2001-2005 Yamaha Raptor 660 YFM660RN YFM660RNC ATV Service Repair Manual

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2001-2005 Yamaha ATV Raptor 660 YFM660RN YFM660RNC Service Repair Workshop Manual

This is the Complete Official Workshop Service and Repair Manual for the Yamaha ATV Raptor 660 YFM660RN YFM660RNC.
Modles: Raptor 660 YFM660RN YFM660RNC
Production model years: 2001 2002 2003 2004 2005.

TABLE OF CONTENTS:
———————————
CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION ……………………………………………………………… 1-1
VEHICLE IDENTIFICATION NUMBER …………………………………………. 1-1
MODEL LABEL ………………………………………………………………………….. 1-1
IMPORTANT INFORMATION …………………………………………………………….. 1-2
PREPARATION FOR REMOVAL PROCEDURES …………………………. 1-2
REPLACEMENT PARTS …………………………………………………………….. 1-2
GASKETS, OIL SEALS AND O-RINGS ………………………………………… 1-2
LOCK WASHERS/PLATES AND COTTER PINS …………………………… 1-3
BEARINGS AND OIL SEALS ………………………………………………………. 1-3
CIRCLIPS …………………………………………………………………………………. 1-3
CHECKING OF CONNECTIONS ………………………………………………………… 1-4
SPECIAL TOOLS ……………………………………………………………………………… 1-5
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ……………………………………………………………. 2-1
MAINTENANCE SPECIFICATIONS ……………………………………………………. 2-4
ENGINE ……………………………………………………………………………………. 2-4
CHASSIS ………………………………………………………………………………… 2-14
ELECTRICAL ………………………………………………………………………….. 2-18
HOW TO USE THE CONVERSION TABLE ……………………………………….. 2-20
GENERAL TORQUE SPECIFICATIONS …………………………………………… 2-20
LUBRICATION POINTS AND LUBRICANT TYPES ……………………………. 2-21
ENGINE ………………………………………………………………………………….. 2-21
COOLANT FLOW DIAGRAMS …………………………………………………………. 2-22
OIL FLOW DIAGRAMS …………………………………………………………………… 2-23
CABLE ROUTING …………………………………………………………………………… 2-27
CHAPTER 3.
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION ………………………………………………………………………………. 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS …………………….. 3-1
SEAT, FENDERS AND FUEL TANK …………………………………………………… 3-3
SEAT, FRONT PANEL, FOOTREST GUARDS
AND ENGINE SKID PLATE ……………………………………………………… 3-3
HEADLIGHTS AND FRONT FENDER ………………………………………….. 3-4
REAR FENDER …………………………………………………………………………. 3-5
FUEL TANK ………………………………………………………………………………. 3-6
ENGINE …………………………………………………………………………………………… 3-8
ADJUSTING THE VALVE CLEARANCE ………………………………………. 3-8
ADJUSTING THE TIMING CHAIN ……………………………………………… 3-11
ADJUSTING THE IDLING SPEED ……………………………………………… 3-11
ADJUSTING THE THROTTLE LEVER FREE PLAY …………………….. 3-12
ADJUSTING THE SPEED LIMITER ……………………………………………. 3-14
ADJUSTING THE STARTER CABLE …………………………………………. 3-15
CHECKING THE SPARK PLUG ………………………………………………… 3-16
CHECKING THE IGNITION TIMING …………………………………………… 3-17
MEASURING THE COMPRESSION PRESSURE ………………………… 3-18
CHECKING THE ENGINE OIL LEVEL ………………………………………… 3-19
CHANGING THE ENGINE OIL ………………………………………………….. 3-20
ADJUSTING THE CLUTCH CABLE ……………………………………………. 3-23
