Basic Information Identification Make: Yamaha Model: Raptor YFM660 Model Designation: YFM660R Vehicle Type: ATV (All-Terrain Vehicle) Generation Generation Codes: First Generation Introduction Market Position Segment: High-performance sport ATV. Target Audience: Enthusiasts, recreational riders, competitive racers, and service technicians. Competitive Analysis Key Competitors: Honda TRX400EX/TRX450R, Suzuki LT-Z400, Kawasaki KFX400/KFX450R, Polaris Predator 500. Key Features Performance Focus: Yamaha's YFM660R Raptor established a benchmark in the sport ATV market with its powerful engine and agile handling. Manual Details Coverage Areas Applicable Years: 2001, 2002, 2003, 2004, 2005 Page Count Total Pages: 327 Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Mechanical: Top end, bottom end, valve train, cooling system, lubrication system, piston and connecting rod assembly, crankshaft, cylinder, cylinder head, camshaft, timing system. Engine Fuel System: Carburetor (Mikuni BSR34) overhaul and adjustment, fuel tank, fuel pump, fuel filter. Engine Ignition System: CDI unit, ignition coil, spark plug specifications, timing. Transmission Drivetrain: Clutch operation (wet, multi-plate), gearbox inspection and repair, final drive, drive shafts, differential (if applicable to model variant, though YFM660R is typically shaft-driven rear). Electrical System: Wiring diagrams, battery specifications, charging system (stator, rectifier/regulator), lighting system, starter system, ignition switch, kill switch, instrumentation. Chassis Frame: Frame inspection, steering system (handlebars, steering stem, bearings), suspension (front A-arms, rear swingarm, shock absorbers), wheel hubs, bearings. Brakes: Front disc brakes (caliper, rotor, master cylinder), rear disc brake, brake fluid specifications, bleeding procedures. Bodywork Trim: Body panel removal and installation, fenders, seat, fuel tank cover, decals. Cooling System: Radiator, fan, coolant specifications, fluid capacity, flushing and filling procedures. Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, spark plug checks, chain adjustment (if applicable, though YFM660R is often shaft drive rear), fluid level checks. Troubleshooting: Diagnostic flowcharts for common problems related to starting, running, electrical systems, and braking. Repair: Detailed step-by-step instructions for disassembly, inspection, repair, and reassembly of all major components. Overhaul: Comprehensive overhaul procedures for engine, carburetor, transmission, and brake systems. Torque Specifications: Precise torque values for critical fasteners throughout the vehicle. Technical Depth Depth Level: Comprehensive (from basic maintenance to full engine rebuilds and electrical diagnostics). Manual Specifications File Format Format Type: PDF Searchability: Likely text-searchable (common for professional PDFs). Print Quality Image Resolution: High resolution, suitable for printing. Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, SOHC, 5-valve, single cylinder. Displacement: 660cc Bore X Stroke: 100.0 mm x 85.0 mm Compression Ratio: 9.1:1 Performance Horsepower Approximate: Approx. 45-50 HP (subject to tuning and specific model year variations). Torque Approximate: Approx. 40-45 lb-ft (subject to tuning and specific model year variations). Fuel System Carburetor Type: Mikuni BSR34 (flat slide, constant velocity). Fuel Type: Unleaded gasoline, minimum 87 octane. Lubrication System Oil Type Specification: Yamalube 4 (or equivalent API SG or higher, SAE 10W-30, 10W-40, or 20W-40). Cooling System Coolant Type: Ethylene glycol base antifreeze, 50/50 mix with distilled water. Transmission Standard Type: 5-speed manual with wet, multi-plate clutch and reverse. Gear Ratios: Detailed in manual, specific ratios for each gear. Final Drive: O-ring sealed chain, 520 pitch (often). Transmission Oil Specification: Yamalube 4 (or equivalent API SG or higher, SAE 10W-30, 10W-40, or 20W-40). Dimensions Exterior Length: Approx. 70.1 inches (1780 mm) Width: Approx. 46.1 inches (1170 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. 2.6 US gal (9.8 L) Safety Features Ratings Classification: Sport ATV, designed for controlled environments and experienced riders. Not a toy. Active Features Braking System: Hydraulic disc brakes front and rear for strong stopping power. Passive Features Footwells: Integrated wide footwells with heel guards for rider protection. Throttle Limiter: Adjustable throttle stop screw for rider training/beginners (covered in manual). Technology Features Infotainment Instrumentation: Digital LCD meter displaying speed, odometer, tripmeter, clock, neutral indicator, reverse indicator, and warning lights. Driver Assistance Throttle Control: Thumb throttle mechanism for acceleration control. Connectivity Electrical System Features: 12V DC electrical system for ignition and lighting. Maintenance Service Intervals Engine Oil Change: Every 1000 km (600 miles) or 6 months, whichever comes first, or more frequently under severe use (detailed in manual). Air Filter Cleaning: Every 500 km (300 miles) or 3 months, or more frequently in dusty conditions. Spark Plug Inspection: Every 1000 km (600 miles) or 6 months. Valve Clearance Check: Every 2000 km (1200 miles) or 12 months. Fluid Specifications Engine Oil Capacity: 3.00 L (3.17 US qt) with filter change, 2.70 L (2.85 US qt) without filter change (verify in manual). Coolant Capacity: 1.80 L (1.90 US qt). Brake Fluid Type: DOT 3 or DOT 4. Known Issues Carburetor Tuning: Mikuni BSR34 can be sensitive to altitude and temperature changes, requiring occasional adjustment. Lean...