YFM660R(P)

SUPPLEMENTARY

SERVICE MANUAL

5LP2-AE2

2002

FOREWORD

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

the YFM660R(P) 2002. For complete information on service procedures, it is necessary to use this

Supplementary Service Manual together with the following manual.

YFM660R(N) 2001 SERVICE MANUAL: 5LP2-AE1

YFM660R(P) 2002

SUPPLEMENTARY

SERVICE MANUAL

©2001 by Yamaha Motor Co., Ltd.

First Edition, August 2001

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 9 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 Chassis

5 Engine

6 Cooling system

7 Carburetion

8 Electrical

9 Troubleshooting

Illustrated symbols 0 to G are used to identify

the specifications appearing in the text.

0 Can be serviced with engine mounted

A Filling fluid

B Lubricant

C Special tool

D Torque

E Wear limit, clearance

F Engine speed

G Ω, V, A

Illustrated symbols H to N in the exploded

diagrams indicate the types of lubricants and

lubrication points.

H Apply engine oil

I Apply gear oil

J Apply molybdenum disulfide oil

K Apply wheel bearing grease

L Apply lightweight lithium soap base grease

M Apply molybdenum disulfide grease

N Apply silicon 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

O

P

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

COOL

CARB

–

+

ELEC

TRBL

SHTG

T R

.

.

E

G

M

B

LS

M

S

L

M

N

LT

New

CONTENTS

SPECIFICATIONS ............................................................................................1

GENERAL SPECIFICATIONS ..................................................................1

MAINTENANCE SPECIFICATIONS .........................................................2

ENGINE ................................................................................................2

CHASSIS ..............................................................................................6

CABLE ROUTING .....................................................................................7

PERIODIC CHECKS AND ADJUSTMENTS ....................................................9

INTRODUCTION .......................................................................................9

PERIODIC MAINTENANCE/LUBRICATION INTERVALS ........................9

CHASSIS .................................................................................................11

ADJUSTING THE REAR SHOCK ABSORBER ..................................11

CHASSIS ........................................................................................................14

REAR SHOCK ABSORBER AND RELAY ARM .....................................14

HANDLING THE REAR SHOCK ABSORBER

AND GAS CYLINDER .........................................................................16

DISPOSING OF A REAR SHOCK ABSORBER

AND GAS CYLINDER .........................................................................16

REMOVING THE REAR SHOCK ABSORBER ...................................17

CHECKING THE REAR SHOCK ABSORBER ...................................17

CHECKING THE RELAY ARM AND CONNECTING ARM ................17

INSTALLING THE RELAY ARM AND CONNECTING ARM ..............18

INSTALLING THE REAR SHOCK ABSORBER .................................18

SWINGARM AND DRIVE CHAIN ...........................................................19

ENGINE ..........................................................................................................21

ENGINE REMOVAL ................................................................................21

INSTALLING THE ENGINE ................................................................21

AC MAGNETO ........................................................................................22

YFM660R(P) 2002 WIRING DIAGRAM

– 1 –

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item

Standard

Model code:

5LP6 : (For CDN)

5LP7 : (For Europe)

Transmission:

Primary reduction system

Spur gear

Primary reduction ratio

71/34 (2.088)

Secondary reduction system

Chain drive

Secondary reduction ratio

40/13 (3.076)

Transmission type

Constant mesh, 5-speed/forward.

1-speed/reverse

Operation

Left foot operation

Gear ratio

1st gear

31/12 (2.583)

2nd gear

30/18 (1.667)

3rd gear

27/21 (1.286)

4th gear

22/21 (1.047)

5th gear

19/21 (0.904)

Reverse gear

33/25 × 25/18 (1.833)

GENERAL SPECIFICATIONS

– 2 –

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item

Standard

Limit

Cylinder head:

Warp limit

----

0.03 mm

(0.001 in)

Timing chain:

Timing chain type/No. of links

82RH2015/126

----

Timing chain adjustment method

Automatic

----

Rocker arm/rocker arm shaft:

Bearing inside diameter

12.000 ~ 12.018 mm

(0.4724 ~ 0.4731 in)

----

Shaft outside diameter

11.976 ~ 11.991 mm

(0.4715 ~ 0.4721 in)

