Yamaha YFM660 01 User Manual

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CHK
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CLEANING THE AIR FILTER
4.Remove:

Air filter element assembly 1
 

Air filter element cap 2
 

Air filter element 3
 
NOTE:
When removing the air filter element, rotate
the air filter element cap 1/4 of a turn and
remove the element.
CAUTION:
Never operate the engine with the air filter
element removed. This will allow unfiltered
air to enter, causing rapid wear and possible
engine damage. Additionally, operation
without the filter element will affect carbure-
tor tuning with subsequent poor perfor-
mance and possible engine overheating.
5.Check:

Air filter element
Damaged →
 Replace.
6.Clean:

Air filter element
***********************************************
Cleaning steps:

Wash the element gently, but thoroughly in
solvent.
WARNING
Use a cleaning solvent which is designed
to clean parts only. Never use gasoline or
low flash point solvents as they may cause
a fire or explosion.

Squeeze the excess solvent out of the ele-
ment and let it dry. 
						

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CHK
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CLEANING THE AIR FILTER
CAUTION:
Do not twist or wring out the element. This
could damage the foam material.

Apply engine oil to the element.

Squeeze out the excess oil.
NOTE:
The element should be wet but not dripping.
***********************************************
7.Install:

Air filter element

Air filter case cover
NOTE:

Insert the lobes 1
 on the filter element into
the receptacles 2
 on the filter case.

To prevent air leaks make sure that the seal-
ing surface of the element matches the seal-
ing surface of the case.
8.Connect:

Crankcase breather hose 1
 
9.Install:

Seat
Refer to “SEAT, FENDERS AND FUEL
TANK”. 
						

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CHK
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CHECKING THE COOLANT LEVEL
1.Place the machine on a level surface.
2.Check:

Coolant level
The coolant level should be between the
minimum level mark a
 and maximum level
mark b
.
Below the minimum level mark →
 Add the
recommended coolant to the proper level.
CAUTION:

Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check
and if necessary, correct the antifreeze
concentration of the coolant.

Use only distilled water. However, soft
water may be used if distilled water is not
available.
3.Start the engine, warm it up for several min-
utes, and then turn it off.
4.Check:

Coolant level
NOTE:
Before inspecting the coolant level, wait a few
minutes until the coolant has settled.
CHANGING THE COOLANT
1.Remove:

Front panel
Refer to “SEAT, FENDERS AND FUEL
TANK”.
2.Remove:

Coolant reservoir cap 1
 
3.Disconnect:

Coolant reservoir hose 2
 
CHECKING THE COOLANT LEVEL/
CHANGING THE COOLANT 
						

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CHANGING THE COOLANT
4.Drain:

Coolant
(from the coolant reservoir)
5.Connect:

Coolant reservoir hose
6.Remove:

Radiator cap 1
 
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause seri-
ous injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radia-
tor cap and slowly turn the radiator cap
counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped, turn
the radiator cap counterclockwise while
pressing down on it and then remove it.
7.Remove:

Coolant drain bolt 1
 
(along with the copper washer)
8.Drain:

Coolant
9.Check:

Copper washer 1
 

Coolant drain bolt 2
 
Damage →
 Replace.
10.Install:

Coolant drain bolt
New
T R..10 Nm (1.0 m  kg, 7.2 ft  lb) 
						

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CHK
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CHANGING THE COOLANT
11.Fill:

Cooling system
(with the specified amount of the recom-
mended coolant)
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING

If coolant splashes in your eyes, thor-
oughly wash them with water and consult
a doctor.

If coolant splashes on your clothes,
quickly wash it away with water and then
with soap and water.

If coolant is swallowed, induce vomiting
and get immediate medical attention.
CAUTION:

Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check,
and if necessary, correct the antifreeze
concentration of the coolant.

Use only distilled water. However, soft
water may be used if distilled water is not
available.

If coolant comes into contact with painted
surfaces, immediately wash them with
water.

