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Download Service & repair manual Yamaha Raptor YFM660 2003
This manual covers the following model(s):
Yamaha RAPTOR YFM660RN 2003
RAPTOR YFM660RNC 2003
We only sell original manuals; the quality of the files is exceptionally good. When you print the file, the pictures are of good quality and very bright. WE DO NOT SELL ANY COPIED MANUALS, ONLY THE ORIGINAL!!!!
In this manual you have the following chapters:
CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
MODEL LABEL
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCEDURES
REPLACEMENT PARTS
GASKETS, OIL SEALS AND O-RINGS
LOCK WASHERS/PLATES AND COTTER PINS
BEARINGS AND OIL SEALS
CIRCLIPS
CHECKING OF CONNECTIONS
SPECIAL TOOLS
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
CHASSIS
ELECTRICAL
HOW TO USE THE CONVERSION TABLE
GENERAL TORQUE SPECIFICATIONS
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
COOLANT FLOW DIAGRAMS
OIL FLOW DIAGRAMS
CABLE ROUTING
CHAPTER 3.
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
SEAT, FENDERS AND FUEL TANK
SEAT, FRONT PANEL, FOOTREST GUARDS
AND ENGINE SKID PLATE
HEADLIGHTS AND FRONT FENDER
REAR FENDER
FUEL TANK
ENGINE
ADJUSTING THE VALVE CLEARANCE
ADJUSTING THE TIMING CHAIN
ADJUSTING THE IDLING SPEED
ADJUSTING THE THROTTLE LEVER FREE PLAY
ADJUSTING THE SPEED LIMITER
ADJUSTING THE STARTER CABLE
CHECKING THE SPARK PLUG
CHECKING THE IGNITION TIMING
MEASURING THE COMPRESSION PRESSURE
CHECKING THE ENGINE OIL LEVEL
CHANGING THE ENGINE OIL
ADJUSTING THE CLUTCH CABLE
CLEANING THE AIR FILTER
CHECKING THE COOLANT LEVEL
CHANGING THE COOLANT
CHECKING THE COOLANT TEMPERATURE WARNING LIGHT
CLEANING THE SPARK ARRESTER
CHASSIS
ADJUSTING THE FRONT BRAKE
ADJUSTING THE REAR BRAKE
ADJUSTING THE PARKING BRAKE
CHECKING THE BRAKE FLUID LEVEL
CHECKING THE FRONT BRAKE PAD
CHECKING THE REAR BRAKE PAD
ADJUSTING THE REAR BRAKE LIGHT SWITCH
CHECKING THE BRAKE HOSE
BLEEDING THE HYDRAULIC BRAKE SYSTEM
ADJUSTING THE SHIFT PEDAL
ADJUSTING THE REVERSE CONTROL CABLE
ADJUSTING THE DRIVE CHAIN SLACK
CHECKING THE STEERING SYSTEM
ADJUSTING THE TOE-IN
ADJUSTING THE FRONT SHOCK ABSORBER
ADJUSTING THE REAR SHOCK ABSORBER
CHECKING THE TIRE
CHECKING THE WHEEL
CHECKING AND LUBRICATING THE CABLE
LUBRICATING THE LEVERS AND PEDAL
ELECTRICAL
CHECKING THE BATTERY
CHECKING THE FUSE
ADJUSTING THE HEADLIGHT BEAM
REPLACING THE HEADLIGHT BULB
CHAPTER 4.
