Yamaha YFM660FP 2001 User manual

YFM660FP
ASSEMBLY MANUAL
5KM-28107-10
LIT-11666-15-01

FOREWORD
This Assembly Manual contains the information required for
the correct reassembly of this Yamaha machine prior to
delivery to the customer. Since some external parts of the
machine have been removed at the Yamaha factory for the
convenience of packing, assembly by the Yamaha dealer is
required. It should be noted that the reassembled machine
shouldbethoroughlycleaned,inspected,andadjustedpriorto
delivery to the customer.
NOTICE
The service specifications given in this assembly manual are
based on the model as manufactured. Modifications and
significantchanges inspecifications and/orprocedures willbe
forwarded to Authorized Yamaha Dealers. The procedures
below are described in the order that the procedures are
carriedoutcorrectlyandcompletely.Failuretodosocanresult
inpoorperformance and possibleharmtothe machineand/or
rider.
CONCERNING CARTE DAMAGE:
Follow the instructions in the Dealer warranty handbook,
procedure section.
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
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.
CAUTION:
A CAUTION indicates special precautions that must be taken
to avoid damage to the machine.
NOTE:
A NOTE provides key information to make procedures easier
or clearer.
PREPARATION
To assemble the machine correctly, supplies and working
space are required:
Supplies Oils, greases, shop rags.
Workshop
The workshop where the machine is assembled should be
clean and large. The floor should be level.
Self-protection
Protect your eyes with suitable safety spectacles or safety
goggles when using compressed air, when grinding or when
doing any operation which may cause particles to fly off.
Protect hands and feet by wearing safety gloves or doing.
Procedure for unpacking
1. To remove the machine and parts packed in the crate, cut
thevinylbandsaroundthecartonusingacutterorscissors.
Next, remove the exterior carton by lifting it straight up.
2. Removetheboltsfromeachcorneroftherack,andremove
the struts.
3. Remove the machine from the bottom board.
4. Before starting the assembly, check for damaged or miss-
ing parts. The parts are contained in the carton and the
machine for damage, scratches and other defects.
YFM660FP
ASSEMBLY MANUAL
© 2001 by Yamaha Motor Corporation, U.S.A.
First Edition, April 2001
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11666-15-01

10
FWD
UP
SYMBOLS USED IN
ASSEMBLY MANUAL
In order to simplify descriptions in assembly manuals,
the following symbols are used:
: Coat with lithium soap base grease.
: Tighten to 10 Nm.
(10 Nm = 1.0 m • kg, 7.2 ft • lb)
: Front ward of the machine.
: Provide a clearance.
: Install so that the arrow mark faces upward.
: Apply a motor oil.
: Made of rubber or plastics.
A: Ref. No. (indicating the order or operations.)
B: Part name
C: Quantity of parts per machine.
D: Place where parts are held.
1: Refer to “PARTS LOCATION”.
V: Stored in vinyl bag.
C: Stored in carton box.
S: Fixed inside the steel frame and/or contained in
the styrofoam tray (upper or lower).
*: Temporarily installed or secured.
Example:
1- V
1signifies the location of the parts and V signifies
that the part is stored in a vinyl bag.
E: Size or material of parts.
d/D:Diameter of part.
r: Length of part.
ex, 5 (0.2) = 5 mm (0.2 in)

–1–
4326
1
6
7
See view a
7
5
7
4
3
See view a
PARTS LOCATION
1Vinyl pack
2Vinyl pack
3Carton box
4Carton box
5Carton box
6Rear wheel
7Front wheel

–2–
2Vinyl pack
Throttle housing Rear brake cable Brake master cylinder
1Vinyl pack
Handlebar
Flange bolts (front shock absorber)
Handlebar switch and panhead screws Rear brake light switch (lever)
Brake master cylinder bracket and flange bolts Throttle housing bracket and panhead
screws with spring washer
Vinyl bag 1
Vinyl bag 2
Vinyl bag 4
Handlebar holder and flange bolts
Vinyl bag 3
Vinyl bag 5

