Yamaha YFM660 01 User Manual
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2 - 9 SPEC Transmission: Main axle deflection limit ---- 0.08 mm (0.0031 in) Drive axle deflection limit ---- 0.08 mm (0.0031 in) Shifter: Shifter type Shift drum and guide bar ---- Decompression device: Device type Auto decomp ---- Air filter oil grade: Engine oil ---- Carburetors: I. D. mark 5LP1 00 ---- Main jet (M.J) Carburetor #1 : #140 Carburetor #2 : #145---- Main air jet (M.A.J) #130 ---- Jet needle (J.N) 5ND16-56-3 ---- Needle jet (N.J) P-6M (#826) ---- Pilot air jet (P.A.J.1) Carburetor #1 : #80 Carburetor #2 : #150---- Pilot air jet (P.A.J.2) 1.3 ---- Pilot outlet (P.O) Carburetor #1 : 1.0 Carburetor #2 : 0.9---- Pilot jet (P.J) #22.5 ---- Bypass 1 (B.P.1) 0.8 ---- Bypass 2 (B.P.2) 0.8 ---- Valve seat size (V.S) 2.0 ---- Starter jet (G.S.1) #95 ---- Starter jet (G.S.2) 0.5 Throttle valve size (Th.V) #80 ---- Float height (F.H) 13 mm (0.51 in) ---- Fuel level (F.L) 3 ~ 4 mm (0.12 ~ 0.16 in) ---- Engine idle speed 1,450 ~ 1,550 r/min ---- Intake vacuum 32.0 ~ 33.3 kPa (240 ~ 250 mmHg, 9.45 ~ 9.83 inHg)---- Oil pump: Oil filter type Paper ---- Oil pump type Trochoid ---- Tip clearance “A” or “B” 0.12 mm (0.005 in) 0.2 mm (0.008 in) Side clearance 0.03 ~ 0.08 mm (0.001 ~ 0.003 in)---- Bypass valve setting pressure 80 ~ 120 kPa (0.8 ~ 1.2 kg/cm 2, 11.6 ~ 17.4 psi)---- Oil pressure (hot) 65 kPa (0.65 kg/cm 2, 9.4 psi) at 1,500 r/min---- Pressure check location Cylinder head ----Item Standard Limit MAINTENANCE SPECIFICATIONS
2 - 10 SPEC Cooling system: Radiator core Width 219 mm (8.62 in) ---- Height 300 mm (11.8 in) ---- Depth 16 mm (0.63 in) ---- Radiator cap opening pressure 95 ~ 125 kPa (0.95 ~ 1.25 kg/cm 2, 13.8 ~ 18.1 psi)---- Radiator capacity 0.55 L (0.48 Imp qt, 0.58 US qt) ---- Coolant reservoir Capacity 0.29 L (0.26 Imp qt, 0.31 US qt) ---- From low to full level 0.165 L (0.15 Imp qt, 0.17 US qt) ---- Water pump: Type Single suction centrifugal pump ---- Reduction ratio 33/34 (0.971) Lubrication chart:Item Standard Limit MAINTENANCE SPECIFICATIONS
2 - 11 SPEC Cylinder head tightening sequence:Item Standard Limit MAINTENANCE SPECIFICATIONS
2 - 12 SPEC Tightening torques Part to be tightenedPart nameThread sizeQ’tyTightening torque Remarks Nm m·kg ft·lb Cylinder head (exhaust pipe) Stud boltM6 4 7 0.7 5.1 Cylinder head Bolt M9 4 38 3.8 27 Bolt M9 2 38 3.8 27 Bolt M6 1 10 1.0 7.2 Spark plug — M12 1 18 1.8 13 Cylinder head cover Bolt M6 17 10 1.0 7.2 Camshaft end cap Bolt M6 1 10 1.0 7.2 Oil check bolt — M6 1 7 0.7 5.1 Tappet cover (exhaust) — M32 2 12 1.2 8.7 Tappet cover (intake) Bolt M6 4 10 1.0 7.2 Cylinder Bolt M10 2 42 4.2 30 Bolt M10 2 42 4.2 30 Bolt M6 2 10 1.0 7.2 Timing chain tensioner Bolt M6 2 10 1.0 7.2 Timing chain tensioner cap Bolt M16 1 22 2.2 16 Timing chain guide (intake) Bolt M6 2 8 0.8 5.8 Camshaft sprocket Bolt M7 2 20 2.0 14 Rocker arm shaft Bolt M6 2 10 1.0 7.2 Valve adjusting screw Nut M6 5 14 1.4 10 Radiator Bolt M6 2 7 0.7 5.1 Coolant drain bolt — M6 1 10 1.0 7.2 Engine oil drain bolt (oil tank) — M10 1 25 2.5 18 Engine oil drain bolt (engine) — M14 1 30 3.0 22 Oil filter bolt