This manual covers the YFM660RNC, commonly known as the Raptor 660, a high-performance sport ATV produced between 2001 and 2006 for the North American market. Engineered by a leader in powersports, this model is renowned for its robust 660cc liquid-cooled engine, aggressive styling, and long-travel suspension, making it a capable machine for recreational off-road riding and demanding terrain. Its powerful 4-stroke, SOHC, 5-valve engine delivers substantial horsepower and torque, supported by a 5-speed manual transmission with reverse and a responsive clutch. The Raptor 660 features dual hydraulic disc front brakes and a single hydraulic disc rear brake, ensuring reliable stopping power, complemented by wide, anti-slip footpegs and tapered handlebars for enhanced rider control and safety. This comprehensive workshop service repair manual provides detailed information essential for the maintenance, repair, and servicing of your YFM660RNC. It covers all major systems, including the engine, transmission, drivetrain, suspension, brakes, electrical system, fuel system, cooling system, and exhaust system. Within its extensive pages, you will find step-by-step repair instructions, detailed troubleshooting guides for common issues, rebuild procedures for key components, and all necessary technical specifications, such as torque values and fluid capacities. This manual is an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their Raptor 660 sport ATV. 🏷️ Basic Information Identification Make: Yamaha Model: YFM660RNC Model Nickname: Raptor 660 Type: ATV (All-Terrain Vehicle) Category: Sport ATV Codes Vin Code: NC 👋 Introduction Market Position Market Segment: High-performance sport ATV, positioned for recreational off-road riding and aggressive terrain. Competitive Analysis Competitors: Honda TRX450R, Suzuki LT-Z400, Kawasaki KFX400, Polaris Predator 500. Key Features Vehicle Features: Powerful 660cc engine, aggressive styling, long-travel suspension, strong braking performance, shaft drive (typical for Yamaha sport ATVs of this era, although chain drive is common for R models). Manual Utility Value Proposition: Provides essential knowledge for maintaining and repairing the Yamaha YFM660RNC, saving owners significant costs on professional servicing and enabling DIY repairs. 📋 Manual Details Coverage Areas Applicable Years: 2001, 2002, 2003, 2004, 2005, 2006 Market Coverage: North America (indicated by 'NC') Page Count Estimated Pages: Extensive (typical for full workshop manuals, likely 300-500+ pages) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, inspection, repair, and assembly of all engine components. Transmission: Clutch operation, gear shifting mechanisms, gearbox disassembly and repair. Drivetrain: Chain drive, rear differential (if applicable), axles, bearings. Suspension: Front A-arm suspension, rear swingarm, shock absorber adjustment and service, steering components. Brakes: Hydraulic brake system, front and rear disc brake caliper service, master cylinders, brake fluid bleeding. Electrical: Ignition system, charging system (stator, regulator/rectifier), lighting, battery, starter motor, wiring diagrams. Fuel System: Carburetor disassembly, cleaning, adjustment, fuel lines, fuel tank, fuel pump (if applicable). Cooling System: Radiator, cooling fan, coolant specifications and replacement. Exhaust System: Exhaust pipe, muffler, heat shields. Frame And Bodywork: Frame inspection, plastic body panel removal and installation, seat, handlebars. Procedures Included Maintenance: Oil changes, filter replacements, chain adjustment, lubrication points, general inspection. Troubleshooting: Diagnostic flowcharts for common problems, symptom-based fault finding. Repair: Step-by-step instructions for component replacement and repair. Rebuilds: Complete engine rebuild procedures, transmission overhauls. Specifications: Torque values, clearances, adjustments, fluid capacities. Technical Depth Depth: Comprehensive workshop level, covering everything from basic maintenance to complete engine and component rebuilds. Diagnostics: Detailed diagnostic procedures and troubleshooting guides. Illustrations: Likely includes detailed diagrams and exploded views of components. 📊 Manual Specifications File Format Format: PDF Searchable: Typically searchable PDF format for easy navigation. Print Quality: High-resolution, suitable for printing specific sections or the entire manual. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Liquid-cooled, SOHC, 5-valve, Single Cylinder Displacement: 660 cc Bore X Stroke: 100.0 mm x 84.0 mm Compression Ratio: 9.2:1 Ignition: CDI (Capacitor Discharge Ignition) Performance Horsepower: Approx. 50-53 HP (factory estimates, varies slightly by region) Torque: Approx. 40-42 lb-ft (factory estimates) Fuel System Carburetor: Mikuni BSR42 (single) with accelerator pump. Fuel Capacity: 3.1 gallons (11.7 L) Lubrication Oil Type: Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher. Oil Capacity: 2.10 US qt (2.0 L) with oil filter change. 🔧 Transmission Standard Type: 5-speed manual with wet multi-disc clutch. Final Drive: O-ring sealed chain, drive sprocket, rear axle. Features Reverse: Yes Transmission Oil: Yamalube 4 (or equivalent) SAE 10W-30 API SE, SF, SG, SH, SJ, SL. Transmission Oil Capacity: 0.70 US qt (0.66 L) 📐 Dimensions Exterior Length: 71.5 in (1815 mm) Width: 46.1 in (1170 mm) Height: 44.9 in (1140 mm) Wheelbase: 50.5 in (1285 mm) Weights Dry Weight: 421 lbs (191 kg) Curb Weight: Not officially specified, but approximately 450-460 lbs with fluids. Suspension Travel Front Suspension Travel: 9.1 in (231 mm) Rear Suspension Travel: 9.5 in (241 mm) Ground Clearance...