Yamaha 2004 YXR660 Manuals

Manuals and User Guides for Yamaha 2004 YXR660. We have 1 Yamaha 2004 YXR660 manual available for free PDF download: Service Manual

Yamaha 2004 YXR660 Service Manual

Yamaha 2004 YXR660 Service Manual (506 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 23.6 MB
Table of contents
Specifications2................................................................................................................................................................
Table Of Contents3................................................................................................................................................................
Vehicle Identification14................................................................................................................................................................
Features15................................................................................................................................................................
Important Information18................................................................................................................................................................
Lock Washers/plates And Cotter Pins19................................................................................................................................................................
Checking Of Connections20................................................................................................................................................................
Special Tools21................................................................................................................................................................
General Specifications26................................................................................................................................................................
Engine Specifications29................................................................................................................................................................
Chassis Specifications37................................................................................................................................................................
Electrical Specifications39................................................................................................................................................................
Tightening Torques41................................................................................................................................................................
Chassis Tightening Torques44................................................................................................................................................................
How To Use The Conversion Table47................................................................................................................................................................
Lubrication Points And Lubricant Types48................................................................................................................................................................
Coolant Flow Diagrams49................................................................................................................................................................
Oil Flow Diagrams52................................................................................................................................................................
Cable Routing57................................................................................................................................................................
Periodic Checks And74................................................................................................................................................................
Engine76................................................................................................................................................................
Adjusting The Timing Chain79................................................................................................................................................................
Adjusting The Throttle Cable80................................................................................................................................................................
Adjusting The Starter Cable81................................................................................................................................................................
Checking The Spark Plug82................................................................................................................................................................
Checking The Ignition Timing83................................................................................................................................................................
Measuring The Compression Pressure84................................................................................................................................................................
Checking The Engine Oil Level86................................................................................................................................................................
Changing The Engine Oil87................................................................................................................................................................
Cleaning The Air Filter89................................................................................................................................................................
Checking The Coolant Level91................................................................................................................................................................
Changing The Coolant92................................................................................................................................................................
Cooling System94................................................................................................................................................................
Checking The Coolant Temperature Warning Light96................................................................................................................................................................
Cleaning The Spark Arrester98................................................................................................................................................................
Chassis99................................................................................................................................................................
Adjusting The Parking Brake100................................................................................................................................................................
Checking The Brake Fluid Level101................................................................................................................................................................
Checking The Front Brake Pads102................................................................................................................................................................
Bleeding The Hydraulic Brake System103................................................................................................................................................................
Adjusting The Select Lever Shift Rod105................................................................................................................................................................
Checking The Final Gear Oil Level106................................................................................................................................................................
Changing The Final Gear Oil107................................................................................................................................................................
Changing The Differential Gear Oil108................................................................................................................................................................
Checking The Constant Velocity Joint Dust Boots109................................................................................................................................................................
Checking The Steering System110................................................................................................................................................................
Adjusting The Front Shock Absorbers112................................................................................................................................................................
Checking The Tires113................................................................................................................................................................
Checking The Wheels115................................................................................................................................................................
Lubricating The Pedal, Etc116................................................................................................................................................................
Electrical117................................................................................................................................................................
Checking The Fuses122................................................................................................................................................................
Adjusting The Headlight Beam124................................................................................................................................................................
Changing The Tail/brake Light Bulb125................................................................................................................................................................
Engine Removal127................................................................................................................................................................
Select Lever Unit And Coolant Reservoir129................................................................................................................................................................
Hoses And Leads130................................................................................................................................................................
Engine Mounting Bolts132................................................................................................................................................................
Installing The Engine134................................................................................................................................................................
Cylinder Head Cover135................................................................................................................................................................
Removing The Cylinder Head Cover137................................................................................................................................................................
Installing The Cylinder Head Cover138................................................................................................................................................................
Rocker Arms139................................................................................................................................................................
Removing The Rocker Arms141................................................................................................................................................................
Installing The Rocker Arms142................................................................................................................................................................
Camshaft And Cylinder Head143................................................................................................................................................................
Removing The Camshaft And Cylinder Head145................................................................................................................................................................
Checking The Camshaft Sprocket146................................................................................................................................................................
Checking The Cylinder Head147................................................................................................................................................................
Installing The Camshaft And Cylinder Head148................................................................................................................................................................
