READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM660RP WARNING LIT-11626-15-31 This ATV should not be ridden by anyone under 16 years of age.
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EBU00923 INTRODUCTION 1- Congratulations on your purchase of the Yamaha YFM660R. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this machine.
EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING CAUTION: NOTE: Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.
EBU00011 IMPORTANT NOTICE This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this machine on any public street, road or highway. This machine complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this machine. EBU00981 AFFIX DEALER LABEL HERE YFM660RP OWNER’S MANUAL ©2001 by Yamaha Motor Corporation, U.S.A.
EBU00014 WARNING Indicates a potential hazard that could result in serious injury or death. CONTENTS 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS....... 1-1 2 SAFETY INFORMATION.................. 2-1 3 DESCRIPTION AND MACHINE IDENTIFICATION ............................. 3-1 Identification number records.......... 3-2 Key identification number................ 3-2 Vehicle identification number .......... 3-3 Model label ...................................... 3-3 4 CONTROL FUNCTIONS.............
5 6 PRE-OPERATION CHECKS ........... 5-1 Front and rear brakes ..................... 5-3 Fuel ................................................. 5-4 Engine oil ........................................ 5-6 Coolant............................................ 5-7 Chain............................................... 5-8 Throttle lever ................................... 5-8 Fittings and Fasteners .................... 5-8 Lights............................................... 5-8 Switches........................
PERIODIC MAINTENANCE AND ADJUSTMENT.................................. 8-1 Owner’s manual and tool kit............ 8-1 Periodic maintenance/ lubrication ...................................... 8-3 Panel removal and installation ........ 8-5 Engine oil and oil filter cartridge ...... 8-6 Cooling system.............................. 8-11 Changing the coolant .................... 8-12 Spark plug inspection.................... 8-15 Air filter element cleaning.............. 8-17 Spark arrester cleaning ........
Troubleshooting ............................ 8-49 Troubleshooting charts ................. 8-50 9 CLEANING AND STORAGE............ 9-1 A. Cleaning...................................... 9-1 B. Storage ....................................... 9-3 10 SPECIFICATIONS.......................... 10-1 11 NOISE REGULATION.................... 11-1 12 MAINTENANCE RECORD ............ 12-1 13 ATV LIMITED WARRANTY ........... 13-1 14 YAMAHA EXTENDED SERVICE (Y.E.S.) ..........................................
EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1-1
2 Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. 1 2 3 Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. 4 5 6 1 7 WARNING 8 UNDER 9 10 11 Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. 12 NEVER operate this ATV if you are under age 16.
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EBU00924 SAFETY INFORMATION 1 2 AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: ● Read this manual and all labels carefully and follow the operating procedures described.
● ● ● ● ● ● ● ● ● ● Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. Never operate an ATV on any public street, road or highway, even a dirt or gravel one. Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV.
● ● ● ● ● Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill.
● ● ● ● ● Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. Always check for obstacles before operating in a new area.
● ● ● ● Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual. Never modify an ATV through improper installation or use of accessories. Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.
WARNING When transporting the ATV in another vehicle, be sure it is kept upright and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank. WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water.
WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation.
EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1. 2. 3. 4. 5. 6. 7. 8. 9. Spark arrester Seat Fuel tank cap Engine oil tank Brake pedal Headlight Fuel cock Throttle stop screw Coolant reservoir 10. 11. 12. 13. 14. 15. 16. 17. 18. Tail/brake light Shift pedal Clutch lever Handlebar switches Parking brake Main switch Reverse knob Throttle lever Brake lever NOTE: The machine you have purchased may differ slightly from those shown in the figures of this manual.
EBU00600 EBU00035 Identification number records Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: Key identification number The key identification number is stamped on the key as shown in the following illustration. This number can be used for ordering a new key. 1 2 3 4 5 6 7 8 2.
EBU00036 EBU00787 Vehicle identification number The vehicle identification number is stamped into the frame. Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Vehicle identification number NOTE: The vehicle identification number is used to identify your machine. 1.
EBU00039 CONTROL FUNCTIONS 1 WARNING 2 Indicates a potential hazard that could result in serious injury or death. 3 4 EBU00942 5 Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights and taillight come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position.
EBU00802 EBU00713 Indicator and warning lights Coolant temperature warning light “ ” When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes. The coolant temperature warning light circuit can be checked according to the procedure on page 4-3. 1. Reverse indicator light “R” 2.
EBU00714 Coolant temperature warning light checking method ACB-09E Turn the main switch to “ON” and the engine stop switch to “ ”. Coolant temperature warning light does not come on. Coolant temperature warning light comes on. Push the start switch with the transmission in the neutral position. Coolant temperature warning light comes on momentarily. Coolant temperature warning light does not come on. Coolant temperature and electrical circuit are OK. Go ahead with riding.
