Yamaha YFM660FR Supplementary Service Manual Download

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YFM660FR

5KM2-AE2

SUPPLEMENTARY

SERVICE MANUAL

Summary of Contents for YFM660FR

Page 1: ...YFM660FR 5KM2 AE2 SUPPLEMENTARY SERVICE MANUAL ...

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Page 3: ... it is necessary to use this Supplementary Service Manual together with the following manual YFM660F P 2002 SERVICE MANUAL 5KM2 AE1 YFM660FR SUPPLEMENTARY SERVICE MANUAL 2002 by Yamaha Motor Co Ltd First edition June 2002 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...fications 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 ...

Page 5: ...ntify 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 5 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 t...

Page 6: ... Special tool E Torque F Wear limit clearance G Engine speed H Ω V A Illustrated symbols I to N in the exploded diagrams indicate the types of lubricants and lubrication points I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply lightweight lithium soap based grease N Apply molybdenum disulfide grease Illustrated symbols O to P in the exploded ...

Page 7: ...T CARRIER FRONT BUMPER AND FRONT GRILL 14 FUEL TANK 15 FOOTREST BOARDS 17 ENGINE 18 CHECKING THE STARTER CABLE 18 ENGINE 19 CAMSHAFT AND CYLINDER HEAD 19 RECOIL STARTER AND AC MAGNETO 21 CHECKING THE STARTER CLUTCH 23 MIDDLE GEAR 24 MIDDLE DRIVEN SHAFT 24 REMOVING THE MIDDLE DRIVEN SHAFT 26 INSTALLING THE MIDDLE DRIVEN SHAFT 28 DRIVE TRAIN 30 FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR 30...

Page 8: ...7 FRONT WHEELS 37 REAR WHEELS AND BRAKE DISC 39 REAR WHEELS 39 STEERING SYSTEM 40 TIE ROD AND STEERING KNUCKLE 40 CHECKING THE STEERING KNUCKLE 42 REAR KNUCKLE AND STABILIZER 43 CHECKING THE REAR KNUCKLE 44 REAR ARMS AND REAR SHOCK ABSORBER 45 ...

Page 9: ...opriate tools or improvised techniques Special tools may differ by shape and part number from country to country In such a case two types are provided When placing an order refer to the list provided below to avoid any mistakes For US and CDN P N YM YU YS YK ACC Except for US and CDN P N 90890 Tool No Tool name How to use Illustration 90890 01486 YM 01486 Coupling gear holding tool This tool is ne...

Page 10: ... for Europe 5KMC for Oceania Bulb wattage quantity Headlight 12 V 30 W 30 W 2 Tail brake light 12 V 5 W 21 W 1 Indicator lights Neutral LED 1 Fuel LCD 1 Reverse LED 1 Coolant temperature warning LED 1 Park position LED 1 High gear LED 1 Low gear LED 1 Diff lock LED 1 GENERAL SPECIFICATIONS ...

Page 11: ...2 psi at 1 500 r min Pressure check location Cylinder head Item Standard Limit C D I Magneto model manufacturer F4T46972 MITSUBISHI Pickup coil resistance color 459 561 Ω at 20 C 68 F White Red White Green Rotor rotation direction sensing coil resis tance color 0 063 0 077 Ω at 20 C 68 F Red White Blue C D I unit model manufacturer F8T38671 MITSUBISHI Charging system Type A C magneto generator Mod...

Page 12: ...lb Exhaust pipe protector Bolt M6 5 11 1 1 8 Oil seal retainer Screw M5 2 7 0 7 5 1 Part to be tightened Thread size Tightening torque Remarks Nm m kg ft lb Front wheel hub and constant velocity joint M20 260 26 0 190 Stake Rear wheel hub and constant velocity joint M20 260 26 0 190 Stake Front brake master cylinder and handlebar M8 7 0 7 5 1 LT TIGHTENING TORQUES ...

Page 13: ...er hose 8 Ground lead 9 Speed sensor lead 0 AC magneto lead A Carburetor breather hose B Starter cable C Fuel hose D Thermo switch 1 lead E Reverse switch lead F AC magneto coupler G Gear position switch coupler H Speed sensor coupler I Radiator fan breather hose J Rectifier regulator lead K Water pump breather hose B B A C D A B B 4 3 2 1 9 8 Ë Ê É È 5 C 6 7 0 A 7 J 2 I F H G D E 8 C B D Í E E D ...

