YAMAHA YFM660F(P) PARTS CATALOGUE 02

2002

YFM660F

(

5KM2-AE1

)

SERVICEMANUAL

YFM660F(P) 2002

SERVICE MANUAL

First edition, May 2001

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

6. 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.

1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetion 7 Drive train 8 Chassis 9 Electrical 0 Troubleshooting

DRIV

–+

ELEC

CHAS

TRBL SHTG

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

A Can be serviced with engine mounted B Filling fluid C Lubricant D Special tool E Torque F Wear limit, clearance G 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.

I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply lightweight lithium-soap base grease N 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.



O Apply the locking agent (LOCTITE P Replace

)

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

ENGINE

COOLING SYSTEM

GEN

INFO

SPEC

CHK

ADJ

ENG

COOL

CARBURETION

DRIVE TRAIN

CHASSIS

ELECTRICAL

TROUBLESHOOTING

CARB

DRIV

CHAS

– +

ELEC

TRBL SHTG

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

GEN

INFO

MACHINE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER ................................................. 1-1

MODEL LABEL ..................................................................................... 1-1

FEATURES

FRONT DIFFERENTIAL ....................................................................... 1-2

TRANSMISSION ................................................................................... 1-9

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCEDURES ............................. 1-10

REPLACEMENT PARTS .................................................................... 1-10

GASKETS, OIL SEALS AND O-RINGS .............................................. 1-10

LOCK WASHERS/PLATES AND COTTER PINS ............................... 1-11

BEARINGS AND OIL SEALS .............................................................. 1-11

CIRCLIPS ............................................................................................ 1-11

CHECKING OF CONNECTIONS

SPECIAL TOOLS

................................................................................................... 1-2

....................................................................................... 1-13

........................................................................ 1-1

.................................................................... 1-10

............................................................... 1-12

GEN

INFO

MACHINE IDENTIFICATION

GENERAL INFORMATION

MACHINE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped into the left side of the frame.

MODEL LABEL

The model label 1 is affixed to the frame. This information will be needed to order spare parts.

GEN

INFO

1 - 1

FEATURES

FRONT DIFFERENTIAL

1 Adapter 2 Drive clutch 3 Differential side gear (left) 4 Differential pinion gear 5 Ring gear 6 Differential side gear (right)

FEATURES

7 Drive pinion gear 8 Gear motor

È To front wheel É From the middle gear

GEN

INFO

1 - 2

GEN

FEATURES

2WD

Power is transmitted as follows: middle gear → front drive shaft → drive pinion gear 7 → ring gear 5 → differential pinion gear 4. In the 2WD mode, the left differential side gear 3 and the drive

clutch 2 are not engaged, therefore, the left side gear runs idle and does not transmit power to the left front constant velocity joint.

INFO

1 - 3

GEN

FEATURES

4WD

When the 4WD mode is selected, the gear motor is operated, and the drive clutch 2 moves to the right and engages with the left differential side gear 3. Accordingly, power is transmitted as follows: ring gear 5 → differential pinion gear 4 → left differential side gear 3 → drive clutch 2 → adapter 1 → left front constant velocity joint. Meanwhile, power from the differential pinion gear 4 is transmitted to the right front constant velocity joint via the right differential side gear 6. The ring gear 5 and the drive clutch 2 are not engaged at this time. Therefore, the rotational difference that occurs between the right and left wheels, while the handlebar is being turned, is absorbed by the difference in the rotational speeds of the ring gear 5 and the left differential side gear 3.

INFO

1 - 4

GEN

FEATURES

4WD (Diff-Lock)

When the 4WD (Diff-Lock) mode is selected, the gear motor moves the drive clutch 2 further to the right, which causes the ring gear 5 and the drive clutch 2 to engage. As a result, power is transmitted directly from the ring gear 5 to the drive clutch 2, then to the left front constant velocity joint via the adapter 1. Meanwhile, because the ring gear 5 and the drive clutch 2 are engaged, the ring gear 5, the drive clutch 2, and the right differential side gear 6 become locked coaxially. Thus, power is transmitted as follows: differential pinion gear 4 → right differential pinion gear 6 → right front constant veloc- ity joint. When the ATV is in the 4WD (Diff-Lock) mode, the right and left wheels rotate constantly at the same speed, which affects the maneuverability of the ATV (e.g., making it difficult to steer). Therefore, the maximum traveling speed is limited to 35 km/h (22 mph).

