Yamaha YFM660FP 2001 Assembly Manual
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Yamaha YFM660FP 2001 Assembly Manual

Yamaha YFM660FP 2001 Assembly Manual

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YFM660FP
ASSEMBLY MANUAL
LIT-11666-15-01
5KM-28107-10

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Summary of Contents for Yamaha YFM660FP 2001

  • Page 1 YFM660FP ASSEMBLY MANUAL LIT-11666-15-01 5KM-28107-10...
  • Page 2 Since some external parts of the Supplies Oils, greases, shop rags. machine have been removed at the Yamaha factory for the Workshop convenience of packing, assembly by the Yamaha dealer is required. It should be noted that the reassembled machine...
  • Page 3 SYMBOLS USED IN ASSEMBLY MANUAL In order to simplify descriptions in assembly manuals, the following symbols are used: : Coat with lithium soap base grease. : Tighten to 10 Nm. (10 Nm = 1.0 m • kg, 7.2 ft • lb) : Front ward of the machine.

  • Page 4: Parts Location

    PARTS LOCATION 1 Vinyl pack 2 Vinyl pack 3 Carton box 4 Carton box 5 Carton box 6 Rear wheel See view 7 Front wheel See view –1–...
  • Page 5 1 Vinyl pack Handlebar 2 Vinyl pack Vinyl bag 1 Throttle housing Rear brake cable Brake master cylinder Vinyl bag 2 Vinyl bag 3 Handlebar switch and panhead screws Rear brake light switch (lever) Handlebar holder and flange bolts Vinyl bag 4 Vinyl bag 5 Brake master cylinder bracket and flange bolts Throttle housing bracket and panhead...
  • Page 6 3 Carton box Rear shock absorbers 4 Carton box Vinyl bag 1 Battery bracket Handlebar cover Fuel tank breather hose Bands (handlebar) Handlebar holder and flange bolts Flange bolts (rear shock absorber) Owner’s tool kit and band Owner’s manual Low-pressure air gauge –3–...
  • Page 7 Vinyl bag 2 Self locking nuts (front and rear shock Flange bolts (battery bracket) Nuts (front and rear wheels) absorbers) Flange bolts (engine skid plate) Flange bolts and spring nuts (front protector) Bolts with plain washer (rear protector) –4–...

  • Page 8: Front Wheels

    5 Carton box Engine skid plate (front) Engine skid plate (center) Engine skid plate (rear) Protectors (front arms) Protectors (rear arms) Fuel tank side panels Electrolyte 6 Front wheels 7 Rear wheels –5–...
  • Page 9 UNPACKING 1. Remove the frame cover 1. 2. Remove the bolts 2 (lower handlebar holder). 3. Remove the bolt 3 and bracket (rear carrier). 4. Remove the packing frames 4. (upward and sideways) 5. Remove the stays 5. (left and right rear arms) –6–...

  • Page 10: Setup Procedures

    SETUP PROCEDURES NOTE: • After opening the crate, place the ATV on a suitable rack and follow the setup procedures. • Before starting the setup, supply the specified tire pressure to the four wheels. WARNING This model is equipped with low pressure tires. Refer to “ADJUSTMENTS AND PREDELIVERY SERVICE”.

  • Page 11: Front Brake Master Cylinder

    1. Handlebar Handlebar 1 - S 2 - V Handlebar holder (upper) 4 - V 2 - V d = 8 (0.31), R= 30 (1.18) Flange bolt 4 - V A: The handlebar holders should be Tightening torque: installed with the punched mark 20 Nm (2.0 m •...

  • Page 12: Handlebar Switch

    4. Rear brake cable and rear brake light switch Rear brake cable Rear brake light switch 5. Handlebar switch Handlebar switch Panhead screw 2 - V d = 5 (0.20), R= 30 (1.17) A: Tighten the screws in stages and maintain an equal gap on each side of the handlebar switch.

  • Page 13: Handlebar Cover

    7. Handlebar cover Handlebar cover 4 - C Fuel tank breather hose 4 - V A: Pass the breather hose through the hole on the handlebar cover. NOTE: Refer to “CABLE ROUTING”. 8. Front shock absorbers Flange bolt 4 - V d = 10 (0.39), R= 48 (1.89) Self lock nut 5 - V...

  • Page 14: Rear Shock Absorbers

    10. Rear shock absorbers Rear shock absorber 3 - C Flange bolt 4 - V d = 10 (0.39), R= 48 (1.89) Self lock nut 4 - V d = 10 (0.39) A: Tighten the nuts to specified torque. Tightening torque: 45 Nm (4.5 m •...

