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2001 yamaha raptor 660 service manual free download.Yamaha Raptor 660 Manuals |
Yamaha Raptor r Service Manual by MaryMcclung - Issuu.Free Yamaha Raptor workshop service manual!
Failure to do so may cause an accident resulting in machine damage and possible operator injury. Use soft metal drift punch and hammer. Remove both bearings as described. Use a socket that matches outside diameter of bearing outer race to drive in bearing. Contact should be made only with the outer race. Brake disc maximum deflection: 0. Brake disc minimum thickness: 3 mm 0. Install: 70 Nm 7. NOTE: Do not loosen the axle nut after torquing it.
If the axle nut groove is not aligned with the cotter pin hole, align the groove with the hole by tightening the axle nut. For installation, reverse the removal procedure.
NOTE: Do not apply the brake pedal and do not use the parking brake when the brake caliper is off of the brake disc as the brake pad will be force shut. YM, Never directly tap the axle end with a hammer, since this will result in damage to the axle thread and spline. Attach a suitable socket 2 on the axle end and tap it with a soft hammer. Pull out the rear axle to the right. Rear axle runout limit: 1.
If distance b is less than 15 mm 0. Put the other end of this hose into an open container. Brake pad holding bolt: 18 Nm 1. For assembly, reverse the disassembly procedure. Brake fluid Drain. Brake fluid reservoir cover 1 Brake fluid reservoir cap 1 Brake fluid reservoir diaphragm holder 1 Brake fluid reservoir diaphragm 1 Brake fluid reservoir 1 Brake fluid reservoir hose 1 Right footrest guard bracket 1. All internal brake components should be cleaned and lubricated with new brake fluid only before installation.
Recommended brake fluid: DOT 4. Correct if necessary. Always clean up spilled brake fluid immediately. Use only the designated quality brake fluid: Other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. Refill with the same type of brake fluid: Mixing brake fluids may result in a harmful chemical reaction and lead to poor brake performance.
Be careful that water does not enter the brake master cylinder when refilling. Water will significantly lower the boiling point of the brake fluid and may result in vapor lock. Lock washer 1. Never try to pry out the caliper piston.
Cover the caliper piston with a rag. Be careful not to get injured when the piston is expelled from the master cylinder. Do not use solvents as they will cause seals to swell and distort. CAUTION: When installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection a on the brake caliper. If side play is noticeable, check the bushings.
If the vertical movement is tight or rough, or if there is binding, check the bushings. Move the spring up and down. Use the ball joint remover and installer set. YM, 3 Body 4 Long bolt. NOTE: Always use a new ball joint set. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following information.
The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber and gas cylinder.
High heat can cause an explosion due to excessive gas pressure. If the rear shock absorber, gas cylinder or both are damaged, damping performance will suffer. To release the gas pressure, press on the gas valve needle with a suitable tool as shown, until all of the gas is released the hissing has stopped. Installed depth of bushing a: 1 mm 0.
Installed depth of bushing a: 6. NOTE: Before removing the drive chain and the sprockets, measure the drive chain slack and a ten link section of the drive chain. If side play is noticeable, check the collar, spacers, bearings, bushings and frame pivot. If vertical movement is tight or rough, or if there is binding, check the collar, spacers, bearings, bushings and frame pivot. Never use high-pressure water or air, steam, gasoline, certain solvents e.
A coarse brush can also damage the O-rings. Therefore, use only kerosine to clean the drive chain. Installed depth of bearing: Left a: 0 mm 0 in Right b: 4 mm 0. Bend the lock washer tab along a flat side of the nut. After all the bolts are loosened, remove them. ACC Yamaha bond No. Rocker arm inside diameter: Clearance greater than 0. Rocker arm to shaft standard clearance: 0. Camshaft lobe limit: Intake: a Cylinder head warpage: Less than 0.
NOTE: To ensure an even surface rotate the cylinder head several times. Tighten the bolts in two stages. Do not install the bolts. Then, install the timing chain on the camshaft sprocket. NOTE: Check that each part is positioned as shown in the illustration. There should be no leakage at the valve seat 2. Clearance stem to guide : Intake: 0. Margin thickness: Intake: 0. Runout limit: 0.
Valve seat width: Intake: 0. Where the valve seat and valve face made contact, blueing will have been removed. NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. NOTE: After every lapping operation be sure to clean off all of the compound from the valve face and valve seat.
If the valve seat width is out of specification, reface and relap the valve seat. Free length valve spring : Inner: Spring tilt limit: Inner: 2. Valve cotters NOTE: Install the valve cotters while compressing the valve spring with the valve spring compressor 1 and attachment 2. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4.
