Yamaha YFM660 01 User Manual
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8 - 40 –+ELECCOOLING SYSTEM C0NTINUITY EB803028 CORRECT 7.Wiring connection Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM”. This circuit is not faulty. * POOR CONNECTION Properly connect the cooling system.
9 - 1 TRBL SHTG STARTING FAILURE/HARD STARTING TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts. STARTING FAILURE/HARD STARTING FUEL SYSTEM Fuel tank Empty Clogged fuel filter Clogged fuel strainer Clogged fuel breather hose Deteriorated or contaminated fuel Fuel cock Clogged fuel hose ELECTRICAL SYSTEM Spark plug Improper plug gap Worn electrodes Wire between terminals broken Improper heat range Faulty spark plug cap Ignition coil Broken or shorted primary/secondary Faulty spark plug lead Broken body CDI system Faulty CDI unit Faulty pickup coil Broken woodruff keyCarburetor Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked-in air Deformed float Worn needle valve Improperly sealed valve seat Improperly adjusted fuel level Improperly set pilot jet Clogged starter jet Starter plunger malfunction Air filter Clogged air filter element Switches and wiring Faulty main switch Faulty engine stop switch Broken or shorted wiring Faulty neutral switch Faulty start switch Faulty clutch switch Starter motor Faulty starter motor Faulty starter relay Faulty starter circuit cut-off relay Faulty starter clutch Battery Faulty battery
9 - 2 TRBL SHTGSTARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head Loose spark plug Loose cylinder head or cylinder Broken cylinder head gasket Broken cylinder gasket Worn, damaged or seized cylinder Valve, camshaft and crankshaft Improperly sealed valve Improperly contacted valve and valve seat Improper valve timing Broken valve spring Seized camshaft Seized crankshaftPiston and piston rings Improperly installed piston ring Worn, fatigued or broken piston ring Seized piston ring Seized or damaged piston Crankcase and crankshaft Improperly seated crankcase Seized crankshaft Valve train Improperly adjusted valve clearance Improperly adjusted valve timing POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor Improperly returned starter plunger Loose pilot jet Clogged pilot jet Clogged pilot air jet Improperly adjusted idle speed (Throttle stop screw) Improper throttle cable play Flooded carburetorElectrical system Faulty spark plug Faulty CDI unit Faulty pickup coil Faulty ignition coil Valve train Improperly adjusted valve clearance Air filter Clogged air filter element POOR MEDIUM AND HIGH-SPEED PERFORMANCE POOR MEDIUM AND HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURE/HARD STARTING” and “POOR IDLE SPEED PERFORMANCE- VALVE TRAIN”. Carburetor Improper jet needle clip position Improperly adjusted fuel level Clogged or loose main jet Deteriorated or contaminated fuelAir filter Clogged air filter element
9 - 3 TRBL SHTGFAULTY GEAR SHIFTING/ CLUTCH SLIPPING/DRAGGING FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH DRAGGING”. SHIFT PEDAL DOES NOT MOVE Shift shaft Bent shift shaft Shift drum and shift fork Groove jammed with impurities Seized shift fork Bent shift fork guide barTransmission Seized transmission gear Jammed impurities Incorrectly assembled transmission Shift guide Broken shift guide JUMP-OUT GEAR Shift shaft Improperly adjusted shift lever position Improperly returned stopper lever Shift fork Worn shift forkShift drum Improper thrust play Worn shift drum groove Transmission Worn gear dog CLUTCH SLIPPING/DRAGGING CLUTCH SLIPPING Clutch Loose clutch spring Fatigued clutch spring Worn friction plate Worn clutch plate Incorrectly assembled clutchEngine oil Low oil level Improper quality (low viscosity) Deterioration CLUTCH DRAGGING Clutch Warped pressure plate Unevenly tensioned clutch springs Match marks not aligned Loose clutch boss nut Burnt primary driven gear bushing Bent clutch plate Swollen friction plate Broken clutch bossTransmission oil High oil level Improper quality (high viscosity) Deterioration
9 - 4 TRBL SHTGOVERHEATING/OVER COOLING/ FAULTY BRAKE OVERHEATING OVERHEATING Ignition system Improper spark plug gap Improper spark plug heat range Faulty CDI unit Fuel system Improper carburetor main jet (improper setting) Improper fuel level Clogged air filter element Compression system Heavy carbon depositEngine oil Improper oil level Improper oil viscosity Inferior oil quality Brake Brake drag Cooling system Low coolant level Clogged or damaged radiator Damaged or faulty water pump Thermostat stays closed OVER COOLING COOLING SYSTEM Thermostat Thermostat stays open FAULTY BRAKE POOR BRAKING EFFECT Disc brake Worn brake pads Worn disc Air in brake fluid Leaking brake fluid Faulty master cylinder kit cup Faulty caliper kit seal Loose union bolt Broken brake hose and pipe Oily or greasy disc/brake pads Improper brake fluid level
9 - 5 TRBL SHTG SHOCK ABSORBER MALFUNCTION MALFUNCTION Bent or damaged damper rod Damaged oil seal lip Fatigued shock absorber spring SHOCK ABSORBER MALFUNCTION/ UNSTABLE HANDLING/LIGHTING SYSTEM UNSTABLE HANDLING UNSTABLE HANDLING Handlebar Improperly installed or bent Steering Incorrect toe-in Bent steering stem Improperly installed steering stem Damaged bearing or bearing race Bent tie rods Deformed steering knuckles Tires Uneven tire pressures on both sides Incorrect tire pressure Uneven tire wearWheels Deformed wheel Loose bearing Bent or loose wheel axle Excessive wheel runout Frame Bent Damaged frame Swingarm Worn bearing or bushing Bent or damaged LIGHTING SYSTEM HEADLIGHT DARK Improper bulb Too many electric accessories Hard charging (broken charging coil and/or faulty rectifier/regulator) Incorrect connection Improperly grounded Poor contacts (main or lights switch) Bulb life expiredBULB BURNT OUT Improper bulb Faulty battery Faulty rectifier/regulator Improperly grounded Faulty main and/or lights switch Bulb life expired
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
YFM660R WIRING DIAGRAM 1AC magneto 2Rectifier/regulator 3Main switch 4Battery 5Fuse 6Starter relay 7Starter motor 8Clutch switch 9Park switch 0CDI unit AIgnition coil BSpark plug CSpeed sensor DCircuit breaker (fan motor) EThermo switch 1 FFan motor GCoolant temperature warning light HReverse indicator light INeutral indicator light JNeutral switch KReverse switch LDiode MThermo switch 2 NHandlebar switch (left) OLights switch PEngine stop switch QStart switch RHeadlight STail/brake light TRear brake switch UFront brake switch COLOR CODE B ............ Black Br ........... Brown G ............ Green L............. Blue O ............ Orange P ............ Pink R ............ Red Sb .......... Sky blueW ...........White Y ............Yellow B/W ........Black/White B/Y .........Black/Yellow Br/L ........Brown/Blue Br/R .......Brown/Red Br/W.......Brown/White G/L .........Green/BlueG/W........Green/White G/Y.........Green/Yellow L/B .........Blue/Black L/G .........Blue/Green L/R .........Blue/Red L/W ........Blue/White L/Y .........Blue/Yellow O/R ........Orange/RedR/B ........ Red/Black R/W ....... Red/White R/Y ........ Red/Yellow W/B ....... White/Black W/G ....... White/Green W/L ....... White/Blue W/R ....... White/Red Y/B ........ Yellow/Black