The Yamaha YFM660 Raptor, produced from 2001 to 2006, is a high-performance all-terrain vehicle celebrated for its powerful 660cc liquid-cooled engine, agile handling, and robust chassis. This sport ATV was engineered to deliver class-leading torque and horsepower for its era, making it a popular choice for off-road enthusiasts and recreational riders seeking capability and reliability. Renowned build quality and durability are key differentiators, ensuring the Raptor can withstand demanding conditions. Its design prioritizes rider comfort and control, contributing to its reputation as a benchmark in the sport ATV segment. This comprehensive service repair manual provides essential information for the maintenance, diagnosis, and repair of the Yamaha YFM660 Raptor for model years 2001 through 2006. It covers all major systems, including detailed overhaul procedures for the engine and transmission, carburetor tuning, brake system servicing, and electrical system troubleshooting. The manual includes step-by-step instructions, technical specifications, torque values, and wiring diagrams, enabling owners and technicians to perform routine maintenance, address common issues like cam chain tensioner wear, and complete complex repairs. Its purpose is to empower users to keep their Raptor in optimal condition, ensuring continued performance and longevity. 🏷️ 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...