CHASSIS
FRONT WHEELS
FRONT WHEELS
CHECKING THE WHEEL
CHECKING THE WHEEL HUB
CHECKING THE BRAKE DISC
INSTALLING WHEEL HUB
INSTALLING THE WHEEL
REAR WHEELS, WHEEL AXLE AND HUB
REAR WHEELS
WHEEL AXLE AND HUB
REMOVING THE REAR AXLE
CHECKING THE WHEEL
CHECKING THE WHEEL HUB
CHECKING THE REAR AXLE
CHECKING THE HUB
CHECKING THE BRAKE DISC
INSTALLING THE NUTS (REAR AXLE)
INSTALLING THE WHEEL HUB
INSTALLING THE WHEEL
FRONT AND REAR BRAKES
FRONT BRAKE PADS
REAR BRAKE PADS
REPLACING THE FRONT BRAKE PAD
REPLACING THE REAR BRAKE PAD
FRONT BRAKE MASTER CYLINDER
REAR BRAKE MASTER CYLINDER
CHECKING THE MASTER CYLINDER
ASSEMBLING THE FRONT
AND REAR BRAKE MASTER CYLINDER
INSTALLING THE FRONT BRAKE MASTER CYLINDER
INSTALLING THE REAR BRAKE MASTER CYLINDER
FRONT BRAKE CALIPERS
REAR BRAKE CALIPER
DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER
CHECKING THE FRONT AND REAR BRAKE CALIPER
ASSEMBLING THE FRONT BRAKE CALIPER
ASSEMBLING THE REAR BRAKE CALIPER
INSTALLING THE FRONT BRAKE CALIPER
INSTALLING THE REAR BRAKE CALIPER
STEERING SYSTEM
HANDLEBAR
REMOVING THE FRONT BRAKE SWITCH, PARK SWITCH
AND CLUTCH SWITCH
REMOVING THE HANDLEBAR GRIP
CHECKING THE HANDLEBAR
INSTALLING THE HANDLEBAR
INSTALLING THE HANDLEBAR GRIP
INSTALLING THE CLUTCH LEVER
INSTALLING THE BRAKE MASTER CYLINDER
STEERING STEM
REMOVING THE BEARING RETAINER
CHECKING THE STEERING STEM
INSTALLING THE BEARING RETAINER
INSTALLING THE LOCK WASHER
TIE-ROD AND STEERING KNUCKLE
REMOVING THE STEERING KNUCKLE
CHECKING THE TIE-ROD
CHECKING THE STEERING KNUCKLE
INSTALLING THE TIE-ROD
FRONT ARMS AND FRONT SHOCK ABSORBERS
REMOVING THE FRONT ARM
CHECKING THE FRONT ARM
CHECKING THE FRONT SHOCK ABSORBER
CHECKING THE BALL JOINT
INSTALLING THE FRONT ARM
REAR SHOCK ABSORBER AND RELAY ARM
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER
DISPOSING OF A REAR SHOCK ABSORBER
AND GAS CYLINDER
REMOVING THE REAR SHOCK ABSORBER
CHECKING THE REAR SHOCK ABSORBER
CHECKING THE RELAY ARM AND CONNECTING ARM
INSTALLING THE RELAY ARM AND CONNECTING ARM
INSTALLING THE REAR SHOCK ABSORBER
SWINGARM AND DRIVE CHAIN
REMOVING THE SWINGARM
CHECKING THE SWINGARM
CHECKING THE DRIVE CHAIN
INSTALLING THE SWINGARM
INSTALLING THE DRIVE SPROCKET
CHAPTER 5.
ENGINE
ENGINE REMOVAL
MUFFLER AND EXHAUST PIPES
LEFT FOOTREST
LEADS, CABLES AND HOSES
ENGINE MOUNTING BOLTS
INSTALLING THE ENGINE
CYLINDER HEAD COVER
REMOVING THE CYLINDER HEAD COVER
CHECKING THE CYLINDER HEAD COVER
CHECKING THE TAPPET COVER
INSTALLING THE CYLINDER HEAD COVER
ROCKER ARMS
REMOVING THE ROCKER ARM
CHECKING THE ROCKER ARM
INSTALLING THE ROCKER ARM
CAMSHAFT AND CYLINDER HEAD
REMOVING THE CAMSHAFT AND CYLINDER HEAD
CHECKING THE CAMSHAFT
CHECKING THE CAMSHAFT SPROCKET
CHECKING THE DECOMPRESSION SYSTEM
CHECKING THE TIMING CHAIN GUIDE
CHECKING THE TIMING CHAIN TENSIONER
CHECKING THE CYLINDER HEAD
INSTALLING THE CAMSHAFT AND CYLINDER HEAD
VALVES AND VALVE SPRINGS
REMOVING THE VALVE AND VALVE SPRING
CHECKING THE VALVE AND VALVE SPRING
INSTALLING THE VALVE AND VALVE SPRING
CYLINDER AND PISTON
REMOVING THE PISTON
CHECKING THE CYLINDER AND PISTON
CHECKING THE PISTON RING