Valves And Valve Springs151................................................................................................................................................................
Removing The Valves And Valve Springs152................................................................................................................................................................
Checking The Valves And Valve Springs153................................................................................................................................................................
Installing The Valves And Valve Springs157................................................................................................................................................................
Cylinder And Piston159................................................................................................................................................................
Removing The Piston160................................................................................................................................................................
Checking The Piston Rings162................................................................................................................................................................
Checking The Piston Pin163................................................................................................................................................................
Installing The Cylinder165................................................................................................................................................................
Engine Cooling Fan And A.c. Magneto166................................................................................................................................................................
Removing The A.c. Magneto169................................................................................................................................................................
Checking The Starter Clutch170................................................................................................................................................................
Checking The Engine Cooling Fan171................................................................................................................................................................
Balancer Gears And Oil Pump Gears174................................................................................................................................................................
Removing The Balancer Drive Gear And Balancer Driven Gear176................................................................................................................................................................
Installing The Balancer Drive Gear And Balancer Driven Gear177................................................................................................................................................................
Primary And Secondary Sheaves178................................................................................................................................................................
Primary Sheave180................................................................................................................................................................
Secondary Sheave181................................................................................................................................................................
Removing The Primary And Secondary Sheaves182................................................................................................................................................................
Checking The Primary Sheave183................................................................................................................................................................
Assembling The Primary Sheave184................................................................................................................................................................
Installing The Primary And Secondary Sheaves186................................................................................................................................................................
Clutch187................................................................................................................................................................
Removing The Clutch189................................................................................................................................................................
Installing The Clutch190................................................................................................................................................................
Crankcase192................................................................................................................................................................
Crankcase Bearings195................................................................................................................................................................
Separating The Crankcase196................................................................................................................................................................
Checking The Relief Valve197................................................................................................................................................................
Installing The Shift Levers198................................................................................................................................................................
Crankshaft And Oil Pump199................................................................................................................................................................
Oil Pump200................................................................................................................................................................
Removing The Crankshaft201................................................................................................................................................................
Checking The Crankshaft203................................................................................................................................................................
Installing The Crankshaft And Balancer204................................................................................................................................................................
Transmission205................................................................................................................................................................
Drive Axle Assembly206................................................................................................................................................................
Removing The Transmission207................................................................................................................................................................
Checking The Shift Drum208................................................................................................................................................................
Checking The Secondary Shaft And Driven Sprocket209................................................................................................................................................................
Assembling The Shift Fork Assembly210................................................................................................................................................................
Middle Gear211................................................................................................................................................................
Middle Driven Shaft212................................................................................................................................................................
Removing The Middle Drive Shaft214................................................................................................................................................................
Checking The Pinion Gears217................................................................................................................................................................
Selecting The Middle Drive And Driven Gear Shims218................................................................................................................................................................
Installing The Middle Driven Shaft221................................................................................................................................................................
Installing The Middle Drive Shaft223................................................................................................................................................................
Measuring The Middle Gear Backlash224................................................................................................................................................................
Radiator And Coolant Reservoir225................................................................................................................................................................
Checking The Radiator227................................................................................................................................................................
Installing The Radiator228................................................................................................................................................................
Water Pump229................................................................................................................................................................
Disassembling The Water Pump231................................................................................................................................................................
Assembling The Water Pump232................................................................................................................................................................
Oil Cooler234................................................................................................................................................................
Checking The Oil Cooler236................................................................................................................................................................
Fuel System237................................................................................................................................................................
Checking The Fuel Pump Operation239................................................................................................................................................................
Carburetor240................................................................................................................................................................
Disassembling The Carburetor244................................................................................................................................................................
Assembling The Carburetor246................................................................................................................................................................
Adjusting The Fuel Level247................................................................................................................................................................
Drive Train248................................................................................................................................................................
Front Constant Velocity Joints, Differential Gear And Drive Shaft251................................................................................................................................................................
Disassembling The Universal Joint256................................................................................................................................................................
Checking The Constant Velocity Joints257................................................................................................................................................................
Checking The Gear Motor258................................................................................................................................................................
Assembling The Differential Gear259................................................................................................................................................................
Assembling The Universal Joint261................................................................................................................................................................
Checking The Differential Gear Operation263................................................................................................................................................................
And Drive Shaft265................................................................................................................................................................