–3–
3Carton box
Rear shock absorbers
4Carton box
Battery bracket Handlebar cover Fuel tank breather hose
Low-pressure air gauge
Bands (handlebar) Handlebar holder and flange bolts
Owner’s tool kit and band Owner’s manual
Vinyl bag 1
Flange bolts (rear shock absorber)

–4–
Nuts (front and rear wheels) Self locking nuts (front and rear shock
absorbers) Flange bolts (battery bracket)
Flange bolts (engine skid plate)
Vinyl bag 2
Flange bolts and spring nuts (front protector) Bolts with plain washer (rear protector)

–5–
Protectors (front arms) Protectors (rear arms) Fuel tank side panels
Engine skid plate (front) Engine skid plate (center) Engine skid plate (rear)
5Carton box
6Front wheels 7Rear wheels
Electrolyte

–6–
5
4
4
3
2
1
UNPACKING
1. Remove the frame cover 1.
2. Remove the bolts 2(lower handlebar holder).
3. Remove the bolt 3and bracket (rear carrier).
4. Remove the packing frames 4. (upward and sideways)
5. Remove the stays 5. (left and right rear arms)

–7–
12345
67
F
B
D
80C
HG
9
E
A
SETUP PROCEDURES
NOTE:
•After opening the crate, place the ATV on a suitable
rack and follow the setup procedures.
•Before starting the setup, supply the specified tire
pressure to the four wheels.
WARNING
This model is equipped with low pressure tires.
Refer to “ADJUSTMENTS AND PREDELIVERY
SERVICE”.

–8–
B
1
2
3
A
7
FWD
A
B
3
20
2
2
1
2. Front brake master cylinder
A: The handlebar holders should be
installed with the punched mark
forward.
CAUTION:
First tighten the bolts on the front
side, and then tighten the bolts on
the rear side.
B: Tighten the bolts to specified
torque.
3. Throttle housing
1. Handlebar
1
2
3
Handlebar
Handlebar holder
(upper)
Flange bolt
1
1
1
2
2
1- S
2- V
4- V
2- V
4- V d = 8 (0.31), R= 30 (1.18)
Tightening torque:
20 Nm (2.0 m • kg, 14 ft • lb)
1
2
3
Master cylinder
Bracket
Flange bolt
1
1
2
2- *
2- V
2- V d = 6 (0.24), R= 22 (0.87)
A: Tighten the bolts to specified
torque.
Tightening torque:
7 Nm (0.7 m • kg, 5.1 ft • lb)
B: Check the brake lever for smooth
action.
1
2
3
Throttle housing
Bracket
Panhead screw with spring
washer
1
1
2
2- *
2- V
2- V d = 5 (0.20), R= 20 (0.79)
A: Fit the throttle housing projection
to the brake master cylinder.
WARNING
Proper cable routing is essential to
assure safe machine operation.
Refer to “CABLE ROUTING”.
B: Tighten the screws in stages and
maintain an equal gap on each
side of the throttle housing
bracket.
C: Check the throttle lever for
smooth action.
WARNING
Proper hose routing is essential to
assure safe machine operation.
Refer to “CABLE ROUTING”.
B
1
2
3
C
A

–9–
1
2
B
1
A
1
1
2
A
6. Handlebar bands
1 Band 44- V
A: Clamp the handlebar switch lead
and the rear brake light switch
lead.
B: Clamp the front brake light switch
leadand on command four-wheel
drive switch lead.
NOTE:
Refer to “CABLE ROUTING”.
4. Rear brake cable and rear brake light switch
1
2
Rear brake cable
Rear brake light switch
1
1
2- *
2-*
5. Handlebar switch
1
2
2- *
2- V
Handlebar switch
Panhead screw
1
2
A: Tighten the screws in stages and
maintain an equal gap on each
side of the handlebar switch.
WARNING
Proper cable routing is essential to
assure safe machine operation.
Refer to “CABLE ROUTING”.
d = 5 (0.20), R= 30 (1.17)

