Yamaha LIT-11626-16-09 manual

5LP-28199-12 LIT-11626-16-09 READ THIS MANUAL CAREFULLY! It contains important safety information. This ATV should not be ridden by anyone under 16 years of age. WARNING YFM660RR OWNERíS MANUAL PRINTED IN JAPAN 2002.04-5.1  1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . EBU00438 LOCATE AND READ OWNERíS MANUAL. FOLLOW ALL INST[...]

EBU00776[...]

EBU01200 1- INTRODUCTION Congratulations on your purchase of the Yamaha YFM660R. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of crafts- manship and reliability that have made Yamaha a[...]

EBU00801 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINE D IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! W ARNING Failure to follow WARNING instru[...]

EBU00011 IMPORTANT NOTICE This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this machine on any public street, road or highway. This machine complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding[...]

EBU00014 W ARNING Indicates a potential hazard that could result in serious injury or death. CONTENTS LOCATION OF THE WAR NING AND SPECIFICATION LABELS................ 1-1 SAFETY INFORMATION.................. 2-1 DESCRIPTION AND MA CHINE IDENTIFICATION ............................. 3-1 Identification number records .......... 3-2 Key identification[...]

PRE-OPERATION CHECKS ........... 5-1 Front and rear brakes ..................... 5-3 Fuel ................................................. 5-4 Engine oil ........................................ 5-6 Coolant .... ........................................ 5-7 Chain ............................................... 5-8 Throttle lever ...................[...]

PERIODIC MAINTENAN CE AND ADJUSTMENT .................................. 8-1 Owner’s manual and tool kit . ........... 8-1 Periodic maintenance/ lubrication ...................................... 8- 3 Panel removal and installation ........ 8-5 Engine oil and oil filter cartridge ...... 8-6 Cooling system .............................. 8-11 Changi[...]

CLEANING AND STORAGE ............ 9-1 A. Cleaning............ .......................... 9-1 B. Storage ....................................... 9-3 SPECIFICATIONS.. ........................ 10-1 NOISE REGULATION .................... 11-1 MAINTENANCE RECORD ............ 12-1 ATV LIMITED WARRANTY............ 13-1 YAMAHA EXTENDED SER VICE (Y.E.S.) ...[...]

1-1 EBU00464 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5LP12.book Page 1 Friday, April 26, 2002 2:47 PM[...]

1-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. 1 2 UNDER WARNING 5FE-21697-01 N[...]

1-3 3 4 5 U5LP12.book Page 3 Friday, April 26 , 2002 2:47 PM[...]

2-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 SAFETY INFORMATION EBU00924 AN ATV IS NOT A TOY AND CAN BE HAZARD OUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take prop[...]

2-2 ● Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, park- ing lots and streets. ● Never operate an ATV on any public street, road or highway, even a dirt or gravel one. ● Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or[...]

2-3 ● Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. ● Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smal ler hills before attempting larger hills. ● Always follow prope[...]

2-4 ● Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stall- ing, use proper gear and maintain a steady speed when cli mbing a hill. If you stall or roll back- wards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Tu[...]

2-5 ● Always use the size and type tires specified in this manual. ● Always maintain proper tire pressure as described in this manual. ● Never modify an ATV through improper installation or use of accessories. ● Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and fol[...]

2-6 WA R N I N G POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refuel- ing. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling[...]

2-7 WA R N I N G POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HA ZARD Always operate your ATV in an area with adequate ventilation. U5LP12.book Page 7 Friday, April 26 , 2002 2:47 PM[...]

3-1 EBU00032 DESCRIPTION AND MACHINE IDENTIFICATION 1. Spark arrester 2. Seat 3. Fuel tank cap 4. Engine oil tank 5. Brake pedal 6. Headli ghts 7. Fuel cock 8. Throttle stop scre w 9. Coolant res ervoir 10. Tail/brake light 11. Shift p edal 12. Clutch leve r 13. Handlebar switches 14. Parking brake 15. Main swi tch 16. Reverse knob 17. Throttle lev[...]

3-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EBU00600 Identification number records Record the key identification number, vehicle identification number and model label infor- mation in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: 2. VEHICLE ID[...]

3-3 EBU00036 Vehicle identification number The vehicle identification number is stamped into the frame. 1. Vehicle identification number N O TE: The vehicle identification number is used to identify your machine. EBU00787 Model label The model label is affixed to the location in the illustration. Record the information on this la- bel in the space [...]

4-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EBU00039 CONTROL FUNCTIONS W ARNING Indicates a potential hazard that could result in serious injury or death. EBU00942 Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights and taillight come on when the light switch is on[...]

4-2 EBU00802 Indicator and warning lights 1. Reverse indicator light “ R ” 2. Neutral indicator light “ N ” 3. Coolant temperature warning light “” EBU00602 Reverse indicator light “ R ” This indicator light comes on when the trans- mission is in reverse. EBU00603 Neutral indicator light “ N ” This indicator light comes on when [...]

4-3 EBU00714 Coolant temperature warning light checking method ACB-09E Turn the main switch to “ ON ” and the engine stop switch to “” . Coolant tem perature warning light does not come o n. Coolant tem perature warning light comes on. Coolant tem perature warning light doe s not come on. Coolant tem perature and electrical c ircuit are OK.[...]

