2005 YAMAHA YFM660R check engine

6-9
EBU00180
Starting a warm engine
To start a warm engine, refer to the “Starting a cold
engine” section. The starter (choke) should not be
used. The throttle should be opened slightly.
EBU01820
Warming up
To get maximum engine life, always warm up the
engine before starting off. Never accelerate hard
with a cold engine! To see whether or not the en-
gine is warm, check if it responds to the throttle
normally with the starter (choke) turned off.
U5LP64.book Page 9 Thursday, April 1, 2004 4:53 PM

8-7
EBU02621
PERIODIC MAINTENANCE/LUBRICATION
NOTE:_

For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.


For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance in-
tervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month mainte-
nance intervals should be followed.
_
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
Valves*Check valve clearance.
Adjust if necessary.
Cooling systemCheck coolant leakage.
Repair if necessary.
Replace coolant every 24 months.Spark plugCheck condition.
Adjust gap and clean.
Replace if necessary.Air filter elementClean.
Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*Check starter (choke) operation.
Adjust engine idling speed.Crankcase breather
system*Check breather hose for cracks or damage.
Replace if necessary.Exhaust system*Check for leakage.
Tighten if necessary.
Replace gasket if necessary.Fuel line*Check fuel hose for cracks or damage.
Replace if necessary.U5LP64.book Page 7 Thursday, April 1, 2004 4:53 PM

8-8 * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
Engine oil
Replace. (Warm engine before draining.)Engine oil filter cartridge
Replace.Drive chain
Check and adjust slack/alignment/clean/lube.Front brake*Check free play/operation/fluid leakage/
See NOTE Page 8-9.
Correct if necessary.Rear brake*Check operation/fluid leakage/See NOTE Page 8-9.
Correct if necessary.Clutch*Check operation.
Adjust if necessary.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 with lithium-soap-based grease.Rear arm pivot*
Lubricate with lithium-soap-based grease.Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.Lights and switches*Check operation.
Adjust headlight beams.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
U5LP64.book Page 8 Thursday, April 1, 2004 4:53 PM

8-19 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
EBU12382
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. _
U5LP64.book Page 19 Thursday, April 1, 2004 4:53 PM

8-21
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.
U5LP64.book Page 21 Thursday, April 1, 2004 4:53 PM

8-25 1. Crankcase engine oil drain bolt
1. Boulon de vidange d’huile du carter
1. Perno de drenaje de aceite de motor del cárter
1. Engine oil tank drain bolt
1. Boulon de vidange du réservoir d’huile de moteur
1. Perno de drenaje del depósito aceite de motor
4. Remove the crankcase engine oil drain bolt.
5. Remove the engine oil tank filler cap and the
oil tank drain bolt.
6. Check the washers for damage, and replace
if necessary.NOTE:_ Skip steps 7–9 if the oil filter cartridge is not being
replaced. _
U5LP64.book Page 25 Thursday, April 1, 2004 4:53 PM

8-29
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.
14. Install the engine oil tank filler cap.Tightening torques:
Crankcase engine oil drain bolt:
30 Nm (3.0 m·kgf)
Engine oil tank drain bolt:
25 Nm (2.5 m·kgf)
U5LP64.book Page 29 Thursday, April 1, 2004 4:53 PM

8-33
15. 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.
16. Turn the engine off, and then check the oil
level and correct it if necessary.
17. Install the engine guard by installing the bolts.
U5LP64.book Page 33 Thursday, April 1, 2004 4:53 PM