2001-2005 Yamaha Raptor 660 ATV Service Repair Manual YFM660R (Highly Detailed FSM, PDF Preview)

2001-2005 Yamaha Raptor 660 ATV Service Repair Manual YFM660R (Highly Detailed FSM, PDF Preview)

Instant download of a COMPLETE OFFICIAL FULL Service & Repair Manual for the Yamaha Raptor 660 atv. Production model years: 2001, 2002, 2003, 2004 and 2005.

This is the same type of service manual your local dealer will use when doing a repair. It contains everything you will need to repair, maintain, rebuild, refurbish or restore your motorcycle. Covers complete tear down and rebuild, pictures and part diagrams, torque specs, maintenance, troubleshooting, etc. You name it and its in here. All pages are printable. Just print it out and take it with you into the garage or workshop.

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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