Union boltM20 1 63 6.3 45E Oil filter cartridge — M20 1 17 1.7 12 Oil delivery pipe 1 Union boltM10 2 20 2.0 14 Oil delivery pipe 2 Union boltM8 2 18 1.8 13 Oil pipe joint — M14 1 50 5.0 36 Oil pipe 1 and oil pipe joint Nut M16 1 35 3.5 25 Oil pipe 2 and oil tank Nut M16 1 35 3.5 25 Air filter case Bolt M6 2 7 0.7 5.1 Carburetor clamp Bolt M4 4 5 0.5 3.6 Exhaust pipe 1 and exhaust pipe 2 Bolt M8 1 16 1.6 12 Exhaust pipe protector Bolt M6 4 10 1.0 7.2 LT Spark arrester Bolt M6 1 8 0.8 5.8 Muffler and exhaust pipe 2 Bolt M8 1 20 2.0 14 Muffler Bolt M8 2 26 2.6 19 Silencer cap Bolt M6 3 10 1.0 7.2 LT Exhaust pipe Nut M6 4 10 1.0 7.2 MAINTENANCE SPECIFICATIONS
2 - 13 SPEC Bearing retainer Screw M6 4 7 0.7 5.1LT AC magneto rotor Nut M14 1 150 15.0 110 Starter clutch Bolt M6 6 16 1.6 11 LT Balancer driven gear Nut M18 1 140 14.0 100M Use a lock washer. Primary drive gear Nut M20 1 150 15.0 110M Use a lock washer. Clutch spring Bolt M6 5 8 0.8 5.8 Clutch boss Nut M20 1 90 9.0 65 Use a lock washer. Pull lever shaft Bolt M6 1 7 0.7 5.1 Drive sprocket Nut M18 1 70 7.0 50 Use a lock washer. Oil seal retainer Bolt M6 2 10 1.0 7.2 Shift drum segment Bolt M8 1 30 3.0 22 Shift guide Bolt M6 2 10 1.0 7.2 LT Stopper lever Bolt M6 1 10 1.0 7.2 Reverse shift lever Bolt M6 1 13 1.3 9.4 Shift arm Bolt M6 1 10 1.0 7.2 Shift pedal adjusting rod Nut M6 1 8 0.8 5.8 Left-hand threads Nut M6 1 8 0.8 5.8 Stator assembly Bolt M5 3 7 0.7 5.1 LT Pick up coil Bolt M5 2 7 0.7 5.1LT AC magneto lead holder Bolt M6 2 10 1.0 7.2LT Ignition coil Bolt M6 2 7 0.7 5.1 Starter motor Bolt M6 2 10 1.0 7.2 Neutral switch — M10 1 20 2.0 14 Reverse switch — M10 1 20 2.0 14 Thermo switch 1 — M18 1 28 2.8 20 Thermo switch 2 — M18 1 28 2.8 20Part to be tightenedPart nameThread sizeQ’tyTightening torque Remarks Nm m·kg ft·lb MAINTENANCE SPECIFICATIONS
2 - 14 SPEC CHASSIS Item Standard Limit Steering system: Steering bearing type Ball and race bearing ---- Front suspension: Shock absorber travel 110 mm (4.33 in) ---- Fork spring free length 316.5 mm (12.46 in) ---- Spring fitting length 293.5 mm (11.56 in) ---- Spring rate (K1) 19.6 N/mm (2.00 kg/mm, 111.92 lb/in)---- Spring rate (K2) 29.4 N/mm (3.00 kg/mm, 167.87 lb/in)---- Optional spring No ---- Rear suspension: Shock absorber travel 100 mm (3.94 in) ---- Spring free length 273 mm (10.75 in) ---- Spring fitting length 253 mm (9.96 in) ---- Spring rate (K1) 55 N/mm (5.61 kg/mm, 314.05 lb/in)---- Stroke (K1) 0 ~ 100 mm (0 ~ 3.94 in) ---- Optional spring No ---- Swingarm: Free play limit end ---- 1 mm (0.04 in) side ---- 1 mm (0.04 in) Front wheel: Type Panel wheel ---- Rim size 10 × 5.5 AT ---- Rim material Aluminum ---- Rim runout limit radial ---- 2 mm (0.08 in) lateral ---- 2 mm (0.08 in) Rear wheel: Type Panel wheel ---- Rim size 9 × 8.5 AT ---- Rim material Aluminum ---- Rim runout limit radial ---- 2 mm (0.08 in) lateral ---- 2 mm (0.08 in) MAINTENANCE SPECIFICATIONS
