🏷️ Basic Information

Make:

Yamaha

Model:

Raptor YFM 660

Category:

ATV (All-Terrain Vehicle)

👋 Introduction

Segment:

High-performance sport ATV, positioned for aggressive trail riding and recreational use.

Competitors:

Competed against models like Honda TRX450R, Suzuki LT-R450, Polaris Predator 500, and Kawasaki KFX400/700.

Engine Power:

Renowned for its powerful 660cc engine, offering strong torque and acceleration.

Handling:

Agile handling and capable suspension system designed for off-road performance.

Durability:

Yamaha's reputation for building robust and reliable engines and chassis.

📋 Manual Details

General Information:

Included

Specifications:

Included

Periodic Checks And Adjustments:

Included

Chassis:

Included

Engine:

Included

Cooling System:

Included

Carburetion:

Included

Electrical System:

Included

Troubleshooting:

Included

Total Pages:

328

Type:

Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Detailed coverage of the 660cc liquid-cooled, SOHC, 4-valve, 5-valve engine.

Cooling System:

Radiator, fan, coolant circuits, thermostat operation and service.

Fuel System:

Carburetor (Mikuni BSR38) specifications, adjustments, cleaning, and overhaul.

Ignition System:

CDI unit, ignition timing, spark plug specifications, and troubleshooting.

Electrical System:

Wiring diagrams, lighting, battery, charging system (stator, regulator/rectifier), starter motor.

Transmission:

5-speed manual transmission with reverse, clutch operation, and internal component service.

Drivetrain:

Shaft drive, bevel gear case, front/rear driveshaft, differential (if applicable).

Suspension:

Front independent suspension (A-arms, shocks), rear swingarm, shock absorber adjustments and service.

Brakes:

Hydraulic disc brakes (front and rear), caliper service, pad replacement, brake fluid specifications.

Steering:

Handlebar assembly, steering shaft, tie rods, and steering bearing service.

Frame And Bodywork:

Frame inspection, body panel removal/installation, seat, fenders, and rack components.

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, air filter cleaning, spark plug checks.

Troubleshooting Diagnostics:

Systematic diagnostic procedures for common performance issues, electrical faults, and mechanical problems.

Engine Overhaul:

Top-end rebuild (cylinder head, piston, rings), bottom-end service (crankshaft, bearings, seals).

Transmission Rebuild:

Disassembly, inspection, and reassembly of the gearbox and clutch components.

Carburetor Tuning:

Jetting, float level adjustment, idle speed, and mixture screw settings.

Electrical Component Testing:

Testing of stator output, regulator/rectifier function, battery condition, and starter solenoid.

Suspension Adjustments:

Preload, compression, and rebound damping adjustments for optimal ride handling.

Brake System Service:

Bleeding, caliper overhaul, pad and rotor replacement.

Wheel Bearing Service:

Replacement of front and rear wheel bearings.

Lubrication Points:

Identification and recommended lubrication for all critical points.

Depth:

Comprehensive. Covers routine maintenance to full engine and transmission rebuilds, including detailed troubleshooting and electrical diagnostics.

📊 Manual Specifications

File Type:

Portable Document Format (PDF)

Clarity:

Likely high resolution, suitable for printing, with clear diagrams and text.

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

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

Displacement:

659cc

Bore X Stroke:

95.0 mm x 92.7 mm

Compression Ratio:

9.1:1

Horsepower:

Approx. 45-50 hp (manufacturer figures often not explicitly stated, performance tune dependent)

Torque:

Strong mid-range torque delivery

Carburetor:

Mikuni BSR38 with throttle position sensor (TPS)

Oil Type:

Yamalube 4 (or equivalent) SAE 10W-40, API SG, JASO MA

Oil Capacity:

Approx. 2.2 L (with filter change)

Ignition System:

TCI (Transistor Controlled Ignition)

🔧 Transmission

Type:

5-speed manual with reverse

Clutch:

Wet, multiple-disc

Drivetrain:

Shaft drive to rear wheels, 2WD

Transmission Oil:

Yamalube 4 (or equivalent) SAE 10W-40, API SG, JASO MA

Transmission Oil Capacity:

Approx. 0.85 L

📐 Dimensions

Length:

Approx. 1830 mm (72.0 in)

Width:

Approx. 1140 mm (44.9 in)

Height:

Approx. 1035 mm (40.7 in)

Wheelbase:

Approx. 1280 mm (50.4 in)

Curb Weight:

Approx. 206 kg (454 lbs)

Fuel Capacity:

10.0 L (2.6 gal) with 1.0 L reserve

🛡️ Safety Features

Atv Safety:

ATVs are inherently high-risk vehicles. Users must always wear helmets, eye protection, gloves, and appropriate riding gear. Follow all safety warnings in the manual and on the vehicle.

Braking System:

Triple hydraulic disc brakes for strong stopping power.

Throttle Limiter:

Often adjustable throttle limiter to control maximum speed, particularly for novice riders.

Parking Brake:

Handlebar-mounted parking brake.

💡 Technology Features

Features:

N/A (As a sport ATV, advanced infotainment systems are not a feature. Basic instrumentation includes speedometer, odometer, trip meter, and indicator lights).

Features:

N/A (No electronic driver assistance systems like traction control or ABS are present on this model).

Features:

N/A

🔧 Maintenance

Engine Oil:

Every 1,000 km (620 miles) or 3 months, whichever comes first. Inspect more frequently for aggressive riding.

Air Filter:

Clean every 1,000 km (620 miles) or 3 months. Replace as needed.

Spark Plug:

Inspect every 1,000 km (620 miles). Replace as needed. Recommended plug: NGK CR7E

Valve Clearance:

Check every 3,000 km (1,860 miles) or 1 year. Intake: 0.09-0.13 mm; Exhaust: 0.13-0.17 mm.

Brake Fluid:

Replace every 2 years. Recommended fluid: DOT 4.

Engine Oil Spec:

Yamalube 4 (or equivalent) SAE 10W-40, API SG, JASO MA

Coolant Spec:

Permanent type antifreeze coolant mixed with distilled water at a 1:1 ratio. (e.g., Yamaha Yamalube Coolant)

Brake Fluid Spec:

DOT 4

Common Problems:

Early models may experience occasional issues with the starter clutch, cam chain tensioner, and carburetor jetting sensitivity to altitude/temperature changes. Overheating can occur under extreme conditions without proper airflow or if cooling system maintenance is neglected.

📚 Vehicle History

Yamaha Atv:

Yamaha has a long and successful history in ATV manufacturing, starting with the 1980 YFM100 'Moto-Bike'.

Raptor Lineage:

The YFM660R Raptor was a groundbreaking sport ATV upon its release, setting new benchmarks for performance and handling in the class. It was eventually succeeded by the fuel-injected YFM700R Raptor.

Production Years:

Approximately 2001-2005.

🏆 Awards & Recognition

Industry Impact:

Widely regarded as a highly influential sport ATV that helped define the segment and inspired many subsequent models.

Performance Reviews:

Consistently received positive reviews from off-road publications for its power, handling, and overall performance.