EBU00053 Handlebar switches CAUTION: _ Do not use the headlights with the engine turned off for more than thirty minutes. The battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. _ EBU00849 1. Light switch “OFF/ / 2. Engine stop switch “ / 3. Start switch “ ” Engine stop switch “ / ” Make sure that the engine stop switch is in the “ ” position.
EBU00607 Start switch “ ” The starter motor cranks the engine when this switch is pushed. CAUTION: See starting instructions prior to starting the engine. (See page 6-1 for details.
EBU00062 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released.
EBU00066 Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV. 1. Locknut 2. Adjuster WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured.
EBU00069 EBU00988 Clutch lever The clutch lever is located on the left handlebar and the ignition circuit cut-off system is incorporated in the clutch lever holder. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. (Refer to “Starting a cold engine” for a description of the ignition circuit cut-off system.
EBU00989 Brake pedal The brake pedal is located on the right side of the machine. Push down on the pedal to apply the rear brake. 1.
EBU00080 Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Squeeze the clutch lever while pushing the button, then push in the lock plate to apply the parking brake. Squeeze the clutch lever to release the parking brake. NOTE: When the parking brake is used, engine speed is limited to 2,300 r/min. Be sure the parking brake is released before moving the throttle lever. Otherwise, the engine will misfire, preventing normal operation. 1.
EBU00788 Shift pedal This machine is equipped with a constantmesh 5-speed forward and 1-speed reverse transmission. The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting. WARNING POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision.
EBU00747* EBU00092 Reverse knob “REV” The reverse knob is used to shift into reverse gear. Refer to the “Reverse knob operation and reverse driving” section (page 6-5) before operating this machine in reverse gear. Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 1. Fuel tank cap 1.
EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position, fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES: This indicates reserve. If you run out of fuel while riding, turn the lever to this position.
EBU00095 EBU01010 Starter (choke) “ ” Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to “Starting a cold engine” for proper operation. (See page 6-1.) Seat To remove the seat, insert your hand between the rear of the seat and the rear fender, pull the seat lock lever upward and pull up the seat at the rear. 1. Seat lock lever 1.
To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. NOTE: Make sure that the seat is securely fitted. _ _ 1. Projection (× 2) 2.
EBU01011 Front shock absorber adjustment The spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows: To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in direction b. Standard position: C A - Minimum (Soft) E - Maximum (Hard) WARNING POTENTIAL HAZARD Improper shock absorber adjustment.
EBU01012* Rear shock absorber adjustment The spring preload, rebound damping and compression damping forces of the rear shock absorber can be adjusted to suit the rider’s weight and the riding conditions. Adjust the spring preload as follows. 1. Loosen the locknut. 2. Turn the adjusting nut in direction a to increase the spring preload and in direction b to decrease the spring preload. WARNING POTENTIAL HAZARD This shock absorber contains highly pressurized nitrogen gas.
3. The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjusting nut. 4. Tighten the locknut to the specified torque. Tightening torque: 42 Nm (4.2 m·kgf, 30 ft·lb) Measurement A: Installed length: Minimum (hard): 232 mm (9.1 in) Standard: 240 mm (9.4 in) Maximum (soft): 247 mm (9.7 in) A. Spring length CAUTION: _ Always tighten the locknut against the spring adjusting nut and tighten it to the specified torque.
Adjust the rebound damping force as follows. Turn the rebound damping force adjusting screw in direction a to increase the rebound damping force and in direction b to decrease the rebound damping force. Adjust the compression damping force as follows. Turn the compression damping force adjusting screw in direction a to increase the compression damping force and in direction b to decrease the compression damping force. 1. Rebound damping force adjusting screw 1.
CAUTION: WARNING _ Never turn an adjusting mechanism beyond the minimum and maximum settings. POTENTIAL HAZARD Suspension components become hot during operation. WHAT CAN HAPPEN You could be burned. HOW TO AVOID THE HAZARD Never touch the compression damping adjuster, rebound damping adjuster or oil reservoir with your bare hand or skin until suspension components have cooled.
PRE-OPERATION CHECKS 1 Before using this machine, check the following points: ITEM ROUTINE PAGE 5-3 ~ 5-4, 8-24 ~ 8-27 2 3 Front brake • Check operation, free play, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if necessary. Rear brake • Check operation, fluid level and fluid leakage. • Fill with DOT4 brake fluid if necessary. 5-3 ~ 5-4, 8-24 ~ 8-26, 8-28 Clutch • Check operation, condition and lever free play.
WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
EBU00982 Brake fluid leakage ● Check to see if any brake fluid is leaking out of the pipe joints or master cylinders. Apply the brakes firmly for one minute. If there is any leaking, have the machine inspected by a Yamaha dealer. Front and rear brakes Brake lever and brake pedal ● Check that there is no free play in the brake lever. If there is free play, have a Yamaha dealer adjust it. ● Check for correct brake pedal height. If the pedal height is incorrect, have a Yamaha dealer adjust it.
EBU00886 Fuel Make sure there is sufficient gasoline in the tank. WARNING POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have the ATV inspected by a Yamaha dealer.
Gasohol There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems. 1. Fuel tank filler tube WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up.
EBU00914 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See page 8-6.) CAUTION: _ Be sure to use motor oils that do not contain anti-friction modifiers. Passenger car motor oils (often labeled “ENERGY CONSERVING II”) contain anti-friction additives which will cause clutch and/or starter clutch slippage, resulting in reduced component life and poor engine performance.
EBU00496 Coolant Check the coolant level in the reservoir tank when the engine is cold. (The coolant level will vary with engine temperature.) The coolant level is satisfactory if it is between the “FULL” and “LOW” marks on the tank. If the coolant level is at or below the “LOW” level, add tap water (soft water) to bring the level up to “FULL”. Change the coolant every two years. (See pages 8-11 ~ 8-14 for details.
EBU00498 EBU00991 Chain Check the general condition of the chain and check the chain slack before every ride. Lubricate and adjust the chain as necessary. (See pages 8-33 ~ 8-35 for details.) Lights Check the headlights and tail/brake light to make sure they are in working condition. Repair as necessary for proper operation. EBU00912 Switches Check the operation of the light switch, engine stop switch and any other switches. Repair as necessary for proper operation.
EBU00157 Tires 2. The tires should be set to the recommended pressure: ● Recommended tire pressure Front 27.5 kPa (0.275 kgf/cm2, 4.0 psi) Rear 27.5 kPa (0.275 kgf/cm2, 4.0 psi) ● Check and adjust tire pressures when the tires are cold. ● Tire pressures must be equal on both sides. 3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums: Front 24.5 kPa (0.245 kgf/cm2, 3.5 psi) Rear 24.5 kPa (0.245 kgf/cm2, 3.
Set pressure with tires cold. Set tire pressures to the following specifications: 4. Use no more than the following pressures when seating the tire beads. Front 250 kPa (2.5 kgf/cm2, 36 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi) Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Fast inflation could cause the tire to burst. Recommended pressure Maximum Front 24.5 kPa 30.5 kPa 27.5 kPa (0.275 kgf/cm2, (0.245 kgf/cm2, (0.305 kgf/cm2, 4.0 psi) 3.5 psi) 4.
EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. 3 mm (0.
EBU00161 EBU00789 OPERATION Starting a cold engine WARNING WARNING POTENTIAL HAZARD Freezing control cables in cold weather. WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or collision. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding. Indicates a potential hazard that could result in serious injury or death.
Position 3: Cold engine startambient temperature above 25 °C (80 °F) and warm engine start position. NOTE: This model is equipped with an ignition circuit cut-off system. The engine can be started under the following conditions. ● When the transmission is in neutral. The neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it. ● When the clutch is disengaged with the transmission in any position.
NOTE: If the engine fails to start, release the start switch, then push it again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. CAUTION: See the “Engine break-in” section prior to operating engine for the first time. 7. If the engine is started with the starter (choke) in position 1, the starter (choke) should be returned to position 2 to warm up the engine.
EBU00180 Starting a warm engine To start a warm engine, refer to the “Starting a cold engine” section. The starter (choke) should not be used. The throttle should be opened slightly. EBU00538 Warming up To get maximum engine life, always warm up the engine before starting off. Never accelerate hard with a cold engine! To see whether or not the engine is warm, check if it responds to the throttle normally with the starter (choke) turned off.
EBU00790 Reverse knob operation and reverse driving CAUTION: Before shifting, stop the machine and return the throttle lever to its closed position. Otherwise the transmission may be damaged. 1. Bring the machine to a complete stop, return the throttle lever to the closed position, apply the clutch lever, and shift the transmission into first gear. 2. While applying the rear brake pedal, turn the reverse knob clockwise with your right hand. 3.
EBU00199 Shifting This model has a 5-speed forward and 1-speed reverse transmission. The transmission allows you to control the amount of power you have available at a given speed or for starting, accelerating, climbing hills, etc. To shift into neutral, return the throttle lever to its original position, apply the clutch and repeatedly depress the shift pedal until it stops. When it stops, it will be in first gear. Raise the pedal slightly to neutral.
