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2001 yamaha raptor 660 service manual free download |
2001 yamaha raptor 660 service manual free download.Yamaha RAPTOR YFM660RP Owner's Manual
Shift the transmission into neutral. Page 55 When the transmission is in neutral. The neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it. However, it is recommended to shift into neutral be- fore starting the engine.
Pause a few sec- operating engine for the first time. Each cranking should be as short as possible to preserve battery energy. The starter choke should not be used. The throttle should be opened slightly. EBU Warming up To get maximum engine life, always warm up the engine before starting off. While applying the rear brake pedal, turn ask a Yamaha dealer to inspect the machine. Check behind you for people or obsta- 3.
The transmission allows Improperly operating in reverse. Release the throttle lever. Even in neutral Always close the throttle while shifting position, the transmission is only gears. Follow the same procedure when shifting To decelerate: to the next higher gear. Page Engine Break-In Because the engine is If any abnormality is noticed during this peri- brand new, you must not put an excessive od, consult a Yamaha dealer.
Locked position 1. Button 2. Lock plate Bring the machine to a stop by applying the brakes in low gear. Parking on a hill or other incline. Your Yamaha dealer has a variety of accessories.
The ATV may handle differ- genuine Yamaha accessories. Other ac- ently than it does without accessories. As originally equipped, this ATV is not de- Make sure cargo in the trailer cannot move signed to carry cargo or tow a trailer. If you around. A shifting load can cause an acci- choose to add accessories so that you can dent. Page 69 R iding Your Pay particular at- This ATV is intended for recreational use by tention to the safety information on pages experienced operators only. They should Beginners should get training from a certified then regularly practice the skills learned instructor.
Page 73 Not recommended for children under 16 years of age. Page 74 This ATV is designed to carry operator only - passengers prohibited. Could cause you to react more slowly. Page 78 Speed limiter WARNING For riders inexperienced with this model, this Indicates a potential hazard that could model is equipped with a speed limiter in the result in serious injury or death. The speed limiter limits the power and top speed of the ATV.
Turning Do not operate at speeds too fast for your the screw in decreases top speed, and turning skills or the conditions. Otherwise your feet may con- Removing hands from handlebars or tact the rear wheels. Page 81 Avoid wheelies and jumping. You may lose control of the ATV or overturn. Page 82 Never modify this ATV through improp- er installation or use of accessories.
All parts and accessories added to this ve- hicle should be genuine Yamaha or equivalent components designed for use on this ATV and should be installed and used according to instructions. If you have questions, consult an autho- rized ATV dealer.
To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. Riding on paved surfaces can cause loss of control. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of con Page 85 Do not ride on any public road, street, or high- way. Riding on public roads can result in colli- sions with other vehicles. Page 86 Know the terrain where you ride.
Ride cau- tiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and oth- er hidden hazards which may cause the ATV to upset. You could a caution flag on the ATV. DO NOT use the be injured. Page 89 Select a large, flat area off-road to become fa- With the engine idling, pull the clutch lever to miliar with your ATV. Make sure that this area disengage the clutch and shift into 1st gear, is free of obstacles and other riders.
You and then release the parking brake. As you slow down, shift to a lower Opening the throttle abruptly or releas- gear. Be sure that the engine has sufficiently ing the clutch lever to quickly. Page 92 Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip.
Be sure that you can ma- for the ATV or for your abilities. Climbing hills improperly. Page 97 Dismount on uphill side or to a side if pointed straight uphill.
ATV as possible. Page 99 Be sure that you hills. Page Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Test your brakes shallow water of up to a maximum of 35 cm after leaving water. If necessary, apply 14 inches in depth. Page Test your brakes after leaving the water. Look out for obstacles which could Improperly operating over obstacles.
Be sure to keep your feet Could cause loss of control or a colli- firmly mounted on the footboards at all times. Page If there is room to do so by steering in the direc- unexpected and uncorrected, sliding could tion of the slide. Bear in mind that You may lose control of this ATV.
Be sure to read each section on the room. If the ATV starts to tip, steer down the hill if there are no obstacles in your way to regain balance. Valve seat width: Intake: 0. NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. Then, find the average of the measurements. Standard Wear limit NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance.
