YFM660FR

5KM2-AE2

SUPPLEMENTARY

SERVICE MANUAL

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

YFM660FR. For complete service information procedures it is necessary to use this Supplementary

Service Manual together with the following manual.

YFM660F(P) 2002 SERVICE MANUAL: 5KM2-AE1

YFM660FR

SUPPLEMENTARY

SERVICE MANUAL

©2002 by Yamaha Motor Co., Ltd.

First edition, June 2002

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

EB001000

NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one

manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on

Yamaha machine has a basic understanding of the mechanical ideas and the procedures of

machine repair. Repairs attempted by anyone without this knowledge are likely to render the

machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death

to the machine operator, a bystander or a person inspecting or repairing the

machine.

A CAUTION indicates special precautions that must be taken to avoid dam-

age to the machine.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title 2: This title indicates the section of the chapter and only appears on the first page of each

section. It is located in the upper left corner of the page.

3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.

2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed

by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

6. The meanings of the symbol marks are given on the next page.

4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition

to the exploded diagram and the job instruction chart.

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 0 are printed on the

top right of each page and indicate the subject

of each chapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 Engine

5 Cooling system

6 Carburetion

7 Drive train

8 Chassis

9 Electrical

0 Troubleshooting

Illustrated symbols A to H are used to identify

the specifications appearing in the text.

A Can be serviced with engine mounted

B Filling fluid

C Lubricant

D Special tool

E Torque

F Wear limit, clearance

G Engine speed

H Ω, V, A

Illustrated symbols I to N in the exploded

diagrams indicate the types of lubricants and

lubrication points.

I Apply engine oil

J Apply gear oil

K Apply molybdenum disulfide oil

L Apply wheel bearing grease

M Apply lightweight lithium-soap-based grease

N Apply molybdenum disulfide grease

Illustrated symbols O to P in the exploded

diagrams indicate where to apply a locking

agent O and when to install a new part P.

O Apply the locking agent (LOCTITE^)

P Replace

1

2

3

4

5

6

7

8

9

0

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

GEN

INFO

SPEC

CHK

ADJ

ENG

COOL

CARB

DRIV

CHAS

–

+

ELEC

TRBL

SHTG

T R

.

.

E

G

M

B

LS

M

LT

New

CONTENTS

GENERAL INFORMATION ..............................................................................1

SPECIAL TOOLS ......................................................................................1

SPECIFICATIONS ............................................................................................2

GENERAL SPECIFICATIONS ..................................................................2

MAINTENANCE SPECIFICATIONS .........................................................3

ENGINE ................................................................................................3

ELECTRICAL ........................................................................................3

TIGHTENING TORQUES .........................................................................4

CABLE ROUTING .....................................................................................5

PERIODIC CHECKS AND ADJUSTMENTS ..................................................12

INTRODUCTION .....................................................................................12

PERIODIC MAINTENANCE/LUBRICATION ...........................................12

SEAT, CARRIERS, FENDERS AND FUEL TANK ..................................14

FRONT CARRIER, FRONT BUMPER AND FRONT GRILL ..............14

FUEL TANK ........................................................................................15

FOOTREST BOARDS .............................................................................17

ENGINE ...................................................................................................18

CHECKING THE STARTER CABLE ..................................................18

ENGINE ..........................................................................................................19

CAMSHAFT AND CYLINDER HEAD ......................................................19

RECOIL STARTER AND AC MAGNETO ...............................................21

CHECKING THE STARTER CLUTCH ................................................23

MIDDLE GEAR ........................................................................................24

MIDDLE DRIVEN SHAFT ...................................................................24

REMOVING THE MIDDLE DRIVEN SHAFT ......................................26

INSTALLING THE MIDDLE DRIVEN SHAFT .....................................28

DRIVE TRAIN .................................................................................................30

FRONT CONSTANT VELOCITY JOINTS

AND DIFFERENTIAL GEAR ...............................................................30

DISASSEMBLING THE DIFFERENTIAL GEAR .................................34

CHECKING THE DIFFERENTIAL GEAR ...........................................34

ASSEMBLING THE DIFFERENTIAL GEAR .......................................35

CHASSIS ........................................................................................................37

FRONT WHEELS AND BRAKE DISCS ..................................................37

FRONT WHEELS ................................................................................37

REAR WHEELS AND BRAKE DISC .......................................................39

REAR WHEELS ..................................................................................39

STEERING SYSTEM ..............................................................................40

TIE ROD AND STEERING KNUCKLE ................................................40

CHECKING THE STEERING KNUCKLE ............................................42

REAR KNUCKLE AND STABILIZER ......................................................43

CHECKING THE REAR KNUCKLE ....................................................44

REAR ARMS AND REAR SHOCK ABSORBER .....................................45

GEN

INFO

– 1 –

SPECIAL TOOLS

GENERAL INFORMATION

EB102001

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. 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. In such a case, two types are provided.

When placing an order, refer to the list provided below to avoid any mistakes.

For US and CDN

P/N. YM-, YU-, YS-, YK-, ACC-

Except for US and CDN

P/N. 90890-

Tool No.

Tool name/How to use

Illustration

90890-01486

YM-01486

Coupling gear holding tool

This tool is needed when removing or

installing the coupling gear nut.