EBU00203 To start out and accelerate: 1. Release the throttle lever. CAUTION: _ ● ● Do not coast for long periods with the engine off, and do not tow the machine a long distance. Even in neutral position, the transmission is only properly lubricated when the engine is running. Inadequate lubrication may cause damage. Always use the clutch when changing gears.
EBU00207 To decelerate: When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possibility of an accident. 8. Follow the same procedure when shifting to the next higher gear.
EBU00209 Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours, the various parts in the engine wear and polish themselves to the correct operating clearances.
EBU00211 Parking When parking, stop the engine and shift into neutral. Turn the fuel cock to “OFF” and apply the parking brake. 1. Locked position 1. Button 2.
EBU00992 Parking on a slope 1. Bring the machine to a stop by applying the brakes in low gear. 2. Stop the engine and release the clutch lever. 3. With the front and rear brakes applied, apply the parking brake and slowly release the brake pedal. WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines.
EBU00221 Accessories and loading ● EBU00222 Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. ● Choose only accessories designed for your ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories may also be available on the market.
EBU00584 Loading As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment. Keep the following points in mind: ● Never exceed the weight limits shown. An overloaded ATV can be unstable.
WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.
EBU00929 WARNING _ Indicates a potential hazard that could result in serious injury or death.
Riding 1- Your ATV 7-1 7
7-2
WARNING _ Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is intended for recreational use by experienced operators only. Even though you are an experienced operator of all other all terrain vehicles or motorcycles, riding the ATV requires special skills acquired through practice. Take your time to fully learn techniques before attempting more difficult maneuvers. the operation of the controls.
RIDE WITH CARE AND GOOD JUDGEMENT HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Yamaha. They should then regularly practice the skills learned in the course and the operating techniques described in this Owner’s Manual. For more information about the training course, contact an authorized ATV dealer or call 1-800-887-2887. Get training if you are inexperienced. Beginners should get training from a certified instructor.
Not recommended for children under 16 years of age. WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc.
This ATV is designed to carry operator only - passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/ or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.
Apparel Operating without protective clothing increases your chances of severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection (goggles or face shield) gloves boots long-sleeved shirt or jacket long pants WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing.
Do not operate after consuming alcohol or drugs. Operator’s performance capability is reduced by the influence of alcohol or drugs. WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
Pre-operation checks Always perform the pre-operation checks listed on page 5-1 before riding for safety and proper care of the ATV. WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident.
Speed limiter For riders inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter limits the power and top speed of the ATV. Turning the screw in decreases top speed, and turning it out increases top speed. WARNING _ Indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions.
Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The ATV’s handling may be adversely affected. Reduce your speed when adding additional loads. WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV.
Avoid wheelies and jumping. You may lose control of the ATV or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
Modifications WARNING POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories.
Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. WARNING POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine area could catch fire. Someone touching the exhaust system during or after operation could be burned.
BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets.
Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control.
WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.
When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. WHAT CAN HAPPEN You could be in a collision. You could be injured. HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles. Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission.
With the engine idling, pull the clutch lever to disengage the clutch and shift into 1st gear, and then release the parking brake. Open the throttle gradually, and at the same time, release the clutch lever slowly. Once the ATV has attained adequate speed, release the throttle lever and at the same time, quickly pull in the clutch lever and shift into 2nd gear. Open the throttle part way and gradually release the clutch. Use this same procedure as you move into the higher gears.
When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improper use of the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possibility of an accident. WARNING POTENTIAL HAZARD Opening the throttle abruptly or releasing the clutch lever to quickly. WHAT CAN HAPPEN The ATV could wheelie.
TURNING YOUR ATV To achieve maximum traction while riding offroad, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed.
Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside. It may also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over.
CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control. HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities.
WARNING An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner’s Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward.
If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then descend the hill. WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in the ATV overturning.
Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner’s Manual.
RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the engine compression to do most of the braking for you. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces.
7-31
CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance. WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.
Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and carefully. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.
Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. CAUTION: _ After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the ATV in fresh water if it has been operated in salt water or muddy conditions. _ 1.
RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn.
7-37
SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. If the rear wheels of your ATV start to slide sideways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide.
With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost. WARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV.
WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. ● WHAT TO DO ... ● If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See pages 7-23 ~ 7-24.
● ● If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 7-32 ~ 7-33.) If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles.
