Yamaha YFM660FR Service Manual

YFM660FR5KM2-AE2SUPPLEMENTARYSERVICE MANUAL

– 2 –SPECSPECIFICATIONSGENERAL SPECIFICATIONSItem StandardModel code: 5KM9: (for CDN)5KMB: (for Europe)5KMC: (for Oceania)Bulb wattage × quantity:Head

– 3 –SPECMAINTENANCE SPECIFICATIONSENGINEELECTRICALItem Standard LimitOil pump:Oil filter type Foam ----Oil pump type Trochoid ----Tip clearance “A” o

– 4 –SPECTIGHTENING TORQUESEngine tightening torquesChassis tightening torquesPart to be tightenedPart nameThread sizeQ’tyTightening torqueRemarksNm m

– 5 –SPECCABLE ROUTING1 Fuel sender lead2 Differential gear case and final drive gear case breather hose3 Vacuum chamber breather hose4 Starter motor

– 6 –SPECÈ Fasten the final drive gear case breather hose, speed sensor lead, ground lead, gear position switch lead,AC magneto lead, wire harness, an

– 7 –SPECÎ Pass the vacuum chamber breather hose through the plastic cover hole.Ï Insert a hook into the third hole from the bottom of the rectifier/r

– 8 –SPEC1 Gear position switch2 Reverse switch3 Crankcase breather hose4 Select lever control cable5 Rear brake cable6 Front brake hose7 Rear brake l

– 9 –SPECÊ Clamp the spark plug lead and radiator inlet hose with a plastic clip.Ë When installing the ignition coil, face the spark plug lead to the

– 10 –SPEC1 Front brake hose2 Throttle cable3 Thermo switch 1 lead4 Crankcase breather hose5 Fuel sender lead6 Differential gear case breather hose7 S

– 11 –SPECÎ Fasten the wire harness speed sensor coupler, thermo switch 1 lead, reverse switch lead, and ground leadwith a plastic locking tie.CCBA -

– 12 –CHKADJINTRODUCTION/PERIODIC MAINTENANCE/LUBRICATIONEB300000PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information nece

– 13 –CHKADJPERIODIC MAINTENANCE/LUBRICATION* It is recommended that these items be serviced by a Yamaha dealer.** Lithium-soap-based greaseNOTE:●Reco

– 14 –CHKADJSEAT, CARRIERS, FENDERS AND FUEL TANKSEAT, CARRIERS, FENDERS AND FUEL TANKFRONT CARRIER, FRONT BUMPER AND FRONT GRILLT R..33 Nm (3.3 m • k

– 15 –CHKADJSEAT, CARRIERS, FENDERS AND FUEL TANKFUEL TANK9931011841076521Order Job name/Part name Q’ty RemarksRemoving the fuel tankRemove the parts

– 16 –CHKADJSEAT, CARRIERS, FENDERS AND FUEL TANK9931011841076521Order Job name/Part name Q’ty Remarks5Clamp 16 Vacuum chamber breather hose 17 Differ

– 17 –CHKADJFOOTREST BOARDSFOOTREST BOARDST R..9 Nm (0.9 m • kg, 6.5 ft • Ib)T R..33 Nm (3.3 m • kg, 24 ft • Ib)134421(4)(12)(8)(12)(8)Order Job name/

– 18 –CHKADJENGINECHECKING THE STARTER CABLE1.Remove:●Seat ●Fuel tank side panel (left)2.Check:●Starter cableUnsmooth operation → Replace.************

– 19 –ENGCAMSHAFT AND CYLINDER HEADENGINECAMSHAFT AND CYLINDER HEAD Order Job name/Part name Q’ty RemarksRemoving the camshaft and cylin-der headRemov

– 20 –ENGCAMSHAFT AND CYLINDER HEADOrder Job name/Part name Q’ty RemarksCylinder head cover Refer to “CYLINDER HEAD COVER” in CHAPTER 4. (Manual No.:

– 21 –ENGRECOIL STARTER AND AC MAGNETORECOIL STARTER AND AC MAGNETOOrder Job name/Part name Q’ty RemarksRemoving the AC magnetoRemove the parts in the

FOREWORDThis Supplementary Service Manual has been prepared to introduce new service and data for theYFM660FR. For complete service information proced

– 22 –ENGRECOIL STARTER AND AC MAGNETOOrder Job name/Part name Q’ty Remarks3 Starter pulley 1Refer to “REMOVING/INSTALLING THEAC MAGNETO” in CHAPTER 4

– 23 –ENGRECOIL STARTER AND AC MAGNETOCHECKING THE STARTER CLUTCH1.Check:●Starter clutch 1 Cracks/damage → Replace.●Bolts 2 (starter clutch)Loose → Re

– 24 –ENGMIDDLE GEARMIDDLE GEARMIDDLE DRIVEN SHAFTOrder Job name/Part name Q’ty RemarksDisassembling the middle driven shaftRemove the parts in the or

– 25 –ENGMIDDLE GEAROrder Job name/Part name Q’ty Remarks7 Bearing retainer 18 Middle driven shaft 1For installation, reverse the removal procedure.

