Yamaha YFM660RP 5LP2-AE2 2002 Supplemental Service Manual
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Yamaha YFM660RP 5LP2-AE2 2002 Supplemental Service Manual

Yamaha YFM660RP 5LP2-AE2 2002 Supplemental Service Manual

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2002
YFM660R
P
(
)
5LP2-AE2
SUPPLEMENTARY
SERVICE MANUAL

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Summary of Contents for Yamaha YFM660RP 5LP2-AE2 2002

  • Page 1 2002 YFM660R 5LP2-AE2 SUPPLEMENTARY SERVICE MANUAL...
  • Page 3 Supplementary Service Manual together with the following manual. YFM660R(N) 2001 SERVICE MANUAL: 5LP2-AE1 YFM660R(P) 2002 SUPPLEMENTARY SERVICE MANUAL ©2001 by Yamaha Motor Co., Ltd. First Edition, August 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 4: Important Information

    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: How To Use This Manual

    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 9 are printed on the SPEC top right of each page and indicate the subject INFO of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments CHAS 4 Chassis 5 Engine 6 Cooling system 7 Carburetion 8 Electrical...

  • Page 7: Table Of Contents

    CONTENTS SPECIFICATIONS ....................1 GENERAL SPECIFICATIONS ..............1 MAINTENANCE SPECIFICATIONS ............2 ENGINE ....................2 CHASSIS ....................6 CABLE ROUTING ..................7 PERIODIC CHECKS AND ADJUSTMENTS ............9 INTRODUCTION ..................9 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ......9 CHASSIS ....................11 ADJUSTING THE REAR SHOCK ABSORBER ........11 CHASSIS ......................14 REAR SHOCK ABSORBER AND RELAY ARM ........14 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER .................16 DISPOSING OF A REAR SHOCK ABSORBER...

  • Page 9: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 5LP6 : (For CDN) 5LP7 : (For Europe) Transmission: Primary reduction system Spur gear Primary reduction ratio 71/34 (2.088) Secondary reduction system Chain drive Secondary reduction ratio 40/13 (3.076) Transmission type Constant mesh, 5-speed/forward.

  • Page 10: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.03 mm (0.001 in) Timing chain: Timing chain type/No. of links 82RH2015/126 ---- Timing chain adjustment method Automatic ---- Rocker arm/rocker arm shaft: Bearing inside diameter 12.000 ~ 12.018 mm ---- (0.4724 ~ 0.4731 in)
  • Page 11 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem outside diameter 5.975 ~ 5.990 mm 5.945 mm (0.2352 ~ 0.2358 in) (0.2341 in) 5.960 ~ 5.975 mm 5.930 mm (0.2346 ~ 0.2352 in) (0.2335 in) Guide inside diameter 6.000 ~ 6.012 mm 6.040 mm (0.2362 ~ 0.2367 in) (0.2378 in)
  • Page 12 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston rings: Top ring Type Barrel ---- Dimensions (B × T) 1.2 × 3.8 mm ---- (0.0472 × 0.1496 in) End gap (installed) 0.30 ~ 0.45 mm 0.70 mm (0.0118 ~ 0.0177 in) (0.0276 in) Side clearance (installed) 0.04 ~ 0.08 mm 0.13 mm...
  • Page 13 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Carburetors: I. D. mark 5LP5 20 ---- Main jet (M.J) Carburetor #1 : #140 ---- Carburetor #2 : #145 ---- Main air jet (M.A.J) #130 ---- Jet needle (J.N) 5ND16-56-3 ---- Needle jet (N.J) P-6M (#826) ---- Pilot air jet...

  • Page 14: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Brake lever and brake pedal: Brake lever free play (at lever end) 0 mm (0 in) ---- Brake pedal position 4 mm (0.16 in) ---- (Below the top of footrest) Throttle lever free play 3 ~ 5 mm (0.12 ~ 0.20 in) ---- Tightening torques...

  • Page 15: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Carburetor air vent hose 0 Tail/brake light lead 2 Coolant reservoir hose A Rectifier/regulator lead 3 Reservoir tank breather hose 4 CDI unit È Pass the negative battery lead between the wire 5 Wire harness harness and frame.
  • Page 16 SPEC CABLE ROUTING 1 Positive battery lead È Fasten the wire harness with the plastic clamp. 2 Tail/brake light lead É Fasten the starter motor lead and starter relay 3 Coolant reservoir breather hose lead with the plastic clamp. 4 Negative battery lead 5 Coolant reservoir hose 6 Starter motor lead 7 Wire harness...

  • Page 17: Periodic Checks And Adjustments

    • Lubricate every 6 months.** 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 base grease – 9 –...
  • Page 18 PERIODIC MAINTENANCE/LUBRICATION INTERVALS NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement: 1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add fluid as required. 2.On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.

