Sharp FO P600 / UX P400 Facsimile Repair Manual

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Basic Information Identification Make: Yamaha Model: Raptor 660 Model Codes: YFM660RNC, YFM660RN Vehicle Type: ATV (All-Terrain Vehicle) Category: Sport ATV Introduction Market Position Positioning: The Yamaha Raptor 660 is positioned...

Type: Atv

Sku: 38691

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Description

Basic Information
Identification
Make:	Yamaha
Model:	Raptor 660
Model Codes:	YFM660RNC, YFM660RN
Vehicle Type:	ATV (All-Terrain Vehicle)
Category:	Sport ATV

Introduction
Market Position
Positioning:	The Yamaha Raptor 660 is positioned as a high-performance sport ATV, renowned for its powerful engine and capable chassis, making it a popular choice for recreational riding, trail riding, and some competitive applications.
Competitive Analysis
Competition:	Competed against other performance-oriented ATVs of its era, such as the Suzuki LT-Z400 (later LT-Z400 Quadsport) and Honda TRX400EX, offering a more potent engine package compared to some of its rivals.
Key Features
Features:	Powerful 660cc liquid-cooled engine, aggressive styling, long-travel suspension, hydraulic disc brakes, electric start, and a reputation for durability and performance.
Manual Value
Value Proposition:	This official factory service manual is an indispensable tool for owners and technicians, providing the most accurate and complete information for maintenance, repair, and troubleshooting, thereby preserving the performance and longevity of the Yamaha Raptor 660.

Manual Details
Coverage
Manual Type:	Complete Official Factory Service / Repair / Workshop Manual
Language:	English
Format:	PDF (Digital Download)
Delivery Method:	Instant Download
Page Count:	Not explicitly stated, but implies comprehensive coverage for a factory manual.
Guarantee:	Full Money Back Guarantee

Manual Coverage
Systems Covered
Engine:	Complete engine overhaul, including disassembly, inspection, assembly, troubleshooting, and specifications for cylinders, pistons, rings, rods, crankshaft, bearings, oil pump, lubrication system.
Cylinder Head And Valve Train:	Detailed procedures for cylinder head removal, valve inspection, valve seat grinding, valve stem seals, valve guides, valve springs, camshaft, timing, lifters, pushrods, and valve adjustment.
Fuel System:	Carburetor (Carb) service, tuning, overhaul, intake manifold, fuel pump (if applicable), fuel filter, fuel lines, and air filter replacement.
Ignition System:	Spark plugs, ignition timing, CDI unit, stator, flywheel, ignition coils, and wiring.
Exhaust System:	Muffler, downpipe, catalytic converter (if applicable), headers, heat wrap, and exhaust gaskets.
Transmission And Drivetrain:	Clutch (pressure plate, clutch shoes, clutch case, clutch lines, clutch hose), transfer case (transfercase, transfer plate), shift linkage, and gears.
Cooling System:	Radiator, radiator fan, oil radiator (oil cooling), coolant hoses, and fan shroud.
Brakes:	Brake system diagnostics, brake pad replacement, brake shoe replacement, rotor replacement, brake lines (clutch lines also listed), and brake fluid changes.
Wheels And Tires:	Tire rotation, tire replacement, wheel alignment, wheel bearings, lug nuts, and hub caps/wheel covers.
Suspension And Steering:	Shocks, struts, steering system components, steering wheel, shifters, pedals, and suspension system.
Electrical System:	Wiring harness (chassis wire harness, main wire harness), electrical pin connectors, sensors (oil sensor, pressure sensor, oil pressure sensor), relays (headlight relay, starter relay, ignition relay), battery, battery replacement, lighting (interior lighting, headlights, taillights, fog lights, turn signals), and meters (volt meter).
Body And Frame:	Body panels, door panels, dashboard, glovebox, center console, trim, bumpers (front bumper, rear bumper), fenders, doors, emblems, fuel cap, fuel door, grilles, hood, jack, lifting, mud guards, mud flaps, window regulator, door handle, hood hinge, hood latch, wiper blade, washer pump, fuel tank cap, courtesy light, door jamb switch, door lock, fuel filler neck, antenna, and insulation/seals (air seals).
Plastics And Trim:	Body trim, trim replacement, interior trim, and trim pieces.
Procedures Included
Maintenance:	Routine maintenance, oil changes, transmission fluid changes, fluid changes, air filter replacement, brake fluid changes, spark plug replacement, battery replacement, fuel filter replacement.
Repair:	Complete repair procedures for all covered systems, including component replacement, rebuilding, and adjustment.
Troubleshooting:	Diagnostic procedures and troubleshooting guides for common and uncommon issues across all vehicle systems.
Rebuilds:	Comprehensive instructions for engine rebuilds, transmission rebuilds, and other major component overhauls.
Installation:	Procedures for installing common aftermarket parts like cold air intakes, different mufflers, and exhaust headers.
Inspection:	Detailed inspection points for various components during routine maintenance and repairs.
Technical Depth
Depth:	Factory-level technical depth, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic maintenance to complete engine and transmission overhauls.
Specifications:	Includes critical torque specifications, fluid capacities, tolerances, and diagnostic parameters.
Wiring Diagrams:	Comprehensive electrical wiring diagrams for all circuits.

