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Yamaha YFM660RN User Manual

Yamaha YFM660RN
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YFM660RN
YFM660RNC
SERVICE MANUAL
LIT-11616-14-21 5LP-28197-E0

Table of Contents

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Yamaha YFM660RN Specifications

General IconGeneral
BrandYamaha
ModelYFM660RN
CategoryOffroad Vehicle
LanguageEnglish

Summary

CHAPTER 1. GENERAL INFORMATION

MACHINE IDENTIFICATION

Identifies the vehicle and model using VIN and labels.

IMPORTANT INFORMATION

Provides crucial notes on procedures, parts, and safety before maintenance.

CHECKING OF CONNECTIONS

Details how to inspect electrical connectors for proper function and continuity.

SPECIAL TOOLS

Lists and illustrates specific tools required for maintenance and assembly tasks.

CHAPTER 2. SPECIFICATIONS

GENERAL SPECIFICATIONS

Lists key dimensions, engine type, capacity, fuel, and tire specifications.

MAINTENANCE SPECIFICATIONS

Provides detailed engine and chassis specifications for maintenance and adjustments.

LUBRICATION POINTS AND LUBRICANT TYPES

Outlines all lubrication points and the specific lubricant types required for each component.

COOLANT FLOW DIAGRAMS

Illustrates the path of coolant through the system for troubleshooting.

OIL FLOW DIAGRAMS

Details the flow of oil through the engine lubrication system.

CABLE ROUTING

Shows the correct routing and fastening of various cables and wires for proper operation.

CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS

SEAT, FENDERS AND FUEL TANK

Covers removal and installation procedures for body panels and fuel tank.

HEADLIGHTS AND FRONT FENDER

Details the removal and installation of the headlight assembly and front fender.

REAR FENDER

Describes the process for removing and installing the rear fender assembly.

FUEL TANK

Outlines the steps for removing and installing the fuel tank and associated components.

ENGINE

Covers engine-related checks and adjustments, including valve clearance and oil.

CHASSIS

Details checks and adjustments for chassis components like brakes, steering, and suspension.

ELECTRICAL

Covers checks and troubleshooting for electrical systems like battery, lights, and ignition.

CHAPTER 4. CHASSIS

FRONT WHEELS

Procedures for removing, checking, and installing front wheels and related parts.

REAR WHEELS, WHEEL AXLE AND HUB

Covers maintenance of rear wheels, axle, and hub components.

FRONT AND REAR BRAKES

Details inspection, replacement, and bleeding of brake system components.

STEERING SYSTEM

Covers maintenance of handlebars, steering stem, tie-rods, and knuckles.

FRONT ARMS AND FRONT SHOCK ABSORBERS

Outlines procedures for servicing front suspension components.

REAR SHOCK ABSORBER AND RELAY ARM

Details the removal, checking, and installation of rear suspension components.

SWINGARM AND DRIVE CHAIN

Covers maintenance and adjustment of the swingarm and drive chain.

CHAPTER 5. ENGINE

ENGINE REMOVAL

Describes the process for removing the entire engine assembly from the vehicle.

CYLINDER HEAD COVER

Details removal, checking, and installation of the cylinder head cover.

ROCKER ARMS

Covers the removal, checking, and installation of rocker arms and related parts.

CAMSHAFT AND CYLINDER HEAD

Procedures for removing, checking, and installing the camshaft and cylinder head assembly.

VALVES AND VALVE SPRINGS

Details inspection, replacement, and installation of valves and valve springs.

CYLINDER AND PISTON

Covers removal, checking, and installation of the cylinder and piston components.

AC MAGNETO

Procedures for removing, checking, and installing the AC magneto and rotor.

CLUTCH

Covers removal, checking, and installation of clutch components.

OIL PUMP

Details the disassembly, checking, and assembly of the engine oil pump.

SHIFT SHAFT

Outlines procedures for checking and installing shift shaft components.

CRANKCASE

Covers separation, checking, and assembly of the crankcase.

CRANKSHAFT AND BALANCER

Details removal, checking, and installation of the crankshaft and balancer.

TRANSMISSION

Procedures for removing, checking, and assembling transmission components.

CHAPTER 6. COOLING SYSTEM

RADIATOR

Covers removal, checking, and installation of the radiator and fan.

THERMOSTAT

Details checking and installation of the engine thermostat and housing.

WATER PUMP

Outlines disassembly, checking, and assembly procedures for the water pump.

CHAPTER 7. CARBURETION

CARBURETORS

Covers removal, disassembly, checking, and assembly of the carburetor system.

CHAPTER 8. ELECTRICAL

ELECTRICAL COMPONENTS

Identifies and lists all electrical components with their corresponding numbers.

CHECKING THE SWITCH

Provides methods for testing switch continuity and operation using a pocket tester.

IGNITION SYSTEM

Details circuit diagrams and troubleshooting for ignition system failures.

ELECTRIC STARTING SYSTEM

Covers circuit diagrams, operation, and troubleshooting for the electric starting system.

STARTER MOTOR

Outlines removal, disassembly, checking, and assembly of the starter motor.

CHARGING SYSTEM

Provides circuit diagrams and troubleshooting for the battery charging system.

LIGHTING SYSTEM

Covers circuit diagrams and troubleshooting for headlights and tail/brake lights.

SIGNAL SYSTEM

Details circuit diagrams and troubleshooting for indicator lights and warning systems.

COOLING SYSTEM

Provides circuit diagrams and troubleshooting for the electric cooling fan system.

CHAPTER 9. TROUBLESHOOTING

STARTING FAILURE/HARD STARTING

Lists common causes and checks for engine starting issues.

POOR IDLE SPEED PERFORMANCE

Addresses issues related to unstable or incorrect engine idle speed.

POOR MEDIUM AND HIGH-SPEED PERFORMANCE

Helps diagnose problems affecting engine performance at higher speeds.

FAULTY GEAR SHIFTING

Covers causes and solutions for difficult or incorrect gear shifting.

CLUTCH SLIPPING/DRAGGING

Diagnoses and resolves issues with clutch engagement and disengagement.

OVERHEATING

Identifies potential causes for engine overheating and suggests checks.

OVER COOLING

Addresses causes for engine overcooling and related checks.

FAULTY BRAKE

Diagnoses issues related to poor braking performance and potential causes.

SHOCK ABSORBER MALFUNCTION

Covers problems related to shock absorber performance and potential damage.

UNSTABLE HANDLING

Addresses factors contributing to unstable vehicle handling and steering issues.

LIGHTING SYSTEM

Troubleshoots issues with headlights, tail lights, and other lighting components.

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