4-4 EBU00053 Handlebar switches 1. Light switch “ OFF/ / ” 2. Engine stop swit ch “ / ” 3. Start switch “” EBU01204 Light switch “ OFF/ / ” Set the switch to “” to turn on the low beam and the taillight. Set the switch to “” to turn on the high beam and the taillight. Set the switch to “ OFF ” to turn off all the lights.[...]

4-5 EBU00607 Start switch “” The starter motor cranks the engine when this switch is pushed. CAUTION: See starting instructions prior to starting the engine. (See page 6-1 for details.) U5LP12.book Page 5 Friday, April 26 , 2002 2:47 PM[...]

4-6 EBU00062 Throttle lever Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. 1. [...]

4-7 EBU01159 Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the ad- justing screw limits the maximum engine pow- er available and decreases the maximum speed of the ATV. 1. Locknut 2. Adjusting screw a. 12 mm (0.47 in) WA R N I N G POTENTIAL HAZARD Improper ad[...]

4-8 EBU00069 Clutch lever The clutch lever is located on the left handle- bar and the ignition circuit cut-off system is in- corporated in the clutch lever holder. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch opera[...]

4-9 EBU00989 Brake pedal The brake pedal is located on the right side of the machine. Push down on the pedal to apply the rear brake. 1. Brake pedal U5LP12.book Page 9 Friday, April 26 , 2002 2:47 PM[...]

4-10 EBU00080 Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Squeeze the clutch lever while push- ing the button, then push in the lock plate to apply the parking brake. Squeeze the clutch lever to release the parking brake. N O TE: When the parking brake is used, engine speed is li[...]

4-11 EBU0078 8 Shift pedal This machine is equipped with a constant- mesh 5-speed forward and 1-speed reverse transmission. The shift pedal is located on the left side of the engine and is used in combina- tion with the clutch when shifting. 1. Shift pedal WA R N I N G POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV coul[...]

4-12 EBU01028 Reverse knob “ REV ” The reverse knob is used to shift into reverse gear. Refer to the “ Reverse knob operation and re- verse driving ” section (page 6-5) before oper- ating this machine in reverse gear. 1. Reverse knob “ REV ” EBU00092 Fuel tank cap Remove the fuel tank cap by turning it coun- terclockwise. 1. Fuel t ank [...]

4-13 EBU00093 Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. OFF: With the lever in this position, fuel will not flow. Always turn the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with th[...]

4-14 EBU00095 Starter (choke) “” Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). Refer to “ Starting a cold engine ” for proper op- eration. (See page 6-1.) 1. Starter (choke) [...]

4-15 To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. NO TE: _ Make sure that the seat is securely fitted. _ 1. Proj ection ( × 2) 2. Seat holder ( × 2) U5LP12.book Page 15 Friday, A pril 26, 2002 2:47 PM[...]

4-16 EBU01104 Front shock absorber adjustment The spring preload can be adjusted to suit the rider ’ s weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the ad- justing ring in direction a . To decrease the spring preload, turn the ad- justing ring in direction b . 1. Spring preload adjusting[...]

4-17 WA R N I N G POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set- ting. U5LP12.book Page 17 Friday, A pril 26, 2002 2:47 PM[...]

4-18 EBU01207 Rear shock absorber adjustment The spring preload, rebound damping and compression damping forces of the rear shock absorber can be adjusted to suit the rid- er ’ s weight and the riding conditions. Adjust the spring preload as follows. 1. Loosen the locknut. 2. Turn the adjusting nut in direction a to increase the spring preload an[...]

4-19 3. The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjusting nut. A. Sp ring length 4. Tighten the locknut to the specified torque. CAUTION: _ Always tighten the locknut against the ad- justing nut and tighten it to the specified torque. _ Measurement A : Installed length: Minimum (hard): 232 mm (9.1 in) Standard:[...]

4-20 Adjust the rebound damping force as follows. Turn the rebound damping force adjusting screw in direction a to increase the rebound damping force and in direction b to decrease the rebound damping force. 1. Rebound damping force adjusting screw Adjust the compression damping force as fol- lows. Turn the compression damping force adjust- ing scr[...]

4-21 CAUTION: _ Never turn an adjusting mechanism be- yond the minimum and maximum settings. _ N O TE: _ Although the total number of clicks of a damp- ing force adjusting mechanism may not exact- ly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjust- ing range. To [...]

5-1 PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE Front brake • Check operation, free play, fluid level and fluid leakage. • Fill with DOT 4 brake fluid if necessary. 5-3 – 5-4, 8-25 – 8-28 Rear brake • Check operation, fluid level and fl uid leakage. • Fill with DOT4 brake fluid if necess[...]

5-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 WA R N I N G POTENTIAL HAZARD Failure to inspect the ATV before oper- ating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe op- erating conditi[...]

5-3 EBU01166 Front and rear brakes Brake lever and brake pedal ● Check that there is no free play in the brake lever. If there is free play, have a Yamaha dealer inspect the brake system. ● Check for correct brake pedal height. (See page 8-29.) If the pedal height is incorrect, have a Yamaha dealer adjust it. ● Check the operation of the leve[...]

5-4 EBU01085 Fuel Make sure there is sufficient gasoline in the tank. CAUTION: _ Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. _ Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane n[...]