CLEANING THE AIR FILTER …………………………………………………….. 3-24
CHECKING THE COOLANT LEVEL …………………………………………… 3-27
CHANGING THE COOLANT ……………………………………………………… 3-27
CHECKING THE COOLANT TEMPERATURE WARNING LIGHT ….. 3-31
CLEANING THE SPARK ARRESTER ………………………………………… 3-31
CHASSIS ………………………………………………………………………………………. 3-33
ADJUSTING THE FRONT BRAKE …………………………………………….. 3-33
ADJUSTING THE REAR BRAKE ……………………………………………….. 3-33
ADJUSTING THE PARKING BRAKE ………………………………………….. 3-34
CHECKING THE BRAKE FLUID LEVEL ……………………………………… 3-35
CHECKING THE FRONT BRAKE PAD ………………………………………. 3-36
CHECKING THE REAR BRAKE PAD …………………………………………. 3-36
ADJUSTING THE REAR BRAKE LIGHT SWITCH ……………………….. 3-36
CHECKING THE BRAKE HOSE ………………………………………………… 3-37
BLEEDING THE HYDRAULIC BRAKE SYSTEM …………………………. 3-38
ADJUSTING THE SHIFT PEDAL ……………………………………………….. 3-39
ADJUSTING THE REVERSE CONTROL CABLE ………………………… 3-40
ADJUSTING THE DRIVE CHAIN SLACK ……………………………………. 3-40
CHECKING THE STEERING SYSTEM ………………………………………. 3-42
ADJUSTING THE TOE-IN …………………………………………………………. 3-42
ADJUSTING THE FRONT SHOCK ABSORBER ………………………….. 3-44
ADJUSTING THE REAR SHOCK ABSORBER ……………………………. 3-45

CHECKING THE TIRE ……………………………………………………………… 3-47
CHECKING THE WHEEL ………………………………………………………….. 3-49
CHECKING AND LUBRICATING THE CABLE …………………………….. 3-49
LUBRICATING THE LEVERS AND PEDAL …………………………………. 3-50
ELECTRICAL …………………………………………………………………………………. 3-51
CHECKING THE BATTERY ………………………………………………………. 3-51
CHECKING THE FUSE …………………………………………………………….. 3-56
ADJUSTING THE HEADLIGHT BEAM ……………………………………….. 3-58
REPLACING THE HEADLIGHT BULB ………………………………………… 3-58
CHAPTER 4.
CHASSIS
FRONT WHEELS ……………………………………………………………………………… 4-1
FRONT WHEELS ………………………………………………………………………. 4-1
CHECKING THE WHEEL ……………………………………………………………. 4-3
CHECKING THE WHEEL HUB ……………………………………………………. 4-3
CHECKING THE BRAKE DISC ……………………………………………………. 4-4
INSTALLING WHEEL HUB …………………………………………………………. 4-5
INSTALLING THE WHEEL ………………………………………………………….. 4-5
REAR WHEELS, WHEEL AXLE AND HUB …………………………………………. 4-6
REAR WHEELS ………………………………………………………………………… 4-6
WHEEL AXLE AND HUB ……………………………………………………………. 4-7
REMOVING THE REAR AXLE …………………………………………………….. 4-9
CHECKING THE WHEEL ………………………………………………………….. 4-10
CHECKING THE WHEEL HUB ………………………………………………….. 4-10
CHECKING THE REAR AXLE …………………………………………………… 4-10
CHECKING THE HUB ………………………………………………………………. 4-11
CHECKING THE BRAKE DISC ………………………………………………….. 4-11
INSTALLING THE NUTS (REAR AXLE) ……………………………………… 4-11
INSTALLING THE WHEEL HUB ………………………………………………… 4-12
INSTALLING THE WHEEL ………………………………………………………… 4-12
FRONT AND REAR BRAKES ………………………………………………………….. 4-13
FRONT BRAKE PADS ……………………………………………………………… 4-13
REAR BRAKE PADS ………………………………………………………………… 4-14
REPLACING THE FRONT BRAKE PAD ……………………………………… 4-15
REPLACING THE REAR BRAKE PAD ……………………………………….. 4-17
FRONT BRAKE MASTER CYLINDER ………………………………………… 4-19
