Yamaha 2004 YXR660 Manuals

Manuals and User Guides for Yamaha 2004 YXR660. We have 1 Yamaha 2004 YXR660 manual available for free PDF download: Service Manual

Yamaha 2004 YXR660 Service Manual

Yamaha 2004 YXR660 Service Manual (506 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 23.6 MB

Table of Contents

Table of Contents

4
- Specifications
  2
  - Table of Contents
    4
- Chapter 1 General Information
  
  14
  - Vehicle Identification
    14
    
    Model Label
    14
    
    Vehicle Identification Number
    14
  - Features
    15
    
    Self-Adjusting Parking Brake Mechanism
    15
  - Important Information
    18
    
    Gaskets, Oil Seals and O-Rings
    18
    
    Preparation for Removal Procedures
    18
    
    Replacement Parts
    18
    
    Bearings and Oil Seals
    19
    
    Circlips
    19
    
    Lock Washers/Plates and Cotter Pins
    19
  - Checking of Connections
    20
  - Special Tools
    21
- Chapter 2 Specifications
  
  26
  - General Specifications
    26
  - Engine Specifications
    29
  - Chassis Specifications
    37
  - Electrical Specifications
    39
  - Tightening Torques
    41
    
    Engine Tightening Torques
    41
    
    Chassis Tightening Torques
    44
  - General Tightening Torque Specifications
    47
  - How to Use the Conversion Table
    47
  - Lubrication Points and Lubricant Types
    48
    
    Engine
    48
  - Coolant Flow Diagrams
    49
  - Oil Flow Diagrams
    52
  - Cable Routing
    57
- Chapter 3 Periodic Checks and Adjustments
  
  74
  - Introduction
    74
  - Periodic Maintenance/Lubrication
    74
  - Engine
    76
    
