2003 YAMAHA YFM660R clutch

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

Brake and shift pedal/brake and
clutch lever lubrication ..................... 8-89
Front upper and lower arm pivot
lubrication ......................................... 8-91
Rear arm pivot lubrication .................. 8-93
Wheel removal ................................... 8-97
Wheel installation .............................. 8-99
Battery ............................................. 8-101
Battery maintenance ....................... 8-105
Fuse replacement ............................ 8-107
Replacing a headlight bulb ............... 8-109
Tail/brake light bulb replacement ..... 8-119
Troubleshooting ............................... 8-121
Troubleshooting chart ...................... 8-123
CLEANING AND STORAGE .................. 9-1
A. Cleaning .......................................... 9-1
B. Storage ........................................... 9-7
SPECIFICATIONS ................................ 10-1
CONVERSION TABLE .......................... 11-1
91011U5LP62.book Page 3 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

4-19 1. Clutch lever
1. Levier d’embrayage
1. Palanca de embrague
1. Brake lever
1. Levier de frein
1. Palanca del freno
EBU00069
Clutch lever
The clutch lever is located on the left handlebar
and the ignition circuit cut-off system is incorporat-
ed in the clutch lever holder. Pull the clutch lever to
the handlebar to disengage the clutch, and release
the lever to engage the clutch. The lever should be
pulled rapidly and released slowly for smooth
clutch operation. (Refer to “Starting a cold engine”
for a description of the ignition circuit cut-off sys-
tem.)
EBU00988
Brake lever
The brake lever is located on the right handlebar.
Pull it toward the handlebar to apply the front
brake.
U5LP62.book Page 19 Wednesday, May 8, 2002 11:24 AM

4-23 1. Button 2. Lock plate
1. Bouton 2. Verrou
1. Botón 2. Placa de bloqueo
1. Locked position
1. Position verrou bloqué
1. Posición bloqueada
EBU00081
Parking brake
Use the parking brake when you have to start the
engine or park the machine, especially on a slope.
Squeeze the clutch lever while pushing the button,
then push in the lock plate to apply the parking
brake. Squeeze the clutch lever to release the
parking brake.NOTE:When the parking brake is used, engine speed is
limited to 2,300 r/min. Be sure the parking brake is
released before moving the throttle lever. Other-
wise, the engine will misfire, preventing normal op-
eration.
U5LP62.book Page 23 Wednesday, May 8, 2002 11:24 AM

4-27 1. Shift pedal
1. Pédale de sélection
1. Pedal de cambios
1. Reverse knob “REV”
1. Bouton de marche arrière “REV”
1. Botón de marcha atrás “REV”
EBU00788
Shift pedal
This machine is equipped with a constant-mesh
5-speed forward and 1-speed reverse transmis-
sion. The shift pedal is located on the left side of
the engine and is used in combination with the
clutch when shifting.
EBU01028
Reverse knob “REV”
The reverse knob is used to shift into reverse gear.
Refer to the “Reverse knob operation and reverse
driving” section (page 6-11) before operating this
machine in reverse gear.
U5LP62.book Page 27 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