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Yamaha YFM660FR Supplementary Service Manual

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YFM660FR
5KM2-AE2
SUPPLEMENTARY
SERVICE MANUAL

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Summary of Contents for Yamaha YFM660FR

  • Page 1 YFM660FR 5KM2-AE2 SUPPLEMENTARY SERVICE MANUAL...
  • Page 3 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YFM660FR. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. YFM660F(P) 2002 SERVICE MANUAL: 5KM2-AE1...
  • Page 4 EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair.
  • Page 5 EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.
  • Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 0 are printed on the SPEC INFO top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetion 7 Drive train COOL...

  • Page 7: Table Of Contents

    CONTENTS GENERAL INFORMATION ................1 SPECIAL TOOLS ..................1 SPECIFICATIONS ....................2 GENERAL SPECIFICATIONS ..............2 MAINTENANCE SPECIFICATIONS ............3 ENGINE ....................3 ELECTRICAL ..................3 TIGHTENING TORQUES .................4 CABLE ROUTING ..................5 PERIODIC CHECKS AND ADJUSTMENTS ..........12 INTRODUCTION ..................12 PERIODIC MAINTENANCE/LUBRICATION ...........12 SEAT, CARRIERS, FENDERS AND FUEL TANK ........14 FRONT CARRIER, FRONT BUMPER AND FRONT GRILL ....14 FUEL TANK ..................15 FOOTREST BOARDS ................17...
  • Page 8 CHASSIS ......................37 FRONT WHEELS AND BRAKE DISCS ..........37 FRONT WHEELS ................37 REAR WHEELS AND BRAKE DISC ............39 REAR WHEELS ..................39 STEERING SYSTEM ................40 TIE ROD AND STEERING KNUCKLE ..........40 CHECKING THE STEERING KNUCKLE ..........42 REAR KNUCKLE AND STABILIZER ............43 CHECKING THE REAR KNUCKLE ............44 REAR ARMS AND REAR SHOCK ABSORBER ........45...

  • Page 9: General Information

    SPECIAL TOOLS INFO GENERAL INFORMATION EB102001 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country.

  • Page 10: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 5KM9: (for CDN) 5KMB: (for Europe) 5KMC: (for Oceania) Bulb wattage × quantity: 12 V 30 W/30 W × 2 Headlight 12 V 5 W/21 W × 1 Tail/brake light Indicator lights LED ×...

  • Page 11: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Oil pump: Oil filter type Foam ---- Oil pump type Trochoid ---- Tip clearance “A” or “B” 0.03 ~ 0.10 mm 0.15 mm (0.0012 ~ 0.0039 in) (0.006 in) Side clearance 0.03 ~ 0.10 mm 0.17 mm (0.0012 ~ 0.0039 in)

  • Page 12: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES Engine tightening torques Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m·kg ft·lb Exhaust pipe protector Bolt Oil seal retainer Screw Chassis tightening torques Tightening torque Part to be tightened Thread size Remarks m·kg ft·lb...

  • Page 13: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Fuel sender lead 8 Ground lead G Gear position switch coupler 2 Differential gear case and final 9 Speed sensor lead H Speed sensor coupler 0 AC magneto lead I Radiator fan breather hose drive gear case breather hose 3 Vacuum chamber breather hose A Carburetor breather hose...
  • Page 14 SPEC CABLE ROUTING È Fasten the final drive gear case breather hose, speed sensor lead, ground lead, gear position switch lead, AC magneto lead, wire harness, and reverse indicator light lead with a plastic locking tie. Be careful not to pinch the breather hose.
  • Page 15 SPEC CABLE ROUTING Î Pass the vacuum chamber breather hose through the plastic cover hole. Ï Insert a hook into the third hole from the bottom of the rectifier/regulator bracket, and then fasten the final drive gear case breather hose onto the hook. È...
  • Page 16 SPEC CABLE ROUTING 1 Gear position switch B Rear brake hose 2 Reverse switch 3 Crankcase breather hose È Pass the rear brake cable and throttle cable 4 Select lever control cable through the cable guide. 5 Rear brake cable É...
  • Page 17 SPEC CABLE ROUTING Ê Clamp the spark plug lead and radiator inlet hose with a plastic clip. Ë When installing the ignition coil, face the spark plug lead to the right side of the frame. Ì To the rear fender hole Í...
  • Page 18 SPEC CABLE ROUTING 1 Front brake hose È Pass the thermo sensor 1 lead through the lead 2 Throttle cable guide. 3 Thermo switch 1 lead É Pass the crankcase breather hose through the 4 Crankcase breather hose hose guide. 5 Fuel sender lead Ê...
  • Page 19 SPEC CABLE ROUTING Î Fasten the wire harness speed sensor coupler, thermo switch 1 lead, reverse switch lead, and ground lead with a plastic locking tie. Í A - A Ì Ë Î È É C - C Ê – 11 –...

