Vehicle Category:
High-performance All-Terrain Vehicle (ATV)
Target Audience:
Enthusiasts, off-road riders, recreational users seeking reliable performance and capability.
Competitors:
Honda TRX450R/Foreman, Suzuki LT-R450/KingQuad, Polaris Sportsman/Scrambler, Kawasaki Brute Force/KFX series.
Key Differentiation:
Powerful 660cc engine, robust chassis, comfortable suspension, and Yamaha's renowned reliability and build quality.
Engine Power:
Class-leading torque and horsepower for its era.
Handling:
Agile handling and stable ride due to well-tuned suspension and chassis geometry.
Durability:
Built for demanding off-road conditions, known for longevity.
Manual Benefit:
Cost-effective maintenance, empowers owners to perform repairs and keep the vehicle in optimal condition.
Engine:
Detailed overhaul, diagnosis, inspection, and repair of the 660cc liquid-cooled, SOHC, 4-stroke engine.
Fuel System:
Carburetor (Mikuni BSR42) tuning, cleaning, and overhaul; fuel pump operation; fuel filter replacement.
Ignition System:
CDI ignition system, spark plug specifications, ignition timing checks, coil testing.
Transmission:
5-speed manual transmission with reverse, clutch operation and adjustment, transmission gear inspection and replacement.
Drivetrain:
Shaft drive system, final drive housing, universal joints, axle inspection and maintenance.
Suspension:
Front independent suspension (A-arms), rear swingarm suspension, shock absorber adjustment and maintenance, bearing lubrication.
Brakes:
Hydraulic disc brakes (front and rear), brake pad replacement, caliper servicing, brake fluid bleeding, master cylinder inspection.
Electrical System:
Stator, flywheel magneto, battery maintenance, starter motor operation, lighting system (headlight, taillight, brake light), wiring diagrams.
Cooling System:
Liquid cooling system, radiator, fan operation, coolant type and capacity, water pump servicing.
Frame And Bodywork:
Chassis inspection, body panel removal and installation, seat, fenders, handlebar replacement.
Lubrication System:
Engine oil type and capacity, oil filter replacement, lubrication points.
Maintenance:
Scheduled maintenance checks, oil changes, filter replacements, spark plug changes, brake adjustments, chain/driveshaft lubrication.
Troubleshooting:
Diagnostic flowcharts for common problems, electrical system troubleshooting, engine performance issues.
Repair:
Complete engine rebuild procedures, transmission overhaul, suspension component replacement, brake system servicing, electrical component repair.
Disassembly And Assembly:
Step-by-step instructions for removing and reinstalling major components and assemblies.
Technical Specifications:
Torque specifications for all fasteners, engine clearances, fluid capacities, electrical system resistance values.
Wiring Diagrams:
Detailed electrical system wiring schematics for all model years covered.
Depth:
Comprehensive, covering from routine maintenance to full engine and transmission rebuilds.
Diagnostic Capabilities:
Includes diagnostic procedures and troubleshooting charts for identifying and resolving mechanical and electrical faults.
Rebuild Procedures:
Detailed step-by-step instructions for overhauling major mechanical components like the engine and transmission.
Type:
Liquid-cooled, four-stroke, SOHC, 5-valve
Bore X Stroke:
100.0 mm x 85.0 mm
Horsepower Estimated:
Approximately 40-45 hp (actual figures vary by market and tune)
Torque Estimated:
Approximately 40-45 lb-ft (actual figures vary by market and tune)
Carburetor:
Mikuni BSR42, diaphragm-type
Fuel Capacity:
3.1 US gal (11.7 L)
Ignition:
CDI (Capacitor Discharge Ignition)
Oil Type Specification:
Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA certified
Oil Capacity With Filter:
2.9 US qt (2.7 L)
Coolant Type:
Permanent Antifreeze/Coolant, 50/50 mix with distilled water
Coolant Capacity:
1.71 US qt (1.6 L)
Atv Safety Classification:
Designed for recreational off-road use; users must wear appropriate safety gear and follow all safety guidelines.
Braking System:
Dual hydraulic disc brakes front, hydraulic disc brake rear provide strong stopping power.
Throttle Limiter:
Some models may have adjustable throttle limiters for novice riders.
Ergonomics:
Designed for rider comfort and control with padded seat and handlebars.
Lighting:
Dual 30W headlights and a 5W brake light for visibility.
Roll Over Protection:
ATVs are not inherently equipped with roll-over protection structures (ROPS); safe riding practices are paramount.
Engine Oil Change:
Every 600 miles (1,000 km) or 6 months, whichever comes first.
Oil Filter Replacement:
Replace every 1200 miles (2,000 km) or 12 months, or at every second oil change.
Air Filter Cleaning:
Clean every 600 miles (1,000 km) or 6 months; replace if damaged.
Spark Plug Replacement:
Inspect every 600 miles (1,000 km), replace as needed (CR9E recommended).
Brake Fluid Flush:
Every 12 months or as needed if contaminated.
Valve Clearance Check:
Every 2,400 miles (4,000 km) or 24 months.
Engine Oil Viscosity:
SAE 10W-40
Brake Fluid Type:
DOT 3 or DOT 4.
Coolant Specification:
Ethylene Glycol based, permanent type antifreeze/coolant (50/50 with distilled water).
Camchain Tensioner:
Some models experienced premature wear or failure of the automatic camchain tensioner, leading to noise. Manual outlines inspection and replacement.
Carburetor Jetting:
Can be sensitive to altitude and modifications; manual provides baseline settings and troubleshooting for performance issues.
Electrical Connections:
Corrosion or loose connections, particularly in off-road environments, can cause intermittent electrical faults. Manual guides testing.
Starter Clutch:
Some units may have issues with the starter clutch mechanism; manual provides diagnostic steps.
Manufacturer:
Yamaha Motor Corporation, a globally recognized leader in motorcycles, marine products, and recreational vehicles.
Predecessor:
Building on Yamaha's experience with models like the Warrior and Banshee, the YFM660 Raptor introduced a larger, more powerful engine and improved chassis.
Successor:
The YFM660 Raptor was succeeded by the fuel-injected YFZ450 and later the YFZ450R, which continued to set benchmarks in the sport ATV segment.
Production Period:
2001-2005 (model years covered by manual), with the YFM660 platform continuing in some variants through 2006.
Manufacturing Location:
Primarily manufactured in Japan and the United States.
Impact On Market:
The YFM660 Raptor was a significant contender in the rapidly growing sport ATV market of the early 2000s, known for its strong performance and reliability.
