2002 YAMAHA YFM660R clutch

8-8 * It is recommended that these items be serviced by a Yamaha dealer.
** Lithium-soap-based grease
NOTE:

Recommended brake fluid: DOT4


Brake fluid replacement:
1. When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the brake
fluid level and add fluid as required.
2. On the inner parts of the master cylinder and caliper, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
Clutch*•Check operation.
•Adjust if necessary.Wheels*•Check balance/damage/runout.
•Replace if necessary.Wheel bearings*•Check bearing assembly for looseness/damage.
•Replace if damaged.Steering system*•Check operation.
•Repair if damaged.
•Check toe-in.
•Adjust if necessary.Upper and lower arm
pivot and steering
shaft*•Lubricate every 6 months.**Rear arm pivot*•Lubricate every 6 months.**Fittings and fasteners*•Check all chassis fittings and fasteners.
•Correct if necessary.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U5LP61.book Page 8 Monday, August 27, 2001 3:49 PM

8-27
11. Add sufficient oil of the recommended type to
raise it to the correct level, and then install
and tighten the oil tank filler cap.CAUTION:_

In order to prevent clutch slippage (since
the engine oil also lubricates the clutch),
do not mix any chemical additives with the
oil or use oils of a grade “CD” or higher. In
addition, do not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign material enters
the crankcase.
_
Recommended engine oil:
See page 10-2.
U5LP61.book Page 27 Monday, August 27, 2001 3:49 PM

8-71 1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
1. Locknut 2. Adjusting bolt
a. Cable length
1. Contre-écrou 2. Boulon de réglage
a. Longueur de câble
1. Contratuerca 2. Perno de ajuste
a. Longitud del cable
EBU00953
Parking brake adjustment
Parking brake adjustment may be required if the
parking brake does not hold properly.
1. Fully loosen the parking brake cable adjust-
ing bolt locknut and the adjusting bolt on the
clutch lever.
2. Loosen the adjusting bolt locknut and the ad-
justing bolt on the rear brake caliper.
3. Turn the adjusting bolt on the clutch lever so
that cable length
a is 64 ~ 68 mm.NOTE:If the cable cannot be adjusted to specification,
consult a Yamaha dealer. _4. Tighten the adjusting bolt locknut on the
clutch lever.
U5LP61.book Page 71 Monday, August 27, 2001 3:49 PM

8-77 1. Locknut 2. Adjusting bolt c. Free play
1. Contre-écrou 2. Boulon de réglage c. Jeu
1. Contratuerca 2. Perno de ajuste c. Juego libre
1. Locknut 2. Adjusting nut
1. Contre-écrou 2.Écrou de réglage
1. Contratuerca 2. Tuerca de ajuste
EBU00741
Clutch lever free play adjustment
The clutch lever free play should be adjusted to
5~10mm.
1. Loosen the locknut at the clutch lever.
2. Turn the adjusting bolt at the clutch lever in
direction
a to increase the free play or in di-
rection
b to decrease the free play.
3. Tighten the locknut at the clutch lever.NOTE:If the specified free play cannot be obtained, pro-
ceed with the following steps.4. Loosen the locknut at the clutch lever.
5. Turn the adjusting bolt at the clutch lever in
direction
a to loosen the cable.
6. Loosen the locknut at the crankcase side.
7. Turn the adjusting nut at the crankcase in di-
rection
a to increase the free play or in direc-
tion
b to decrease the free play.
8. Tighten the locknut at the crankcase and the
clutch lever.
U5LP61.book Page 77 Monday, August 27, 2001 3:49 PM

8-87
EBU00570
Cable inspection and lubrication
WARNING
Inspect cables frequently and replace if dam-
aged. Corrosion can result when the outer cov-
ering of control cables becomes damaged.
Cables can also become frayed or kinked. Op-
eration of controls could be restricted, which
could cause an accident or injury.Lubricate the inner cables and the cable ends. If
the cables do not operate smoothly, ask a Yamaha
dealer to replace them.
EBU00737
Brake and shift pedal/brake and clutch lever
lubrication
Lubricate the pivoting parts of each lever and ped-
al.Recommended lubricant:
Engine oil
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5LP61.book Page 87 Monday, August 27, 2001 3:49 PM

10-2
10
Engine oil:
Type
Recommended engine oil classification API Service SE, SF, SG type or higher
Quantity:
Periodic oil change
With oil filter replacement
Total amount1.9 L
1.95 L
2.3 L MODEL YFM660R
-20˚-10˚0˚
10˚20˚30˚40˚50˚C
10W/30
15W/4020W/4020W/50
10W/40
5W/30
CAUTION:Be sure to use motor oils that do not contain anti-
friction modifiers. Passenger car motor oils (often
labeled “ENERGY CONSERVING II”) contain anti-
friction additives which will cause clutch and/or
starter clutch slippage, resulting in reduced com-
ponent life and poor engine performance.
U5LP61.book Page 2 Monday, August 27, 2001 3:49 PM

10-3
Radiator capacity (including all routes) 1.3 L
Air filter Wet element
Fuel:
Type
Tank capacity
Reserve amountRegular unleaded gasoline only
12 L
2.6 L
Carburetor:
Type
× quantity
ManufacturerBSR33
× 2
MIKUNI
Spark plug:
Type/manufacturer
GapDPR8EA-9/NGK
0.8 ~ 0.9 mm
Clutch:
Type
OperationWet, multiple-disc
Left hand operation
Transmission:
Primary Reduction System
Primary Reduction Ratio
Secondary Reduction System
Secondary Reduction Ratio
Transmission type
OperationSpur gear
71/34 (2.088)
Chain drive
40/13 (3.076)
Constant mesh, 5-speed forward, 1-speed reverse
Left foot operation MODEL YFM660R
U5LP61.book Page 3 Monday, August 27, 2001 3:49 PM