2001 2002 2003 2004 2005 Yamaha RAPTOR 660 ATV Service Repair Manual

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Type: Atv

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Sku: 93329

Tags: 2001 2002 2003 2004 2005 ATV Powersports RAPTOR 660 Raptor Models Yamaha

Product variants

Description

The Yamaha Raptor 660, produced between 2001 and 2005, represents a significant milestone in the high-performance sport ATV market. Known for its powerful liquid-cooled, 660cc 4-stroke engine, aggressive styling, and long-travel suspension, this model set a benchmark for speed, agility, and off-road capability. The heritage in crafting high-performance vehicles is evident in the Raptor 660's robust engineering and sought-after performance, making it a popular choice for enthusiasts and a platform for modification and racing. Its steel frame with an aluminum subframe contributes to its rigidity and optimized weight, further enhancing its dynamic performance. This comprehensive service repair manual provides detailed information essential for the maintenance, repair, and troubleshooting of the Yamaha Raptor 660 (model codes YFM660R, YFM660RN, YFM660RNC). It covers all major systems, including the engine, chassis, cooling, carburetion, electrical, and transmission, detailing procedures from routine checks and fluid changes to complete engine disassembly and component overhaul. With in-depth explanations, specifications, torque values, and diagnostic guides, this manual is an indispensable resource for owners, mechanics, and technicians aiming to keep their Raptor 660 in optimal condition.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

Raptor 660

Model Code:

YFM660R, YFM660RN, YFM660RNC

Generation

Generation Identifier:

First Generation Raptor 660

Codes

Engine Code Primary:

👋 Introduction

Market Position

Market Segment:

High-performance sport ATV

Competitive Analysis

Competitors:

Honda TRX400EX/TRX450R, Suzuki LT-Z400, Kawasaki KFX400/KFX450R

Key Features

Unique Selling Points:

Powerful liquid-cooled 4-stroke engine, aggressive styling, long-travel suspension, highly capable off-road performance, sought-after model for modification and racing.

📋 Manual Details

Coverage Areas

Applicable Model Years:

2001, 2002, 2003, 2004, 2005

Page Count

Estimated Page Count:

500-600 (estimated based on chapter structure and depth)

Manual Type

Manual Type:

Service Repair Manual / Workshop Manual / Factory Manual

Language

Language:

English

Format

Format:

Digital Download (PDF, potentially ZIP/RAR)

📖 Manual Coverage

Systems Covered

Major Systems:

Engine, Chassis, Cooling System, Carburetion, Electrical System, Transmission, Brakes, Steering System, Suspension

Procedures Included

Maintenance Procedures:

Periodic checks, lubrication, fluid changes, filter cleaning/replacement, spark plug inspection, valve clearance adjustment, timing chain adjustment, idle speed adjustment, throttle lever free play adjustment, speed limiter adjustment, starter cable adjustment, brake adjustments, clutch adjustment, drive chain adjustment, steering alignment (toe-in), shock absorber adjustment, battery checks, fuse checks, headlight beam adjustment, headlight bulb replacement, coolant level checks, coolant changes, air filter cleaning, spark arrester cleaning.

Repair Procedures:

Engine removal/installation, cylinder head cover removal/installation, rocker arm inspection/installation, camshaft and cylinder head removal/installation, valve and valve spring removal/installation, cylinder and piston inspection/installation, AC magneto rotor removal/installation, clutch removal/installation, oil pump inspection/assembly, shift shaft inspection/installation, crankcase separation/assembly, crankshaft removal/installation, transmission inspection/assembly, radiator checking/installation, thermostat checking/assembly, water pump disassembly/assembly, carburetor disassembly/assembly, electrical system component checks (switches, ignition system, starting system, starter motor, charging system, lighting system, signal system, cooling system), brake pad replacement, master cylinder service, brake caliper service, steering stem service, tie-rod and steering knuckle service, front arm and shock absorber service, rear shock absorber and relay arm service, swingarm and drive chain service.

Troubleshooting:

Starting failures, hard starting, poor idle speed, poor medium/high-speed performance, faulty gear shifting, hard shifting, shift pedal issues, gear jump-out, clutch slipping/dragging, overheating, overcooling, faulty brakes, poor braking effect, shock absorber malfunction, unstable handling, lighting system issues (dark headlights, burnt bulbs).

