The Yamaha Raptor 660, produced from 2001 to 2005, is a high-performance sport All-Terrain Vehicle (ATV) that revolutionized its segment. As the first generation of the Raptor line, it set a benchmark for power and aggressive styling, distinguishing itself from contemporaries like the Honda TRX450R and Polaris Predator 500. The Raptor 660 is powered by a 660cc liquid-cooled, four-stroke engine, delivering approximately 50 horsepower and 45 lb-ft of torque, paired with a 5-speed transmission with reverse and a wet, multi-plate clutch. Its engineering quality is evident in its independent double wishbone front suspension and swingarm rear suspension, both featuring adjustable spring preload, contributing to its renowned handling and capability for enthusiasts and professional riders alike. This comprehensive service repair manual provides essential information for the maintenance, repair, and troubleshooting of Yamaha Raptor 660 models (YFM660RN and YFM660RNC) from 2001 to 2005. It covers a wide array of systems, including detailed procedures for the engine, cooling system, fuel system, electrical system, chassis, suspension, and brakes. The manual includes routine maintenance tasks, complex repair procedures, and detailed specifications. Its purpose is to empower owners and technicians with the knowledge needed to preserve the vehicle's performance, ensure its longevity, and facilitate cost-effective DIY repairs, covering everything from basic fluid changes to in-depth component overhauls and diagnostics for common issues. 🏷️ 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...