2003 YAMAHA YFM660R service

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

8-59
EBU00303
Valve clearance adjustment
The correct valve clearance changes with use, re-
sulting in improper fuel/air supply or engine noise.
To prevent this, the valve clearance must be ad-
justed regularly. This adjustment however, should
be left to a professional Yamaha service techni-
cian.
U5LP62.book Page 59 Wednesday, May 8, 2002 11:24 AM

8-67

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.
EBU01186
Brake fluid replacement
Complete fluid replacement should be done only
by trained Yamaha service personnel. Have a
Yamaha dealer replace the following components
during periodic maintenance or when they are
damaged or leaking.

Replace the oil seals every two years.


Replace the brake hoses every four years.
U5LP62.book Page 67 Wednesday, May 8, 2002 11:24 AM

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

8-121
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

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

10-8
Huile de moteur:
Type
Classification d’huile de moteur recommandée Huiles de type API Service, de classe SE, SF, SG minimum
Quantité:
Vidange périodique
Avec changement du filtre à huile
Quantité totale1,9 l
1,95 l
2,3 l Modèle YFM660R
-20˚-10˚0˚
10˚20˚30˚40˚50˚C
10W/30
15W/4020W/4020W/50
10W/40
5W/30
ATTENTION:
Ne pas mélanger d’additif chimique à l’huile afin d’éviter
tout patinage de l’embrayage, car l’huile moteur lubrifie
également l’embrayage. Ne pas utiliser des huiles de grade
diesel “CD” ni des huiles de grade supérieur à celui spéci-
fié. S’assurer également de ne pas utiliser une huile por-
tant la désignation “ENERGY CONSERVING II” ou la
même désignation avec un chiffre plus élevé.
U5LP62.book Page 8 Wednesday, May 8, 2002 11:24 AM