Yamaha YFM660 01 User Manual

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GEN
INFO
SPECIAL TOOLS
90890-01469
YM-01469
Oil filter wrench
This tool is needed to loosen or tighten 
the oil filter cartridge.
90890-01474
YM-01474Ball joint remover/installer set
These tools are used to removing or 
installing the ball joint.
90890-01480
YM-01480Ball joint remover/installer attachment set
These tools are used to removing or 
installing the ball joint.
90890-01701
YS-01880Sheave holder
This tool is needed to hold the AC mag-
neto rotor when removing or installing the 
AC magneto rotor bolts.
Set
90890-03081
YU-33223
Adapter
90890-04082
YU-33223-3Compression gauge set
Adapter
These tools are needed to measure 
engine compression.
90890-03112
YU-03112Pocket tester
This instrument is needed for checking the 
electrical system.
90890-03141
YM-33277-ATiming light
This tool is necessary for checking ignition 
timing.
Compressor
90890-04019
YM-04019
Attachment
90890-01243Valve spring compressor
Valve spring compressor attachment
This tool is needed to remove and install 
the valve assemblies.
Tool No. Tool name/How to use Illustration 
						

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GEN
INFO
SPECIAL TOOLS
Middle driven shaft 
bearing driver
90890-04058
YM-04058-1
Mechanical seal 
installer
90890-04078
YM-33221Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to install the water 
pump seal.
90890-04064
YM-4064-AValve guide remover (ø 6)
This tool is needed to remove and install 
the valve guide.
90890-04065
YM-04065-AValve guide installer (ø 6)
This tool is needed to install the valve 
guide.
90890-04066
YM-04066Valve guide reamer (ø 6)
This tool is needed to rebore the new 
valve guide.
90890-04086
YM-91042Clutch holding tool
This tool is needed to hold the clutch car-
rier when removing or installing the carrier 
nut.
90890-06754Ignition checker
This instrument is necessary for checking 
the ignition system components.
YM-34487Dynamic spark tester
This instrument is necessary for checking 
the ignition system components.
Bond
90890-85505
Sealant
ACC-11001-05-01Yamaha bond No. 1215
Sealant (Quick Gasket
®)
This sealant (bond) is used on crankcase 
mating surfaces, etc.
Tool No. Tool name/How to use Illustration 
						

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SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model code: 5LP1 : (Except for California)
5LP3 : (For California)
Dimensions:
Overall length 1,830 mm (72.0 in)
Overall width 1,100 mm (43.3 in)
Overall height 1,150 mm (45.3 in)
Seat height 860 mm (33.9 in)
Wheelbase 1,245 mm (49.0 in)
Minimum ground clearance 265 mm (10.4 in)
Minimum turning radius 3,300 mm (129.9 in)
Basic weight:
With oil and full fuel tank 193 kg (426 lb)
Engine:
Engine type Liquid-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 660 cm
3 
Bore × 
stroke 100.0 × 
84.0 mm (3.94 ×
 3.31 in)
Compression ratio 9.2 : 1
Standard compression pressure (at sea level) 1,250 kPa (12.5 kg/cm
2, 181 psi)
Starting system Electric starter
Lubrication system: Dry sump
Oil type or grade:
Engine oil
API service SE, SF, SG type or higher
Oil capacity:
Engine oil
Periodic oil change 1.9 L (1.67 lmp qt, 2.01 US qt)
With oil filter replacement 1.95 L (1.72 lmp qt, 2.06 US qt)
Total amount 2.3 L (2.02 lmp qt, 2.43 US qt)
Radiator capacity (including all routes) 1.3 L (1.14 lmp qt, 1.37 US qt)
Air filter: Wet type element
Fuel:
Type Unleaded fuel
Fuel tank capacity 12 L (2.64 lmp gal, 3.17 US gal)
Fuel reserve amount 2.6 L (0.57 lmp gal, 0.69 US gal)