REAR BRAKE MASTER CYLINDER ………………………………………….. 4-21
CHECKING THE MASTER CYLINDER ………………………………………. 4-24
ASSEMBLING THE FRONT
AND REAR BRAKE MASTER CYLINDER ……………………………….. 4-25
INSTALLING THE FRONT BRAKE MASTER CYLINDER ……………… 4-25
INSTALLING THE REAR BRAKE MASTER CYLINDER ……………….. 4-27
FRONT BRAKE CALIPERS ………………………………………………………. 4-29
REAR BRAKE CALIPER …………………………………………………………… 4-31
DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER …….. 4-34

CHECKING THE FRONT AND REAR BRAKE CALIPER ………………. 4-34
ASSEMBLING THE FRONT BRAKE CALIPER ……………………………. 4-35
ASSEMBLING THE REAR BRAKE CALIPER ……………………………… 4-36
INSTALLING THE FRONT BRAKE CALIPER ……………………………… 4-37
INSTALLING THE REAR BRAKE CALIPER ………………………………… 4-38
STEERING SYSTEM ………………………………………………………………………. 4-40
HANDLEBAR …………………………………………………………………………… 4-40
REMOVING THE FRONT BRAKE SWITCH, PARK SWITCH
AND CLUTCH SWITCH ………………………………………………………… 4-42
REMOVING THE HANDLEBAR GRIP ………………………………………… 4-42
CHECKING THE HANDLEBAR …………………………………………………. 4-42
INSTALLING THE HANDLEBAR ……………………………………………….. 4-43
INSTALLING THE HANDLEBAR GRIP ……………………………………….. 4-43
INSTALLING THE CLUTCH LEVER …………………………………………… 4-43
INSTALLING THE BRAKE MASTER CYLINDER …………………………. 4-44
STEERING STEM ……………………………………………………………………. 4-45
REMOVING THE BEARING RETAINER …………………………………….. 4-47
CHECKING THE STEERING STEM …………………………………………… 4-47
INSTALLING THE BEARING RETAINER ……………………………………. 4-47
INSTALLING THE LOCK WASHER ……………………………………………. 4-47
TIE-ROD AND STEERING KNUCKLE ………………………………………… 4-48
REMOVING THE STEERING KNUCKLE ……………………………………. 4-49
CHECKING THE TIE-ROD ………………………………………………………… 4-49
CHECKING THE STEERING KNUCKLE …………………………………….. 4-49
INSTALLING THE TIE-ROD ………………………………………………………. 4-49
FRONT ARMS AND FRONT SHOCK ABSORBERS ………………………….. 4-50
REMOVING THE FRONT ARM …………………………………………………. 4-52
CHECKING THE FRONT ARM ………………………………………………….. 4-52
CHECKING THE FRONT SHOCK ABSORBER …………………………… 4-52
CHECKING THE BALL JOINT …………………………………………………… 4-53
INSTALLING THE FRONT ARM ………………………………………………… 4-54
REAR SHOCK ABSORBER AND RELAY ARM …………………………………. 4-55
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER …………………………………………………………… 4-57
DISPOSING OF A REAR SHOCK ABSORBER
AND GAS CYLINDER …………………………………………………………… 4-57
REMOVING THE REAR SHOCK ABSORBER …………………………….. 4-58
CHECKING THE REAR SHOCK ABSORBER ……………………………… 4-58
CHECKING THE RELAY ARM AND CONNECTING ARM …………….. 4-58
INSTALLING THE RELAY ARM AND CONNECTING ARM …………… 4-59
INSTALLING THE REAR SHOCK ABSORBER ……………………………. 4-59
SWINGARM AND DRIVE CHAIN ……………………………………………………… 4-60
REMOVING THE SWINGARM …………………………………………………… 4-62
CHECKING THE SWINGARM …………………………………………………… 4-62
CHECKING THE DRIVE CHAIN ………………………………………………… 4-63
INSTALLING THE SWINGARM …………………………………………………. 4-65
INSTALLING THE DRIVE SPROCKET ……………………………………….. 4-65

CHAPTER 5.
