2002 YAMAHA YFM660R brake fluid

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 ............................7-69
67
What 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
Throttle lever adjustment ................... 8-55
Valve clearance adjustment .............. 8-57
Front and rear brake pad inspection... 8-59
Inspecting the brake fluid level ........... 8-61
Brake fluid replacement ...................... 8-65
Front brake adjustment ...................... 8-67
Rear brake adjustment ....................... 8-69
Parking brake adjustment ................... 8-71
Adjusting the rear brake light switch ... 8-75
Clutch lever free play adjustment ...... 8-77
Drive chain slack check ..................... 8-79
Drive chain slack adjustment .............. 8-81
8
U5LP61.book Page 2 Monday, August 27, 2001 3:49 PM

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5 ~ 5-7,
8-59 ~ 8-67
Rear brakeCheck operation, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5 ~ 5-7,
8-59 ~ 8-65, 8-69
ClutchCheck operation, condition and lever free play. 8-77
Parking brakeCheck operation, condition and cable free play. 8-71 ~ 8-73
FuelCheck fuel level.
Fill with fuel if necessary.5-9 ~ 5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13 ~ 5-15,
8-17 ~ 8-29
Coolant reservoirCheck coolant level.
Fill with coolant if necessary.5-17 ~ 5-19,
8-31 ~ 8-39
Drive chainCheck chain slack and condition.
Adjust if necessary.5-19, 8-77 ~ 8-83
ThrottleCheck for proper throttle cable operation and free play. 5-21, 8-55
Wheels and tiresCheck tire pressure, wear and damage.5-23 ~ 5-29,
8-95 ~ 8-97
Fittings and fastenersCheck all fittings and fasteners. 5-21
LightsCheck for proper operation. 5-21, 8-107 ~ 8-117
U5LP61.book Page 1 Monday, August 27, 2001 3:49 PM

5-5
EBU00990
Front and rear brakes
Brake lever and brake pedal

Check that there is no free play in the brake le-
ver. If there is free play, have a Yamaha dealer
adjust it. Check for correct brake pedal height.
If the pedal height is incorrect, have a Yamaha
dealer adjust it. (See pages 8-67 ~ 8-69.)


Check the operation of the lever and pedal.
They should move smoothly and there should
be a firm feeling when the brakes are applied. If
not, have the machine inspected by a Yamaha
dealer.
Brake fluid level


Check the brake fluid level. Add fluid if neces-
sary. (See page 8-61.)
Recommended brake fluid: DOT 4
U5LP61.book Page 5 Monday, August 27, 2001 3:49 PM

5-7
Brake fluid leakage

Check to see if any brake fluid is leaking out of
the pipe joints or master cylinders. Apply the
brakes firmly for one minute. If there is any
leakage, have the machine inspected by a
Yamaha dealer.
Brake operation


Test the brakes at slow speed after starting out
to make sure they are working properly. If the
brakes do not provide proper braking perfor-
mance, inspect the brake pads for wear. (See
page 8-59.)WARNING
_ Always check the brakes at the start of every
ride. Do not ride the ATV if you find any prob-
lem with the brakes or you could lose braking
ability, which could lead to an accident. If a
problem cannot be corrected by the adjust-
ment procedures provided in this manual,
have the ATV inspected by a Yamaha dealer. _
U5LP61.book Page 7 Monday, August 27, 2001 3:49 PM

8-7
EBU00262
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.)
Carburetors*•Check starter (choke) operation.
•Adjust engine idling speed and synchronization.Crankcase breather
system*•Check breather hose for cracks or damage.
•Replace if necessary.Exhaust system*•Check for leakage.
•Tighten 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.Front brake•Check free play/operation/fluid leakage/
See NOTE Page 8-8.
•Correct if necessary.Rear brake*•Check operation/fluid leakage/See NOTE Page 8-8.
•Correct if necessary.U5LP61.book Page 7 Monday, August 27, 2001 3:49 PM

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

8-61 1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
Front
Avant
Delantero1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo Rear
Arrière
Trasero
EBU01017*
Inspecting the brake fluid level
Insufficient brake fluid may let air enter the brake
system, possibly causing the brakes to become in-
effective.
Before riding, check that the brake fluid is above
the lower level and replenish when necessary.NOTE:_ To access the rear brake fluid reservoir, remove
the reservoir cover by removing the bolts. (See
page 8-63.)_
U5LP61.book Page 61 Monday, August 27, 2001 3:49 PM

8-63 1. Brake fluid reservoir cover
2. Bolt (× 2)
1. Couvercle du réservoir de liquide de frein
2. Boulon (× 2)
1. Cubierta del depósito de líquido de frenos
2. Perno (× 2)
Rear
Arrière
Trasero
Observe these precautions:

When checking the fluid level, make sure the
top of the brake fluid reservoir is level.


Use only the designated quality brake fluid.
Otherwise, the rubber seals may deteriorate,
causing leakage and poor brake performance.


Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor brake performance.


Be careful that water does not enter the brake
fluid reservoir when refilling. Water will signifi-
cantly lower the boiling point of the fluid and
may result in vapor lock.


Brake fluid may deteriorate painted surfaces or
plastic parts. Always clean up spilled fluid im-
mediately.


Have a Yamaha dealer check the cause if the
brake fluid level goes down. Recommended brake fluid: DOT 4
U5LP61.book Page 63 Monday, August 27, 2001 3:49 PM