The Yamaha YFM660 Raptor 660, part of the first generation Raptor lineage, is a groundbreaking sport All-Terrain Vehicle (ATV) renowned for its high-performance capabilities and robust engineering. Produced from 2001 to 2005, this model set new benchmarks in its class, combining a powerful 660cc liquid-cooled, 5-valve, DOHC, 4-stroke engine with exceptional handling. The legacy in powersports is evident in the Raptor's design, which prioritizes a thrilling riding experience for sport and recreational use, supported by a reputation for quality and reliability. This comprehensive Workshop Service Manual, presented in English and spanning 432 pages, provides essential repair and overhaul information for the Yamaha YFM660 Raptor 660 models from 2001 through 2005. It is meticulously detailed, covering all major systems including the engine, fuel, ignition, lubrication, exhaust, electrical, transmission, drivetrain, suspension, brakes, steering, and bodywork. The manual includes routine maintenance procedures, troubleshooting guides, removal and installation instructions, and overhaul procedures, making it an indispensable resource for mechanical technicians and knowledgeable ATV owners seeking to maintain and repair their vehicle effectively. 🏷️ Basic Information Identification Make: Yamaha Model: YFM660 Raptor 660 Model Designation: Raptor 660 Vehicle Type: ATV (All-Terrain Vehicle) Generation Generation Identifier: First Generation Raptor Codes Model Codes: YFM660 👋 Introduction Market Position Target Audience: Mechanical technicians and knowledgeable ATV owners. Value Proposition: Enables users to build and maintain a reputation of quality service by providing reliable information. Competitive Analysis Benefit To Owner: Empowers owners to perform DIY maintenance and repairs, saving money on labor and overhead. Key Features Emphasis Symbols: Utilizes WARNING, CAUTION, and NOTE to highlight critical information. Information Source: Based on information available in authorized Yamaha dealer service departments. Accuracy Statement: Endeavored to ensure accuracy of all information. Completeness: Contains all necessary instructions for any required repair. 📋 Manual Details Coverage Areas Covered Years: 2001, 2002, 2003, 2004, 2005 Page Count Total Pages: 432 Manual Type Type: Workshop Service Manual Purpose: Repair and Overhaul Language Language: English Format File Format: PDF Delivery Method: Digital Download (Email) Printability: Yes 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage including disassembly, assembly, and repair of engine components. Fuel System: Detailed instructions for fuel delivery, carburetor (or fuel injection if applicable), fuel tank, and lines. Ignition System: Information on ignition timing, components (spark plug, coil, CDI unit), and troubleshooting. Lubrication System: Procedures for oil changes, oil pump, oil filter, and lubrication system maintenance. Exhaust System: Details on exhaust manifold, muffler, and related components. Electrical System: Wiring diagrams, troubleshooting for starting, charging, lighting, and other electrical components. Transmission: Complete coverage of transmission removal, disassembly, assembly, and repair. Drivetrain: Information on drive shafts, differentials (if applicable), and final drive systems. Suspension: Details on front and rear suspension systems, including shocks, springs, and linkages. Brakes: Procedures for brake system maintenance, caliper repair, fluid replacement, and bleeding. Steering: Information on steering mechanism, tie rods, and alignment. Bodywork: Procedures for removal and installation of body panels, fenders, seat, and other exterior components. Wheels And Tires: Specifications for wheel sizes, tire pressures, and mounting. Chassis: Frame inspection, repair, and related components. Procedures Included Maintenance: Routine maintenance procedures, tune-ups, and preventative servicing. Troubleshooting: Diagnostic procedures for identifying and resolving common and complex issues. Repair: Step-by-step instructions for repairing and replacing various components. Removal Installation: Detailed procedures for removing and reinstalling major assemblies and components. Overhaul: Complete overhaul procedures for engine, transmission, and other critical systems. Adjustments: Instructions for making various adjustments, such as valve clearance, carburetor settings, and brake adjustments. Technical Depth Depth: Comprehensive, suitable for professional technicians and experienced DIY mechanics. Diagnostic Support: Includes diagnostic flowcharts and troubleshooting guides. Proprietary Components: Incorporates instructions from proprietary component manufacturers for integrated understanding. Special Tools: Identifies and illustrates Yamaha special tool numbers required for specific procedures. 📊 Manual Specifications File Format Quality: PDF format, designed for clarity and readability. Print Quality Printability: High resolution, suitable for printing individual pages or the entire manual. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 5-valve, DOHC, 4-stroke Engine Displacement: 660cc Bore X Stroke: 100.0 mm x 85.0 mm Compression Ratio: 9.1:1 Performance Horsepower Estimate: Approximately 42-45 HP (stock, varies by region and specific model year). Torque Estimate: Approximately 40-43 lb-ft (stock, varies by region and specific model year). Fuel System Fuel Delivery: Mikuni BSR42 carburetor Fuel Type: Unleaded gasoline Fuel Capacity: 3.2 gallons (12 L) 🔧 Transmission Standard Transmission Type: 5-speed manual with reverse Clutch Type: Wet, multi-plate Features Gear Ratios: Detailed gear ratios are available within the manual. Drive System: Shaft drive 📐 Dimensions Exterior Length: Approx. 70.7 in (1795 mm) Width: Approx. 45.5 in (1155 mm) Height: Approx. 43.7 in (1110 mm) Weights Dry Weight: Approx. 410 lbs (186 kg) Ground Clearance: Approx. 4.4 in (112 mm) 🛡️ Safety Features Ratings Atv Safety Standards: Designed to meet industry safety standards for...