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Yamaha YFM660 2001-2006 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Yamaha Model: YFM660 Model Variant: Raptor Product Type: Workshop Service Repair Manual Codes Engine Code Prefix: 4WV Vin Code Digit Engine: 4 👋 Introduction Market...
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类型: Atv
厂商:
斯库: 66195
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🏷️ Basic Information
Identification
Make:
Yamaha
Model:
YFM660
Model Variant:
Raptor
Product Type:
Workshop Service Repair Manual
Codes
Engine Code Prefix:
4WV
Vin Code Digit Engine:
4
👋 Introduction
Market Position
Vehicle Category:
High-performance All-Terrain Vehicle (ATV)
Target Audience:
Enthusiasts, off-road riders, recreational users seeking reliable performance and capability.
Competitive Analysis
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.
Key Features
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.
📋 Manual Details
Coverage Areas
Years Covered:
2001, 2002, 2003, 2004, 2005, 2006
Region Of Operation:
Global (primarily North American and European specifications)
Page Count
Estimated Pages:
~400+
Manual Type
Type:
Comprehensive Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
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.
Procedures Included
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.
Technical Depth
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.
📊 Manual Specifications
File Format
Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Compatibility:
Viewable on most devices with PDF reader (computers, tablets, smartphones).
Print Quality
Quality:
High-resolution scans with clear text and diagrams.
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Type:
Liquid-cooled, four-stroke, SOHC, 5-valve
Displacement:
660 cc
Bore X Stroke:
100.0 mm x 85.0 mm
Compression Ratio:
9.2:1
Performance
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)
Fuel System
Carburetor:
Mikuni BSR42, diaphragm-type
Fuel Capacity:
3.1 US gal (11.7 L)
Ignition System
Ignition:
CDI (Capacitor Discharge Ignition)
Lubrication System
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)
Cooling System
Coolant Type:
Permanent Antifreeze/Coolant, 50/50 mix with distilled water
Coolant Capacity:
1.71 US qt (1.6 L)
🔧 Transmission
Standard
Type:
Constant mesh, 5-speed sequential with reverse
Clutch:
Wet, multiple disc
Final Drive:
O-ring sealed chain
Features
Reverse Gear:
Standard feature for enhanced maneuverability.
Clutch Actuation:
Manual lever operation.
📐 Dimensions
Exterior
Length:
73.7 in (1,872 mm)
Width:
43.3 in (1,100 mm)
Height:
41.4 in (1,052 mm)
Wheelbase:
50.4 in (1,280 mm)
Ground Clearance:
9.5 in (242 mm)
Weights
Dry Weight:
518 lbs (235 kg)
Curb Weight Estimated:
Approximately 530-540 lbs (240-245 kg) with fluids
Tires
Front Tire Size:
AT21x7-10
Rear Tire Size:
AT20x10-9
Wheels
Front Wheel Size:
10 x 5.5 AT
Rear Wheel Size:
9 x 8 AT
🛡️ Safety Features
Ratings
Atv Safety Classification:
Designed for recreational off-road use; users must wear appropriate safety gear and follow all safety guidelines.
Active Features
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.
Passive Features
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.
💡 Technology Features
Infotainment
Display:
Basic LCD meter displaying speedometer, odometer, trip meter, and neutral indicator. No advanced infotainment.
Driver Assistance
Assistance Systems:
None (basic mechanical design).
Connectivity
Connectivity Features:
None.
Performance Enhancements
Carburetor Tuning:
Manual provides guidance for adjusting the carburetor for optimal performance in varying conditions, a key aspect of tuning this model.
🔧 Maintenance
Service Intervals
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.
Fluid Specifications
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).
Known Issues
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.
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Corporation, a globally recognized leader in motorcycles, marine products, and recreational vehicles.
Model Evolution
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
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.
Significance
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.
🏆 Awards & Recognition
Recognitions
Atv Industry Impact:
The YFM660 Raptor was widely acclaimed as a benchmark sport ATV upon its release, influencing subsequent designs in the category.
Ratings
Consumer Reviews:
Consistently rated highly by ATV enthusiasts for its power, handling, and durability during its production run.
Certifications
Emission Standards:
Compliant with applicable emissions standards for its model years (details in manual).