Yamaha YFM660FS Supplementary Service Manual

Category
Motorcycles
Type
Supplementary Service Manual
LIT-11616-17-14 5KM-28197-E2
YFM660FS
SUPPLEMENTARY
SERVICE MANUAL
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
YFM660FS. For complete service information procedures it is necessary to use this Supplementary
Service Manual together with the following manual.
YFM660FP SERVICE MANUAL: LIT-11616-15-01 (5KM-28197-E0)
YFM660FR SUPPLEMENTARY SERVICE MANUAL: LIT-11616-16-34 (5KM-28197-E1)
YFM660FS
SUPPLEMENTARY
SERVICE MANUAL
©2003 by Yamaha Motor Corporation, U.S.A.
First Edition, April 2003
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.
LIT-11616-17-14
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
4
is provided for removal and disassembly jobs.
2. Numbers
5
are 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
7
accompanies 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
8
are given in addition
to the exploded diagram and the job instruction chart.
EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols
1
to
0
are printed on the
top right of each page and indicate the subject
of each chapter.
1
General information
2
Specifications
3
Periodic checks and adjustments
4
Engine
5
Cooling system
6
Carburetion
7
Drive train
8
Chassis
9
Electrical
0
Troubleshooting
Illustrated symbols
A
to
H
are used to identify
the specifications appearing in the text.
A
Can be serviced with engine mounted
B
Filling fluid
C
Lubricant
D
Special tool
E
Torque
F
Wear limit, clearance
G
Engine speed
H
, V, A
Illustrated symbols
I
to
N
in the exploded
diagrams indicate the types of lubricants and
lubrication points.
I
Apply engine oil
J
Apply gear oil
K
Apply molybdenum disulfide oil
L
Apply wheel bearing grease
M
Apply lightweight lithium-soap-based grease
N
Apply molybdenum disulfide grease
Illustrated symbols
O
to
P
in the exploded
diagrams indicate where to apply a locking
agent
O
and when to install a new part
P
.
O
Apply the locking agent (LOCTITE
)
P
Replace
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
.
.
E
G
M
B
LS
M
LT
New
CONTENTS
GENERAL INFORMATION
..............................................................................1
FEATURES ...............................................................................................1
OVERRIDE SWITCH (DEACTIVATING THE SPEED LIMITER
WHEN THE DIFFERENTIAL IS LOCKED) ...........................................1
SPECIFICATIONS
............................................................................................3
GENERAL SPECIFICATIONS ..................................................................3
MAINTENANCE SPECIFICATIONS .........................................................4
ENGINE ................................................................................................4
CHASSIS ..............................................................................................5
ELECTRICAL ........................................................................................5
CHASSIS
..........................................................................................................6
STEERING SYSTEM ................................................................................6
INSTALLING THE REAR BRAKE LEVER ............................................6
ELECTRICAL
...................................................................................................7
CHECKING THE SWITCH ........................................................................7
CHECKING THE SWITCH CONTINUITY .............................................7
SIGNAL SYSTEM .....................................................................................9
CIRCUIT DIAGRAM ..............................................................................9
YFM660FS WIRING DIAGRAM
GEN
INFO
1
GENERAL INFORMATION
FEATURES
OVERRIDE SWITCH
(DEACTIVATING THE SPEED LIMITER WHEN THE DIFFERENTIAL IS LOCKED)
This model is equipped with a speed limiter system (35 km/h [22 mph]) that operates when the dif-
ferential is locked and the ATV is traveling forward. If additional engine power is required (e.g., to
free the ATV from mud) when the ATV is traveling forward and the differential is locked, the speed
limiter can be temporarily deactivated by pressing the override switch.
N
OTE:
The speed limiter is deactivated only while the override switch is being pressed.
1
Override switch
When the override switch is pressed, the segments of the speedometer digits are displayed as fol-
lows.
N
OTE:
When the front differential gear is locked and the drive select lever is in the L, H, N, or P
position, the display changes when the override switch is pressed. (The speedometer display is
not displayed at this time.)