5-5 Gasohol There are two types of gasohol; gasohol con- taining ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gaso- hol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems. 1. Fuel tank filler tube 2. Fuel lev[...]

5-6 EBU01084 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See page 8-6.) CAUTION: _ ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “ CD ” or oils of a high- er quality than specif[...]

5-7 EBU01127 Coolant Check the coolant level in the coolant reser- voir when the engine is cold. (The coolant lev- el will vary with engine temperature.) The coolant level is satisfactory if it is between the upper and lower level marks on the coolant reservoir. If the coolant level is at or below the lower level mark, add tap water (soft water) to[...]

5-8 EBU00498 Chain Check the general condition of the chain and check the chain slack before every ride. Lubri- cate and adjust the chain as necessary. (See pages 8-34 – 8-37 for details.) EBU01083 Throttle lever Check to see that the throttle lever operates correctly. It must open smoothly and spring back to the idle position when released. Have[...]

5-9 EBU00157 Tires WA R N I N G POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pres- sure. WHAT CAN HAPPEN Use of improper tires on this ATV, or op- eration of this ATV with improper or un- even tire pressure, may cause loss of control, increasing your risk of acci- dent. HOW TO AVOID THE HAZARD 1. The tire[...]

5-10 EBU00159 How to measure tire pressure Use the low-pressure tire gauge. N O TE: The low-pressure tire gauge is included as standard equipment. Make two measure- ments of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set pressure with tires cold. Set tire pressures to the f[...]

5-11 EBU00160 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. 3 mm (0.12 in) U5LP12.book Page 11 Friday, A pril 26, 2002 2:47 PM[...]

6-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EBU00161 OPERATION W ARNING Indicates a potential hazard that could result in serious injury or death. EBU0078 9 Starting a cold engine 1. Set the parking brake. 2. Turn the fuel cock to “ ON ” . 3. Turn the main switch to “ ON ” and the en- gine stop switch to “” . 4. Shift the transmission into neu[...]

6-2 NO TE: This model is equipped with an ignition circuit cut-off system. The engine can be started un- der the following conditions. ● When the transmission is in neutral. The neutral indicator light should come on. If the light does not come on, ask a Yamaha dealer to inspect it. ● When the clutch is disengaged with the transmission in any p[...]

6-3 NO TE: If the engine fails to start, release the start switch, then push it again. Pause a few sec- onds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. 7. If the engine is started with the starter (choke) in position 1 , the starter [...]

6-4 EBU00180 Starting a warm engine To start a warm engine, refer to the “ Starting a cold engine ” section. The starter (choke) should not be used. The throttle should be opened slightly. EBU00538 Warming up To get maximum engine life, always warm up the engine before starting off. Never acceler- ate hard with a cold engine! To see whether or [...]

6-5 EBU01209 Reverse knob operation and reverse driving CAUTION: _ Before shifting, stop the machine and re- turn the throttle lever to its closed posi- tion, otherwise the transmission may be damaged. _ 1. Bring the machine to a complete stop, re- turn the throttle lever to the closed posi- tion, apply the clutch lever, and shift the transmission [...]

6-6 EBU01173 Shifting This model h as a 5-speed forward a nd 1-speed reverse transmission. The tra nsmission allows you to control t he amount of power you have available at a given speed or for starting, accel- erating, climbing hills, e tc. To shift into neutral, return the throttle lever to the closed position, apply the clutch and repea tedly d[...]

6-7 CAUTION: _ ● Do not coast for long periods with the engine off, and do not tow the ma- chine a long distance. Even in neutral position, the transmission is only properly lubricated when the engine is running. Inadequate lubrication may cause damage. ● Always use the clutch when changing gears. The engine, transmission and drive train are no[...]

6-8 8. Follow the same procedure when shifting to the next higher gear. EBU00207 To decelerate: When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improp- er use of the brakes or shifting [...]

6-9 EBU00209 Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first several hours of running. During the first 20 hours[...]

6-10 EBU00211 Parking When parking, stop the engine and shift into neutral. Turn the fuel cock to “ OFF ” and apply the parking brake. 1. Button 2. Lock plate 1. Locked positio n U5LP12.book Page 10 Friday, A pril 26, 2002 2:47 PM[...]

6-11 EBU01174 Parking on a slope 1. Bring the machine to a stop by applying the brakes in low gear. 2. Stop the engine and release the clutch lever. 3. With the rear brake applied, apply the parking brake and slowly release the brake pedal. WA R N I N G POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of c[...]

6-12 EBU00221 Accessories and loading EBU00222 Accessories Accessories can affect the handling and con- trol of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. ● Choose only accessories designed for your ATV. Your Yamaha dealer has a va riety of genuine Yamaha accessories. Other ac- ce[...]

6-13 EBU00584 * Loading As originally equipped, this ATV is not de- signed to carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good judgment. Keep the following points in mind: ● Never exceed the weight limits shown. An overloaded ATV can be unstable. ● Lo[...]

6-14 WA R N I N G POTENTIAL HAZARD Overloading this ATV or carrying or tow- ing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle han- dling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carryin[...]

6-15 U5LP12.book Page 15 Friday, A pril 26, 2002 2:47 PM[...]

