Yamaha YFM660FP

To Next Page

To Previous Page

YFM660FP

SERVICE MANUAL

First edition, May 2001

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

LIT-11616-15-01

Main Page

Default Chapter3
- Specifications3
- How to Use this Manual4
- Periodic Checks and5
- Table of Contents8
Machine Identification20
- Vehicle Identification Number20
- Model Label20
Chapter 1. General Information20
Features21
- Front Differential21
- Transmission28
Important Information29
- Preparation for Removal Procedures29
- Replacement Parts29
- Gaskets, Oil Seals and O-Rings29
- Lock Washers/Plates and Cotter Pins30
- Bearings and Oil Seals30
- Circlips30
Checking of Connections31
Special Tools32
General Specifications37
Chapter 2. Specifications37
Maintenance Specifications40
- Engine40
- Chassis50
- Electrical54
How to Use the Conversion Table56
General Torque Specifications56
Lubrication Points and Lubricant Types57
- Engine57
Coolant Flow Diagrams58
Oil Flow Diagrams60
Cable Routing63
Introduction78
Periodic Maintenance/Lubrication Intervals78
Chapter 3. Periodic Checks and Adjustments78
Seat, Carriers, Fenders and Fuel Tank80
- Seat and Side Panels80
- Front Carrier, Front Bumper and Front Grill81
- Handlebar Cover, Fuel Tank Cover and Front Fender82
- Rear Carrier and Rear Fender84
- Engine Skid Plate (Center) and Engine Skid Plate (Rear)86
- Fuel Tank87
Footrest Boards89
Engine90
- Adjusting the Valve Clearance90
- Adjusting the Timing Chain93
- Adjusting the Idling Speed94
- Adjusting the Throttle Lever Free Play94
- Adjusting the Speed Limiter96
- Adjusting the Starter Cable98
- Checking the Spark Plug98
- Checking the Ignition Timing99
- Measuring the Compression Pressure101
- Checking the Engine Oil Level103
- Changing the Engine Oil104
- Cleaning the Air Filter107
- Checking the Coolant Level108
- Changing the Coolant109
- Checking the Coolant Temperature Warning Light113
- Checking the V-Belt114
- Cleaning the Spark Arrester114
Chassis116
- Adjusting the Rear Brake116
- Checking the Brake Fluid Level118
- Checking the Front Brake Pad120
- Checking the Rear Brake Pad120
- Checking the Brake Hose121
- Bleeding the Hydraulic Brake System121
- Adjusting the Select Lever Control Cable and Shift Rod123
- Adjusting the Rear Brake Light Switch124
- Checking the Final Gear Oil Level125
- Changing the Final Gear Oil125
- Checking the Differential Gear Oil126
- Changing the Differential Gear Oil127
- Checking the Constant Velocity Joint Dust Boot128
- Checking the Steering System128
- Adjusting the Toe-In129
- Adjusting the Front Shock Absorber130
- Adjusting the Rear Shock Absorber131
- Checking the Tire131
- Checking the Wheel133
- Checking and Lubricating the Cable134
- Lubricating the Levers, Pedal, Etc134
Electrical135
- Checking the Battery135
- Checking the Fuse141
- Adjusting the Headlight Beam142
- Changing the Headlight Bulb143
Engine Removal144
- Air Ducts, Muffler and Exhaust Pipe144
- Select Lever Unit and Coolant Reservoir146
- Hoses and Leads147
- Engine Mounting Bolts148
- Installing the Engine150
Chapter 4. Engine144
Cylinder Head Cover151
- Removing the Cylinder Head Cover153
- Checking the Cylinder Head Cover153
- Checking the Tappet Cover154
- Installing the Cylinder Head Cover154
Rocker Arms157
- Removing the Rocker Arm157
- Checking the Rocker Arm157
- Installing the Rocker Arm158
Camshaft and Cylinder Head159
- Removing the Camshaft and Cylinder Head161
- Checking the Camshaft162
- Checking the Camshaft Sprocket162
- Checking the Decompression System162
- Checking the Timing Chain Guide163
- Checking the Timing Chain Tensioner163
- Checking the Cylinder Head163
- Installing the Camshaft and Cylinder Head164
Valves and Valve Springs167
- Removing the Valve and Valve Spring168
- Checking the Valve and Valve Spring169
- Installing the Valve and Valve Spring173
Cylinder and Piston175
- Removing the Piston176
- Checking the Cylinder and Piston176