Page 14: ...ds in the following order ground lead reverse switch lead speed sensor lead gear position switch lead and AC magneto lead Ê Pass the final drive gear case breather hose through the hole in air duct assembly 3 Ë To the rear fender Ì 70 90 mm 2 8 3 5 in Í Clamp the thermostat assembly breather hose and carburetor breather hose with the cable guide B B A C D A B B 4 3 2 1 9 8 Ë Ê É È 5 C 6 7 0 A 7 J ...

Page 15: ...hole Ï Insert a hook into the third hole from the bottom of the rectifier regulator bracket and then fasten the final drive gear case breather hose onto the hook B B A C D A B B 4 3 2 1 9 8 Ë Ê É È 5 C 6 7 0 A 7 J 2 I F H G D E 8 C B D Í E E D K E E Ï 3Î Ì 7 I 5 CABLE ROUTING ...

Page 16: ...e light switch lead 8 Spark plug lead 9 Fan motor breather hose 0 Fan motor lead A Brake fluid reservoir hose B Rear brake hose È Pass the rear brake cable and throttle cable through the cable guide É Pass the rear brake light switch lead main switch lead and auxiliary DC jack lead over the front fender B A 0 9 8 7 6 5 4 3 2 1 È É Ê Ë Í Ì CABLE ROUTING ...

Page 17: ...tion coil face the spark plug lead to the right side of the frame Ì To the rear fender hole Í Pass the brake light switch lead on the inside of the rear brake cable and select lever control cable and through the cable guide of the brake master cylinder cover B A 0 9 8 7 6 5 4 3 2 1 È É Ê Ë Í Ì CABLE ROUTING ...

Page 18: ...ther hose È Pass the thermo sensor 1 lead through the lead guide É Pass the crankcase breather hose through the hose guide Ê Pass the fuel sender lead through the lead guide Ë Pass the select lever control cable through the hole of the select lever unit bracket Ì Clamp the starter cable with a cable holder Í Pass the throttle cable through the cable guide C C B A A B C C 0 6 9 4 3 2 1 8 7 6 5 Ê É ...

Page 19: ...PEC Î Fasten the wire harness speed sensor coupler thermo switch 1 lead reverse switch lead and ground lead with a plastic locking tie C C B A A B C C 0 6 9 4 3 2 1 8 7 6 5 Ê É È Î Ì Ë A A 8 Í CABLE ROUTING ...

Page 20: ...ecessary Cooling system Check coolant leakage Repair if necessary Replace coolant every 24 months Spark plug Check condition Adjust gap and clean Replace if necessary Air filter Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor Check and adjust idle speed starter operation Adjust if necessary Crankcase breather system Check breather hose for cracks or damage ...

Page 21: ...hazard that could result in serious injury or death Wheel bearing Check bearing assemblies for looseness damage Replace if damaged Front and rear suspension Check operation Correct if necessary Steering system Check operation Replace if damaged Check toe in Adjust if necessary Rear upper and lower knuckle pivots Lubricate Drive shaft universal joint Lubricate Engine mount Check for cracks or damag...

Page 22: ...me Part name Q ty Remarks Removing the front carrier front bumper and front grill Remove the parts in the order below Seat and fuel tank side panels Refer to SEAT AND SIDE PANELS in CHAPTER 3 Manual No 5KM2 AE1 1 Cap 2 2 Front carrier cover 2 3 Front carrier 1 4 Front fender panel 1 5 Engine skid plate front 1 6 Front bumper protector 2 7 Front bumper 1 8 Headlight coupler 2 Disconnect 9 Front gri...

Page 23: ...AT AND SIDE PANELS in CHAPTER 3 Manual No 5KM2 AE1 Fuel tank cover Refer to HANDLEBAR COVER FUEL TANK COVER AND FRONT FENDER in CHAPTER 3 Manual No 5KM2 AE1 1 Fuel sender coupler 1 Disconnect 2 Fuel hose 1 NOTE Before disconnecting the fuel hose turn the fuel cock to OFF 3 Fuel cock lever 1 4 Fuel tank 1 NOTE When installing the fuel tank pass the fuel tank breather hose through the hole in the ha...