CHECKING THE PISTON PIN INSPECTION
INSTALLING THE PISTON
INSTALLING THE CYLINDER
AC MAGNETO
REMOVING THE AC MAGNETO ROTOR
CHECKING THE COIL
CHECKING THE STARTER CLUTCH
INSTALLING THE AC MAGNETO ROTOR
CLUTCH
REMOVING THE CLUTCH
REMOVING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEAR
CHECKING THE FRICTION PLATE
CHECKING THE CLUTCH PLATE
CHECKING THE CLUTCH SPRING
CHECKING THE CLUTCH HOUSING
CHECKING THE CLUTCH BOSS
CHECKING THE PRESSURE PLATE
CHECKING THE PULL LEVER SHAFT AND PULL ROD
CHECKING THE PRIMARY DRIVE
CHECKING THE BALANCER DRIVE
INSTALLING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEAR
INSTALLING THE CLUTCH
OIL PUMP
CHECKING THE OIL PUMP
ASSEMBLING THE OIL PUMP
SHIFT SHAFT
CHECKING THE SHIFT SHAFT
CHECKING THE STOPPER LEVER
CHECKING THE SHIFT GUIDE AND SHIFT LEVER
CHECKING THE SEGMENT
INSTALLING THE SHIFT LEVER
INSTALLING THE STOPPER LEVER
INSTALLING THE SHIFT SHAFT
CRANKCASE
TIMING CHAIN AND SPEED SENSOR ROTOR
CRANKCASE
CRANKCASE BEARING
SEPARATING THE CRANKCASE
CHECKING THE TIMING CHAIN AND GUIDE
CHECKING THE OIL STRAINER
CHECKING THE CRANKCASE
CHECKING THE BEARINGS
ASSEMBLING THE CRANKCASE
CRANKSHAFT AND BALANCER
REMOVING THE CRANKSHAFT
CHECKING THE CRANKSHAFT
INSTALLING THE CRANKSHAFT
TRANSMISSION
MAIN AXLE
DRIVE AXLE
CHECKING THE SHIFT FORK
CHECKING THE SHIFT DRUM
CHECKING THE TRANSMISSION
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE
INSTALLING THE TRANSMISSION
CHAPTER 6.
COOLING SYSTEM
RADIATOR
CHECKING THE RADIATOR
INSTALLING THE RADIATOR
THERMOSTAT
CHECKING THE THERMOSTAT
ASSEMBLING THE THERMOSTAT
WATER PUMP
DISASSEMBLING THE WATER PUMP
CHECKING THE WATER PUMP
ASSEMBLING THE WATER PUMP
CHAPTER 7.
CARBURETION
CARBURETORS
DISASSEMBLING THE CARBURETOR
CHECKING THE CARBURETOR
ASSEMBLING THE CARBURETOR
ADJUSTING THE FUEL LEVEL
7
CHAPTER 8.
ELECTRICAL
ELECTRICAL COMPONENTS
CHECKING THE SWITCH
CHECKING THE SWITCH
CHECKING A SWITCH SHOWN IN THE MANUAL
CHECKING THE SWITCH CONTINUITY
IGNITION SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
STARTING CIRCUIT OPERATION
TROUBLESHOOTING
STARTER MOTOR
CHECKING THE STARTER MOTOR
ASSEMBLING THE STARTER MOTOR
CHARGING SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
LIGHTING SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
CHECKING THE LIGHTING SYSTEM
SIGNAL SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
CHECKING THE SIGNAL SYSTEM
COOLING SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
CHAPTER 9.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING
FUEL SYSTEM
ELECTRICAL SYSTEM
COMPRESSION SYSTEM
POOR IDLE SPEED PERFORMANCE
POOR IDLE SPEED PERFORMANCE
POOR MEDIUM AND HIGH-SPEED PERFORMANCE
POOR MEDIUM AND HIGH-SPEED PERFORMANCE
FAULTY GEAR SHIFTING
HARD SHIFTING
SHIFT PEDAL DOES NOT MOVE
JUMP-OUT GEAR
CLUTCH SLIPPING/DRAGGING
CLUTCH SLIPPING
CLUTCH DRAGGING
OVERHEATING
OVERHEATING
OVER COOLING
COOLING SYSTEM
FAULTY BRAKE
POOR BRAKING EFFECT
SHOCK ABSORBER MALFUNCTION
MALFUNCTION
UNSTABLE HANDLING
UNSTABLE HANDLING
LIGHTING SYSTEM
HEADLIGHT DARK
BULB BURNT OUT
Language: English
Format: PDF
Pages: 328
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