– 2 –

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item

Standard

Model code:

5KM9: (for CDN)

5KMB: (for Europe)

5KMC: (for Oceania)

Bulb wattage × quantity:

Headlight

12 V 30 W/30 W × 2

Tail/brake light

12 V 5 W/21 W × 1

Indicator lights

Neutral

LED × 1

Fuel

LCD × 1

Reverse

LED × 1

Coolant temperature warning

LED × 1

Park position

LED × 1

High gear

LED × 1

Low gear

LED × 1

Diff-lock

LED × 1

GENERAL SPECIFICATIONS

– 3 –

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

ELECTRICAL

Item

Standard

Limit

Oil pump:

Oil filter type

Foam

----

Oil pump type

Trochoid

----

Tip clearance “A” or “B”

0.03 ~ 0.10 mm

(0.0012 ~ 0.0039 in)

0.15 mm

(0.006 in)

Side clearance

0.03 ~ 0.10 mm

(0.0012 ~ 0.0039 in)

0.17 mm

(0.007 in)

Bypass valve setting pressure

441 ~ 637 kPa (4.41 ~

6.37 kg/cm², 62.7 ~ 90.6 psi)

----

Oil pressure (hot)

65 kPa (0.65 kg/cm², 9.2 psi) at

1,500 r/min

----

Pressure check location

Cylinder head

----

Item

Standard

Limit

C.D.I.:

Magneto model/manufacturer

F4T46972/MITSUBISHI

----

Pickup coil resistance/color

459 ~ 561 Ω at 20 °C (68 °F)/

White/Red – White/Green

----

Rotor rotation direction sensing coil resis-

tance/color

0.063 ~ 0.077 Ω at 20 °C (68 °F)/

Red – White/Blue

----

C.D.I. unit model/manufacturer

F8T38671/MITSUBISHI

----

Charging system:

Type

A.C. magneto generator

----

Model/manufacturer

F4T469/MITSUBISHI

----

Nominal output

14 V 21 A at 5,000 r/min

----

Charging coil resistance/color

0.32 ~ 0.43 Ω at 20 °C (68 °F)/

White – White

----

MAINTENANCE SPECIFICATIONS

– 4 –

SPEC

TIGHTENING TORQUES

Engine tightening torques

Chassis tightening torques

Part to be tightened

Part

name

Thread

size

Q’ty

Tightening torque

Remarks

Nm

m·kg

ft·lb

Exhaust pipe protector

Bolt

M6

5

11

1.1

8

Oil seal retainer

Screw

M5

2

7

0.7

5.1

Part to be tightened

Thread size

Tightening torque

Remarks

Nm

m·kg

ft·lb

Front wheel hub and constant velocity joint

M20

260

26.0

190

Stake

Rear wheel hub and constant velocity joint

M20

260

26.0

190

Stake

Front brake master cylinder and handlebar

M8

7

0.7

5.1

LT

TIGHTENING TORQUES

– 5 –

SPEC

CABLE ROUTING

1 Fuel sender lead

2 Differential gear case and final

drive gear case breather hose

3 Vacuum chamber breather hose

4 Starter motor lead

5 Wire harness

6 Gear position switch lead

7 Final drive gear case breather

hose

8 Ground lead

9 Speed sensor lead

0 AC magneto lead

A Carburetor breather hose

B Starter cable

C Fuel hose

D Thermo switch 1 lead

E Reverse switch lead

F AC magneto coupler

G Gear position switch coupler

H Speed sensor coupler

I Radiator fan breather hose

J Rectifier/regulator lead

K Water pump breather hose

B - B

A

C

D

A

B

B

4

3

2

1

9

8

Ë

Ê

É

È

5

C

6

7

0

A

7

J

2

I

F

H G

D

E

8

C

B

D

Í

E

E

D

K

E - E

Ï

3Î

Ì

7

I

5

CABLE ROUTING

– 6 –

SPEC

È Fasten the final drive gear case breather hose, speed sensor lead, ground lead, gear position switch lead,

AC magneto lead, wire harness, and reverse indicator light lead with a plastic locking tie. Be careful not to

pinch the breather hose.

É Fasten the leads in the following order: ground lead, reverse switch lead, speed sensor lead, gear position

switch lead, and AC magneto lead.

Ê Pass the final drive gear case breather hose through the hole in air duct assembly 3.

Ë To the rear fender

Ì 70 ~ 90 mm (2.8 ~ 3.5 in)

Í Clamp the thermostat assembly breather hose and carburetor breather hose with the cable guide.

B - B

A

C

D

A

B

B

4

3

2

1

9

8

Ë

Ê

É

È

5

C

6

7

0

A

7

J

2

I

F

H G

D

E

8

C

B

D

Í

E

E

D

K

E - E

Ï

3Î

Ì

7

I

5

CABLE ROUTING

– 7 –

SPEC

Î Pass the vacuum chamber breather hose through the plastic cover hole.

Ï Insert a hook into the third hole from the bottom of the rectifier/regulator bracket, and then fasten the final

drive gear case breather hose onto the hook.

B - B

A

C

D

A

B

B

4

3

2

1

9

8

Ë

Ê

É

È

5

C

6

7

0

A

7

J

2

I

F

H G

D

E

8

C

B

D

Í

E

E

D

K

E - E

Ï

3Î

Ì

7

I

5

CABLE ROUTING