Side clearance Standard Limit Outside diameter piston pin : Engine oil Drain. Coolant Drain. Starter wheel gear Washer Starter idle gear shaft Spring Sheave drum Rope Coil spring For assembly, reverse the disassembly YU, 2. If not, reinstall the key and rotor. Straighten the lock washer tabs. Guide pin Secondary sliding sheave O-ring Secondary fixed sheave Oil seal Weight outside diameter: 30 mm 1. One-way clutch bearing Clutch carrier assembly For installation, reverse the removal Remove them after all of them are loosened.
Straighten: Punched portion of the nut 1. Clutch shoe thickness: 1. Fit the left crankcase onto the right case. Tap lightly on the case with a soft hammer. Rotor cover Shaft Inner rotor Outer rotor Oil pump housing For assembly, reverse the disassembly procedure.
Crank width: Low wheel gear Shift cam Shift fork assembly Short spring White painting. YM 3. In the example above, the calculated shim thickness is 0.
The chart instructs you, however, to round off 4 to 5. Hundredths Round value 0, 1, 2 3, 4, 5, 6, 7 8, 9 Shims are supplied in the following thickness. The needles can eas- ily fall out of their races. Page Chapter 5. Radiator outlet hose Disconnect.
Radiator Radiator fan Thermo switch For installation, reverse the removal procedure. Apply compressed air to the rear of the radia- tor. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. Page Chapter 6. Pilot jet Starter jet For assembly, reverse the disassembly procedure. Insert the piston valve into the carburetor body, and check for free movement.
Page Chapter 7. Bearing damage. Improper gear lash. This must not be confused with engine surging or transmission characteris- C. Gear tooth damage. If a test ride following reas- sembly indicates this condition, stop riding immediately to minimize gear damage. This noise must be distinguished from normal machine operation. Feel for Replace the wheel bearing. Check the wheel nuts and hub nuts for Torque to specification. Do not disassem- ble the differential gear.
Move the spring up and down. Molybdenum disulfide grease: 40 g 1. Insert the double off-set joint into the differ- ential gear, and turn the gear back and forth. Secure the gear case in a vise or another supporting device.
Block the rear wheels, and elevate the front wheels by placing a suitable stand under the frame. Remove the wheel cap and cotter pin from the axle nut right or left. Measure the starting torque of the front wheel i. Boss Ring gear stopper shim Ring gear stopper Bearing retainer Bearing Pinion gear bearing housing Final drive gear case In the example above, the calculated number is 0. The chart instructs you to round off 7 to 5 at the hundredth place.
Do not reuse the oil seal. Page Chapter 8. Wheel runout limit: Radial 2: 2. Check: Wheel balance If wheel runout is within the limits, replace the brake disc. Brake disc maximum deflection: 0. Install each nut with its tapered side towards the wheel.
Page ATV that is being ridden normally. Do not attempt to diagnose such problems yourself. Instead, take the ATV to a Yamaha dealer.
You should periodically remove and inspect 1. Spark plug wrench the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. Page Installation Tightening torque: 1. Measure the electrode gap with a wire Spark plug: thickness gauge and, if necessary, adjust If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. Page 8. Apply Yamaha foam air filter oil or other Install the seat.
If foam air filter oil is not available, The air filter element should be cleaned every engine oil may be used. Remove the tailpipe by pulling it out of Be sure the exhaust pipe and muffler are cool the muffler. Tap the tailpipe lightly, then use a wire 1. Remove the bolt. Most Improper cleaning of the spark arrester. The engine is warm when it quickly responds to the 1. Page Valve Clearance Adjustment This adjust- ment however, should be left to a professional 1. Loosen the locknut. Yamaha service technician.
Turn the adjusting bolt until the throttle le- ver free play is 3—5 mm 0. Tighten the locknut. Page Front And Rear Brake Pad Inspection If the pad is worn to the point that the wear indicator grooves are al- most in contact with the disc plate, ask a Yamaha dealer to replace the pads.
Wear indicator groove Front 1. Wear indicator groove Page Brake Fluid Level Inspection EBU Brake fluid level inspection Rear Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective.
Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. Page Brake Fluid Replacement 1. Brake fluid reservoir cover 2. Observe these precautions: Have a Yamaha dealer check the cause if When checking the brake fluid level, make the brake fluid level goes down.
If not, Operating with improperly serviced or have a Yamaha dealer check the brake sys- adjusted brakes. If not, have a Yamaha dealer adjust adjusted brakes. Page Parking Brake Adjustment A. Cable length If the cable cannot be adjusted to specifica- 1.
Fully loosen the locknut and the adjusting tion, consult a Yamaha dealer. Tighten the locknut at the clutch lever. Loosen the locknut and the adjusting bolt at the rear brake caliper.
Tighten the Operating with improperly adjusted locknut to the specified torque. Page Adjusting The Rear Brake Light Switch EBU EBU Adjusting the rear brake light switch Clutch lever free play adjustment The rear brake light switch, which is activated The clutch lever free play should be adjusted by the brake pedal and brake lever, is proper- to 5—10 mm 0.
Page 6. Loosen the locknut at the crankcase side. Turn the adjusting nut at the crankcase in direction a to increase the free play or in direction b to decrease the free play. Tighten the locknut at the crankcase and the clutch lever. To check the drive chain slack, all tires must be touching the ground and there should be no weight on it. Loosen the rear wheel hub upper and the swingarm and on the hub. Use them to lower nuts. Upper wheel hub nut 2. Clean the drive chain with kerosene and Cable inspection and lubrication a small soft brush.
Lubricate the pivoting parts of each lever and pedal. Recommended lubricant: Lithium-soap-based grease Left side 1. Upper grease nipple 2. Recommended lubricant: Lithium-soap-based grease 1. Grease nipple 1. Grease nipple Loosen the wheel nuts. Elevate the ATV and place a suitable stand under the frame.
Remove the nuts from the wheel. Remove the wheel. Front 1. NOTE: When installing a front wheel, the arrow mark on the tire must point toward the rotating direction of the wheel. Page Battery Keep out of reach of chil- tery. If the battery seems to have discharged, dren. Page Battery Maintenance Then turn on the switch- es. Using an improper fuse. An improper fuse can cause damage to the electrical system which could lead to a fire. Page 2. Disconnect the headlight coupler.
Remove the screw. Headlight coupler 1. Screw 4. Remove the headlight cover from the headlight assembly. Page NOTE: 5. Remove the screw and pull the headlight Pull outward on the rear of the headlight unit, unit out from its case.
Remove the headlight bulb holder cover. Screw 1. Headlight bulb holder cover Page 7. A headlight bulb is hot when it is on and immediately after it is turned off. Place the headlight assembly in the orig- is securely fitted over the bulb holder and inal position, and then install the bolts. Have a Yamaha dealer adjust the head- light beam if necessary. Remove the lens by removing the screws. Bulb 3.
Install a new bulb by pushing it inward and turning it clockwise. Install the lens by installing the screws. Lens 2.
Any prob- ing or near an open flame. Page N. Page Brake Fluid Replacement Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid im- mediately. Have a Yamaha dealer check the cause if the brake fluid level goes down.
EBU Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel. If not, have a Yamaha dealer check the brake system.
Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge. These procedures should be performed by a Yamaha dealer. Contratuerca 2. Perno de ajuste If the cable cannot be adjusted to specification, A.
Longitud del cable consult a Yamaha dealer. Tighten the locknut at the clutch lever. Adjusting bolt 1. Tighten the locknut to the speci- fied torque. Tightening torque: Locknut: 16 Nm 1. Page Adjusting The Rear Brake Light Switch EBU Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and brake lever, is properly adjust- ed when the brake light comes on just before brak- ing takes effect.
If necessary, adjust the brake light switch as follows. Loosen the locknut at the clutch lever. Turn the adjusting bolt at the clutch lever in direction a to increase the free play or in di- rection b to decrease the free play.
To check the drive chain slack, all tires must be touching the ground and there should be no weight on it. Loosen the rear wheel hub upper and lower nuts. Loosen the locknuts on each side of the swin- garm. To tighten the drive chain, turn the ad- justing bolts in direction a. To loosen the drive chain, turn the adjusting bolts in direc- tion b and push the wheels forward. Page Lubricating The Drive Chain EBU Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas.