Page 24: ...8 4 10 7 6 5 2 1 Order Job name Part name Q ty Remarks 5 Clamp 1 6 Vacuum chamber breather hose 1 7 Differential gear case breather hose 1 8 Crankcase breather hose 1 9 Plastic band 3 10 Bushing 2 11 Plastic cover 1 For installation reverse the removal procedure ...

Page 25: ...12 8 Order Job name Part name Q ty Remarks Removing the footrest boards Remove the parts in the order below Fuel tank side panels Refer to SEAT AND SIDE PANELS in CHAPTER 3 Manual No 5KM2 AE1 1 Footrest 2 2 Left footrest board 1 3 Right footrest board 1 4 Footrest bracket 2 For installation reverse the removal procedure ...

Page 26: ...tarter cable Measure the starter plunger stroke distance a of the starter lever 3 from the fully closed to fully open positions È Fully closed position É Fully open position Connect the starter cable to the carburetor WARNING After checking the cable turn the handle bar right and left and make sure that the engine idling speed does not increase 3 Install Fuel tank side panel left Seat Starter plun...

Page 27: ...ND FUEL TANK in CHAPTER 3 Manual No 5KM2 AE1 Fuel tank plastic covers Carburetors Refer to CARBURETOR in CHAPTER 6 Manual No 5KM2 AE1 Thermostat Refer to THERMOSTAT in CHAPTER 5 Manual No 5KM2 AE1 Thermostat assembly breather hose Refer to WATER PUMP in CHAPTER 5 Manual No 5KM2 AE1 Muffler exhaust pipe Refer to ENGINE REMOVAL in CHAP TER 4 Manual No 5KM2 AE1 Thermo switch lead Refer to HOSES AND L...

Page 28: ...ap bolt 1 Refer to REMOVING INSTALLING THE CAMSHAFT AND CYLINDER HEAD in CHAPTER 4 Manual No 5KM2 AE1 2 Timing chain tensioner gasket 1 1 3 Timing chain guide exhaust 1 4 Decompressor cam guide plate 2 5 Camshaft sprocket 1 6 Camshaft 1 7 Thermo switch 1 8 Cylinder head 1 9 Cylinder head gasket 1 10 Dowel pin 2 11 Carburetor joint 1 For installation reverse the removal procedure ...

Page 29: ...olant Drain Refer to CHANGING THE COOLANT in CHAPTER 3 Manual No 5KM2 AE1 Seat and side panels engine side cover Refer to SEAT AND SIDE PANELS in CHAPTER 4 Manual No 5KM2 AE1 Left footrest board Refer to FOOTREST BOARDS Select lever unit Refer to SELECT LEVER UNIT AND COOLANT RESERVOIR in CHAPTER 4 Manual No 5KM2 AE1 Water pump assembly Refer to WATER PUMP in CHAPTER 5 Manual No 5KM2 AE1 1 Recoil ...

Page 30: ...KM2 AE1 4 Crankcase cover left gasket 1 1 5 Dowel pin 2 6 Lead holder 1 7 Pickup coil 1 8 Starter assembly 1 9 CDI rotor 1 Refer to REMOVING INSTALLING THE AC MAGNETO in CHAPTER 4 Manual No 5KM2 AE1 10 Woodruff key 1 11 Starter wheel gear 1 12 Washer 1 13 Starter idle gear shaft 1 14 Bearing 1 15 Starter idle gear 1 For installation reverse the removal procedure ...

Page 31: ...tch and hold the starter clutch NOTE Install the starter wheel gear with the groove 1 facing the CDI rotor Turn the starter wheel gear counterclockwise È to check that the starter clutch and wheel gear engage If the starter clutch and wheel gear do not engaged replace the starter clutch Turn the starter wheel gear clockwise É to check the starter wheel gear for smooth operation If operation is not...

Page 32: ...separation Refer to CRANKCASE in CHAPTER 4 Manual No 5KM2 AE1 1 Front drive shaft coupling 1 Refer to INSTALLING REMOVING THE MIDDLE DRIVEN SHAFT 2 Coupling gear 1 3 Bearing housing O ring 1 1 4 Shim Refer to MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION Manual No 5KM2 AE1 5 Middle driven pinion gear 1 Refer to REMOVING INSTALLING THE MIDDLE DRIVEN SHAFT 6 Bearing retainer 1 ...