INFO

1 - 5

GEN

FEATURES

In addition, the 4WD (Diff-Lock) mode can be engaged only when the ATV is stopped. Even if an attempt is made to select this mode when the ATV is traveling, it will only result in a standby condition (i.e., when the differential lock select switch and the differential gear are not matched). (1) When the ATV is traveling Even if the 4WD (Diff-Lock) mode is selected, the gear motor will stand by, instead of operating. Therefore, the ATV can be driven in the normal 4WD mode. When this occurs, the differential gear lock indicator light “” in the speedometer unit will flash to alert the driver that the control is on standby. When the ATV is stopped, the control transfers to the condition described in (2).

(2) When the ATV is stopped The gear motor operates to connect the drive clutch to the differential case, thus resulting in the differential lock condition. When this occurs, the differential gear lock indicator light “” in the speedometer unit changes to a constant illumination. * Until the drive clutch and the differential case mesh together (i.e., the splines are unmeshed) the engine misfires to control the engine speed. During this time, the differential gear lock indicator light in the speedometer unit continues to flash.

DIFF. LOCK

INFO

DIFF. LOCK

1 - 6

FEATURES

Shift mechanism

A new shift mechanism with a parking position has been added to the YFM660F.

1.Shift cam

2.Shift fork guide bar

3.Drive axle

4.Stopper lever shaft

GEN

INFO

1 - 7

GEN

FEATURES

Parking

(1) L (Low), H (High), N (Neutral), and R (Reverse) positions

The end of the stopper lever is held by the return spring 1. Then, the stopper lever tab is separated from the drive axle stopper to free the drive axle.

(2) P (Park) position

When the drive select lever is shifted to the “P” position, the cam lever of the shift cam pushes up on the end of the stopper lever. Then, the stopper lever tab pushes against the drive axle stopper to lock the drive axle.

(3) Not synchronized

If the stopper lever tab and the drive axle stopper are not synchronized, the torsion spring is compressed. As a result, the spring pushes the stopper lever tab against the drive axle stopper and waits until the synchronization is completed. When the stop lever tab and the drive axle are synchronized, the stop lever tab pushes against the drive axle stopper in order to lock the drive axle.

1 Stopper lever 2 Return spring 3 Shift cam 4 Drive axle

INFO

(1) (2) (3)

1 - 8

GEN

FEATURES

TRANSMISSION

To create a compact, 3-axle transmission, a chain drive has been adopted for the reverse transmission.

1 Secondary shaft 2 Drive axle 3 Middle drive shaft 4 Low wheel gear 5 Chain

INFO

1 Secondary shaft 2 Drive axle

L (Low) or H (High) mode

When the transmission is in either the low or high mode, the drive axle is driven via the secondary shaft and gear. Therefore, the rotation of the drive axle is the opposite of the secondary shaft.

R (Reverse) mode

When the transmission is in the reverse mode, the drive axle is driven via the drive chain. Therefore, the rotation of the drive axle is the same as the secondary shaft. (As a result, the rotation of the drive axle is opposite to that of the low and high modes.)

1 - 9

IMPORTANT INFORMATION

EB101000

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCEDURES

1.Remove all dirt, mud, dust and foreign material before removal and disassembly.

2.Use proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS” section.

3.When disassembling the machine, always keep mated parts together. This includes gears, cylinder, piston and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly.

4.During machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.

5.Keep all parts away from any source of fire.

GEN

INFO

EB101010

REPLACEMENT PARTS

1.Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS

1.Replace all gaskets, seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings must be cleaned.

2.Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

1 - 10

IMPORTANT INFORMATION

EB101030

LOCK WASHERS/PLATES AND COTTER PINS

1.Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification.

EB101040

BEARINGS AND OIL SEALS

1.Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Oil bearings liberally when installing, if appropriate.

1 Oil seal

GEN

INFO

CAUTION:

Do not use compressed air to spin the bearings dry. This will damage the bearing surfaces.

1 Bearing

EB101050

CIRCLIPS

1.Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharpedged corner 2 is positioned opposite the thrust 3 it receives. See sectional view.

4 Shaft

1 - 11

CHECKING OF CONNECTIONS

EB801000

CHECKING OF CONNECTIONS

Check the connectors for stains, rust, moisture, etc.

1.Disconnect:

●

Connector

2.Check:

●

Connector Moisture → Dry each terminal with an air blower. Stains/rust → Connect and disconnect the terminals several times.

3.Check:

●

Connector leads Looseness → Bend up the pin 1 and connect the terminals.

GEN

INFO

4.Connect:

●

Connector terminals

OTE:

The two terminals “click” together.

5.Check:

●

Continuity (using a pocket tester)

OTE:

●

If there is no continuity, clean the terminals.

●

When checking the wire harness be sure to perform steps 1 to 3.

●

As a quick remedy, use a contact revitalizer available at most part stores.

●

Check the connector with a pocket tester as shown.

1 - 12

GEN

SPECIAL TOOLS

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

Spacer

90890-01309

This tool is used to install the crankshaft.