 0
  °
 10
  °

 30
  °

 50
  °

 70
  °

 90
  °

 110
  °

 YAMALUBE 4 (10W30) or SAE 10W30


-20 
°

-10 
°

0 
°

10 
°

20 
°

30 
°

40 
°

 YAMALUBE 4 (20W40) or SAE 20W40

 SAE 5W30

 130°F


50 
°C
GENERAL SPECIFICATIONS 
						

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SPEC
Carburetor:
Type/quantity BSR33/2
Manufacturer MIKUNI
Spark plug:
Type/manufacturer DPR8EA-9/NGK
Spark plug gap 0.8 ~ 0.9 mm (0.031 ~ 0.035 in)
Clutch type: Wet, multiple disc
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 71/34 (2.088)
Secondary reduction system Chain drive
Secondary reduction ratio 40/13 (3.076)
Transmission type Constant mesh, 5-speed/forward.
1-speed/reverse
Operation Left foot operation
Gear ratio
1st gear 34/14 (2.428)
2nd gear 29/19 (1.526)
3rd gear 26/21 (1.238)
4th gear 22/21 (1.047)
5th gear 19/21 (0.904)
Reverse gear 28/23 ×
 23 ×
 16 (1.750)
Chassis:
Frame type Steel tube frame
Caster angle 8°
Camber angle –1°
Kingpin angle 14.5°
Kingpin offset 5 mm (0.20 in)
Trail 47 mm (1.85 in)
Tread (STD) front 925 mm (36.42 in)
rear 840 mm (33.07 in)
Toe-in 0 ~ 10 mm (0 ~ 0.39 in)
Tire:
Type Tubeless
Size front AT21 ×
 7–10
rear AT20 ×
 10–9
Manufacturer front DUNLOP
rear DUNLOP
Type front KT331 Radial
rear KT335 Radial Item Standard
GENERAL SPECIFICATIONS 
						

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SPEC
Tire pressure (cold tire):
Maximum load* 100 kg (220 lb)
Off-road riding front 27.5 kPa (0.275 kg/cm
2, 4.0 psi)
rear 27.5 kPa (0.275 kg/cm
2, 4.0 psi)
*Load in total weight of cargo, rider and acces-
sories
Brake:
Front brake type Dual disc brake
operation Right hand operation
Rear brake type Single disc brake
operation Right foot operation
Suspension:
Front suspension Double wishbone
Rear suspension Swingarm (link suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas-oil damper
Wheel travel:
Front wheel travel 230 mm (9.06 in)
Rear wheel travel 220 mm (8.66 in)
Electrical:
Ignition system DC-C.D.I.
Generator system A.C. magneto
Battery type YTX14-BS
Battery capacity 12 V 12 Ah
Headlight type: Krypton bulb
Bulb voltage/wattage × 
quantity:
Headlight 12 V 30 W/30 W ×
 2
Tail/brake light 12 V 5 W/21 W ×
 1
Indicator and warning lights
Neutral 12 V 1.7 W ×
 1
Reverse 12 V 1.7 W ×
 1
Coolant temperature 12 V 1.7 W ×
 1 Item Standard
GENERAL SPECIFICATIONS 
						

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SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ---- 0.05 mm 
(0.002 in)
Cylinder:
Bore size 100.005 ~ 100.045 mm
(3.9372 ~ 3.9388 in)100.1 mm 
(3.94 in)
Measuring point 
*50 mm (2.0 in) ----
Camshaft:
Drive method Chain drive (Left) ----
Camshaft cap inside diameter 23.000 ~ 23.021 mm
(0.9055 ~ 0.9063 in)----
Camshaft journal diameter 22.967 ~ 22.980 mm
(0.9042 ~ 0.9047 in)----
Camshaft journal-to-camshaft cap clearance 0.020 ~ 0.054 mm
(0.0008 ~ 0.0021 in)----
Cam dimensions
Intake “A” 35.69 ~ 35.79 mm 
(1.4051 ~ 1.4091 in)35.59 mm 
(1.4012 in)
“B” 30.15 ~ 30.25 mm 
(1.1870 ~ 1.1909 in)30.05 mm 
(1.1831 in)
“C” 5.74 mm (0.2260 in) ----
Exhaust “A” 36.50 ~ 36.60 mm 
(1.437 ~ 1.441 in)36.40 mm 
(1.4331 in)
“B” 30.15 ~ 30.25 mm
(1.187 ~ 1.191 in)30.05 mm 
(1.1831 in)
“C” 6.55 mm (0.2579 in) ----
C
A
B
MAINTENANCE SPECIFICATIONS 
						