  • Page 20: Periodic Checks And Adjustments

    INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 21 • Check for cracks or damage. Fittings and Fasten- • Check all chassis fittings and fasteners. ers* • Correct if necessary. It is recommended that these items be serviced by a Yamaha dealer. ** Lithium-soap-based grease NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement: 1.When disassembling the master cylinder or caliper, replace the brake fluid.

  • Page 22: Seat, Carriers, Fenders And Fuel Tank

    SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT, CARRIERS, FENDERS AND FUEL TANK FRONT CARRIER, FRONT BUMPER AND FRONT GRILL 33 Nm (3.3 m kg, 24 ft • • 33 Nm (3.3 m kg, 24 ft • • 9 Nm (0.9 m kg, 6.5 ft •...

  • Page 23: Fuel Tank

    SEAT, CARRIERS, FENDERS AND FUEL TANK FUEL TANK Order Job name/Part name Q’ty Remarks Removing the fuel tank Remove the parts in the order below. Seat and side panels Refer to “SEAT AND SIDE PANELS” in CHAPTER 3. (Manual No.: 5KM2-AE1) Fuel tank cover Refer to “HANDLEBAR COVER, FUEL TANK COVER AND FRONT FENDER”...
  • Page 24 SEAT, CARRIERS, FENDERS AND FUEL TANK Order Job name/Part name Q’ty Remarks Clamp Vacuum chamber breather hose Differential gear case breather hose Crankcase breather hose Plastic band Bushing Plastic cover For installation, reverse the removal procedure. – 16 –...

  • Page 25: Footrest Boards

    FOOTREST BOARDS FOOTREST BOARDS 9 Nm (0.9 m kg, 6.5 ft • • (12) (12) 33 Nm (3.3 m kg, 24 ft • • Order Job name/Part name Q’ty Remarks Removing the footrest boards Remove the parts in the order below. Fuel tank side panels Refer to “SEAT AND SIDE PANELS”...

  • Page 26: Engine

    CHECKING THE STARTER CABLE ENGINE CHECKING THE STARTER CABLE 1.Remove: Seat Fuel tank side panel (left) 2.Check: Starter cable Unsmooth operation → Replace. ***************************************************** Checking steps: Disconnect the starter cable 1 from the car- buretor body. NOTE: Do not remove the starter plunger 2 from the starter cable.

  • Page 27: Engine

    CAMSHAFT AND CYLINDER HEAD ENGINE CAMSHAFT AND CYLINDER HEAD Order Job name/Part name Q’ty Remarks Removing the camshaft and cylin- Remove the parts in the order below. der head Seat/front fender Refer to “SEAT, CARRIERS, FEND- ERS AND FUEL TANK” in CHAPTER 3. Fuel tank/plastic covers (Manual No.: 5KM2-AE1) Carburetors...
  • Page 28 CAMSHAFT AND CYLINDER HEAD Order Job name/Part name Q’ty Remarks Cylinder head cover Refer to “CYLINDER HEAD COVER” in CHAPTER 4. (Manual No.: 5KM2-AE1) Timing chain tensioner cap bolt Timing chain tensioner/gasket Refer to “REMOVING/INSTALLING THE Timing chain guide (exhaust) CAMSHAFT AND CYLINDER HEAD”...