INFO

Bolt

90890-01083

Weight

90890-01084

Set

YU-01083-A

90890-01135

YU-01135-A

90890-01229

YM-01230

90890-01231

YM-01231

Slide hammer bolt (M6)/weight/set

These tools are used to remove the rocker arm shaft.

Crankcase separating tool

This tool is used to separate the crankcase.

Coupling gear/middle shaft tool

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

Gear lash measurement tool

This tool is used to removing or installing the coupling gear nut.

Rotor holding tool

90890-01235

YU-01235

Pot

90890-01274

Bolt

90890-01275

This tool is needed to hold the starter puller when removing/installing the starter puller bolt or camshaft sprocket bolts.

Crankshaft installer pot Crankshaft installer bolt

These tools are used to install the crankshaft.

1 - 13

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Piston pin puller

90890-01304

YU-01304

This tool is used to remove the piston pin.

Tappet adjusting tool (3 mm)

90890-01311

YU-08035

This tool is necessary for adjusting the valve clearance.

Fuel level gauge

90890-01312

YM-01312-A

This gauge is used to measure the fuel level in the float chamber.

Radiator cap tester

INFO

90890-01325 YU-24460-01

90890-01327

YM-01327

90890-01348

90890-01352

YU-33984

90890-01404

YM-01404

This tool is used to check the cooling system.

Damper rod holder (30 mm)

This tool is needed to loosen and tighten the steering stem bearing retainer.

Locknut wrench

This tool is needed when removing or installing the secondary sheave spring.

Radiator cap tester adapter

This tool is used to check the cooling system.

Flywheel puller

These tools are needed to remove the rotor.

90890-01426

YU-38411

Oil filter wrench

This tool is needed to loosen or tighten the oil filter cartridge.

1 - 14

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Ring nut wrench

INFO

90890-01430

YM-38404

90890-01467

YM-01467

90890-01701

YU-01880

Set

90890-03081

YU-33223

Adapter

90890-04082

YU-33223-3

90890-03112

YU-03112

This tool is needed to removing and installing the middle driven shaft bearing retainer.

Gear lash measurement tool

This tool is used to measure the gear lash.

Sheave holder

This tool is needed to hold the primary sheave when removing or installing the sheave bolts.

Compression gauge Adapter (Compression gauge)

These tools are needed to measure engine compression.

Pocket tester

This instrument is needed for checking the electrical system.

90890-03113

90890-03141

YM-33277-A

Compressor

90890-04019

YM-04019

Attachment

90890-01243

Middle driven shaft

bearing driver

90890-04058

YM-04058-1

Mechanical seal

installer

90890-04078

YM-33221

Engine tachometer

This tool is needed for observing engine rpm.

Timing light

This tool is necessary for checking ignition timing.

Valve spring compressor Valve spring compressor attachment

This tool is needed to remove and install the valve assemblies.

Middle driven shaft bearing driver Mechanical seal installer

These tools are used to install the water pump seal.

1 - 15

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

INFO

Adapter

90890-04059

YM-90069

Spacer

90890-04081

YM-91044

90890-04062

YM-04062

90890-04064

YM-04064-A

90890-04065

YM-04065-A

Adapter Spacer (crankshaft installer)

These tools are used to install the crankshaft.

Universal joint holder

This tool is needed when removing or installing the universal joint yoke nut.

Valve guide remover (ø 6)

This tool is needed to remove and install the valve guide.

Valve guide installer (ø 6)

This tool is needed to install the valve guide.

Valve guide reamer (ø 6)

90890-04066

YM-04066

90890-04086

YM-91042

90890-04128

YM-04128

90890-04134

YM-04134

90890-04135

YM-04135

This tool is needed to rebore the new valve guide.

Universal clutch holder

This tool is needed to hold the clutch carrier when removing or installing the carrier nut.

Bearing retainer wrench

This tool is needed when removing or installing the middle driven pinion gear bearing retainer.

Sheave spring compressor

This tool is needed when removing or installing the secondary sheave spring.

Sheave fixed block

This tool is needed when removing or installing the secondary sheave spring.

1 - 16

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Ignition checker

90890-06754

This instrument is necessary for checking the ignition system components.

INFO

Bond

90890-85505

Sealant

ACC-11001-05-01

YM-34487

YU-8036-A

YU-90050

Yamaha bond No. 1215 Sealant (Quick Gasket

This sealant (bond) is used on crankcase mating surfaces, etc.

Dynamic spark tester

This instrument is necessary for checking the ignition system components.

Inductive tachometer

This tool is needed for observing engine rpm.

Crankshaft installer set

These tools are used to install the crankshaft.

)

1 - 17

SPEC

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