6-16 EBU01176 W ARNING _ Indicates a potential hazard that could result in serious injury or death. U5LP12.book Page 16 Friday, A pril 26, 2002 2:47 PM[...]

7-1 7 1- Riding Your ATV U5LP12.book Page 1 Friday, April 26, 2002 2:47 PM[...]

7-2 U5LP12.book Page 2 Friday, April 26 , 2002 2:47 PM[...]

7-3 W ARNING _ Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is intended for recreational use by experienced operators only. Even though you are an experienced operator of all other all terrain vehicles or motorcycles, riding the ATV requires special skills acquired through practice. Ta[...]

7-4 RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced. Beginners should get training from a certified instructor. Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum perfor- mance until you are totally familiar with the ATV ’ s handling and perform[...]

7-5 Not recommended for children under 16 years of age. WA R N I N G POTENTIAL HAZARD Failure to follow the age recommenda- tions for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not rec- ommended for their age can lead to se- vere injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with [...]

7-6 This ATV is designed to carry operator only - passengers prohibited. WA R N I N G POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/ or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long sea[...]

7-7 Apparel WA R N I N G POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye pro- tection and protective clothing. WHAT CAN HAPPEN Operating without an approved motor- cycle helmet in- creases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can re- sult i[...]

7-8 Do not operate after consuming alcohol or drugs. Operator ’ s performance capability is reduced by the influence of alcohol or drugs. WA R N I N G POTENTIAL HAZARD Operating this ATV after consuming al- cohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and per[...]

7-9 Pre-operation checks Always perform the pre-operation checks list- ed on page 5-1 before riding for safety and proper care of the ATV. WA R N I N G POTENTIAL HAZARD Failure to inspect the ATV before oper- ating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE H[...]

7-10 W ARNING _ Indicates a potential hazard that could result in serious injury or death. Do not operate at speeds too fast for your skills or the conditions. Speed limiter For riders inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter limits the power and top speed of the ATV[...]

7-11 Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or car- go. The ATV ’ s handling may be adversely af- fected. Reduce your speed when adding additional loads. MAXIMUM LOADING LIMIT Vehicle loading limit (total weight of rider, cargo and accessories): 100 kg (220 lb) WA R N I N G POTENTI[...]

7-12 During operation Always keep your feet on the footboards dur- ing operation. Otherwise your feet may con- tact the rear wheels. WA R N I N G POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can re- duce your ability to control the ATV or could cause you to [...]

7-13 Avoid wheelies and jumping. You may lose control of the ATV or overturn. WA R N I N G POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, in- cluding an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don ’ t try to show off. U5LP12.book Page 1[...]

7-14 Modifications WA R N I N G POTENTIAL HAZARD Operating this ATV with improper modi- fications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ- ations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improp- er installation or u[...]

7-15 Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the ATV in a place where pedestrians or children are not likely to touch it. WA R N I N G POTENTIAL HAZARD Hot exhaust system. WHAT CAN HAPPEN Dry grass or brush or other combustible material accumu[...]

7-16 BE CAREFUL WHERE YOU RID E This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of control. WA R N I N G POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the AT V, and may cause the vehicle t[...]

7-17 Do not ride on any public road, street, or high- way. Riding on public roads can result in colli- sions with other vehicles. WA R N I N G POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or hi[...]

7-18 Know the terrain where you ride. Ride cau- tiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and oth- er hidden hazards which may cause the ATV to upset. WA R N I N G POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, [...]

7-19 WA R N I N G POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an acci- dent, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you hav[...]

7-20 When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. Do not ride in areas posted “ no trespassing ” . Do not ride on private property without getting permission. WA R N I N G POTENTIAL HAZARD Operating in areas where you migh[...]

7-21 Select a large, flat area off-road to become fa- miliar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedures, and turning techniques in this area before trying more difficult terrain. Al- ways avoid riding on paved surfaces: the ATV is designed f[...]

7-22 CAUTION: _ Do not shift gears without releasing the throttle. Damage to the engine or drive train may occur. _ When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Be sure that the engine has sufficiently slowed before engaging a lower gear. Improp- er use of the[...]

7-23 TURNING YOUR ATV To achieve maximum traction while riding off- road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the in- side of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to[...]

7-24 This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesn ’ t turn, come to a stop and then practice the procedure again. If the riding sur- face is slippery or loose, it may help to posi- tion more of your [...]

7-25 CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can ma- neuver your ATV well on flat ground before at- tempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose su[...]

7-26 WA R N I N G POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Own- er ’ s Manual. Always check the terrain carefully be- fore you start up any hill. Never climb hills with excess[...]

7-27 If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. WA R N I N G POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause los[...]

7-28 If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dis- mount the ATV on the uphill side. Physically turn the ATV around and then descend the hill. If you start to roll [...]

7-29 Dismount on uphill si de or to a side if pointed straight uphill. Turn the ATV around and remount, following the pro- cedure described in the Owner ’ s Manu- al. U5LP12.book Page 29 Friday, A pril 26, 2002 2:47 PM[...]

7-30 RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Choose a low gear which will allow the engine compression to do most of the braking for you. Improper braking may cause a loss of traction. Use caution while descendi[...]

7-31 U5LP12.book Page 31 Friday, A pril 26, 2002 2:47 PM[...]

