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

–3 –
SPEC
Stem outside diameter IN 5.975 ~ 5.990 mm
(0.2352 ~ 0.2358 in)
5.945 mm
(0.2341 in)
EX 5.960 ~ 5.975 mm
(0.2346 ~ 0.2352 in)
5.930 mm
(0.2335 in)
Guide inside diameter IN 6.000 ~ 6.012 mm
(0.2362 ~ 0.2367 in)
6.040 mm
(0.2378 in)
EX 6.000 ~ 6.012 mm
(0.2362 ~ 0.2367 in)
6.040 mm
(0.2378 in)
Stem-to-guide clearance IN 0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
0.08 mm
(0.0031 in)
EX 0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)
0.10 mm
(0.0039 in)
Stem runout limit ---- 0.01 mm
(0.0004 in)
Valve 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)
Piston:
Piston to cylinder clearance 0.05 ~ 0.07 mm
(0.0020 ~ 0.0028 in)
0.15 mm
(0.0059 in)
Piston size “D”99.945 ~ 99.995 mm
(3.9348 ~ 3.9368 in)
----
Measuring point “H”2.5 mm (0.10 in) ----
Piston off-set 1.0 mm (0.04 in) ----
Off-set direction Intake side ----
Piston pin bore inside diameter 22.004 ~ 22.015 mm
(0.8663 ~ 0.8667 in)
22.045 mm
(0.8679 in)
Piston pin outside diameter 21.991 ~ 22.000 mm
(0.8658 ~ 0.8661 in)
21.971 mm
(0.8650 in)
Item Standard Limit
H
D
MAINTENANCE SPECIFICATIONS

–4 –
SPEC
Piston rings:
Top ring
Type Barrel ----
Dimensions (B ×T) 1.2 ×3.8 mm
(0.0472 ×0.1496 in)
----
End gap (installed) 0.30 ~ 0.45 mm
(0.0118 ~ 0.0177 in)
0.70 mm
(0.0276 in)
Side clearance (installed) 0.04 ~ 0.08 mm
(0.0016 ~ 0.0031 in)
0.13 mm
(0.0051 in)
2nd ring
Type Taper ----
Dimensions (B ×T) 1.2 ×4.0 mm
(0.0472 ×0.1575 in)
----
End gap (installed) 0.30 ~ 0.45 mm
(0.0118 ~ 0.0177 in)
0.80 mm
(0.0315 in)
Side clearance 0.03 ~ 0.07 mm
(0.0012 ~ 0.0028 in)
0.13 mm
(0.0051 in)
Oil ring
Dimensions (B ×T) 2.5 ×3.4 mm
(0.0984 ×0.1339 in)
----
End gap (installed) 0.2 ~ 0.7 mm
(0.0079 ~ 0.0276 in)
----
Side clearance 0.06 ~ 0.15 mm
(0.0024 ~ 0.0059 in)
----
Item Standard Limit
T
B
B
T
B
T
MAINTENANCE SPECIFICATIONS

–5 –
SPEC
Tightening torques
Carburetors:
I. D. mark 5LP5 20 ----
Main jet (M.J) Carburetor #1 : #140
Carburetor #2 : #145
----
----
Main air jet (M.A.J) #130 ----
Jet needle (J.N) 5ND16-56-3 ----
Needle jet (N.J) P-6M (#826) ----
Pilot air jet (P.A.J.1) Carburetor #1 : #80
Carburetor #2 : #150
----
----
Pilot air jet (P.A.J.2) 1.3 ----
Pilot outlet (P.O) Carburetor #1 : 1.0
Carburetor #2 : 0.9
----
----
Pilot jet (P.J) #22.5 ----
Bypass 1 (B.P.1) 0.8 ----
Bypass 2 (B.P.2) 0.8 ----
Valve seat size (V.S) 2.0 ----
Starter jet (G.S.1) #95 ----
Starter jet (G.S.2) 0.5 ----
Throttle valve size (Th.V) #80 ----
Float height (F.H) 13 mm (0.51 in) ----
Fuel level (F.L) 3 ~ 4 mm (0.12 ~ 0.16 in) ----
Engine idle speed 1,450 ~ 1,550 r/min ----
Intake vacuum 32.0 ~ 33.3 kPa (240 ~ 250 mmHg,
9.45 ~ 9.83 inHg)
----
Part to be tightened Part
name
Thread
size Q’ty Tightening torque Remarks
Nm m·kg ft·lb
Air filter case Bolt M6 2 9 0.9 6.5
Carburetor clamp Bolt M4 4 4 0.4 2.9
Muffler and exhaust pipe 2 Bolt M8 1 18 1.8 13
Muffler Bolt M8 2 33 3.3 24
AC magneto rotor Nut M14 1 140 14.0 100
Item Standard Limit
MAINTENANCE SPECIFICATIONS

–6 –
SPEC
CHASSIS
Tightening torques
Item Standard Limit
Brake lever and brake pedal:
Brake lever free play (at lever end) 0 mm (0 in) ----
Brake pedal position 4 mm (0.16 in)
(Below the top of footrest)
----
Throttle lever free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----
Part to be tightened Thread size Tightening torque Remarks
Nm m·kg ft·lb
Rear shock absorber and frame M12 80 8.0 58
Relay arm and swingarm M10 43 4.3 31
Connecting arm and frame M12 80 8.0 58
Relay arm and rear shock absorber M10 43 4.3 31
Relay arm and connecting arm M10 43 4.3 31
Steering stem, pitman arm and frame M14 180 18 130
Frame and bearing retainer M42 65 6.5 47
Rear brake fluid reservoir cover and bracket M6 11 1.1 8.0
Rear carrier bar and frame M8 33 3.3 24
Footrest guard bracket and frame M8 26 2.6 19
Air filter case and frame M6 9 0.9 6.5
Carburetor clamp screw M4 4 0.4 2.9
MAINTENANCE SPECIFICATIONS

