Market Segment:
High-performance sport ATV, positioned for recreational off-road riding and aggressive terrain.
Competitors:
Honda TRX450R, Suzuki LT-Z400, Kawasaki KFX400, Polaris Predator 500.
Vehicle Features:
Powerful 660cc engine, aggressive styling, long-travel suspension, strong braking performance, shaft drive (typical for Yamaha sport ATVs of this era, although chain drive is common for R models).
Value Proposition:
Provides essential knowledge for maintaining and repairing the Yamaha YFM660RNC, saving owners significant costs on professional servicing and enabling DIY repairs.
Applicable Years:
2001, 2002, 2003, 2004, 2005, 2006
Market Coverage:
North America (indicated by 'NC')
Estimated Pages:
Extensive (typical for full workshop manuals, likely 300-500+ pages)
Type:
Workshop Service Repair Manual
Engine:
Detailed disassembly, inspection, repair, and assembly of all engine components.
Transmission:
Clutch operation, gear shifting mechanisms, gearbox disassembly and repair.
Drivetrain:
Chain drive, rear differential (if applicable), axles, bearings.
Suspension:
Front A-arm suspension, rear swingarm, shock absorber adjustment and service, steering components.
Brakes:
Hydraulic brake system, front and rear disc brake caliper service, master cylinders, brake fluid bleeding.
Electrical:
Ignition system, charging system (stator, regulator/rectifier), lighting, battery, starter motor, wiring diagrams.
Fuel System:
Carburetor disassembly, cleaning, adjustment, fuel lines, fuel tank, fuel pump (if applicable).
Cooling System:
Radiator, cooling fan, coolant specifications and replacement.
Exhaust System:
Exhaust pipe, muffler, heat shields.
Frame And Bodywork:
Frame inspection, plastic body panel removal and installation, seat, handlebars.
Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication points, general inspection.
Troubleshooting:
Diagnostic flowcharts for common problems, symptom-based fault finding.
Repair:
Step-by-step instructions for component replacement and repair.
Rebuilds:
Complete engine rebuild procedures, transmission overhauls.
Specifications:
Torque values, clearances, adjustments, fluid capacities.
Depth:
Comprehensive workshop level, covering everything from basic maintenance to complete engine and component rebuilds.
Diagnostics:
Detailed diagnostic procedures and troubleshooting guides.
Illustrations:
Likely includes detailed diagrams and exploded views of components.
Engine Type:
4-stroke, Liquid-cooled, SOHC, 5-valve, Single Cylinder
Bore X Stroke:
100.0 mm x 84.0 mm
Ignition:
CDI (Capacitor Discharge Ignition)
Horsepower:
Approx. 50-53 HP (factory estimates, varies slightly by region)
Torque:
Approx. 40-42 lb-ft (factory estimates)
Carburetor:
Mikuni BSR42 (single) with accelerator pump.
Fuel Capacity:
3.1 gallons (11.7 L)
Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher.
Oil Capacity:
2.10 US qt (2.0 L) with oil filter change.
Type:
5-speed manual with wet multi-disc clutch.
Final Drive:
O-ring sealed chain, drive sprocket, rear axle.
Transmission Oil:
Yamalube 4 (or equivalent) SAE 10W-30 API SE, SF, SG, SH, SJ, SL.
Transmission Oil Capacity:
0.70 US qt (0.66 L)
Atv Safety Standards:
Complies with ANSI standards for recreational ATVs.
Brakes:
Dual hydraulic disc front brakes, Single hydraulic disc rear brake.
Handlebars:
Tapered handlebars with protective padding.
Footwells:
Wide, anti-slip footpegs with heel guards.
Features:
Basic digital display showing speed, odometer, trip meter, and neutral/reverse indicators. No advanced infotainment features.
Features:
N/A (No electronic driver-assistance systems).
Features:
N/A (No connectivity features).
Engine Oil Change:
Every 3000 km (1800 miles) or 6 months. More frequently under severe use.
Air Filter Cleaning:
Inspect every 500 km (300 miles) or monthly. Clean as needed.
Spark Plug Replacement:
Replace every 10000 km (6000 miles).
Valve Clearance Check:
Every 10000 km (6000 miles).
Engine Oil:
Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher.
Coolant:
Permanent type antifreeze with a 50/50 mix of water. Yamaha recommends Yamalube 60% ethylene glycol coolant.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Common Problems:
Carburetor jetting issues (especially at altitude), occasional starter motor issues, wear on suspension components due to aggressive riding.
Maintenance Tips:
Regularly clean the air filter, check tire pressures, and perform chain lubrication and adjustment. Inspect for any signs of wear or damage to suspension and brake components.