Do not mix different types of antifreeze.
12.Install:

Radiator cap
Recommended antifreeze:
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio:
1:1 (antifreeze:water)
Quantity:
Total amount:
1.3 L
(1.14 lmp qt, 1.37 US qt)
Coolant reservoir capacity:
0.29 L
(0.26 lmp qt, 0.31 US qt) 
						

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CHANGING THE COOLANT
13.Fill:

Coolant reservoir
(with the recommended coolant to the proper
level)
14.Install:

Coolant reservoir cap
15.Start the engine, warm it up for several min-
utes, and then turn it off.
16.Check:

Coolant level
Refer to “CHECKING THE COOLANT
LEVEL”.
NOTE:
Before inspecting the coolant level, wait a few
minutes until the coolant has settled.
17.Install:

Front panel
Refer to “SEAT, FENDERS AND FUEL
TANK”. 
						

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CHK
ADJCHECKING THE COOLANT TEMPERATURE WARNING
LIGHT/CLEANING THE SPARK ARRESTER
CHECKING THE COOLANT TEMPERATURE 
WARNING LIGHT
1Coolant temperature warning light
CLEANING THE SPARK ARRESTER 
1.Clean:

Spark arrester
***********************************************
Cleaning steps:
WARNING

Select a well-ventilated area free of com-
bustible materials.

Always let the exhaust system cool
before performing this operation.

Do not start the engine when removing
the tailpipe from the muffler.

Remove the bolt 1
.

Remove the tailpipe 2
 by pulling it out of the
muffler. 
						

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Tap the tailpipe lightly with a soft-face ham-
mer or suitable tool, then use a wire brush to
remove any carbon deposits from the spark
arrester portion of the tailpipe and the inner
contact surfaces of the muffler.

Insert the tailpipe into the muffler and align
the bolt holes.

Insert the bolt and tighten it.

Remove the purging bolt 3
.

Start the engine and rev it up approximately
twenty times while momentarily creating
exhaust system back pressure by blocking
the end of the muffler with a shop towel.

Stop the engine and allow the exhaust pipe
to cool.

Install the purging bolt 3
 and tighten it.
***********************************************
CLEANING THE SPARK ARRESTER 
						

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CHK
ADJADJUSTING THE FRONT BRAKE/
ADJUSTING THE REAR BRAKE
CHASSIS
ADJUSTING THE FRONT BRAKE
1.Check:

Brake lever free play a
 
Out of specification →
 Bleed the front brake
system.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)”.
Brake lever free play (at the brake
lever end):
0 mm (0 in)
ADJUSTING THE REAR BRAKE
1.Check:

Rear brake pedal height a
 
Out of specification →
 Adjust.
2.Adjust:

Rear brake pedal height
***********************************************
Adjustment steps:

Loosen the locknut 1
.

Turn the adjusting bolt 2
 until the brake
pedal height is within the specified limits.

Tighten the locknut 1
.
NOTE:
When adjusting the brake pedal height make
sure the locknut-to-adjusting bolt clearance a
does not exceed 2.2 ~ 3.2 mm (0.09 ~ 0.13 in).
Rear brake pedal height:
4 mm (0.16 in)
Brake pedal height:
4 mm (0.16 in) 
						

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CHK
ADJADJUSTING THE REAR BRAKE/
ADJUSTING THE PARKING BRAKE
WARNING
After this adjustment is performed, lift the
rear wheels off the ground by placing a
block under the engine, and spin the rear
wheels to ensure there is no brake drag. If
any brake drag is noticed perform the
above steps again.
***********************************************
ADJUSTING THE PARKING BRAKE
1.Check:

Parking brake cable end length a
 
Out of specification →
 Adjust.
Parking brake cable end length:
64 ~ 68 mm (2.5 ~ 2.7 in)
2.Adjust:

Parking brake cable end length
***********************************************
Adjustment steps:

Loosen the locknut 1
 and adjusting bolt 2
.

Pull the rubber cover 3
 off.

Loosen the locknut 4
.

Turn the adjuster 5
 in or out until the speci-
fied brake cable end length is obtained.

Tighten the locknut 4
.

Slowly turn the adjusting bolt 2
 clockwise
until resistance is felt.

Turn it 1/8 counterclockwise.

Tighten the locknut 1
.

Check the parking brake cable free play a
.

If the free play is incorrect, adjust the free
play by adjuster 5
.

Pull the rubber cover 3
 in.
T R..
Locknut:
16 Nm (1.6 m  kg, 11 ft  lb)
Free play (parking brake cable):
0 mm (0 in)
at parking brake lever pivot