- Checking the Piston Ring178
- Checking the Piston Pin179
- Installing the Piston179
- Installing the Cylinder180
Recoil Starter and Ac Magneto181
- Removing the Ac Magneto184
- Disassembling the Recoil Starter184
- Checking the Ac Magneto184
- Checking the Starter Clutch185
- Checking the Starter Pulley186
- Checking the Recoil Starter186
- Assembleing the Recoil Starter186
Balancer Gears and Oil Pump Gears190
- Removing the Balancer Drive Gear and Balancer Driven Gear191
- Removing the Balancer Drive Gear and Buffer Boss191
- Checking the Oil Pump Drive191
- Checking the Balancer Drive192
- Installing the Balancer Drive Gear and Balancer Driven Gear192
Primary and Secondary Sheaves194
- Primary Sheave196
- Secondary Sheave197
- Removing the Primary and Secondary Sheaves198
- Disassembling the Secondary Sheave198
- Cheking the Primary Sheave199
- Checking the Secondary Sheave199
- Assembling the Primary Sheave200
- Assembling the Secondary Sheave200
- Installing the Primary and Secondary Sheaves202
Clutch203
- Removing the Clutch205
- Checking the Clutch205
- Installing the Clutch206
Crankcase208
- Starter Motor, Timing Chain and Oil Filter208
- Crankcase209
- Crankcase Bearing211
- Separating the Crankcase212
- Checking the Timing Chain and Guide212
- Checking the Oil Delivery Pipe212
- Checking the Crankcase213
- Checking the Bearings213
- Assembling the Crankcase213
- Installating the Shift Lever214
Crankshaft and Oil Pump215
- Oil Pump216
- Removing the Crankshaft217
- Checking the Oil Pump217
- Checking the Relief Valve218
- Checking the Oil Strainer218
- Assembling the Oil Pump218
- Checking the Crankshaft219
- Installing the Crankshaft and Balancer220
Transmission221
- Removing the Transmission224
- Checking the Shift Fork224
- Checking the Shift Cam225
- Checking the Drive Axle225
- Checking the High Wheel Gear and Middle Drive Gear225
- Checking the Secondary Shaft and Driven Sprocket226
- Checking the Chain226
- Checking the Stopper Lever and Stopper Wheel226
- Assembling the Shift Fork Assembly227
- Installing the Transmission227
Middle Gear228
- Middle Drive Shaft228
- Middle Driven Shaft230
- Removing the Middle Drive Shaft231
- Removing the Middle Driven Shaft231
- Checking the Pinion Gear234
- Middle Drive and Driven Gear Shim Selection234
- Installing the Middle Driven Shaft237
- Installing the Middle Drive Shaft239
- Measuring the Middle Gear Backlash240
Radiator241
- Checking the Radiator243
- Installing the Radiator244
Chapter 5. Cooling System241
Thermostat245
- Checking the Thermostat246
- Installing the Thermostat246
Water Pump247
- Disassembling the Water Pump249
- Checking the Water Pump249
- Assembling the Water Pump250
Carburetor252
- Disassembling the Carburetor255
- Checking the Carburetor255
- Assembling the Carburetor257
- Adjusting the Fuel Level258
Chapter 6. Carburetion252
Troubleshooting259
Chapter 7. Drive Train259
Front Constant Velocity Joints and Differential Gear262
- Disassembling the Universal Joint267
- Removing the Ring Gear268
- Checking the Constant Velocity Joint268
- Checking the Differential Gear268
- Checking the Gear Motor269
- Assembling the Front Constant Velocity Joint269
- Assembling the Differential Gear270
- Installing the Universal Joint272
- Measuring and Adjusting the Differential Gear Lash273
- Checking the Differential Gear Operation275
Rear Constant Velocity Joint/Final Drive Gear and Drive Shaft276
- Assembling the Rear Constant Velocity Joint280
- Removing and Disassembling the Final Drive Roller Bearing281
- Positioning the Final Drive Pinion Gear and Ring Gear282
- Checking the Drive Shaft287
- Checking the Final Drive Gear287
- Measurement and Adjusting the Final Gear Lash288
- Assembling the Final Drive Gear290
- Installing the Final Drive Gear290
Front Wheels and Brake Discs291
- Checking the Front Wheel293
- Checking the Front Wheel Hub293
- Checking the Front Brake Disc294
