Yamaha YXR660FA User Manual

YXR660FAS

5UG2-AE1

SERVICE MANUAL

EBS00000

YXR660FAS

SERVICE MANUAL

First Edition, September 2003

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

EBS00002

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 vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle 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.

NOTE:

Designs and specifications are subject to change without notice.

EBS00003

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 vehicle operator, passenger, a bystander, or a person checking or repairing the vehicle.

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

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

EBS00004

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “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

DRIV

FUEL

CHAS

EBS00006

SYMBOLS

The following symbols are not relevant to every vehicle. Symbols 1 to 0 indicate the subject of each chapter.

General information

Specifications

Periodic checks and adjustments

Engine

Cooling system

Fuel system

Drive train

Chassis

Electrical

Troubleshooting

ELEC

–+

IJK

LMN

TRBL

SHTG

New

Symbols A to H indicate the following.

Can be serviced with engine mounted

Filling fluid

Lubricant

Special tool

Torque

Wear limit, clearance

Engine speed

Electrical data (Ω, V, A)

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 lithium-soap-based grease

Apply molybdenum disulfide grease

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

)

EBS00008

– +

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

ENGINE

COOLING SYSTEM

GEN

INFO

SPEC

CHK

ADJ

ENG

COOL

FUEL SYSTEM

DRIVE TRAIN

CHASSIS

ELECTRICAL

TROUBLESHOOTING

FUEL

DRIV

CHAS

ELEC

TRBL SHTG

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

GEN

INFO

VEHICLE IDENTIFICATION

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

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

FEATURES

SELF-ADJUSTING PARKING BRAKE MECHANISM...............................1-2

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCEDURES ...................................1-5

REPLACEMENT PARTS...........................................................................1-5

GASKETS, OIL SEALS AND O-RINGS .................................................... 1-5

LOCK WASHERS/PLATES AND COTTER PINS .....................................1-6

BEARINGS AND OIL SEALS ....................................................................1-6

CIRCLIPS ..................................................................................................1-6

CHECKING OF CONNECTIONS

SPECIAL TOOLS

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

............................................................................................1-8

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

.........................................................................1-5

....................................................................1-7

GEN

INFO

VEHICLE IDENTIFICATION

GENERAL INFORMATION

VEHICLE 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

GEN

FEATURES

SELF-ADJUSTING PARKING BRAKE MECHANISM

Usually, for vehicles equipped with a parking brake that must be adjusted manually, it is necessary to adjust the adjusting bolt to achieve the proper clearance between the brake caliper piston and the adjusting bolt. This adjustment procedure is unnecessary for vehicles equipped with a self-adjusting parking brake mechanism. The proper clearance is automatically maintained at all times, ensuring stable braking performance when parking the vehicle.

INFO

Parking brake arm

Parking brake arm shaft

Set bolt

Adjusting bolt sleeve

Adjusting bolt

Nut

Brake caliper piston

1 - 2

Parking Brake Operation

FEATURES

GEN

INFO

1 Parking brake arm 2 Parking brake arm shaft 3 Set bolt

When the parking brake is operated, the parking brake cable turns the parking brake arm 1. The rotation of the parking brake arm is changed to axial thrust in the parking brake arm shaft 2 and the set bolt 3 is pushed against the adjusting bolt sleeve 4. When the adjusting bolt sleeve receives the force, the dark shaded area in the above illustration is pushed together and the brake pad 6 is pushed against the brake disc. When the brake pad wears, the clearance between the brake caliper piston 5 and the brake pad becomes larger and the force applied to the brake pad becomes weaker. If this occurs, the self-adjusting parking brake mechanism adjusts automatically to achieve the proper clearance.

4 Adjusting bolt sleeve 5 Brake caliper piston 6 Brake pad

1 - 3

Parking Brake Adjustment

FEATURES

GEN

INFO

1 Brake caliper piston 2 Nut

When the brake pedal is operated, the brake fluid pressure in the master cylinder increases and the brake caliper piston 1 and the nut 2 are pushed. When there is proper clearance between the brake caliper piston and the brake pad, no other parts move because the movement of the brake caliper piston and the nut is absorbed by the backlash of the threads of the nut and the adjusting bolt 3. When the movement of the nut is greater than the backlash between the nut and the adjusting bolt, the parking brake adjusts automatically. The amount of the adjustment varies with brake fluid pressure. Operating the parking brake makes no adjustment. The adjustment operation is as follows.

1. When the brake pedal is operated, the brake fluid pressure increases and the brake caliper piston and the nut move.

2. When the movement of the brake caliper piston and the nut is greater than the backlash of the threads of the nut and the adjusting bolt, the force È will be required to pull the adjusting bolt. The force to pull the adjusting bolt will be turned into the rotation torque É by the shape of the threads of the nut and the adjusting bolt.

3. At this time, the clutch torque Ê between the adjusting bolt and the adjusting bolt sleeve 4 will decrease depending on the force required to pull the adjusting bolt. When the rotation torque exceeds the clutch torque, the adjusting bolt rotates and the clearance between the brake caliper piston and the brake pad decreases by the movement of the threads of the nut and the adjusting bolt.