Then, find the average of the measurements. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance Standard. Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore.
NOTE: You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings. End gap. If out of specification, replace the piston pin. Outside diameter piston pin : Piston pin-to-piston clearance: 0.
Be careful not to damage the timing chain damper during installation. Pass the timing chain through the timing chain cavity. After all of the bolts are fully loosened, remove them. YS, If not, the starter clutch is faulty.
Replace it. If not, reinstall the key and rotor. Straighten the lock washer tab. Straighten the lock washer tabs. NOTE: Measure the friction plate at four places. Friction plate 1 thickness: 2. Maximum clutch plate warpage: 0. Clutch spring free length: NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. Bend the lock washer tabs along the balancer driven gear nut. Bend the lock washer tabs along a flat side of the primary drive gear nut.
NOTE: While holding the clutch boss 2 with the clutch holding tool 3, tighten the clutch boss nut. YM, 3. Tip clearance a: 0. Cylinder and piston AC rotor Clutch, balancer drive gear and balancer driven gear Oil pump Shift shaft and shift drum segment Timing chain guide intake Timing chain.
Tap only on reinforced portions of the crankcase. Do not tap on the crankcase mating surfaces. Work slowly and carefully. Make sure that the crankcase halves separate evenly. Thoroughly wash the case halves in a mild solvent.
Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly. CAUTION: Before installing and torquing the crankcase holding bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift cam in both directions.
YUA, Crank width: Big end side clearance: 0. Runout limit: C1: 0. Operate the installing tool until the crankshaft bottoms against the bearing. Maximum main axle runout: 0. Maximum drive axle runout: 0. Coolant Radiator fan coupler Thermo switch coupler Coolant reservoir hose Radiator fan breather hose Radiator outlet hose Radiator inlet hose Radiator Radiator fan Thermo switch 1 Coolant reservoir breather hose. Apply compressed air to the rear of the radiator.
OTE: Straighten any flattened fins with a thin, flathead screwdriver. Remarks Remove the parts in the order listed. OTE: If the accuracy of the thermostat is in doubt, replace it.
A faulty thermostat could cause serious overheating or overcooling. OTE: Install the water pump seal with the special tools. OTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position.
Do not use any caustic carburetor cleaning solution. OTE: Always replace the needle valve and valve seat as a set. Insert the piston valve into the carburetor body, and check for free movement. OTE: The float arm should be resting on the needle valve, but not compressing it.
YMA, the drain screw 3. If the continuity is faulty at any point, replace the switch. This chart shows the switch positions in the column and the switch lead colors in the top row. The coupler locations are circled. Procedure Check: 1. Fuse 2. Battery 3. Spark plug 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance. Engine stop switch 8. Main switch 9. Pickup coil resistance Wiring connection the entire ignition system. YU These tools are used to install the crankshaft.
Tappet adjusting tool 3 mm YM This tool is necessary for adjusting the valve clearance. Fuel level gauge YMA This gauge is used to measure the fuel level in the float chamber.
Radiator cap tester YU This tool is used to check the cooling system. Adapter YU This tool is used to check the cooling system. Damper rod holder 30 mm YM This tool is needed to loosen and tighten the steering stem bearing retainer. Flywheel puller YU These tools are needed to remove the rotor. Axle nut wrench 50 mm YM This tool is needed to loosen or tighten the rear axle nut.
Sheave holder YS This tool is needed to hold the AC magneto rotor when removing or installing the AC magneto rotor bolts. Compression gauge set Adapter. Timing light YMA This tool is necessary for checking ignition timing. Compressor YM Attachment Middle driven shaft bearing driver YM Mechanical seal installer YM Clutch holding tool YM This tool is needed to hold the clutch carrier when removing or installing the carrier nut.
Ignition checker. Dynamic spark tester YM This instrument is necessary for checking the ignition system components. Bond Sealant ACC Oil capacity: Engine oil Periodic oil change With oil filter replacement Total amount Radiator capacity including all routes Air filter: Fuel: Type Fuel tank capacity Fuel reserve amount.
Camshaft: Drive method Camshaft cap inside diameter Camshaft journal diameter Camshaft journal-to-camshaft cap clearance. Chain drive Left Barrel 1. Taper 1. Paper Trochoid 0. Timing chain tensioner Timing chain tensioner cap Timing chain guide intake Camshaft sprocket Rocker arm shaft Valve adjusting screw Radiator Coolant drain bolt Engine oil drain bolt oil tank Engine oil drain bolt engine Oil filter bolt Oil filter cartridge Oil delivery pipe 1 Oil delivery pipe 2 Oil pipe joint Oil pipe 1 and oil pipe joint Oil pipe 2 and oil tank Air filter case Carburetor clamp Exhaust pipe 1 and exhaust pipe 2 Exhaust pipe protector Spark arrester Muffler and exhaust pipe 2 Muffler Silencer cap Exhaust pipe.