7-32 CROSSING A SLOPE Traversing a sloping surface on your ATV re- quires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance. As you travel [...]

7-33 Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. U5LP12.book Page 33 Friday, A pril 26, 2002 2:47 PM[...]

7-34 CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 inches) in depth. Before entering the wa- ter, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or up- set the ATV. Drive slowly and carefully. WA R N[...]

7-35 Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. CAUTION: _ After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case. Wash the ATV in fresh water if it has been operated in salt wa[...]

7-36 RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. WA R N I N G POTEN[...]

7-37 U5LP12.book Page 37 Friday, A pril 26, 2002 2:47 PM[...]

7-38 SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, position- ing your weight over the front wheels will sometimes help. If the rear whee[...]

7-39 With practice, over a period of time, skill at controlled sliding can be developed. The ter- rain should be chosen carefully before at- tempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost. WA[...]

7-40 WHAT TO DO IF ... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. WHAT TO DO ... ● If your ATV doesn ’ t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the [...]

7-41 ● If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to main- tain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you dis- cover that the ATV is going to tip over, dis- mount on the uphill side[...]

8-1 EBU00515 PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection, adjustment and lubrica- tion will keep your machine in the sa fest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, ad- justment and lubrication are explained on the following pages. EBU01221 Own[...]

8-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 The service information included in this man- ual is intended to provide you, the owner, with the necessary information for completing your own preventive maintenance and minor re- pairs. The tools provided in the owner ’ s tool kit are sufficient for this purpose, except that a torque wrench is also necessary[...]

8-3 EBU00261 PERIODIC MAINTENANCE/LUBRICATION ITEM ROUTINE INITIAL EVERY 1 month 3 months 6 months 6 months 1 year Valves* • Chec k valve clear ance. • Adjust if nece ssary. Cooling system • Check coolan t leakage. • Repair if ne cessary. • Replace co olant every 24 months. Spark plug • Check condit ion. • Adjust gap an d clean. • R[...]

8-4 * It is recommended that these items be serviced by a Yamaha dealer. ** Lithium-soap-based grease NO TE: ● Recommended brake fluid: DOT4 ● Brake fluid replacement: • When disassembli ng the master cylin ders or calipers, re- place the brake fluid. Normally check the brake fluid level and add fl uid as re- quired. • On the inner parts of[...]

8-5 EBU00807 Panel removal and installation 1. Panel A The panel illustrated needs to be removed to perform some of the maintenance described in this chapter. Refer to this section each time the panel has to be removed or installed. EBU01013 Panel A 1. Panel A 2. Bolt ( × 2) To remove Remove the bolts, and then take the panel off. To install Place[...]

8-6 EBU01238 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the inter- vals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Place the ATV on a level surface. 2. Start the engine, w[...]

8-7 4. If the engine oil is below the minimum level mark, add sufficient oil of the recom- mended type to raise it to the correct lev- el. NO TE: _ When adding oil, be careful not to overfill the engine oil tank; the oil level rises faster start- ing from the half-level-portion on the dipstick. _ 5. Insert the dipstick into the oil filler hole, and[...]

8-8 4. Remove the crankcase engine oil drain bolt. 1. Crankcase engine oil drain bolt 1. Engine oil tank drain bolt 5. Remove the engine oil tank filler cap and the oil tank drain bolt. 6. Check the washers for damage, and re- place if necessary. U5LP12.book Page 8 Friday, April 26 , 2002 2:47 PM[...]

8-9 NO TE: _ Skip steps 7 – 8 if the oil filter cartridge is not being replaced. _ 7. Remove the oil filter cartridge with an oil filter wrench. 1. Oil filter cartridge 2. Oil filter wrench NO TE: _ An oil filter wrench is available at a nearby Yamaha dealer. _ 1. O-ring 8. Apply a thin coat of engine oil to the O- ring of the new oil filter cart[...]

8-10 10. Install the crankcase engine oil drain bolt and the engine oil tank drain bolt, and then tighten them to the specified torques. 11. Pour only 1.75 L (1.54 Imp qt, 1.88 US qt) of the specified amount of recommended engine oil through the engine oil tank filler hole, insert the dipstick, and then tighten the oil tank filler cap. 12. Start th[...]

8-11 14. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 15. Turn the engine off, and then check the oil level and correct it if necessary. EBU01015 Cooling system 1. Check the coolant level in the coolant reservoir when the eng[...]

8-12 CAUTION: _ Hard water or salt water is harmful to the engine. You may use soft water if you can ’ t get distilled water. _ N O TE: _ ● If water is added, have a Yamaha dealer check the antifreeze content of the cool- ant as soon as possible. ● The radiator fan operation is completely automatic. It is switched on or off accord- ing to the[...]

8-13 1. Place the ATV on a level surface. 2. Remove panel A. (See page 8-5 for pan- el removal and installation procedures.) 3. Place a container under the engine, and then remove the coolant drain bolt. 1. Coolant drain bolt 4. Remove the radiator cap. 1. Radiator cap U5LP12.book Page 13 Friday, A pril 26, 2002 2:47 PM[...]

8-14 5. Remove the coolant reservoir cap. 6. Disconnect the hose on the coolant res- ervoir side, and then drain the coolant from the coolant reservoir. 1. Coolant reservoir cap 2. Hose 7. After draining the coolant, thoroughly flush the cooling system with clean tap water. 8. Replace the coolant drain bolt washer if it is damaged, and then tighten[...]