----

Arm-to-shaft clearance

0.009 ~ 0.042 mm

(0.0004 ~ 0.0017 in)

----

Valve, valve seat, valve guide:

Valve clearance (cold)

IN

0.10 ~ 0.15 mm

(0.0039 ~ 0.0059 in)

----

EX

0.15 ~ 0.20 mm

(0.0059 ~ 0.0079 in)

----

Valve dimensions

“A” head diameter

IN

29.9 ~ 30.1 mm

(1.1772 ~ 1.1850 in)

----

EX

31.9 ~ 32.1 mm

(1.2559 ~ 1.2638 in)

----

“B” face width

IN

2.25 mm (0.0886 in)

----

EX

2.26 mm (0.0890 in)

----

“C” seat width

IN

1.1 ~ 1.3 mm

(0.0433 ~ 0.0512 in)

1.6 mm

(0.0630 in)

EX

0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

1.6 mm

(0.0630 in)

“D” margin thickness

IN

0.85 ~ 1.15 mm

(0.0335 ~ 0.0453 in)

----

EX

0.85 ~ 1.15 mm

(0.0335 ~ 0.0453 in)

----

B

C

D

A

Head Diameter

Face Width

Seat Width

Margin Thickness

MAINTENANCE SPECIFICATIONS

– 3 –

SPEC

Stem outside diameter

IN

5.975 ~ 5.990 mm

(0.2352 ~ 0.2358 in)

5.945 mm

(0.2341 in)

EX

5.960 ~ 5.975 mm

(0.2346 ~ 0.2352 in)

5.930 mm

(0.2335 in)

Guide inside diameter

IN

6.000 ~ 6.012 mm

(0.2362 ~ 0.2367 in)

6.040 mm

(0.2378 in)

EX

6.000 ~ 6.012 mm

(0.2362 ~ 0.2367 in)

6.040 mm

(0.2378 in)

Stem-to-guide clearance

IN

0.010 ~ 0.037 mm

(0.0004 ~ 0.0015 in)

0.08 mm

(0.0031 in)

EX

0.025 ~ 0.052 mm

(0.0010 ~ 0.0020 in)

0.10 mm

(0.0039 in)

Stem runout limit

----

0.01 mm

(0.0004 in)

Valve seat width

IN

1.1 ~ 1.3 mm

(0.0433 ~ 0.0512 in)

1.6 mm

(0.0630 in)

EX

0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

1.6 mm

(0.0630 in)

Piston:

Piston to cylinder clearance

0.05 ~ 0.07 mm

(0.0020 ~ 0.0028 in)

0.15 mm

(0.0059 in)

Piston size “D”

99.945 ~ 99.995 mm

(3.9348 ~ 3.9368 in)

----

Measuring point “H”

2.5 mm (0.10 in)

----

Piston off-set

1.0 mm (0.04 in)

----

Off-set direction

Intake side

----

Piston pin bore inside diameter

22.004 ~ 22.015 mm

(0.8663 ~ 0.8667 in)

22.045 mm

(0.8679 in)

Piston pin outside diameter

21.991 ~ 22.000 mm

(0.8658 ~ 0.8661 in)

21.971 mm

(0.8650 in)

Item

Standard

Limit

H

D

MAINTENANCE SPECIFICATIONS

– 4 –

SPEC

Piston rings:

Top ring

Type

Barrel

----

Dimensions (B × T)

1.2 × 3.8 mm

(0.0472 × 0.1496 in)

----

End gap (installed)

0.30 ~ 0.45 mm

(0.0118 ~ 0.0177 in)

0.70 mm

(0.0276 in)

Side clearance (installed)

0.04 ~ 0.08 mm

(0.0016 ~ 0.0031 in)

0.13 mm

(0.0051 in)

2nd ring

Type

Taper

----

Dimensions (B × T)

1.2 × 4.0 mm

(0.0472 × 0.1575 in)

----

End gap (installed)

0.30 ~ 0.45 mm

(0.0118 ~ 0.0177 in)

0.80 mm

(0.0315 in)

Side clearance

0.03 ~ 0.07 mm

(0.0012 ~ 0.0028 in)

0.13 mm

(0.0051 in)

Oil ring

Dimensions (B × T)