Page 33: ... 25 ENG MIDDLE GEAR Order Job name Part name Q ty Remarks 7 Bearing retainer 1 8 Middle driven shaft 1 For installation reverse the removal procedure ...

Page 34: ...ing gear holding tool P N YM 01486 90890 01486 Coupling gear middle shaft tool P N YM 01230 90890 01229 1 2 3 Remove Bearing housing assembly 1 Removal steps Clean the outside of the middle driven shaft Place the middle driven shaft onto a hydrau lic press CAUTION Never directly press the shaft end with a hydraulic press this will result in damage to the shaft thread Install the suitable socket 2 ...

Page 35: ...hreads To loosen the retainer turn it clockwise Remove the bearing retainer and bearing Bearing retainer wrench P N YM 04128 90890 04128 5 Remove Front drive shaft coupling Oil seal 1 Bearing retainer 2 Bearing NOTE Attach the ring nut wrench 3 CAUTION The middle driven shaft bearing retainer has left handed threads To loosen the retainer turn it clockwise Ring nut wrench P N YM 38404 90890 01430 ...

Page 36: ...g retainer 1 Installation steps Place a rag 2 in the vise Secure the bearing housing edge in the vise Attach the bearing retainer wrench 3 Tighten the bearing retainer CAUTION The middle driven shaft bearing retainer has left handed threads To tighten the retainer turn it counterclockwise 3 Install Shims 1 Bearing housing NOTE Install the shims so that the tabs are positioned as shown in the illus...

Page 37: ...R 4 Install Front drive shaft coupling Washer Nut 1 NOTE Use the coupling gear holding tool 2 to hold the front drive shaft coupling Coupling gear holding tool P N YM 01486 90890 01486 1 2 LT T R 97 Nm 9 7 m kg 70 ft lb ...

Page 38: ...d plate front Front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Manual No 5KM2 AE1 Differential gear oil Drain Steering knuckle Refer to STEERING SYSTEM in CHAP TER 8 Manual No 5KM2 AE1 Front arms lower Refer to FRONT ARMS AND FRONT SHOCK ABSORBER in CHAPTER 8 Manual No 5KM2 AE1 Brake master cylinder cover Refer to FRONT AND REAR BRAKES in CHAPTER 8 Manual No 5KM2 AE1 1 Consta...

Page 39: ...R LS LS LS T R 55 Nm 5 5 m kg 40 ft Ib LS 1 5 6 3 2 1 4 Order Job name Part name Q ty Remarks 3 Differential gear case breather hose 1 Disconnect 4 Differential gear 1 5 Compression spring 1 6 Drive shaft assembly 1 For installation reverse the removal procedure ...

Page 40: ...Remove the parts in the order below 1 Gear motor O ring 1 1 NOTE Do not disassemble the gear motor or remove the pinion gear 2 Coupling gear O ring 1 1 Refer to DISASSEMBLING ASSEM BLING THE DIFFERENTIAL GEAR 3 Sttoper bolt shaft 1 1 4 Shift fork sliding gear 1 5 Shift fork 1 6 Differential gear case cover 1 7 Drive clutch 1 8 Shim left ...

Page 41: ...TY JOINTS AND DIFFERENTIAL GEAR Order Job name Part name Q ty Remarks 9 Differential gear assembly 1 0 Shim right A Circlip bearing 1 1 B Drive pinion gear 1 C Differential gear case 1 For assembly reverse the disassembly procedure ...

Page 42: ... set Bearing Pitting damage Replace Oil seal O ring Damage Replace 2 Check Drive shaft splines Front drive gear splines Wear damage Replace Spring Fatigue Replace Move the spring up and down 3 Check Dust boots Cracks damage Replace the front drive shaft assembly 4 Check Front drive shaft Bends Replace the front drive shaft assembly WARNING Do not attempt to straighten a bent shaft this may dangero...

Page 43: ...or terminal 2 to operate the pinion gear 3 Operate the pinion gear until the paint mark 4 on the gear is aligned with the paint mark 5 on the gear motor case CAUTION Do not use a 12 V battery to operate the pinion gear Insert 8 mm bolts 6 into the gear motor 7 and use them as a guide to set the motor on the differential gear assembly 8 so that the shift fork sliding gear 9 does not move CAUTION If...

