Vehicle Segment:
High-performance sport ATV, known for its powerful engine and agile handling.
Key Competitors:
Honda TRX450R, Suzuki LT-Z400, Polaris Predator 500, Kawasaki KFX400.
Performance Focus:
The Raptor 660 was renowned for its potent 660cc engine, offering superior power and torque in its class during its production run.
Manual Value Proposition:
Empowers owners to perform their own maintenance and repairs, saving on dealership labor costs and increasing self-sufficiency.
Technical Accuracy:
Provides factory-level technical data, ensuring accuracy and adherence to OEM specifications.
Years Covered:
2001, 2002, 2003, 2004, 2005
Specific Models Covered:
YFM660RN (Standard), YFM660RNC (Special Edition)
Estimated Pages:
Varies by manual, typically 300-600 pages for comprehensive service manuals of this era.
Type:
Factory Service Manual / Workshop Manual
Language:
English (Assumed, standard for most North American market manuals)
Digital Format:
PDF (Portable Document Format)
Engine:
Complete engine overhaul, lubrication, cooling system, fuel system (carburetion, fuel pump), ignition system, starting system, exhaust system.
Transmission:
Clutch operation, gearbox disassembly and reassembly, lubrication, shifting mechanism.
Drivetrain:
Shaft drive system, differential, final drive, driveshaft, axle components.
Suspension:
Front and rear suspension systems, shock absorbers, control arms, steering knuckles, wheel bearings.
Brakes:
Hydraulic brake system (front and rear), caliper maintenance, rotor inspection, brake fluid replacement, bleeding procedures.
Electrical:
Wiring diagrams, charging system (stator, rectifier/regulator), battery, lighting, ignition switch, fuses, relays, starter motor, sensors.
Chassis And Body:
Frame inspection, body panel removal and installation, seat, handlebars, controls, footpegs, skid plates.
Maintenance:
Oil changes, filter replacements, chain adjustment (if applicable, though this is shaft-driven), spark plug service, air filter cleaning/replacement, brake system checks, tire pressure, lubrication points.
Troubleshooting:
Diagnostic procedures for common starting issues, engine performance problems, electrical faults, braking system irregularities, and suspension issues.
Repair:
Step-by-step instructions for component disassembly, inspection, repair, and reassembly of all major systems.
Rebuilds:
Detailed guidance for engine internal component overhauls, gearbox rebuilds, and suspension component refurbishment.
Level Of Detail:
Comprehensive, covering everything from basic user maintenance to advanced diagnostic and repair procedures suitable for professional technicians.
Diagnostic Tools:
Includes information on required tools and diagnostic methods, though specialized electronic diagnostic equipment may not be as prevalent as on modern vehicles.
Engine Type:
Liquid-cooled, four-stroke, SOHC, four-valve
Displacement:
660 cc (660cc)
Bore X Stroke:
100 mm x 84 mm (Approximate, may vary slightly)
Compression Ratio:
9.2:1 (Typical for this era engine)
Horsepower:
Approx. 46-50 HP (At crankshaft, manufacturer figures vary)
Torque:
Approx. 44-48 lb-ft (At crankshaft, manufacturer figures vary)
Carburetion:
Mikuni BSR42 (42mm) flat-slide carburetor (Single)
Fuel Type:
Unleaded gasoline, 87 octane minimum (AKI) / 91 RON (Europe)
Ignition System:
Digital TCI (Transistor Controlled Ignition) with electronic advance
Oil Type:
Yamaha Genuine 4-Stroke Motor Oil or equivalent motorcycle-specific oil (e.g., Yamalube 10W-40 API SG or higher)
Oil Capacity:
Approx. 2.0 Liters (2.1 US qt) with filter change
Cooling System:
Liquid-cooled
Coolant Type:
Yamaha All-Weather Engine Coolant (50/50 mix of ethylene glycol and deionized water) or equivalent.
Transmission Type:
Constant-mesh 5-speed with reverse
Transmission Options:
N/A (Standard 5-speed gearbox)
Clutch Type:
Wet, multi-disc clutch (Manual operation)
Drive System:
Shaft drive
Gear Ratios:
Specific ratios detailed in the manual (e.g., 1st gear: 2.714, 2nd: 1.933, etc.)
Gear Oil Type:
Yamaha Gear Oil API GL-4 or API GL-5 (e.g., Yamalube Hypoid Gear Oil) SAE 80
Gear Oil Capacity:
Approx. 0.70 Liters (0.74 US qt)
Length:
Approx. 73.6 inches (1870 mm)
Width:
Approx. 45.1 inches (1145 mm)
Height:
Approx. 42.7 inches (1085 mm)
Wheelbase:
Approx. 50.4 inches (1280 mm)
Dry Weight:
Approx. 510 lbs (231 kg)
Fuel Capacity:
Approx. 3.2 US gallons (12 Liters)
Front Tire Size:
AT22x7-10 (Typical, may vary)
Rear Tire Size:
AT20x10-9 (Typical, may vary)
Front Wheel Size:
10 x 5.5 AT
Rear Wheel Size:
9 x 8 AT
Front Suspension Type:
Independent double wishbone with adjustable preload
Rear Suspension Type:
Swingarm with adjustable preload shock absorber
Front Wheel Travel:
Approx. 7.1 inches (181 mm)
Rear Wheel Travel:
Approx. 8.1 inches (205 mm)
Front Brake Type:
Dual hydraulic disc
Rear Brake Type:
Dual hydraulic disc
Atv Safety Standards:
Conforms to ANSI standards (as per typical US market ATV regulations of the era).
Throttle Limiter:
Not a standard safety feature for performance ATVs, but manual may cover adjustment.
Handlebar Design:
Dampened handlebar for reduced vibration and improved control.
Footwell Protection:
Integrated floorboards with heel guards for rider protection.
Engine Oil Change:
Every 3,000 km (1,800 miles) or 6 months, whichever comes first, under normal use. More frequently for severe use.
Oil Filter Replacement:
Every 3,000 km (1,800 miles) or 6 months, recommended with oil change.
Air Filter Cleaning:
Every 1,000 km (600 miles) or 3 months, or more frequently in dusty conditions. Replacement as needed.
Spark Plug Inspection:
Every 1,000 km (600 miles).
Valve Clearance Check:
Every 6,000 km (3,600 miles) or 12 months.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Camchain Tensioner:
Early models sometimes experienced issues with the automatic camchain tensioner, leading to noise or potential damage. Manual will cover inspection and manual conversion if applicable.
Carburetor Jetting:
Carburetor jetting can be sensitive to altitude and modifications. Manual provides stock settings and troubleshooting.
Electrical Connections:
As with many ATVs of this era, checking and cleaning electrical connectors for corrosion is good preventative maintenance. Manual provides wiring diagrams.
Manufacturer:
Yamaha Motor Company, known for its long history in motorsports and powersports.
Predecessor:
The Raptor 660 followed Yamaha's successful line of Banshee and Warrior models, representing a leap forward in sport ATV technology.
Innovation:
Introduced a powerful 660cc single-cylinder engine in a lightweight chassis, setting a new benchmark for performance. Featured a robust shaft drive system, unlike many chain-driven competitors.
Production Run:
The 660cc Raptor was produced from 2001 to 2005. It was succeeded by the fuel-injected Raptor 700 in 2006.
