2003 YAMAHA YFM660R clutch

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

8-29
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.
_
Recommended engine oil:
See page 10-2.
Oil quantity:
Periodic oil change:
1.9 L
With oil filter cartridge replacement:
1.95 L
Total amount:
2.3 L
U5LP62.book Page 29 Wednesday, May 8, 2002 11:24 AM

8-73 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
1. Locknut 2. Adjusting bolt
1. Contre-écrou 2. Boulon de réglage
1. Contratuerca 2. Perno de ajuste
EBU01192
Parking brake adjustment
Parking brake adjustment may be required if the
parking brake does not hold properly. The cable
length
A should be adjusted to 64–68 mm.
1. Fully loosen the locknut and the adjusting bolt
at the clutch lever.
2. Loosen the locknut and the adjusting bolt at
the rear brake caliper.
3. Turn the adjusting bolt at the clutch lever in
direction
a to increase the cable length or in
direction
b to decrease the cable length.NOTE:_ If the cable cannot be adjusted to specification,
consult a Yamaha dealer. _4. Tighten the locknut at the clutch lever.
U5LP62.book Page 73 Wednesday, May 8, 2002 11:24 AM

8-79 1. Locknut 2. Adjusting bolt
c. Clutch lever free play
1. Contre-écrou 2. Boulon de réglage
c. Jeu du levier d’embrayage
1. Contratuerca 2. Perno de ajuste
c. Juego libre de la palanca del embrague
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
5–10 mm.
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.
U5LP62.book Page 79 Wednesday, May 8, 2002 11:24 AM

8-89
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)
U5LP62.book Page 89 Wednesday, May 8, 2002 11:24 AM

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:In order to prevent clutch slippage (since the en-
gine 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.
U5LP62.book Page 2 Wednesday, May 8, 2002 11:24 AM

10-3
Radiator capacity (including all routes) 1.3 L
Air filter Wet element
Fuel:
Type
Tank capacity
Reserve amountUnleaded gasoline only
For Europe: Regular unleaded gasoline only with a
research octane number of 91 or higher
12 L
2.6 L
Carburetor:
Type
× quantity
ManufacturerBSR33
× 1
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
U5LP62.book Page 3 Wednesday, May 8, 2002 11:24 AM