Yamaha YFM660FGX User Manual
OWNER’S MANUAL
MANUEL DU PROPRIÉTAIRE
MANUAL DEL PROPIETARIO
YFM66FGX
23D-28199-60
PRINTED ON RECYCLED PAPER
IMPRIMÉ SUR PAPIER RECYCLÉ
IMPRESO EN PAPEL RECICLADO
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
2007.03-0.3×1 CR
(E,F,S)
OWNER’S MANUAL
YFM66FGX
23D-28199-60-E0
EBU17161
EC Declaration of Conformity
conforming to Directive 98/37/EC
We,
Koolhovenlaan 101, 1119 NC Schiphol-Rijk, The Netherlands,
representing YAMAHA MOTOR CO., LTD., Iwata, Japan,
declare in sole responsibility, that the product
YAMAHA MOTOR EUROPE N.V.,
(Name of supplier)
YFM660FWA (JY4AM03W050000001~)
(Make, model)
to which this declaration applies, conforms to the essential
health and safety requirements of Directive 98/37/EC,
(if applicable)
and to the other relevant EEC Directives:
(Title and/or number and date of issue of the other EEC Directives)
(if applicable)
To effect correct application of the essential health and safety
requirements stated in the EEC Directives, the following
standards and/or technical specifications were consulted:
(Title and/or number and date of issue of standards and/or specifications)
NL-1119 NC Schiphol,
(Place and date of issue)
Executive Vice President
(Name and job function of authorized person)
89/336/EEC
EN292, ANSI/SVIA-1-2001
February 28, 2005
T. Mabuchi
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INTRODUCTION
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Congratulations on your purchase of the Yamaha YFM66FGX. This ATV represents the result of many
years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines.
With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability
that have made Yamaha a leader in these fields.
This manual will provide you with a good basic understanding of the features and operation of this ATV.
This manual includes important safety information. It provides information about special techniques and skills necessary to ride the ATV. It also includes basic maintenance and inspection proce-
dures. If you have any questions regarding the operation or maintenance of your ATV, please consult a
Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
● READ THIS MANUAL COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDER-
STAND ALL INSTRUCTIONS.
● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.
● THIS ATV, AND ANY OTHER ATV OVER 90 cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16
YEARS OF AGE.
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IMPORTANT MANUAL INFORMATION
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FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury
WARNING
or death to the ATV operator, a bystander, or a person inspecting or
repairing the ATV.
CAUTION:
NOTE:
A CAUTION indicates special precautions that must be taken to avoid
damage to the ATV.
A NOTE provides key information to make procedures easier or clearer.
* Product and specifications are subject to change without notice.
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IMPORTANT NOTICE
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Welcome to the Yamaha world of motor sports!
This ATV is designed and manufactured for use on UNPAVED surfaces only. It is unsafe to operate this
ATV on any paved surface, paved street, paved road or motorway.
Please check your local riding laws and regulations before operating this ATV.
EBU17390
YFM66FGX
OWNER’S MANUAL
©2007 by Yamaha Motor Co., Ltd.