Oil seal retainer Shift drum segment Shift guide Stopper lever Reverse shift lever Shift arm Shift pedal adjusting rod. Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Brake lever and brake pedal: Brake lever free play at lever end Brake pedal position Throttle lever free play.
This information will be needed to order spare parts. In the 2WD mode, the left differential side gear 3 and the drive clutch 2 are not engaged, therefore, the left side gear runs idle and does not transmit power to the left front constant velocity joint. As a result, power is transmit- ted directly from the ring gear 5 to the drive clutch 2, then to the left front constant velocity joint via the adapter 1.
Even if an attempt is made to select this mode when the ATV is traveling, it will only result in a standby condi- tion i. Shift cam 2. Shift fork guide bar 3. Drive axle 4. Stopper lever shaft 1 - Then, the stopper lever tab is sepa- rated from the drive axle stopper to free the drive axle. Page Important Information 5. Keep all parts away from any source of fire. Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and appearance, but inferior in quality. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. Tappet adjusting tool 3 mm YU This tool is necessary for adjusting the valve clearance.
Fuel level gauge YMA Gear lash measurement tool YM This tool is used to measure the gear lash. Universal joint holder YM This tool is needed when removing or installing the universal joint yoke nut. Yamaha bond No. Page Chapter 2. Be sure not to inlet. Be careful not to pinch the breather hose. Page Chapter 3. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life.
The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. It is recommended that these items be serviced by a Yamaha dealer. Front brake light switch coupler Disconnect. Rear brake light switch coupler Disconnect. Main switch coupler Disconnect. Auxiliary DC jack coupler Disconnect. Fan motor breather hose Differential gear case breather hose Coolant reservoir breather hose Taillight connector Disconnect.
Crankcase breather hose Clamp screw Loosen. Air filter case Rear fender For installation, reverse the removal procedure. Valve clearance cold : Intake: 0. Start the engine and let it warm up for sev- eral minutes. Idling speed becomes Turning in higher.
Turning in Free play is increased. Speed limiter length is Turning in decreased. NOTE: Do not remove the starter plunger 2 from the starter cable. Normal color is a medium-to-light tan color. Below the minimum pressure: Squirt a few drops of oil into the affected cyl- inder and measure again. Refer to the table below. Place the machine on a level surface. Stop the engine and place an oil pan under the engine. Oil quantity: Periodic oil change: 1.
Oil gallery bolt: 7 Nm 0. Install: Engine side cover This could damage the foam material. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant. Use only distilled water. NOTE: Tightening the bolts 1 will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen. Rear brake lever free play: 0. Check: Rear brake pedal height a Rear brake pedal height: 45 mm 1.
NOTE: When adjusting the brake pedal height make sure the locknut-to-adjusting bolt clearance b does not exceed 2 mm 0. WARNING After this adjustment is performed, lift the front and rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake NOTE: Hold the machine in an upright position and apply the front or rear brake.
Add the proper brake fluid to the reservoir. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. Place the machine on a level place.
Place a receptacle under the differential gear case. Install: Drain plug 10 Nm 1. This reference point will be needed during adjustment. The tires listed below have been approved by Yamaha Motor Co. Recommended lubricant: Yamaha chain and cable lube or Engine oil NOTE: Hold the cable end up and apply several drops of lubricant to the cable. Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals.
Always follow these preventive measures: Charge batteries in a well-ventilated area. Connect a charger and ammeter to the battery and start charging. NOTE: After cleaning the terminals, apply a light coat of grease. Turning in Headlight beam raised. Turning out Headlight beam lowered. Page Chapter 4.
Shift arm Select lever shift rod Select lever unit Coolant reservoir breather hose Spark plug lead Crankcase breather hose Thermo switch lead Dowel pin For installation, reverse the removal procedure. ACC Yamaha bond No. Rocker arm shaft outside diameter: Measure: Cam lobes length a and b. Camshaft lobe limit: Intake: a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand.
Cylinder head warpage: Less than 0. Camshaft sprocket bolt: 20 Nm 2. Clearance stem to guide : Intake: 0. Margin thickness: Intake: 0. Valve seat width: Intake: 0.
2001 yamaha raptor 660 service manual free download.Yamaha YFM660FP Service Manual
Table Of Contents. Quick Links. See also: Owner's Manual. Table of Contents. Previous Page. Next Page.