When the front differential gear is not locked or the drive select lever is in the R position, the dis-
play does not change even if the override switch is pressed.
mph
ODOTRIP AB
CLOCKHOUR
E
F
F
F
OFF
LOCK
0.2s 0.2s
0.2s 0.2s
0.2s 0.2s
FEATURES
GEN
INFO
2
FEATURES
CAUTION:
If the segments of the speedometer digits show the override display when the override
switch is not pressed, the speed limiter system is malfunctioning. Check the override switch
and ignition system, and then repair if necessary.
3
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model code: 5KMH
5KMM
5KMN
5KMP
Transmission:
Primary reduction system V-belt
Secondary reduction system Shaft drive
Secondary reduction ratio 41/21 × 24/18 × 33/9 (9.544)
Transmission type V-belt automatic
Operation Left hand operation
Single speed automatic 2.45 ~ 0.70 : 1
Sub transmission ratio low 35/17 (2.058)
high 26/21 (1.238)
Reverse gear 25/17 (1.471)
GENERAL SPECIFICATIONS
4
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Carburetor:
I. D. mark 5KMA 10 ----
Main jet (M.J) #153.8 ----
Main air jet (M.A.J) #70 ----
Jet needle (J.N) 6JPH9-53-2 ----
Needle jet (N.J) O-0M ----
Pilot air jet (P.A.J.1) #60 ----
Pilot air jet (P.A.J.2) 1.5 ----
Pilot outlet (P.O) 1.1 ----
Pilot jet (P.J) #40 ----
Bypass 1 (B.P.1) 0.8 ----
Bypass 2 (B.P.2) 0.8 ----
Bypass 3 (B.P.3) 0.8 ----
Valve seat size (V.S) 3.0 ----
Starter jet (G.S.1) #55 ----
Starter jet (G.S.2) 0.8 ----
Throttle valve size (Th.V) #105 ----
Float height (F.H) 13 mm (0.51 in) ----
Fuel level (F.L) 4.5 mm (0.18 in) ----
Engine idle speed 1,450 ~ 1,550 r/min ----
Intake vacuum 30.7 ~ 33.3 kPa
(230 ~ 250 mmHg, 9.07 ~ 9.83 inHg)
----
MAINTENANCE SPECIFICATIONS
5
SPEC
CHASSIS
ELECTRICAL
Item Standard Limit
Front suspension:
Shock absorber travel 86 mm (3.39 in) ----
Fork spring free length 296.5 mm (11.67 in) 290.6 mm
(11.44 in)
Spring fitting length 237 mm (9.33 in) ----
Spring rate (K1) 20 N/mm
(2.04 kg/mm, 114.2 lb/in)
----
Stroke (K1) 0 ~ 86 mm (0 ~ 3.39 in) ----
Optional spring No ----
Rear suspension:
Shock absorber travel 95 mm (3.74 in) ----
Spring free length 278.5 mm (10.96 in) ----
Spring fitting length 237 mm (9.33 in) ----
Spring rate (K1) 36.4 N/mm
(3.71 kg/mm, 207.84 lb/in)
----
Stroke (K1) 0 ~ 95 mm (0 ~ 3.74 in) ----
Optional spring No ----
Item Standard Limit
C.D.I.:
Magneto model/manufacturer F4T469/MITSUBISHI ----
Pickup coil resistance/color 459 ~ 561 at 20 °C (68 °F)/
White/Red White/Green
----
Rotor rotation direction sensing coil resis-
tance/color
0.063 ~ 0.077 at 20 °C (68 °F)/
Red White/Blue
----
C.D.I. unit model/manufacturer F8T40372/MITSUBISHI ----
Charging system:
Type A.C. magneto generator ----
Model/manufacturer F4T469/MITSUBISHI ----
Nominal output 14 V 21 A at 5,000 r/min ----
Charging coil resistance/color 0.32 ~ 0.43 at 20 °C (68 °F)/
White White
----
MAINTENANCE SPECIFICATIONS
6
CHAS
STEERING SYSTEM
CHASSIS
STEERING SYSTEM
INSTALLING THE REAR BRAKE LEVER
1.Install:
Handlebar switch 1
Rear brake lever
Lever bracket 2
N
OTE:
Install the lever bracket as shown.
a
74.5 mm (2.9 in)
7
+
ELEC
CHECKING THE SWITCH
ELECTRICAL
CHECKING THE SWITCH
CHECKING THE SWITCH CONTINUITY
Refer to CHECKING THE SWITCH in CHAPTER 9 (Manual No.: 5KM-28197-E0) and check for
continuity between lead terminals.