1st edition, February 2007
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
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TABLE OF CONTENTS
SAFETY INFORMATION .............................. 1-1
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 2-1
DESCRIPTION .............................................. 3-1
Left view ...................................................... 3-1
Right view.................................................... 3-1
Controls and instruments ............................ 3-2
INSTRUMENT AND
CONTROL FUNCTIONS................................ 4-1
Main switch ................................................ 4-1
Indicator lights and warning light ................ 4-2
Multifunction display ................................... 4-4
Handlebar switches .................................... 4-6
Throttle lever ............................................ 4-11
Speed limiter ............................................ 4-12
Front brake lever ...................................... 4-12
Brake pedal and rear brake lever ............. 4-13
Drive select lever ...................................... 4-14
Recoil starter ............................................ 4-14
Fuel tank cap ............................................ 4-14
Fuel .......................................................... 4-15
Fuel cock ..................................................4-16
Starter (choke) ..........................................4-17
Seat ..........................................................4-18
Storage compartment ...............................4-19
Front carrier ..............................................4-20
Rear carrier ...............................................4-20
Adjusting the front and
rear shock absorber assemblies .............4-20
Auxiliary DC jack .......................................4-21
PRE-OPERATION CHECKS ..........................5-1
Pre-operation check list ..............................5-1
Fuel .............................................................5-3
Engine oil ....................................................5-3
Final gear oil ...............................................5-3
Differential gear oil ......................................5-3
Coolant .......................................................5-3
Front and rear brakes .................................5-4
Throttle lever ...............................................5-5
Tires ............................................................5-5
Measuring the tire pressure ........................5-6
Tire wear limit .............................................5-7
Chassis fasteners .......................................5-7
Instruments, lights and switches .................5-7
OPERATION .................................................. 6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-3
Operating the drive select lever and
driving in reverse ...................................... 6-3
Engine break-in .......................................... 6-5
Parking ....................................................... 6-6
Parking on a slope ..................................... 6-6
Accessories and loading ............................ 6-6
RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV............... 7-2
RIDE WITH CARE AND
GOOD JUDGEMENT ................................ 7-2
BE CAREFUL WHERE YOU RIDE............. 7-9
TURNING YOUR ATV .............................. 7-13
CLIMBING UPHILL ................................... 7-14
RIDING DOWNHILL.................................. 7-17
CROSSING A SLOPE............................... 7-18
CROSSING THROUGH
SHALLOW WATER................................. 7-19
RIDING OVER ROUGH TERRAIN ........... 7-22
SLIDING AND SKIDDING ......................... 7-22
WHAT TO DO IF... .................................... 7-23
WHAT TO DO... ........................................ 7-23
PERIODIC MAINTENANCE AND
MINOR REPAIR .............................................8-1
Owner’s manual and tool kit .......................8-1
Periodic maintenance chart for
the emission control system .....................8-3
General maintenance and
lubrication chart ........................................8-5
Removing and installing panels ..................8-9
Checking the spark plug ...........................8-16
Engine oil and oil filter cartridge ................8-18
Final gear oil .............................................8-22
Differential gear oil ....................................8-24
Coolant .....................................................8-26
Cleaning the air filter element ...................8-30
Cleaning the spark arrester ......................8-34
V-belt cooling duct check hose .................8-35
V-belt case drain plug ...............................8-35
Adjusting the carburetor ............................8-36
Adjusting the engine idling speed .............8-36
Adjusting the throttle cable free play .........8-37
Valve clearance ........................................8-38
Adjusting the drive select lever
safety system cable ................................8-38
Checking the front and rear brake pads ...8-38
Checking the brake fluid level ...................8-39
Changing the brake fluid ...........................8-41
Checking the front brake lever free play ...8-41
Adjusting the rear brake lever free play
and checking the brake pedal position ... 8-42
Axle boots ................................................ 8-44
Brake light switches ................................. 8-44
Checking and lubricating the cables ........ 8-45
Checking and lubricating
the front and rear brake levers ............... 8-45
Checking and
lubricating the brake pedal ..................... 8-46
Checking the wheel hub bearings ............ 8-47
Checking the stabilizer bushes ................ 8-47
Lubricating the rear knuckle pivots ........... 8-47
Lubricating the steering shaft ................... 8-48
Battery ...................................................... 8-48
Replacing a fuse ...................................... 8-50
Replacing a headlight bulb ....................... 8-51
Adjusting a headlight beam ...................... 8-53
Replacing the tail/brake light bulb ............ 8-53
Removing a wheel .................................... 8-54
Installing a wheel ...................................... 8-54
Troubleshooting ....................................... 8-56
Troubleshooting charts ............................. 8-57
CLEANING AND STORAGE.......................... 9-1
Cleaning ..................................................... 9-1
Storage ....................................................... 9-2
SPECIFICATIONS .......................................10-1
CONSUMER INFORMATION.......................11-1
Identification numbers ...............................11-1
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SAFETY INFORMATION
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AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
An ATV handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine
maneuvers such as turning and riding on hills or
over obstacles, if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do
not follow these instructions:
● Read this manual and all labels carefully and fol-
low the operating procedures described.
● Never operate an ATV without proper training or
instruction.
