Yamaha YFM660FP 2001, Assembly Manual

Page 1: ...YFM660FP ASSEMBLY MANUAL 5KM 28107 10 LIT 11666 15 01 ...

Page 2: ... bystander or a person inspecting or repairing the machine CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedures easier or clearer PREPARATION To assemble the machine correctly supplies and working space are required Supplies Oils greases shop rags Workshop The workshop where the machine is assemble...

Page 3: ...of rubber or plastics A Ref No indicating the order or operations B Part name C Quantity of parts per machine D Place where parts are held 1 Refer to PARTS LOCATION V Stored in vinyl bag C Stored in carton box S Fixed inside the steel frame and or contained in the styrofoam tray upper or lower Temporarily installed or secured Example 1 V 1 signifies the location of the parts and V signifies that t...

Page 4: ... 1 4 3 2 6 1 6 7 See view a 7 5 7 4 3 See view a PARTS LOCATION 1 Vinyl pack 2 Vinyl pack 3 Carton box 4 Carton box 5 Carton box 6 Rear wheel 7 Front wheel ...

Page 5: ...nge bolts front shock absorber Handlebar switch and panhead screws Rear brake light switch lever Brake master cylinder bracket and flange bolts Throttle housing bracket and panhead screws with spring washer Vinyl bag 1 Vinyl bag 2 Vinyl bag 4 Handlebar holder and flange bolts Vinyl bag 3 Vinyl bag 5 ...

Page 6: ...rbers 4 Carton box Battery bracket Handlebar cover Fuel tank breather hose Low pressure air gauge Bands handlebar Handlebar holder and flange bolts Owner s tool kit and band Owner s manual Vinyl bag 1 Flange bolts rear shock absorber ...

Page 7: ...d rear wheels Self locking nuts front and rear shock absorbers Flange bolts battery bracket Flange bolts engine skid plate Vinyl bag 2 Flange bolts and spring nuts front protector Bolts with plain washer rear protector ...

Page 8: ... 5 Protectors front arms Protectors rear arms Fuel tank side panels Engine skid plate front Engine skid plate center Engine skid plate rear 5 Carton box 6 Front wheels 7 Rear wheels Electrolyte ...

Page 9: ...PACKING 1 Remove the frame cover 1 2 Remove the bolts 2 lower handlebar holder 3 Remove the bolt 3 and bracket rear carrier 4 Remove the packing frames 4 upward and sideways 5 Remove the stays 5 left and right rear arms ...

Page 10: ... opening the crate place the ATV on a suitable rack and follow the setup procedures Before starting the setup supply the specified tire pressure to the four wheels WARNING This model is equipped with low pressure tires Refer to ADJUSTMENTS AND PREDELIVERY SERVICE ...

Page 11: ...bolt 1 1 2 2 2 V 2 V d 6 0 24 R 22 0 87 A Tighten the bolts to specified torque Tightening torque 7 Nm 0 7 m kg 5 1 ft lb B Check the brake lever for smooth action 1 2 3 Throttle housing Bracket Panhead screw with spring washer 1 1 2 2 2 V 2 V d 5 0 20 R 20 0 79 A Fit the throttle housing projection to the brake master cylinder WARNING Proper cable routing is essential to assure safe machine opera...

Page 12: ...ead NOTE Refer to CABLE ROUTING 4 Rear brake cable and rear brake light switch 1 2 Rear brake cable Rear brake light switch 1 1 2 2 5 Handlebar switch 1 2 2 2 V Handlebar switch Panhead screw 1 2 A Tighten the screws in stages and maintain an equal gap on each side of the handlebar switch WARNING Proper cable routing is essential to assure safe machine operation Refer to CABLE ROUTING d 5 0 20 R 3...

Page 13: ...er to CABLE ROUTING 8 Front shock absorbers 1 2 4 V 5 V Flange bolt Self lock nut 2 2 d 10 0 39 R 48 1 89 d 10 0 39 A Tighten the nuts to specified torque Tightening torque 45 Nm 4 5 m kg 32 ft lb 9 Protectors front arms Protector Spring nut Flange bolt 1 2 3 2 2 2 5 C 4 V 4 V d 6 0 24 R 12 0 47 A Tighten the bolt to specified torque Tightening torque 7 Nm 0 7 m kg 5 1 ft lb ...

Page 14: ...bsorber Flange bolt Self lock nut 1 2 3 2 4 4 3 C 4 V 4 V d 10 0 39 R 48 1 89 d 10 0 39 12 Front wheels 1 2 Front wheel Nut 2 8 6 S 4 V d 10 0 39 A Install the wheels so that air valve is outside B The arrow mark on the tire must point toward the rotating direction of the wheel C Tighten the nuts to specified torque Tightening torque 55 Nm 5 5 m kg 40 ft lb A Tighten the bolts to specified torque ...

Page 15: ...Tighten the bolts to specified torque Tightening torque 7 Nm 0 7 m kg 5 1 ft lb 1 2 Rear wheel Nut 2 8 7 S 4 V d 10 0 39 A Install the wheels so that air valve is outside B The arrow mark on the tire must point toward the rotating direction of the wheel C Tighten the nuts to specified torque Tightening torque 55 Nm 5 5 m kg 40 ft lb 15 Fuel tank side panels 1 Fuel tank side panel 2 5 C d 6 0 24 R ...