Poor connection, no continuity Correct or replace.
*
The coupler locations are circled.
L
B
Y
G
Br
L/B
1
5
6
B
7
23
PUSH
Br L Y G B
R/W
L/BL/G
Br/L
BrR
L/R
Sb Br Gy
G/R
B
R/BL/B
2WD
4WD
LOCK
L/G
L/B
L/R
Sb
Gy
Br
G/R
B
(BLACK) (GRAY)
P
L
Gy
W
ON
OFF
R
Br
Br/L
Br
Y
(BLACK)
8
BB
(BLACK)
9
0
A
BB
4
PUSH
B
Lg
R/BR/W
Lg
8
+
ELEC
CHECKING THE SWITCH
1 Light switch
2 Engine stop switch
3 Start switch
4 Override switch
5 On-command four-wheel drive switch and differential gear lock switch
6 Main switch
7 Rear brake light switch
8 Front brake light switch
9 Rear brake switch
0 Gear position switch
A Reverse switch
B Fuse
9
+
ELEC
SIGNAL SYSTEM
EB806000
SIGNAL SYSTEM
CIRCUIT DIAGRAM
2WD
4WD
LOCK
ON
OFF
B
B
RR
L/WL/B
R/B L/W
W/R
B/Y
R
O
W/G
B
Sb
G/W
W/B
G/R
(BLACK) (BLACK)
(BLACK)
(BLACK)
(GRAY)
(GRAY)
(BLACK)
(BLACK)
(BLACK)
R
W/G
W/LW/R
W/G
R
W/RW/G
L/G
L/B
L/R
Sb
R/Y
L/B
L
B
Y
G
L/G
L/B
L/R
Sb
L
B
Y
G
Br
L/B
Gy
Br
G/R
B
Gy
Br
G/R
B
Sb
W
L/W
B/RW/L
G/L
Sb
L/W
B/RW/L
W
G/L
L/Y
G/Y
L/RW/R
W/BR/W
P
L
Gy
W
Sb
L/R
L/WW/R
(BLACK)
Br
G/Y
L/R
L/YW/B
W/R
W
WW
W
WW
BR
WWW
(BLACK)
B/Y
B
LB
BL
OB
O
B
G
W/B
PB
Br
Y
Br
Y
Br
Y
B
B
(DARK GRAY)
(GRAY)
(GRAY)
G/Y
B
(BLACK)(BLACK)
(BLACK) (BLACK)
Br/B
W
L
B
L/Y
W
B
G/RR/G
B
G/R R/G
B
GY
B
YG
B
GY
B
YG
B
R/BR/W
Lg
R/WR/B
Lg
W
W
W
W B
R
RR
R
B
B
R
B
P
L
L
B B
B
P
Y
Y
G
Y GY G
B
B
B
O O
B B
W
W/R
W/B
L/W
R
W/G
Y/B
R/B
B/Y
B/Y
G/W
G/W
L/W
L/B
Br/L
Br/L
Br
Br
Br
L/Y
W
B
B
B
B
Br
L
L
B
B
L/Y
G/R
B/R
Lg
G/W
Sb
WIRE HARNESS
IGNITION COIL LEAD
C
WIRE HARNESS
B
WIRE HARNESS
SUB-WIRE HARNESS
SUB-WIRE HARNESS
A
B
B/R
W/B
W/B
B
B/R
C
C
1
8
4
5
6
7
A
9
C
B
D
E
GH IJK LM
O
N
P
Q
R
a
]
`
g
3
[
Br/L
cde
Br/L
Br/L
b
U
V
\
Z
L/B
R/BBr/B
Br
B/Y
Sb
L/B
R/BBr/B
Br
B/Y
Sb
R
W/R
W/G
W/G
W W
2
R
R/G
R
R
Br
Br
Br/L
R
Br/L
=
G/L
B/Y L/R
Y/B
R/B
R/B
L/W
L/W
L/R
L/R
W/R
W/R
Sb
Sb
B
L/B
Sb
Br
B
T
S
X
Y
B
L
R/B
Br/L
Br/R
Br/R
Br/B
Br/R
Br/R
L/G
B
Br/R
Br/R
Br/B
B
L/G
W
Br/R Br/R
B/Y
B
L/R
G/R
Gy
Gy
L/G
(BLACK)
B/Y
Br/R
Br/R
L/R
B
(BLACK)
Y/B
L/RBr/R
Gy
(BLACK) (GRAY)
(GRAY)(BLACK)
B
B
BB
B
B B B B
B
A
A
A
L/R
L/B
L/B
B/Y
B/Y
B/R
B/R B/R
Br/B
Br/B Br/B
W/B
W/B W/B
L/B
Sb
Sb
Br
Br
Sb
Br
R/G
B/R
W/B
R/W
W/L
W/L
W/L
G/R
G/Y
G/Y
G/L
W
ff
i
h
R/Y
R/W
R/Y R/B L/BR/W
R/W
j
Y
Y
