Yamaha YFM660 01 User Manual

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SPEC
1Throttle cable
2Fuel tank breather hose
3Fuel hose
4Carburetor air vent hose
5Negative battery lead
6AC magneto lead
7Thermo switch 1
8Coolant reservoir hose
9Starter cableÈPut the wire harness and coolant reservoir hose 
with the plastic holder.
ÉFasten the wire harness, AC magneto lead, 
speed sensor lead, negative battery lead and 
rear brake switch lead with the plastic band.
Ê70 mm (2.76 in)
Ë25 ~ 35 mm (0.98 ~ 1.38 in)
Ì60 mm (2.36 in)
Í0 ~ 5 mm (0 ~ 0.20 in)
Î80 ~ 90 mm (3.15 ~ 3.54 in)
CABLE ROUTING 
						

							2 - 30
SPEC
1Coolant reservoir hose
2Carburetor air vent hose
3Reservoir tank breather hose
4Rectifier/regulator
5CDI unit
6Negative battery lead
7AC magneto lead
8Wire harness
9Starter motor lead
0Tail/brake light lead
ARectifier/regulator leadÈPass the negative battery lead between the wire 
harness and frame.
CABLE ROUTING 
						

							2 - 31
SPEC
1Radiator fan breather hose
2Reverse control cable
3Parking brake cable
4Clutch cableÈFasten the reverse control cable to the frame 
with the plastic band.
É15 ~ 25 mm (0.59 ~ 0.98 in)
CABLE ROUTING 
						

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SPEC
1Rear brake hose
2Parking brake cable
3Negative battery lead
4AC magneto lead
5Crankcase breather hose
6Carburetor drain hose
7Rear brake switch
8Speed sensor
9Speed sensor lead
0Rear brake switch lead
CABLE ROUTING 
						

							2 - 33
SPEC
1Thermo switch 1 lead
2Headlight lead (right)
3Radiator fan breather hose
4Thermo switch 2 lead
5Carburetor breather hose
6Headlight lead (left)
7Wire harness
8Coolant reservoir hoseÈFasten the fan motor lead, headlight lead (right) 
and thermo switch 1 lead to the frame with the 
plastic band.
CABLE ROUTING 
						

							2 - 34
SPEC
1Positive battery lead
2Tail/brake light lead
3Coolant reservoir breather hose
4Negative battery lead
5Coolant reservoir hose
6Starter motor lead
7Wire harness
8Rectifier/regulator leadÈFasten the wire harness with the plastic clamp.
ÉFasten the starter motor lead and starter relay 
lead with the plastic clamp.
CABLE ROUTING 
						

							3 - 1
CHK
ADJINTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
EB300000
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle
operation and a longer service life. The need for costly overhaul work will be greatly reduced. This
information applies to vehicles already in service as well as to new vehicles that are being prepared
for sale. All service technicians should be familiar with this entire chapter.
EB301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
* It is recommended that these items be serviced by a Yamaha dealer.
** Lithium soap base grease
ITEM ROUTINEINITIAL EVERY1
month3
months6
months6
months1
year
Valves*
(See page 3-8.) Check valve clearance. 
 Adjust if necessary.
Cooling system
(See page 3-27.) Check coolant leakage.
 Repair if necessary.
 Replace coolant every 24 months.
Spark plug
(See page 3-16.) Check condition. 
 Adjust gap and clean.
 Replace if necessary.
Air filter
(See page 3-24.) Clean. 
 Replace if necessary.Every 20~40 hours
(More often in wet or dusty areas.)
Carburetor*
(See page 3-11.) Check and adjust idle speed/starter operation.
 Adjust if necessary.
Crankcase breather 
system* Check breather hose for cracks or damage.
 Replace if necessary.
Exhaust system* Check for leakage.
 Retighten if necessary.
 Replace gasket if necessary.
Spark arrester
(See page 3-31.) Clean.
Fuel line* Check fuel hose for cracks or damage.
 Replace if necessary.
Engine oil
(See page 3-19.) Replace (Warm engine before draining).
Engine oil filter
 Replace if necessary.
Drive chain
(See page 3-40.) Check and adjust slack/alignment/clean/lube.
Brake*
(See page 3-33.) Check operation/fluid leakage/See NOTE page 3-2.
 Correct if necessary.
Clutch*
(See page 3-23.) Check operation.
 Adjust if necessary.
Wheels*
(See page 4-3.) Check balance/damage/runout.
 Replace if necessary.
Wheel bearings* Check bearing assembly for looseness/damage.
 Replace if damaged.
Steering system*
(See page 3-42.) Check operation.
 Replace if damaged.
 Check toe-in.
 Adjust if necessary.
Upper and lower arm 
pivot and steering 
shaft* Lubricate every 6 months.**
Rear arm pivot*
 Lubricate every 6 months.**
Fittings and fasten-
ers* Check all chassis fittings and fasteners.
 Correct if necessary. 
						

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CHK
ADJ
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
NOTE:

Recommended brake fluid: DOT 4

Brake fluid replacement:
1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid. 
Normally check the brake fluid level and add fluid as required.
2.On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two
years.
3.Replace the brake hoses every four years, or if cracked or damaged.
WARNING
Indicates a potential hazard that could result in serious injury or death. 
						

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CHK
ADJ
SEAT, FENDERS AND FUEL TANK
SEAT, FENDERS AND FUEL TANK
SEAT, FRONT PANEL, FOOTREST GUARDS AND ENGINE SKID PLATE
Order Job name/Part name Q’ty Remarks
Removing the seat, front panel, foot-
rest guard and engine skid plateRemove the parts in the order below.
1Seat 1
NOTE:
Pull back the seat lock lever, than pull up
on the rear of the seat.
2 Front panel 1
3 Left footrest guard 1
4 Right footrest guard 1
5 Engine skid plate 1
For installation, reverse the removal pro-
cedure. 
						

							3 - 4
CHK
ADJ
SEAT, FENDERS AND FUEL TANK
HEADLIGHTS AND FRONT FENDER
Order Job name/Part name Q’ty Remarks
Removing the headlight and front 
fenderRemove the parts in the order below.
Seat and front panel Refer to “SEAT, FRONT PANEL, FOOT-
REST GUARDS AND ENGINE SKID 
PLATE”.
1 Headlight coupler 2 Disconnect.
2 Left headlight 1
3 Right headlight 1
4 Fuel tank top panel 1
5 Front fender 1
For installation, reverse the removal pro-
cedure.