Yamaha YFM660FS Manuals

Manuals and User Guides for Yamaha YFM660FS. We have 2 Yamaha YFM660FS manuals available for free PDF download: Supplementary Service Manual, Owner's Manual

Yamaha YFM660FS Supplementary Service Manual

Yamaha YFM660FS Supplementary Service Manual (478 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 26.05 MB

Table of Contents

Table of Contents

6
- Important Information
  3
- General Information
  7
  - Features
    7
    
    Override Switch (Deactivating the Speed Limiter When the Differential Is Locked)
    7
- Specifications
  9
  - General Specifications
    9
  - Maintenance Specifications
    10
    
    Engine
    10
    
    Chassis
    11
    
    Electrical
    11
- Chassis
  12
  - Steering System
    12
    
    Installing the Rear Brake Lever
    12
- Electrical
  13
  - Checking the Switch
    13
    
    Checking the Switch Continuity
    13
  - Signal System
    15
    
    Circuit Diagram
    15
- Yfm660Fs Wiring Diagram
  18
  - Front Constant Velocity Joints/Differential Gear
    55
  - Cooling System
    76
  - Chassis
    76
Table of Contents

77
- General Information
  78
- Specifications
  78
- Engine
  80
- Cooling System
  83
- Carburetion
  84
- Drive Train
  84
- Chassis
  85
- Troubleshooting
  88
- Chapter 1. General Information
  
  90
  - Gen Info
    90
  - Machine Identification
    90
    
    Vehicle Identification Number
    90
    
    Model Label
    90
  - Features
    91
    
    Front Differential
    91
    
    Transmission
    98
  - Important Information
    99
    
    Preparation for Removal Procedures
    99
    
    Replacement Parts
    99
    
    Gaskets, Oil Seals and O-Rings
    99
    
    Lock Washers/Plates and Cotter Pins
    100
    
    Bearings and Oil Seals
    100
    
    Circlips
    100
  - Checking of Connections
    101
  - Special Tools
    102
- Chapter 2. Specifications
  
  107
  - General Specifications
    107
  - Maintenance Specifications
    110
    
    Engine
    110
    
    Chassis
    120
    
    Electrical
    124
  - General Torque Specifications
    126
  - How to Use the Conversion Table
    126
  - Lubrication Points and Lubricant Types
    127
    
    Engine
    127
  - Coolant Flow Diagrams
    128
  - Oil Flow Diagrams
    130
  - Cable Routing
    133
- Chapter 3. Periodic Checks and Adjustments
  
  148
  - Introduction
    148
  - Periodic Maintenance/Lubrication Intervals
    148
  - Seat, Carriers, Fenders and Fuel Tank
    150
    