Technical Depth

Depth Of Information:

Comprehensive. Covers detailed disassembly, inspection, repair, and reassembly of all major vehicle components. Includes specifications, torque values, diagnostic procedures, and troubleshooting guides for professional-level repairs and DIY enthusiasts.

📊 Manual Specifications

File Format

File Format Details:

PDF. Compatible with all PDF readers. May be delivered as a ZIP or RAR archive requiring unzipping software (WinZip, WinRAR).

Print Quality

Print Quality:

Printable. Allows users to print specific sections or the entire manual. Resolution and clarity suitable for following diagrams and instructions.

Binding Type

Binding Type:

N/A (Digital Download - no physical binding)

Paper Type

Paper Type:

N/A (Digital Download - no physical paper)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, 5-valve

Displacement:

660 cc

Bore X Stroke:

100.0 mm x 85.0 mm

Compression Ratio:

9.2:1

Performance

Horsepower:

Approx. 45-50 HP (stock, may vary by region/tuning)

Torque:

Approx. 40-45 lb-ft (stock, may vary by region/tuning)

Fuel System

Carburetion:

Mikuni BSR42 (x1)

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Lubrication

Oil Capacity:

Approx. 2.2 L (with filter change)

Recommended Oil Grade:

Yamaha 4-stroke motor oil 10W-40 API SG, SAE 20W-40 API SG, or SAE 10W-30 API SG

Cooling System

Coolant Type:

Permanent type anti-freeze coolant (50/50 mixture with distilled water)

Coolant Capacity:

Approx. 1.6 L

Ignition

Ignition System:

Digital CDI

Spark Plug Type:

NGK CR9E (or equivalent)

Starting System

Starter Type:

Electric Start

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh with reverse

Optional

Clutch Type:

Wet, multiple-disc, cable-actuated

Features

Drive System:

O-ring sealed chain, 520 pitch

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 70.9 in (1800 mm)

Width:

Approx. 45.1 in (1145 mm)

Height:

Approx. 43.7 in (1110 mm)

Weights

Dry Weight:

Approx. 423 lbs (192 kg)

Fuel Capacity:

3.2 gal (12 L)

🛡️ Safety Features

Ratings

Safety Features:

Adjustable handlebars, handguards (factory standard on some models), parking brake, kill switch with lanyard, bright lighting.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Passive Features

Frame Construction:

Steel frame with aluminum subframe for rigidity and weight optimization.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic ATV design, no integrated infotainment system)

Driver Assistance

Driver Assistance Features:

N/A (Focus on mechanical control and rider input)

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 600 miles (1000 km) or 6 months, whichever comes first.

Air Filter Cleaning Interval:

Every 300 miles (500 km) or 3 months (more frequently in dusty conditions).

Spark Plug Replacement Interval:

Check every 600 miles (1000 km), replace as needed.

Valve Clearance Check Interval:

Every 600 miles (1000 km) or 6 months.

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4

Coolant Specification:

Ethylene glycol based, permanent type anti-freeze coolant (50% solution with distilled water)

Known Issues

Common Problems:

Cam chain tensioner failure (leading to cam chain rattle or jump), oil leaks from the crankcase, carburetor tuning issues, rear shock absorber leaks or loss of damping, starter clutch wear.

Specific Component Concerns:

Early models (2001-2002) were more prone to cam chain tensioner issues. Regular oil changes and using quality oil are crucial for engine longevity.

📚 Vehicle History

Brand Heritage

Manufacturer Specialty:

Yamaha is renowned for its high-performance motorcycles and off-road vehicles, consistently pushing boundaries in engineering and performance.

Model Evolution

Raptor Lineage:

The Raptor 660 was Yamaha's groundbreaking entry into the high-performance sport ATV market, setting a benchmark for speed, handling, and agility. It was succeeded by the fuel-injected Raptor 700.

Production

Production Years:

2001-2005

🏆 Awards & Recognition

Recognitions

Industry Recognition:

Widely regarded as a benchmark in the sport ATV segment for its performance and handling characteristics during its production run.