Yamaha YFM660RN Utility Vehicle Manuals

Manuals and User Guides for Yamaha YFM660RN Utility Vehicle. We have 1 Yamaha YFM660RN Utility Vehicle manual available for free PDF download: Service Manual

Yamaha YFM660RN Service Manual (328 pages)

Yamaha Atv

Brand: Yamaha | Category: Offroad Vehicle | Size: 37.77 MB

Specifications
2
How to Use this Manual
3
Periodic Checks and Adjustments

4
- Table of Contents
  5
Chassis

4
Engine

4
Cooling System

4
Electrical

13
Troubleshooting

14
Machine Identification

15
- Vehicle Identification Number
  15
- Model Label
  15
Gen Info

15
Chapter 1. General Information

15
Important Information

16
- Preparation for Removal Procedures
  16
- Replacement Parts
  16
- Gaskets, Oil Seals and O-Rings
  16
- Lock Washers/Plates and Cotter Pins
  17
- Bearings and Oil Seals
  17
- Circlips
  17
Checking of Connections

18
Special Tools

19
General Specifications

23
Chapter 2. Specifications

23
Spec

26
Maintenance Specifications

26
- Engine
  26
- Chassis
  36
- Electrical
  40
How to Use the Conversion Table

42
General Torque Specifications

42
Lubrication Points and Lubricant Types

43
- Engine
  43
Coolant Flow Diagrams

44
Oil Flow Diagrams

45
Cable Routing

49
Chapter 3

57
- Periodic Checks and Adjustments
  57
Introduction

57
Periodic Maintenance/Lubrication Intervals

57
Chk Adj

57
Seat, Fenders and Fuel Tank

59
- Seat, Front Panel, Footrest Guards
  59
- Headlights and Front Fender
  60
  - And Engine Skid Plate
    60
- Rear Fender
  61
- Fuel Tank
  62
Engine

64
- Chk Adj
  64
- Adjusting the Valve Clearance
  64
- Adjusting the Timing Chain
  67
- Adjusting the Idling Speed
  67
- Adjusting the Throttle Lever Free Play
  68
- Adjusting the Speed Limiter
  70
- Adjusting the Starter Cable
  71
- Checking the Spark Plug
  72
- Checking the Ignition Timing
  73
- Measuring the Compression Pressure
  74
- Checking the Engine Oil Level
  75
- Changing the Engine Oil
  76
- Adjusting the Clutch Cable
  79
- Cleaning the Air Filter
  80
- Checking the Coolant Level
  83
- Changing the Coolant
  83
- Checking the Coolant Temperature Warning Light
  87
- Cleaning the Spark Arrester
  88
Chassis

89
- Adjusting the Front Brake
  89
- Adjusting the Rear Brake
  89
- Adjusting the Parking Brake
  90
- Checking the Brake Fluid Level
  91
- Checking the Front Brake Pad
  92
- Checking the Rear Brake Pad
  92
- Checking the Brake Hose
  93
- Bleeding the Hydraulic Brake System
  94
- Adjusting the Shift Pedal
  95
- Adjusting the Reverse Control Cable
  96
- Adjusting the Drive Chain Slack
  96
- Checking the Steering System
  98
- Adjusting the Toe-In
  98
- Adjusting the Front Shock Absorber
  100
- Adjusting the Rear Shock Absorber
  101
- Checking the Tire
  103
- Checking the Wheel
  105
- Checking and Lubricating the Cable
  105
- Lubricating the Levers and Pedal
  106
Electrical

107
- Checking the Battery
  107
- Checking the Fuse
  113
- Adjusting the Headlight Beam
  114
- Replacing the Headlight Bulb
  114
Front Wheels

116
Chapter 4. Chassis

116
Chas

117
- Checking the Wheel
  118
- Checking the Wheel Hub
  118
- Checking the Brake Disc
  119
- Installing Wheel Hub
  120
- Installing the Wheel
  120
Rear Wheels, Wheel Axle and Hub

121
- Rear Wheels
  121
- Wheel Axle and Hub
  122
- Removing the Rear Axle
  124
- Checking the Wheel
  125
- Checking the Wheel Hub
  125
- Checking the Rear Axle
  125
- Checking the Hub
  126
- Checking the Brake Disc
  126
- Installing the Nuts (Rear Axle)
  126
- Installing the Wheel Hub
  127
- Installing the Wheel
  127
Front and Rear Brakes