    Adjusting the Valve Clearance
    76
    
    Adjusting the Idling Speed
    79
    
    Adjusting the Timing Chain
    79
    
    Adjusting the Throttle Cable
    80
    
    Adjusting the Starter Cable
    81
    
    Checking the Spark Plug
    82
    
    Checking the Ignition Timing
    83
    
    Measuring the Compression Pressure
    84
    
    Checking the Engine Oil Level
    86
    
    Changing the Engine Oil
    87
    
    Cleaning the Air Filter
    89
    
    Checking the Coolant Level
    91
    
    Changing the Coolant
    92
    
    Cooling System
    94
    
    Checking the Coolant Temperature Warning Light
    96
    
    Checking the V-Belt
    97
    
    Cleaning the Spark Arrester
    98
  - Chassis
    99
    
    Adjusting the Brake Pedal
    99
    
    Adjusting the Parking Brake
    100
    
    Checking the Brake Fluid Level
    101
    
    Checking the Front Brake Pads
    102
    
    Checking the Rear Brake Pads
    102
    
    Bleeding the Hydraulic Brake System
    103
    
    Checking the Brake Hoses and Brake Pipes
    103
    
    Adjusting the Brake Light Switch
    105
    
    Adjusting the Select Lever Shift Rod
    105
    
    Checking the Final Gear Oil Level
    106
    
    Changing the Final Gear Oil
    107
    
    Checking the Differential Gear Oil
    107
    
    Changing the Differential Gear Oil
    108
    
    Checking the Constant Velocity Joint Dust Boots
    109
    
    Adjusting the Toe-In
    110
    
    Checking the Steering System
    110
    
    Adjusting the Front Shock Absorbers
    112
    
    Adjusting the Rear Shock Absorbers
    112
    
    Checking the Tires
    113
    
    Checking and Lubricating the Cables
    115
    
    Checking the Wheels
    115
    
    Lubricating the Pedal, Etc
    116
  - Electrical
    117
    
    Checking and Charging the Battery
    117
    
    Checking the Fuses
    122
    
    Adjusting the Headlight Beam
    124
    
    Changing the Headlight Bulb
    124
    
    Changing the Tail/Brake Light Bulb
    125
- Chapter 4 Engine
  
  127
  - Engine Removal
    127
    
    Air Ducts, Muffler and Exhaust Pipe
    127
    
    Select Lever Unit and Coolant Reservoir
    129
    
    Hoses and Leads
    130
    
    Engine Mounting Bolts
    132
    
    Installing the Engine
    134
  - Cylinder Head Cover
    135
    
    Checking the Cylinder Head Cover
    137
    
    Checking the Tappet Covers
    137
    
    Removing the Cylinder Head Cover
    137
    
    Installing the Cylinder Head Cover
    138
  - Rocker Arms
    139
    
    Checking the Rocker Arms
    141
    
    Removing the Rocker Arms
    141
    
    Installing the Rocker Arms
    142
  - Camshaft and Cylinder Head
    143
    
    Checking the Camshaft
    145
    
    Removing the Camshaft and Cylinder Head
    145
    
    Checking the Camshaft Sprocket
    146
    
    Checking the Decompression System
    146
    
    Checking the Timing Chain Guide (Exhaust Side)
    146
    
    Checking the Timing Chain Tensioner
    146
    
    Checking the Cylinder Head
    147
    
    Installing the Camshaft and Cylinder Head
    148
  - Valves and Valve Springs
    151
    
    Removing the Valves and Valve Springs
    152
    
    Checking the Valves and Valve Springs
    153
    
    Installing the Valves and Valve Springs
    157
  - Cylinder and Piston
    159
    
    Checking the Cylinder and Piston
    160
    
    Removing the Piston
    160
    
    Checking the Piston Rings
    162
    
    Checking the Piston Pin
    163
    
    Installing the Piston
    163
    
    Installing the Cylinder
    165
  - Engine Cooling Fan and A.C. Magneto
    166
    
    Checking the A.C. Magneto
    169
    
    Removing the A.C. Magneto
    169
    
    Checking the Starter Clutch
    170
    
    Checking the Engine Cooling Fan
    171
    
    Installing the A.C. Magneto
    171
  - Balancer Gears and Oil Pump Gears
    174
    
    Checking the Balancer Drive Gear and Balancer Driven Gear
    176
    
    Checking the Oil Pump Drive Gear and Oil Pump Driven Gear
    176
    
    Removing the Balancer Drive Gear and Balancer Driven Gear
    176
    
    Installing the Balancer Drive Gear and Balancer Driven Gear
    177
  - Primary and Secondary Sheaves
    178
    