PUSH PUSH
OFF
R
Lg
F
L/R
B
Br
W
B/R
Lg
Y/B
G/L
R
W/BB/YB/R
B
10
+
ELEC
SIGNAL SYSTEM
3 Main switch
4 Backup fuse
5 Battery
6 Main fuse
9 Reverse switch
0 CDI unit
D Speed sensor
F Multi-function meter
G Differential gear lock indicator light
H Coolant temperature indicator light
I Reverse indicator light
J Neutral indicator light
K Park indicator light
L High-range indicator light
M Low-range indicator light
N Gear position switch
P Fuel sender
Q Thermo switch 1
Y On-command four-wheel drive switch and differential gear lock switch
Z Gear motor
] Ignition fuse
e Override switch
g Signaling system fuse
h Rear brake light switch
i Front brake light switch
j Tail/brake light
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
PRINTED IN U.S.A.
YFM660FS WIRING DIAGRAM
2WD
4WD
LOCK
ON
OFF
B
B
RR
L/WL/B
R/B L/W
W/R
B/Y
R
O
W/G
B
Sb
G/W
W/B
G/R
(BLACK) (BLACK)
(BLACK)
(BLACK)
(GRAY)
(GRAY)
(BLACK)
(BLACK)
(BLACK)
R
W/G
W/LW/R
W/G
R
W/RW/G
L/G
L/B
L/R
Sb
R/Y
L/B
L
B
Y
G
L/G
L/B
L/R
Sb
L
B
Y
G
Br
L/B
Gy
Br
G/R
B
Gy
Br
G/R
B
Sb
W
L/W
B/RW/L
G/L
Sb
L/W
B/RW/L
W
G/L
L/Y
G/Y
L/RW/R
W/BR/W
P
L
Gy
W
Sb
L/R
L/WW/R
(BLACK)
Br
G/Y
L/R
L/YW/B
W/R
W
WW
W
WW
BR
WWW
(BLACK)
B/Y
B
LB
BL
OB
O
B
G
W/B
PB
Br
Y
Br
Y
Br
Y
B
B
(DARK GRAY)
(GRAY)
(GRAY)
G/Y
B
(BLACK)(BLACK)
(BLACK) (BLACK)
Br/BB/RW/BB/Y
W
L
B
L/Y
W
B
G/RR/G
B
G/R R/G
B
GY
B
YG
B
GY
B
YG
B
R/BR/W
Lg
R/WR/B
Lg
W
W
W
W B
R
RR
R
B
B
R
B
P
L
L
B B
B
P
Y
Y
G
Y GY G
B
B
B
O O
B B
W
W/R
W/B
L/W
R
W/G
Y/B
R/B
B/Y
B/Y
G/W
G/W
L/W
L/B
Br/L
Br/L
Br
Br
Br
L/Y
W
B
B
B
B
Br
L
L
B
B
L/Y
G/R
B/R
Lg
G/W
Sb
WIRE HARNESS
IGNITION COIL LEAD
C
WIRE HARNESS
B
WIRE HARNESS
SUB-WIRE HARNESS
SUB-WIRE HARNESS
A
B
B/R
W/B
W/B
B
B/R
C
C
1
8
4
5
6
7
A
9
C
B
D
E
GH I JK LM
O
N
P
Q
R
a
]
`
g
3
[
Br/L
cde
Br/L
Br/L
b
U
V
\
Z
L/B
R/BBr/B
Br
B/Y
Sb
L/B
R/BBr/B
Br
B/Y
Sb
R
W/R
W/G
W/G
W W
2
R
R/G
R
R
Br
Br
Br/L
R
Br/L
=
G/L
B/Y L/R
Y/B
R/B
R/B
L/W
L/W
L/R
L/R
W/R
W/R
Sb
Sb
B
L/B
Sb
Br
B
T
S
X
Y
B
L
R/B
Br/L
Br/R
Br/R
Br/B
Br/R
Br/R
L/G
B
Br/R
Br/R
Br/B
B
L/G
W
Br/R Br/R
B/Y
B
L/R
G/R
Gy
Gy
L/G
(BLACK)
B/Y
Br/R
Br/R
L/R
B
(BLACK)
Y/B
L/RBr/R
Gy
(BLACK) (GRAY)
(GRAY)(BLACK)
B
B
BB
B
B B B B
B
A
A
A
L/R
L/B
L/B
B/Y
B/Y
B/R
B/R B/R
Br/B
Br/B Br/B
W/B
W/B W/B
L/B