  • Page 19: Chassis

    ADJUSTING THE REAR SHOCK ABSORBER CHASSIS ADJUSTING THE REAR SHOCK ABSORBER 1.Adjust: Spring preload *********************************************** Adjustment steps: Elevate the rear wheels by placing a suitable stand under the frame. Loosen the locknut 1. Turn the adjusting ring 2 in direction a or Spring preload is Direction a increased (suspension...
  • Page 20 ADJUSTING THE REAR SHOCK ABSORBER 2.Adjust: Rebound damping force *********************************************** Adjustment steps: Turn the adjusting screw 1 in direction a or Rebound damping force Direction a is increased. Rebound damping force Direction b is decreased. From the fully turned-out position: Standard: 7 clicks in Minimum: 1 clicks in Maximum: 12 clicks in...
  • Page 21 ADJUSTING THE REAR SHOCK ABSORBER CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. *********************************************** – 13 –...

  • Page 22: Chassis

    CHAS REAR SHOCK ABSORBER AND RELAY ARM CHASSIS REAR SHOCK ABSORBER AND RELAY ARM Order Job name/Part name Q’ty Remarks Removing the rear shock absorber Remove the parts in the order below. and relay arm Muffler/exhaust pipe Refer to “ENGINE REMOVAL” in CHAP- TER 5.
  • Page 23 CHAS REAR SHOCK ABSORBER AND RELAY ARM Order Job name/Part name Q’ty Remarks Self-locking nut/bolt Relay arm Spacer/oil seal/bushing 1/2/2 Refer to “INSTALLING THE RELAY ARM AND CONNECTING ARM”. Connecting arm Dust cover Spacer Spacer Bushing Refer to “INSTALLING THE RELAY ARM AND CONNECTING ARM”.

  • Page 24: Handling The Rear Shock Absorber And Gas Cylinder

    CHAS REAR SHOCK ABSORBER AND RELAY ARM HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following information.

  • Page 25: Removing The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER AND RELAY ARM REMOVING THE REAR SHOCK ABSORBER 1.Remove: Connecting arm-to-frame bolt Rear shock absorber upper bolt NOTE: While removing the connecting arm-to-frame bolt, hold the swingarm so that it does not drop down. CHECKING THE REAR SHOCK ABSORBER 1.Check: Shock absorber Oil leaks →...

  • Page 26: Installing The Relay Arm And Connecting Arm

    CHAS REAR SHOCK ABSORBER AND RELAY ARM INSTALLING THE RELAY ARM AND CONNECTING ARM 1.Install: Bushing 1 (to connecting arm) NOTE: Apply the lithium soap base grease on the bushing when installing. Installed depth of bushing a: 1 mm (0.04 in) 2.Install: Bushing 1 Oil seal 2...

  • Page 27: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN SWINGARM AND DRIVE CHAIN Order Job name/Part name Q’ty Remarks Removing the swingarm and drive Remove the parts in the order below. chain Rear wheels and hub Refer to “REAR WHEELS, WHEEL AXLE AND HUB”. Rear shock absorber Refer to “REAR SHOCK ABSORBER AND RELAY ARM”.
  • Page 28 CHAS SWINGARM AND DRIVE CHAIN Order Job name/Part name Q’ty Remarks Refer to “INSTALLING THE DRIVE Lock washer SPROCKET”. Drive sprocket Drive chain Collar Spacer Oil seal Bearing Dust cover/oil seal/washer 1/1/1 Spacer Oil seal Bushing Refer to “INSTALLING THE SWING- ARM”.

  • Page 29: Engine

    ENGINE REMOVAL ENGINE ENGINE REMOVAL INSTALLING THE ENGINE 1.Install: Engine brackets (lower) 1 Engine bracket bolts (lower) 2 Engine brackets (middle) 3 Engine mounting bolt (lower)/nut 4 Engine mounting bolt (middle)/nut 5 Engine bracket (upper) 6 Engine bracket bolts (upper) 7 Engine mounting bolt (upper)/nut 8 NOTE: Do not fully tighten the bolts and nuts.

  • Page 30: Ac Magneto

    AC MAGNETO AC MAGNETO Order Job name/Part name Q’ty Remarks Removing the AC magneto Remove the parts in the order below. Engine oil Drain. Shift pedal link Disconnect. Oil pipe 1 Disconnect. AC magneto coupler Starter idle gear cover/gasket Dowel pin Starter idle gear 1 Starter idle gear 1 shaft Bearing...
  • Page 31 AC MAGNETO Order Job name/Part name Q’ty Remarks Dowel pin/O-ring Lead holder Pickup coil Stator assembly Starter idle gear 2 Starter idle gear 2 shaft AC magneto rotor Refer to “REMOVING/INSTALLING THE AC MAGNETO ROTOR”. Starter wheel gear Woodruff key Bush/washer For installation, reverse the removal pro- cedure.

  • Page 33: Yfm660R(P) 2002 Wiring Diagram

    YFM660R(P) 2002 WIRING DIAGRAM 1 AC magneto 2 Rectifier/regulator R/B Y/B 3 Main switch 4 Battery (BLACK) (BLACK) (BLACK) WIRE HARNESS SUB-WIRE HARNESS 5 Fuse 6 Starter relay 7 Starter motor 8 Clutch switch 9 Park switch 0 CDI unit W/G R A Ignition coil W/L W/R...

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