–10–
3
2
1
A
7
45
A
1
2
1
2
A
7. Handlebar cover
1
2
4- C
4- V
Handlebar cover
Fuel tank breather hose
1
1
A: Pass the breather hose through
the hole on the handlebar cover.
NOTE:
Refer to “CABLE ROUTING”.
8. Front shock absorbers
1
2
4- V
5- V
Flange bolt
Self lock nut
2
2
d = 10 (0.39), R= 48 (1.89)
d = 10 (0.39)
A: Tighten the nuts to specified
torque.
Tightening torque:
45 Nm (4.5 m • kg, 32 ft • lb)
9. Protectors (front arms)
Protector
Spring nut
Flange bolt
1
2
3
2
2
2
5- C
4- V
4- V d = 6 (0.24), R= 12 (0.47)
A: Tighten the bolt to specified
torque.
Tightening torque:
7 Nm (0.7 m • kg, 5.1 ft • lb)

–11–
A
C
2
55
B
1
21
7
2
A
A
45
A
1
2
45
A
3
3
2
10. Rear shock absorbers
11. Protectors (rear arms)
1
2
5- C
4- V
Protector
Bolt with plain washer
2
4
A: Tighten the nuts to specified
torque.
Tightening torque:
45 Nm (4.5 m • kg, 32 ft • lb)
Rear shock absorber
Flange bolt
Self lock nut
1
2
3
2
4
4
3- C
4- V
4- V
d = 10 (0.39), R= 48 (1.89)
d = 10 (0.39)
12. Front wheels
1
2
Front wheel
Nut
2
8
6- S
4- V d = 10 (0.39)
A: Install the wheels so that air valve
is outside.
B: The arrow mark on the tire must
point toward the rotating direction
of the wheel.
C: Tighten the nuts to specified
torque.
Tightening torque:
55 Nm (5.5 m • kg, 40 ft • lb)
A: Tighten the bolts to specified
torque.
Tightening torque:
7 Nm (0.7 m • kg, 5.1 ft • lb)

–12–
1
1
3
4
5
25
14
7
A
A
A
A
7
7
A
C
2
55
1
B
14. Engine skid plates
1
2
3
4
5
Engine skid plate (rear)
Engine skid plate (center)
Engine skid plate (front)
Flange bolt
Flange bolt
1
1
1
4
4
5- C
5- C
5- C
4- V
4- V
13. Rear wheels
A: Tighten the bolts to specified
torque.
Tightening torque:
7 Nm (0.7 m • kg, 5.1 ft • lb)
1
2
Rear wheel
Nut
2
8
7- S
4- V d = 10 (0.39)
A: Install the wheels so that air valve
is outside.
B: The arrow mark on the tire must
point toward the rotating direction
of the wheel.
C: Tighten the nuts to specified
torque.
Tightening torque:
55 Nm (5.5 m • kg, 40 ft • lb)
15. Fuel tank side panels
1 Fuel tank side panel 2 5- C
d = 6 (0.24), R= 8 (0.31)
d = 6 (0.24), R= 12 (0.47)

–13–
1A
1
4
3
2
A
23
4
A
DB
C
4
1
7
16. Battery
A: NOTE:
Before installing the battery, refer
to “ADJUSTMENTS AND
PREDELIVERY SERVICE”.
B: Tighten the bolts to specified
torque.
Tightening torque:
7 Nm (0.7 m • kg, 5.1 ft • lb)
C: First, connect the +lead (red
lead) to the +terminal.
D: Next, connect the -lead (black
lead) to the -terminal.
1
2
3
4
Battery
Battery bracket
Flange bolt
Bolt
1
1
2
2
*
4- C
4- V
*d = 6 (0.24), R= 12 (0.47)
d = 6 (0.24), R= 16 (0.63)
17. Owner’s manual
A: NOTE:
Put this owner’s manual in the
vinylbagandalwayscarrythemin
the rear fender.
18. Seat
1 Seat 1 *
A: Insert the lobes on the seat front
into the receptacles on the frame,
then push down the seat at the
end.
Owner’s manual
Owner’s tool kit
Low-pressure air gauge
Band
1
2
3
4
1
1
1
1
4- V
4- V
4- V
4- V