EBU00515 PERIODIC MAINTENANCE AND ADJUSTMENT Have a Yamaha dealer perform service if you are not familiar with machine service. Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages.
The service information included in this manual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor repairs. The tools provided in the Owner’s tool kit are sufficient for this purpose, except that a torque wrench is also necessary to properly tighten nuts and bolts. WARNING POTENTIAL HAZARD Operating this ATV with improper modifications.
EBU00261 PERIODIC MAINTENANCE/LUBRICATION ITEM Valves* Cooling system Spark plug Air filter element Carburetors* Crankcase breather system* Exhaust system* Spark arrester Fuel line* Engine oil Engine oil filter cartridge Drive chain • • • • • • • • • • • • • • • • • • • • • • • • Front brake Rear brake* Clutch* INITIAL EVERY 1 3 6 6 1 month months months months year ROUTINE • • • • • Check valve clearance. Adjust if necessary. Check coolant leakage. Repair if necessary.
ITEM Wheels* Wheel bearings* Steering system* INITIAL EVERY 1 3 6 6 1 month months months months year ROUTINE • • • • • • • • Check balance/damage/runout. Replace if necessary. Check bearing assembly for looseness/damage. Replace if damaged. Check operation. Repair if damaged. Check toe-in. Adjust if necessary. Upper and lower arm piv- • Lubricate every 6 months.** ot and steering shaft* Rear arm pivot* • Lubricate every 6 months.** • Check all chassis fittings and fasteners.
EBU00807 EBU01013 Panel removal and installation Panel A 1. Panel A 1. Panel A The panel illustrated needs to be removed to perform some of the maintenance described in this chapter. Refer to this section each time the panel has to be removed or installed. To remove Remove the bolts, and then take the panel off. 2. Bolt (× 2) To install Place the panel in the original position, and then install the bolts.
EBU01014 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. 3. Wait a few minutes until the oil settles, remove the engine oil tank filler cap, wipe the dipstick clean with a clean rag, insert it back into the filler hole (without screwing it in), and then remove it again to check the oil level.
To change the engine oil (with or without oil filter cartridge replacement) 4. If the engine oil is below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. NOTE: When adding oil, be careful not to overfill the engine oil tank; the oil level rises faster starting from the half-level-portion on the dipstick. _ _ 5. Insert the dipstick into the oil filler hole, and then tighten the oil filler cap. CAUTION: 1.
4. Remove the crankcase engine oil drain bolt. 1. Engine oil tank drain bolt 5. Remove the engine oil tank filler cap and the oil tank drain bolt. 6. Check the washers for damage, and replace if necessary. 1.
NOTE: Skip steps 7–8 if the oil filter cartridge is not being replaced. _ _ 7. Remove the oil filter cartridge with an oil filter wrench. 1. O-ring 8. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. NOTE: Make sure that the O-ring is properly seated. _ _ 1. Oil filter cartridge 2. Oil filter wrench 9. Install a new oil filter cartridge and tighten it to the specified torque with a torque wrench. NOTE: An oil filter wrench is available at a nearby Yamaha dealer.
10. Install the crankcase engine oil drain bolt and the engine oil tank drain bolt, then tighten them to the specified torques. CAUTION: _ ● Tightening torques: Crankcase engine oil drain bolt: 30 Nm (3.0 m·kgf, 22 ft·lb) Engine oil tank drain bolt: 25 Nm (2.5 m·kgf, 18 ft·lb) ● 11. Add sufficient oil of the recommended type to raise it to the correct level, and then install and tighten the oil tank filler cap.
EBU01015 Cooling system 1. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature. The coolant level should be between the maximum and minimum marks. Coolant reservoir capacity: 0.29 L (0.26 Imp qt, 0.31 US qt) CAUTION: _ Hard water or salt water is harmful to the engine. You may use soft water if you can’t get distilled water.
EBU01016 Changing the coolant 1. Place the ATV on a level surface. 2. Remove panel A. (See page 8-5 for panel removal and installation procedures.) 3. Place a container under the engine, and then remove the coolant drain bolt. WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap.
4. Remove the radiator cap. 5. Remove the coolant reservoir cap. 6. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir. 1. Radiator cap 1. Coolant reservoir cap 2. Hose 7. After draining the coolant, thoroughly flush the cooling system with clean tap water. 8. Replace the coolant drain bolt washer if it is damaged, and then tighten the coolant drain bolt to the specified torque.
CAUTION: Tightening torque: Coolant drain bolt: 10 Nm (1.0 m·kgf, 7 ft·lb) _ Hard water or salt water is harmful to the engine. You may use soft water if you cannot get distilled water. 9. Install the coolant reservoir hose. 10. Pour the recommended coolant into the radiator until it is full. 11. Fill the coolant reservoir with coolant up to the maximum level. _ 12. Install the radiator cap and the coolant reservoir cap. 13. Start the engine and let it idle for several minutes.
