INSTANT DOWNLOAD: Yamaha YFM660 (YFM 660 R) Raptor Service Repair Manual MAINTENANCE / TROUBLESHOOTING / ENGINE OVERHAUL 2001 2005

Service Manual Model / Years Covered: Yamaha Raptor YFM660R, (YFM 660) (YFM 660R) (YFM 660 R),2001, 2002, 2003, 2004, 2005, 01, 02, 03, 04, 05 Models.

This is a Great quality service repair manual with everything you need to fix anything on you Yamaha vehicle, or just to fully understand your YFM660 Raptor ATV. This PDF format file is complete with hundreds of pages of diagrams and pictures illustrations. It is very detailed and as complete as it gets with step by step procedures on how to maintain and fix your ride.

This manual is book marked by chapter for ease and fast navigation.

**** Chapters Include ****

**** GENERAL INFORMATION ****

MACHINE IDENTIFICATION:

VEHICLE IDENTIFICATION NUMBER / MODEL LABEL

IMPORTANT INFORMATION:

PREPARATION FOR REMOVAL PROCEDURES / REPLACEMENT PARTS / GASKETS, OIL SEALS AND O-RINGS / LOCK WASHERS/PLATES AND COTTER PINS / BEARINGS AND OIL SEALS / CIRCLIPS

CHECKING OF CONNECTIONS

SPECIAL TOOLS

**** SPECIFICATIONS ****

GENERAL SPECIFICATIONS

MAINTENANCE SPECIFICATIONS:

ENGINE / CHASSIS / ELECTRICAL

HOW TO USE THE CONVERSION TABLE

GENERAL TORQUE SPECIFICATIONS

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE:

COOLANT FLOW DIAGRAMS / OIL FLOW DIAGRAMS / CABLE ROUTING
PERIODIC INSPECTIONS & ADJUSTMENTS

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

SEAT, FENDERS AND FUEL TANK:

SEAT, FRONT PANEL, FOOTREST GUARDS / AND ENGINE SKID PLATE / HEADLIGHTS AND FRONT FENDER / REAR FENDER / FUEL TANK

ENGINE:

ADJUSTING THE VALVE CLEARANCE / ADJUSTING THE TIMING CHAIN / ADJUSTING THE IDLING SPEED / ADJUSTING THE THROTTLE LEVER FREE PLAY / ADJUSTING THE SPEED LIMITER / ADJUSTING THE STARTER CABLE / CHECKING THE SPARK PLUG / CHECKING THE IGNITION TIMING / MEASURING THE COMPRESSION PRESSURE / CHECKING THE ENGINE OIL LEVEL / CHANGING THE ENGINE OIL / ADJUSTING THE CLUTCH CABLE / CLEANING THE AIR FILTER / CHECKING THE COOLANT LEVEL / CHANGING THE COOLANT / CHECKING THE COOLANT TEMPERATURE WARNING LIGHT / CLEANING THE SPARK ARRESTER

CHASSIS:

ADJUSTING THE FRONT BRAKE / ADJUSTING THE REAR BRAKE / ADJUSTING THE PARKING BRAKE / CHECKING THE BRAKE FLUID LEVEL / CHECKING THE FRONT BRAKE PAD / CHECKING THE REAR BRAKE PADS / ADJUSTING THE REAR BRAKE LIGHT SWITCH / CHECKING THE BRAKE HOSE / BLEEDING THE HYDRAULIC BRAKE SYSTEM / ADJUSTING THE SHIFT PEDAL / ADJUSTING THE REVERSE CONTROL CABLE / ADJUSTING THE DRIVE CHAIN SLACK / CHECKING THE STEERING SYSTEM / ADJUSTING THE TOE-IN / ADJUSTING THE FRONT SHOCK ABSORBER / ADJUSTING THE REAR SHOCK ABSORBER / CHECKING THE TIRE / CHECKING THE WHEEL / CHECKING AND LUBRICATING THE CABLE / LUBRICATING THE LEVERS AND PEDAL

ELECTRICAL:

CHECKING THE BATTERY / CHECKING THE FUSE / ADJUSTING THE HEADLIGHT BEAM / REPLACING THE HEADLIGHT BULB

COOLING SYSTEM

RADIATOR:

CHECKING THE RADIATOR / INSTALLING THE RADIATOR

THERMOSTAT:

CHECKING THE THERMOSTAT / ASSEMBLING THE THERMOSTAT

WATER PUMP:

DISASSEMBLING THE WATER PUMP / CHECKING THE WATER PUMP / ASSEMBLING THE WATER PUMP

**** ENGINE ****

ENGINE REMOVAL:

MUFFLER AND EXHAUST PIPES / LEFT FOOTREST / LEADS, CABLES AND HOSES / ENGINE MOUNTING BOLTS / INSTALLING THE ENGINE

CYLINDER HEAD COVER:

REMOVING THE CYLINDER HEAD COVER / CHECKING THE CYLINDER HEAD COVER / CHECKING THE TAPPET COVER / INSTALLING THE CYLINDER HEAD COVER

ROCKER ARMS:

REMOVING THE ROCKER ARM / CHECKING THE ROCKER ARM / INSTALLING THE ROCKER ARM

CAMSHAFT AND CYLINDER HEAD:

REMOVING THE CAMSHAFT AND CYLINDER HEAD / CHECKING THE CAMSHAFT / CHECKING THE CAMSHAFT SPROCKET / CHECKING THE DECOMPRESSION SYSTEM / CHECKING THE TIMING CHAIN GUIDE / CHECKING THE TIMING CHAIN TENSIONER / CHECKING THE CYLINDER HEAD / INSTALLING THE CAMSHAFT AND CYLINDER HEAD

VALVES AND VALVE SPRINGS:

REMOVING THE VALVE AND VALVE SPRING / CHECKING THE VALVE AND VALVE SPRING / INSTALLING THE VALVE AND VALVE SPRING

CYLINDER AND PISTON:

REMOVING THE PISTON / CHECKING THE CYLINDER AND PISTON / CHECKING THE PISTON RING / CHECKING THE PISTON PIN INSPECTION / INSTALLING THE PISTON / INSTALLING THE CYLINDER

AC MAGNETO:

REMOVING THE AC MAGNETO ROTOR / CHECKING THE COIL / CHECKING THE STARTER CLUTCH / INSTALLING THE AC MAGNETO ROTOR

CLUTCH:

REMOVING THE CLUTCH / REMOVING THE PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR / CHECKING THE FRICTION PLATE / CHECKING THE CLUTCH PLATE / CHECKING THE CLUTCH SPRING / CHECKING THE CLUTCH HOUSING / CHECKING THE CLUTCH BOSS / CHECKING THE PRESSURE PLATE / CHECKING THE PULL LEVER SHAFT AND PULL ROD / CHECKING THE PRIMARY DRIVE / CHECKING THE BALANCER DRIVE / INSTALLING THE PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR / INSTALLING THE CLUTCH

OIL PUMP:

CHECKING THE OIL PUMP / ASSEMBLING THE OIL PUMP

SHIFT SHAFT:

CHECKING THE SHIFT SHAFT / CHECKING THE STOPPER LEVER / CHECKING THE SHIFT GUIDE AND SHIFT LEVER / CHECKING THE SEGMENT / INSTALLING THE SHIFT LEVER / INSTALLING THE STOPPER LEVER / INSTALLING THE SHIFT SHAFT

CRANKCASE:

TIMING CHAIN AND SPEED SENSOR ROTOR / CRANKCASE CRANKCASE BEARING / SEPARATING THE CRANKCASE / CHECKING THE TIMING CHAIN AND GUIDE / CHECKING THE OIL STRAINER / CHECKING THE CRANKCASE / CHECKING THE BEARINGS / ASSEMBLING THE CRANKCASE

CRANKSHAFT AND BALANCER:

REMOVING THE CRANKSHAFT / CHECKING THE CRANKSHAFT / INSTALLING THE CRANKSHAFT

TRANSMISSION:

MAIN AXLE / DRIVE AXLE / CHECKING THE SHIFT FORK / CHECKING THE SHIFT DRUM / CHECKING THE TRANSMISSION / ASSEMBLING THE MAIN AXLE AND DRIVE AXLE / INSTALLING THE TRANSMISSION

**** CARBURETION ****

CARBURETORS:

CHECKING THE CARBURETOR / ASSEMBLING THE CARBURETOR / ADJUSTING THE FUEL LEVEL

DRIVE TRAIN

**** CHASSIS ****

FRONT WHEELS:

FRONT WHEELS / CHECKING THE WHEEL / CHECKING THE WHEEL HUB / CHECKING THE BRAKE DISC / INSTALLING WHEEL HUB / INSTALLING THE WHEEL


REAR WHEELS, WHEEL AXLE AND HUB:

REAR WHEELS / WHEEL AXLE AND HUB / REMOVING THE REAR AXLE / CHECKING THE WHEEL / CHECKING THE WHEEL HUB / CHECKING THE REAR AXLE / CHECKING THE HUB / CHECKING THE BRAKE DISC / INSTALLING THE NUTS (REAR AXLE) / INSTALLING THE WHEEL HUB / INSTALLING THE WHEEL

FRONT AND REAR BRAKES:

FRONT BRAKE PADS / REAR BRAKE PADS / REPLACING THE FRONT BRAKE PAD / REPLACING THE REAR BRAKE PAD / FRONT BRAKE MASTER CYLINDER / REAR BRAKE MASTER CYLINDER / CHECKING THE MASTER CYLINDER / ASSEMBLING THE FRONT AND REAR BRAKE MASTER CYLINDER / INSTALLING THE FRONT BRAKE MASTER CYLINDER / INSTALLING THE REAR BRAKE MASTER CYLINDER / FRONT BRAKE CALIPERS / REAR BRAKE CALIPER / DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER / CHECKING THE FRONT AND REAR BRAKE CALIPER / ASSEMBLING THE FRONT BRAKE CALIPER / ASSEMBLING THE REAR BRAKE CALIPER / INSTALLING THE FRONT BRAKE CALIPER / INSTALLING THE REAR BRAKE CALIPER