  • Page 29: Recoil Starter And Ac Magneto

    RECOIL STARTER AND AC MAGNETO RECOIL STARTER AND AC MAGNETO Order Job name/Part name Q’ty Remarks Removing the AC magneto Remove the parts in the order below. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3. (Manual No.: 5KM2-AE1) Coolant Drain.
  • Page 30 RECOIL STARTER AND AC MAGNETO Order Job name/Part name Q’ty Remarks Starter pulley Refer to “REMOVING/INSTALLING THE Crankcase cover (left)/gasket AC MAGNETO” in CHAPTER 4. (Manual No.: 5KM2-AE1) Dowel pin Lead holder Pickup coil Starter assembly CDI rotor Refer to “REMOVING/INSTALLING THE Woodruff key AC MAGNETO”...

  • Page 31: Checking The Starter Clutch

    RECOIL STARTER AND AC MAGNETO CHECKING THE STARTER CLUTCH 1.Check: Starter clutch 1 Cracks/damage → Replace. Bolts 2 (starter clutch) Loose → Replace with new ones, and clinch the end of the bolts. NOTE: The arrow mark on the starter clutch must face inward, away from the CDI rotor.

  • Page 32: Middle Gear

    MIDDLE GEAR MIDDLE GEAR MIDDLE DRIVEN SHAFT Order Job name/Part name Q’ty Remarks Disassembling the middle driven Remove the parts in the order below. shaft Crankcase separation Refer to “CRANKCASE” in CHAPTER 4. (Manual No.: 5KM2-AE1) Front drive shaft coupling Refer to “INSTALLING/REMOVING THE Coupling gear MIDDLE DRIVEN SHAFT”.
  • Page 33 MIDDLE GEAR Order Job name/Part name Q’ty Remarks Bearing retainer Middle driven shaft For installation, reverse the removal procedure. – 25 –...

  • Page 34: Removing The Middle Driven Shaft

    MIDDLE GEAR REMOVING THE MIDDLE DRIVEN SHAFT 1.Remove: Nut 1 Washer Front drive shaft coupling NOTE: Use the coupling gear holding tool 2 to hold the front drive shaft coupling. Coupling gear holding tool: P/N. YM-01486, 90890-01486 2.Remove: Nut 1 Washer Coupling gear 2 NOTE:...
  • Page 35 MIDDLE GEAR 4.Remove: Bearing retainer Bearing ***************************************************** Removal steps: Place a rag 1 in the vise. Secure the bearing housing edge in the vise. Attach the bearing retainer wrench 2. Bearing retainer wrench: P/N. YM-04128, 90890-04128 CAUTION: The middle driven shaft bearing retainer has left-handed threads.

  • Page 36: Installing The Middle Driven Shaft

    MIDDLE GEAR INSTALLING THE MIDDLE DRIVEN SHAFT 1.Install: Bearing retainer 1 80 Nm (8.0 m • kg, 58 ft • lb) NOTE: Attach the ring nut wrench 2. Ring nut wrench: P/N. YM-38404, 90890-01430 CAUTION: The middle driven shaft bearing retainer has left-handed threads.
  • Page 37 MIDDLE GEAR 4.Install: Front drive shaft coupling Washer Nut 1 97 Nm (9.7 m • kg, 70 ft • lb) NOTE: Use the coupling gear holding tool 2 to hold the front drive shaft coupling. Coupling gear holding tool: P/N. YM-01486, 90890-01486 –...

  • Page 38: Drive Train

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR DRIVE TRAIN FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR 55 Nm (5.5 m kg, 40 ft • • Order Job name/Part name Q’ty Remarks Removing the front constant veloc- Remove the parts in the order below. ity joint and differential gear Engine skid plate (front) Refer to “SEAT, CARRIERS, FENDERS...
  • Page 39 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 55 Nm (5.5 m kg, 40 ft • • Order Job name/Part name Q’ty Remarks Differential gear case breather hose Disconnect. Differential gear Compression spring Drive shaft assembly For installation, reverse the removal procedure.
  • Page 40 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Disassembling the differential gear Remove the parts in the order below. Gear motor/O-ring NOTE: Do not disassemble the gear motor or remove the pinion gear. Coupling gear/O-ring Refer to “DISASSEMBLING/ASSEM- BLING THE DIFFERENTIAL GEAR”.
  • Page 41 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job name/Part name Q’ty Remarks Differential gear assembly Shim (right) Circlip/bearing Drive pinion gear Differential gear case For assembly, reverse the disassembly procedure. – 33 –...

