Yamaha YXR660FAS Service Manual Page 3
- Page / 421
- Table of contents
- TROUBLESHOOTING
- BOOKMARKS
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EBS00002
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 vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle
repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe
and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
_
Designs and specifications are subject to change without notice.
EBS00003
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death
to the vehicle operator, passenger, a bystander, or a person checking or
repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid dam-
age to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:
- YXR660FAS 1
- EBS00001 2
- HOW TO USE THIS MANUAL 4
- EBS00006 5
- TABLE OF CONTENTS 7
- CONTENTS 8
- CHAPTER 1 8
- CHAPTER 2 8
- SPECIFICATIONS 8
- CHAPTER 3 9
- CHAPTER 4 10
- CHAPTER 8 14
- CHAPTER 9 15
- CHAPTER 10 17
- TROUBLESHOOTING 17
- GENERAL INFORMATION 18
- FEATURES 19
- IMPORTANT INFORMATION 22
- CHECKING OF CONNECTIONS 24
- SPECIAL TOOLS 25
- SAE 5W30 30
- GENERAL SPECIFICATIONS 31
- ENGINE SPECIFICATIONS 33
- (2.5°/0.055 in) 35
- (2.5°/0.063 in) 35
- CHASSIS SPECIFICATIONS 41
- ELECTRICAL SPECIFICATIONS 43
- TIGHTENING TORQUES 45
- EBS00022 51
- EBS00023 51
- EBS00024 52
- COOLANT FLOW DIAGRAMS 53
- OIL FLOW DIAGRAMS 56
- CABLE ROUTING 61
- INTRODUCTION 78
- INTRODUCTION/ 78
- ADJUSTING THE VALVE CLEARANCE 80
- ADJUSTING THE TIMING CHAIN/ 83
- ADJUSTING THE IDLING SPEED 83
- ADJUSTING THE IDLING SPEED/ 84
- ADJUSTING THE THROTTLE CABLE 84
- ADJUSTING THE THROTTLE CABLE/ 85
- ADJUSTING THE STARTER CABLE 85
- 18 Nm (1.8 m 86
- CHECKING THE IGNITION TIMING 87
- CHECKING THE IGNITION TIMING/ 88
- CHECKING THE ENGINE OIL LEVEL 90
- CHANGING THE ENGINE OIL 91
- 30 Nm (3.0 m 92
- CHANGING THE ENGINE OIL/ 93
- CLEANING THE AIR FILTER 93
- CLEANING THE AIR FILTER/ 95
- CHECKING THE COOLANT LEVEL 95
- CHECKING THE COOLANT LEVEL/ 96
- CHANGING THE COOLANT 96
- LIGHT/CHECKING THE V-BELT 100
- CHECKING THE V-BELT 101
- CHECKING THE V-BELT/ 102
- CLEANING THE SPARK ARRESTER 102
- ADJUSTING THE BRAKE PEDAL 103
- ADJUSTING THE PARKING BRAKE 104
- 4 Reverse 109
- 5 Select lever shift rod 109
- 1 Neutral 109
- 23 Nm (2.3 m 110
- CHANGING THE FINAL GEAR OIL/ 111
- CHECKING THE STEERING SYSTEM/ 114
- ADJUSTING THE TOE-IN 114
- Rawhide 117
- CHECKING THE TIRES 118
- CHECKING THE WHEELS/ 119
- LUBRICATING THE PEDAL, ETC 120
- ELECTRICAL 121
- Open-circuit voltage (V) 122
- CAUTION: 125
- CHECKING THE FUSES 126
- ADJUSTING THE HEADLIGHT BEAM/ 128
- CHANGING THE HEADLIGHT BULB 128
- CHANGING THE HEADLIGHT BULB/ 129
- 7 Nm (0.7 m 130
- ENGINE REMOVAL 131
- 10 Nm (1.0 m 134
- CYLINDER HEAD COVER 139
- ROCKER ARMS 143
- CAMSHAFT AND CYLINDER HEAD 147
- VALVES AND VALVE SPRINGS 155
- CYLINDER AND PISTON 163
- Order Job/Part Q’ty Remarks 172
- 18 Starter idle gear 1 172
- PRIMARY AND SECONDARY SHEAVES 182
- CRANKCASE 196
- CRANKSHAFT AND OIL PUMP 203
- TRANSMISSION 209
- MIDDLE GEAR 215
- COOLING SYSTEM 229
- 11 Coolant reservoir 1 230
- WATER PUMP 234
- OIL COOLER 238
- FUEL SYSTEM 241
- FUEL PUMP AND FUEL TANK 242
- CARBURETOR 244
- DRIVE TRAIN 252
- GEAR AND DRIVE SHAFT 255
- DRIVE SHAFT 255
- 13 Passenger seat support 1 291
- FRONT WHEELS AND BRAKE DISCS 296
- REAR WHEELS AND BRAKE DISC 300
- FRONT AND REAR BRAKES 304
- 9 Nm (0.9 m 311
- 16 Nm (1.6 m 329
- PEDAL ASSEMBLY 330
- STEERING SYSTEM 331
- 40 Nm (4.0 m 332
- 10 Circlip 1 343
- 11 Ball joint 1 343
- REAR KNUCKLE AND STABILIZER 348
- ELECTRICAL COMPONENTS 354
- CHECKING THE SWITCH 355
- CHECKING THE BULBS AND 358
- BULB SOCKETS 358
- IGNITION SYSTEM 361
- ELECTRIC STARTING SYSTEM 367
- CHARGING SYSTEM 375
- LIGHTING SYSTEM 378
- SIGNALING SYSTEM 384
- 2WD/4WD SELECTING SYSTEM 403
- CARBURETOR HEATING SYSTEM 408
- POOR IDLE SPEED PERFORMANCE 413
- FAULTY DRIVE TRAIN 414
- FAULTY GEAR SHIFTING/ 415
- FAULTY CLUTCH PERFORMANCE 415
- FAULTY GEAR SHIFTING 415
- OVERHEATING 416
- FAULTY BRAKE 416
- SHOCK ABSORBER MALFUNCTION 416
- UNSTABLE HANDLING/ 417
- UNSTABLE HANDLING 417
- PRINTED IN U.S.A 420
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