Periodic Checks And Adjustments; Introduction; Periodic Maintenance/Lubrication Intervals - Yamaha YFM660RP 5LP2-AE2 2002 Supplemental Service Manual

INTRODUCTION/PERIODIC MAINTENANCE/
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. All service technicians should be familiar with this entire chapter.
EB301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

ITEM
• Check valve clearance.
Valves*
• Adjust if necessary.
• Check coolant leakage.
Cooling system • Repair if necessary.
• Replace coolant every 24 months.
• Check condition.
Spark plug • Adjust gap and clean.
• Replace if necessary.
• Clean.
Air filter element
• Replace if necessary.
• Check starter (choke) operation.
Carburetors*
• Adjust engine idling speed and synchronization.
Crankcase breather • Check breather hose for cracks or damage.
system* • Replace if necessary.
• Check for leakage.
Exhaust system* • Tighten if necessary.
• Replace gasket if necessary.
• Check fuel hose for cracks or damage.
Fuel line*
• Replace if necessary.
Engine oil • Replace (Warm engine before draining).
Engine oil filter car-
• Replace if necessary.
tridge
Drive chain • Check and adjust slack/alignment/clean/lube.
• Check free play/operation/fluid leakage/See NOTE
Front brake
Page 10.
• Correct if necessary.
• Check operation/fluid leakage/See NOTE Page 10.
Rear brake*
• Correct if necessary.
• Check operation.
Clutch*
• Adjust if necessary.
• Check balance/damage/runout.
Wheels*
• Replace if necessary.
• Check bearing assembly for looseness/damage.
Wheel bearings*
• Replace if damaged.
• Check operation.
• Repair if damaged.
Steering system*
• Check toe-in.
• Adjust if necessary.
Upper and lower arm
pivot and steering • Lubricate every 6 months.**
shaft*
Rear arm pivot* • 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
LUBRICATION INTERVALS
ROUTINE
– 9 –
CHK
ADJ
INITIAL
1 3 6
month months months
Every 20 ~ 40 hours
(More often in wet or dusty areas.)
EVERY
6 1
months year