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2001 2002 2003 2004 2005 YAMAHA RAPTOR 660 YFM660RN YFM660RNC ATV SERVICE REPAIR MANUAL
This original 2001 2002 2003 2004 2005 YAMAHA RAPTOR 660 YFM660RN YFM660RNC ATV manual is a detailed file and it is illustrated with clear step-by-step instructions.
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2001 2002 2003 2004 2005 YAMAHA RAPTOR 660 YFM660RN YFM660RNC ATV pdf (How to fix...) - This is a specific and detailed pdf manual.
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2001-2005 YAMAHA RAPTOR 660 YFM660RN YFM660RNC ATV SERVICE REPAIR MANUAL
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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. SPECIFICS GENERAL SPECIFICS 2-1 MAINTENANCE SPECIFICS . 2-4 ENGINE . 2-4 CHASSIS . 2-14 ELECTRICAL 2-18 HOW TO USE THE CONVERSION TABLE . 2-20 GENERAL TORQUE SPECIFICS . 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 © Designated trademarks and brands are the property of their respective owners. All Rights reserved.
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