- Installing the Front Wheel Hub294
- Installing the Front Wheel294
Chapter 8. Chassis291
Rear Wheels and Brake Disc296
- Rear Wheels296
- Rear Brake Disc297
- Checking the Rear Wheel298
- Checking the Rear Wheel Hub298
- Checking the Rear Brake Disc298
- Installing the Rear Wheel Hub299
- Installing the Rear Wheel299
Front and Rear Brakes300
- Front Brake Pads300
- Rear Brake Pads301
- Replacing the Front Brake Pad302
- Replacing the Rear Brake Pad304
- Front Brake Master Cylinder306
- Rear Brake Master Cylinder308
- Checking the Master Cylinder311
- Assembling the Front Brake Master Cylinder312
- Assembling the Rear Brake Master Cylinder312
- Installing the Front Brake Master Cylinder313
- Installing the Rear Brake Master Cylinder314
- Front Brake Caliper316
- Rear Brake Caliper318
- Disassembling the Brake Caliper320
- Disassembling the Rear Brake Caliper320
- Checking the Front and Rear Brake Caliper321
- Assembling the Front Brake Caliper322
- Installing the Front Brake Caliper322
- Assembling the Rear Brake Caliper324
- Installing the Rear Brake Caliper325
- Handlebar326
- Steering System326
- Removing the Rear Brake Switch327
- Checking the Handlebar327
- Installing the Handlebar327
- Installing the Rear Brake Lever327
- Installing the Master Cylinder Assembly328
- Steering Stem329
- Removing the Bearing Retainer331
- Checking the Steering Stem331
- Installing the Bearing Retainer331
- Installing the Steering Stem331
- Installing the Cable Guide332
- Tie Rod and Steering Knuckle333
- Removing the Steering Knuckle334
- Checking the Tie Rod334
- Checking the Steering Knuckle334
- Checking the Ball Joint335
- Checking the Tie Rod335
Front Arms and Front Shock Absorber336
- Removing the Front Arms338
- Checking the Front Arm338
- Checking the Front Shock Absorber338
- Installing the Front Arms and Front Shock Absorber339
Rear Knuckle and Stabilizer340
- Checking the Rear Knuckle341
- Checking the Stabilizer341
Rear Arms and Rear Shock Absorber342
- Checking the Rear Arm343
- Checking the Rear Shock Absorber343
- Checking the Rear Arms and Rear Shock Absorber343
Electrical Components345
Chapter 9. Electrical345
Checking the Switch346
- Checking a Switch Shown in the Manual346
- Checking the Switch Continuity348
Checking the Bulbs and Bulb Sockets350
- Types of Bulbs350
- Checking the Condition of the Bulbs350
- Checking the Condition of the Bulb Sockets352
- CHECKING the Leds352
Ignition System353
- Circuit Diagram353
- Troubleshooting354
Electric Starting System359
- Circuit Diagram359
- Starting Circuit Operation360
- Troubleshooting361
- Starter Motor361
- Checking the Starter Motor366
- Assembling the Starter Motor367
Charging System368
- Circuit Diagram368
- Troubleshooting369
Lighting System371
- Circuit Diagram371
- Troubleshooting372
- Checking the Lighting System374
Signal System376
- Circuit Diagram376
- Troubleshooting378
- Checking the Signal System380
- Circuit Diagram391
- Troubleshooting392
2Wd/4Wd Selecting System396
- Circuit Diagram396
- Troubleshooting401
Chapter 10401
- Electrical System401
- Compression System402
Starting Failure/Hard Starting401
Poor Idle Speed Performance402
Poor Medium and High-Speed Performance402
Faulty Drive Train403
Faulty Gear Shifting404
- Hard Shifting404
- Shift Lever Does Not Move404
- Jumps out of Gear404
Faulty Clutch Performance404
- Engine Operates but Machine will Not Move404
- Clutch Slipping404
- Poor Starting Performance404
- Poor Speed Performance405
Overheating405
Faulty Brake405
- Poor Braking Effect405
  - Shock Absorber Malfunction406
  - Unstable Handling406

Related product manuals

Yamaha YFM660FS Grizzly 4x4

478 pages

GRIZZLY Ultramatic YFM660FP

442 pages

ULTRAMATIC GRIZZLY 660 YFM660FS

444 pages

ULTRAMATIC GRIZZLY 660 YFM660FR

Yamaha RAPTOR YFM660R

414 pages

Yamaha Raptor YFM660RT

186 pages

Yamaha RAPTOR YFM660RP

180 pages

Yamaha YFM660FP - Page 2

Table of Contents

Related product manuals