2003 YAMAHA YFM660R warning

8-69 a. Brake lever free play
a. Jeu du levier de frein
a. Juego de la palanca de freno
EBU01188
Front brake lever free play
The front brake lever should have a free play of
zero mm at the lever end. If not, have a Yamaha
dealer check the brake system.
WARNING
_ Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly
and that the free play is correct.


Make sure the brakes do not drag.


Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
_
U5LP62.book Page 69 Wednesday, May 8, 2002 11:24 AM

8-71 a. Brake pedal position
a. Position de la pédale de frein
a. Posición del pedal del freno
EBU01079
Brake pedal height adjustment
The top of the brake pedal should be positioned
4 mm below the top of the footrest. If not, have a
Yamaha dealer adjust it.
WARNING
_ Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident. After servic-
ing:

Make sure the brakes operate smoothly
and that the brake pedal position is cor-
rect.


Make sure the brakes do not drag.


Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
_
U5LP62.book Page 71 Wednesday, May 8, 2002 11:24 AM

8-75
5. Screw in the adjusting bolt at the rear brake
caliper by hand until it feels tight, then screw it
out 1/8 turn. Tighten the locknut to the speci-
fied torque.CAUTION:_ When tightening the locknut, hold the adjust-
ing bolt with a wrench so that the adjusting
bolt does not turn together with the locknut. _
WARNING
_ Operating with improperly adjusted brakes
could cause the brakes to malfunction, result-
ing in reduced braking performance. This
could increase the chance of a collision or ac-
cident. After adjusting the parking brake, block
the rear of the machine off the ground and spin
the rear wheels. Check to make sure there is
no brake drag. If brake drag is noticed, perform
the adjustment again. _
Tightening torque:
Locknut:
16 Nm (1.6 m·kgf)
U5LP62.book Page 75 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

8-103
WARNING
Battery electrolyte is poisonous and danger-
ous, causing severe burns, etc. It contains sul-
furic acid. Avoid contact with skin, eyes or
clothing.
Antidote:

EXTERNAL: Flush with water.


INTERNAL: Drink large quantities of water
or milk. Follow with milk of magnesia, beat-
en egg or vegetable oil. Call a physician
immediately.


EYES: Flush with water for 15 minutes and
get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes or other sources of
ignition away. Ventilate when charging or us-
ing in an enclosed space. Always shield your
eyes when working near batteries. KEEP OUT
OF REACH OF CHILDREN.
U5LP62.book Page 103 Wednesday, May 8, 2002 11:24 AM

8-107 1. Fuse 2. Spare fuse
1. Fusible 2. Fusible de rechange
1. Fusible 2. Fusible de repuesto
EBU00391
Fuse replacement
1. The fuse case is located under the seat.
2. If the fuse is blown, turn off the main switch
and install a new fuse of the specified amper-
age. Then turn on the switches. If the fuse im-
mediately blows again, consult a Yamaha
dealer.
WARNING
Always use a fuse of the specified rating. Nev-
er use a material in place of the proper fuse. An
improper fuse can cause damage to the electri-
cal system which could lead to a fire. CAUTION:
To prevent accidental short-circuiting, turn off
the main switch when checking or replacing a
fuse. Specified fuse: 20 A
U5LP62.book Page 107 Wednesday, May 8, 2002 11:24 AM

8-113 1. Headlight bulb holder cover
1. Cache de la fixation d’ampoule de phare
1. Cubierta del portabombillas del faro
1. Headlight bulb holder
1. Fixation d’ampoule de phare
1. Portabombillas del faro
6. Remove the headlight bulb holder cover.
7. Push the headlight bulb holder inward, turn it
counterclockwise and remove the defective
bulb.
WARNING
_ A headlight bulb is hot when it is on and imme-
diately after it is turned off. Wait for the bulb to
cool down before touching or removing it. You
can be burned, or a fire could start if the bulb
touches something flammable. _
U5LP62.book Page 113 Wednesday, May 8, 2002 11:24 AM

8-121
EBU00413
Troubleshooting
Although Yamaha machines receive a rigid in-
spection before shipment from the factory, trouble
may occur during operation.
Any problem in the fuel, compression, or ignition
systems can cause poor starting and loss of pow-
er. The troubleshooting chart describes a quick,
easy procedure for making checks. If your ma-
chine requires any repair, take it to a Yamaha
dealer.
The skilled technicians at a Yamaha dealership
have the tools, experience, and know-how to prop-
erly service your machine. Use only genuine
Yamaha parts on your machine. Imitation parts
may look like Yamaha parts, but they are often in-
ferior. Consequently, they have a shorter service
life and can lead to expensive repair bills.
WARNING
Do not smoke when checking the fuel system.
Fuel can ignite or explode, causing severe in-
jury or property damage. Make sure there are
no open flames or sparks in the area, including
pilot lights from water heaters or furnaces.
U5LP62.book Page 121 Wednesday, May 8, 2002 11:24 AM