3 Adjusting bolt 4 Adjusting bolt sleeve

1 - 4

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 “SPECIAL TOOLS”.

3. When disassembling the vehicle, 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 vehicle 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 - 5

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 visi- ble. When installing oil seals, apply a light coating of lithium-soap-based grease to the seal lips. Oil bearings liberally when installing, if appropriate.

Oil seal

GEN

INFO

CAUTION:

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

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 sharp-edged corner 2 is positioned opposite the thrust 3 it receives. See sectional view.

Shaft

1 - 6

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

NOTE:

The two terminals “click” together.

5. Check:

• continuity (using a pocket tester)

NOTE:

• 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 - 7

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/Function Illustration

INFO

Bolt

90890-01083

Weight

90890-01084

Set

YU-01083-A

90890-01135

YU-01135-A

90890-01229

YM-01229

Pot

90890-01274

Bolt

90890-01275

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.

Crankshaft installer pot Crankshaft installer bolt

These tools are used to install the crankshaft.

90890-01304

YU-01304

90890-01309

Piston pin puller

This tool is used to remove the piston pin.

Spacer

This tool is used to install the crankshaft.

1 - 8

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Tappet adjusting tool

90890-01311

YM-08035-A

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

90890-01325 YU-24460-01

This tool is used to check the cooling system.

INFO

90890-01348

YM-01348

90890-01352

YU-33984

Adapter

90890-01383

YM-01383

Spacer

90890-04081

YM-91044

90890-01404

YM-01404

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.

Adapter Spacer (crankshaft installer)

These tools are used to install the crankshaft.

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 - 9

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Ring nut wrench

90890-01430

YM-38404

90890-01467

YM-01467

90890-01474

YM-01474

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.

Ball joint remover/installer set Ball joint adapter set

These tools are used to removing or installing the ball joints.

INFO

90890-01701

YS-01880-A

Set

90890-03081

YU-33223

Adapter

90890-04082

YU-33223-4

90890-03112

YU-03112-C

90890-03113

Sheave holder Primary 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.

Engine tachometer

This tool is needed for observing engine rpm.

90890-03141

YM-33277-A

Timing light Battery powered timing light

This tool is necessary for checking ignition timing.

1 - 10

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

INFO

Compressor

90890-04019

YM-04019

Attachment

90890-01243

YM-01253-1

Middle driven shaft

bearing driver 90890-04058

YM-04058-1

Mechanical seal

installer

90890-04078

YM-33221

90890-04062

YM-04062

90890-04064

YM-04064-A

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 Water pump seal installer

These tools are used to install the water pump seal.

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.

90890-04065

YM-04065-A

90890-04066

YM-04066

90890-04086

YM-91042

90890-04128

YM-04128

Valve guide installer (ø 6)

This tool is needed to install the valve guide.

Valve guide reamer (ø 6)

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 bearing retainer.

1 - 11

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Sheave spring compressor

90890-04134

YM-04134

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

Sheave fixed block

90890-04135

YM-04135

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

Ignition checker Pulse ignition spark checker

90890-06754

YM-34487

This instrument is necessary for checking the ignition system components.

INFO

Bond

90890-85505

Sealant

ACC-11001-05-01

YM-01477

YU-8036-C

YU-90050

Yamaha bond No. 1215 Sealant (Quick Gasket

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

Ball joint remover/installer attachment set

This tool is used to remove and install the ball joints.

Digital engine test tachometer

This tool is needed for observing engine rpm.

Crankshaft installer set

These tools are used to install the crankshaft.

)

1 - 12

SPEC

CHAPTER 2

SPECIFICATIONS

SPEC

GENERAL SPECIFICATIONS

ENGINE SPECIFICATIONS

CHASSIS SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES.........................................................2-16

CHASSIS TIGHTENING TORQUES....................................................... 2-19

HOW TO USE THE CONVERSION TABLE

GENERAL TIGHTENING TORQUE SPECIFICATIONS

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE...................................................................................................2-23

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

............................................................................2-4

........................................................................2-12

.................................................................2-14

..............................................................................2-16

..................................................2-22

...............................2-22

....................................2-23

COOLANT FLOW DIAGRAMS

OIL FLOW DIAGRAMS

CABLE ROUTING

.................................................................................2-27

.........................................................................................2-32

.....................................................................2-24

SPEC

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

SPEC

Model code

5UG2

Dimensions

Overall length 2,885 mm (113.6 in) Overall width 1,385 mm (54.5 in) Overall height 1,853 mm (73.0 in) Seat height 818 mm (32.2 in) Wheelbase 1,910 mm (75.2 in) Minimum ground clearance 273 mm (10.75 in) Minimum turning radius 3,900 mm (153.5 in)

Basic weight

With oil and full fuel tank 510 kg (1,124 lb)

Engine

Engine type Liquid-cooled 4-stroke, SOHC Cylinder arrangement Forward-inclined single cylinder Displacement 660 cm

Bore × stroke 100 × 84 mm (3.94 × 3.31 in) Compression ratio 9.1 : 1 Standard compression pressure (at sea level) 1,324 kPa (13.24 kg/cm

