Yamaha Raptor 660 Service Manual.pdf

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YFM660RN

YFM660RNC

SERVICEMANUAL

LIT-11616-14-21

5LP-28197-E0

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EB001000

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 machine has a basic understanding of the mechanical ideas and the procedures of

machine repair. Repairs attempted by anyone without this knowledge are likely to render the

machine 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.

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!

WARNING

Failure to follow WARNING instructions could result in severe injury or death

to the machine operator, a bystander or a person inspecting or repairing the

machine.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid dam-

age to the machine.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

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EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

1st title

1

: This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title

: This title indicates the section of the chapter and only appears on the first page of each

section. It is located in the upper left corner of the page.

2

3rd title

: This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

3

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.

2. Numbers

are given in the order of the jobs in the exploded diagram. A number that is enclosed

by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

6

5

. The meanings of the symbol marks are given on the next page.

4. A job instruction chart

7

accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements

are given in addition

8

to the exploded diagram and the job instruction chart.

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EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols

1

2

GEN

INFO

are printed on the

top right of each page and indicate the subject

of each chapter.

1

to

9

SPEC

3

4

General information

1

CHK

ADJ

Specifications

2

CHAS

Periodic checks and adjustments

3

Chassis

4

Engine

5

5

6

Cooling system

6

Carburetion

7

Electrical

ENG

COOL

8

Troubleshooting

9

7

8

ELEC

–

+

CARB

Illustrated symbols

are used to identify

the specifications appearing in the text.

to

0

G

9

0

TRBL

SHTG

Can be serviced with engine mounted

0

Filling fluid

A

Lubricant

B

A

B

Special tool

C

Torque

D

Wear limit, clearance

E

Engine speed

G Ω

F

, V, A

C

D

E

F

G

Illustrated symbols H to N in the exploded

diagrams indicate the types of lubricants and

lubrication points.

H

I

J

E

G

M

Apply engine oil

H

Apply gear oil

I

K

L

M

N

Apply molybdenum disulfide oil

J

Apply wheel bearing grease

K

B

M

LS

S

Apply lightweight lithium soap base grease

L

Apply molybdenum disulfide grease

M

Apply silicon grease

Illustrated symbols

N

O

P

in the exploded

diagrams indicate where to apply a locking

agent

O

to

P

New

O

and when to install a new part

P

.

LT

Apply the locking agent (LOCTITE )

O

Replace

P

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TABLE OF CONTENTS

GENERAL INFORMATION

1

GEN

INFO

SPECIFICATIONS

2

SPEC

PERIODIC CHECKS AND

ADJUSTMENTS

3

CHK

ADJ

CHASSIS

4

CHAS

ENGINE

5

ENG

COOLING SYSTEM

6

COOL

CARBURETION

7

CARB

–

+

ELECTRICAL

8

ELEC

TROUBLESHOOTING

9

TRBL

SHTG

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