    Primary Sheave
    180
    
    Secondary Sheave
    181
    
    Disassembling the Secondary Sheave
    182
    
    Removing the Primary and Secondary Sheaves
    182
    
    Checking the Primary Sheave
    183
    
    Checking the Secondary Sheave
    183
    
    Assembling the Primary Sheave
    184
    
    Assembling the Secondary Sheave
    184
    
    Installing the Primary and Secondary Sheaves
    186
  - Clutch
    187
    
    Checking the Clutch
    189
    
    Removing the Clutch
    189
    
    Installing the Clutch
    190
  - Crankcase
    192
    
    Starter Motor, Timing Chain and Oil Filter
    192
    
    Crankcase
    193
    
    Crankcase Bearings
    195
    
    Checking the Oil Delivery Pipe
    196
    
    Checking the Timing Chain and Guides
    196
    
    Separating the Crankcase
    196
    
    Assembling the Crankcase
    197
    
    Checking the Bearings
    197
    
    Checking the Crankcase
    197
    
    Checking the Relief Valve
    197
    
    Installing the Shift Levers
    198
  - Crankshaft and Oil Pump
    199
    
    Oil Pump
    200
    
    Checking the Oil Pump
    201
    
    Removing the Crankshaft
    201
    
    Assembling the Oil Pump
    202
    
    Checking the Oil Strainer
    202
    
    Checking the Relief Valve
    202
    
    Checking the Crankshaft
    203
    
    Installing the Crankshaft and Balancer
    204
  - Transmission
    205
    
    Drive Axle Assembly
    206
    
    Checking the Shift Forks
    207
    
    Removing the Transmission
    207
    
    Checking the Drive Axle
    208
    
    Checking the High Wheel Gear and Middle Drive Gear
    208
    
    Checking the Shift Drum
    208
    
    Checking the Chain
    209
    
    Checking the Secondary Shaft and Driven Sprocket
    209
    
    Assembling the Shift Fork Assembly
    210
    
    Installing the Transmission
    210
  - Middle Gear
    211
    
    Middle Drive Shaft
    211
    
    Middle Driven Shaft
    212
    
    Removing the Middle Drive Shaft
    214
    
    Removing the Middle Driven Shaft
    214
    
    Checking the Pinion Gears
    217
    
    Selecting the Middle Drive and Driven Gear Shims
    218
    
    Installing the Middle Driven Shaft
    221
    
    Installing the Middle Drive Shaft
    223
    
    Measuring the Middle Gear Backlash
    224
- Chapter 5 Cooling System
  
  225
  - Radiator and Coolant Reservoir
    225
    
    Checking the Radiator
    227
    
    Installing the Radiator
    228
  - Water Pump
    229
    
    Checking the Water Pump
    231
    
    Disassembling the Water Pump
    231
    
    Assembling the Water Pump
    232
  - Oil Cooler
    234
    
    Checking the Oil Cooler
    236
- Chapter 6 Fuel System
  
  237
  - Fuel Pump and Fuel Tank
    237
    
    Checking the Fuel Pump Operation
    239
  - Carburetor
    240
    
    Checking the Carburetor
    244
    
    Disassembling the Carburetor
    244
    
    Assembling the Carburetor
    246
    
    Adjusting the Fuel Level
    247
- Chapter 7 Drive Train
  
  248
- Chapter 8
  
  283
  - Chassis
    283
  - Front Bumper and Hood
    283
  - Seats, Console and Instrument Panels
    284
  - Panels and Footrest Cover
    286
  - Cargo Bed
    288
  - Skid Plates
    290
  - Enclosure and Seat Belts
    291
  - Front Wheels and Brake Discs
    292
    
    Checking the Front Wheel
    294
    
    Checking the Front Wheel Hub
    294
    
    Checking the Front Brake Disc
    295
    
    Installing the Front Wheel
    295
    
    Installing the Front Wheel Hub
    295
  - Rear Wheels and Brake Disc
    296
    
    Rear Wheels
    296
    
    Rear Brake Disc
    297
    
    Checking the Rear Brake Disc
    298
    
    Checking the Rear Wheel
    298
    
    Checking the Rear Wheel Hub
    298
    
    Installing the Rear Wheel
    299
    
    Installing the Rear Wheel Hub
    299
  - Front and Rear Brakes
    300
    
    Front Brake Pads
    300
    
    Rear Brake Pads
    301
    
    Replacing the Front Brake Pads
    302
    
    Replacing the Rear Brake Pads
    303
    
    Brake Master Cylinder
    306
    
    Assembling the Brake Master Cylinder
    308
    
    Checking the Master Cylinder
    308
    
    Installing the Brake Master Cylinder
    309
    
    Front Brake Caliper
    311
    
    Rear Brake Caliper
    313
    
    Disassembling the Front Brake Calipers
    317
    
    Disassembling the Rear Brake Caliper
    317
    
    Checking the Front and Rear Brake Calipers
    318
    
    Assembling the Front Brake Calipers
    319
    
    Assembling the Rear Brake Caliper
    320
    
    Installing the Front Brake Calipers
    322
    
    Installing the Rear Brake Caliper
    323
  - Pedal Assembly
    325
  - Steering System
    327
    
    Steering Column and Steering Assembly
    327
    
    Checking the Steering Assembly
    330
    
    Checking the Steering Joint
    330
    
    Disassembling the Steering Assembly
    330
    
    Assembling the Steering Assembly
    331
    
    Installing the Steering System
    332
    
    Tie-Rod and Steering Knuckle
    333
    
    Checking the Steering Knuckles
    334
    
    Checking the Tie-Rods
    334
    
    Removing the Steering Knuckles
    334
  - Front Arms and Front Shock Absorber
    338
    
    Checking the Front Arms
    340
    
    Removing the Front Arms
    340
    
    Checking the Front Shock Absorber
    342
    
    Installing the Front Arms and Front Shock Absorber
    343
  - Rear Knuckle and Stabilizer
    344
    
    Checking the Rear Knuckle
    345
    
    Checking the Stabilizer
    345
  - Rear Arms and Rear Shock Absorber
    346
    
    Checking the Rear Arms
    347
    
    Checking the Rear Shock Absorber
    347
    
    Installing the Rear Arms and Rear Shock Absorber
    348
- Chapter 9 Electrical
  
  349
  - Electrical Components
    350
  - Checking the Switch
    351
    
    Checking a Switch Shown in the Manual
    351
    
    Checking the Switch Continuity
    352
  - Checking the Bulbs and Bulb Sockets
    354
    
