2001 YAMAHA YFM660R maintenance

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INTRODUCTION
Congratulations on your purchase of the
Yamaha YFM660R. It represents the result of
many years of Yamaha experience in the pro-
duction of fine sporting, touring, and paceset-
ting racing machines. With the purchase of this
Yamaha, you can now appreciate the high de-
gree 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 machine. This manual includes important
safety information. It provides information
about special techniques and skills necessary
to ride your machine. It also includes basic
maintenance and inspection procedures. If you
have any questions regarding the operation or
maintenance of your machine, please consult a
Yamaha dealer.

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OPERATION ........................................... 6-1
Starting a cold engine ....................... 6-3
Starting a warm engine ..................... 6-9
Warming up ........................................ 6-9
Reverse knob operation and
reverse driving ............................... 6-11
Shifting ............................................. 6-15
To start out and accelerate .............. 6-17
To decelerate .................................... 6-21
Engine break-in ................................ 6-23
Parking .............................................. 6-27
Parking on a slope ........................... 6-29
Accessories and loading ................. 6-31
Accessories....................................... 6-31
Loading ............................................. 6-33
RIDING YOUR ATV ................................ 7-1
Getting to know your ATV ................. 7-3
Ride with care and good judgement 7-5
Be careful where you ride ............... 7-27
Turning your ATV ............................ 7-39
Climbing uphill ................................. 7-45
Riding downhill ................................ 7-55
Crossing a slope ............................... 7-59
Crossing through shallow water .... 7-63
Riding over rough terrain ................ 7-67
Sliding and skidding ........................ 7-69What to do if... .................................. 7-73
What to do... ..................................... 7-73
PERIODIC MAINTENANCE AND
ADJUSTMENT ....................................... 8-1
Owner’s manual and tool kit ............. 8-3
Periodic maintenance/lubrication ..... 8-7
Panel removal and installation ....... 8-15
Engine oil and oil filter cartridge .... 8-17
Cooling system ................................ 8-31
Changing the coolant ...................... 8-33
Spark plug inspection ...................... 8-41
Air filter element cleaning ............... 8-45
Carburetor adjustment .................... 8-51
Idle speed adjustment ..................... 8-53
Valve clearance adjustment ............ 8-55
Reverse lock release cable
adjustment ..................................... 8-55
Throttle lever adjustment ................ 8-57
Front and rear brake pad
inspection ....................................... 8-59
Brake fluid level inspection ............. 8-61
Brake fluid replacement .................. 8-65
Front brake adjustment ................... 8-67
Rear brake adjustment .................... 8-69
Parking brake adjustment ............... 8-71
Clutch lever free play adjustment .... 8-756
7
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Drive chain slack check .................... 8-77
Drive chain slack adjustment .......... 8-79
Lubricating the drive chain.............. 8-81
Cable inspection and lubrication .... 8-85
Brake and shift pedal/brake and
clutch lever lubrication .................. 8-85
Upper arm and lower arm pivot
lubrication....................................... 8-87
Rear arm pivot lubrication............... 8-89
Wheel removal ................................. 8-93
Wheel installation ............................ 8-95
Battery ............................................... 8-97
Battery maintenance ...................... 8-101
Fuse replacement ........................... 8-103
Replacing the headlight bulb ........ 8-105
Tail/brake light bulb
replacement.................................. 8-115
Troubleshooting ............................. 8-117
Troubleshooting chart ................... 8-119
CLEANING AND STORAGE................... 9-1
A. Cleaning ......................................... 9-1
B. storage ............................................ 9-7SPECIFICATIONS ..................................10-1
HOW TO USE THE CONVERSION
TABLE ....................................................11-1
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Never attempt wheelies, jumps, or other
stunts.


Always inspect your ATV each time you use
it to make sure it is in safe operating condi-
tion. Always follow the inspection and
maintenance procedures and schedules de-
scribed 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
operating on unfamiliar terrain. Always be
alert to changing terrain conditions when
operating the ATV.


Never operate on excessively rough, slip-
pery or loose terrain until you have learned
and practiced the skills necessary to control
the ATV on such terrain. Always be espe-
cially cautious on these kinds of terrain.

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WARNING
Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Owner’s
Manual. Failure to inspect increases the possibility of an accident or equipment damage.
AVERTISSEMENT
Toujours effectuer ces contrôles avant chaque départ afin de s’assurer que le VTT peut être utilisé en toute sécurité.
Toujours respecter les procédés et intervalles de contrôle et d’entretien repris dans ce manuel. Omettre ces con-
trôles accroît les risques d’accident ou d’endommagement du véhicule.
ADVERTENCIA
Inspeccionar siempre el ATV cada vez que vaya a utilizarse, para asegurarse de que está en condiciones
de funcionar sin peligro.
Seguir siempre los procedimientos y programas de inspección y mantenimiento descritos en el
Manual del Usuario. Si no se inspecciona la máquina, aumenta el riesgo de accidente o avería.

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PERIODIC MAINTENANCE AND
ADJUSTMENT
Periodic inspection, adjustment and lubrica-
tion will keep your machine in the safest and
most efficient condition possible. Safety is an
obligation of the machine owner. The most im-
portant points of machine inspection, adjust-
ment and lubrication are explained on the
following pages.
WARNING
Never service an engine while it is running.
Moving parts can catch clothing or parts of the
body, causing injury. Electrical components
can cause shocks or can start fires. Turn off the
engine when performing maintenance unless
otherwise specified. Have a Yamaha dealer
perform service if you are not familiar with
machine service.

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1. Owner’s manual
2. Owner’s tool kit
3. Low-pressure tire gauge
1. Manuel du propriétaire
2. Trousse à outils
3. Manomètre basse pression pour pneus
1. Manual del propietario
2. Equipo de herramientas
3. Manómetro de baja presión
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Owner’s manual and tool kit
You are recommended to put this owner’s
manual and low-pressure tire gauge in the vi-
nyl bag and always carry them along with the
owner’s tool kit under the seat. The service in-
formation included in this manual is intended
to provide you, the owner, with the necessary
information for completing your own preven-
tive maintenance and minor repairs. The tools
provided in the Owner’s tool kit are sufficient
for this purpose, except that a torque wrench is
also necessary to properly tighten nuts and
bolts.
NOTE:
If you do not have a torque wrench available
during a service operation requiring one, take
your machine to a Yamaha dealer to check the
torque settings and adjust them as necessary.

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PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
Valves*• Check valve clearance.
• Adjust if necessary.
Cooling system• Check coolant leakage.
• Repair if necessary.
• Replace coolant every 24 months.
Spark plug• Check condition.
• Adjust gap and clean.
• Replace if necessary.
Air filter element• Clean.
• Replace if necessary.Every 20~40 hours
(More often in wet or dusty areas.)
Carburetor*• Check and adjust idle speed/starter operation.
• Adjust if necessary.
Crankcase breather
system*• Check breather hose for cracks or damage.
• Replace if necessary.
Exhaust system*• Check for leakage.
• Retighten if necessary.
• Replace gasket if necessary.
Fuel line*• Check fuel hose for cracks or damage.
• Replace if necessary.
Engine oil• Replace (Warm engine before draining.)
Engine oil filter cartridge• Replace if necessary.
Drive chain• Check and adjust slack/alignment/clean/lube.
Brakes*• Check operation/fluid leakage/See NOTE Page 8-8.
• Correct if necessary.
Clutch*• Check operation.
• Adjust if necessary.