Yamaha YFM660RNC 2001-2006 Workshop Service Manual Repair

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🏷️ Basic Information Identification Make: Yamaha Model: YFM660RNC Model Nickname: Raptor 660 Vehicle Type: Sport ATV (All-Terrain Vehicle) Codes Manual Product Code: YFM660RNC 👋 Introduction Market Position Vehicle Segment: High-performance sport ATV, competitive in its era. Competitive Analysis Key Competitors: Honda TRX450R, Suzuki LT-Z400, Bombardier DS650. Key Features Engine Type: Liquid-cooled, four-stroke, SOHC, 4-valve, single-cylinder. Transmission Type: 5-speed manual with reverse. Suspension Setup: Long-travel independent front suspension (IFP) and a rear swingarm with a monoshock. Braking System Type: Hydraulic disc brakes front and rear. Design Philosophy: Emphasis on power, handling, and rider comfort for aggressive off-road riding. 📋 Manual Details Coverage Areas Years Covered: 2001, 2002, 2003, 2004, 2005, 2006 Page Count Estimated Page Count: Approximately 400-500 pages (typical for this era of comprehensive service manuals) Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English (standard for most Yamaha service documentation) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Overhaul: Complete disassembly, inspection, repair, and reassembly of the engine. Fuel System: Carburetor tuning, cleaning, and overhaul; fuel pump operation; fuel tank and lines. Ignition System: Ignition timing, CDI unit, spark plug specifications, stator and rotor inspection. Cooling System: Radiator, fan, water pump, coolant type and capacity, thermostat. Transmission And Drivetrain: Clutch operation, gearbox disassembly and inspection, chain drive maintenance, final drive assembly. Suspension System: Front and rear suspension geometry, shock absorber overhaul and adjustment, A-arm and linkage maintenance. Braking System: Hydraulic brake system troubleshooting, caliper rebuild, master cylinder service, brake pad replacement, rotor inspection. Electrical System: Wiring diagrams, lighting system, battery maintenance, starter motor, charging system (alternator/stator), fuses, relays. Chassis And Frame: Frame inspection for damage, steering system maintenance, handlebar and control adjustments. Bodywork And Trim: Plastic panel removal and installation, fender and seat maintenance. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark...

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Type: Atv

Satıcı:

Sku: 56766

Collections: ALL ATV

Availability: 9999 in stock

Tags: 2001 2002 2003 2004 2005 2006 Atv Misc Motorcycles Yamaha YFM660RNC

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Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

YFM660RNC

Model Nickname:

Raptor 660

Vehicle Type:

Sport ATV (All-Terrain Vehicle)

Codes

Manual Product Code:

YFM660RNC

👋 Introduction

Market Position

Vehicle Segment:

High-performance sport ATV, competitive in its era.

Competitive Analysis

Key Competitors:

Honda TRX450R, Suzuki LT-Z400, Bombardier DS650.

Key Features

Engine Type:

Liquid-cooled, four-stroke, SOHC, 4-valve, single-cylinder.

Transmission Type:

5-speed manual with reverse.

Suspension Setup:

Long-travel independent front suspension (IFP) and a rear swingarm with a monoshock.

Braking System Type:

Hydraulic disc brakes front and rear.

Design Philosophy:

Emphasis on power, handling, and rider comfort for aggressive off-road riding.

📋 Manual Details

Coverage Areas

Years Covered:

2001, 2002, 2003, 2004, 2005, 2006

Page Count

Estimated Page Count:

Approximately 400-500 pages (typical for this era of comprehensive service manuals)

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Language

Language:

English (standard for most Yamaha service documentation)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete disassembly, inspection, repair, and reassembly of the engine.

Fuel System:

Carburetor tuning, cleaning, and overhaul; fuel pump operation; fuel tank and lines.

Ignition System:

Ignition timing, CDI unit, spark plug specifications, stator and rotor inspection.

Cooling System:

Radiator, fan, water pump, coolant type and capacity, thermostat.

Transmission And Drivetrain:

Clutch operation, gearbox disassembly and inspection, chain drive maintenance, final drive assembly.

Suspension System:

Front and rear suspension geometry, shock absorber overhaul and adjustment, A-arm and linkage maintenance.

Braking System:

Hydraulic brake system troubleshooting, caliper rebuild, master cylinder service, brake pad replacement, rotor inspection.

Electrical System:

Wiring diagrams, lighting system, battery maintenance, starter motor, charging system (alternator/stator), fuses, relays.

Chassis And Frame:

Frame inspection for damage, steering system maintenance, handlebar and control adjustments.

Bodywork And Trim:

Plastic panel removal and installation, fender and seat maintenance.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, air filter cleaning, chain adjustments, pre-ride inspections.

Troubleshooting:

Diagnosis of common mechanical and electrical issues with step-by-step troubleshooting guides.

