2004 YAMAHA YFM660R service

8-8 * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
** 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.
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 beams.
ITEM ROUTINEINITIAL EVERY
1
month3
months6
months6
months1
year
U5LP63.book Page 8 Monday, March 10, 2003 2:06 PM

8-61
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.
U5LP63.book Page 61 Monday, March 10, 2003 2:06 PM

8-69

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.
U5LP63.book Page 69 Monday, March 10, 2003 2:06 PM

8-71 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.
_
U5LP63.book Page 71 Monday, March 10, 2003 2:06 PM

8-73 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.
_
U5LP63.book Page 73 Monday, March 10, 2003 2:06 PM

8-118
8. Mettre une nouvelle ampoule de phare en place et
la fixer à l’aide de la fixation d’ampoule.ATTENTION:_ Ne jamais toucher le verre d’une ampoule de phare
afin de ne pas laisser de résidus graisseux. La graisse
réduit la transparence du verre mais aussi la lumino-
sité de l’ampoule, ainsi que sa durée de service. Net-
toyer soigneusement toute crasse ou trace de doigts
sur l’ampoule avec un chiffon imbibé d’alcool ou de
diluant pour peinture. _9. Mettre le cache de la fixation d’ampoule en place.ATTENTION:_ S’assurer de remettre correctement le cache en place
sur la fixation d’ampoule et veiller à ce qu’il soit bien
assis contre le réflecteur. _
8. Ponga una bombilla nueva en su posición y fí-
jela en su lugar con el portabombillas.AT E N C I O N :_ No toque la parte de vidrio de la bombilla del faro
para que no se adhiera grasa a la misma, porque,
de lo contrario, la transparencia del vidrio, la lu-
minosidad de la bombilla, y la vida de servicio de
la bombilla se verían adversamente afectadas.
Limpie bien toda la suciedad y huellas dactilares
de la bombilla del faro con un paño humedecido
en alcohol o disolvente. _9. Instale la cubierta del portabombillas del faro.AT E N C I O N :_ Asegúrese de que la cubierta del portabombillas
del faro esté fijada con seguridad encima del
portabombillas y que esté asentada contra el re-
flector. _
U5LP63.book Page 118 Monday, March 10, 2003 2:06 PM

8-123
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.
U5LP63.book Page 123 Monday, March 10, 2003 2:06 PM

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 cartridge 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.
U5LP63.book Page 2 Monday, March 10, 2003 2:06 PM