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Yamaha YFM660FS, Owner'S Manual

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Yamaha YFM660FS Owner'S Manual Download Page 8

PERIODIC MAINTENANCE AND 
ADJUSTMENT.................................. 8-1

Owner’s manual and tool kit............ 8-1
Periodic maintenance/

lubrication ...................................... 8-3

Panel removal and installation ........ 8-5
Engine oil and oil filter cartridge .... 8-12
Final gear oil .................................. 8-17
Differential gear oil......................... 8-19
Cooling system.............................. 8-21
Axle boots...................................... 8-26
Spark plug inspection .................... 8-27
Air filter element cleaning .............. 8-30
Spark arrester cleaning ................. 8-33
Carburetor adjustment................... 8-35
Idle speed adjustment ................... 8-36
Valve clearance adjustment .......... 8-36
Throttle lever adjustment............... 8-37
Front brake pad check .................. 8-37
Rear brake pad inspection ............ 8-38
Inspecting the brake fluid level...... 8-38
Brake fluid replacement................. 8-40
Front brake lever free play ............ 8-41

Rear brake lever and pedal 

adjustment ...................................8-42

Adjusting the rear brake light 

switch ...........................................8-44

Cable inspection and lubrication....8-44
Brake lever and brake pedal 

lubrication.....................................8-45

Rear knuckle upper and lower 

pivot lubrication ............................8-46

Wheel removal ...............................8-46
Wheel installation...........................8-47
Battery............................................8-48
Battery maintenance......................8-49
Fuse replacement ..........................8-49
Replacing a headlight bulb ............8-51
Headlight beam adjustment...........8-52
Tail/brake light bulb 

replacement .................................8-53

Troubleshooting .............................8-53
Troubleshooting charts ..................8-55

8

U5KM12.book  Page 3  Wednesday, March 26, 2003  3:50 PM

Summary of Contents for YFM660FS

Page 1: ...r riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control Improper ATV use can result in SEVERE INJ...

Page 2: ...EBU00776...

Page 3: ...l techniques and skills necessary to ride your ATV It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your ATV please cons...

Page 4: ...ol 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...

Page 5: ...rrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine EBU00981 YFM660FS OWNER S MANUAL 2003 by Yamaha Moto...

Page 6: ...l 3 3 1 2 3 CONTROL FUNCTIONS 4 1 Main switch 4 1 Indicator and warning lights 4 2 Speedometer unit 4 4 Fuel gauge 4 6 Handlebar switches 4 6 Throttle lever 4 13 Speed limiter 4 14 Front brake lever 4...

Page 7: ...Warming up 6 3 Drive select lever operation and reverse driving 6 4 Engine break in 6 7 Parking 6 8 Parking on a slope 6 9 Accessories and loading 6 10 RIDING YOUR ATV 7 1 Getting to know your ATV 7 3...

Page 8: ...brake pad check 8 37 Rear brake pad inspection 8 38 Inspecting the brake fluid level 8 38 Brake fluid replacement 8 40 Front brake lever free play 8 41 Rear brake lever and pedal adjustment 8 42 Adjus...

Page 9: ...A Cleaning 9 1 B Storage 9 3 SPECIFICATIONS 10 1 NOISE REGULATION 11 1 MAINTENANCE RECORD 12 1 ATV LIMITED WARRANTY 13 1 YAMAHA EXTENDED SERVICE Y E S 14 1 9 10 11 12 13 14 U5KM12 book Page 4 Wednesd...

Page 10: ...1 1 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5KM12 book Page 1 Wednesday March 26 2003 3 50 PM...

Page 11: ...move any labels from your ATV If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 85 kg 187 lbs 4WV 24877 A0 LOAD LIMIT PULLING LOAD TONGUE WEIGH...

Page 12: ...1 3 5 6 7 U5KM12 book Page 3 Wednesday March 26 2003 3 50 PM...

Page 13: ...if you are under the age of 16 increases your chance of severe injury or death WARNING Turning the ATV in 4WD LOCK DIFF LOCK takes more effort Operate at a slow speed and allow extra time and distance...

Page 14: ...urse Begin ners should receive training from a certified instructor Contact an authorized ATV dealer or call 1 800 887 2887 to find out about the training courses nearest you Always follow the age rec...

