Segment:
High-performance sport ATV segment.
Target Audience:
Enthusiasts, off-road riders, competitive racers, and DIY mechanics.
Competitors:
Honda TRX450R, Suzuki LT-Z400, Kawasaki KFX700.
Performance Orientation:
The YFM660R Raptor was a benchmark for sport ATVs with its powerful engine and advanced chassis for its era.
Manual Value:
Provides the essential technical knowledge for owners to maintain and repair their high-performance machine, ensuring longevity and optimal performance.
Covered Years:
2001, 2002, 2003, 2004, 2005, 2006
Estimated Pages:
300-400 (typical for this model's comprehensive service manuals)
Type:
Service Repair Workshop Manual
Format:
Digital Download (PDF)
Engine:
Complete engine overhaul, diagnosis, tuning, lubrication, cooling system, fuel system (carburetor, fuel lines), ignition system, exhaust system.
Transmission:
Clutch system (wet multi-plate), gearbox, shifting mechanism, drive shafts, final drive (chain drive), lubrication.
Chassis:
Frame, suspension (front and rear), steering system, hubs, bearings, axles, wheels, tires.
Brakes:
Front and rear hydraulic disc brakes, brake fluid, lines, calipers, master cylinders, bleeding procedures.
Electrical:
Wiring diagrams, battery, charging system (stator, rectifier/regulator), lighting (headlights, taillights, indicators), ignition switch, starter motor, relays, fuses, CDI unit, sensors.
Bodywork:
Body panels, fenders, seat, handlebars, controls, plastics, graphics.
Maintenance:
Regular inspection, cleaning, lubrication, oil changes, filter replacements, spark plug replacement, brake adjustments, chain maintenance.
Repair:
Engine rebuild, transmission repair, carburetor overhaul, suspension component replacement, brake caliper rebuild, electrical component troubleshooting and replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon problems, fault finding charts, symptom-based troubleshooting.
Technical Specifications:
Detailed torque specifications, clearances, tolerances, fluid capacities, electrical specifications, engine timings.
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams.
Engine Type:
Four-stroke, liquid-cooled, DOHC, 5-valve, single cylinder
Bore X Stroke:
100.0 mm x 83.0 mm
Carburetor:
Mikuni BSR34 (single)
Ignition:
CDI (Capacitor Discharge Ignition)
Starting System:
Electric Start
Horsepower Estimated:
~40-45 hp @ 6000 rpm (approximate, depending on tuning and model year variations)
Torque Estimated:
~45-50 lb-ft @ 5000 rpm (approximate)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
3.2 US gal (12 L)
Crash Test Ratings:
N/A (ATVs are not subjected to standardized automotive crash testing.)
Brakes:
Hydraulic disc brakes front and rear for strong stopping power.
Suspension:
Long-travel, adjustable suspension for stability and control over varied terrain.
Tires:
Aggressively treaded ATV tires for optimal traction.
Handlebars:
Standard handlebars with protective padding.
Footwells:
Wide, integrated footwells with serrated pegs for secure foot placement.
Lighting:
Halogen headlights and taillight for visibility.
Engine Oil Change:
Every 1000 km (600 miles) or 6 months, whichever comes first. Also after every 20 hours of operation.
Oil Filter Replacement:
Replace at every oil change (Yamaha part number 5GH-13440-00-00 or equivalent).
Air Filter Cleaning:
Clean every 500 km (300 miles) or 10 hours. Replace as needed.
Spark Plug Inspection:
Inspect every 1000 km (600 miles) or 6 months. Replace as needed (NGK CR9E or equivalent).
Chain Tension Adjustment:
Check and adjust every 500 km (300 miles) or 10 hours.
Brake Fluid Flush:
Flush and replace brake fluid every 2 years or as recommended by manual (DOT 4 recommended).
Engine Oil Type:
Yamalube 4 (or equivalent motorcycle oil) SAE 10W-40 API SG or higher, JASO MA certified.
Engine Oil Capacity:
2.4 L (2.5 US qt) without filter change; 2.5 L (2.6 US qt) with filter change.
Coolant Type:
Permanent type antifreeze coolant mixed with distilled water (50/50 ratio).
Carburetor Tuning:
Can be sensitive to altitude and temperature changes, requiring periodic adjustment or re-jetting for optimal performance.
Starter Clutch:
Some early models may experience wear on the starter clutch mechanism; manual will detail inspection and replacement.
Rear Axle Bearing:
Regular inspection of rear axle bearings for wear and proper lubrication is advised.
Cam Chain Tensioner:
Manual will guide on checking and replacing the automatic cam chain tensioner if it becomes noisy.
Heritage:
Yamaha has a long-standing reputation for building high-quality, performance-oriented recreational vehicles, including motorcycles and ATVs.
Raptor Introduction:
The original YFM660R Raptor, introduced in 2001, was Yamaha's first foray into the high-performance sport ATV market and quickly became a class leader.
Key Innovations:
It featured a powerful liquid-cooled, 5-valve, single-cylinder engine, which was a significant departure from previous multi-cylinder designs common in the sport ATV segment at the time, offering excellent low-end torque and broad powerband.
Market Impact:
The Raptor's success paved the way for subsequent generations and solidified Yamaha's position in the performance ATV market.
Production Period:
2001-2005 for the YFM660R model, succeeded by the fuel-injected YFZ450.
