The YFM660R Raptor is a high-performance sport All-Terrain Vehicle (ATV) produced from 2001 to 2005. Renowned for its powerful 660cc liquid-cooled, 5-valve, single-cylinder engine and advanced chassis for its time, the Raptor set a benchmark in the sport ATV segment. It was designed for enthusiasts, off-road riders, and racers, offering a potent combination of engine performance and handling capabilities. The heritage in building quality recreational vehicles is evident in the Raptor's engineering, making it a significant model in the evolution of performance ATVs. This comprehensive Service Repair Workshop Manual provides detailed information for the YFM660R Raptor, covering model years 2001 through 2006. It is an essential resource for owners and technicians, offering guidance on all aspects of maintenance and repair. The manual includes in-depth procedures for engine overhaul, transmission service, chassis and suspension work, brake system maintenance, and electrical system troubleshooting. With clear instructions, technical specifications, and diagnostic information, this manual ensures the longevity and optimal performance of your Raptor. 🏷️ Basic Information Identification Make: Yamaha Model: YFM660R Raptor Model Code: YFM660RN Vehicle Type: ATV (All-Terrain Vehicle) / Quad Codes Vin Code Prefix: 1UY 👋 Introduction Market Position Segment: High-performance sport ATV segment. Target Audience: Enthusiasts, off-road riders, competitive racers, and DIY mechanics. Competitive Analysis Competitors: Honda TRX450R, Suzuki LT-Z400, Kawasaki KFX700. Key Features Performance Orientation: The YFM660R Raptor was a benchmark for sport ATVs with its powerful engine and advanced chassis for its era. Manual Value: Provides the essential technical knowledge for owners to maintain and repair their high-performance machine, ensuring longevity and optimal performance. 📋 Manual Details Coverage Areas Covered Years: 2001, 2002, 2003, 2004, 2005, 2006 Page Count Estimated Pages: 300-400 (typical for this model's comprehensive service manuals) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnosis, tuning, lubrication, cooling system, fuel system (carburetor, fuel lines), ignition system, exhaust system. Transmission: Clutch system (wet multi-plate), gearbox, shifting mechanism, drive shafts, final drive (chain drive), lubrication. Chassis: Frame, suspension (front and rear), steering system, hubs, bearings, axles, wheels, tires. Brakes: Front and rear hydraulic disc brakes, brake fluid, lines, calipers, master cylinders, bleeding procedures. Electrical: Wiring diagrams, battery, charging system (stator, rectifier/regulator), lighting (headlights, taillights, indicators), ignition switch, starter motor, relays, fuses, CDI unit, sensors. Bodywork: Body panels, fenders, seat, handlebars, controls, plastics, graphics. Procedures Included Maintenance: Regular inspection, cleaning, lubrication, oil changes, filter replacements, spark plug replacement, brake adjustments, chain maintenance. Repair: Engine rebuild, transmission repair, carburetor overhaul, suspension component replacement, brake caliper rebuild, electrical component troubleshooting and replacement. Troubleshooting: Diagnostic procedures for common and uncommon problems, fault finding charts, symptom-based troubleshooting. Technical Specifications: Detailed torque specifications, clearances, tolerances, fluid capacities, electrical specifications, engine timings. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable (OCR optimized for efficient information retrieval) Print Quality Quality: High-resolution, clear and legible text and diagrams. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Manual Completeness Completeness: Factory authorized service manual, providing complete coverage for all aspects of maintenance and repair. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, DOHC, 5-valve, single cylinder Bore X Stroke: 100.0 mm x 83.0 mm Displacement: 660 cc Compression Ratio: 9.1:1 Carburetor: Mikuni BSR34 (single) Ignition: CDI (Capacitor Discharge Ignition) Starting System: Electric Start Performance Horsepower Estimated: ~40-45 hp @ 6000 rpm (approximate, depending on tuning and model year variations) Torque Estimated: ~45-50 lb-ft @ 5000 rpm (approximate) Fuel System Fuel Type: Unleaded gasoline Fuel Tank Capacity: 3.2 US gal (12 L) 🔧 Transmission Standard Type: 5-speed constant mesh with manual clutch Clutch Type: Wet, multi-disc Final Drive: O-ring sealed chain, drive sprocket, driven sprocket Features Reverse: Yes Gear Ratios: Specific ratios detailed in manual 📐 Dimensions Exterior Length: ~70.1 in (1780 mm) Width: ~44.7 in (1135 mm) Height: ~45.3 in (1150 mm) Wheelbase: ~50.0 in (1270 mm) Ground Clearance: ~5.1 in (130 mm) Weights Dry Weight: ~430 lbs (195 kg) Curb Weight: ~450 lbs (204 kg) (with all necessary fluids) Towing Capacity: Not specified for sport ATVs, primarily designed for recreational use, not towing. 🛡️ Safety Features Ratings Crash Test Ratings: N/A (ATVs are not subjected to standardized automotive crash testing.) Active Features Brakes: Hydraulic disc brakes front and rear for strong stopping power. Suspension: Long-travel, adjustable suspension for stability and control over varied terrain. Tires: Aggressively treaded ATV tires for optimal traction. Passive Features Handlebars: Standard handlebars with protective padding. Footwells: Wide, integrated footwells with serrated pegs for secure foot placement. Lighting: Halogen headlights and taillight for visibility. 💡 Technology Features Infotainment System: Basic instrumentation cluster: speedometer, odometer, trip meter, neutral indicator, high-beam indicator, oil warning lamp. Driver Assistance Features: None specific to...