Page 15: ...ocedures and schedules described in this man ual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always go slowly and be extra careful when operati...

Page 16: ...possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the...

Page 17: ...your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When i...

Page 18: ...of ignition such as the pi lot lights of water heaters and clothes dryers When transporting the ATV in another vehicle be sure it is kept upright and that the fuel cock is in the OFF posi tion Otherwi...

Page 19: ...n a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate v...

Page 20: ...select lever 11 Fuel tank cap 12 Fuel cock 13 Fuses 14 Battery 15 Engine oil dipstick 16 Recoil starter 17 Coolant reservoir 18 Drive select lever box check hose 19 V belt cooling duct check hose 20 R...

Page 21: ...ng spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION EBU00035 Key identification num...

Page 22: ...hicle identification number is used to identify your machine EBU00787 Model label The model label is affixed to the location in the illustration Record the information on this la bel in the space prov...

Page 23: ...U00942 Main switch Functions of the respective switch positions are as follows ON The engine can be started only at this position and the headlights and taillight come on when the light switch is on O...

Page 24: ...dicator light comes on along with the differential gear lock indicator in the display when the differential gear lock switch is set to the LOCK 4WD position EBU01122 Low range indicator light L This i...

Page 25: ...mes on when the drive select lever is in the P park position EBU01131 Four wheel drive indicator This indicator comes on when the 2WD 4WD switch is set to the 4WD position The differential lock indica...

Page 26: ...reduce the load to specification After restarting make sure that the light is out Continuous use while the light is on may cause damage to the engine _ EBU01132 Speedometer unit 1 Speedometer 2 Odome...

Page 27: ...s tance that can be traveled with a full tank of fu el This information will enable you to plan future fuel stops NOTE _ Holding in the TRIP ODO button and then turning the key to ON switches the disp...

Page 28: ...el cock to reserve and re fuel as soon as possible 1 Fuel level warning indicator 2 Fuel gauge 3 E segment EBU00053 Handlebar switches 1 Light switch OFF 2 Start switch 3 Engine stop switch 4 Override...

Page 29: ...otor cranks the engine when this switch is pushed CAUTION See starting instructions prior to starting the engine See page 6 1 for details EBU12050 Engine stop switch Make sure that the engine stop swi...

Page 30: ...ion about the differential gear lock switch and its function Releasing the switch restores the speed limiting function While this switch is pushed the segments of the speedometer digits will appear as...

Page 31: ...ower is supplied to the rear wheels only WARNING POTENTIAL HAZARD Riding too fast while the ATV is in 4WD LOCK WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it t...

Page 32: ...o 4WD LOCK DIFF LOCK or vice versa while the ATV is moving WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4WD and in 4WD LOCK in some circumstances Changing from 2WD to 4WD or from 4WD to...

Page 33: ...D 1 Differential gear lock switch LOCK 4WD 2 Lever Differential gear lock switch LOCK 4WD To lock the differential gear in 4WD make sure the on command four wheel drive switch is set to 4WD stop the A...

Page 34: ...ver if conditions require full engine power to be available push and hold the override switch to dis able the 4WD LOCK speed limiter See page 4 8 for a detailed explanation of this switch _ WARNING PO...

Page 35: ...sure it is operating smoothly Make sure it returns to the idle position as soon as the le ver is released WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard t...

Page 36: ...rew a 12 mm 0 47 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You cou...

Page 37: ...Front brake lever EBU00073 Rear brake pedal and lever The brake pedal is located on the right side of the machine and the brake lever is located on the left handlebar Push down on the pedal or pull t...

Page 38: ...ark positions Refer to page 6 4 for the drive select lever operation 1 Drive select lever EBU00855 Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt Then pull force...

Page 39: ...D Starting the engine without setting the drive select lever to the park position P WHAT CAN HAPPEN The ATV could start to move unexpect edly which could cause an accident HOW TO AVOID THE HAZARD Set...

Page 40: ...t running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding turn the...

Page 41: ...e A separate starter circuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op erat...

Page 42: ...the rear 1 Seat 2 Seat lock lever To install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE Make sure that the seat is secur...

Page 43: ...other documents in the storage compartment be sure to wrap them in a plastic bag so that they will not get wet When washing the ATV be careful not to let any water enter the storage compartment 1 Sto...