ENGINE
ENGINE REMOVAL ………………………………………………………………………….. 5-1
MUFFLER AND EXHAUST PIPES ………………………………………………. 5-1
LEFT FOOTREST ……………………………………………………………………… 5-2
LEADS, CABLES AND HOSES …………………………………………………… 5-3
ENGINE MOUNTING BOLTS ……………………………………………………… 5-5
INSTALLING THE ENGINE …………………………………………………………. 5-7
CYLINDER HEAD COVER ………………………………………………………………… 5-8
REMOVING THE CYLINDER HEAD COVER ………………………………. 5-10
CHECKING THE CYLINDER HEAD COVER ………………………………. 5-10
CHECKING THE TAPPET COVER …………………………………………….. 5-11
INSTALLING THE CYLINDER HEAD COVER …………………………….. 5-11
ROCKER ARMS …………………………………………………………………………….. 5-12
REMOVING THE ROCKER ARM ………………………………………………. 5-14
CHECKING THE ROCKER ARM ……………………………………………….. 5-14
INSTALLING THE ROCKER ARM ……………………………………………… 5-15
CAMSHAFT AND CYLINDER HEAD ………………………………………………… 5-16
REMOVING THE CAMSHAFT AND CYLINDER HEAD ………………… 5-18
CHECKING THE CAMSHAFT ……………………………………………………. 5-19
CHECKING THE CAMSHAFT SPROCKET …………………………………. 5-19
CHECKING THE DECOMPRESSION SYSTEM …………………………… 5-19
CHECKING THE TIMING CHAIN GUIDE ……………………………………. 5-20
CHECKING THE TIMING CHAIN TENSIONER ……………………………. 5-20
CHECKING THE CYLINDER HEAD …………………………………………… 5-20
INSTALLING THE CAMSHAFT AND CYLINDER HEAD ……………….. 5-21
VALVES AND VALVE SPRINGS ……………………………………………………… 5-24
REMOVING THE VALVE AND VALVE SPRING ………………………….. 5-25
CHECKING THE VALVE AND VALVE SPRING …………………………… 5-26
INSTALLING THE VALVE AND VALVE SPRING …………………………. 5-30
CYLINDER AND PISTON ………………………………………………………………… 5-32
REMOVING THE PISTON ………………………………………………………… 5-33
CHECKING THE CYLINDER AND PISTON ………………………………… 5-33
CHECKING THE PISTON RING ………………………………………………… 5-35
CHECKING THE PISTON PIN INSPECTION ………………………………. 5-36
INSTALLING THE PISTON ……………………………………………………….. 5-36
INSTALLING THE CYLINDER …………………………………………………… 5-37
AC MAGNETO ……………………………………………………………………………….. 5-38
REMOVING THE AC MAGNETO ROTOR …………………………………… 5-40
CHECKING THE COIL ……………………………………………………………… 5-40
CHECKING THE STARTER CLUTCH ………………………………………… 5-41
INSTALLING THE AC MAGNETO ROTOR …………………………………. 5-42

CLUTCH ………………………………………………………………………………………… 5-43
REMOVING THE CLUTCH ……………………………………………………….. 5-47
REMOVING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEAR …………………………………………… 5-47
CHECKING THE FRICTION PLATE …………………………………………… 5-48
CHECKING THE CLUTCH PLATE …………………………………………….. 5-48
CHECKING THE CLUTCH SPRING …………………………………………… 5-49
CHECKING THE CLUTCH HOUSING ………………………………………… 5-49
CHECKING THE CLUTCH BOSS ………………………………………………. 5-49
CHECKING THE PRESSURE PLATE ………………………………………… 5-49
CHECKING THE PULL LEVER SHAFT AND PULL ROD ……………… 5-50
CHECKING THE PRIMARY DRIVE ……………………………………………. 5-50
