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Yamaha YFM660FP User Manual

Yamaha YFM660FP
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YFM660FP
SERVICE MANUAL
LIT-11616-15-01 5KM-28197-E0

Table of Contents

Questions and Answers:

Yamaha YFM660FP Specifications

General IconGeneral
BrandYamaha
ModelYFM660FP
CategoryOffroad Vehicle
LanguageEnglish

Summary

YFM660FP SERVICE MANUAL

CHAPTER 1. GENERAL INFORMATION

MACHINE IDENTIFICATION

Details for identifying the vehicle and model.

FEATURES

Describes front differential operation in 2WD, 4WD, and Diff-Lock modes.

TRANSMISSION

Explains the 3-axle transmission with chain drive for reverse.

IMPORTANT INFORMATION

Guidelines for maintenance preparation, parts, and seals.

CHAPTER 2. SPECIFICATIONS

GENERAL SPECIFICATIONS

Provides overall dimensions, weight, engine type, and capacities.

MAINTENANCE SPECIFICATIONS

Details engine component measurements, tolerances, and limits.

CHASSIS

Covers steering, suspension, wheels, and brake specifications.

ELECTRICAL

Lists specifications for ignition, charging, starting, and lighting systems.

CABLE ROUTING

Illustrates the correct routing of wires, hoses, and cables.

CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

Outlines recommended service intervals for various components and fluids.

SEAT, CARRIERS, FENDERS AND FUEL TANK

Details the removal and installation of the seat and side panels.

ENGINE

Covers engine adjustments like valve clearance and idling speed.

CHASSIS

Details chassis maintenance, including brakes, steering, and suspension.

ELECTRICAL

Procedures for checking and adjusting electrical components.

CHAPTER 4. ENGINE

ENGINE REMOVAL

Step-by-step instructions for removing the engine assembly and its related parts.

CYLINDER HEAD COVER

Procedures for removing, checking, and installing the cylinder head cover.

ROCKER ARMS

Instructions for removing, checking, and installing rocker arms and shafts.

CAMSHAFT AND CYLINDER HEAD

Details removal, inspection, and installation of camshaft and cylinder head components.

VALVES AND VALVE SPRINGS

Procedures for removing, checking, and installing valves and springs.

CYLINDER AND PISTON

Steps for removing, checking, and installing the cylinder and piston assembly.

RECOIL STARTER AND AC MAGNETO

Procedures for removing, disassembling, and checking starter and magneto components.

BALANCER GEARS AND OIL PUMP GEARS

Instructions for removing and checking balancer and oil pump gears.

CHAPTER 5. COOLING SYSTEM

RADIATOR

Procedures for removing, checking, and installing the radiator and fan.

THERMOSTAT

Instructions for checking and installing the thermostat and its housing.

WATER PUMP

Procedures for removing, disassembling, checking, and assembling the water pump.

CHAPTER 6. CARBURETION

CARBURETOR

Steps for removing, disassembling, checking, and assembling the carburetor.

CHAPTER 7. DRIVE TRAIN

TROUBLESHOOTING

Lists common symptoms and possible causes for drive train issues.

FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR

Procedures for removing, disassembling, and checking CV joints and differential gear.

REAR CONSTANT VELOCITY JOINT/FINAL DRIVE GEAR AND DRIVE SHAFT

Instructions for removing, disassembling, and assembling rear drive components.

CHAPTER 8. CHASSIS

FRONT WHEELS AND BRAKE DISCS

Procedures for removing, checking, and installing front wheels and brake discs.

REAR WHEELS AND BRAKE DISC

Instructions for removing, checking, and installing rear wheels and brake discs.

FRONT AND REAR BRAKES

Covers procedures for front and rear brake pads, master cylinders, and calipers.

CHAPTER 9. ELECTRICAL

ELECTRICAL COMPONENTS

Identification of various electrical components with a circuit diagram.

CHECKING THE SWITCH

Methods for checking switch continuity and terminal connections.

CHECKING THE BULBS AND BULB SOCKETS

Procedures for checking bulb condition, types, and continuity.

IGNITION SYSTEM

Circuit diagram and troubleshooting for the ignition system.

ELECTRIC STARTING SYSTEM

Circuit diagram and troubleshooting for the electric starting system.

CHARGING SYSTEM

Circuit diagram and troubleshooting for the charging system.

LIGHTING SYSTEM

Circuit diagram and troubleshooting for headlights and taillights.

SIGNAL SYSTEM

Circuit diagram and troubleshooting for various indicator and warning lights.

COOLING SYSTEM

Circuit diagram and troubleshooting for the cooling fan motor and thermo switch.

2WD/4WD SELECTING SYSTEM

Circuit diagram and troubleshooting for the 2WD/4WD selection system.

CHAPTER 10. TROUBLESHOOTING

STARTING FAILURE/HARD STARTING

Lists possible causes for engine starting issues related to fuel, electrical, and carburetor systems.

POOR IDLE SPEED PERFORMANCE

Identifies issues affecting engine idle speed, related to carburetor and electrical systems.

POOR MEDIUM AND HIGH-SPEED PERFORMANCE

Troubleshooting for issues affecting engine performance at medium and high speeds.

FAULTY DRIVE TRAIN

Symptoms and causes of damage or malfunction in shaft drive components.

FAULTY GEAR SHIFTING

Common problems and potential causes for gear shifting issues.

FAULTY CLUTCH PERFORMANCE

Issues related to engine operation but no movement, clutch slipping, and starting performance.

OVERHEATING

Potential causes for engine overheating related to ignition, fuel, and cooling systems.

FAULTY BRAKE

Common causes for poor braking effect.

SHOCK ABSORBER MALFUNCTION

Identifies issues related to bent damper rods or fatigued springs.

UNSTABLE HANDLING

Factors affecting handling, including tires, wheels, steering, and frame.

LIGHTING SYSTEM

Troubleshooting for dark headlights and burnt-out bulbs.

YFM660FP WIRING DIAGRAM

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