2003 YAMAHA YFM660R oil level

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

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

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:
•When disassembling the master cylinders or calipers, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
•On the inner parts of the master cylinders and calipers, replace the oil seals every two years.
•Replace the brake hoses every four years, or if cracked or damaged.
Wheels*•Check balance/damage/runout.
•Replace if necessary.Wheel bearings*•Check bearing assemblies for looseness/damage.
•Replace if damaged.Steering system*•Check operation.
•Repair if damaged.
•Check toe-in.
•Adjust if necessary.Front and rear
suspension*•Check operation.
•Correct 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.Lights and switches*•Check operation.
•Adjust headlight beam.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U5LP62.book Page 8 Wednesday, May 8, 2002 11:24 AM

8-17 1. Engine oil tank
2. Engine oil tank filler cap
3. Dipstick
4. Maximum level mark
5. Minimum level mark
1. Réservoir d’huile de moteur
2. Bouchon de remplissage de l’huile de moteur
3. Jauge
4. Repère de niveau maximum
5. Repère de niveau minimum
1. Depósito de aceite de motor
2. Tapa de relleno del depósito de aceite de motor
3. Varilla de medición
4. Marca de nivel máximo
5. Marca de nivel mínimo
EBU01238
Engine oil and oil filter cartridge
The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter cartridge replaced at the intervals
specified in the periodic maintenance and lubrica-
tion chart.
To check the engine oil level
1. Place the ATV on a level surface.
2. Start the engine, warm it up until the engine
oil has reached a normal temperature of
60°C, let it continue to idle for twenty to thirty
seconds. During this period, rev the engine
two or three times to approximately
3,000 r/min, and then turn the engine off.NOTE:_ To achieve the proper engine oil temperature for
an accurate oil level reading, the engine must
have first completely cooled down, and then
warmed up again for several minutes to normal
operating temperature. _
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8-19
3. Wait a few minutes until the oil settles, re-
move the engine oil tank filler cap, wipe the
dipstick clean with a clean rag, insert it back
into the filler hole (without screwing it in), and
then remove it again to check the oil level.NOTE:_ The engine oil should be between the minimum
and maximum level marks. _4. If the engine oil is below the minimum level
mark, add sufficient oil of the recommended
type to raise it to the correct level.NOTE:_ When adding oil, be careful not to overfill the en-
gine oil tank; the oil level rises faster starting from
the half-level-portion on the dipstick. _5. Insert the dipstick into the oil filler hole, and
then tighten the oil filler cap.
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8-27
11. Pour only 1.75 L of the specified amount of
recommended engine oil through the engine
oil tank filler hole, insert the dipstick, and then
tighten the oil tank filler cap.
12. Start the engine, rev it several times, and
then turn it off.
13. Remove the engine oil tank filler cap, and
then gradually fill the oil tank with the remain-
ing oil quantity while regularly checking the oil
level on the dipstick. Tightening torques:
Crankcase engine oil drain bolt:
30 Nm (3.0 m·kgf)
Engine oil tank drain bolt:
25 Nm (2.5 m·kgf)
U5LP62.book Page 27 Wednesday, May 8, 2002 11:24 AM

8-31
14. Start the engine, and then let it idle for seve-
ral minutes while checking it for oil leakage. If
oil is leaking, immediately turn the engine off
and check for the cause.
15. Turn the engine off, and then check the oil
level and correct it if necessary.
U5LP62.book Page 31 Wednesday, May 8, 2002 11:24 AM