends/cracks/damage →
 Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the
handlebar. 
						

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CHASSTEERING SYSTEM
INSTALLING THE HANDLEBAR
1.Install:

Handlebar 

Handlebar holders

Handlebar cover brackets
NOTE:
The upper handlebar holder should be
installed with the punched mark 1
 forward 2
.
CAUTION:
First tighten the bolts 3 on the front side of
the handlebar holder, and then tighten the
bolts 4 on the rear side.
T R..23 Nm (2.3 m  kg, 17 ft  lb)
INSTALLING THE HANDLEBAR GRIP
1.Install:

Handlebar grips 1
 
NOTE:

Before applying the adhesive, wipe off
grease or oil on the handlebar surface a
with a lacquer thinner.

Install the handlebar grips to the handlebar
so that the line b
 between the two arrow
marks faces straight upward.
INSTALLING THE CLUTCH LEVER
1.Install:

Handlebar switch 1
 

Clutch lever

Lever bracket 2
 
NOTE:
Install the lever bracket as shown.
a
80 mm (3.1 in) 
						

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CHAS
INSTALLING THE BRAKE MASTER 
CYLINDER
1.Install:

Throttle lever assembly

Collar

Brake master cylinder
NOTE:

Engage the indentations a
 in the collar with
the lobes b
 on the throttle lever assembly
and brake master cylinder.

The “UP” mark on the brake master cylinder
bracket should face up.
T R..7 Nm (0.7 m  kg, 5.1 ft  lb)
STEERING SYSTEM 
						

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CHASSTEERING SYSTEM
STEERING STEM
Order Job name/Part name Q’ty Remarks
Removing the steering stem
Remove the parts in the order below.
Front fender  Refer to “SEAT, FENDERS AND FUEL 
TANK” in CHAPTER 3.
Fuel tank
Handlebar Refer to “HANDLEBAR”.
1 Pitman arm 1
2 Lock washer 1 Refer to “INSTALLING THE LOCK 
WASHER”.
3 Steering stem bushing 2
4 Collar 2
5 Oil seal 2
6 Steering stem 1
7 Oil seal 1
8 Oil seal 1