Page 44: ...l and installation proce dures _ Adjust the spring preload as follows To increase the spring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in...

Page 45: ...tment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right si...

Page 46: ...iary DC jack should only be used when the engine is running 1 Auxiliary DC jack cap 1 Set the light switch to OFF 2 Start the engine See pages 6 1 6 3 3 Open the auxiliary DC jack cap and then insert...

Page 47: ...ssories are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may be come difficult Do not use an automotive cigarette lighter or ot...

Page 48: ...ary 5 7 8 12 8 17 Coolant reservoir tank Check coolant level Fill with coolant if necessary 8 21 8 25 Final gear oil Differential gear oil Check for leakage 5 8 8 17 8 20 Throttle Check for proper thr...

Page 49: ...CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe op erating condition Always...

Page 50: ...fluid level Check the brake fluid level Add fluid if necessary See pages 8 38 8 40 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or master cylinder Apply the b...

Page 51: ...d to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any problem with the brakes If a problem cannot be corrected by the ad justm...

Page 52: ...g occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Gasohol There are two types of gasohol gasohol con t...

Page 53: ...ank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pip...

Page 54: ...oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase _ EBU00493 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessa...

Page 55: ...l gear oil Make sure the differential gear oil is at the specified level Add oil as necessary See pages 8 19 8 20 for details Recommended oil SAE 80 API GL 4 Hypoid gear oil U5KM12 book Page 8 Wednesd...

Page 56: ...details CAUTION _ Hard water or salt water is harmful to the engine You may use soft water if you can not get distilled water _ Coolant reservoir capacity up to the maximum level mark 0 3 L 0 26 Imp...

Page 57: ...e tightness of chassis fittings and fasteners before a ride Take the machine to a Yamaha dealer or refer to the Service Manual for correct tightening torque EBU10030 Lights Check the headlights and ta...

Page 58: ...are not recommended ACE 01EACE 01E Manufacturer Size Type Front DUNLOP AT25 8 12 KT131 Rear DUNLOP AT25 10 12 KT135 2 The tires should be set to the rec ommended pressure Recommended tire pressure Fr...

Page 59: ...e tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the ti...

Page 60: ...e could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifica tions ACE 02EACE 02E 1 Low pressure tire gauge Recommended pressure Minimum M...

Page 61: ...5 14 EBU00160 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit U5KM12 book Page 14 Wednesday March 26 2003 3 50 PM...

Page 62: ...liar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not un...

Page 63: ...ark before starting the engine 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 2 Cold engine start ambient temperature at 0...

Page 64: ...keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the starter choke to position 3 before riding CAUTION See the Engine b...

Page 65: ..._ Shifting Neutral to High and High to Low 1 Bring the machine to a complete stop and return the throttle lever to the closed position 2 Apply the brakes then shift by moving the drive select lever al...

Page 66: ...r from re verse to park and vice versa by moving the drive select lever along the shift guide 1 Drive select lever NOTE _ When in reverse the reverse indicator light should be on If the light does not...

Page 67: ...properly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person be hind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obs...

Page 68: ...h might result in ex cessive engine heating must be avoided However momentary 2 3 seconds maxi mum full throttle operation under load does not harm the engine Each full throttle acceleration sequence...

Page 69: ...ll throttle at any time 3 After break in Avoid prolonged full throttle operation Vary speeds occasionally EBU00612 Parking When parking stop the engine and shift the drive select lever into the park p...

Page 70: ...HAPPEN The ATV could roll out of control in creasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the machine transve...

Page 71: ...a genuine Yamaha accessory or one that is equiva lent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are riding c...

Page 72: ...the maximum vehicle load limit Load cargo on the carrier as close to the center of the vehicle as possible Put cargo at the front of the rear carrier Center the load from side to side Tie down cargo s...

Page 73: ...d hills and rough terrain Choose ter rain carefully Added weight affects the sta bility and handling of the ATV WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improperly WH...

Page 74: ...6 13 EBU00956 WARNING _ Indicates a potential hazard that could result in serious injury or death U5KM12 book Page 13 Wednesday March 26 2003 3 50 PM...

Page 75: ...7 1 7 Riding Your ATV U5KM12 book Page 1 Wednesday March 26 2003 3 50 PM...