  • Page 15: Engine Skid Plates

    13. Rear wheels Rear wheel 7 - S 4 - V d = 10 (0.39) A: Install the wheels so that air valve is outside. B: The arrow mark on the tire must point toward the rotating direction of the wheel. C: Tighten the nuts to specified torque.
  • Page 16 16. Battery Battery Battery bracket 4 - C Flange bolt 4 - V d = 6 (0.24), R= 12 (0.47) d = 6 (0.24), R= 16 (0.63) Bolt A: NOTE: C: First, connect the + lead (red Before installing the battery, refer lead) to the + terminal.

  • Page 17: Cable Routing

    CABLE ROUTING CAUTION: Proper cable and lead routing is essential to insure safe machine operation. Rear brake light switch Rear brake cable Starter cable Front brake hose Throttle cable Battery negative lead Battery positive lead Å Clamp the handlebar switch lead and rear brake light switch lead.
  • Page 18 ADJUSTMENTS AND PREDELIVERY SERVICE CHI A KLMO –15–...

  • Page 19: Battery Inspection

    A. Battery inspection 1. Fill: h. Be certain that all the electrolyte has been drained from container. CAUTION: Fit the strip of caps (battery plugs) securely into the • filler ports. Make sure the top of the strip is at the Never remove the sealing sheet (aluminium same level as the top of the battery.
  • Page 20 B. Tire pressure measurement 1. Check: WARNING a. Use an appropriate low-pressure tire gauge. Set This model is equipped with low pressure tires. tire pressures to the following specifications: Pay attention to the following points: Recommended tire pressure: Reference tire pressure: Front: 35 kPa (0.35 kgf/cm , 5.0 psi) Front: 35 kPa (0.35 kgf/cm...

  • Page 21: Final Gear Oil Level Inspection

    E. Differential gear oil level inspection 1. Place the machine on a level place. CAUTION: 2. Remove: • Take care not allow foreign material to enter the Oil filler bolt 1 differential gear case. 3. Check: • Oil level 4. Install: Oil level should be up to the brim of hole.

  • Page 22: Starter Cable Adjustment

    H. Starter cable adjustment • 1. Remove: Pull back the boot • • Seat Loosen the locknut • • Fuel tank side panel (left) Turn the adjuster in or out until the correct 2. Adjust: distance is obtained. • Disconnect the starter cable from the carburetor body.

  • Page 23: Rear Brake Light Switch Adjustment

    K. Rear brake adjustment • Turn the brake lever cable adjuster (handlebar) 2 WARNING until the rear brake lever free play d is within the Always adjust both the brake pedal and the rear specified limits. brake lever whenever adjusting the rear brake. Rear brake lever free play: 1.

  • Page 24: Brake Fluid Level Inspection

    Å M. Brake fluid level inspection 1. Place the machine on a level surface. CAUTION: Brake fluid may erode painted surfaces or plastic NOTE: parts. Always clean up spilled fluid immediately. When inspecting the brake fluid level, make sure that the top of the brake fluid reservoir top is horizontal.

  • Page 25: Front Shock Absorber Adjustment

    O. Select lever control cable and shift rod adjustment • When the brake begins to work “a = 20 ~ 30 mm WARNING (0.8 ~ 1.2 in)”, verify that the select lever can be Before moving the select lever, bring the machine shifted to REVERSE from NEUTRAL and to NEU- to a complete stop and return the throttle lever to TRAL from REVERSE.

  • Page 26: Headlight Beam Adjustment

    R. Headlight beam adjustment 1. Adjust: • Headlight beam (vertically) Turn the adjuster 1 in or out. Turning in Headlight beam raised. Turning out Headlight beam lowered. –23–...

  • Page 27: Service Data

    APPENDICES SERVICE DATA YFM660FP Idling engine speed: 1,450 ~ 1,550 r/min Spark plug: Type DPR8EA-9/NGK 0.8 ~ 0.9 mm (0.031 ~ 0.035 in) Fuel: Recommended fuel UNLEADED FUEL Fuel tank capacity 20 L (4.40 Imp gal, 5.28 US gal) Valve clearance (cold): 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) 0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in) STANDARD EQUIPMENT...

  • Page 28: Tightening Torque

    TIGHTENING TORQUE Tightening torque Part to be tightened Thread size m • kg ft • lb Engine: Spark plug – Engine oil drain bolt Chassis: Engine bracket and engine Engine bracket and rubber damper (front) Engine bracket and rubber damper (front) Engine and rubber damper (rear) Engine and rubber damper (rear) Rubber damper and frame...
  • Page 29 Tightening torque Part to be tightened Thread size m • kg ft • lb Gear motor and differential gear case cover Universal joint yoke and drive pinion gear Final drive gear case and frame Final drive gear case filler plug Final drive gear case drain bolt Final drive gear oil check bolt Ring gear bearing housing and final drive gear case...
  • Page 30 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.

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