The Yamaha Raptor 660, model designation YFM660R, is a high-performance All-Terrain Vehicle (ATV) that set a benchmark in its segment. Produced between 2001 and 2005, this sport ATV is powered by a 660 cc single-cylinder, 4-stroke engine, known for its robust performance and liquid-cooled design. Its engineering quality is evident in its advanced features for its time, including a 5-speed transmission with reverse, a wet, multi-disc clutch, and a reliable chain drive system. The Raptor 660 was a pioneering model, building on a strong lineage in sport ATVs and offering exhilarating performance for recreational riders and enthusiasts. This Factory Service Manual (FSM) provides comprehensive technical information for the Yamaha Raptor 660 (YFM660R) models from 2001 through 2005. It covers all essential aspects of the vehicle, including detailed procedures for engine mechanicals, fuel and ignition systems, cooling, transmission, suspension, brakes, and the electrical system. The manual includes routine maintenance schedules, troubleshooting guides for common issues, component replacement instructions, and critical torque specifications. This resource is invaluable for owners, DIY mechanics, and professional repair shops, enabling confident and accurate maintenance, diagnosis, and repair to ensure optimal performance and longevity of the vehicle. 🏷️ 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...