2 - 15 SPEC Front disc brake: Type Dual ---- Disc outside diameter × thickness 161.0 × 3.5 mm (6.34 × 0.14 in) ---- Pad thickness inner 4.2 mm (0.17 in) 1 mm (0.04 in) Pad thickness outer 4.2 mm (0.17 in) 1 mm (0.04 in) Master cylinder inside diameter 12.7 mm (0.50 in) ---- Caliper cylinder inside diameter 32.03 mm (1.26 in) ---- Brake fluid type DOT 4 ---- Rear disc brake: Type Single ---- Disc outside diameter × thickness 220.0 × 3.6 mm (8.66 × 0.14 in) ---- Pad thickness inner 4.5 mm (0.18 in) 1 mm (0.04 in) Pad thickness outer 4.5 mm (0.18 in) 1 mm (0.04 in) Master cylinder inside diameter 12.7 mm (0.50 in) ---- Caliper cylinder inside diameter 33.96 mm (1.34 in) ---- Brake fluid type DOT 4 ---- Brake lever and brake pedal: Brake lever free play (at lever end) 0 mm (0 in) ---- Brake pedal position 4 mm (0.16 in) (Below the top of footrest)---- Throttle lever free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit MAINTENANCE SPECIFICATIONS
2 - 16 SPEC Tightening torques Part to be tightened Thread sizeTightening torque Remarks Nm m·kg ft·lb Engine bracket (upper) and frame M8 33 3.3 24 Engine bracket (upper) and engine M10 40 4.0 29 Engine bracket (lower) and frame M10 56 5.6 40 Engine bracket (lower) and engine M10 56 5.6 40 Engine bracket (middle and lower) and engine M10 56 5.6 40 Swingarm pivot shaft, engine and frame M16 95 9.5 68 Rear shock absorber and frame M10 32 3.2 23 Relay arm and swingarm M10 32 3.2 23 Connecting arm and frame M10 32 3.2 23 Relay arm and rear shock absorber M10 32 3.2 23 Relay arm and connecting arm M10 32 3.2 23 Drive chain guide and swingarm M6 7 0.7 5.1 Hub, brake caliper bracket and swingarm M12 90 9.0 65 Drive chain adjusting bolt and locknut M8 16 1.6 11 Front shock absorber and frame M10 45 4.5 32 Front shock absorber and front arm (lower) M10 45 4.5 32 Front arm (upper) and frame M10 38 3.8 27 Front arm (lower) and frame M10 32 3.2 23 Brake hose holder and front arm (upper) M6 7 0.7 5.1 Steering stem, pitman arm and frame M14 110 11 80 Steering stem bushing and frame M8 23 2.3 17 Use a lock washer. Steering stem and handlebar holder M8 23 2.3 17 Tie-rod end and locknut M10 15 1.5 11 Steering knuckle and front wheel hub M14 70 7.0 50 Steering knuckle and front arm (upper and lower) M10 25 2.5 18 Steering knuckle and tie-rod ball joint M10 25 2.5 18 Pitman arm and tie-rod ball joint M10 25 2.5 18 Frame and bearing retainer M42 40 4.0 29 Fuel tank and fuel cock M6 4 0.4 2.9 Fuel tank and frame M6 7 0.7 5.1 Front wheel and front wheel hub M10 45 4.5 32 Steering knuckle and front brake caliper M8 28 2.8 20 Front brake disc and front wheel hub M8 28 2.8 20 LT Rear axle and rear wheel hub M14 120 12 85 Rear brake caliper and brake caliper bracket M8 28 2.8 20 Rear wheel and rear wheel hub M10 45 4.5 32 Driven sprocket and sprocket bracket M8 24 2.4 17 Front brake pipe nut M10 19 1.9 13 Front brake master cylinder and handlebar M6 7 0.7 5.1 MAINTENANCE SPECIFICATIONS