Major Repairs:

Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnosis.

Component Disassembly Reassembly:

Detailed instructions for removing, servicing, and reinstalling all major and minor components.

Torque Specifications:

Precise torque values for all critical fasteners.

Technical Depth

Depth Of Coverage:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds.

Diagnostic Capabilities:

Includes diagnostic procedures, fault finding charts, and symptom-based troubleshooting.

Diagrams And Illustrations:

Richly illustrated with exploded views, schematics, and step-by-step diagrams.

📊 Manual Specifications

File Format

File Type:

Print Quality

Image Resolution:

High-resolution scans suitable for printing individual pages or the entire manual.

Binding Type

Binding Type For Download:

N/A (Digital Download)

Paper Type

Paper Type For Download:

N/A (Digital Document)

Searchability

Searchable Text:

Likely searchable if the PDF is text-based (not purely image-scanned without OCR).

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, liquid-cooled, SOHC, 4-valve

Displacement:

660 cc

Bore X Stroke:

100.0 mm x 84.0 mm

Compression Ratio:

9.2:1

Carburetor:

Keihin FCR41 (single, flat-slide, with accelerator pump)

Performance

Horsepower Estimate:

Approximately 45-50 HP (stock, at crankshaft)

Torque Estimate:

Approximately 42-45 lb-ft (stock, at crankshaft)

Fuel System

Fuel Type:

Unleaded gasoline, 87 octane minimum

Fuel Capacity:

2.6 gallons (9.8 L)

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 5-speed manual

Clutch Type:

Wet, multi-plate

Reverse Gear:

Features

Drivetrain:

2WD (Rear Wheel Drive)

Final Drive:

O-ring sealed chain, 520

Gear Ratios:

Detailed in manual, specific ratios for each gear.

📐 Dimensions

Exterior

Overall Length:

70.9 inches (1800 mm)

Overall Width:

47.2 inches (1200 mm)

Overall Height:

44.1 inches (1120 mm)

Wheelbase:

50.0 inches (1270 mm)

Weights

Dry Weight:

412 lbs (187 kg)

Curb Weight:

Approximately 420-430 lbs (depending on fluids)

Ground Clearance:

4.4 inches (112 mm)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Meets ANSI and/or relevant industry safety standards for ATVs.

Active Features

Brakes:

Dual hydraulic disc front, single hydraulic disc rear.

Suspension:

Long-travel suspension for stability and control.

Passive Features

Footwells:

Integrated floorboards with heel guards for rider foot protection.

Handlebars:

Handlebar-mounted front and rear brake levers for independent control.

💡 Technology Features

Infotainment

Display Panel:

Digital multi-function meter: speedometer, odometer, trip meter, clock, neutral indicator, reverse indicator, oil temp warning light.

Driver Assistance

Engine Features:

Accelerator pump in the carburetor provides crisp throttle response.

Connectivity

Charging System:

12V DC generator (stator) for battery charging and electrical systems.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1000 miles or 6 months (whichever comes first), or more frequently with hard use.

Air Filter Cleaning:

Every 10-15 hours of operation or as needed, depending on conditions.

Spark Plug Inspection Replacement:

Inspect every 500 miles, replace as needed (typically NGK CR9E or equivalent).

Chain Lubrication Adjustment:

Lubricate every 200-300 miles, adjust tension every 500 miles.

Fluid Specifications

Engine Oil Type:

Yamalube 4 10W-40 or equivalent API SG or higher, JASO MA certified motorcycle oil.

Engine Oil Capacity:

2.08 US qt (1.97 L) with oil filter replacement.

Coolant Type:

Permanent type antifreeze (ethylene glycol based), 50/50 mix with distilled water.

Coolant Capacity:

1.70 L (1.8 US qt)

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Camchain Tensioner:

Some models experienced premature wear or failure of the automatic cam chain tensioner, often replaced with a manual unit.

Carburetor Jetting:

Carburetor may require re-jetting for modifications or significant altitude changes.

Oil Leaks:

Potential for oil leaks from valve cover or crankcase seals if not properly maintained or torqued.

📚 Vehicle History

Brand Heritage

Yamaha Atv Legacy:

Yamaha has a long history in ATV manufacturing, known for innovation and performance.

Model Evolution

Predecessor:

The YFM660RNC replaced earlier Yamaha sport ATVs and was a significant step up in performance and technology.

Successor:

Was eventually succeeded by the fuel-injected Yamaha YFZ450 and later models.

Production

Production Period:

2001-2006

Manufacturing Location:

Japan (typical for Yamaha performance vehicles)

🏆 Awards & Recognition

Recognitions

Market Reception:

Generally well-received by enthusiasts for its powerful engine and capable chassis, a solid performer in the sport ATV market of its time.