Manual Specifications
File
File Format:	PDF
Zoom Capability:	Yes
Searchability:	Implied by PDF format and factory origin, likely searchable text.
Quality
Quality:	Factory Quality
Print
Printable:	Yes
Binding Type
Binding:	N/A (Digital Download)
Paper Type
Paper:	N/A (Digital Download)

Engine Specifications
Primary Engine
Engine Type:	Four-stroke, liquid-cooled, SOHC, five-valve
Displacement:	660cc
Bore X Stroke:	Not specified in product info, but typically around 100 mm x 84 mm.
Compression Ratio:	Not specified in product info, but typically around 9.5:1.
Performance
Horsepower:	Approx. 50-55 HP (manufacturer figures can vary slightly).
Torque:	Not specified in product info, but known for strong mid-range torque.
Fuel System
Carburetor:	Mikuni BSR42 (typically a single 42mm carburetor).
Fuel Type:	Unleaded gasoline
Lubrication
Oil Type:	Yamalube 4 (or equivalent SAE 10W-30 API SG or higher motorcycle oil).
Oil Capacity:	Approx. 2.5-3.0 liters with filter change (refer to manual for exact spec).
Ignition
Ignition Type:	Digital TCI (Transistor Controlled Ignition)
Spark Plug Type:	NGK CR9E (or equivalent).

Transmission
Standard
Transmission Type:	5-speed manual with wet multi-plate clutch
Optional
Reverse:	Yes
Features
Final Drive:	O-ring sealed chain
Fluid Type
Transmission Oil:	Yamalube Gear Oil (or equivalent SAE 80 API GL-4 gear oil).
Fluid Capacity
Transmission Oil Capacity:	Approx. 0.8 liters (refer to manual for exact spec).

Dimensions
Exterior
Length:	Approx. 70.1 inches (1780 mm)
Width:	Approx. 44.5 inches (1130 mm)
Height:	Approx. 43.7 inches (1110 mm)
Wheelbase:	Approx. 49.2 inches (1250 mm)
Weights
Dry Weight:	Approx. 423 lbs (192 kg)
Fuel Capacity:	Approx. 3.2 gallons (12 liters)
Suspension
Front Suspension Type:	Independent double-wishbone with adjustable shocks
Rear Suspension Type:	Swingarm with adjustable shock
Brakes
Front Brake Type:	Dual hydraulic disc
Rear Brake Type:	Hydraulic disc
Tires
Front Tire Size:	AT21x7R-10
Rear Tire Size:	AT20x10R-9
Ground Clearance
Ground Clearance:	Approx. 4.4 inches (112 mm)

Technology Features
Infotainment
Infotainment System:	N/A - This is a performance ATV, not equipped with typical automotive infotainment systems like CD players or advanced displays.
Driver Assistance
Driver Assistance Features:	N/A - Focus is on rider control and mechanical performance.
Connectivity
Connectivity Features:	N/A
Lighting
Lighting System:	Dual halogen headlights, LED taillight/brake light. The manual covers bulb replacement and wiring for these components.

Maintenance
Service Intervals
Oil Change Interval:	Every 20 hours or 3 months, whichever comes first (refer to manual for specific recommendations).
Air Filter Cleaning:	Every 10 hours or as needed depending on operating conditions.
Spark Plug Inspection:	Every 100 hours or annually.
Valve Adjustment Interval:	Every 200 hours or annually.
Fluid Specifications
Engine Oil Spec:	SAE 10W-30 API SG or higher motorcycle oil (e.g., Yamalube 4).
Coolant Type:	High-quality ethylene glycol-based antifreeze with demineralized water (50/50 mix).
Brake Fluid Type:	DOT 4 hydraulic brake fluid.
Known Issues
Common Problems:	While generally robust, some common issues can include carburetor jetting issues (requiring recalibration for modifications or altitude changes), occasional starter clutch wear, and clutch plate wear under aggressive use. The manual will provide specific diagnostics and solutions for these.
Torque Specifications
Torque Values:	The manual contains detailed torque specifications for critical fasteners throughout the vehicle, essential for proper assembly and preventing damage.

Vehicle History
Brand Heritage
Brand Focus:	Yamaha is a renowned Japanese manufacturer with a long history in motorcycles, powersports vehicles, and musical instruments, known for innovation, performance, and quality.
Model Evolution
Predecessor:	The Raptor 660 was preceded by models like the Yamaha Banshee and Warrior, building on Yamaha's legacy in the sport ATV market.
Successor:	The Raptor 660 was succeeded by the Yamaha Raptor 700, which featured a more modern engine and chassis.
Production
Production Years:	The Yamaha Raptor 660 was produced roughly from 2001 to 2005.

Awards & Recognition
Recognitions
Awards And Recognition:	While specific awards are not listed in the product information, the Yamaha Raptor 660 itself was widely regarded by enthusiasts and media as a leading sport ATV of its generation for its performance and handling.