    Checking the Condition of the Bulbs
    354
    
    Types of Bulbs
    354
    
    Checking the Condition of the Bulb Sockets
    356
  - Ignition System
    357
    
    Circuit Diagram
    357
    
    Troubleshooting
    358
  - Electric Starting System
    363
    
    Circuit Diagram
    363
    
    Starting Circuit Operation
    364
    
    Troubleshooting
    365
    
    Starter Motor
    368
    
    Checking the Starter Motor
    369
    
    Assembling the Starter Motor
    370
  - Charging System
    371
    
    Circuit Diagram
    371
    
    Troubleshooting
    372
  - Lighting System
    374
    
    Circuit Diagram
    374
    
    Troubleshooting
    375
    
    Checking the Lighting System
    377
  - Signaling System
    379
    
    Circuit Diagram
    379
    
    Troubleshooting
    381
    
    Circuit Diagram
    382
    
    Checking the Signal System
    383
  - Cooling System
    393
    
    Circuit Diagram
    393
    
    Troubleshooting
    394
    
    Circuit Diagram
    397
  - 2Wd/4Wd Selecting System
    398
    
    Circuit Diagram
    398
    
    Troubleshooting
    399
    
    Circuit Diagram
    402
  - Carburetor Heating System
    403
    
    Circuit Diagram
    403
    
    Troubleshooting
    404
    
    Circuit Diagram
    406
    
    Troubleshooting
    407
  - Starting Failure/Hard Starting
    407
- Chapter 10
  
  407
  - Electrical System
    407
  - Fuel System
    407
  - Compression System
    408
  - Poor Idle Speed Performance
    408
  - Poor Medium and High-Speed Performance
    408
  - Faulty Drive Train
    409
  - Faulty Clutch Performance
    410
    
    Clutch Slipping
    410
    
    Engine Operates but Vehicle will Not Move
    410
    
    Poor Starting Performance
    410
    
    Poor Speed Performance
    411
  - Faulty Gear Shifting
    410
    
    Hard Shifting
    410
    
    Jumps out of Gear
    410
    
    Shift Lever Does Not Move
    410
  - Faulty Brake
    411
    
    Poor Braking Effect
    411
  - Overheating
    411
  - Shock Absorber Malfunction
    411
    
    Malfunction
    411
  - Lighting System
    412
    
    Bulb Burnt out
    412
    
    Headlight Does Not Come on
    412
  - Unstable Handling
    412
Table of Contents

416
- Specifications
  417
  - General Specifications
    417
  - Engine Specifications
    418
  - Chassis Specifications
    418
  - Electrical Specifications
    418
  - Tightening Torques
    419
    
    Chassis Tightening Torques
    419
    
    Engine Tightening Torques
    419
  - Cable Routing
    420
- Periodic Checks and Adjustments
  436
  - Introduction
    436
  - Periodic Maintenance/Lubrication
    436
  - Engine
    438
    
    Cleaning the Air Filter Elements
    438
  - Chassis
    441
    
    Adjusting the Parking Brake
    441
- Engine
  442
  - Engine Removal
    442
    
    Air Ducts, Muffler and Exhaust Pipe
    442
- Fuel System
  444
  - Carburetor
    444
    
    Installing the Air Filter Case Joint
    446
- Chassis
  447
  - Seats, Enclosure, Hood and Cargo Bed
    447
    
    Seats, Console and Instrument Panels
    447
    
    Panels and Footrest Cover
    449
    
    Cargo Bed
    450
    
    Enclosure and Seat Belts
    451
- Yxr660Fat Wiring Diagram
  452
Table of Contents

455
- Specifications
  456
  - General Specifications
    456
  - Chassis Specifications
    457
  - Electrical Specifications
    458
  - Tightening Torques
    458
    
    Chassis Tightening Torques
    458
  - Cable Routing
    459
- Periodic Checks and Adjustments
  476
  - Electrical
    476
    
    Changing a Headlight Bulb
    476
- Engine
  478
  - Engine Cooling Fan and A.C. Magneto
    478
- Cooling System
  481
  - Oil Cooler
    481
- Chassis
  483
  - Seats, Enclosure, Hood and Cargo Bed
    483
    
    Front Guard and Hood
    483
    
    Panels and Footrest Cover
    484
    
    Cargo Bed
    485
    
    Skid Plates
    487
    
    Installing the Rear Skid Plate
    488
    
    Enclosure and Seat Belts
    489
  - Front Wheels and Brake Discs
    490
  - Rear Wheels and Brake Disc
    492
    
    Rear Wheels
    492
  - Front Arms and Front Shock Absorbers
    493
  - Rear Knuckle and Stabilizer
    495
- Electrical
  496
  - Electrical Components
    496
  - Lighting System
    498
    
    Circuit Diagram
    498
    
    Troubleshooting
    499
  - SIGNALING SYSTEM (for Special Edition Models)
    501
    
    Circuit Diagram
    501
    
    Checking the Signal System
    503
- Yxr66Fav 2006 Wiring Diagram
  506

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