128
- Front Brake Pads
  128
- Rear Brake Pads
  129
- Replacing the Front Brake Pad
  130
- Replacing the Rear Brake Pad
  132
- Front Brake Master Cylinder
  134
- Rear Brake Master Cylinder
  136
- Checking the Master Cylinder
  139
- Assembling the Front and Rear Brake Master Cylinder
  140
- Installing the Front Brake Master Cylinder
  140
- Installing the Rear Brake Master Cylinder
  142
- Front Brake Calipers
  144
- Rear Brake Caliper
  146
- Disassembling the Front and Rear Brake Caliper
  149
- Checking the Front and Rear Brake Caliper
  149
- Assembling the Front Brake Caliper
  150
- Assembling the Rear Brake Caliper
  151
- Installing the Front Brake Caliper
  152
- Installing the Rear Brake Caliper
  153
Steering System

155
- Handlebar
  155
- Removing the Front Brake Switch, Park Switch and Clutch Switch
  157
- Removing the Handlebar Grip
  157
- Checking the Handlebar
  157
- Installing the Handlebar
  158
- Installing the Handlebar Grip
  158
- Installing the Clutch Lever
  158
- Installing the Brake Master Cylinder
  159
- Steering Stem
  160
- Removing the Bearing Retainer
  162
- Checking the Steering Stem
  162
- Installing the Bearing Retainer
  162
- Installing the Lock Washer
  162
- Tie-Rod and Steering Knuckle
  163
- Removing the Steering Knuckle
  164
- Checking the Tie-Rod
  164
- Checking the Steering Knuckle
  164
- Installing the Tie-Rod
  164
Front Arms and Front Shock Absorbers

165
- Removing the Front Arm
  167
- Checking the Front Arm
  167
- Checking the Front Shock Absorber
  167
- Checking the Ball Joint
  168
- Installing the Front Arm
  169
Rear Shock Absorber and Relay Arm

170
Swingarm and Drive Chain

175
- Removing the Swingarm
  177
- Checking the Swingarm
  177
- Checking the Drive Chain
  178
- Installing the Swingarm
  180
- Installing the Drive Sprocket
  180
Engine Removal

181
- Muffler and Exhaust Pipes
  181
- Left Footrest
  182
- Leads, Cables and Hoses
  183
- Engine Mounting Bolts
  185
- Installing the Engine
  187
Chapter 5. Engine

181
Cylinder Head Cover

188
- Removing the Cylinder Head Cover
  190
- Checking the Cylinder Head Cover
  190
Eng

191
- Checking the Tappet Cover
  191
- Installing the Cylinder Head Cover
  191
Rocker Arms

192
- Removing the Rocker Arm
  194
- Checking the Rocker Arm
  194
- Installing the Rocker Arm
  195
Camshaft and Cylinder Head

196
- Removing the Camshaft and Cylinder Head
  198
- Checking the Camshaft
  199
- Checking the Camshaft Sprocket
  199
- Checking the Decompression System
  199
- Checking the Timing Chain Guide
  200
- Checking the Timing Chain Tensioner
  200
- Checking the Cylinder Head
  200
- Installing the Camshaft and Cylinder Head
  201
Valves and Valve Springs

204
Cylinder and Piston

212
- Removing the Piston
  213
- Checking the Cylinder and Piston
  213
- Checking the Piston Ring
  215
- Checking the Piston Pin Inspection
  216
- Installing the Piston
  216
- Installing the Cylinder
  217
Ac Magneto

218
- Removing the Ac Magneto Rotor
  220
- Checking the Coil
  220
- Checking the Starter Clutch
  221
- Installing the Ac Magneto Rotor
  222
- Clutch
  223
- Removing the Primary Drive Gear and Balancer Driven Gear
  227
- Checking the Friction Plate
  228
- Checking the Clutch Plate
  228
- Checking the Clutch Spring
  229
- Checking the Clutch Housing
  229
- Checking the Clutch Boss
  229
- Checking the Pressure Plate
  229
- Checking the Pull Lever Shaft and Pull Rod
  230
- Checking the Primary Drive
  230
  - Checking the Balancer Drive
    230
- Installing the Primary Drive Gear and Balancer Driven Gear
  231
- Installing the Clutch
  232
Oil Pump

234
- Checking the Oil Pump
  236
- Assembling the Oil Pump
  236
- Shift Shaft
  237
Checking the Shift Shaft

239
- Checking the Stopper Lever
  239
- Checking the Segment
  239
- Installing the Shift Lever
  239
- Installing the Stopper Lever
  240
- Installing the Shift Shaft
  241
Crankcase

242
- Timing Chain and Speed Sensor Rotor
  242
- Crankcase
  244
- Crankcase Bearing
  245
- Separating the Crankcase
  246
- Checking the Timing Chain and Guide
  246
- Checking the Oil Strainer
  246
- Checking the Crankcase
  247
- Checking the Bearings
  247
- Assembling the Crankcase
  247
Crankshaft and Balancer