STEERING SYSTEM:

HANDLEBAR / REMOVING THE FRONT BRAKE SWITCH, PARK SWITCH AND CLUTCH SWITCH / REMOVING THE HANDLEBAR GRIP / CHECKING THE HANDLEBAR / INSTALLING THE HANDLEBAR / INSTALLING THE HANDLEBAR GRIP / INSTALLING THE CLUTCH LEVER / INSTALLING THE BRAKE MASTER CYLINDER / STEERING STEM / REMOVING THE BEARING RETAINER / CHECKING THE STEERING STEM / INSTALLING THE BEARING RETAINER / INSTALLING THE LOCK WASHER / TIE-ROD AND STEERING KNUCKLE / REMOVING THE STEERING KNUCKLE / CHECKING THE TIE-ROD / CHECKING THE STEERING KNUCKLE / INSTALLING THE TIE-ROD

FRONT ARMS AND FRONT SHOCK ABSORBERS:

REMOVING THE FRONT ARM / CHECKING THE FRONT ARM / CHECKING THE FRONT SHOCK ABSORBER / CHECKING THE BALL JOINT / INSTALLING THE FRONT ARM

REAR SHOCK ABSORBER AND RELAY ARM :

HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER / DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER / REMOVING THE REAR SHOCK ABSORBER/ CHECKING THE REAR SHOCK ABSORBER / CHECKING THE RELAY ARM AND CONNECTING ARM / INSTALLING THE RELAY ARM AND CONNECTING ARM / INSTALLING THE REAR SHOCK ABSORBER

SWINGARM AND DRIVE CHAIN:

REMOVING THE SWINGARM / CHECKING THE SWINGARM/ CHECKING THE DRIVE CHAIN / INSTALLING THE SWINGARM / INSTALLING THE DRIVE SPROCKET

**** ELECTRICAL ****

ELECTRICAL COMPONENTS

CHECKING THE SWITCH

CHECKING THE SWITCH / CHECKING A SWITCH SHOWN IN THE MANUAL / CHECKING THE SWITCH CONTINUITY

IGNITION SYSTEM:

CIRCUIT DIAGRAM / TROUBLESHOOTING

ELECTRIC STARTING SYSTEM:

CIRCUIT DIAGRAM / STARTING CIRCUIT OPERATION / TROUBLESHOOTING / STARTER MOTOR / CHECKING THE STARTER MOTOR / ASSEMBLING THE STARTER MOTOR

CHARGING SYSTEM:

CIRCUIT DIAGRAM / TROUBLESHOOTING

LIGHTING SYSTEM:

CIRCUIT DIAGRAM / TROUBLESHOOTING / CHECKING THE LIGHTING SYSTEM

SIGNAL SYSTEM:

CIRCUIT DIAGRAM / TROUBLESHOOTING / CHECKING THE SIGNAL SYSTEM

COOLING SYSTEM:

DIAGRAM / TROUBLESHOOTING

**** TROUBLESHOOTING ****

STARTING FAILURE/HARD STARTING:

FUEL SYSTEM / ELECTRICAL SYSTEM / COMPRESSION SYSTEM

POOR IDLE SPEED PERFORMANCE:

POOR IDLE SPEED PERFORMANCE

POOR MEDIUM AND HIGH-SPEED PERFORMANCE:

POOR MEDIUM AND HIGH-SPEED PERFORMANCE

FAULTY GEAR SHIFTING:

HARD SHIFTING / SHIFT PEDAL DOES NOT MOVE / JUMP-OUT GEAR

CLUTCH SLIPPING/DRAGGING:

CLUTCH SLIPPING / CLUTCH DRAGGING

OVERHEATING:

OVERHEATING

OVER COOLING:

COOLING SYSTEM

FAULTY BRAKE:

POOR BRAKING EFFECT

SHOCK ABSORBER MALFUNCTION:

MALFUNCTION

UNSTABLE HANDLING:

UNSTABLE HANDLING

LIGHTING SYSTEM:

HEADLIGHT DARK / BULB BURNT OUT

**** WIRING DIAGRAMS ****


If your a pro or someone who likes to just do the repair work yourself than you will need this manual. It will help you understand, care for and show you how to repair your 2001, 2002, 2003, 2004, 2005 Yamaha Raptor YFM660 (YFM 660) (YFM660R) . This manual does not contain information on how to modify ride, just a complete breakdown of how to maintain and service your oem ride just like a pro.

This is not a CD. This is a PDF manual for you to store, view and print pages from your computer when ever you need it. You receive it upon purchase with high speed download.

Technical highlights of chapters include: Service Information, Troubleshooting, Removal, Installation, Dissassembly, Assembly, Inspection and more.


MANUAL LANGUAGE: ENGLISH
PAGES: 358
FORMAT: PDF
DELIVERED IN: PDF FORMAT
ZOOM IN/ OUT: YES
FULLY INDEXED: YES
WORD SEARCH: YES
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