Assembling The Rear Constant Velocity Joints271................................................................................................................................................................
Removing The Final Drive Roller Bearings272................................................................................................................................................................
Installing The Final Drive Roller Bearings273................................................................................................................................................................
Checking The Drive Shaft278................................................................................................................................................................
Measuring And Adjusting The Final Gear Lash279................................................................................................................................................................
Assembling The Final Gear Case280................................................................................................................................................................
Seats, Console And Instrument Panels284................................................................................................................................................................
Panels And Footrest Cover286................................................................................................................................................................
Cargo Bed288................................................................................................................................................................
Skid Plates290................................................................................................................................................................
Enclosure And Seat Belts291................................................................................................................................................................
Front Wheels And Brake Discs292................................................................................................................................................................
Checking The Front Wheel294................................................................................................................................................................
Checking The Front Brake Disc295................................................................................................................................................................
Rear Wheels And Brake Disc296................................................................................................................................................................
Rear Brake Disc297................................................................................................................................................................
Checking The Rear Wheel298................................................................................................................................................................
Installing The Rear Wheel Hub299................................................................................................................................................................
Front And Rear Brakes300................................................................................................................................................................
Rear Brake Pads301................................................................................................................................................................
Replacing The Front Brake Pads302................................................................................................................................................................
Replacing The Rear Brake Pads303................................................................................................................................................................
Brake Master Cylinder306................................................................................................................................................................
Checking The Master Cylinder308................................................................................................................................................................
Installing The Brake Master Cylinder309................................................................................................................................................................
Front Brake Caliper311................................................................................................................................................................
Rear Brake Caliper313................................................................................................................................................................
Disassembling The Front Brake Calipers317................................................................................................................................................................
Checking The Front And Rear Brake Calipers318................................................................................................................................................................
Assembling The Front Brake Calipers319................................................................................................................................................................
Assembling The Rear Brake Caliper320................................................................................................................................................................
Installing The Front Brake Calipers322................................................................................................................................................................
Installing The Rear Brake Caliper323................................................................................................................................................................
Pedal Assembly325................................................................................................................................................................
Steering System327................................................................................................................................................................
Disassembling The Steering Assembly330................................................................................................................................................................
Assembling The Steering Assembly331................................................................................................................................................................
Installing The Steering System332................................................................................................................................................................
Tie-rod And Steering Knuckle333................................................................................................................................................................
Removing The Steering Knuckles334................................................................................................................................................................
Front Arms And Front Shock Absorber338................................................................................................................................................................
Removing The Front Arms340................................................................................................................................................................
Checking The Front Shock Absorber342................................................................................................................................................................
Installing The Front Arms And Front Shock Absorber343................................................................................................................................................................
Rear Knuckle And Stabilizer344................................................................................................................................................................
Checking The Rear Knuckle345................................................................................................................................................................
Rear Arms And Rear Shock Absorber346................................................................................................................................................................
Checking The Rear Arms347................................................................................................................................................................
Installing The Rear Arms And Rear Shock Absorber348................................................................................................................................................................
Checking The Switch351................................................................................................................................................................
Checking The Switch Continuity352................................................................................................................................................................
Checking The Bulbs And Bulb Sockets354................................................................................................................................................................
Checking The Condition Of The Bulb Sockets356................................................................................................................................................................
Ignition System357................................................................................................................................................................
Troubleshooting358................................................................................................................................................................
Electric Starting System363................................................................................................................................................................
Starting Circuit Operation364................................................................................................................................................................
Starter Motor368................................................................................................................................................................
Checking The Starter Motor369................................................................................................................................................................
Assembling The Starter Motor370................................................................................................................................................................
Charging System371................................................................................................................................................................
Lighting System374................................................................................................................................................................
Checking The Lighting System377................................................................................................................................................................
Signaling System380................................................................................................................................................................
Circuit Diagram382................................................................................................................................................................
Starting Failure/hard Starting407................................................................................................................................................................
Compression System408................................................................................................................................................................
Faulty Drive Train409................................................................................................................................................................
Faulty Gear Shifting410................................................................................................................................................................
Poor Speed Performance411................................................................................................................................................................
Unstable Handling412................................................................................................................................................................
Periodic Checks And Adjustments436................................................................................................................................................................
Checking The Signal System455................................................................................................................................................................

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