🏷️ Basic Information Identification Make: Yamaha Model: YFM660 Model Variant: Raptor Product Type: Workshop Service Repair Manual Codes Engine Code Prefix: 4WV Vin Code Digit Engine: 4 👋 Introduction Market Position Vehicle Category: High-performance All-Terrain Vehicle (ATV) Target Audience: Enthusiasts, off-road riders, recreational users seeking reliable performance and capability. Competitive Analysis Competitors: Honda TRX450R/Foreman, Suzuki LT-R450/KingQuad, Polaris Sportsman/Scrambler, Kawasaki Brute Force/KFX series. Key Differentiation: Powerful 660cc engine, robust chassis, comfortable suspension, and Yamaha's renowned reliability and build quality. Key Features Engine Power: Class-leading torque and horsepower for its era. Handling: Agile handling and stable ride due to well-tuned suspension and chassis geometry. Durability: Built for demanding off-road conditions, known for longevity. Manual Benefit: Cost-effective maintenance, empowers owners to perform repairs and keep the vehicle in optimal condition. 📋 Manual Details Coverage Areas Years Covered: 2001, 2002, 2003, 2004, 2005, 2006 Region Of Operation: Global (primarily North American and European specifications) Page Count Estimated Pages: ~400+ Manual Type Type: Comprehensive Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed overhaul, diagnosis, inspection, and repair of the 660cc liquid-cooled, SOHC, 4-stroke engine. Fuel System: Carburetor (Mikuni BSR42) tuning, cleaning, and overhaul; fuel pump operation; fuel filter replacement. Ignition System: CDI ignition system, spark plug specifications, ignition timing checks, coil testing. Transmission: 5-speed manual transmission with reverse, clutch operation and adjustment, transmission gear inspection and replacement. Drivetrain: Shaft drive system, final drive housing, universal joints, axle inspection and maintenance. Suspension: Front independent suspension (A-arms), rear swingarm suspension, shock absorber adjustment and maintenance, bearing lubrication. Brakes: Hydraulic disc brakes (front and rear), brake pad replacement, caliper servicing, brake fluid bleeding, master cylinder inspection. Electrical System: Stator, flywheel magneto, battery maintenance, starter motor operation, lighting system (headlight, taillight, brake light), wiring diagrams. Cooling System: Liquid cooling system, radiator, fan operation, coolant type and capacity, water pump servicing. Frame And Bodywork: Chassis inspection, body panel removal and installation, seat, fenders, handlebar replacement. Lubrication System: Engine oil type and capacity, oil filter replacement, lubrication points. Procedures Included Maintenance: Scheduled maintenance checks, oil changes, filter replacements, spark plug changes, brake adjustments, chain/driveshaft lubrication. Troubleshooting: Diagnostic flowcharts for common problems, electrical system troubleshooting, engine performance issues. Repair: Complete engine rebuild procedures, transmission overhaul, suspension component replacement, brake system servicing, electrical component repair. Disassembly And Assembly: Step-by-step instructions for removing and reinstalling major components and assemblies. Technical Specifications: Torque specifications for all fasteners, engine clearances, fluid capacities, electrical system resistance values. Wiring Diagrams: Detailed electrical system wiring schematics for all model years covered. Technical Depth Depth: Comprehensive, covering from routine maintenance to full engine and transmission rebuilds. Diagnostic Capabilities: Includes diagnostic procedures and troubleshooting charts for identifying and resolving mechanical and electrical faults. Rebuild Procedures: Detailed step-by-step instructions for overhauling major mechanical components like the engine and transmission. 📊 Manual Specifications File Format Type: PDF Searchability: Searchable text content for quick information retrieval. Compatibility: Viewable on most devices with PDF reader (computers, tablets, smartphones). Print Quality Quality: High-resolution scans with clear text and diagrams. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, four-stroke, SOHC, 5-valve Displacement: 660 cc Bore X Stroke: 100.0 mm x 85.0 mm Compression Ratio: 9.2:1 Performance Horsepower Estimated: Approximately 40-45 hp (actual figures vary by market and tune) Torque Estimated: Approximately 40-45 lb-ft (actual figures vary by market and tune) Fuel System Carburetor: Mikuni BSR42, diaphragm-type Fuel Capacity: 3.1 US gal (11.7 L) Ignition System Ignition: CDI (Capacitor Discharge Ignition) Lubrication System Oil Type Specification: Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA certified Oil Capacity With Filter: 2.9 US qt (2.7 L) Cooling System Coolant Type: Permanent Antifreeze/Coolant, 50/50 mix with distilled water Coolant Capacity: 1.71 US qt (1.6 L) 🔧 Transmission Standard Type: Constant mesh, 5-speed sequential with reverse Clutch: Wet, multiple disc Final Drive: O-ring sealed chain Features Reverse Gear: Standard feature for enhanced maneuverability. Clutch Actuation: Manual lever operation. 📐 Dimensions Exterior Length: 73.7 in (1,872 mm) Width: 43.3 in (1,100 mm) Height: 41.4 in (1,052 mm) Wheelbase: 50.4 in (1,280 mm) Ground Clearance: 9.5 in (242 mm) Weights Dry Weight: 518 lbs (235 kg) Curb Weight Estimated: Approximately 530-540 lbs (240-245 kg) with fluids Tires Front Tire Size: AT21x7-10 Rear Tire Size: AT20x10-9 Wheels Front Wheel Size: 10 x 5.5 AT Rear Wheel Size: 9 x 8 AT 🛡️ Safety Features Ratings Atv Safety Classification: Designed for recreational off-road use; users must wear appropriate safety gear and follow all safety guidelines. Active Features Braking System: Dual hydraulic disc brakes front, hydraulic disc brake rear provide strong stopping power. Throttle Limiter: Some models may have adjustable throttle limiters for novice riders. Passive Features Ergonomics: Designed for rider comfort and control with padded seat and handlebars. Lighting: Dual...