2 - 17 SPEC HINWEIS:NOTE: Apply locking agent (LOCTITE®) to ring nuts threads. 1st: Tighten the inside ring nut 55 Nm (5.5 m kg, 40 ft lb). 2nd: Tighten the outside ring nut while holding the inside ring nut 190 Nm (19 m kg, 140 ft lb). 3rd: Loosen the inside ring nut while holding the outside ring nut 240 Nm (24 m kg, 170 ft lb).Front brake master cylinder and brake lever M6 6 0.6 4.3 Front brake master cylinder and brake hose M10 27 2.7 19 Brake hose joint and frame M6 10 1.0 7.2 Bleed screw M8 6 0.6 4.3 Front brake pad holding bolt M10 18 1.8 13 Front brake caliper and brake hose M10 27 2.7 19 Front brake caliper retaining bolt M8 23 2.3 17 Rear axle ring nut M38 SEE NOTE Rear brake pad holding bolt M10 18 1.8 13 Use a lock washer. Rear brake caliper and brake hose M10 30 3.0 22 Rear brake master cylinder and frame M8 20 2.0 14 Rear brake master cylinder and brake hose M10 30 3.0 22 Parking brake adjusting bolt and locknut M8 16 1.6 11 Rear brake disc and brake disc bracket M8 28 2.8 20 Rear brake fluid reservoir cover and bracket M6 4 0.4 2.9 Rear brake fluid reservoir and bracket M6 4 0.4 2.9 Brake hose holder and swingarm M6 7 0.7 5.1 Front bumper and frame M8 31 3.1 22 Front fender bracket and frame M8 16 1.6 11 Rear carrier bar and frame M8 23 2.3 17 Footrest and frame M10 65 6.5 48 Footrest guard bracket and frame M8 33 3.3 24 Footrest and footrest guard bracket M8 16 1.6 11 Footrest guard bracket and rear fender M6 7 0.7 5.1 Battery holding bracket and frame M6 7 0.7 5.1 Air filter case and frame M6 7 0.7 5.1 Carburetor clamp screw M4 5 0.5 3.6 Tail/brake light bracket and frame M6 7 0.7 5.1 Tail/brake light bracket and tail/brake light M6 7 0.7 5.1 Swingarm skid plate and swingarm M6 7 0.7 5.1 Swingarm skid plate and swingarm M8 16 1.6 11 Drive chain tensioner and frame M8 32 3.2 23 Engine skid plate and frame M6 7 0.7 5.1 Main frame and rear frame M10 53 5.3 38Part to be tightened Thread sizeTightening torque Remarks Nm m·kg ft·lb MAINTENANCE SPECIFICATIONS
2 - 18 SPEC ELECTRICAL Item Standard Limit Voltage: 12 V ---- Ignition system: Ignition timing (B.T.D.C.) 12°/ 1,500 r/min ---- Advancer type Digital type ---- C.D.I.: Magneto model/manufacturer F4T260/MITSUBISHI ---- Pickup coil resistance/color 445 ~ 545 Ω at 20 °C (68 °F)/ White/Red – White/Green---- Rotor rotation direction detection coil resis- tance/color0.069 ~ 0.085 Ω at 20 °C (68 °F)/ Red – White/Blue---- C.D.I. unit model/manufacturer F8T37971/MITSUBISHI ---- Ignition coil: Model/manufacturer 2JN/YAMAHA ---- Minimum spark gap 6 mm (0.24 in) ---- Primary winding resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) ---- Secondary winding resistance 6.32 ~ 9.48 kΩ at 20 °C (68 °F) ---- Spark plug cap: Type Resin type ---- Resistance 10 kΩ ---- Charging system: Type A.C. magneto generator ---- Model/manufacturer F4T260/MITSUBISHI ---- Nominal output 14 V 16 A at 5,000 r/min ---- Charging coil resistance/color 0.43 ~ 0.65 Ω at 20 °C (68 °F)/ White – White---- Rectifier: Type Semi conductor-short circuit ---- Model/manufacturer SH640E-11/SHINDENGEN ---- No load voltage (DC) 14.1 ~ 14.9 V ---- Capacity 14 A ---- Withstand voltage 200 V ---- Electric starter system: Type Constantmesh type ---- Starter motor Model/manufacturer SM-13/MITSUBA ---- Output 0.8 kW ---- Armature coil resistance 0.025 ~ 0.035 Ω at 20 °C (68 °F) ---- Brush overall length 12.5 mm (0.49 in) 5 mm (0.20 in) Spring force 7.65 ~ 10.01 N (27.54 ~ 36.03 oz) ---- Commutator diameter 28 mm (1.10 in) 27 mm (1.06 in) Mica undercut 0.7 mm (0.03 in) ---- MAINTENANCE SPECIFICATIONS