8-15 CAUTION: _ Hard water or salt water is harmful to the engine. You may use soft water if you can- not get distilled water. _ 12. Install the radiator cap and the coolant reservoir cap. 13. Start the engine and let it idle for several minutes. Stop the engine, and then check the coolant level in the radiator. If it is low, add more coolant until[...]

8-16 2. Use the spark plug wrench in the tool kit to remove the spark plug as shown. 1. Spark plug wrench Inspection The spark plug is an important engine compo- nent and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. The ideal color on the white insulator around the center electrode is a medium-to-lig[...]

8-17 Installation 1. Measure the electrode gap with a wire thickness gauge and, if necessary, adjust the gap to specification. a. Spark plug gap 2. Clean the gasket surface. Wipe off any grime from the threads. 3. Install the spark plug and tighten it to the specified torque. NO TE: _ If a torque wrench is not available when you are installing a sp[...]

8-18 EBU01211 Air filter element cleaning NO TE: _ There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. _ 1. Check hose 1. Remove the seat. (See page 4-14 for seat removal and installation proce- dures.) 1. Air filter case cover 2. Ho[...]

8-19 1. Unlock 2. Element retaining plate 5. Wash the air filter element gently but thoroughly in solvent. 1. Frame 2. Air filter element 3. Element retaining plate 6. Squeeze the excess solvent out of the air filter element and let it dry. CAUTION: _ Do not twist the air filter element when squeezing it. _ 7. Inspect the air filter element and rep[...]

8-20 8. Apply Yamaha foam air filter oil or other quality foam air filter oil to the air filter el- ement. If foam air filter oil is not available, engine oil may be used. NO TE: _ The air filter element should be wet but not dripping. _ 9. Pull the air filter element over its frame. 10. Install the air filter element. 1. Hose 11. Install the air f[...]

8-21 EBU00780 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolt. 1. Bolt 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe. 1. Tailpipe 2. [...]

8-22 EBU0029 6 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and ex- perience to do so. However, the idling speed may be performed by the owner as a part of the usual maintenance routine. CAUTION: The [...]

8-23 EBU01143 Idle speed adjustment NO TE: _ A diagnostic tachometer must be used for this procedure. _ 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Connect the tachometer to the spark p[...]

8-24 EBU00303 Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clear- ance must be adjusted regularly. This adjust- ment however, should be left to a professional Yamaha service technician. EBU0030 7 Throttle lever adjustment N O TE: Adjust the[...]

8-25 EBU01027 Front and rear brake pad inspection Each brake pad is provided with a wear indi- cator groove. The indicators allow checking of brake pad wear without disassembling the brake. Apply the brake and inspect the wear indicator grooves. If the pad is worn to the point that the wear indicator grooves are al- most in contact with the disc pl[...]

8-26 EBU01214 Brake fluid level inspection Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indi- cate worn brake pads and/or brake system leakage. If the br[...]

8-27 1. Brake fluid reservoir cover 2. Bolt ( × 2) Observe these precautions: ● When checking the brake fluid level, make sure the top of the brake fluid reservoir is level. ● Use only the designated quality brake fluid, otherwise, the rubber seals may deterio- rate, causing leakage and poor brake per- formance. ● Refill with the same type o[...]

8-28 EBU01187 Front brake lever free play The front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have a Yamaha dealer check the brake sys- tem. a. Brake lever free play WA R N I N G POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which coul[...]

8-29 EBU01191 Brake pedal height adjustment The top of the brake pedal should be posi- tioned 4 mm (0.16 in) below the top of the footrest. If not, have a Yamaha dealer adjust it. a. Brake pedal position WA R N I N G POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could l[...]

8-30 EBU01193 Parking brake adjustment Parking brake adjustment may be required if the parking brake does not hold properly. The cable length A should be adjusted to 64 – 68 mm (2.52 – 2.68 in) 1. Locknut 2. Adjusting bolt A. Cable length 1. Fully loosen the locknut and the adjusting bolt at the clutch lever. 2. Loosen the locknut and the adjus[...]

8-31 5. Screw in the adjusting bolt at the rear brake caliper by hand until it feels tight, then screw it out 1/8 turn. Tighten the locknut to the specified torque. CAUTION: _ When tightening the locknut, hold the ad- justing bolt with a wrench so that the ad- justing bolt does not turn together with the locknut. _ Tightening torque: Locknut: 16 Nm[...]

8-32 EBU00833 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and brake lever, is proper- ly adjusted when the brake light comes on just before braking takes effect. If necessary, ad- just the brake light switch as follows. Turn the adjusting nut while holding the rear brake light switch in p[...]

8-33 1. Locknut 2. Adjusting bolt c. Cl utch lever free pl ay 6. Loosen the locknut at the crankcase side. 7. Turn the adjusting nut at the crankcase in direction a to increase the free play or in direction b to decrease the free play. 8. Tighten the locknut at the crankcase and the clutch lever. 1. Locknu t 2. Ad justing nu t U5LP12.book Page 33 F[...]

