Yamaha YFM660FWA Supplementary Service Manual Download | Manualshive

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YFM660FS

5KM2-AE3

SUPPLEMENTARY

SERVICE MANUAL

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Summary of Contents for YFM660FWA

Page 1: ...YFM660FS 5KM2 AE3 SUPPLEMENTARY SERVICE MANUAL ...

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Page 3: ...this Supplementary Service Manual together with the following manual YFM660F P 2002 SERVICE MANUAL 5KM2 AE1 YFM660FR SUPPLEMENTARY SERVICE MANUAL 5KM2 AE2 YFM660FS SUPPLEMENTARY SERVICE MANUAL 2003 by Yamaha Motor Co Ltd First edition April 2003 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: ...TIAL IS LOCKED 1 SPECIFICATIONS 3 GENERAL SPECIFICATIONS 3 MAINTENANCE SPECIFICATIONS 4 ENGINE 4 CHASSIS 5 ELECTRICAL 5 CHASSIS 6 STEERING SYSTEM 6 INSTALLING THE REAR BRAKE LEVER 6 ELECTRICAL 7 CHECKING THE SWITCH 7 CHECKING THE SWITCH CONTINUITY 7 SIGNAL SYSTEM 9 CIRCUIT DIAGRAM 9 YFM660FS WIRING DIAGRAM ...

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Page 9: ...e switch NOTE The speed limiter is deactivated only while the override switch is being pressed 1 Override switch When the override switch is pressed the segments of the speedometer digits are displayed as fol lows NOTE When the front differential gear is locked and the drive select lever is in the L H N or P position the display changes when the override switch is pressed The speedometer display i...

Page 10: ...N If the segments of the speedometer digits show the override display when the override switch is not pressed the speed limiter system is malfunctioning Check the override switch and ignition system and then repair if necessary ...

Page 11: ...smission Primary reduction system V belt Secondary reduction system Shaft drive Secondary reduction ratio 41 21 24 18 33 9 9 544 Transmission type V belt automatic Operation Left hand operation Single speed automatic 2 45 0 70 1 Sub transmission ratio low 35 17 2 058 high 26 21 1 238 Reverse gear 25 17 1 471 GENERAL SPECIFICATIONS ...

Page 12: ...jet P A J 2 1 5 Pilot outlet P O 1 1 Pilot jet P J 40 Pilot screw P S 3 turns out Bypass 1 B P 1 0 8 Bypass 2 B P 2 0 8 Bypass 3 B P 3 0 8 Valve seat size V S 3 0 Starter jet G S 1 55 Starter jet G S 2 0 8 Throttle valve size Th V 105 Float height F H 13 mm 0 51 in Fuel level F L 4 5 mm 0 18 in Engine idle speed 1 450 1 550 r min Intake vacuum 30 7 33 3 kPa 230 250 mmHg 9 07 9 83 inHg MAINTENANCE ...

Page 13: ...4 in for Europe and Oceania Spring fitting length 237 mm 9 33 in Spring rate K1 36 4 N mm 3 71 kg mm 207 84 lb in Stroke K1 0 95 mm 0 3 74 in Optional spring No Item Standard Limit C D I Magneto model manufacturer F4T469 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 B...

Page 14: ... 6 CHAS STEERING SYSTEM CHASSIS STEERING SYSTEM INSTALLING THE REAR BRAKE LEVER 1 Install Handlebar switch 1 Rear brake lever Lever bracket 2 NOTE Install the lever bracket as shown a 74 5 mm 2 9 in ...

Page 15: ... conti nuity between lead terminals Poor connection no continuity Correct or replace The coupler locations are circled L B Y G Br L B 1 5 6 C 7 2 3 PUSH Br L Y G B R W L B L G Br L Br R L R Sb Br Gy G R B R B L B 2WD 4WD LOCK L G L B L R Sb Gy Br G R B BLACK GRAY P L Gy W ON OFF R Br Br L Br B OFF ON P P Br Br Y BLACK 8 B B BLACK 9 0 A B B B 4 PUSH B Lg R B R W Lg ...

Page 16: ...art switch 4 Override switch 5 On command four wheel drive switch and differential gear lock switch 6 Main switch 7 Rear brake light switch 8 Front brake light switch 9 Rear brake switch 0 Horn switch for Europe and Oceania A Gear position switch B Reverse switch C Fuse ...

Page 17: ... Y G W G W L W L B Br L Br L Br Br Br L Y W B B B B Br L L B B L Y G R B R Lg G W Sb WIRE HARNESS IGNITION COIL LEAD C WIRE HARNESS B WIRE HARNESS SUB WIRE HARNESS SUB WIRE HARNESS A B B R W B W B B B R C C 1 8 4 5 6 7 A 9 C B D E G H I J K L M O N P Q R a g 3 Br L c d e Br L Br L b U V Z L B R B Br B Br B Y Sb L B R B Br B Br B Y Sb R W R W G W G W W 2 R R G R R Br Br Br L R Br L G L B Y L R Y B ...

Page 18: ...dicator light J Neutral indicator light K Park indicator light L High range indicator light M Low range indicator light N Gear position switch P Fuel sender Q Thermo switch 1 Y On command four wheel drive switch and differential gear lock switch Z Gear motor Ignition fuse e Override switch g Signaling system fuse h Rear brake light switch i Front brake light switch j Tail brake light k Horn switch...

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Page 20: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 21: ...W R W j k Y Br B Br B Y OFF ON PUSH PUSH OFF B B B R P Lg Br F L R B P Br W B R Lg Y B G L R o n m Br R B B 1 AC magneto 2 Rectifier regulator 3 Main switch 4 Backup fuse 5 Battery 6 Main fuse 7 Starter relay 8 Starter motor 9 Reverse switch 0 CDI unit A Rear brake switch B Ignition coil C Spark plug D Speed sensor E Meter assembly F Multi function meter G Differential gear lock indicator light H ...

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