Page 76: ...7 2 U5KM12 book Page 2 Wednesday March 26 2003 3 50 PM...

Page 77: ...ice over a period of time Take the time to learn the basic tech niques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of...

Page 78: ...e attempting more difficult maneu vers WARNING POTENTIAL HAZARD Operating this ATV without proper in struction WHAT CAN HAPPEN The risk of an accident is greatly in creased if the operator does not kn...

Page 79: ...mmenda tions for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not rec ommended for their age can lead to se vere injury or death of the child HOW TO AVOID THE HAZARD A child under 16 shou...

Page 80: ...PPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat i...

Page 81: ...ident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your chances...

Page 82: ...ARD Operating this ATV after consuming al cohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and percep tion Could resul...

Page 83: ...n Always follow the in spection and maintenance procedures and schedules described in the Owner s Manual WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire...

Page 84: ...crewing in the adjuster limits the max imum engine power available and decreases the maximum speed of the ATV Turning the screw in decreases top speed and turning it out increases top speed 1 Locknut...

Page 85: ...0 kgf 1 212 lbf Total weight of trailer and cargo Tongue weight 15 kgf 33 lbf Vertical weight on trailer hitch point WARNING POTENTIAL HAZARD Overloading this ATV or carrying or tow ing cargo improper...

Page 86: ...even one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into c...

Page 87: ...ING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident in cluding an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies...

Page 88: ...ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improp er installation or use of accessories All parts and accessories added to this ve hicle should be genuine Y...

Page 89: ...brush or other combustible material accumulated around the en gine area could catch fire Someone touching the exhaust system during or after operation could be burned HOW TO AVOID THE HAZARD Do not o...

Page 90: ...ng this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of con tro...

Page 91: ...erating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dir...

Page 92: ...se extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturn ing or going out...

Page 93: ...or vehicle control which could result in an acci dent including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced t...

Page 94: ...assing Do not ride on private property without getting permission WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a c...

Page 95: ...ing to come in contact with these components With the engine idling shift the drive select le ver to the low position L or the high position H Apply the throttle slowly and smoothly The centrifugal cl...

Page 96: ...tion As you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through...

Page 97: ...is technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much sp...

Page 98: ...rtant when climbing a hill to make sure that your weight is transferred forward on the ATV This can be accomplished by lean ing forward and on steeper inclines standing on the footboards and leaning f...

Page 99: ...n er s Manual Always check the terrain carefully be fore you start up any hill Never climb hills with excessively slip pery or loose surfaces Shift your weight forward Never open the throttle suddenly...

Page 100: ...TENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on an...

Page 101: ...a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV U5KM12 book Page 27 W...

Page 102: ...ill brake all wheels When descending hills using either brake lever or the brake ped al will brake the wheels on the downhill side Avoid sudden application of either the front or rear brake because th...

Page 103: ...t brake 4WD or 4WD LOCK Apply both front and rear brakes gradually When fully stopped shift to the park ing position P Dismount on uphill side or to a side if pointed straight uphill Turn the ATV arou...

Page 104: ...y also cause a loss of traction When this ATV is in 4WD or 4WD LOCK all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake wi...

Page 105: ...anual Note a special technique is required when braking as you go down a hill HOW TO AVOID THE HAZARD Always check the terrain carefully be fore you start down any hill Shift your weight backward Neve...

Page 106: ...gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING POTENTIAL HAZARD Improp...

Page 107: ...7 33 U5KM12 book Page 33 Wednesday March 26 2003 3 50 PM...

Page 108: ...NG POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE...

Page 109: ...N _ After riding your ATV in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case and the check hose on the V belt cooling duct Wash the ATV in fres...

Page 110: ...7 36 1 V belt cooling duct check hose Left side 1 V belt case drain plug 1 Drive select lever box check hose U5KM12 book Page 36 Wednesday March 26 2003 3 50 PM...

Page 111: ...rol and damage to the ATV may result WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a colli sion Could cause the ATV to overturn HOW TO AVO...

Page 112: ...wheels to slide in loose or slippery conditions position ing your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways control can usually be regaine...

Page 113: ...ontrol may be lost WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overtur...

