🏷️ Basic Information Identification Make: Yamaha Model: Raptor 660 Model Code: YFM660RN (2001-2004), YFM660RNC (2005) Vehicle Type: All-Terrain Vehicle (ATV) Generation Generation Code: 1st Generation (2001-2005) Generation Description: The initial and sole generation of the Raptor 660, establishing a benchmark for high-performance sport ATVs. 👋 Introduction Market Position Category: High-performance sport ATV Target Audience: Enthusiasts and professionals seeking to maintain, repair, or optimize their Yamaha Raptor 660. Competitive Analysis Key Competitors Era: Honda TRX450R, Polaris Predator 500, Suzuki LT-Z400. Competitive Advantage: The Raptor 660 was renowned for its powerful engine and aggressive styling, setting a new standard for the sport ATV segment. Key Features Manual Benefit 1: Cost savings through DIY repairs and maintenance. Manual Benefit 2: Restoration and preservation of vehicle performance and longevity. Manual Benefit 3: Empowerment through in-depth knowledge of the vehicle's systems. 📋 Manual Details Coverage Areas Years Covered: 2001, 2002, 2003, 2004, 2005 Model Variants Covered: YFM660RN, YFM660RNC Page Count Estimated Page Count: Likely over 300 pages (typical for comprehensive service manuals of this era) Manual Type Type: Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Rocker arms, camshaft, cylinder head, valves, valve springs, cylinder, piston, AC magneto, clutch, oil pump, shift shaft, crankcase, crankshaft, balancer, transmission Cooling System: Radiator, thermostat, water pump Fuel System: Carburetor (disassembly, inspection, reassembly) Electrical System: Switches, ignition system, electric starting system, starter motor, charging system, lighting system, signal system Chassis And Suspension: Likely covers suspension components, steering, and frame due to troubleshooting section mentioning shock absorbers and handling issues. Brakes: Brake system (mentioned in troubleshooting) Procedures Included Maintenance: Routine maintenance, fluid changes, lubrication, filter replacement. Repair: Engine rebuilds, transmission repairs, carburetor overhaul, electrical component replacement. Troubleshooting: Starting problems, idle speed issues, gear shifting problems, clutch problems, overheating, brake problems, shock absorber malfunctions, handling issues, lighting system problems. Disassembly And Assembly: Detailed procedures for component removal, overhaul, and reinstallation. Specifications And Data: Torque values, clearances, fluid capacities, electrical specifications. Technical Depth Depth: Comprehensive, covering detailed diagnostics, rebuild procedures, and technical specifications for professional mechanics and advanced DIY enthusiasts. 📊 Manual Specifications File Format Format: PDF Compatibility: PC & MAC compatible (Windows 97-10, macOS) Printability: Printable without restrictions Searchability: Likely searchable text within the PDF Print Quality Quality Description: High-resolution digital reproduction with clear illustrations and diagrams. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, SOHC, 4-valve, single cylinder Displacement: 660cc Bore X Stroke: 100.0 mm x 83.9 mm Compression Ratio: 9.2:1 Performance Horsepower Estimated: Approximately 50 HP (at crankshaft, varies slightly by year/tune) Torque Estimated: Approximately 45 lb-ft (at crankshaft, varies slightly by year/tune) Fuel System Carburetor: Mikuni BSR42 Fuel Type: Unleaded gasoline Ignition System Ignition: CDI Starting System Starter: Electric Start Cooling System Cooling Method: Liquid-cooled Lubrication System Oil Type Recommendation: Yamalube 4 (or equivalent SAE 10W-30, 20W-40, or 20W-50 4-stroke motorcycle oil depending on temperature) Oil Capacity With Filter Change: Approximately 2.3 L (2.4 US qt) 🔧 Transmission Standard Transmission Type: Constant mesh, 5-speed with reverse Clutch Type: Wet, multi-plate Features Drive System: O-ring sealed chain drive 📐 Dimensions Exterior Overall Length: Approx. 1,830 mm (72.0 in) Overall Width: Approx. 1,160 mm (45.7 in) Overall Height: Approx. 1,100 mm (43.3 in) Weights Dry Weight: Approx. 210 kg (463 lbs) Curb Weight: Approx. 219 kg (483 lbs) (with all standard equipment and full fluids) Suspension Front Suspension: Independent double wishbone with adjustable spring preload, 9.1 inches travel Rear Suspension: Swingarm with adjustable spring preload, 8.1 inches travel Wheels And Tires Front Tires: AT21x7-10 Rear Tires: AT20x10-9 Brakes Front Brakes: Dual hydraulic disc Rear Brakes: Dual hydraulic disc 🛡️ Safety Features Ratings Atv Safety Considerations: As a high-performance sport ATV, operator skill and protective gear are paramount. Not designed for novice riders. Active Features Throttle Limiter: While not a standard feature on this model in terms of electronic limiting, proper throttle control is essential. Passive Features Anti Kickback Steering: Yamaha's steering design aims to mitigate kickback, though terrain can influence this. 💡 Technology Features Infotainment Infotainment System: N/A (No integrated infotainment system typical for ATVs of this era). Driver Assistance Driver Assistance Features: N/A (No electronic driver assistance systems). Connectivity Connectivity Features: N/A (No connectivity features). 🔧 Maintenance Service Intervals Engine Oil Change: Every 1,000 km (600 miles) or 6 months, whichever comes first. Also recommended after intensive use. Air Filter Cleaning: Every 500 km (300 miles) or 3 months, or more frequently in dusty conditions. Spark Plug Inspection: Every 2,000 km (1,200 miles) or 12 months. Fluid Specifications Coolant Type: High-quality ethylene glycol-based coolant (50% solution with distilled water) Brake Fluid Type: DOT 3 or DOT 4 brake fluid Known Issues Common Wear Item 1: Cam chain tensioner (can become noisy or fail, leading to potential engine...