– 26 –ENGMIDDLE GEARREMOVING THE MIDDLE DRIVEN SHAFT1.Remove:●Nut 1 ●Washer●Front drive shaft couplingNOTE:Use the coupling gear holding tool 2 to hol

– 27 –ENGMIDDLE GEAR4.Remove:●Bearing retainer●Bearing*****************************************************Removal steps:●Place a rag 1 in the vise.●S

– 28 –ENGINSTALLING THE MIDDLE DRIVEN SHAFT1.Install:●Bearing retainer 1 NOTE:Attach the ring nut wrench 2.CAUTION:The middle driven shaft bearing ret

– 29 –ENGMIDDLE GEAR4.Install:●Front drive shaft coupling●Washer●Nut 1 NOTE:Use the coupling gear holding tool 2 to holdthe front drive shaft coupling

– 30 –DRIVFRONT CONSTANT VELOCITY JOINTS ANDDIFFERENTIAL GEARDRIVE TRAINFRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEARLSLSLST R..55 Nm (5.5 m •

– 31 –DRIVFRONT CONSTANT VELOCITY JOINTS ANDDIFFERENTIAL GEARLSLSLST R..55 Nm (5.5 m • kg, 40 ft • Ib)LS1563214Order Job name/Part name Q’ty Remarks3

EB001000NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealersand their qualified mechanics. It is not possibl

– 32 –DRIVFRONT CONSTANT VELOCITY JOINTS ANDDIFFERENTIAL GEAROrder Job name/Part name Q’ty RemarksDisassembling the differential gearRemove the parts

– 33 –DRIVFRONT CONSTANT VELOCITY JOINTS ANDDIFFERENTIAL GEAROrder Job name/Part name Q’ty Remarks9 Differential gear assembly 10 Shim (right)A Circli

– 34 –DRIVDISASSEMBLING THE DIFFERENTIAL GEAR1.Remove:●Coupling gearUse a coupling gear holding tool 1.Coupling gear holding tool:P/N. YM-01486, 90890

– 35 –DRIVFRONT CONSTANT VELOCITY JOINTS ANDDIFFERENTIAL GEAR5.Check:●Front drive shaft assembly operationUnsmooth operation → Replace the frontdrive

– 36 –DRIVFRONT CONSTANT VELOCITY JOINTS ANDDIFFERENTIAL GEAR3.Install:●Coupling gear●O-ring●Washer●NutUse a coupling gear holding tool 1.Coupling gea

– 37 –CHASFRONT WHEELS AND BRAKE DISCSCHASSISFRONT WHEELS AND BRAKE DISCSFRONT WHEELST R..30 Nm (3.0 m • kg, 22 ft • Ib)T R..30 Nm (3.0 m • kg, 22 ft

– 38 –CHASFRONT WHEELS AND BRAKE DISCST R..30 Nm (3.0 m • kg, 22 ft • Ib)T R..30 Nm (3.0 m • kg, 22 ft • Ib)46532LTLTT R..260 Nm (26.0 m • kg, 190 ft

– 39 –CHASREAR WHEELS AND BRAKE DISCREAR WHEELS AND BRAKE DISCREAR WHEELS234T R..55 Nm (5.5 m • kg, 40 ft • Ib)T R..260 Nm (26.0 m • kg, 190 ft • lb)1

– 40 –CHASSTEERING SYSTEMSTEERING SYSTEMTIE ROD AND STEERING KNUCKLET R..25 Nm (2.5 m • kg, 18 ft • Ib)T R..25 Nm (2.5 m • kg, 18 ft • Ib)T R..25 Nm (

– 41 –CHAST R..25 Nm (2.5 m • kg, 18 ft • Ib)T R..25 Nm (2.5 m • kg, 18 ft • Ib)T R..25 Nm (2.5 m • kg, 18 ft • Ib)T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)

EB002000HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)1st

– 42 –CHASSTEERING SYSTEMCHECKING THE STEERING KNUCKLE1.Check:●Steering knuckleDamage/pitting → Replace.2.Check:●Front wheel bearingsBearings allow pl

– 43 –CHASREAR KNUCKLE AND STABILIZERREAR KNUCKLE AND STABILIZERT R..30 Nm (3.0 m • kg, 22 ft • Ib)T R..48 Nm (4.8 m • kg, 35 ft • Ib)T R..48 Nm (4.8

– 44 –CHASREAR KNUCKLE AND STABILIZERCHECKING THE REAR KNUCKLE1.Check:●Rear knuckleDamage/pitting → Replace.2.Check:●Rear wheel bearingsBearings allow

– 45 –CHASREAR ARMS AND REAR SHOCK ABSORBER1315522436365115T R..45 Nm (4.5 m • kg, 32 ft • Ib)T R..45 Nm (4.5 m • kg, 32 ft • Ib)T R..45 Nm (4.5 m • k

YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPAN

EB003000ILLUSTRATED SYMBOLSIllustrated symbols 1 to 0 are printed on thetop right of each page and indicate the subjectof each chapter.1General inform

CONTENTSGENERAL INFORMATION ...1SPECIAL TOOLS ...

CHASSIS .......37FRONT WHEELS AND BRAKE DISCS ...

GENINFO– 1 –SPECIAL TOOLSGENERAL INFORMATIONEB102001SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assem