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, 90890-01327
T R..40 Nm (4.0 m  kg, 29 ft  lb)
INSTALLING THE LOCK WASHER
1.Install:

Lock washer
2.Bend the lock washer tab along a flat side of
the bolt.New
T R..23 Nm (2.3 m  kg, 17 ft  lb) 
						

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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 tie-rod which must be installed on the out
side has grooves 1
.
T R..25 Nm (2.5 m  kg, 18 ft  lb)
2.Adjust:

Toe-in
Refer to “ADJUSTING THE TOE-IN” in
CHAPTER 3. 
						

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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
CHECKING THE FRONT ARM
1.Check:

Front arms 1
 
Bends/damage →
 Replace.
2.Check:

Bushings 2
 
Wear/damage →
 Replace.
CHECKING THE FRONT SHOCK 
ABSORBER
1.Check:

Shock absorber rod
Bends/damage →
 Replace the shock 
absorber assembly.

Shock absorber assembly
Oil leaks →
 Replace the shock absorber 
assembly.

Spring
Fatigue →
 Replace the shock absorber 
assembly.
Move the spring up and down. 
						

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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 front lower arm.

Remove the circlip 1
 and rubber boot 2
.
Use the ball joint remover and installer set.

Install the body 3
, long bolt 4
, base 5
 and
attachment 6
 onto ball joint.

Hold the body 3
 in place while turning in the
long bolt 4
 to remove the ball joint 9
 from
the front lower arm 0
.

Remove the ball joint remover/installer.
Ball joint remover/installer set:
P/N. YM-01474, 90890-01474
Ball joint remover/installer attach-
ment set:
P/N. YM-01480, 90890-01480
3BodyYM-01474
90890-01474
4Long bolt
5Base
YM-01480
90890-014806Remover attachment
7Installer spacer
8Installer washer 
						

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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.
***********************************************
INSTALLING THE FRONT ARM
1.Install:

Front upper arm 1
 

Front lower arm 2
 
NOTE:
Be sure to position the bolts (upper and lower)
so that the bolt head faces outward.
T R..38 Nm (3.8 m  kg, 27 ft  lb)
T R..32 Nm (3.2 m  kg, 23 ft  lb)
FRONT ARMS AND FRONT SHOCK ABSORBERS 
						

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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 2/2