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02 raptor 660 repair manualAny reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-15-01. 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. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts. 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.e., when the differential lock select switch and the differential gear are not matched). EB101010 REPLACEMENT PARTS 1.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. EB101040 BEARINGS AND OIL SEALS 1.Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. 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) 90890-01311 YU-08035 This tool is necessary for adjusting the valve clearance. Fuel level gauge 90890-01312 YM-01312-A. Gear lash measurement tool 90890-01467 YM-01467 This tool is used to measure the gear lash. Universal joint holder 90890-04062 YM-04062 This tool is needed when removing or installing the universal joint yoke nut. Be sure not to inlet. Be careful not to pinch the breather hose.http://www.studiolegalecatapano.it/studiolegalecatapano/immagini/userfiles/3g2c7-lk201-ev1-manual.xml

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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. Seat NOTE: Pull up the seat lock lever, then pull up on the rear of the seat. 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. Seat and side panels Refer to “SEAT AND SIDE PANELS”. Fuel tank cover Refer to “HANDLEBAR COVER, FUEL TANK COVER AND FRONT FENDER”. Fuel tank side panels Refer to “SEAT AND SIDE PANELS”. ADJUSTING THE TIMING CHAIN Adjustment free. ADJUSTING THE IDLING SPEED 1.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. MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. Below the minimum pressure: Squirt a few drops of oil into the affected cyl- inder and measure again. Refer to the table below. Oil quantity: Periodic oil change: 1.9 L (1.7 Imp qt, 2.0 US qt) With oil filter replacement:. CAUTION: Do not twist or wring out the element.If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant. Use only distilled water.http://www.buyanycarnow.co.uk/uploadedfiles/3g-service-manual.xmlNOTE: Tightening the bolts 1 will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen. 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. Refer to “FRONT AND REAR BRAKES”. Refer to “FRONT AND REAR BRAKES” in CHAPTER 8. NOTE: Hold the machine in an upright position and apply the front or rear brake. Be careful not to spill any fluid or allow the reservoir to overflow. c. Refer to “FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR” in CHAPTER 7. CHECKING THE STEERING SYSTEM 1.Place the machine on a level surface. Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals. Connect a charger and ammeter to the battery and start charging. Turning in Headlight beam raised. Turning out Headlight beam lowered. WARNING Keep flammable products and your hands away from the bulb while it is on, since it will be hot. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3. Refer to “CHANGING THE COOLANT” in CHAPTER 3. Shift arm Select lever shift rod Select lever unit Coolant reservoir breather hose. Radiator inlet hose Refer to “THERMOSTAT” in CHAPTER 5. Water pump assembly Refer to “WATER PUMP” in CHAPTER 5. Spark plug lead Crankcase breather hose Thermo switch lead. Engine skid plate (front) Refer to “SEAT, CARRIERS, FENDERS Engine skid plate (center) AND FUEL TANK” in CHAPTER 3. Engine skid plate (rear) Rear wheels Refer to “REAR WHEELS AND BRAKE. Dowel pin For installation, reverse the removal procedure. 4 - 9. When the “I”. Cylinder head cover Refer to “CYLINDER HEAD COVER”.Camshaft lobe limit: Intake: a 35.59 mm (1.4012 in) b 29.96 mm (1.1795 in) Exhaust: a 36.40 mm (1.4331 in) b 30.01 mm (1.1815 in) When the “I”. NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.http://www.drupalitalia.org/node/66016 Water pump outlet hose Refer to “WATER PUMP” in CHAPTER 5. Cylinder head Refer to “CAMSHAFT AND CYLINDER HEAD”. 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 Limit. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3. Coolant Drain. Starter wheel gear Washer Starter idle gear shaft. Spring Sheave drum Rope Coil spring For assembly, reverse the disassembly. NOTE: The arrow mark on the starter clutch must face inward, away from the CDI rotor. If not, reinstall the key and rotor. Primary pulley sheave cap Primary pulley slider Spacer Primary pulley cam Refer to “ASSEMBLING THE PRIMARY Primary pulley weight SHEAVE”. Guide pin Secondary sliding sheave O-ring Secondary fixed sheave Oil seal. Primary and secondary sheaves Refer to “PRIMARY AND SECONDARY SHEAVES”. One-way clutch bearing Clutch carrier assembly For installation, reverse the removal. Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing For assembly, reverse the disassembly procedure. 