    Seat and Side Panels
    150
    
    Front Carrier, Front Bumper and Front Grill
    151
    
    Handlebar Cover, Fuel Tank Cover and Front Fender
    152
    
    Rear Carrier and Rear Fender
    154
    
    Engine Skid Plate (Center) and Engine Skid Plate (Rear)
    156
    
    Fuel Tank
    157
  - Footrest Boards
    159
  - Engine
    160
    
    Adjusting the Valve Clearance
    160
    
    Adjusting the Timing Chain
    163
    
    Adjusting the Idling Speed
    164
    
    Adjusting the Throttle Lever Free Play
    164
    
    Adjusting the Speed Limiter
    166
    
    Adjusting the Starter Cable
    168
    
    Checking the Spark Plug
    168
    
    Checking the Ignition Timing
    169
    
    Measuring the Compression Pressure
    171
    
    Checking the Engine Oil Level
    173
    
    Changing the Engine Oil
    174
    
    Cleaning the Air Filter
    177
    
    Checking the Coolant Level
    178
    
    Changing the Coolant
    179
    
    Checking the Coolant Temperature Warning Light
    183
    
    Checking the V-Belt
    184
    
    Cleaning the Spark Arrester
    184
  - Chassis
    186
    
    Adjusting the Rear Brake
    186
    
    Checking the Brake Fluid Level
    188
    
    Checking the Front Brake Pad
    190
    
    Checking the Rear Brake Pad
    190
    
    Checking the Brake Hose
    191
    
    Bleeding the Hydraulic Brake System
    191
    
    Adjusting the Select Lever Control Cable and Shift Rod
    193
    
    Adjusting the Rear Brake Light Switch
    194
    
    Checking the Final Gear Oil Level
    195
    
    Changing the Final Gear Oil
    195
    
    Checking the Differential Gear Oil
    196
    
    Changing the Differential Gear Oil
    197
    
    Checking the Constant Velocity Joint Dust Boot
    198
    
    Checking the Steering System
    198
    
    Adjusting the Toe-In
    199
    
    Adjusting the Front Shock Absorber
    200
    
    Adjusting the Rear Shock Absorber
    201
    
    Checking the Tire
    201
    
    Checking the Wheel
    203
    
    Checking and Lubricating the Cable
    204
    
    Lubricating the Levers, Pedal, Etc
    204
  - Electrical
    205
    
    Checking the Battery
    205
    
    Checking the Fuse
    211
    
    Adjusting the Headlight Beam
    212
    
    Changing the Headlight Bulb
    213
- Chapter 4. Engine
  
  214
  - Engine Removal
    214
    
    Air Ducts, Muffler and Exhaust Pipe
    214
    
    Select Lever Unit and Coolant Reservoir
    216
    
    Hoses and Leads
    217
    
    Engine Mounting Bolts
    218
    
    Installing the Engine
    220
  - Cylinder Head Cover
    221
    
    Removing the Cylinder Head Cover
    223
    
    Checking the Cylinder Head Cover
    223
    
    Checking the Tappet Cover
    224
    
    Installing the Cylinder Head Cover
    224
  - Rocker Arms
    225
    
    Removing the Rocker Arm
    227
    
    Checking the Rocker Arm
    227
    
    Installing the Rocker Arm
    228
  - Camshaft and Cylinder Head
    229
    
    Removing the Camshaft and Cylinder Head
    231
    
    Checking the Camshaft
    232
    
    Checking the Camshaft Sprocket
    232
    
    Checking the Decompression System
    232
    
    Checking the Timing Chain Guide
    233
    
    Checking the Timing Chain Tensioner
    233
    
    Checking the Cylinder Head
    233
    
    Installing the Camshaft and Cylinder Head
    234
  - Valves and Valve Springs
    237
    
    Removing the Valve and Valve Spring
    238
    
    Checking the Valve and Valve Spring
    239
    
    Installing the Valve and Valve Spring
    243
  - Cylinder and Piston
    245
    
    Removing the Piston
    246
    
    Checking the Cylinder and Piston
    246
    
    Checking the Piston Ring
    248
    
    Checking the Piston Pin
    249
    
    Installing the Piston
    249
    
    Installing the Cylinder
    250
  - Recoil Starter and Ac Magneto
    251
    
    Removing the Ac Magneto
    254
    
    Disassembling the Recoil Starter
    254
    
    Checking the Ac Magneto
    254
    
    Checking the Starter Clutch
    255
    
    Checking the Starter Pulley
    256
    
    Checking the Recoil Starter
    256
    
    Assembleing the Recoil Starter
    256
    
    Installing the Ac Magneto
    257
  - Balancer Gears and Oil Pump Gears
    260
    
    Removing the Balancer Drive Gear and Balancer Driven Gear
    261
    
    Removing the Balancer Drive Gear and Buffer Boss
    261
    
    Checking the Oil Pump Drive
    261
    
    Checking the Balancer Drive
    262
    
    Installing the Balancer Drive Gear and Balancer Driven Gear
    262
  - Primary and Secondary Sheaves
    264
    