–14–
CABLE ROUTING
CAUTION:
Proper cable and lead routing is essential to insure
safe machine operation.
1Rear brake light switch
2Rear brake cable
3Starter cable
4Front brake hose
5Throttle cable
6Battery negative lead
7Battery positive lead
ÅClamp the handlebar switch lead and rear brake light switch
lead.
ıClamp the front brake light switch lead and on-command four-
wheel drive switch lead.
76
1
2
3
4
5
Å ı

–15–
ADJUSTMENTS AND PREDELIVERY SERVICE
B
KG
E CHI A FO
BD
KLMO NP
JM QH
Q

–16–
A. Battery inspection
1. Fill:
CAUTION:
•Never remove the sealing sheet (aluminium
seal) from the battery until the battery is filled
with electrolyte.
If battery plates are exposed to air, they will
oxidize.Asaresult,powerwillnotbegeneratedas
specified.
•Add electrolyte so that its level is correct as
specified.
Anincorrectelectrolytelevelhasanadverseeffect
on battery performance.
The quantity of electrolyte varies with the type of
the electrolyte container. Use only the amount of
electrolyte in the container which comes with the
battery.
•Avoid using any electrolyte other than
specified.
ThespecificgravityoftheMFbatteryelectrolyteis
1.320 (20 ˚C). (the specific gravity of the general
type battery electrolyte is 1.280.)
Iftheelectrolytewhosespecificgravityislessthan
1.320, the sulfuric acid will decrease and thus low
battery performance will result.
Should any electrolyte, whose specific gravity is
1.320 or more, be used, the battery plates will
corrode and battery life will shorten.
a. Place the battery on a level surface.
b. Remove the sealing sheet 1.
2Filler port
c. Takethe electrolytecontainer out ofthe vinyl bag.
d. Detachthestripofcaps(usedasbatteryplugs)3.
4Six sealed areas of container
NOTE:
Donot lose thestrip of caps becauseit will beused as
battery plugs.
CAUTION:
Do not peel or pierce the sealed areas.
e. Turn the electrolyte container upside-down with
the six sealed areas in line with the six filler ports
of the battery.
f. Pushthecontainerdownstronglyenoughtobreak
the seals. The electrolyte will start to flow into the
battery.
CAUTION:
•Do not tilt the container as the electrolyte may
stop flowing.
•Never remove the container from the battery
until all electrolyte has drained from the
container.
g. Leavethe container in this positionfor20 minutes
or longer to allow proper chemical reaction.
NOTE:
•Make sure air bubbles are rising from all six filler
ports.
•Ifairbubblesarenotrisingfromafillerport,tapthe
top of the container a few times.
h. Becertainthatalltheelectrolytehasbeendrained
from container.
i. Fitthestripofcaps(batteryplugs)securelyintothe
filler ports. Make sure the top of the strip is at the
same level as the top of the battery.
5Press down horizontally with both hands.
CAUTION:
Never remove the strip of caps, nor add any water
or electrolyte.
WARNING
•Do not attempt boost charging under any cir-
cumstances.
•Battery electrolyte is poisonous and
dangerous, causing severe burns, etc.
Containssulfuricacid.Avoidcontactwithskin,
eyes or clothing.
Antidote: External – Flush with water. Internal
–Drinklarge quantities ofwater or milk.Follow
withmilkofmagnesia,beatenegg,orvegetable
oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get
prompt medical attention. Batteries produce
explosive gases. Keep sparks, flame,
cigarettes, etc., away. Ventilate when charging
orusinginenclosedspace.Alwaysshieldeyes
when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
2. Check:
Usingadigitalvoltmeter,thestateofadischarged
MF battery can be checked by measuring open-
circuit voltage (the voltage measured with the
positive and negative terminals being
disconnected).
CAUTION:
The battery must charged after it is filled with
electrolyte.Ifthisis notdone,thelifeofthebattery
will be shortened drastically. Since the procedure
for charging the battery is not explained in the
assembly manual, refer to the service manual for
more details.