First edition, May All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U. Printed in 2001 yamaha raptor 660 service manual free download. It is not possible to include 2001 yamaha raptor 660 service manual free download the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this 2001 yamaha raptor 660 service manual free download to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair.
Page Chapter 1. This information will be needed to order spare parts. In the 2WD mode, the left differential side gear 3 and the drive clutch 2 are not engaged, therefore, the left side gear runs idle and does not transmit power to the left front constant velocity joint.
As a result, power is transmit- ted directly from the ring gear 5 to the drive clutch 2, then to the left front constant velocity joint via the adapter 1. Even if an attempt is made to select this mode when the ATV is traveling, it will only result in a standby condi- tion i. Shift cam 2. Shift fork guide bar 3. Drive axle 4. Stopper lever shaft 1 - Then, the stopper lever tab is sepa- rated from the drive axle stopper to free the drive axle. Page Important Information 5. Keep all parts away from any source of fire.
Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. Use only the appropriate special tools; this will help prevent damage caused by the use вот ссылка inappropriate tools or improvised techniques.
Special tools may differ by shape and part number from country to country. Tappet adjusting tool 3 mm YU This tool is necessary for adjusting the valve clearance. Fuel level gauge YMA Gear lash measurement tool YM This tool is used to measure the gear lash.
Universal joint holder YM This tool is needed when removing or installing the universal joint yoke nut. Yamaha bond No. Page Chapter 2. Be sure not to inlet. Be careful not to pinch the breather hose. Page Chapter 3. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced.
This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. It is recommended that these items be serviced by a Yamaha dealer. Front brake light switch coupler Disconnect. Rear brake light switch coupler Disconnect. Main switch coupler Disconnect. Auxiliary DC jack coupler Disconnect. Fan motor breather hose Differential gear case breather hose Coolant reservoir breather 2001 yamaha raptor 660 service manual free download Taillight connector Disconnect.
Crankcase breather hose Clamp screw Loosen. Air filter case Rear fender For installation, reverse the removal procedure. Valve clearance cold : Intake: 0. Start the 2001 yamaha raptor 660 service manual free download and let it warm up for sev- eral minutes. Idling speed becomes Turning in higher. Turning in Free play is increased. Speed limiter length is Turning in decreased.
NOTE: Do not remove the starter plunger 2 from the starter cable. Normal color is a medium-to-light tan color. Below the minimum pressure: Squirt a few drops of oil into the affected cyl- inder and measure again.
Refer to the table below. Place the machine on a level surface. Stop the engine and place an oil pan under the engine. Oil quantity: Periodic oil change: 1. Oil gallery bolt: 7 Nm 0. Install: Engine side cover This could damage the foam material. If water is used instead of coolant, check, 2001 yamaha raptor 660 service manual free download if necessary, correct the antifreeze concentration of the coolant.
Use only distilled water. NOTE: Tightening the bolts 1 will push the secondary sliding sheave 2001 yamaha raptor 660 service manual free download, causing the gap between the secondary fixed and sliding sheaves to widen. Rear brake lever free play: 0. Check: Rear brake pedal height a Rear brake pedal height: 45 mm 1. NOTE: When adjusting the brake pedal height make sure the locknut-to-adjusting bolt clearance b does not exceed 2 mm 0.
WARNING After this adjustment is performed, lift the front and rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake NOTE: Hold the machine in an upright position and apply the front or rear brake.
Add the proper brake fluid to the reservoir. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. Place the machine on a level place. Place a receptacle under the differential gear case. Install: Drain plug 10 Nm 1.
This reference point will be needed during adjustment. The tires listed below have been approved by Yamaha Motor Co. Recommended lubricant: Yamaha chain and cable lube or Engine oil NOTE: Hold the cable end up and apply several drops of lubricant to the cable. Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals.
Always follow these preventive measures: Charge batteries in a well-ventilated area. Connect a charger and ammeter to the battery and start charging. NOTE: After cleaning the terminals, apply a light coat of grease. Turning in Headlight beam autodesk maya 2017 offline help free. Turning out Headlight beam lowered. Page Chapter 4. Shift arm Select lever shift rod Select lever unit Coolant reservoir breather hose Spark plug lead Crankcase breather hose Thermo switch lead Dowel pin For installation, reverse the removal procedure.
Фраза download windows 10 operating system 64 bit free download признать Yamaha bond No. Rocker arm shaft outside diameter: Measure: Cam lobes length a and b. Camshaft lobe limit: Intake: a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. Cylinder head warpage: Less than 0.
Camshaft sprocket bolt: 20 Nm 2.
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