2.5 × 3.4 mm

(0.0984 × 0.1339 in)

----

End gap (installed)

0.2 ~ 0.7 mm

(0.0079 ~ 0.0276 in)

----

Side clearance

0.06 ~ 0.15 mm

(0.0024 ~ 0.0059 in)

----

Item

Standard

Limit

T

B

B

T

B

T

MAINTENANCE SPECIFICATIONS

– 5 –

SPEC

Tightening torques

Carburetors:

I. D. mark

5LP5 20

----

Main jet

(M.J)

Carburetor #1 : #140

Carburetor #2 : #145

----

----

Main air jet

(M.A.J)

#130

----

Jet needle

(J.N)

5ND16-56-3

----

Needle jet

(N.J)

P-6M (#826)

----

Pilot air jet

(P.A.J.1)

Carburetor #1 : #80

Carburetor #2 : #150

----

----

Pilot air jet

(P.A.J.2)

1.3

----

Pilot outlet

(P.O)

Carburetor #1 : 1.0

Carburetor #2 : 0.9

----

----

Pilot jet

(P.J)

#22.5

----

Bypass 1

(B.P.1)

0.8

----

Bypass 2

(B.P.2)

0.8

----

Valve seat size

(V.S)

2.0

----

Starter jet

(G.S.1)

#95

----

Starter jet

(G.S.2)

0.5

----

Throttle valve size

(Th.V)

#80

----

Float height

(F.H)

13 mm (0.51 in)

----

Fuel level

(F.L)

3 ~ 4 mm (0.12 ~ 0.16 in)

----

Engine idle speed

1,450 ~ 1,550 r/min

----

Intake vacuum

32.0 ~ 33.3 kPa (240 ~ 250 mmHg,

9.45 ~ 9.83 inHg)

----

Part to be tightened

Part

name

Thread

size

Q’ty

Tightening torque

Remarks

Nm

m·kg

ft·lb

Air filter case

Bolt

M6

2

9

0.9

6.5

Carburetor clamp

Bolt

M4

4

4

0.4

2.9

Muffler and exhaust pipe 2

Bolt

M8

1

18

1.8

13

Muffler

Bolt

M8

2

33

3.3

24

AC magneto rotor

Nut

M14

1

140

14.0

100

Item

Standard

Limit

MAINTENANCE SPECIFICATIONS

– 6 –

SPEC

CHASSIS

Tightening torques

Item

Standard

Limit

Brake lever and brake pedal:

Brake lever free play (at lever end)

0 mm (0 in)

----

Brake pedal position

4 mm (0.16 in)

(Below the top of footrest)

----

Throttle lever free play

3 ~ 5 mm (0.12 ~ 0.20 in)

----

Part to be tightened

Thread size

Tightening torque

Remarks

Nm

m·kg

ft·lb

Rear shock absorber and frame

M12

80

8.0

58

Relay arm and swingarm

M10

43

4.3

31

Connecting arm and frame

M12

80

8.0

58

Relay arm and rear shock absorber

M10

43

4.3

31

Relay arm and connecting arm

M10

43

4.3

31

Steering stem, pitman arm and frame

M14

180

18

130

Frame and bearing retainer

M42

65

6.5

47

Rear brake fluid reservoir cover and bracket

M6

11

1.1

8.0

Rear carrier bar and frame

M8

33

3.3

24

Footrest guard bracket and frame

M8

26

2.6

19

Air filter case and frame

M6

9

0.9

6.5

Carburetor clamp screw

M4

4

0.4

2.9

MAINTENANCE SPECIFICATIONS

– 7 –

SPEC

CABLE ROUTING

1 Carburetor air vent hose

2 Coolant reservoir hose

3 Reservoir tank breather hose

4 CDI unit

5 Wire harness

6 Rectifier/regulator

7 Negative battery lead

8 AC magneto lead

9 Starter motor lead

0 Tail/brake light lead

A Rectifier/regulator lead

È Pass the negative battery lead between the wire

harness and frame.

É 25 ~ 35 mm (0.98 ~ 1.38 in)

Ê 50 ~ 60 mm (1.97 ~ 2.36 in)

Ë 50 ~ 70 mm (1.97 ~ 2.76 in)

CABLE ROUTING