–17–
1
2
B. Tire pressure measurement
WARNING
This model is equipped with low pressure tires.
Pay attention to the following points:
Recommended tire pressure:
Front: 35 kPa (0.35 kgf/cm2, 5.0 psi)
Rear: 30 kPa (0.30 kgf/cm2, 4.3 psi)
Maximum vehicle load: 220 kg (485 lbs)
Tire size: Front AT25 ×8–12
Rear AT25 ×10–12
1. Excessive tire pressure [over 250 kPa (2.5 kgf/
cm2, 36 psi)] may cause tires to burst. Inflate
tires very slowly. Fast inflation could cause
tire to burst.
2. Toolowapressure[Front:32kPa(0.32kgf/cm2,
4.6psi),Rear: 27 kPa (0.27kgf/cm2,3.9 psi)] will
cause the rim to dislodge from the tire.
3. Put the same pressure in both rear tires.
Uneven tire pressure will severally affect the
handling.
4. Set tire pressure cold.
C. Fuel draining
1. Remove:
•Seat
•Fuel tank side panel (left)
2. Put a rag under the carburetor so fuel does not
contact the crankcase.
3. Loosen the drain screw 1and drain the standing
fuel.
1. Check:
a. Use an appropriate low-pressure tire gauge. Set
tire pressures to the following specifications:
Reference tire pressure:
Front: 35 kPa (0.35 kgf/cm2, 5.0 psi)
Rear: 30 kPa (0.30 kgf/cm2, 4.3 psi)
Minimum tire pressure:
Front: 32 kPa (0.32 kgf/cm2, 4.6 psi)
Rear: 27 kPa (0.27 kgf/cm2, 3.9 psi)
CAUTION:
Never use a tire pressure below minimum
specification. The tire could separate from the
wheel under severe operating conditions.
WARNING
FUEL IS HIGHLY FLAMMABLE:
•Always turn off the engine when draining.
•Take care not to spill any fuel on the engine or
exhaust pipe(s)/muffler(s) when draining.
•Neverdrainfuelwhilesmokingorinthevicinity
of an open flame.
4. Retighten the drain screw securely and connect
the drain hose 2.
5. Install:
•Fuel tank side panel (left)
•Seat
D. Engine oil level inspection
1. Place the machine on a level place.
2. Remove:
•Engine side panel
3. Inspect:
•Engine oil level
Oil level should be between maximum 1mark.
Oil level low →Add oil to proper level.
NOTE:
Donot screw the dipstick 2in when inspecting the oil
level.
Recommended engine oil:
At 0 °C (32 °F) or higher:
Yamalube 4 (20W40) or
SAE20W40 type SE/SF motor oil
At –10 °C (14 °F) or higher:
Yamalube 4 (10W30) or
SAE10W30 type SE/SF motor oil
At 0 °C (32 °F) or lower:
SAE5W30 type SE/SF motor oil
Oil quantity (periodic oil change):
Engine:
1.9 L (1.7 Imp qt, 2.0 US qt)
CAUTION:
Do not allow foreign material to enter the
crankcase.
4. Start the engine and let it warm up for several
minutes.
5. Stop the engine and inspect the oil level once
again.
NOTE:
Wait a few minutes until the oil settles before
inspecting the oil level.
WARNING
Never remove the dipstick just after high speed
operation because the heated oil could spurt out.
Wait until the oil cools down before removing the
dipstick.
6. Install:
•Engine side panel