    Primary Sheave
    266
    
    Secondary Sheave
    267
    
    Removing the Primary and Secondary Sheaves
    268
    
    Disassembling the Secondary Sheave
    268
    
    Cheking the Primary Sheave
    269
    
    Checking the Secondary Sheave
    269
    
    Assembling the Primary Sheave
    270
    
    Assembling the Secondary Sheave
    270
    
    Installing the Primary and Secondary Sheaves
    272
  - Clutch
    273
    
    Removing the Clutch
    275
    
    Checking the Clutch
    275
    
    Installing the Clutch
    276
  - Crankcase
    278
    
    Starter Motor, Timing Chain and Oil Filter
    278
    
    Crankcase
    279
    
    Crankcase Bearing
    281
    
    Separating the Crankcase
    282
    
    Checking the Timing Chain and Guide
    282
    
    Checking the Oil Delivery Pipe
    282
    
    Checking the Crankcase
    283
    
    Checking the Bearings
    283
    
    Assembling the Crankcase
    283
    
    Installating the Shift Lever
    284
  - Crankshaft and Oil Pump
    285
    
    Oil Pump
    286
    
    Removing the Crankshaft
    287
    
    Checking the Oil Pump
    287
    
    Checking the Relief Valve
    288
    
    Checking the Oil Strainer
    288
    
    Assembling the Oil Pump
    288
    
    Checking the Crankshaft
    289
    
    Installing the Crankshaft and Balancer
    290
    
    Transmission
    291
    
    Removing the Transmission
    294
    
    Checking the Shift Fork
    294
    
    Checking the Shift Cam
    295
    
    Checking the Drive Axle
    295
    
    Checking the High Wheel Gear and Middle Drive Gear
    295
    
    Checking the Secondary Shaft and Driven Sprocket
    296
    
    Checking the Chain
    296
    
    Checking the Stopper Lever and Stopper Wheel
    296
    
    Assembling the Shift Fork Assembly
    297
    
    Installing the Transmission
    297
  - Middle Gear
    298
    
    Middle Drive Shaft
    298
    
    Middle Driven Shaft
    299
    
    Removing the Middle Drive Shaft
    301
    
    Removing the Middle Driven Shaft
    301
    
    Checking the Pinion Gear
    304
    
    Middle Drive and Driven Gear Shim Selection
    304
    
    Installing the Middle Driven Shaft
    307
    
    Installing the Middle Drive Shaft
    309
    
    Measuring the Middle Gear Backlash
    310
- Chapter 5. Cooling System
  
  311
  - Radiator
    311
    
    Checking the Radiator
    313
    
    Installing the Radiator
    314
  - Thermostat
    315
    
    Checking the Thermostat
    316
    
    Installing the Thermostat
    316
  - Water Pump
    317
    
    Disassembling the Water Pump
    319
    
    Checking the Water Pump
    319
    
    Assembling the Water Pump
    320
- Chapter 6. Carburetion
  
  322
  - Carburetor
    323
    
    Disassembling the Carburetor
    325
    
    Checking the Carburetor
    325
    
    Assembling the Carburetor
    327
    
    Adjusting the Fuel Level
    328
- Chapter 7. Drive Train
  
  329
- Chapter 8. Chassis
  
  361
  - Front Wheels and Brake Discs
    361
    
    Checking the Front Wheel
    363
    
    Checking the Front Wheel Hub
    363
    
    Checking the Front Brake Disc
    364
    
    Installing the Front Wheel Hub
    364
    
    Installing the Front Wheel
    364
  - Rear Wheels and Brake Disc
    366
    
    Rear Wheels
    366
    
    Rear Brake Disc
    367
    
    Checking the Rear Wheel
    368
    
    Checking the Rear Wheel Hub
    368
    
    Checking the Rear Brake Disc
    368
    
    Installing the Rear Wheel Hub
    369
    
    Installing the Rear Wheel
    369
  - Front and Rear Brakes
    370
    
    Front Brake Pads
    370
    
    Rear Brake Pads
    371
    
    Replacing the Front Brake Pad
    372
    
    Replacing the Rear Brake Pad
    374
    
    Front Brake Master Cylinder
    376
    
    Rear Brake Master Cylinder
    378
    
    Checking the Master Cylinder
    381
    
    Assembling the Front Brake Master Cylinder
    382
    
    Assembling the Rear Brake Master Cylinder
    382
    
    Installing the Front Brake Master Cylinder
    383
    