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SPEC
Camshaft runout limit ---- 0.03 mm 
(0.0012 in)
Timing chain:
Timing chain type/No. of links 75-RH2015/126 ----
Timing chain adjustment method Automatic ----
Rocker arm/rocker arm shaft:
Shaft outside diameter 11.976 ~ 11.991 mm 
(0.4715 ~ 0.4721 in)----
Arm-to-shaft clearance 0.009 ~ 0.042 mm 
(0.0004 ~ 0.0017 in)----
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.10 ~ 0.15 mm
(0.0039 ~ 0.0059 in)----
EX 0.15 ~ 0.20 mm
(0.0059 ~ 0.0079 in)----
Valve dimensions
“A” head diameter IN 29.9 ~ 30.1 mm
(1.1772 ~ 1.1850 in)----
EX 31.9 ~ 32.1 mm
(1.2559 ~ 1.2638 in)----
“B” face width IN 2.25 mm (0.0886 in) ----
EX 2.26 mm (0.0890 in) ----
“C” seat width IN 0.9 ~ 1.1 mm 
(0.0354 ~ 0.0433 in)1.6 mm 
(0.0630 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm 
(0.0630 in)
“D” margin thickness IN 0.85 ~ 1.15 mm
(0.0335 ~ 0.0453 in)----
EX 0.85 ~ 1.15 mm 
(0.0335 ~ 0.0453 in)----
Stem outside diameter IN 5.975 ~ 5.990 mm
(0.2352 ~ 0.2358 in)5.945 mm 
(0.2341 in)
EX 5.960 ~ 5.975 mm
(0.2346 ~ 0.2352 in)5.930 mm 
(0.2335 in)
Guide inside diameter IN 6.000 ~ 6.012 mm 
(0.2362 ~ 0.2367 in)6.040 mm 
(0.2378 in)
EX 6.000 ~ 6.012 mm 
(0.2362 ~ 0.2367 in)6.040 mm 
(0.2378 in) Item Standard Limit
Head Diameter
B
Face WidthC
Seat Width
D
Margin ThicknessA
MAINTENANCE SPECIFICATIONS 
						

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SPEC
Stem-to-guide clearance IN 0.010 ~ 0.037 mm 
(0.0004 ~ 0.0015 in)0.08 mm 
(0.0031 in)
EX 0.025 ~ 0.052 mm 
(0.0010 ~ 0.0020 in)0.10 mm 
(0.0039 in)
Stem runout limit ---- 0.01 mm 
(0.0004 in)
Valve seat width IN 0.9 ~ 1.1 mm 
(0.0354 ~ 0.0433 in)1.6 mm 
(0.0630 in)
EX 0.9 ~ 1.1 mm 
(0.0354 ~ 0.0433 in)1.6 mm 
(0.0630 in)
Valve spring:
Free length IN 35.95 mm (1.42 in) 34.15 mm 
(1.34 in)
EX 37.75 mm (1.49 in) 35.86 mm 
(1.41 in)
Set length (valve closed) IN 27.2 mm (1.07 in) ----
EX 30.7 mm (1.21 in) ----
Compressed pressure
(installed) IN 149 ~ 173 N (15.19 ~ 17.64 kg, 
33.50 ~ 38.89 lb)----
EX 165 ~ 191 N (16.83 ~ 19.49 kg, 
37.09 ~ 42.94 lb)----
Tilt limit IN 2.5°/1.6 mm 
(2.5°/0.06 in)
EX 2.5°/1.6 mm 
(2.5°/0.06 in)
Direction of winding
(top view) IN Clockwise ----
EX Clockwise ---- Item Standard Limit
*
MAINTENANCE SPECIFICATIONS 
						