Sb
Sb
Br
Br
Sb
Br
R/G
B/R
W/B
R/W
W/L
W/L
W/L
G/R
G/Y
G/Y
G/L
W
ff
i
h
R/Y
R/W
R/Y R/B L/BR/W
R/W
j
Y
Y
PUSH PUSH
OFF
R
Lg
F
L/R
B
Br
W
B/R
Lg
Y/B
G/L
R
B
1 AC magneto
2 Rectifier/regulator
3 Main switch
4 Backup fuse
5 Battery
6 Main fuse
7 Starter relay
8 Starter motor
9 Reverse switch
0 CDI unit
A Rear brake switch
B Ignition coil
C Spark plug
D Speed sensor
E Meter assembly
F Multi-function meter
G Differential gear lock indicator light
H Coolant temperature indicator light
I Reverse indicator light
J Neutral indicator light
K Park indicator light
L High-range indicator light
M Low-range indicator light
N Gear position switch
O Diode
P Fuel sender
Q Thermo switch 1
R Circuit breaker (fan motor)
S Thermo switch 2
T Fan motor
U Four-wheel drive fuse
V Four-wheel drive relay 1
W Four-wheel drive relay 2
X Four-wheel drive relay 3
Y On-command four-wheel drive switch and
differential gear lock switch
Z Gear motor
[ Auxiliary DC jack fuse
\ Auxiliary DC jack
] Ignition fuse
^ Headlight fuse
a Handlebar switch (left)
b Light switch
c Engine stop switch
d Start switch
e Override switch
f Headlight
g Signaling system fuse
h Rear brake light switch
i Front brake light switch
j Tail/brake light
COLOR CODE
B ............Black
Br........... Brown
G............ Green
L.............Blue
Lg...........Light green
O............ Orange
P ............Pink
R............ Red
Sb ..........Sky blue
Gy ..........Gray
W ...........White
Y ............Yellow
B/R.........Black/Red
B/Y.........Black/Yellow
Br/B........Brown/Black
Br/L ........Brown/Blue
Br/R .......Brown/Red
G/L.........Green/Blue
G/R ........Green/Red
G/W........Green/White
G/Y.........Green/Yellow
L/B .........Blue/Black
L/G .........Blue/Green
L/R .........Blue/Red
L/W ........Blue/White
L/Y .........Blue/Yellow
R/B.........Red/Black
R/G ....... Red/Green
R/W....... Red/White
R/Y........ Red/Yellow
W/B ....... White/Black
W/G....... White/Green
W/L ....... White/Blue
W/R....... White/Red
Y/B ........ Yellow/Black
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Yamaha YFM660FS Supplementary Service Manual

Category
Motorcycles
Type
Supplementary Service Manual

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