  • Page 42: Disassembling The Differential Gear

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR DISASSEMBLING THE DIFFERENTIAL GEAR 1.Remove: Coupling gear Use a coupling gear holding tool 1. Coupling gear holding tool: P/N. YM-01486, 90890-01486 CHECKING THE DIFFERENTIAL GEAR 1.Check: Gear teeth Pitting/galling/wear → Replace drive pinion gear and ring gear as a set.

  • Page 43: Assembling The Differential Gear

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 5.Check: Front drive shaft assembly operation Unsmooth operation → Replace the front drive shaft assembly. ASSEMBLING THE DIFFERENTIAL GEAR 1.Measure: Gear lash Refer to “MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH”. in CHAPTER 7.
  • Page 44 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 3.Install: Coupling gear O-ring Washer 62 Nm (6.2 m • kg, 45 ft • lb) Use a coupling gear holding tool 1. Coupling gear holding tool: P/N. YM-01486, 90890-01486 4.Check: Differential gear operation Unsmooth operation →...

  • Page 45: Chassis

    CHAS FRONT WHEELS AND BRAKE DISCS CHASSIS FRONT WHEELS AND BRAKE DISCS FRONT WHEELS 30 Nm (3.0 m kg, 22 ft • • 260 Nm (26.0 m kg, 190 ft • • 30 Nm (3.0 m kg, 22 ft • •...
  • Page 46 CHAS FRONT WHEELS AND BRAKE DISCS 30 Nm (3.0 m kg, 22 ft • • 260 Nm (26.0 m kg, 190 ft • • 30 Nm (3.0 m kg, 22 ft • • 55 Nm (5.5 m kg, 40 ft •...

  • Page 47: Rear Wheels And Brake Disc

    CHAS REAR WHEELS AND BRAKE DISC REAR WHEELS AND BRAKE DISC REAR WHEELS 260 Nm (26.0 m kg, 190 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job name/Part name Q’ty Remarks Removing the rear wheel Remove the parts in the order below.

  • Page 48: Steering System

    CHAS STEERING SYSTEM STEERING SYSTEM TIE ROD AND STEERING KNUCKLE 25 Nm (2.5 m kg, 18 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 25 Nm (2.5 m kg, 18 ft • • 48 Nm (4.8 m kg, 35 ft •...
  • Page 49 CHAS STEERING SYSTEM 25 Nm (2.5 m kg, 18 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 25 Nm (2.5 m kg, 18 ft • • 48 Nm (4.8 m kg, 35 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 50: Checking The Steering Knuckle

    CHAS STEERING SYSTEM CHECKING THE STEERING KNUCKLE 1.Check: Steering knuckle Damage/pitting → Replace. 2.Check: Front wheel bearings Bearings allow play in the wheel hubs or unsmooth wheel operation → Replace. Oil seals Damage → Replace. ***************************************************** Replacement steps: Clean the outside of the steering knuckle. Remove the circlip 1.

  • Page 51: Rear Knuckle And Stabilizer

    CHAS REAR KNUCKLE AND STABILIZER REAR KNUCKLE AND STABILIZER 30 Nm (3.0 m kg, 22 ft • • 48 Nm (4.8 m kg, 35 ft • • 45 Nm (4.5 m kg, 32 ft • • 48 Nm (4.8 m kg, 35 ft •...

  • Page 52: Checking The Rear Knuckle

    CHAS REAR KNUCKLE AND STABILIZER CHECKING THE REAR KNUCKLE 1.Check: Rear knuckle Damage/pitting → Replace. 2.Check: Rear wheel bearings Bearings allow play in the wheel hubs or unsmooth wheel operation → Replace. Oil seals Damage → Replace. ***************************************************** Replacement steps: Clean the outside of the rear knuckle.

  • Page 53: Rear Arms And Rear Shock Absorber

    CHAS REAR ARMS AND REAR SHOCK ABSORBER REAR ARMS AND REAR SHOCK ABSORBER 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft •...
  • Page 56 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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