, 188.31 psi)

at 850 r/min

Starting system Electric starter

Lubrication system

Wet sump

Oil type or grade

Engine oil

0° 10° 30° 50° 70° 90° 110°

130°F

API service SE, SF, SG type or higher

YAMALUBE 4 (20W40) or SAE 20W40

YAMALUBE 4 (10W30) or SAE 10W30

SAE 5W30

-20° -10° 0° 10° 20° 30° 40°

50°C

Final gear oil SAE 80API “GL-4” Hypoid Gear Oil Differential gear oil SAE 80API “GL-4” Hypoid Gear Oil

Oil capacity

Engine oil

Periodic oil change 1.90 L (1.67 Imp qt, 2.01 US qt) With oil filter replacement 2.00 L (1.76 Imp qt, 2.11 US qt) Total amount 2.80 L (2.46 Imp qt, 2.96 US qt)

Final gear case oil

Periodic oil change 0.25 L (0.22 Imp qt, 0.26 US qt) Total amount 0.28 L (0.25 Imp qt, 0.30 US qt)

2 - 1

GENERAL SPECIFICATIONS

Item Standard

Differential gear case oil

Periodic oil change 0.32 L (0.28 Imp qt, 0.34 US qt) Total amount 0.33 L (0.29 Imp qt, 0.35 US qt)

Air filter Fuel

Type Regular unleaded gasoline only Fuel tank capacity 30 L (6.60 Imp gal, 7.93 US gal)

Carburetor

Type/quantity BSR42/1 Manufacturer MIKUNI

Spark plug

Type/manufacturer DPR8EA–9/NGK Spark plug gap 0.8 ~ 0.9 mm (0.031 ~ 0.035 in)

Clutch type Transmission

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 Right hand operation Single speed automatic 2.37 ~ 0.91 : 1 Sub transmission ratio low 35/17 (2.058)

high 28/19 (1.473)

Reverse gear 25/17 (1.471)

Chassis

Frame type Steel tube frame Caster angle 5.0° Camber angle 0° Kingpin angle 12° Kingpin offset 0 mm (0 in) Trail 26 mm (1.02 in) Tread (STD) front 1,115 mm (43.90 in)

rear 1,107 mm (43.58 in)

Toe-in 15 ~ 25 mm (0.59 ~ 0.98 in)

Tire

Type Tubeless Size front AT25 × 8–12NHS

rear AT25 × 10–12NHS

Manufacturer front GOODYEAR

rear GOODYEAR

Type front Rawhide RS

rear Rawhide RS

Wet type element

Wet, centrifugal automatic

SPEC

2 - 2

GENERAL SPECIFICATIONS

Item Standard

Tire pressure (cold tire)

Maximum load* 397 kg (876 lb) Off-road riding front 63 ~ 77 kPa (0.63 ~ 0.77 kg/cm

rear 91 ~ 105 kPa (0.91 ~ 1.05 kg/cm * Load in total weight of cargo, operator, passenger, accessories and tongue weight

Brake

Front brake type Dual disc brake

operation Foot brake Rear brake type Single disc brake

operation Foot brake

Suspension

Front suspension Double wishbone Rear suspension Double wishbone

Shock absorber

Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/oil damper

Wheel travel

Front wheel travel 185 mm (7.28 in) Rear wheel travel 185 mm (7.28 in)

Electrical

Ignition system DC. C.D.I. Generator system A.C. magneto Battery type U1L-11 Battery capacity 12 V, 28 AH

Headlight type Bulb wattage × quantity

Headlight 12 V 30 W/30 W × 2 Tail/brake light 12 V 5 W/21 W × 2 Indicator lights

Neutral 12 V 1.7 W × 1 Reverse 12 V 1.7 W × 1 Coolant temperature 12 V 1.7 W × 1 Parking brake 12 V 1.7 W × 1 Four-wheel drive 12 V 1.7 W × 1 Differential gear lock 12 V 1.7 W × 1

Krypton bulb

SPEC

, 9 ~ 11 psi)

, 13 ~ 15 psi)

2 - 3

ENGINE SPECIFICATIONS

SPEC

ENGINE SPECIFICATIONS

Item Standard Limit

Cylinder head

Warp limit ---- 0.03 mm

(0.0012 in)

Cylinder

Bore size 100.005 ~ 100.055 mm

(3.9372 ~ 3.9392 in)

Measuring point 50 mm (1.97 in) ----

Camshaft

Drive method Chain drive (Left) ---Cam dimensions

100.10 mm (3.9410 in)

Intake “A” 35.69 ~ 35.79 mm

(1.4051 ~ 1.4091 in)

“B” 30.06 ~ 30.16 mm

(1.1835 ~ 1.1874 in)

Exhaust “A” 36.50 ~ 36.60 mm

(1.4370 ~ 1.4409 in)

“B” 30.11 ~ 30.21 mm

(1.1854 ~ 1.1894 in)

Camshaft runout limit ---- 0.03 mm

35.59 mm (1.4012 in)

29.96 mm (1.1795 in)

36.40 mm (1.4331 in)

30.01 mm (1.1815 in)

(0.0012 in)

2 - 4

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