2003 YAMAHA YFM660R oil

EBU00015
1-CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ...................... 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION AND MACHINE
IDENTIFICATION ................................... 3-1
Identification number records .............. 3-3
Key identification number .................... 3-5
Vehicle identification number .............. 3-5
Model label ........................................... 3-7
CONTROL FUNCTIONS ........................ 4-1
Main switch........................................... 4-1
Indicator and warning lights ................. 4-3
Handlebar switches ........................... 4-11
Throttle lever ..................................... 4-15
Speed limiter ...................................... 4-17
Clutch lever ....................................... 4-19
Brake lever ......................................... 4-19
Brake pedal ........................................ 4-21
Parking brake .................................... 4-23
Shift pedal ......................................... 4-27
Reverse knob ..................................... 4-27
1234
Fuel tank cap .................................... 4-29
Fuel cock ........................................... 4-29
Starter (choke) ................................... 4-31
Seat.................................................... 4-33
Front shock absorber adjustment ...... 4-35
Rear shock absorber adjustment ....... 4-37
PRE-OPERATION CHECKS .................. 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil ........................................... 5-13
Coolant............................................... 5-17
Chain ................................................. 5-19
Throttle lever ...................................... 5-21
Fittings and fasteners......................... 5-21
Lights ................................................. 5-21
Switches............................................. 5-21
Tires .................................................. 5-23
How to measure tire pressure ........... 5-27
Tire wear limit .................................... 5-29
5
U5LP62.book Page 1 Wednesday, May 8, 2002 11:24 AM

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
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
What to do if .......................................7-73
What to do ..........................................7-73
67
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 ................................... 8-33
Changing the coolant.......................... 8-35
Spark plug inspection ......................... 8-43
Air filter element cleaning ................... 8-47
Carburetor adjustment ....................... 8-53
Idle speed adjustment ........................ 8-55
Throttle lever adjustment ................... 8-57
Valve clearance adjustment .............. 8-59
Front and rear brake pad inspection... 8-61
Brake fluid level inspection ................. 8-63
Brake fluid replacement ...................... 8-67
Front brake lever free play.................. 8-69
Brake pedal height adjustment ........... 8-71
Parking brake adjustment ................... 8-73
Adjusting the rear brake light switch ... 8-77
Clutch lever free play adjustment ...... 8-79
Drive chain slack check ...................... 8-81
Drive chain slack adjustment .............. 8-83
Lubricating the drive chain ................. 8-85
Cable inspection and lubrication ........ 8-89
8
U5LP62.book Page 2 Wednesday, May 8, 2002 11:24 AM

3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Seat
2. Fuel tank cap
3. Engine oil tank
4. Brake pedal
5. Headlights
6. Fuel cock
7. Throttle stop screw
8. Coolant reservoir
9. Tail/brake light10. Shift pedal
11. Clutch lever
12. Handlebar switches
13. Parking brake
14. Main switch
15. Reverse knob
16. Throttle lever
17. Brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5LP62.book Page 1 Wednesday, May 8, 2002 11:24 AM

4-45
WARNING
_ Suspension components become hot during
operation. Never touch the compression
damping adjusting screw, the rebound damp-
ing adjusting screw or the oil reservoir with
your bare hand or skin until suspension com-
ponents have cooled. _
U5LP62.book Page 45 Wednesday, May 8, 2002 11:24 AM

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,
8-61–8-69
Rear brakeCheck operation, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-61–8-67, 8-71
ClutchCheck operation, condition and lever free play. 8-79
Parking brakeCheck operation, condition and cable length. 8-73–8-75
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,
8-17–8-31
Coolant reservoirCheck coolant level.
Fill with coolant if necessary.5-17–5-19,
8-33–8-41
Drive chainCheck chain slack and condition.
Adjust if necessary.5-19, 8-81–8-87
ThrottleCheck for proper throttle cable operation and free play. 5-21, 8-57
Wheels and tiresCheck tire pressure, wear and damage.5-23–5-29,
8-97–8-99
Fittings and fastenersCheck all fittings and fasteners. 5-21
Lights and switchesCheck for proper operation.5-21, 8-77,
8-109–8-119
U5LP62.book Page 1 Wednesday, May 8, 2002 11:24 AM

5-13
EBU01180
Engine oil
Make sure the engine oil is at the specified level.
Fill with oil as necessary. (See pages 8-17–8-31
for details.)
Recommended oil:
Recommended engine oil classification:
API Service SE, SF, SG type or higher
-20˚ -10˚ 0˚
10˚20˚ 30˚40˚50˚C
10W/30
15W/4020W/4020W/50
10W/40
5W/30
U5LP62.book Page 13 Wednesday, May 8, 2002 11:24 AM

5-15
CAUTION:_

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


Make sure that no foreign material enters
the crankcase.
_
Oil quantity:
Periodic oil change:
1.9 L
With oil filter element replacement:
1.95 L
Total amount:
2.3 L
U5LP62.book Page 15 Wednesday, May 8, 2002 11:24 AM

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.)
Carburetor*•Check starter (choke) operation.
•Adjust engine idling speed.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.Clutch*•Check operation.
•Adjust if necessary.U5LP62.book Page 7 Wednesday, May 8, 2002 11:24 AM