● Always follow the age recommendation:
– A child under 16 years old should never operate an ATV with engine size greater than 90 cc.
● Never allow a child under age 16 to operate an
ATV without adult supervision, and never allow
continued use of an ATV by a child if he or she
does not have the abilities to operate it safely.
1
● Never carry a passenger on an ATV.
● Always avoid operating an ATV on any paved
surfaces, including sidewalks, driveways, parking lots and paved streets.
● Never operate an ATV on any paved street,
paved road or motorway.
● Watch carefully for other vehicles when operat-
ing on unpaved public streets or roads. Make
sure you know your country’s laws and regulations before you ride on unpaved public streets
or roads.
● Never operate an ATV without wearing an ap-
proved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face
shield), gloves, boots, a long-sleeved shirt or a
jacket, and long pants.
● Never consume alcohol or drugs before or while
operating this ATV.
● Never operate at speeds too fast for your skills
or the riding conditions. Always go at a speed
that is proper for the terrain, visibility, operating
conditions, and your experience.
● Never attempt wheelies, jumps, or other stunts.
1-1
● Always inspect your ATV each time you use it to
make sure it is in safe operating condition. Al-
1
ways follow the inspection and maintenance
procedures and schedules described in this
manual.
● 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 op-
erating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the
ATV.
● Never operate on excessively rough, slippery or
loose terrain until you have learned and practiced the skills necessary to control the ATV on
such terrain. Always be especially cautious on
these kinds of terrain.
● Always follow proper procedures for turning as
described in this manual. Practice turning at low
speeds before attempting to turn at faster
speeds and never turn at excessive speeds.
● Never operate the ATV on hills too steep for the
ATV or for your abilities. Practice on smaller hills
before attempting larger hills.
● Always follow proper procedures for climbing
hills as described in this manual. Check the terrain carefully before you start up any hill. Never
climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the
throttle suddenly. Never go over the top of a hill
at high speed.
● Always follow proper procedures for going down
hills and for braking on hills as described in this
manual. Check the terrain carefully before you
start down any hill. Shift your weight backward.
Never go down a hill at high speed. Avoid going
down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight
down the hill where 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
ATV. Never attempt to turn the ATV around on
any hill until you have mastered the turning technique described in this manual on level ground.
Avoid crossing the side of a steep hill if possible.
● Always use proper procedures if you stall or roll
backwards when climbing a hill. To avoid stalling, use the proper gear range and maintain a
1-2
steady speed when climbing a hill. If you stall or
roll backwards, follow the special procedure for
braking described in this manual. Dismount on
the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following
the procedure described in this manual.
● Always check for obstacles before operating in a
new area.
● Never attempt to operate over large obstacles,
such as large rocks or fallen trees. Always follow
proper procedures when operating over obstacles as described in this manual.
● Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth
terrain. On extremely slippery surfaces, such as
ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.
● Never operate an ATV in fast flowing water or in
water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test 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
it is safe to proceed in reverse, go slowly.
● Always use the size and type of tires specified in
this manual.
● Always maintain proper tire pressure as de-
scribed in this manual.
● Never modify an ATV through improper installa-
tion or use of accessories.
● Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for braking.
EWB00061
WARNING
● Always turn off the engine when refueling.
● Do not refuel right after the engine has been
running and is still very hot.
● Do not spill gasoline on the engine or ex-
haust pipe/muffler when refueling. Never refuel while smoking, or in the vicinity of
sparks, open flames, or other sources of ig-
1
1-3
nition such as the pilot lights of water heaters and clothes dryers. Gasoline can catch
1
fire and you could be burned.
● When transporting the ATV in another vehi-
cle, be sure it is kept upright and that the fuel
cock is in the “OFF” position. Otherwise, fuel
may leak out of the carburetor or fuel tank.
● Gasoline is poisonous. If you should swal-
low some gasoline or inhale a lot of gasoline
vapor, or get some gasoline in your eyes,
seek medical help immediately. If gasoline
spills on your skin, wash with soap and water. If gasoline spills on your clothing,
change your clothes.
EWB00070
WARNING
Always operate your ATV in an area with adequate ventilation. Never start or run the engine
in a closed area. Exhaust fumes are poisonous
and may cause loss of consciousness and
death within a short time.
