2004 YAMAHA YFM660R load

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.......................... 8-37
Spark plug inspection ......................... 8-45
Air filter element cleaning ................... 8-49
Carburetor adjustment ....................... 8-55
Idle speed adjustment ........................ 8-57
Throttle lever adjustment ................... 8-59
Valve clearance adjustment .............. 8-61
Front and rear brake pad inspection... 8-63
Brake fluid level inspection ................. 8-65
Brake fluid replacement ...................... 8-69
Front brake lever free play.................. 8-71
Brake pedal height adjustment ........... 8-73
Parking brake adjustment ................... 8-75
Adjusting the rear brake light switch ... 8-79
Clutch lever free play adjustment ...... 8-81
Drive chain slack check ...................... 8-83
Drive chain slack adjustment .............. 8-85
Lubricating the drive chain ................. 8-87
Cable inspection and lubrication ........ 8-91
8
U5LP63.book Page 2 Monday, March 10, 2003 2:06 PM

2-15

Never modify an ATV through improper instal-
lation or use of accessories.


Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow
instructions in this manual for carrying cargo or
pulling a trailer. Allow greater distance for brak-
ing.
U5LP63.book Page 15 Monday, March 10, 2003 2:06 PM

4-5 1. Reverse indicator light “R”
2. Neutral indicator light “N”
3. Coolant temperature warning light “”
1. Témoin de marche arrière “R”
2. Témoin de point mort “N”
3. Témoin d’avertissement de la température du liquide de
refroidissement “”
1. Luz de control de marcha atrás “R”
2. Luz de control de punto muerto “N”
3. Luz de aviso de la temperatura del refrigerante “”
EBU00713
Coolant temperature warning light “”
When the coolant temperature reaches a specified
level, this light comes on to warn that the coolant
temperature is too hot. If the light comes on during
operation, stop the engine as soon as it is safe to
do so and allow the engine to cool down for about
10 minutes.
The coolant temperature warning light circuit can
be checked according to the procedure on page
4-7.CAUTION:

The engine may overheat if the ATV is
overloaded. If this happens, reduce the
load to specification.


Restart after making sure that the light is
out. Continuous use while the light is on
may cause damage to the engine.
U5LP63.book Page 5 Monday, March 10, 2003 2:06 PM

4-15 1. Throttle lever
1. Levier d’accélération
1. Palanca de aceleración
EBU00063
Throttle lever
Once the engine is running, movement of the
throttle lever will increase the engine speed.
Regulate the speed of the machine by varying the
throttle position. Because the throttle is spring-
loaded, the machine will decelerate, and the en-
gine will return to an idle any time the hand is re-
moved from the throttle lever.
Before starting the engine, check the throttle to be
sure it is operating smoothly. Make sure it returns
to the idle position as soon as the lever is released.
WARNING
Malfunction of the throttle could make it diffi-
cult to speed up or slow down when you need
to. This could cause an accident. Check the
operation of the throttle lever before you start
the engine. If the throttle does not work
smoothly, check for the cause. Correct the
problem before riding the ATV or consult a
Yamaha dealer.
U5LP63.book Page 15 Monday, March 10, 2003 2:06 PM

4-35 1. Spring preload adjusting ring
2. Position indicator
1. Anneau de réglage de la précontrainte de ressort
2. Indicateur de position
1. Anillo de ajuste de precarga del resorte
2. Indicador de posición
1. Special wrench
1. Clé spéciale
1. Llave especial
EBU01163
Front shock absorber adjustment
The spring preload can be adjusted to suit the rid-
er’s weight and riding conditions.
Adjust the spring preload as follows.
To increase the spring preload, turn the adjusting
ring in direction
a.
To decrease the spring preload, turn the adjusting
ring in direction
b.NOTE:_ A special wrench can be obtained at a Yamaha
dealer to make this adjustment. _
WARNING
_ Always adjust the shock absorbers on the left
and right side to the same setting. Uneven ad-
justment can cause poor handling and loss of
stability, which could lead to an accident. _
Standard position: C
A - Minimum (soft)
E - Maximum (hard)
U5LP63.book Page 35 Monday, March 10, 2003 2:06 PM

4-37
EBU01208
Rear shock absorber adjustment
The spring preload, rebound damping and com-
pression damping forces of the rear shock absorb-
er can be adjusted to suit the rider’s weight and the
riding conditions.
WARNING
_ This shock absorber contains highly pressur-
ized nitrogen gas. Read and understand the
following information before handling the
shock absorber.

Do not tamper with or attempt to open the
cylinder assembly.


Do not subject the shock absorber to an
open flame or other high heat source. This
may cause the unit to explode due to ex-
cessive gas pressure.


Do not deform or damage the cylinder in
any way. Cylinder damage will result in
poor damping performance.


Take the shock absorber to a Yamaha deal-
er for any service.
_
U5LP63.book Page 37 Monday, March 10, 2003 2:06 PM

4-39 1. Spring preload adjusting nut
2. Locknut 3. Special wrench
1.Écrou de réglage de la précontrainte de ressort
2. Contre-écrou 3. Clé spéciale
1. Tuerca de ajuste de precarga del resorte
2. Contratuerca 3. Llave especial
A. Spring length
A. Longueur du ressort
A. Longitud del muelle
Adjust the spring preload as follows.
1. Loosen the locknut.
2. Turn the adjusting nut in direction
a to in-
crease the spring preload and in direction
b
to decrease the spring preload.
3. The length of the spring (installed) changes
1.5 mm per turn of the adjusting nut.NOTE:_ A special wrench can be obtained at a Yamaha
dealer to make this adjustment. _4. Tighten the locknut to the specified torque.CAUTION:_ Always tighten the locknut against the adjust-
ing nut, then tighten it to the specified torque. _
Measurement
A:
Installed length:
Minimum (hard): 232 mm
Standard: 240 mm
Maximum (soft): 247 mm
Tightening torque:
42 Nm (4.2 m·kgf)
U5LP63.book Page 39 Monday, March 10, 2003 2:06 PM

6-23
EBU00209
Engine break-in
There is never a more important period in the life of
your machine than the period between zero and
20 hours.
For this reason, we ask that you carefully read the
following material. Because the engine is brand
new, you must not put an excessive load on it for
the first several hours of running. During the first
20 hours, the various parts in the engine wear and
polish themselves to the correct operating clear-
ances.
During this period, prolonged full throttle operation
or any condition which might result in excessive
engine heating must be avoided. However, mo-
mentary (2–3 seconds maximum) full throttle oper-
ation under load does not harm the engine.
Each full throttle acceleration sequence should be
followed with a substantial rest period for the en-
gine by cruising at lower r/min so the engine can
rid itself of the temporary build up of heat.
If any abnormality is noticed during this period,
consult a Yamaha dealer.
U5LP63.book Page 23 Monday, March 10, 2003 2:06 PM