CHECKING THE BALANCER DRIVE …………………………………………. 5-50
INSTALLING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEAR …………………………………………… 5-51
INSTALLING THE CLUTCH ………………………………………………………. 5-52
OIL PUMP ……………………………………………………………………………………… 5-54
CHECKING THE OIL PUMP ……………………………………………………… 5-56
ASSEMBLING THE OIL PUMP…………………………………………………… 5-56
SHIFT SHAFT ………………………………………………………………………………… 5-57
CHECKING THE SHIFT SHAFT ………………………………………………… 5-59
CHECKING THE STOPPER LEVER ………………………………………….. 5-59
CHECKING THE SHIFT GUIDE AND SHIFT LEVER ……………………. 5-59
CHECKING THE SEGMENT ……………………………………………………… 5-59
INSTALLING THE SHIFT LEVER ………………………………………………. 5-59
INSTALLING THE STOPPER LEVER ………………………………………… 5-60
INSTALLING THE SHIFT SHAFT ………………………………………………. 5-61
CRANKCASE …………………………………………………………………………………. 5-62
TIMING CHAIN AND SPEED SENSOR ROTOR ………………………….. 5-62
CRANKCASE ………………………………………………………………………….. 5-64
CRANKCASE BEARING …………………………………………………………… 5-65
SEPARATING THE CRANKCASE………………………………………………. 5-66
CHECKING THE TIMING CHAIN AND GUIDE …………………………….. 5-66
CHECKING THE OIL STRAINER ………………………………………………. 5-66
CHECKING THE CRANKCASE …………………………………………………. 5-67
CHECKING THE BEARINGS …………………………………………………….. 5-67
ASSEMBLING THE CRANKCASE ……………………………………………… 5-67
CRANKSHAFT AND BALANCER …………………………………………………….. 5-69
REMOVING THE CRANKSHAFT ………………………………………………. 5-70
CHECKING THE CRANKSHAFT ……………………………………………….. 5-70
INSTALLING THE CRANKSHAFT ……………………………………………… 5-71

TRANSMISSION …………………………………………………………………………….. 5-72
MAIN AXLE …………………………………………………………………………….. 5-74
DRIVE AXLE …………………………………………………………………………… 5-75
CHECKING THE SHIFT FORK ………………………………………………….. 5-77
CHECKING THE SHIFT DRUM …………………………………………………. 5-77
CHECKING THE TRANSMISSION …………………………………………….. 5-77
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE …………………….. 5-78
INSTALLING THE TRANSMISSION …………………………………………… 5-79
CHAPTER 6.
COOLING SYSTEM
RADIATOR ………………………………………………………………………………………. 6-1
CHECKING THE RADIATOR ………………………………………………………. 6-3
INSTALLING THE RADIATOR …………………………………………………….. 6-4
THERMOSTAT …………………………………………………………………………………. 6-5
CHECKING THE THERMOSTAT …………………………………………………. 6-7
ASSEMBLING THE THERMOSTAT …………………………………………….. 6-7
WATER PUMP …………………………………………………………………………………. 6-8
DISASSEMBLING THE WATER PUMP ………………………………………. 6-11
CHECKING THE WATER PUMP ……………………………………………….. 6-11
ASSEMBLING THE WATER PUMP ……………………………………………. 6-12
CHAPTER 7.
CARBURETION
CARBURETORS ………………………………………………………………………………. 7-1
DISASSEMBLING THE CARBURETOR ……………………………………….. 7-5
CHECKING THE CARBURETOR ………………………………………………… 7-5
ASSEMBLING THE CARBURETOR …………………………………………….. 7-7
ADJUSTING THE FUEL LEVEL …………………………………………………… 7-8

CHAPTER 8.