    Installing the Rear Brake Master Cylinder
    384
    
    Front Brake Caliper
    386
    
    Rear Brake Caliper
    388
    
    Disassembling the Brake Caliper
    390
    
    Disassembling the Rear Brake Caliper
    390
    
    Checking the Front and Rear Brake Caliper
    391
    
    Assembling the Front Brake Caliper
    392
    
    Installing the Front Brake Caliper
    392
    
    Assembling the Rear Brake Caliper
    394
    
    Installing the Rear Brake Caliper
    395
    
    Handlebar
    396
    
    Steering System
    396
    
    Removing the Rear Brake Switch
    397
    
    Checking the Handlebar
    397
    
    Installing the Handlebar
    397
    
    Installing the Rear Brake Lever
    397
    
    Installing the Master Cylinder Assembly
    398
    
    Steering Stem
    399
    
    Removing the Bearing Retainer
    401
    
    Checking the Steering Stem
    401
    
    Installing the Bearing Retainer
    401
    
    Installing the Steering Stem
    401
    
    Installing the Cable Guide
    402
    
    Tie Rod and Steering Knuckle
    403
    
    Removing the Steering Knuckle
    404
    
    Checking the Tie Rod
    404
    
    Checking the Steering Knuckle
    404
    
    Checking the Ball Joint
    405
    
    Checking the Tie Rod
    405
  - Front Arms and Front Shock Absorber
    406
    
    Removing the Front Arms
    408
    
    Checking the Front Arm
    408
    
    Checking the Front Shock Absorber
    408
    
    Installing the Front Arms and Front Shock Absorber
    409
  - Rear Knuckle and Stabilizer
    410
    
    Checking the Rear Knuckle
    411
    
    Checking the Stabilizer
    411
  - Rear Arms and Rear Shock Absorber
    412
    
    Checking the Rear Arm
    413
    
    Checking the Rear Shock Absorber
    413
    
    Checking the Rear Arms and Rear Shock Absorber
    413
- Chapter 9
  
  415
  - Electrical
    415
  - Electrical Components
    415
  - Checking the Switch
    416
    
    Checking a Switch Shown in the Manual
    416
    
    Checking the Switch Continuity
    418
  - Checking the Bulbs and Bulb Sockets
    420
    
    Types of Bulbs
    420
    
    Checking the Condition of the Bulbs
    420
    
    Checking the Condition of the Bulb Sockets
    422
    
    CHECKING the Leds
    422
  - Ignition System
    423
    
    Circuit Diagram
    423
    
    Troubleshooting
    424
  - Electric Starting System
    429
    
    Circuit Diagram
    429
    
    Starting Circuit Operation
    430
    
    Troubleshooting
    431
    
    Starter Motor
    431
    
    Checking the Starter Motor
    436
    
    Assembling the Starter Motor
    437
  - Charging System
    438
    
    Circuit Diagram
    438
    
    Troubleshooting
    439
  - Lighting System
    441
    
    Circuit Diagram
    441
    
    Troubleshooting
    442
    
    Checking the Lighting System
    444
  - Signal System
    446
    
    Circuit Diagram
    446
    
    Troubleshooting
    448
    
    Checking the Signal System
    450
    
    Circuit Diagram
    461
    
    Troubleshooting
    462
  - 2Wd/4Wd Selecting System
    466
    
    Circuit Diagram
    466
    
    Troubleshooting
    471
  - Starting Failure/Hard Starting
    471
- Chapter 10
  
  471
  - Electrical System
    471
  - Fuel System
    471
  - Compression System
    472
  - Poor Idle Speed Performance
    472
  - Poor Medium and High-Speed Performance
    472
  - Faulty Drive Train
    473
  - Faulty Clutch Performance
    474
    
    Engine Operates but Machine will Not Move
    474
    
    Clutch Slipping
    474
    
    Poor Starting Performance
    474
    
    Poor Speed Performance
    475
  - Faulty Gear Shifting
    474
    
    Hard Shifting
    474
    
    Shift Lever Does Not Move
    474
    
    Jumps out of Gear
    474
  - Faulty Brake
    475
    
    Poor Braking Effect
    475
  - Overheating
    475
  - Shock Absorber Malfunction
    476
  - Unstable Handling
    476
    
    Lighting System
    476
    
    Headlight Dark
    476
    
    Bulb Burnt out
    476

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Yamaha YFM660FS Owner's Manual