Page 44: ... a coupling gear holding tool 1 Coupling gear holding tool P N YM 01486 90890 01486 LT T R 62 Nm 6 2 m kg 45 ft lb 1 4 Check Differential gear operation Unsmooth operation Replace the differen tial gear assembly Insert the double off set joint into the differ ential gear and then turn the gear back and forth ...

Page 45: ...40 ft Ib 1 New Order Job name Part name Q ty Remarks Removing the front wheel Remove the parts in the order below Place the machine on a level surface WARNING Securely support the machine so there is no danger of it falling over 1 Front wheel 1 Refer to INSTALLING THE FRONT WHEEL in CHAPTER 8 Manual No 5KM2 AE1 2 Wheel cap 1 Refer to INSTALLING THE FRONT WHEEL HUB in CHAPTER 8 Manual No 5KM2 AE1 3...

Page 46: ...26 0 m kg 190 ft lb T R 55 Nm 5 5 m kg 40 ft Ib 1 New Order Job name Part name Q ty Remarks 4 Brake caliper assembly 1 NOTE Do not squeeze the brake lever when the brake caliper is off of the brake disc as the brake pads will be forced shut 5 Front wheel hub 1 6 Brake disc 1 For installation reverse the removal procedure ...

Page 47: ... wheel Remove the parts in the order below Place the machine on a level surface WARNING Securely support the machine so there is no danger of it falling over 1 Rear wheel 1 Refer to INSTALLING THE REAR WHEEL in CHAPTER 8 Manual No 5KM2 AE1 2 Wheel cap 1 Refer to INSTALLING THE REAR WHEEL HUB in CHAPTER 8 Manual No 5KM2 AE1 3 Axle nut 1 4 Rear wheel hub 1 For installation reverse the removal proced...

Page 48: ...Ib 3 4 5 7 2 4 6 New New New New LS 1 Order Job name Part name Q ty Remarks Removing the tie rod and steering knuckle Remove the parts in the order below Front fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK in CHAPTER 3 Manual No 5KM2 AE1 Front wheel brake disc Refer to FRONT WHEELS 1 Tie rod 1 Refer to INSTALLING THE TIE ROD in CHAPTER 8 Manual No 5KM2 AE1 2 Brake disc guard 1 3 Front protec...

Page 49: ...ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 3 4 5 7 2 4 6 New New New New LS 1 Order Job name Part name Q ty Remarks 6 Brake hose holder bolt 1 7 Steering knuckle 1 Refer to REMOVING THE STEERING KNUCKLE in CHAPTER 8 Manual No 5KM2 AE1 For installation reverse the removal procedure STEERING SYSTEM ...

Page 50: ...ce Oil seals Damage Replace Replacement steps Clean the outside of the steering knuckle Remove the circlip 1 Drive out the bearing 2 WARNING Eye protection is recommended when using striking tools Apply lithium soap based grease to the bear ing Install the new bearing CAUTION Do not strike the center race or balls of the bearing Contact should be made only with the outer race Install a new circlip...

Page 51: ...5 3 3 2 4 3 3 4 1 LS LS Order Job name Part name Q ty Remarks Removing the rear knuckle and stabilizer Remove the parts in the order below Rear wheel hubs Refer to REAR WHEELS AND BRAKE DISC 1 Rear protector 1 2 Rear knuckle 1 3 Spacer cover 4 4 Spacer 2 5 Stabilizer joint 2 6 Brake hose holder 1 7 Stabilizer holder 2 8 Bushing 2 9 Stabilizer 1 For installation reverse the removal procedure ...

Page 52: ...eplace Oil seals Damage Replace Replacement steps Clean the outside of the rear knuckle Remove the circlip 1 Drive out the bearing 2 WARNING Eye protection is recommended when using striking tools Apply lithium soap based grease to the bear ing Install the new bearing CAUTION Do not strike the center race or balls of the bearing Contact should be made only with the outer race Install a new circlip...

Page 53: ...e Part name Q ty Remarks Removing the rear arms and rear shock absorber Remove the parts in the order below Rear protector rear knuckle stabilizer Refer to REAR KNUCKLE AND STABI LIZER 1 Nut bolt 2 2 2 Rear arm upper bushing washer 1 2 1 3 Nut bolt 2 2 4 Rear shock absorber 1 5 Nut bolt 2 2 6 Rear arm lower bushing 1 2 For installation reverse the removal procedure REAR ARMS AND REAR SHOCK ABSORBE...

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