–7 –
SPEC
CABLE ROUTING
1Carburetor air vent hose
2Coolant reservoir hose
3Reservoir tank breather hose
4CDI unit
5Wire harness
6Rectifier/regulator
7Negative battery lead
8AC magneto lead
9Starter motor lead
0Tail/brake light lead
ARectifier/regulator lead
ÈPass the negative battery lead between the wire
harness and frame.
É25 ~ 35 mm (0.98 ~ 1.38 in)
Ê50 ~ 60 mm (1.97 ~ 2.36 in)
Ë50 ~ 70 mm (1.97 ~ 2.76 in)
CABLE ROUTING

–8 –
SPEC
1Positive battery lead
2Tail/brake light lead
3Coolant reservoir breather hose
4Negative battery lead
5Coolant reservoir hose
6Starter motor lead
7Wire harness
ÈFasten the wire harness with the plastic clamp.
ÉFasten the starter motor lead and starter relay
lead with the plastic clamp.
CABLE ROUTING

–9 –
CHK
ADJ
INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
EB300000
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle
operation and a longer service life. The need for costly overhaul work will be greatly reduced. This
information applies to vehicles already in service as well as to new vehicles that are being prepared
for sale. All service technicians should be familiar with this entire chapter.
EB301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
* It is recommended that these items be serviced by a Yamaha dealer.
** Lithium soap base grease
ITEM ROUTINE
INITIAL EVERY
1
month
3
months
6
months
6
months
1
year
Valves* •Check valve clearance.
•Adjust if necessary.
Cooling system
•Check coolant leakage.
•Repair if necessary.
•Replace coolant every 24 months.
Spark plug
•Check condition.
•Adjust gap and clean.
•Replace if necessary.
Air filter element •Clean.
•Replace if necessary.
Every 20 ~ 40 hours
(More often in wet or dusty areas.)
Carburetors* •Check starter (choke) operation.
•Adjust engine idling speed and synchronization.
Crankcase breather
system*
•Check breather hose for cracks or damage.
•Replace if necessary.
Exhaust system*
•Check for leakage.
•Tighten if necessary.
•Replace gasket if necessary.
Fuel line* •Check fuel hose for cracks or damage.
•Replace if necessary.
Engine oil •Replace (Warm engine before draining).
Engine oil filter car-
tridge •Replace if necessary.
Drive chain •Check and adjust slack/alignment/clean/lube.
Front brake
•Check free play/operation/fluid leakage/See NOTE
Page 10.
•Correct if necessary.
Rear brake* •Check operation/fluid leakage/See NOTE Page 10.
•Correct if necessary.
Clutch* •Check operation.
•Adjust if necessary.
Wheels* •Check balance/damage/runout.
•Replace if necessary.
Wheel bearings* •Check bearing assembly for looseness/damage.
•Replace if damaged.
Steering system*
•Check operation.
•Repair if damaged.
•Check toe-in.
•Adjust if necessary.
Upper and lower arm
pivot and steering
shaft*
•Lubricate every 6 months.**
Rear arm pivot* •Lubricate every 6 months.**
Fittings and fasten-
ers*
•Check all chassis fittings and fasteners.
•Correct if necessary.

–10 –
CHK
ADJ
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
NOTE:
●Recommended brake fluid: DOT 4
●Brake fluid replacement:
1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid.
Normally check the brake fluid level and add fluid as required.
2.On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two
years.
3.Replace the brake hoses every four years, or if cracked or damaged.

–11 –
CHK
ADJ
CHASSIS
ADJUSTING THE REAR SHOCK
ABSORBER
1.Adjust:
●Spring preload
***********************************************
Adjustment steps:
●Elevate the rear wheels by placing a suitable
stand under the frame.
●Loosen the locknut 1.
●Turn the adjusting ring 2in direction aor
b.
NOTE:
●Be sure to remove all dirt and mud from
around the locknut and adjusting ring before
adjustment.
●The length of the spring (installed) changes
1.5 mm (0.06 in) per turn of the adjuster.
CAUTION:
Never attempt to turn the adjusting ring
beyond the maximum or minimum setting.
●Tighten the locknut 1.
NOTE:
Always tighten the locknut against the adjust-
ing ring, then torque it to specification.
***********************************************
Direction a
Spring preload is
increased (suspension
is harder).
Direction b
Spring preload is
decreased (suspension
is softer).
Adjusting length c:
Standard: 240 mm (9.45 in)
Minimum: 232 mm (9.13 in)
Maximum: 247 mm (9.72 in)
T
R
.
.
Locknut:
42 Nm (4.2 m •kg, 30 ft •lb)
ADJUSTING THE REAR SHOCK ABSORBER

–12 –
CHK
ADJ
2.Adjust:
●Rebound damping force
***********************************************
Adjustment steps:
●Turn the adjusting screw 1in direction aor
b.
CAUTION:
Do not force the adjuster past the minimum
or maximum extent of adjustment. The
adjuster may be damaged.
***********************************************
Direction aRebound damping force
is increased.
Direction bRebound damping force
is decreased.
From the fully turned-out position:
Standard: 7 clicks in
Minimum: 1 clicks in
Maximum: 12 clicks in
3.Adjust:
●Compression damping force
***********************************************
Adjustment steps:
●Turn the adjusting screw 1in direction aor
b.
Direction aCompression damping
force is increased.
Direction bCompression damping
force is decreased.
From the fully turned-in position:
Standard: 10 clicks out
Minimum: 20 clicks out
Maximum: 3 clicks out
ADJUSTING THE REAR SHOCK ABSORBER