1-4
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LOCATION OF THE WARNING AND SPECIFICATION LABELS
2
2-1
EBU27150
Read and understand all of the labels on your ATV. These labels contain important information for safe and
proper operation.
Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace-
2
ment label from your Yamaha dealer.
For Europe and Oceania
2-2
For Europe
2
2-3
For Europe
2
2-4
For Europe
2
2-5
For Oceania
2
2-6
For Oceania
2
2-7
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DESCRIPTION
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Left view
3
1. Radiator cap
2. Fuel tank cap
3. Fuel cock
4. Oil filter cartridge
5. Throttle stop screw
6. Fuses
7. Engine oil filler cap
8. Recoil starter
9. Coolant reservoir
10.Drive select lever box check hose
11.V-belt cooling duct check hose
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Right view
1. Rear shock absorber assembly spring preload adjusting
ring
2. Spark arrester
3. Storage compartment and tool kit
4. Battery
5. Air filter case
6. Spark plug
7. Front brake fluid reservoir
8. Front shock absorber assembly spring preload adjusting
ring
9. Rear brake fluid reservoir
10.Brake pedal
11.V-belt case drain plug
3-1
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Controls and instruments
1. Drive select lever
2. Rear brake lever
3. Handlebar switches
4. Horn switch
5. Starter (choke)
6. Multifunction display
7. Main switch
8. On-Command four-wheel-drive/differential gear lock
switch
9. Throttle lever
10.Front brake lever
11.Auxiliary DC jack
NOTE:
The ATV you have purchased may differ slightly
from the figures shown in this manual.
3
3-2
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INSTRUMENT AND CONTROL FUNCTIONS
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Main switch
The positions of the main switch are as follows:
ON
All electrical systems are supplied with power. The
4
headlights and taillight come on when the light
switch is on, and the engine can be started. The
key cannot be removed.
OFF
All electrical systems are off. The key can be removed.
1. Main switch
4-1
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Indicator lights and warning light
1. On-Command differential gear lock indicator light “DIFF.
LOCK”
2. Low-range indicator light “L”
3. High-range indicator light “H”
4. Neutral indicator light “N”
5. Reverse indicator light “R”
6. Park indicator light “P”
7. On-Command four-wheel-drive/differential gear lock
indicator “”/“”
8. Coolant temperature warning light “”
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Reverse indicator light “”
This indicator light comes on when the transmission is in the reverse position.
Furthermore, this indicator light flashes when the
engine is being raced for 10 seconds or more.
NOTE:
If the indicator light flashes under any other circumstances or the speedometer does not show the
speed while riding, have a Yamaha dealer check
the speed sensor circuit.
4
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Neutral indicator light “”
This indicator light comes on when the transmission is in the neutral position.
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Coolant temperature warning light “”
This warning light comes on when the engine overheats. When this occurs during operation, stop the
engine as soon as it is safe to do so and allow it to
cool down for about 10 minutes.
ECB00010
CAUTION:
● The engine may overheat if the ATV is over-
loaded. In this case, reduce the load to specification.
4-2
● Start the engine after making sure that the
warning light is out. Continuous use while
the warning light is on may cause damage to
the engine.
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On-Command four-wheel-drive/differential
gear lock indicator “”/“”
4
The On-Command four-wheel-drive indicator “”
comes on when the On-Command four-wheeldrive switch is set to the “4WD” position.
The On-Command differential gear lock indicator
“” in the On-Command four-wheel-drive indicator also comes on when the On-Command differential gear lock switch is set to the “LOCK”
position.
NOTE:
● Due to the synchronizing mechanism in the dif-
ferential gear case, the four-wheel-drive indicator may not come on until the ATV starts moving.
● When the On-Command differential gear lock
switch is set to “LOCK”, the indicator “” will
flash until the differential gear is locked.
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Park indicator light “”
This indicator light comes on when the transmission is in the park position.
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High-range indicator light “”
This indicator light comes on when the transmission is in the high-range position.
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Low-range indicator light “”
This indicator light comes on when the transmission is in the low-range position.
