Yamaha YFM660 01 User Manual
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GEN INFO 1 SPEC2 CHK ADJ 3 CHAS4 ENG5 COOL6 CARB7 ELEC8 TRBL SHTG 9 –+ 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
GEN INFO 1 SPEC2 CHK ADJ 3 CHAS4 ENG5 COOL6 CARB7 ELEC8 TRBL SHTG 9 –+ 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
1 - 1 GEN INFO MACHINE IDENTIFICATION GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. MODEL LABEL The model label 1 is affixed to the air filter case cover. This information will be needed to order spare parts.
1 - 2 GEN INFO EB101000 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1.Remove all dirt, mud, dust and foreign mate- rial before removal and disassembly. 2.Use proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS” section. 3.When disassembling the machine, always keep mated parts together. This includes gears, cylinder, piston and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.During machine disassembly, clean all parts and place them in trays in the order of disas- sembly. This will speed up assembly and allow for the correct installation of all parts. 5.Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1.Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. EB101020 GASKETS, OIL SEALS AND O-RINGS 1.Replace all gaskets, seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2.Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. IMPORTANT INFORMATION
1 - 3 GEN INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1.Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1.Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, apply a light coat- ing of lightweight lithium base grease to the seal lips. Oil bearings liberally when install- ing, if appropriate. 1Oil seal CAUTION: Do not use compressed air to spin the bearings dry. This will damage the bearing surfaces. 1Bearing EB101050 CIRCLIPS 1.Check all circlips carefully before reassem- bly. Always replace piston pin clips after one use. Replace distorted circlips. When install- ing a circlip 1 , make sure that the sharp- edged corner 2 is positioned opposite the thrust 3 it receives. See sectional view. 4Shaft IMPORTANT INFORMATION
1 - 4 GEN INFO CHECKING OF CONNECTIONS EB801000 CHECKING OF CONNECTIONS Check the connectors for stains, rust, mois- ture, etc. 1.Disconnect: Connector 2.Check: Connector Moisture → Dry each terminal with an air blower. Stains/rust → Connect and disconnect the terminals several times. 3.Check: Connector leads Looseness → Bend up the pin 1 and con- nect the terminals. 4.Connect: Connector terminals NOTE: The two terminals “click” together. 5.Check: Continuity (using a pocket tester) NOTE: If there is no continuity, clean the terminals. When checking the wire harness be sure to perform steps 1 to 3. As a quick remedy, use a contact revitalizer available at most part stores. Check the connector with a pocket tester as shown.
1 - 5 GEN INFO SPECIAL TOOLS EB102001 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided. When placing an order, refer to the list provided below to avoid any mistakes. For US and CDN P/N. YM-, YU-, YS-, YK-, ACC- Except for US and CDN P/N. 90890- Tool No. Tool name/How to use Illustration Bolt 90890-01083 Weight 90890-01084 Set YU-01083-ASlide hammer bolt (M6)/weight/set These tools are used to remove the rocker arm shaft. 90890-01135 YU-01135-ACrankcase separating tool This tool is used to separate the crank- case. Pot 90890-01274 Bolt 90890-01275Crankshaft installer pot Crankshaft installer bolt These tools are used to install the crank- shaft. YU-90050Crankshaft installer set These tools are used to install the crank- shaft. Adapter 90890-04059 YM-90069 Spacer 90890-04081 YM-91044Adapter Spacer (crankshaft installer) These tools are used to install the crank- shaft. 90890-01016Spacer This tool is used to install the crankshaft.
1 - 6 GEN INFO SPECIAL TOOLS 90890-01304 YU-01304Piston pin puller This tool is used to remove the piston pin. 90890-01311 YM-08035Tappet adjusting tool (3 mm) This tool is necessary for adjusting the valve clearance. 90890-01312 YM-01312-AFuel level gauge This gauge is used to measure the fuel level in the float chamber. 90890-01325 YU-24460-01Radiator cap tester This tool is used to check the cooling sys- tem. 90890-01352 YU-33984Adapter This tool is used to check the cooling sys- tem. 90890-01327 YM-01327Damper rod holder (30 mm) This tool is needed to loosen and tighten the steering stem bearing retainer. 90890-01362 YU-33270Flywheel puller These tools are needed to remove the rotor. 90890-01419 YM-37132Axle nut wrench (50 mm) This tool is needed to loosen or tighten the rear axle nut. Tool No. Tool name/How to use Illustration