YAMAHA YFM660FP SERVICE MANUAL SUPPLEMENTARY

YFM660FR

5KM2-AE2

SUPPLEMENTARY

SERVICE MANUAL

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the YFM660FR. For complete service information procedures 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

First edition, June 2002

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

EB001000

NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

OTE:

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

CAUTION:

NOTE:

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

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

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

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

1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.

3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.

EXPLODED DIAGRAMS

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

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

2. Numbers 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-to-read way by the use of symbol marks

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

4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart.

GEN

INFO

SPEC

CHK

ENG

ADJ

COOL

CARB

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 0 are printed on the top right of each page and indicate the subject of each chapter.

General information

Specifications

Periodic checks and adjustments

Engine

Cooling system

Carburetion

Drive train

Chassis

Electrical

Troubleshooting

DRIV

–+

ELEC

CHAS

TRBL SHTG

Illustrated symbols A to H are used to identify the specifications appearing in the text.

Can be serviced with engine mounted

Filling fluid

Lubricant

Special tool

Torque

Wear limit, clearance

Engine speed

, V, A

Ω

IJK

New

LMN

Illustrated symbols I to N in the exploded diagrams indicate the types of lubricants and lubrication points.

Apply engine oil

Apply gear oil

Apply molybdenum disulfide oil

Apply wheel bearing grease

Apply lightweight lithium-soap-based grease

Apply molybdenum disulfide grease

Illustrated symbols O to P in the exploded diagrams indicate where to apply a locking agent O and when to install a new part P.



Apply the locking agent (LOCTITE

Replace

)

CONTENTS

GENERAL INFORMATION

SPECIAL TOOLS ......................................................................................1

SPECIFICATIONS

GENERAL SPECIFICATIONS ..................................................................2

MAINTENANCE SPECIFICATIONS .........................................................3

ENGINE ................................................................................................3

ELECTRICAL ........................................................................................3

TIGHTENING TORQUES .........................................................................4

CABLE ROUTING .....................................................................................5

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION .....................................................................................12

PERIODIC MAINTENANCE/LUBRICATION ...........................................12

SEAT, CARRIERS, FENDERS AND FUEL TANK ..................................14

FRONT CARRIER, FRONT BUMPER AND FRONT GRILL ..............14

FUEL TANK ........................................................................................15

FOOTREST BOARDS .............................................................................17

ENGINE ...................................................................................................18

CHECKING THE STARTER CABLE ..................................................18

............................................................................................2

..............................................................................1

..................................................12

ENGINE

DRIVE TRAIN

..........................................................................................................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

.................................................................................................30

FRONT CONSTANT VELOCITY JOINTS

AND DIFFERENTIAL GEAR ...............................................................30

DISASSEMBLING THE DIFFERENTIAL GEAR .................................34

CHECKING THE DIFFERENTIAL GEAR ...........................................34

ASSEMBLING THE DIFFERENTIAL GEAR .......................................35

CHASSIS ........................................................................................................37

FRONT WHEELS AND BRAKE DISCS ..................................................37

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

GEN

SPECIAL TOOLS

GENERAL INFORMATION

EB102001

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate 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

Coupling gear holding tool

90890-01486

YM-01486

This tool is needed when removing or installing the coupling gear nut.

INFO

– 1 –

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

Model code: 5KM9: (for CDN)

5KMB: (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

SPEC

– 2 –

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Oil pump:

Oil filter type Foam ---Oil pump type Trochoid ---Tip clearance “A” or “B” 0.03 ~ 0.10 mm

(0.0012 ~ 0.0039 in)

Side clearance 0.03 ~ 0.10 mm

(0.0012 ~ 0.0039 in)

Bypass valve setting pressure 441 ~ 637 kPa (4.41 ~

6.37 kg/cm

Oil pressure (hot) 65 kPa (0.65 kg/cm

1,500 r/min

Pressure check location Cylinder head ----

ELECTRICAL

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 resistance/color

C.D.I. unit model/manufacturer F8T38671/MITSUBISHI ----

Charging system:

Type A.C. magneto generator ---Model/manufacturer F4T469/MITSUBISHI ---Nominal output 14 V 21 A at 5,000 r/min ---Charging coil resistance/color 0.32 ~ 0.43 Ω at 20 °C (68 °F)/

0.063 ~ 0.077 Ω at 20 °C (68 °F)/ Red – White/Blue

White – White

, 62.7 ~ 90.6 psi)

, 9.2 psi) at

0.15 mm (0.006 in)

0.17 mm (0.007 in)

----

– 3 –

TIGHTENING TORQUES

Engine tightening torques

TIGHTENING TORQUES

SPEC

Part to be tightened

Exhaust pipe protector Bolt M6 5 11 1.1 8 Oil seal retainer Screw M5 2 7 0.7 5.1

Chassis tightening torques

Part to be tightened Thread size

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

Par t

name

Thread

size

Q’ty

Tightening torque

Remarks

Nm m·kg ft·lb

Tightening torque

Remarks

Nm m·kg ft·lb

– 4 –

CABLE ROUTING

1 Fuel sender lead 2 Differential gear case and final

drive gear case breather hose

3 Vacuum chamber breather hose 4 Starter motor lead 5 Wire harness 6 Gear position switch lead 7 Final drive gear case breather

hose

CABLE ROUTING

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

SPEC

G Gear position switch coupler H Speed sensor coupler I Radiator fan breather hose J Rectifier/regulator lead K Water pump breather hose

E - E

B - B

C D

– 5 –

CABLE ROUTING

È Fasten the final drive gear case breather hose, speed sensor lead, ground lead, gear position switch lead,

AC magneto lead, wire harness, and reverse indicator light lead with a plastic locking tie. Be careful not to pinch the breather hose.

É Fasten the leads 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.

SPEC

E - E

B - B

C D

– 6 –

CABLE ROUTING

Î Pass the vacuum chamber breather hose through the plastic cover 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.

SPEC

E - E

B - B

C D

– 7 –

CABLE ROUTING

SPEC

1 Gear position switch 2 Reverse switch 3 Crankcase breather hose 4 Select lever control cable 5 Rear brake cable 6 Front brake hose 7 Rear brake 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.

É Ê

– 8 –

CABLE ROUTING

Ê Clamp the spark plug lead and radiator inlet hose with a plastic clip. Ë When installing the ignition 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.

SPEC

– 9 –

+ 39 hidden pages