Page 114: ...sary gradually let off the throttle and or steer to the outside of the turn See pag es 7 22 7 23 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying...

Page 115: ...mount on the uphill side See pages 7 32 7 33 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the ATV an...

Page 116: ...ag and always carry it in the storage box Put the owner s tool kit and low pressure tire gauge in the space beside the battery 1 Owner s manual 2 Owner s tool kit 3 Low pressure tire gauge WARNING POT...

Page 117: ...er to check the torque settings and adjust them as neces sary _ WARNING POTENTIAL HAZARD Operating this ATV with improper modi fications WHAT CAN HAPPEN Improper installation of accessories or modific...

Page 118: ...Adjust engine idling speed Crankcase breather system Check breather hose for cracks or damage Replace engine idling speed Exhaust system Check for leakage Tighten if necessary Replace gasket s if nec...

Page 119: ...cracks or damage Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary Lights and switches Check operation Adjust headlight beam ITEM ROUTINE Whichever comes first INITI...

Page 120: ...d need to be removed to perform some of the maintenance described in this chapter Refer to this section each time a panel has to be removed or reinstalled 1 Panel A 2 Panel C 3 Panel B 4 Panel D 5 Pan...

Page 121: ...D To remove 1 Remove the seat See page 4 20 for seat removal and installation proce dures 2 Pull outward on the area shown and then pull upward as shown 1 Panel A 1 Panel D U5KM12 book Page 6 Wednesd...

Page 122: ...ll 1 Insert the panel projections in the numer ical order shown in the illustration and then push inward on the area shown 2 Install the seat 1 Panel A 1 Panel D U5KM12 book Page 7 Wednesday March 26...

Page 123: ...e the bolts To install Place the panel in the original position and in stall the bolts 1 Panel B 2 Bolt 2 CAUTION _ When installing the panel be sure not to pinch the cables or wires _ U5KM12 book Pag...

Page 124: ...front carrier by removing the stay covers at the rear then by removing the bolts 2 Remove the quick fasteners and pull the panel upward 1 Front carrier stay cover 2 1 Bolt 2 TOP 1 Bolt 2 TOP U5KM12 b...

Page 125: ...nstall the quick fasteners 2 Install the front carrier by installing the bolts and tightening them to the specified torques 3 Install the stay covers Tightening torques Carrier bolt top 26 Nm 2 6 m kg...

Page 126: ...and then take the panel off To install Place the panel in the original position and then install the bolts 1 Panel E 2 Bolt 6 EBU00638 Panel F To remove Pull outward on the areas shown 1 Panel F U5KM...

Page 127: ...cartridge replaced at the inter vals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Remove panel F See pages 8 11 8 12 for panel removal and installation...

Page 128: ...cap 2 Dipstick 6 Insert the dipstick in the oil filler hole without screwing it in and then remove it again to check the oil level NOTE _ The engine oil should be between the mini mum and maximum leve...

Page 129: ...ne oil with or without oil filter cartridge replacement 1 Remove panel F See pages 8 11 8 12 for panel removal and installation proce dures 2 Start the engine warm it up for several minutes and then t...

Page 130: ...move the oil filter cartridge with an oil filter wrench 1 Engine oil filter cartridge 2 Oil filter wrench NOTE _ An oil filter wrench is available at a nearby Yamaha dealer _ 7 Apply a light coat of e...

Page 131: ...fied amount of recommend ed engine oil and then install the engine oil filler cap and tighten it Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drain bol...

Page 132: ...oil leakage If oil leakage is found turn the engine off immediately and check for the cause 13 Turn the engine off and then check the oil level and correct it if necessary 14 Install panel F EBU00880...

Page 133: ...tighten to the specified torque 7 Check for oil leakage If oil leakage is found check for the cause Tightening torque Drain bolt final gear case 23 Nm 2 3 m kgf 16 ft lbf Recommended oil See page 10 3...

Page 134: ...l filler bolt 3 Specified level CAUTION _ Be sure no foreign material enters the dif ferential gear case _ 3 Install the oil filler bolt and tighten it to the specified torque Differential gear oil re...

Page 135: ...nstall the filler bolt and tighten it to the specified torque 7 Check for oil leakage If oil leakage is found check for the cause Tightening torque Drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf Recommended oi...