4 - 61. Cylinder head Refer to “CAMSHAFT AND CYLINDER HEAD”. Crankshaft and oil pump Refer to “CRANKSHAFT AND OIL PUMP”. Transmission Refer to “TRANSMISSION”. Tap lightly on the case with a soft hammer. Rotor cover Shaft Inner rotor Outer rotor Oil pump housing For assembly, reverse the disassembly procedure. 4 - 73. Crankcase separation Refer to “CRANKCASE”. Middle driven gear Refer to “MIDDLE GEAR”. Low wheel gear Shift cam Shift fork assembly Short spring White painting. Crankcase separation Refer to “CRANKCASE”. Middle drive pinion gear Shim Refer to “MIDDLE DRIVE AND DRIVEN. MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION When the drive and driven gear, bearing hous-. In the example above, the calculated shim thickness is 0.64 mm. The chart instructs you, however, to round off 4 to 5.APARTMANGYULA.COM/images/02-raptor-660-repair-manual.pdf Hundredths Round value 0, 1, 2 3, 4, 5, 6, 7 8, 9 Shims are supplied in the following thickness. CAUTION: The middle driven shaft bearing retainer has left-handed threads. CAUTION: Check each bearing. The needles can eas- ily fall out of their races. Seat and side panels Refer to “SEAT AND SIDE PANELS”. Radiator outlet hose Disconnect. Radiator Radiator fan Thermo switch For installation, reverse the removal procedure. Apply compressed air to the rear of the radia- tor.Seat and fuel tank side panel (right) Refer to “SEAT AND SIDE PANELS” in CHAPTER 3. Seat, fuel tank side panel (left) and Refer to “SEAT AND SIDE PANELS” in engine side cover CHAPTER 3. Water pump housing cover Gasket Circlip Impeller Rubber damper holder Rubber damper Water pump seal Oil seal Bearing Water pump housing For assembly, reverse the disassembly procedure. CAUTION: Make sure that the rubber damper and rub- ber damper holder are flush with the impel- ler. Max. impeller shaft tilt: 0.15 mm (0.006 in) 1 Straightedge 2 Impeller 5 - 11. Throttle stop screw Vacuum chamber cover Spring Jet needle holder Spring Jet needle set Piston valve Coasting enricher diaphragm Pilot air jet Drain screw Float chamber Float. Pilot jet Starter jet For assembly, reverse the disassembly procedure. 6 - 3. ASSEMBLING THE CARBURETOR NOTE: Before assembling the carburetor, make sure. If a test ride following reas- sembly indicates this condition, stop riding immediately to minimize gear damage. c.A slight “thunk” evident at low speed opera- tion. This noise must be distinguished from normal machine operation. Feel for Replace the wheel bearing.Circlip Refer to “DISASSEMBLING AND Bearing. Do not disassem- ble the differential gear. CAUTION: The differential gears are assembled into a proper unit at the factory by means of spe- cialized equipment. Insert the double off-set joint into the differ- ential gear, and turn the gear back and forth.Rear brake disc Refer to “REAR WHEELS AND BRAKE DISC” in CHAPTER 8. Boss Ring gear stopper shim Ring gear stopper. Bearing retainer Bearing Pinion gear bearing housing Final drive gear case. In the example above, the calculated number is 0.97. The chart instructs you to round off 7 to 5 at the hundredth place. Do not reuse the oil seal.If wheel runout is within the limits, replace the brake disc. Brake disc maximum deflection: 0.15 mm (0.006 in) Brake disc thickness a. Install each nut with its tapered side towards the wheel. 8 - 5. Brake caliper assembly Refer to “REAR BRAKE CALIPER”. Final drive gear Refer to “FINAL DRIVE GEAR AND DRIVE SHAFT”. Wheel runout limit: Radial: 2.0 mm (0.08 in) Lateral: 2.0 mm (0.08 in) 3.Check: Wheel balance. Front wheel Refer to “FRONT WHEELS”. Brake caliper mounting bolt Brake pad holding bolt Refer to “REPLACING THE FRONT BRAKE PAD”. Rear wheel (left) Refer to “REAR WHEELS AND BRAKE DISC”. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”. On command four-wheel drive switch Refer to “HANDLEBAR”. Brake fluid reservoir cap Brake fluid reservoir diaphragm Brake lever Union bolt. Brake master cylinder kit For assembly, reverse the disassembly procedure. For assembly, reverse the disassembly procedure. Always clean up spilled brake fluid immediately.Brake fluid Drain. Front wheel Refer to “FRONT WHEELS”. Union bolt Copper washer Brake hose Disconnect. Always clean up spilled brake fluid immediately. WARNING Do not attempt to straighten a bent handle- bar as this may dangerously weaken the. WARNING Do not attempt to straighten a bent stem; this may dangerously weaken the stem. NOTE: Pass the cables and hoses through the cable guide. NOTE: Install the outside bearing first. CAUTION: Do not strike the center race or balls of the bearing. NOTE: When installing the oil seals, the “seal side”. If side play is noticeable, check the bushings.If the continuity is faulty at any point, replace the switch.The coupler locations are circled.Refer to “CIRCUIT DIAGRAM”. Properly connect the ignition system. CORRECT Replace the CDI unit. 9 - 14. If the main switch is on and the engine stop switch is in the RUN position, the starter motor can be operated only if: The transmission is in neutral (the neutral. CORRECT Replace the main switch. INCORRECT 6.Engine stop switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the handlebar switch (right). INCORRECT 7.Gear position switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the gear position switch. Check the diode for continuity as follows. Bracket 1 Washer kit Bracket 2. Outside diameter: 28 mm (1.10 in) 27 mm (1.06 in) 3.Measure: Mica undercut b. The charging circuit is not faulty.CORRECT Replace the main switch. INCORRECT 4.Light switch Refer to “CHECKING THE SWITCH”.CORRECT Replace the main switch. Refer to “CIRCUIT DIAGRAM”. Properly connect the signal system. CORRECT Check the condition of each of the signal sys- tem’s circuits. NO CONTINUITY 2.Brake light switches Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the meter assembly. NO CONTINUITY 2.Gear position switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the meter assembly. NO CONTINUITY 2.Gear position switch Refer to “CHECKING THE SWITCH”. Refer to “CHECKING THE LEDs”. Replace the meter assembly. CONTINUITY NO CONTINUITY 2.Gear position switch Refer to “CHECKING THE SWITCH”. Refer to “CHECKING THE LEDs”. Replace the meter assembly. CONTINUITY NO CONTINUITY 2.Gear position switch Refer to “CHECKING THE SWITCH”. Refer to “CHECKING THE LEDs”. Replace the meter assembly. CONTINUITY NO CONTINUITY 2.Reverse switch Refer to “CHECKING THE SWITCH”. Refer to “CHECKING THE LEDs”. Replace the meter assembly. CONTINUITY NO CONTINUITY 2.Four-wheel drive switch. Check the operation of the fan motor. Refer to “CIRCUIT DIAGRAM”. Properly connect the cooling system. CORRECT This circuit is not faulty. 9 - 51. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts. For a better experience, please enable JavaScript in your browser before proceeding. It may not display this or other websites correctly. You should upgrade or use an alternative browser. My 01 Raptor has been running really well. I was missing a tailight so I wired up a after market 1. I just cut the OEM clip and wired in tail light. All seamed well, took it for a ride tonight and it starts,idles and even runs fine, that is UNTIL, you. Big gun slip on. PB delete. Have replaced base and head gaskets, timing chain, and reset valves.Once I did get it hooked it is very hard to spin. Is this normal of new seals. I'm worried if I put it back on that it may lock up and cause my engine to overheat. Only orange wire on diagram is ignition coil. Never mind, it is the speed sensor. I was attempting to erase this post but couldn't. Come join the discussion about performance, modifications, classifieds, racing, maintenance, and more. Open to Banshees, Raptors, Blasters, and others for recreational riding and racing. Warning! ThisElite System. 3) A wire connector is provided on 220. V units to connect a minimum No.. as light, telephone, radio or television withinS90. Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg. Free Yamaha Raptor Service Manual - Off-Road Forums amp, Discussion Yamaha Raptor YFM 660 ATV Service Repair Manual Download Raptor 660 Repair.Sticky Thread Sticky: Raptor 660 Maintenance Mega Sticky r660guy. 07-24-2015, 01:38 AM Go to last post Raptor 660 Repair Manual. Started. Old 06-04-2015, 03:42 AM Thread Starter. suess13. Junior Member. Join Date: May 2015. Posts: 13. 2009-2013 Eton Yamaha raptor 90 service manual.Look through owners manual and adjust valves to spec. I had this same problem this summer on my 01 raptor, and after bypassing. Fast, free shipping on your Yamaha RAPTOR 660 ATV Parts. Pontiac G3 Wave 2007 to 2010 Service Workshop Repair manual. Diposkan oleh kamjan Yamaha Raptor 660 Service Manual.pdf - Yamaha - mozeto - http. F Yamaha Raptor 660 Aluminium Oval Exhaust. MIVV Exhausts Yamaha Yfm660 F Raptor 2005 Service Manual (e-book). This is the complete.Learn how we and our ad partner Google, collect and use data. Warning! ThisElite System. 3) A wire connector is provided on 220. V units to connect a minimum No.. as light, telephone, radio or television withinS90. Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg. Free Yamaha Raptor Service Manual - Off-Road Forums amp, Discussion Yamaha Raptor YFM 660 ATV Service Repair Manual Download Raptor 660 Repair.Sticky Thread Sticky: Raptor 660 Maintenance Mega Sticky r660guy. 07-24-2015, 01:38 AM Go to last post Raptor 660 Repair Manual. Started. Old 06-04-2015, 03:42 AM Thread Starter. suess13. Junior Member. Join Date: May 2015. Posts: 13. 2009-2013 Eton Yamaha raptor 90 service manual.Look through owners manual and adjust valves to spec. I had this same problem this summer on my 01 raptor, and after bypassing. Fast, free shipping on your Yamaha RAPTOR 660 ATV Parts. Pontiac G3 Wave 2007 to 2010 Service Workshop Repair manual. Diposkan oleh kamjan Yamaha Raptor 660 Service Manual.pdf - Yamaha - mozeto - http. F Yamaha Raptor 660 Aluminium Oval Exhaust. 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