Yamaha YFM660FS Owner's Manual (191 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 10.5 MB

Table of Contents

Warning

4
Important Notice
5
Table of Contents
6
1 Location of the Warning and Specification Labels

10
2 Safety Information

14
3 Description and Machine Identification

20
- Identification Number Records
  21
- Key Identification Number
  21
- Vehicle Identification Number
  22
- Model Label
  22
- Control Functions
  23
- Main Switch
  23
- Indicator and Warning Lights
  24
- Speedometer Unit
  26
- Fuel Gauge
  28
- Handlebar Switches
  28
- Throttle Lever
  35
- Speed Limiter
  36
- Front Brake Lever
  37
- Rear Brake Pedal and Lever
  37
- Drive Select Lever
  38
- Recoil Starter
  38
- Fuel Tank Cap
  39
- Fuel Cock
  40
- Starter (Choke)
  41
- Seat
  42
- Storage Compartment
  43
- Front Carrier
  43
- Rear Carrier
  43
- Front and Rear Shock Absorber Adjustment
  44
- Auxiliary DC Jack
  46
  - Pre-Operation Checks
    48
  - Front and Rear Brakes
    50
  - Fuel
    52
  - Engine Oil
    54
  - Final Gear Oil
    54
  - Differential Gear Oil
    55
  - Coolant
    56
  - Throttle Lever
    57
  - Fittings and Fasteners
    57
  - Lights
    57
  - Switches
    57
  - Tires
    58
  - How to Measure Tire Pressure
    60
  - Tire Wear Limit
    61
6 Operation

62
- Starting a Cold Engine
  62
- Starting a Warm Engine
  64
- Warming up
  64
- Drive Select Lever Operation and Reverse Driving
  65
- Engine Break-In
  68
- Parking
  69
- Parking on a Slope
  70
- Accessories and Loading
  71
- Riding Your Atv
  75
- Getting to Know Your ATV
  77
- Ride with Care and Good Judgement
  78
- Be Careful Where You Ride
  90
- Turning Your ATV
  96
- Climbing Uphill
  98
- Riding Downhill
  104
- Crossing a Slope
  106
- Crossing through Shallow Water
  108
- Riding over Rough Terrain
  111
- Sliding and Skidding
  112
- What to Do if
  114
- What to Do
  114
8 Periodic Maintenance and Adjustment

116
- Owner's Manual and Tool Kit
  116
- Periodic Maintenance/Lubrication
  118
- Panel Removal and Installation
  120
- Engine Oil and Oil Filter Cartridge
  127
- Final Gear Oil
  132
- Differential Gear Oil
  134
- Cooling System
  136
- Axle Boots
  141
- Spark Plug Inspection
  142
- Air Filter Element Cleaning
  145
- Spark Arrester Cleaning
  148
- Carburetor Adjustment
  150
- Idle Speed Adjustment
  151
- Valve Clearance Adjustment
  151
- Throttle Lever Adjustment
  152
- Front Brake Pad Check
  152
- Rear Brake Pad Inspection
  153
- Inspecting the Brake Fluid Level
  153
- Brake Fluid Replacement
  155
- Front Brake Lever Free Play
  156
- Rear Brake Lever and Pedal Adjustment
  157
- Adjusting the Rear Brake Light Switch
  159
- Cable Inspection and Lubrication
  159
- Brake Lever and Brake Pedal Lubrication
  160
- Rear Knuckle Upper and Lower Pivot Lubrication
  161
- Wheel Removal
  161
- Wheel Installation
  162
- Battery
  163
- Battery Maintenance
  164
- Fuse Replacement
  164
- Replacing a Headlight Bulb
  166
- Headlight Beam Adjustment
  167
- Tail/Brake Light Bulb Replacement
  168
- Troubleshooting
  168
- Troubleshooting Charts
  170
- 9 Cleaning and Storage
  
  172
  - Cleaning
    172
  - Storage
    174
10 Specifications

176
11 Noise Regulation

182
12 Maintenance Record

183
13 Atv Limited Warranty

184
14 Yamaha Extended Service (Y.e.s.)

186

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