EBU00680 Spark plug inspection Removal 1. Remove the spark plug cap. 2. Use the spark plug wrench in the tool kit to remove the spark plug as shown. Inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. The ideal color on the white insulator around the center electrode is a medium-to-light tan color for a ATV that is being ridden normally. Do not attempt to diagnose such problems yourself.
Installation 1. Measure the electrode gap with a wire thickness gauge and, if necessary, adjust the gap to specification. Tightening torque: Spark plug: 17.5 Nm (1.75 m·kgf, 12.7 ft·lb) NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible. Spark plug gap: 0.8 ~ 0.9 mm (0.03 ~ 0.04 in) _ _ 4. Install the spark plug cap. a.
EBU00792 Air filter element cleaning NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. 1. Air filter case cover 2. Holder (× 6) 3. Remove the air filter element and remove it from its frame. 1. Check hose 1. Remove the seat. (See page 4-14 for seat removal procedure.) 2. Remove the air filter case cover by unhooking the holders. 1. Unlock 8-17 2.
WARNING 1. Frame 3. Element retaining plate POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element. 2. Air filter element 4. Wash the element gently but thoroughly in solvent. 5. Squeeze the excess solvent out of the filter element and let it dry.
7. Apply Yamaha foam air filter oil or other quality foam air filter oil to the element. If foam air filter oil is not available, motor oil may be used. NOTE: The air filter element should be cleaned every 20 ~ 40 hours. It should be cleaned and lubricated more often if the machine is operated in extremely dusty areas. Each time the filter element maintenance is performed, check the air inlet to the filter case for obstructions.
EBU00780 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolt. 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe. 1. Bolt 1. Tailpipe 2. Spark arrester 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install the bolt and tighten it.
EBU00296 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idling speed may be performed by the owner as a part of the usual maintenance routine. WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system WHAT CAN HAPPEN Could injure the eyes. Could cause burns.
EBU00301 Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Connect the tachometer and set the idle to the specified idling speed by adjusting the throttle stop screw. Turn the screw in to increase engine speed, and out to decrease engine speed. 1.
EBU00303 EBU00307 Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician. Throttle lever adjustment NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play is 3 ~ 5 mm (0.
EBU00983 Front and rear brake pad inspection Each brake pad is provided with a wear indicator groove. The indicators allow checking of brake pad wear without disassembling the brake. Apply the brake and inspect the wear indicators grooves. If the pad is worn to the point that the wear indicator grooves are almost in contact with the disc plate, ask a Yamaha dealer to replace the pads. Rear 1.
Rear 1. Reservoir cover 2. Bolt (× 2) 1. Minimum level mark Observe these precautions: ● When checking the fluid level, make sure the top of the brake fluid reservoir is level. ● Use only the designated quality brake fluid. Otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. Front Recommended brake fluid: DOT 4 ● 1. Minimum level mark 8-25 Refill with the same type of brake fluid.
● ● ● Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. Have a Yamaha dealer check the cause if the brake fluid level goes down. WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes.
EBU00623 Front brake adjustment The front brake lever should have a free play of 0 mm (0.0 in) at the lever end. If not, ask a Yamaha dealer to adjust it. WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: sure the brakes operate ● Make smoothly and that the free play is correct. ● Make sure the brakes do not drag. ● Make sure the brakes are not spongy.
EBU00920 Rear brake adjustment Pedal height adjustment The top of the brake pedal should be positioned 4 mm (0.16 in) below the top of the footrest. If not, ask a Yamaha dealer to adjust it. WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: sure the brakes operate ● Make smoothly and that the brake pedal position is correct.
EBU00932 Parking brake adjustment Parking brake adjustment may be required if the parking brake does not hold properly. 1. Fully loosen the parking brake cable adjusting bolt locknut and the adjusting bolt on the clutch lever. 1. Locknut a. Cable length 2. Adjusting bolt 3. Turn the adjusting bolt on the clutch lever so that cable length a is 64 ~ 68 mm (2.52 ~ 2.68 in). NOTE: If the cable cannot be adjusted to specification, consult a Yamaha dealer. _ 1. Locknut 2. Adjusting bolt 2.
5. Screw in the adjusting bolt on the brake caliper by hand until it feels tight, then screw it out 1/8 turn. Tighten the adjusting bolt locknut to the specified torque. WARNING POTENTIAL HAZARD Operating with improperly adjusted brakes. WHAT CAN HAPPEN The brakes could malfunction, causing reduced braking performance. This could increase the chance of a collision or accident. HOW TO AVOID THE HAZARD After adjusting the parking brake, block the rear of the machine off the ground and spin the rear wheels.
