🏷️ Basic Information

Make:

Yamaha

Model:

YFM660 F Raptor

Model Year:

2005

Vehicle Type:

All-Terrain Vehicle (ATV)

Engine Code:

660cc 4-stroke liquid-cooled single-cylinder

👋 Introduction

Market Position:

High-performance sport ATV, known for power and agility in its class.

Competitors:

Polaris Predator 500, Suzuki LT-Z400, Honda TRX400EX, Bombardier DS650.

Key Features:

Powerful 660cc engine, R-series transmission, long-travel suspension, aggressive styling.

📋 Manual Details

Primary Coverage:

Complete service, repair, and workshop procedures

Secondary Coverage:

Maintenance, troubleshooting, diagnostics, parts replacement

Estimated Page Count:

Varies by specific factory release, typically 300-500+ pages for complete manuals

Manual Type:

Factory Service Manual / Workshop Manual / Repair Manual

Language:

English (assumed, standard for factory service manuals)

File Format:

PDF

📖 Manual Coverage

Engine:

Complete engine overhaul, top-end and bottom-end components (pistons, rings, crankshaft, connecting rod, bearings, cylinder, head, valves, camshaft, timing system)

Fuel System:

Carburetor assembly and tuning, fuel pump, fuel filter, fuel lines, fuel tank

Ignition System:

CDI unit, ignition coil, spark plugs, wiring

Cooling System:

Radiator, cooling fan, coolant hoses, thermostat, oil cooler (if applicable)

Transmission:

5-speed manual transmission, clutch operation and adjustment, gear shifting mechanism

Drivetrain:

Shaft drive, differential, axles, CV joints, hubs

Brakes:

Hydraulic disc brakes (front and rear), brake caliper service, brake pad replacement, brake fluid bleeding, master cylinder and slave cylinder service

Suspension:

Front and rear suspension components, shocks, springs, A-arms, linkage, steering components

Steering:

Handlebars, steering stem, tie rods, steering knuckle

Electrical System:

Wiring harnesses, lighting (headlights, taillights, brake lights), battery, charging system, starter motor, switches, sensors

Body Chassis:

Frame, body panels, fenders, seat, racks, skid plates

Maintenance:

Scheduled maintenance, oil changes, filter replacements, lubrication, valve adjustments, spark plug replacement, chain/belt tensioning (if applicable)

Repair:

Detailed step-by-step instructions for disassembly, reassembly, and repair of all major and minor components

Troubleshooting:

Diagnostic charts, symptom-to-cause analysis, common problems and their solutions

Diagnostics:

Electrical system testing, fuel system testing, engine performance analysis

Torque Specifications:

Precise torque values for all critical fasteners

Wiring Diagrams:

Comprehensive electrical wiring diagrams for easy troubleshooting and repair

Depth Level:

Comprehensive (suitable for professional mechanics and experienced DIY enthusiasts)

Specific Procedures:

Engine rebuilds, transmission overhauls, suspension tuning, electrical diagnostics, carburetor jetting

📊 Manual Specifications

File Format Details:

PDF - Searchable text, zoomable graphics

Print Quality:

High-quality factory original scans, clear diagrams and text

Printable:

Yes

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

4-stroke, liquid-cooled, SOHC, 5-valve, single-cylinder

Displacement:

660cc

Bore X Stroke:

100.0 mm x 84.0 mm (typical for this engine family)

Horsepower:

Approx. 50-53 HP (factory stock, varies slightly)

Torque:

Approx. 43-45 lb-ft (factory stock, varies slightly)

Carburetor:

Mikuni BSR42 flat-slide carburetor

Fuel Type:

Unleaded gasoline, 87 octane minimum

Oil Type:

Yamalube 4 (or equivalent API SG, SAE 10W-30 or 20W-40 based on temperature)

Oil Capacity:

Approx. 2.0 L (2.1 US qt) with filter change

🔧 Transmission

Transmission Type:

5-speed manual with wet, multi-plate clutch

Reverse:

Yes

Transmission Fluid:

Yamalube Gear Oil 80W-90 (or equivalent API GL-4)

Transmission Fluid Capacity:

Approx. 0.8 L (0.85 US qt)

📐 Dimensions

Length:

Approx. 70.9 in (1803 mm)

Width:

Approx. 45.3 in (1151 mm)

Height:

Approx. 43.1 in (1095 mm)

Wheelbase:

Approx. 50.4 in (1280 mm)

Dry Weight:

Approx. 428 lbs (194 kg)

Curb Weight:

Approx. 450 lbs (204 kg) (with all fluids)

Front Rack Capacity:

Approx. 110 lbs (50 kg)

Rear Rack Capacity:

Approx. 198 lbs (90 kg)

🛡️ Safety Features

Rollover Resistance:

N/A (ATVs are not rated for rollover resistance in the same way as cars)

Brakes:

Hydraulic disc brakes front and rear

Parking Brake:

Mechanical drum or disc brake (location varies, often on rear drive shaft or caliper)

Hand Guards:

Standard on most sport ATVs for hand protection

Footwells With Heel Guards:

Standard for rider foot protection

💡 Technology Features

Infotainment System:

N/A (Sport ATV, typically no infotainment features)

Driver Assistance Features:

N/A (Sport ATV, focus is on rider control and performance)

Connectivity:

N/A (Sport ATV)

🔧 Maintenance

Oil Change Interval:

Every 1,000 miles (1600 km) or 6 months, whichever comes first, or per operating hours recommendation (e.g., 100 hours).

Air Filter Cleaning:

Inspect and clean every 200 miles (320 km) or every 20 operating hours; replace as needed.

Spark Plug Replacement:

Replace every 4,000 miles (6400 km) or annually.

Valve Adjustment Interval:

Every 2,000 miles (3200 km) or annually.

Engine Oil Spec:

Yamalube 4 (or equivalent API SG, SAE 10W-30 or 20W-40 based on temperature)

Transmission Fluid Spec:

Yamalube Gear Oil 80W-90 (or equivalent API GL-4)

Coolant Spec:

Permanent type antifreeze (50/50 mixture of ethylene glycol and water recommended)

Brake Fluid Spec:

DOT 3 or DOT 4 hydraulic brake fluid

Common Issues:

Carburetor jetting can be sensitive to altitude and modifications. Camshaft wear can occur in high-mileage units. Rear differential seals can sometimes leak. Overheating can occur if cooling system is not maintained.

📚 Vehicle History

Yamaha Heritage:

Yamaha has a long and successful history in motorsports, including ATVs, motorcycles, and snowmobiles, known for innovation and reliability.

Raptor Evolution:

The YFM660F Raptor was a highly influential sport ATV, bridging the gap between earlier models and the fuel-injected Raptor 700R. It was lauded for its potent engine and handling.

Production Years:

The YFM660F Raptor was produced from 2001 to 2005.

🏆 Awards & Recognition

Industry Recognition:

The YFM660F Raptor was widely praised by ATV publications for its power and handling upon release, often considered a benchmark in its class during its production run.