Page 136: ...nimum level mark 3 If the coolant is at or below the minimum level mark remove panel D See pages 8 6 8 7 for panel removal and installa tion procedures remove the reservoir cap add coolant to the maxi...

Page 137: ...e 8 56 for de tails EBU00887 Changing the coolant WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and st...

Page 138: ...container under the engine and then remove the coolant drain bolt Use a trough or a similar object as shown to prevent coolant from spilling on the foot rest 1 Coolant drain bolt 1 Trough 4 Remove the...

Page 139: ...coolant reservoir 1 Coolant reservoir drain hose 8 After draining the coolant thoroughly flush the cooling system with clean tap water 9 Replace the coolant drain bolt washer if it is damaged and then...

Page 140: ...aches the top of the radiator 14 Fill the coolant reservoir with coolant up to the maximum level 15 Install the coolant reservoir cap and check for coolant leakage NOTE _ If any leakage is found have...

Page 141: ...ots Check the protective boots for holes or tears If any damage is found have them replaced by a Yamaha dealer 1 Front axle boot 2 each side 1 Rear axle boot 2 each side U5KM12 book Page 26 Wednesday...

Page 142: ...See pages 8 6 8 7 for panel removal and installation proce dures 2 Remove the spark plug cap 1 Spark plug cap 3 Use the spark plug wrench in the tool kit to remove the spark plug as shown 1 Spark plu...

Page 143: ...ng ridden normally Do not attempt to diagnose such problems yourself Instead take the ATV to a Yamaha dealer You should periodically re move and inspect the spark plug because heat and deposits will c...

Page 144: ...specified torque NOTE _ If a torque wrench is not available when you are installing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightene...

Page 145: ...and clean the air filter element and air filter case _ 1 Air filter case check hose 1 Remove the seat See page 4 20 for seat removal and installation proce dures 2 Remove the air filter case cover by...

Page 146: ...t the air filter element when squeezing it _ 7 Inspect the air filter element and replace it if damaged WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the air filter ele...

Page 147: ...the machine is operated in extremely dusty areas Each time air filter ele ment maintenance is performed check the air inlet to the air filter case for obstructions Check the air filter element rubber...

Page 148: ...pipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon depos its from the spark arrester portion of the tailpipe 4 Insert the tailpipe into the...

Page 149: ...g of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Could cause carbon monoxide poison ing possibly leading to death Could start a fire HOW TO AVOID THE...

Page 150: ...tment The carburetor is a vital part of the engine and requires very sophisticated adjustment Most adjusting should be left to a Yamaha dealer who has the professional knowledge and ex perience to do...

Page 151: ...lug lead and then set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in direction a to increase the engine speed and in direc tion b to decrease the engine...

Page 152: ...the locknut 1 Locknut 2 Adjusting bolt a Throttle lever free play EBU13090 Front brake pad check Check the brake pads for damage and wear If a brake pad thickness is less than 1 mm 0 04 in have a Yam...

Page 153: ...U00875 Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above...

Page 154: ...s may dete riorate causing leakage and poor brake performance 3 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance 4 Be...

Page 155: ...goes down EBU11860 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service personnel Have a Yamaha dealer replace the following components during periodic mai...

Page 156: ...akes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct Make...

Page 157: ...lever free play 2 Turn the adjusting bolt in direction a to increase free play and in direction b to decrease free play 3 Tighten the locknut If correct free play cannot be obtained ask a Yamaha deal...

Page 158: ...HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brake...

Page 159: ...t in direction b 1 Rear brake light switch 2 Adjusting nut EBU00356 Cable inspection and lubrication Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a Yamaha de...

Page 160: ...45 EBU00717 Brake lever and brake pedal lubrication Lubricate the pivoting parts Recommended lubricant Lithium soap based grease all purpose grease U5KM12 book Page 45 Wednesday March 26 2003 3 50 PM...

Page 161: ...ase gun 1 Upper knuckle 2 Lower knuckle EBU01112 Wheel removal 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel...

Page 162: ...side towards the wheel The arrow mark on the tire must point toward the rotating direction of the wheel _ 1 Arrow mark 1 Tapered nut 2 Lower the ATV so that the wheel is on the ground 3 Tighten the wh...

Page 163: ...severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near bat...