EBU00833 EBU00741 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and brake lever, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. Turn the adjusting nut while holding the rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction a.
6. Loosen the locknut at the crankcase side. 7. Turn the adjusting nut at the crankcase in direction a to increase the free play or in direction b to decrease the free play. 8. Tighten the locknut at the crankcase and the clutch lever. 1. Locknut c. Free play 2. Adjusting bolt 1. Locknut 8-32 2.
EBU00350 EBU00917 Drive chain slack check Inspect the drive chain while all tires are touching the ground. Check the slack at the position shown in the figure. The normal vertical deflection is approximately 27 ~ 37 mm (1.1 ~ 1.5 in). If the deflection exceeds 37 mm (1.5 in), adjust the chain slack. Drive chain slack adjustment 1. Loosen the rear wheel hub upper and lower nuts. 1. Upper wheel hub nut 2. Lower wheel hub nut 2. Loosen the adjusting bolt locknuts on each side of the swingarm.
There are alignment marks on each side of the swingarm and on the hub. Use them to check for proper wheel axle alignment. 1. Locknut (× 2) 3. Alignment marks Tightening torque: Locknut: 16 Nm (1.6 m·kgf, 12 ft·lb) Upper wheel hub nut: 90 Nm (9.0 m·kgf, 65 ft·lb) Lower wheel hub nut: 90 Nm (9.0 m·kgf, 65 ft·lb) 2. Adjusting bolt (× 2) 3. After adjusting, tighten the adjusting bolt locknuts and the wheel hub nuts to the specified torques.
EBU00805 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. 1. Clean the drive chain with kerosene and a small soft brush. CAUTION: To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate solvents. 2.
EBU00356 Cable inspection and lubrication Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury. HOW TO AVOID THE HAZARD Inspect cables frequently. Replace damaged cables.
EBU01018 Front upper and lower arm pivot lubrication Lubricate the upper and lower arm pivots. Right side Recommended lubricant: Lithium-soap-based grease Left side 1. Upper 1. Upper 2. Lower 8-37 2.
EBU01019 Rear arm pivot lubrication Lubricate the rear arm pivot.
EBU00373 Wheel removal 1. Elevate the wheel by placing a suitable stand under the frame. 2. Remove the nuts from the wheel. 3. Remove the wheel assembly. Rear Front 1. Nut (× 4) 1.
EBU00782 Rear Wheel installation When installing a wheel, reverse the removal procedure. NOTE: ● When installing a front wheel, the arrow mark on the tire must point toward the rotating direction of the wheel. ● When installing a rear wheel, the wording on the tire “SIDE FACING OUTWARDS” must be facing outwards. 1. “SIDE FACING OUTWARDS” Tighten the wheel nuts to the specified torque. Front Wheel nut torque: Front: 45 Nm (4.5 m·kgf, 33 ft·lb) Rear: 45 Nm (4.5 m·kgf, 33 ft·lb) 1.
EBU00380 Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a Yamaha dealer. HOW TO AVOID THE HAZARD Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of reach of children. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk.
EBU00385 EBU00390 Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. Fuse replacement 1. The fuse case is located under the seat. 2. If the fuse is blown, turn off the main switch and install a new fuse of the specified amperage. Then turn on the switches. If the fuse immediately blows again, consult a Yamaha dealer.
EBU01020 Replacing a headlight bulb 1. Remove the headlight assembly by removing the bolts. WARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse. CAUTION: 1. Headlight assembly To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 8-43 2.
2. Disconnect the headlight coupler. 3. Remove the screw. 1. Headlight coupler 1. Screw 4. Remove the headlight cover from the headlight assembly.
NOTE: Pull outward on the rear of the headlight unit, and then pull outward on the front. 5. Remove the screw and pull the headlight unit out from its case. _ _ 6. Remove the headlight bulb holder cover. 1. Screw 1. Headlight bulb holder cover 1. Headlight unit 2.
7. Push the headlight bulb holder inward, turn it counterclockwise and remove the defective bulb. WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it. 1.
8. Put a new headlight bulb into position and secure it in place with the bulb holder. 1. Headlight bulb 10. Align the projections with the holders, install the headlight unit into the case, and install the screw. 11. Install the headlight cover in the original position, and then install the screw. 12. Connect the headlight coupler. 13. Install the headlight assembly in the original position and tighten the bolts. 14. Have a Yamaha dealer adjust the headlight beam if necessary. 2.