8-34 EBU01144 Drive chain slack check NO TE: _ Move the ATV back and forth and find the tightest position of the drive chain. Check and/ or adjust the chain slack while it is in this tight- est position. _ To check the drive chain slack, all tires must be touching the ground and there should be no weight on it. Check the drive chain slack at the po[...]

8-35 EBU01194 Drive chain slack adjustment 1. Loosen the rear wheel hub upper and lower nuts. 1. Upper wheel hub nut 2. Lower wheel hub nut 2. Loosen the locknuts on each side of the swingarm. To tighten the drive chain, turn the adjusting bolts in direction a . To loosen the drive chain, turn the adjusting bolts in direction b and push the wheels [...]

8-36 EBU0080 5 Lubricating the drive chain The drive chain must be cleaned and lubricat- ed at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. 1. O-rings CAUTION: The drive chain must be lubricated after w[...]

8-37 1. Clean the drive chain with kerosene and a small soft brush. CAUTION: To prevent damaging the O-rings, do not clean the drive chain with steam cleaners, high-pressure washers or inappropriate solvents. 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant. CAUTION: Do not use engine oil or[...]

8-38 Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. EBU0073 7 Brake and shift pedal/brake and clutch lever lubrication Lubricate the pivoting parts of each lever and pedal. Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil Recommended lubricant: Lith[...]

8-39 EBU01018 Front upper and lower arm pivot lubrication Lubricate the upper and lower arm pivots. 1. Upper grease nipple 2. Lower grease nipple ( × 2) 1. Upper grease nipple 2. Lower g rease nipple ( × 2) Recommended lubricant: Lithium-soap-based grease Left side Right side U5LP12.book Page 39 Friday, A pril 26, 2002 2:47 PM[...]

8-40 EBU00987 Rear arm pivot lubrication Lubricate the rear arm pivots. 1. Grease nipple 1. Grease nipple Recommended lubricant: Lithium-soap-based grease U5LP12.book Page 40 Friday, A pril 26, 2002 2:47 PM[...]

8-41 EBU01112 Wheel removal 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. 1. Nut ( × 4) 1. Nut ( × 4) Front Rear U5LP12.book Page 41 Friday, A pril 26, 2002 2:47 PM[...]

8-42 EBU00782 Wheel installation When installing a wheel, reverse the removal procedure. N O TE: ● When installing a front wheel, the arrow mark on the tire must point toward the rotating direction of the wheel. ● When installing a rear wheel, the wo rding on the tire “ SIDE FACING OUTWARDS ” must be facing outwards. 1. Arrow mark 1. “ SI[...]

8-43 EBU00380 Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the bat- tery. If the battery seems to have discharged, consult a Yamaha dealer. CAUTION: Do not try to remove the sealing caps of the battery cells. You may damage the bat- tery. WA R N I N G P[...]

8-44 EBU00385 Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. CAUTION: A special battery charger (constant volt- age/ampere or constant voltage) is re- quired for recharging a sealed-type battery. Using a conventi[...]

8-45 CAUTION: To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. EBU01215 Replacing a headlight bulb If a headlight bulb burns out, replace the bulb as follows. 1. Remove the headlight assembly by re- moving the bolts. 1. Headlight assembly 2. Bolt ( × 2) WA R N I N G POTENTIAL HAZARD Using an impro[...]

8-46 2. Disconnect the headlight coupler. 1. Headlight couple r 3. Remove the screw. 1. Screw 4. Remove the headlight cover from the headlight assembly. U5LP12.book Page 46 Friday, A pril 26, 2002 2:47 PM[...]

8-47 5. Remove the screw and pull the headlight unit out from its case. 1. Screw NO TE: _ Pull outward on the rear of the headlight unit, and then pull outward on the front. _ 6. Remove the headlight bulb holder cover. 1. Headlight bulb holder cover U5LP12.book Page 47 Friday, A pril 26, 2002 2:47 PM[...]

8-48 7. Push the headlight bulb holder inward, turn it counterclockwise and remove the defective bulb. 1. Headlight bulb holder WA R N I N G POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flamma- ble. HOW TO AVOID T[...]

8-49 8. Put a new headlight bulb into position and secure it in place with the bulb hold- er. 1. Headlight bulb 2. Headlight bulb holder 9. Install the headlight bulb holder cover. CAUTION: _ Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated against the reflector. _ 10. Align the projections on the headlig[...]

8-50 EBU01217 Tail/brake light bulb replacement 1. Remove the lens by removing the screws. 1. Lens 2. Screw ( × 2) 2. Remove the defective bulb by pushing it inward and turning it counterclockwise. 1. Bulb 3. Install a new bulb by pushing it inward and turning it clockwise. 4. Install the lens by installing the screws. CAUTION: _ Do not overtighte[...]

8-51 EBU00412 Troubleshooting Although Yamaha machines receive a rigid in- spection before shipment from the factory, trouble may occur during operation. Any prob- lem in the fuel, compression, or ignition sys- tems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your mach[...]

8-52 EBU00806 Troubleshooting charts Starting problems or poor engine performance 1. Fuel Check if there is fuel in the fuel tank. There is fuel. Turn the fuel cock lever to “ OFF ” . No fuel. Fuel cock is clogged. Clean the fuel cock. Some fuel. Turn the fuel cock lever to “ RES ” . Restart the engine. No fuel. Supply fuel. 2. Compression [...]