Ser- vice the drive chain as follows. Wipe the drive chain dry. Thoroughly lubricate the drive chain with a special O-ring chain lubricant. Op- eration of controls could be restricted, which could cause an accident or injury. Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. Recommended lubricant: Engine oil Si le fonctionne- bles.
Lado izquierdo Recommended lubricant: Lithium-soap-based grease 1. Upper grease nipple 2. Lubrique los pivotes del brazo superior y del brazo inferior.
Recommended lubricant: Lithium-soap-based grease 1. Grease nipple 1. Graisseur 1. Boquilla de engrase Lubrique los pivotes del brazo trasero.
Loosen the wheel nuts. Delantera 2. Elevate the ATV and place a suitable stand under the frame. Remove the nuts from the wheel. Remove the wheel. Afloje las tuercas de la rueda. Levante el ATV y coloque un soporte adecuado le cadre. NOTE: When installing a front wheel, the arrow mark on the tire must point toward the rotating direction of the wheel. Page Battery Therefore it is not necessary to check the electrolyte or add distilled water in the battery.
If the battery seems to have discharged, consult a Yamaha dealer. You may damage the battery. It contains sul- furic acid. Avoid contact with skin, eyes or clothing.
Follow with milk of magnesia, beat- en egg or vegetable oil. Evite que entre en contacto con sulfurique. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. Page Fuse Replacement 2. If the fuse is blown, turn off the main switch and install a new fuse of the specified amper- age. Then turn on the switches.
If the fuse im- mediately blows again, consult a Yamaha dealer. Specified fuse: 20 A 1. Si el fusible vuelve a saltar inmediatamente, consulte a un conce- diatement, consulter un concessionnaire Yamaha. Remove the headlight assembly by removing the bolts. Headlight assembly 2. Bloc de phare 2. Remove the screw. Remove the headlight cover from the head- light assembly. Screw 1. Vis 1. Tornillo 5.
Remove the screw and pull the headlight unit out from its case. NOTE: Pull outward on the rear of the headlight unit, and then pull outward on the front.
Retirer la vis. Extraiga el tornillo. Extraiga la cubierta del faro del conjunto del fa- 5. Extraiga el tornillo y tire de la unidad del faro support. Remove the headlight bulb holder cover. Headlight bulb holder cover 1. Cubierta del portabombillas del faro 7. Push the headlight bulb holder inward, turn it counterclockwise and remove the defective bulb.
Extraiga la cubierta del portabombillas del faro. Page 8. Put a new headlight bulb into position and se- cure it in place with the bulb holder. CAUTION: Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affect- ed.
Mettre une nouvelle ampoule de phare en place et 8. Connect the headlight coupler. Place the headlight assembly in the original position, and then install the bolts.
Have a Yamaha dealer adjust the headlight 1. Headlight unit 2. Headlight case beam if necessary. Remove the lens by removing the screws. Remove the defective bulb by pushing it in- ward and turning it counterclockwise. Lens 2. Lentille 2. Lente 2. Extraiga la lente sacando los tornillos. Page Troubleshooting Use only genuine Yamaha parts on your machine. Imitation parts may look like Yamaha parts, but they are often in- ferior. Consequently, they have a shorter service life and can lead to expensive repair bills.
Page Troubleshooting Chart No fuel. Compression There is compression. Compression normal. Use the electric starter to see if there is compression. Ask a Yamaha dealer to No compression. Ignition Wipe clean with dry cloth. Ignition system is Spark is good.
Page Restart the engine. If the engine overheats again, ask a Level is OK. NOTE: If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recommended coolant as soon as possible.
Allumage Humides Nettoyer avec un chiffon sec. Page Remettre le moteur en marche. Page Arranque el motor. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components.
Before cleaning the machine: a. Block off the end of the exhaust pipe to pre- vent water entry. Page CAUTION: Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical de- vices. Many expensive repair bills have result- ed from improper high pressure detergent applications such as those available in coin- operated car washers.
Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protec- tive finish.