Page 164: ...sealed type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the machine EBU00876 Fuse replacem...

Page 165: ...ecified fuses Main fuse 30A Headlight fuse 15A Ignition fuse 10A Auxiliary DC jack fuse 10A Four wheel drive fuse 3A Signaling system fuse 10A Odometer fuse backup 10A WARNING POTENTIAL HAZARD Using a...

Page 166: ...out replace it as fol lows 1 Remove the bulb holder cover at the rear of the headlight by pulling it off 1 Cover 1 Bulb holder cover 2 Remove the headlight bulb holder by turning it counterclockwise...

Page 167: ...It is advisable to have a Yamaha dealer make this adjustment _ To raise the beam turn the adjusting screw in direction a To lower the beam turn the adjusting screw in direction b 1 Headlight beam adju...

Page 168: ...arting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your machine requires any repair take it to a Yamaha dealer The skilled technicians at a Yamaha...

Page 169: ...PEN Fuel can ignite or explode causing se vere injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area inc...

Page 170: ...compression Ask a Yamaha dealer to inspect 3 Ignition Remove the spark plug and check the electrodes Wet Wipe clean with dry cloth Dry Attach spark plug cap and ground to chassis Use the electric sta...

Page 171: ...Wait for the engine to cool before re moving the radiator cap Always use a thick rag over the cap Allow any re maining pressure to escape before completely removing the cap Wait until the engine has c...

Page 172: ...3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes trans...

Page 173: ...ch may mar the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brake...

Page 174: ...ve the spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and rein stall the spark plug Ground the spark plug wire and turn the engine over seve ral times to c...

Page 175: ...dry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F NOTE Make any necessary repairs before storing the machi...

Page 176: ...arance 275 mm 10 8 in Minimum turning radius 3 200 mm 126 0 in Basic weight With oil and full fuel tank 290 kg 639 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclin...

Page 177: ...ter cartridge replacement 1 9 L 1 67 Imp qt 2 01 US qt With oil filter cartridge replacement 2 0 L 1 76 Imp qt 2 11 US qt Model YFM660F CAUTION In order to prevent clutch slippage since the en gine oi...

Page 178: ...I GL 4 Hypoid gear oil Quantity Periodic oil change 0 28 L 0 25 Imp qt 0 30 US qt Total amount 0 33 L 0 29 Imp qt 0 35 US qt Air filter Wet type element Fuel Type UNLEADED GASOLINE ONLY Fuel tank capa...

Page 179: ...Shaft drive Secondary reduction ratio 41 21 24 18 33 9 9 544 Transmission type V belt automatic Operation Left hand operation Reverse gear 25 17 1 471 Sub transmission ratio low 35 17 2 058 high 26 21...

Page 180: ...ion Double wishbone Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 170 mm 6 69 in Rear wheel travel 225 mm 8 86 i...

Page 181: ...ture warning light LED 1 Park indicator light LED 1 High range indicator light LED 1 Low range indicator light LED 1 Differential gear lock indicator light LED 1 Fuses Main fuse 30A Headlight fuse 15A...

Page 182: ...ose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inope...

Page 183: ...enance work ACL 02EACL 02E MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS 200 mi 320 km or 20 hours 750 mi 1 200 km or 75 hours 1 500 mi 2 400 km or 150 hours 3...

Page 184: ...13 1 EBU00432 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY U5KM12 book Page 1 Wednesday March 26 2003 3 50 PM...

Page 185: ...13 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 U5KM12 book Page 2 Wednesday March 26 2003 3 50 PM...

Page 186: ...14 1 EBU00435 YAMAHA EXTENDED SERVICE Y E S U5KM12 book Page 1 Wednesday March 26 2003 3 50 PM...

Page 187: ...14 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EBU00436 WARNING _ Indicates a potential hazard that could result in serious injury or death U5KM12 book Page 2 Wednesday March 26 2003 3 50 PM...

Page 188: ...EBU00437 U5KM12 book Page 3 Wednesday March 26 2003 3 50 PM...

Page 189: ...r riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control Improper ATV use can result in SEVERE INJ...

Page 190: ...Card fm Page 1 Wednesday June 13 2001 9 35 AM...

Page 191: ...Card fm Page 2 Wednesday June 13 2001 9 35 AM...

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