🏷️ Basic Information Identification Make: Yamaha Model: Raptor 660 Model Designation: YFM660R Vehicle Type: All-Terrain Vehicle (ATV) Codes Engine Code: YFM660 👋 Introduction Market Position Target Audience: Yamaha Raptor 660 owners, DIY mechanics, and repair shops. Competitive Analysis Value Proposition: Provides dealer-level repair information, enabling cost savings on maintenance and repairs. Key Features Information Source: Contains the same in-depth information used by authorized Yamaha dealers. Benefit: Empowers users to perform repairs and maintenance with confidence. 📋 Manual Details Coverage Areas Production Years Covered: 2001, 2002, 2003, 2004, 2005 Page Count Estimated Page Count: Refer to FSM for exact count (typically 300-500+ pages for a comprehensive FSM) Manual Type Manual Type: Factory Service Manual (FSM) Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, repair, and assembly of the engine. Engine Fuel System: Carburetor tuning, cleaning, and component replacement. Engine Ignition System: CDI unit, ignition coil, spark plug specifications, and testing. Engine Cooling System: Radiator, fan, thermostat, coolant specifications, and bleeding procedures. Transmission Drivetrain: Clutch operation, gearbox disassembly and reassembly, drive shaft maintenance. Suspension Steering: Front and rear suspension component inspection, repair, and alignment specifications. Brakes System: Hydraulic brake system bleeding, caliper, rotor, and master cylinder service. Electrical System: Wiring diagrams, lighting, battery, starter motor, and charging system diagnostics. Chassis Bodywork: Frame inspection, plastic body panel removal and installation, seat service. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug checks. Troubleshooting Guides: Diagnostic charts for common problems and their solutions. Rebuild Procedures: Detailed instructions for engine and transmission rebuilds. Component Replacement: Step-by-step guides for replacing various parts. Torque Specifications: Accurate torque values for all critical fasteners. Technical Depth Depth Of Coverage: Comprehensive Factory Service Manual (FSM) level detail. 📊 Manual Specifications File Format File Type: PDF Searchability: Typically text-searchable PDF for easy information retrieval. Print Quality Print Capability: Printable without restrictions. Color Format: Full-color illustrations and diagrams. Binding Type Binding Type: N/A (Digital download) Paper Type Paper Type: N/A (Digital download) Compatibility Operating Systems: Compatible with all versions of Windows and Mac. ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, liquid-cooled, DOHC, 5-valve Displacement: 660 cc Performance Bore X Stroke: 100.0 mm x 85.0 mm (typical) Compression Ratio: 9.2:1 (typical) Horsepower Rating: Approximately 45-50 HP (engine output, may vary by year/region) Fuel System Fuel Delivery: Carburetor (likely Mikuni BSR42) Fuel Type: Unleaded gasoline 🔧 Transmission Standard Transmission Type: 5-speed constant mesh with reverse Optional Clutch Type: Wet, multiple-disc Features Drive System: O-ring sealed chain drive 📐 Dimensions Exterior Overall Length: Approximately 72.0 in (1828 mm) Overall Width: Approximately 45.7 in (1161 mm) Overall Height: Approximately 43.5 in (1105 mm) Weights Dry Weight: Approximately 423 lbs (192 kg) Fuel Capacity: 3.7 US gal (14 L) 🛡️ Safety Features Ratings Atv Classification: Performance Sport ATV Active Features Parking Brake: Mechanical parking brake Passive Features Throttle Limiter: Thumb throttle with potential for adjustment or restrictors (covered in manual). 💡 Technology Features Infotainment Display: Digital multi-function meter (speedometer, odometer, trip meter, clock). Driver Assistance Traction Control: N/A (This era of sport ATVs did not typically feature electronic traction control). Connectivity Diagnostic Ports: Diagnostic connectors for connecting service tools (details in manual). 🔧 Maintenance Service Intervals Engine Oil Change: Refer to manual for specific intervals (typically every 1,000 miles or annually). Air Filter Cleaning: Frequent checks and cleaning recommended, especially in dusty conditions. Chain Lubrication Adjustment: Regular checks and adjustments are critical for drivetrain longevity. Fluid Specifications Engine Oil Type: Yamalube 4 (or equivalent 10W-40 or 20W-50 motorcycle oil meeting API SG or higher). Coolant Type: Permanent type antifreeze (e.g., Yamaha's recommended coolant) mixed 50/50 with distilled water. Brake Fluid Type: DOT 3 or DOT 4 brake fluid. Known Issues Cam Chain Tensioner: Known to fail, leading to engine noise or damage. Manual provides inspection and replacement procedures. Carburetor Jetting: Can require adjustment due to altitude or modifications. Manual details carburetor service. Reverse Gear Engagement: Some units may exhibit difficulty engaging reverse. Manual covers transmission inspection. 📚 Vehicle History Brand Heritage Manufacturer: Yamaha Motor Company Model Evolution Predecessor: Yamaha Warrior 350 (established a strong sport ATV lineage). Segment Impact: The Raptor 660 was a pioneering model in the high-performance sport ATV segment. Production Production Period: 2001-2005 (as covered by this manual). Successor: Yamaha Raptor 700 (introduced in 2006). 🏆 Awards & Recognition Recognitions Atv Industry Impact: Widely recognized as a benchmark in performance and capability for its time.