Page 16: ...t connect the lead black lead to the terminal 1 2 3 4 Battery Battery bracket Flange bolt Bolt 1 1 2 2 4 C 4 V d 6 0 24 R 12 0 47 d 6 0 24 R 16 0 63 17 Owner s manual A NOTE Put this owner s manual in the vinyl bag and always carry them in the rear fender 18 Seat 1 Seat 1 A Insert the lobes on the seat front into the receptacles on the frame then push down the seat at the end Owner s manual Owner ...

Page 17: ... brake light switch 2 Rear brake cable 3 Starter cable 4 Front brake hose 5 Throttle cable 6 Battery negative lead 7 Battery positive lead Å Clamp the handlebar switch lead and rear brake light switch lead ı Clamp the front brake light switch lead and on command four wheel drive switch lead 7 6 1 2 3 4 5 Å ı ...

Page 18: ... 15 ADJUSTMENTS AND PREDELIVERY SERVICE B K G E CHI A F O B D KLMO N P JM Q H Q ...

Page 19: ...electrolyte may stop flowing Never remove the container from the battery until all electrolyte has drained from the container g Leave the container in this position for 20 minutes or longer to allow proper chemical reaction NOTE Make sure air bubbles are rising from all six filler ports If air bubbles are not rising from a filler port tap the top of the container a few times h Be certain that all ...

Page 20: ...specification The tire could separate from the wheel under severe operating conditions WARNING FUEL IS HIGHLY FLAMMABLE Always turn off the engine when draining Take care not to spill any fuel on the engine or exhaust pipe s muffler s when draining Never drain fuel while smoking or in the vicinity of an open flame 4 Retighten the drain screw securely and connect the drain hose 2 5 Install Fuel tan...

Page 21: ... level inspection 1 Place the machine on a level place 2 Remove Oil filler bolt 1 3 Check Oil level Oil level should be up to the brim of hole Oil level low Add oil to proper level Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity periodic oil change 0 28 L 0 25 Imp qt 0 30 US qt CAUTION Take care not allow foreign material to enter the differential gear case 4 Install Oil filler bolt T...

Page 22: ...several minutes 2 Check Engine idling speed Out of specification Adjust Engine idling speed 1 450 1 550 r min 3 Remove Seat Fuel tank side panel left 4 Adjust Turn the throttle stop screw 1 in or out until specified idling speed is obtained Turning in Idling speed becomes higher Turning out Idling speed becomes lower 5 Install Fuel tank side panel left Seat 1 2 a J Throttle lever free play adjustm...

Page 23: ...emove the rear brake master cylinder cover Loosen the locknut 3 Turn the adjusting bolt 4 until the brake pedal height is with in the specified limits Rear brake pedal height 45 mm 1 77 in Tighten the locknut 3 NOTE When adjusting the brake pedal height make sure the locknut to adjusting bolt clearance b does not exceed 1 mm 0 04 in Loosen the locknut 5 Pull up the brake outer cable and turn the b...

Page 24: ...s been disassembled A brake hose or brake pipe have been loosened or removed The brake fluid has been very low The brake operation has been faulty A loss of braking performance may occur if the brake system is not properly bled Å Front brake ı Rear brake Air bleeding steps a Add proper brake fluid to the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to ...

Page 25: ...REVERSE Check that locknuts 2 are tightened correctly If the operation of the select lever is incorrect adjust the select lever control cable 3 with the adjuster 4 Select lever shift rod Make sure the select lever is in NEUTRAL Loosen both locknuts 5 Adjust the shift rod length for smooth and correct shifting Tighten the locknuts 5 P Front shock absorber adjustment WARNING Always adjust both front...

Page 26: ... 23 1 R Headlight beam adjustment 1 Adjust Headlight beam vertically Turn the adjuster 1 in or out Turning in Headlight beam raised Turning out Headlight beam lowered ...

Page 27: ... engine speed Spark plug Type Gap Fuel Recommended fuel Fuel tank capacity Valve clearance cold IN EX STANDARD EQUIPMENT No 1 2 3 Parts name Owner s manual Owner s tool kit Low pressure air gauge Q ty 1 1 1 OWNER S TOOL KIT No 1 2 3 4 5 6 7 Parts name Owner s tool bag Spark plug wrench 19 Screwdriver grip Screwdriver bit Phillips head and slotted head Pliers Wrench 10 12 Wrench 14 17 Q ty 1 1 1 1 ...

Page 28: ...w M8 6 0 6 4 3 Rear brake caliper and drive pinion gear bearing housing M10 40 4 0 29 Rear brake caliper bleed screw M8 6 0 6 4 3 Handlebar holder M8 20 2 0 14 Steering stem bearing retainer M42 40 4 0 29 Steering stem and pitman arm M14 110 11 0 80 Steering stem and frame M8 23 2 3 17 Pitman arm and tie rod M10 25 2 5 18 Steering knuckle and tie rod M10 25 2 5 18 Steering knuckle and front arm up...

Page 29: ...ame M10 55 5 5 40 Final drive gear case filler plug M20 23 2 3 16 Final drive gear case drain bolt M14 23 2 3 16 Final drive gear oil check bolt M8 10 1 0 7 2 Ring gear bearing housing and final drive gear case M10 40 4 0 29 Ring gear bearing housing and final drive gear case M8 23 2 3 16 Drive pinion gear bearing housing and final drive case M8 23 2 3 16 Coupling gear and final drive pinion gear ...

Page 30: ...PRINTED IN U S A YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...