EBU01021 Tail/brake light bulb replacement 1. Remove the screws and the lens. 1. Bulb 1. Lens 3. Install a new bulb by pushing it inward and turning it clockwise. 4. Install the lens and tighten the screws. 2. Screw (× 2) 2. Remove the defective bulb by pushing it inward and turning it counterclockwise. CAUTION: _ Do not overtighten the screws as the lens may break.
EBU00412 Troubleshooting Although Yamaha machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a Yamaha dealer.
EBU00806 Troubleshooting charts Starting problems or poor engine performance Turn the fuel cock lever to “ON”. There is fuel. Turn the fuel cock lever to “OFF”. Remove the fuel hose from the fuel cock. Some fuel. Turn the fuel cock lever to “RES”. Restart the engine. No fuel. Supply fuel. 1. Fuel Check if there is fuel in the fuel tank. 2. Compression Use the electric starter to see if there is compression. 3. Ignition There is compression. Compression normal. No compression.
Engine overheating WARNING HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap. Always use a thick rag over the cap. Allow any remaining pressure to escape before completely removing the cap. POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. Leakage. Ask a Yamaha dealer to inspect and repair the cooling system. No leakage. Add coolant. (See NOTE.
EBU00417 CLEANING AND STORAGE CAUTION: Excessive water pressure may cause water seepage and deterioration of wheel bearings, brakes, transmission seals and electrical devices. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers. A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1.
7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes. WARNING POTENTIAL HAZARD Operation with wet brakes after washing. WHAT CAN HAPPEN Wet brakes may have reduced stopping ability, increasing the chance of an accident.
EBU00525 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive procedures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equivalent product. 2. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug.
8. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0°C (30°F) or more than 30°C (90°F)). NOTE: Make any necessary repairs before storing the machine.
EBU00428 SPECIFICATIONS MODEL YFM660R Dimension: Overall length Overall width Overall height Seat height Wheel base Ground clearance Minimum turning radius 1,830 mm ( 72 in) 1,100 mm ( 43.3 in) 1,150 mm ( 45.3 in) 860 mm ( 33.9 in) 1,245 mm ( 49 in) 265 mm ( 10.4 in) 3,300 mm ( 129.
MODEL YFM660R Engine oil: Type 0˚ 10˚ 30˚ 50˚ 70˚ 90˚ 110˚ 130˚F 1 2 YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 3 4 SAE 5W30 -20˚ Recommended engine oil classification: -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C API Service SE, SF, SG type or higher CAUTION: Be sure to use motor oils that do not contain antifriction modifiers.
MODEL YFM660R Radiator capacity (including all routes): 1.3 L (1.14 lmp qt, 1.37 US qt) Air filter: Wet type element Fuel: Type Tank capacity Reserve amount UNLEADED GASOLINE ONLY 12 L (2.64 Imp gal, 3.17 US gal) 2.6 L (0.57 Imp gal, 0.69 US gal) Carburetor: Type × quantity Manufacturer BSR33 × 2 MIKUNI Spark plug: Type/manufacturer Gap DPR8EA-9/NGK 0.8 ~ 0.9 mm (0.03 ~ 0.
MODEL YFM660R Gear ratio: 31/12 (2.583) 30/18 (1.667) 27/21 (1.286) 22/21 (1.047) 19/21 (0.904) 33/25 × 25/18 (1.833) 1st 2nd 3rd 4th 5th Reverse Chassis: Frame type Caster angle Trail Steel tube 8° 47 mm (1.
MODEL YFM660R Wheel travel: Front Rear 230 mm (9.06 in) 220 mm (8.66 in) Electrical: Ignition system Generator system Battery type/voltage capacity DC-C.D.I. A.C. magneto YTX14-BS/12V, 12Ah Headlight type: Krypton bulb Bulb voltage, wattage × quantity: Headlight Tail/brake light Indicator/warning lights: Neutral Reverse Coolant temperature 12V, 30W/30W × 2 12V, 5W/21W × 1 12V, 1.7W × 1 12V, 1.7W × 1 12V, 1.
EBU00430 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has b
EBU00431 MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.
EBU00432 YAMAHA MOTOR CORPORATION, U.S.A.
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EBU00435 YAMAHA EXTENDED SERVICE (Y.E.S.
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EBU00436 WARNING Indicates a potential hazard that could result in serious injury or death.
EBU00437 14-5
EBU00438 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: • without proper training or instruction. • use proper riding techniques to avoid • at speeds too fast for your skills or vehicle overturns on hills and rough terrain and in turns. the conditions.