8-53 Engine overheating N O TE: If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recommended coolant as soon as possible. WA R N I N G POTENTIAL HAZARD Removing the radiator cap when the en- gine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and s[...]

9-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EBU00417 CLEANING AND STORAGE A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to prevent water entry. A pla[...]

9-2 7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes. WA R N[...]

9-3 EBU00525 B. STORAGE Long term storage (60 days or more) of your machine will require some preventive proce- dures to guard against deterioration. After thoroughly cleaning the machine, prepare for storage as follows: 1. Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or an equiva- lent p[...]

9-4 8. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an ex- cessively warm or cold place (less than 0 ° C (30 ° F) or more than 30 ° C (90 ° F)). N O TE: Make any necessary repairs before storing the machine. U5LP12.book Page 4 Friday, April 26 , 2002 2:47 PM[...]

10-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EBU00428 SPECIFICATIONS MODEL YFM660R Dimension: Overall length Overall width Overall height Seat height Wheel base Ground clearance Minimum turning radiu s 1,830 mm ( 72 in) 1,100 mm ( 43.3 in) 1,150 mm ( 45.3 in) 860 mm ( 33.9 in) 1,245 mm ( 49 in) 265 mm ( 10.4 in) 3,300 mm ( 129 .9 in) Basic weight: With oi[...]

10-2 Engine oil: Type Recommended engine oil classification : API Service SE, SF, SG type or highe r Quantity: Periodic oil chang e With oil filter replacement Total amount 1.9 L (1.67 Imp qt, 2.01 US qt) 1.95 L (1.72 Imp qt, 2.06 US qt) 2.3 L (2.02 Imp qt, 2.43 US qt) MODEL YFM660R 0 ˚ 10 ˚ 30 ˚ 50 ˚ 70 ˚ 90 ˚ 110 ˚ 130 ˚ F YAMALUBE 4 (10W[...]

10-3 Radiator capacity (includin g all routes): 1.3 L (1.14 lmp qt, 1.37 US qt) Air filter: Wet element Fuel: Type Tank capacity Reserve amount UNLEADED GASOLINE ONLY 12 L (2.64 Imp gal, 3.17 US gal) 2.6 L (0.57 Imp gal, 0.69 US gal) Carburetor: Type × quantity Manufactur er BSR33 × 1 MIKUNI Spark plug: Type/manufacturer Gap DPR8EA-9/NGK 0.8 – [...]

10-4 Gear ratio: 1st 2nd 3rd 4th 5th Reverse 31/12 (2.583) 30/18 (1.667) 27/21 (1.286) 22/21 (1.047) 19/21 (0.904) 33/25 × 25/18 (1.833) Chassis: Frame type Caster angle Trail Steel tube 8 ° 47 mm (1.85 in) Tire: Type Size: Front Size: Rear Tubeless AT21 × 7 - 10 AT20 × 10 - 9 Brake: Front brake type Operatio n Rear brake type Operatio n Dual d[...]

10-5 Wheel travel: Front Rear 230 mm (9.06 in) 220 mm (8.66 in) Electrical: Ignition system Generator system Battery type/voltage capacity DC-C.D.I. A.C. magneto YTX14-BS/12 V, 12 Ah Headlight type: Krypton bulb Bulb voltage, wattage × quantity: Headlight Tail/brake light Indicator/warning lights: Neutral Reverse Coolant temperature 12V, 30 W/ 30 [...]

11-1 EBU00430 NOISE REGULATION TAMPERING WITH NOISE CONTROL SYS TEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop- erative by any person other than for purposes of maintenance, repair, or replacement of any de- vice or element of design incorporated into any new vehicle for the purpos[...]

12-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 EBU00431 MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and insta ll will be required to docu- ment maintenance done in accordance with the warranty. The chart below is printed only as a re- minder to you that the maintenance work is required. It is not acceptable proof of maint[...]

13-1 EBU00432 YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY U5LP12.book Page 1 Friday, April 26 , 2002 2:47 PM[...]

13-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 U5LP12.book Page 2 Friday, April 26 , 2002 2:47 PM[...]

14-1 EBU00435 YAMAHA EXTENDED SERVIC E (Y.E.S.) U5LP12.book Page 1 Friday, April 26 , 2002 2:47 PM[...]

14-2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 U5LP12.book Page 2 Friday, April 26 , 2002 2:47 PM[...]

14-3 EBU00436 W ARNING Indicates a potential hazard that could result in serious injury or death. U5LP12.book Page 3 Friday, April 26 , 2002 2:47 PM[...]

14-4 U5LP12.book Page 4 Friday, April 26 , 2002 2:47 PM[...]

14-5 EBU00437 U5LP12.book Page 5 Friday, April 26 , 2002 2:47 PM[...]

EBU00776[...]

5LP-28199-12 LIT-11626-16-09 READ THIS MANUAL CAREFULLY! It contains important safety information. This ATV should not be ridden by anyone under 16 years of age. WARNING YFM660RR OWNER’S MANUAL PRINTED IN JAPAN 2002.04-5.1 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . EBU00438 LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INS[...]

Card.fm Page 1 Wednesday, June 13, 200 1 9:35 AM[...]

Card.fm Page 2 Wednesday, June 13, 200 1 9:35 AM[...]