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On-Command differential gear lock indicator
light “DIFF. LOCK”
This indicator light and the On-Command differential gear lock indicator in the display come on when
the On-Command differential gear lock switch is
set to the “LOCK” position.
NOTE:
When the switch is set to “LOCK”, the On-Command differential gear lock indicator light will flash
until the differential gear is locked.
4-3
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Multifunction display
● two tripmeters (which show the distance trav-
eled since they were last set to zero)
● a clock
● an hour meter (which shows the total time the
key has been turned to “ON”)
● a fuel meter
1. Speedometer
2. Fuel meter
3. “H” button
4. “M” button
5. Clock/Hour meter
6. Odometer/Tripmeter A/Tripmeter B
7. “TRIP/ODO” button
8. Clock/Hour “”/“” button
The multifunction display is equipped with the following:
● a speedometer (which shows the riding speed)
● an odometer (which shows the total distance
traveled)
Odometer and tripmeter modes
Pushing the “TRIP/ODO” button switches the display between the odometer mode “ODO” and the
tripmeter modes “A” and “B” in the following order:
ODO → TRIP A → TRIP B → ODO
To reset a tripmeter, select it by pushing the
“TRIP/ODO” button, and then push the
“TRIP/ODO” button for at least three seconds. The
tripmeters can be used to estimate the distance
that can be traveled with a full tank of fuel. 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 display between
“mph” and “km/h”.
4-4
4
Clock mode
Pushing the “”/“” button switches the display
between the clock mode “CLOCK” and the hour
meter mode “HOUR” in the following order:
CLOCK → HOUR → CLOCK
To set the clock
1. Set the display to the clock mode.
4
2. Push the “”/“” button until the clock starts
flashing.
3. Set the hours by pushing the “H” button.
4. Set the minutes by pushing the “M” button.
5. Push the “”/“” button, and then release it
to start the clock.
Fuel meter
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear from “F” (full) towards “E” (empty) as the
fuel level decreases. When the “E” segment disappears and the fuel level warning indicator flashes,
set the fuel cock to reserve and refuel as soon as
possible.
1. Fuel level warning indicator
2. Fuel meter
3. “E” segment
4-5
EBU18061
Handlebar switches
1. Light switch “ //OFF”
2. Start switch “”
3. Engine stop switch “ / ”
4. Override switch “OVERRIDE”
5. Horn switch “”
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Engine stop switch “ / ”
Set this switch to “” before starting the engine.
The engine stop switch controls the ignition and
stops the engine when it is running. Use this switch
to stop the engine in an emergency situation. The
engine will not start or run when this switch is set
to “”.
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Start switch “”
Push this switch to crank the engine with the starter.
ECB00050
CAUTION:
See the starting instructions on page 6-1 prior
to starting the engine.
4
EBU18151
Light switch “ //OFF”
Set this switch to “” to turn on the low beams
and the taillight. Set the switch to “” to turn on
the high beams and the taillight. Set the switch to
“OFF” to turn off all the lights.
ECB00040
CAUTION:
Do not use the headlights with the engine
turned off for an extended period of time, otherwise the battery may discharge to the point
that the starter motor will not operate properly.
If this should happen, remove the battery and
recharge it.
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Horn switch “”
Press the switch to sound the horn.
4-6
EBU18190
Override switch “OVERRIDE”
4
1. Override switch “OVERRIDE”
Top speed is normally limited when operating in
differential gear lock. If conditions require more engine power when riding forward, push and hold this
switch to override the differential gear lock speed
limiting function. (See page 4-9.) Releasing the
switch restores the speed limiting function.
While the override switch is pushed, the segments
of the speedometer digits will appear as shown in
the figure.
NOTE:
If the digits of the speedometer appear as shown
when the switch is NOT being pushed, this could
indicate a malfunction in the electrical system. In
this case, take the ATV to a Yamaha dealer at the
first opportunity.
EWB00150
WARNING
Always ride at a slow speed when the ATV is in
four-wheel-drive differential gear lock, and allow extra time and distance for maneuvers.
All wheels turn at the same speed when the differential is locked, so it takes more effort to
turn the ATV. The effort needed to turn increas-
4-7
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