Yamaha YFM660RP 5LP2-AE2 2002 User manual

YFM660R(P)
SUPPLEMENTARY
SERVICE MANUAL
5LP2-AE2
2002

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and new data for
the YFM660R(P) 2002. For complete information on service procedures, it is necessary to use this
Supplementary Service Manual together with the following manual.
YFM660R(N) 2001 SERVICE MANUAL: 5LP2-AE1
YFM660R(P) 2002
SUPPLEMENTARY
SERVICE MANUAL
©2001 by Yamaha Motor Co., Ltd.
First Edition, August 2001
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

EB001000
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha machine has a basic understanding of the mechanical ideas and the procedures of
machine repair. Repairs attempted by anyone without this knowledge are likely to render the
machine unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
N
OTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
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.
A CAUTION indicates special precautions that must be taken to avoid dam-
age to the machine.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
N
O
TE:

EB002000
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram 4is provided for removal and disassembly jobs.
2. Numbers 5are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8are given in addition
to the exploded diagram and the job instruction chart.

EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1to 9are printed on the
top right of each page and indicate the subject
of each chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Cooling system
7Carburetion
8Electrical
9Troubleshooting
Illustrated symbols 0to Gare used to identify
the specifications appearing in the text.
0Can be serviced with engine mounted
AFilling fluid
BLubricant
CSpecial tool
DTorque
EWear limit, clearance
FEngine speed
GΩ, V, A
Illustrated symbols Hto Nin the exploded
diagrams indicate the types of lubricants and
lubrication points.
HApply engine oil
IApply gear oil
JApply molybdenum disulfide oil
KApply wheel bearing grease
LApply lightweight lithium soap base grease
MApply molybdenum disulfide grease
NApply silicon grease
Illustrated symbols Oto Pin the exploded
diagrams indicate where to apply a locking
agent Oand when to install a new part P.
OApply the locking agent (LOCTITE)
PReplace
12
34
56
78
90
AB
CD
EFG
HIJ
K
OP
GEN
INFO SPEC
CHK
ADJ
CHAS
ENG
COOL
CARB
–+
ELEC
TRBL
SHTG
T
R
.
.
EGM
BLS MS
LMN
LT New

CONTENTS
SPECIFICATIONS ............................................................................................1
GENERAL SPECIFICATIONS ..................................................................1
MAINTENANCE SPECIFICATIONS .........................................................2
ENGINE ................................................................................................2
CHASSIS ..............................................................................................6
CABLE ROUTING .....................................................................................7
PERIODIC CHECKS AND ADJUSTMENTS ....................................................9
INTRODUCTION .......................................................................................9
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ........................9
CHASSIS .................................................................................................11
ADJUSTING THE REAR SHOCK ABSORBER ..................................11
CHASSIS ........................................................................................................14
REAR SHOCK ABSORBER AND RELAY ARM .....................................14
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER .........................................................................16
DISPOSING OF A REAR SHOCK ABSORBER
AND GAS CYLINDER .........................................................................16
REMOVING THE REAR SHOCK ABSORBER ...................................17
CHECKING THE REAR SHOCK ABSORBER ...................................17
CHECKING THE RELAY ARM AND CONNECTING ARM ................17
INSTALLING THE RELAY ARM AND CONNECTING ARM ..............18
INSTALLING THE REAR SHOCK ABSORBER .................................18
SWINGARM AND DRIVE CHAIN ...........................................................19
ENGINE ..........................................................................................................21
ENGINE REMOVAL ................................................................................21
INSTALLING THE ENGINE ................................................................21
AC MAGNETO ........................................................................................22
YFM660R(P) 2002 WIRING DIAGRAM

–1 –
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model code: 5LP6 : (For CDN)
5LP7 : (For Europe)
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 71/34 (2.088)
Secondary reduction system Chain drive
Secondary reduction ratio 40/13 (3.076)
Transmission type Constant mesh, 5-speed/forward.
1-speed/reverse
Operation Left foot operation
Gear ratio
1st gear 31/12 (2.583)
2nd gear 30/18 (1.667)
3rd gear 27/21 (1.286)
4th gear 22/21 (1.047)
5th gear 19/21 (0.904)
Reverse gear 33/25 ×25/18 (1.833)
GENERAL SPECIFICATIONS

–2 –
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ---- 0.03 mm
(0.001 in)
Timing chain:
Timing chain type/No. of links 82RH2015/126 ----
Timing chain adjustment method Automatic ----
Rocker arm/rocker arm shaft:
Bearing inside diameter 12.000 ~ 12.018 mm
(0.4724 ~ 0.4731 in)
----
Shaft outside diameter 11.976 ~ 11.991 mm
(0.4715 ~ 0.4721 in)
----
Arm-to-shaft clearance 0.009 ~ 0.042 mm
(0.0004 ~ 0.0017 in)
----
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.10 ~ 0.15 mm
(0.0039 ~ 0.0059 in)
----
EX 0.15 ~ 0.20 mm
(0.0059 ~ 0.0079 in)
----
Valve dimensions
“A”head diameter IN 29.9 ~ 30.1 mm
(1.1772 ~ 1.1850 in)
----
EX 31.9 ~ 32.1 mm
(1.2559 ~ 1.2638 in)
----
“B”face width IN 2.25 mm (0.0886 in) ----
EX 2.26 mm (0.0890 in) ----
“C”seat width IN 1.1 ~ 1.3 mm
(0.0433 ~ 0.0512 in)
1.6 mm
(0.0630 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
1.6 mm
(0.0630 in)
“D”margin thickness IN 0.85 ~ 1.15 mm
(0.0335 ~ 0.0453 in)
----
EX 0.85 ~ 1.15 mm
(0.0335 ~ 0.0453 in)
----
BC
D
A
Head Diameter Face Width Seat Width Margin Thickness
MAINTENANCE SPECIFICATIONS