When finished, start the engine and let it idle for several minutes. Afin de parfaire le travail, appliquer une cire pour 8. Page B. Storage if available. NOTE: Use of fuel stabilizer eliminates the need to drain the fuel system. Consult a Yamaha dealer if the fuel system is to be drained instead.
Remove the spark plug, pour about one ta- blespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug. Si debe drenar el sistema de combustible, consulte a 2. Block up the frame to raise all wheels off the ground. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering.
If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces with a light film of oil. Fixer un sac en plastique sur la sortie du pot 6. Generator system A. This manual is also suitable for: Raptor yfmrr. Print page 1 Print document pages.
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YAMAHA RAPTOR YFMRR OWNER'S MANUAL Pdf Download | ManualsLib.
Table Of Contents. Quick Links. It contains important safety information. This ATV should not be ridden by anyone under 16 years of age. Table of Contents.
Previous Page. Next Page. Troubleshooting Troubleshooting Troubleshooting charts LIT 5LP Page 2 EBU Page 3 Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of crafts- manship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this machine.
Page 5 Please check your local riding laws and regulations before operating this machine. Handlebar switches Page 9 Troubleshooting Page 11 ATV.
Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.
An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions. You should also wear eye protection goggles or face shield , gloves, boots, long-sleeved shirt or jacket, and long pants. Practice turning at low speeds before attempting to turn at faster speeds.
Do not turn at excessive speed. Page 16 Always use proper procedures if you stall or roll backwards when climbing a hill. If you stall or roll back- wards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill.
Always maintain proper tire pressure as described in this manual. Cargo should be properly distributed and securely attached. Spark arrester Seat Shift pedal 3.
Fuel tank cap Clutch lever 4. Engine oil tank Handlebar switches 5. Brake pedal Parking brake 6. Headlight Main switch 7.
Page Identification Number Records This number can be used for ordering a new when ordering spare parts from a Yamaha key. Page Vehicle Identification Number Record the information on this la- bel in the space provided. This information will be needed to order spare parts from your Yamaha dealer.
EBU Main switch Functions of the respective switch positions are as follows: The engine can be started only at this position and the headlights and taillight come on when the light switch is on. If the light comes on during operation, stop the en- gine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.
Page 25 Coolant temperature Coolant temperature warning light comes on warning light does not momentarily. Coolant temperature and electrical circuit are OK. Go Ask a Yamaha dealer to ahead with riding. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. See page for details. Page Throttle Lever Check the operation of the throttle lever before you start the engine.
If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you 1. Screwing in the ad- er and throttle. Pull it toward the handlebar to apply the corporated in the clutch lever holder. Push down on the pedal to apply the rear brake. Brake pedal Page Parking Brake EBU Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope.
Squeeze the clutch lever while push- ing the button, then push in the lock plate to apply the parking brake. Squeeze the clutch lever to release the parking brake. The fuel cock has three positions. OFF: With the lever in this position, fuel will not flow.
Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. A separate starter circuit supplies this the rear of the seat and the rear fender, pull mixture. Page 37 To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear.
NOTE: Make sure that the seat is securely fitted. Take the unit to a Yamaha dealer. Page 40 3. The length of the spring installed 4. Tighten the locknut to the specified changes 1. Tightening torque: Measurement A: 42 Nm 4. Page 41 Adjust the rebound damping force as follows. Adjust the compression damping force as fol- Turn the rebound damping force adjusting lows. Suspension components become hot during operation.
Failure to properly maintain the ATV. If there is lever. If there is free play, have a Yamaha any leaking, have the machine inspected dealer adjust it. Page Fuel Yamaha dealer. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Page 47 Fuel can spill, which can cause a fire hol containing methanol is not recommended and severe injury. If the damage or vehicle performance problems. Add oil as necessary. See page The coolant level will Removing the radiator cap when the en- vary with engine temperature.
The coolant gine and radiator are still hot. Page Chain Repair as necessary for proper operation. EBU Fittings and Fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque. Page Tires The following are minimums: 1. The tires listed below have been ap- Front Rear Other tire combina- tions are not recommended.
Use no more than the following Set tire pressures to the following specifica- pressures when seating the tire tions: beads. Front kPa 2. Page Operation 2. Shift the transmission into neutral.
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