249
- Removing the Crankshaft
  250
- Checking the Crankshaft
  250
- Installing the Crankshaft
  251
Transmission

252
- Main Axle
  254
- Drive Axle
  255
- Checking the Shift Fork
  257
- Checking the Shift Drum
  257
- Checking the Transmission
  257
- Assembling the Main Axle and Drive Axle
  258
- Installing the Transmission
  259
Chapter 6

260
Radiator

260
Cooling System

260
Cool

262
- Checking the Radiator
  262
- Installing the Radiator
  263
Thermostat

264
- Checking the Thermostat
  266
- Assembling the Thermostat
  266
Water Pump

267
- Disassembling the Water Pump
  270
- Checking the Water Pump
  270
- Assembling the Water Pump
  271
Carburetors

273
Chapter 7. Carburetion

273
Carb

274
- Disassembling the Carburetor
  277
- Checking the Carburetor
  277
- Assembling the Carburetor
  279
- Adjusting the Fuel Level
  280
Electrical Components

282
Chapter 8

282
Elec

282
Checking the Switch

283
- Checking a Switch Shown in the Manual
  283
- Checking the Switch Continuity
  284
Ignition System

286
- Circuit Diagram
  286
- Troubleshooting
  287
Electric Starting System

292
- Circuit Diagram
  292
- Starting Circuit Operation
  293
- Troubleshooting
  294
- Starter Motor
  297
- Checking the Starter Motor
  298
- Assembling the Starter Motor
  299
Charging System

300
- Circuit Diagram
  300
- Troubleshooting
  301
Lighting System

303
- Circuit Diagram
  303
  - Troubleshooting
    304
  - Checking the Lighting System
    306
Signal System

308
- Circuit Diagram
  308
- Troubleshooting
  309
- Checking the Signal System
  311
Cooling System

317
- Circuit Diagram
  317
Starting Failure/Hard Starting

322
Chapter 9

322
- Fuel System
  322
- Electrical System
  322
- Compression System
  323
Trbl Shtg

322
- Troubleshooting
  322
Poor Idle Speed Performance

323
Poor Medium and High-Speed Performance

323
Faulty Gear Shifting

324
- Hard Shifting
  324
- Shift Pedal Does Not Move
  324
- Jump-Out Gear
  324
Clutch Slipping/Dragging

324
- Clutch Slipping
  324
- Clutch Dragging
  324
Overheating

325
Over Cooling

325
- Cooling System
  325
Faulty Brake

325
- Poor Braking Effect
  325
Shock Absorber Malfunction

326
- Malfunction
  326
Unstable Handling

326
Lighting System

326
- Headlight Dark
  326
- Bulb Burnt out
  326

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Yamaha YFM660RN Utility Vehicle Manuals

Yamaha YFM660RN Service Manual (328 pages)

Table of Contents

Periodic Checks and Adjustments

Chassis

Engine

Cooling System

Electrical

Troubleshooting

Machine Identification

Gen Info

Chapter 1. General Information

Important Information

Checking of Connections

Special Tools

General Specifications

Chapter 2. Specifications

Spec

Maintenance Specifications

How to Use the Conversion Table

General Torque Specifications

Lubrication Points and Lubricant Types

Coolant Flow Diagrams

Oil Flow Diagrams

Cable Routing

Chapter 3

Introduction

Periodic Maintenance/Lubrication Intervals

Chk Adj

Seat, Fenders and Fuel Tank

Engine

Chassis

Electrical

Front Wheels

Chapter 4. Chassis

Chas

Rear Wheels, Wheel Axle and Hub

Front and Rear Brakes

Steering System

Front Arms and Front Shock Absorbers

Rear Shock Absorber and Relay Arm

Swingarm and Drive Chain

Engine Removal

Chapter 5. Engine

Cylinder Head Cover

Eng

Rocker Arms

Camshaft and Cylinder Head

Valves and Valve Springs

Cylinder and Piston

Ac Magneto

Oil Pump

Checking the Shift Shaft

Crankcase

Crankshaft and Balancer

Transmission

Chapter 6

Radiator

Cooling System

Cool

Thermostat

Water Pump

Carburetors

Chapter 7. Carburetion

Carb

Electrical Components

Chapter 8

Elec

Checking the Switch

Ignition System

Electric Starting System

Charging System

Lighting System

Signal System

Cooling System

Starting Failure/Hard Starting

Chapter 9

Trbl Shtg

Poor Idle Speed Performance

Poor Medium and High-Speed Performance