Yamaha 5KM2-AE1 User manual

YFM660F(P)
5KM2-AE1
SERVICEMANUAL
2002

YFM660F(P) 2002
SERVICE MANUAL
© 2001 by Yamaha Motor Co., Ltd.
First edition, May 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:
NOTE:

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 0are printed on the
top right of each page and indicate the subject
of each chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Cooling system
6Carburetion
7Drive train
8Chassis
9Electrical
0Troubleshooting
Illustrated symbols Ato Hare used to identify
the specifications appearing in the text.
ACan be serviced with engine mounted
BFilling fluid
CLubricant
DSpecial tool
ETorque
FWear limit, clearance
GEngine speed
HΩ, V, A
Illustrated symbols Ito Nin the exploded
diagrams indicate the types of lubricants and
lubrication points.
IApply engine oil
JApply gear oil
KApply molybdenum disulfide oil
LApply wheel bearing grease
MApply lightweight lithium-soap base grease
NApply molybdenum disulfide 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
EF
GH
IJK
LMN
OP
GEN
INFO SPEC
CHK
ADJ ENG
COOL CARB
DRIV
CHAS
–+
ELEC TRBL
SHTG
T
R
.
.
EGM
BLS M
LT New

TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC 2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
ENGINE ENG 4
COOLING SYSTEM COOL 5
CARBURETION CARB 6
DRIVE TRAIN DRIV 7
CHASSIS CHAS 8
ELECTRICAL ELEC 9
TROUBLESHOOTING TRBL
SHTG
10
–+

GEN
INFO 1

GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION ........................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER ................................................. 1-1
MODEL LABEL ..................................................................................... 1-1
FEATURES ................................................................................................... 1-2
FRONT DIFFERENTIAL ....................................................................... 1-2
TRANSMISSION ................................................................................... 1-9
IMPORTANT INFORMATION .................................................................... 1-10
PREPARATION FOR REMOVAL PROCEDURES ............................. 1-10
REPLACEMENT PARTS .................................................................... 1-10
GASKETS, OIL SEALS AND O-RINGS .............................................. 1-10
LOCK WASHERS/PLATES AND COTTER PINS ............................... 1-11
BEARINGS AND OIL SEALS .............................................................. 1-11
CIRCLIPS ............................................................................................ 1-11
CHECKING OF CONNECTIONS ............................................................... 1-12
SPECIAL TOOLS ....................................................................................... 1-13