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SPEC
Piston:
Piston to cylinder clearance 0.05 ~ 0.07 mm 
(0.0020 ~ 0.0028 in)0.15 mm 
(0.0059 in)
Piston size “D” 99.945 ~ 99.995 mm 
(3.9348 ~ 3.9368 in)----
Measuring point “H” 2.5 mm (0.10 in) ----
Piston off-set 1.0 mm (0.04 in) ----
Piston pin bore inside diameter 22.004 ~ 22.015 mm
(0.8663 ~ 0.8667 in)22.045 mm 
(0.8679 in)
Piston pin outside diameter 21.991 ~ 22.000 mm
(0.8658 ~ 0.8661 in)21.971 mm 
(0.8650 in)
Piston rings:
Top ring
Type Barrel ----
Dimensions (B × 
T) 1.2 ×
 3.8 mm
(0.0472 ×
 0.1496 in)----
End gap (installed) 0.30 ~ 0.45 mm
(0.0118 ~ 0.0177 in)0.70 mm 
(0.0276 in)
Side clearance (installed) 0.04 ~ 0.08 mm 
(0.0016 ~ 0.0031 in)0.13 mm 
(0.0051 in)
2nd ring
Type Taper ----
Dimensions (B × 
T) 1.2 ×
 4.0 mm
(0.0472 ×
 0.1575 in)----
End gap (installed) 0.30 ~ 0.45 mm
(0.0118 ~ 0.0177 in)0.80 mm 
(0.0315 in)
Side clearance 0.03 ~ 0.07 mm 
(0.0012 ~ 0.0028 in)0.13 mm 
(0.0051 in)
Oil ring
Dimensions (B × 
T) 2.5 ×
 3.4 mm
(0.0984 ×
 0.1339 in)----
End gap (installed) 0.2 ~ 0.7 mm
(0.0079 ~ 0.0276 in)---- Item Standard Limit
H
D
T
B
B
T
B
T
MAINTENANCE SPECIFICATIONS 
						

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SPEC
Crankshaft:
Crank width “A” 74.95 ~ 75.00 mm 
(2.9508 ~ 2.9528 in)----
Runout limit C1 ---- 0.03 mm 
(0.0012 in)
C2 ---- 0.03 mm 
(0.0012 in)
Big end side clearance “D” 0.32 ~ 0.64 mm 
(0.0126 ~ 0.0252 in)1.0 mm 
(0.0394 in)
Big end radial clearance “E” 0.010 ~ 0.025 mm 
(0.0004 ~ 0.0010 in)----
Small end free play “F” 0.8 mm (0.0315 in) ----
Balancer:
Balancer drive method Gear ----
Clutch:
Friction plate 1
Thickness 2.74 ~ 2.86 mm
(0.108 ~ 0.113 in)2.6 mm 
(0.102 in)
Quantity 6 ----
Friction plate 2
Thickness 2.94 ~ 3.06 mm
(0.116 ~ 0.120 in)2.8 mm 
(0.110 in)
Quantity 2 ----
Clutch plate
Thickness 1.1 ~ 1.3 mm 
(0.043 ~ 0.051 in)----
Quantity 7 ----
Max. warpage ---- 0.2 mm 
(0.008 in)
Clutch spring
Free length 42.8 mm (1.69 in) 40.7 mm 
(1.60 in)
Quantity 5 ----
Min. length ---- 40.8 mm 
(1.61 in)
Clutch release method Outer pull, rack and pinion pull ----Item Standard Limit
MAINTENANCE SPECIFICATIONS