ELECTRICAL
ELECTRICAL COMPONENTS …………………………………………………………… 8-1
CHECKING THE SWITCH …………………………………………………………………. 8-2
CHECKING THE SWITCH ………………………………………………………….. 8-2
CHECKING A SWITCH SHOWN IN THE MANUAL ……………………….. 8-2
CHECKING THE SWITCH CONTINUITY ……………………………………… 8-3
IGNITION SYSTEM …………………………………………………………………………… 8-5
CIRCUIT DIAGRAM …………………………………………………………………… 8-5
TROUBLESHOOTING ……………………………………………………………….. 8-6
ELECTRIC STARTING SYSTEM ……………………………………………………… 8-11
CIRCUIT DIAGRAM …………………………………………………………………. 8-11
STARTING CIRCUIT OPERATION …………………………………………….. 8-12
TROUBLESHOOTING ……………………………………………………………… 8-13
STARTER MOTOR ………………………………………………………………….. 8-16
CHECKING THE STARTER MOTOR …………………………………………. 8-17
ASSEMBLING THE STARTER MOTOR ……………………………………… 8-18
CHARGING SYSTEM ……………………………………………………………………… 8-19
CIRCUIT DIAGRAM …………………………………………………………………. 8-19
TROUBLESHOOTING ……………………………………………………………… 8-20
LIGHTING SYSTEM ………………………………………………………………………… 8-22
CIRCUIT DIAGRAM …………………………………………………………………. 8-22
TROUBLESHOOTING ……………………………………………………………… 8-23
CHECKING THE LIGHTING SYSTEM ………………………………………… 8-25
SIGNAL SYSTEM …………………………………………………………………………… 8-27
CIRCUIT DIAGRAM …………………………………………………………………. 8-27
TROUBLESHOOTING ……………………………………………………………… 8-28
CHECKING THE SIGNAL SYSTEM …………………………………………… 8-30
COOLING SYSTEM ………………………………………………………………………… 8-36
CIRCUIT DIAGRAM …………………………………………………………………. 8-36
TROUBLESHOOTING …………………………………………………………….. 8-37
CHAPTER 9.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING …………………………………………….. 9-1
FUEL SYSTEM ………………………………………………………………………….. 9-1
ELECTRICAL SYSTEM ………………………………………………………………. 9-1
COMPRESSION SYSTEM ………………………………………………………….. 9-2
POOR IDLE SPEED PERFORMANCE ……………………………………………….. 9-2
POOR IDLE SPEED PERFORMANCE …………………………………………. 9-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE …………………………. 9-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ………………….. 9-2
FAULTY GEAR SHIFTING ………………………………………………………………… 9-3
HARD SHIFTING ……………………………………………………………………….. 9-3
SHIFT PEDAL DOES NOT MOVE ……………………………………………….. 9-3
JUMP-OUT GEAR ……………………………………………………………………… 9-3
CLUTCH SLIPPING/DRAGGING ……………………………………………………….. 9-3
CLUTCH SLIPPING …………………………………………………………………… 9-3
CLUTCH DRAGGING ………………………………………………………………… 9-3
OVERHEATING ……………………………………………………………………………….. 9-4
OVERHEATING ………………………………………………………………………… 9-4
OVER COOLING ………………………………………………………………………………. 9-4
COOLING SYSTEM …………………………………………………………………… 9-4
FAULTY BRAKE ………………………………………………………………………………. 9-4
POOR BRAKING EFFECT ………………………………………………………….. 9-4
SHOCK ABSORBER MALFUNCTION ………………………………………………… 9-5
MALFUNCTION …………………………………………………………………………. 9-5
UNSTABLE HANDLING ……………………………………………………………………. 9-5
UNSTABLE HANDLING ……………………………………………………………… 9-5
LIGHTING SYSTEM ………………………………………………………………………….. 9-5
HEADLIGHT DARK ……………………………………………………………………. 9-5
BULB BURNT OUT ……………………………………………………………………. 9-5

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