Yamaha YFM660RP 5LP2-AE2 2002 Manuel utilisateur

YFM660R(P)

SUPPLEMENTARY

SERVICE MANUAL

5LP2-AE2

2002

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and new data for

the YFM660R(P) 2002. For complete information on service procedures, it is necessary to use this

Supplementary Service Manual together with the following manual.

YFM660R(N) 2001 SERVICE MANUAL: 5LP2-AE1

YFM660R(P) 2002

SUPPLEMENTARY

SERVICE MANUAL

First Edition, August 2001

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

EB001000

NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one

manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on

Yamaha machine has a basic understanding of the mechanical ideas and the procedures of

machine repair. Repairs attempted by anyone without this knowledge are likely to render the

machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

OTE:

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death

to the machine operator, a bystander or a person inspecting or repairing the

machine.

A CAUTION indicates special precautions that must be taken to avoid dam-

age to the machine.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

TE:

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title 2: This title indicates the section of the chapter and only appears on the first page of each

section. It is located in the upper left corner of the page.

3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

1. An easy-to-see exploded diagram 4is provided for removal and disassembly jobs.

2. Numbers 5are given in the order of the jobs in the exploded diagram. A number that is enclosed

by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

6. The meanings of the symbol marks are given on the next page.

4. A job instruction chart 7accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements 8are given in addition

to the exploded diagram and the job instruction chart.

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1to 9are printed on the

top right of each page and indicate the subject

of each chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Cooling system

7Carburetion

8Electrical

9Troubleshooting

Illustrated symbols 0to Gare used to identify

the specifications appearing in the text.

0Can be serviced with engine mounted

AFilling fluid

BLubricant

CSpecial tool

DTorque

EWear limit, clearance

FEngine speed

GΩ, V, A

Illustrated symbols Hto Nin the exploded

diagrams indicate the types of lubricants and

lubrication points.

HApply engine oil

IApply gear oil

JApply molybdenum disulfide oil

KApply wheel bearing grease

LApply lightweight lithium soap base grease

MApply molybdenum disulfide grease

NApply silicon grease

Illustrated symbols Oto Pin the exploded

diagrams indicate where to apply a locking

agent Oand when to install a new part P.

OApply the locking agent (LOCTITE)

PReplace

EFG

HIJ

GEN

INFO SPEC

CHK

ADJ

CHAS

ENG

COOL

CARB

–+

ELEC

TRBL

SHTG

EGM

BLS MS

LMN

LT New

CONTENTS

SPECIFICATIONS ............................................................................................1

GENERAL SPECIFICATIONS ..................................................................1

MAINTENANCE SPECIFICATIONS .........................................................2

ENGINE ................................................................................................2

CHASSIS ..............................................................................................6

CABLE ROUTING .....................................................................................7

PERIODIC CHECKS AND ADJUSTMENTS ....................................................9

INTRODUCTION .......................................................................................9

PERIODIC MAINTENANCE/LUBRICATION INTERVALS ........................9

CHASSIS .................................................................................................11

ADJUSTING THE REAR SHOCK ABSORBER ..................................11

CHASSIS ........................................................................................................14

REAR SHOCK ABSORBER AND RELAY ARM .....................................14

HANDLING THE REAR SHOCK ABSORBER

AND GAS CYLINDER .........................................................................16

DISPOSING OF A REAR SHOCK ABSORBER

AND GAS CYLINDER .........................................................................16

REMOVING THE REAR SHOCK ABSORBER ...................................17

CHECKING THE REAR SHOCK ABSORBER ...................................17

CHECKING THE RELAY ARM AND CONNECTING ARM ................17

INSTALLING THE RELAY ARM AND CONNECTING ARM ..............18

INSTALLING THE REAR SHOCK ABSORBER .................................18

SWINGARM AND DRIVE CHAIN ...........................................................19

ENGINE ..........................................................................................................21

ENGINE REMOVAL ................................................................................21

INSTALLING THE ENGINE ................................................................21

AC MAGNETO ........................................................................................22

YFM660R(P) 2002 WIRING DIAGRAM

–1 –

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

Model code: 5LP6 : (For CDN)

5LP7 : (For Europe)

Transmission:

Primary reduction system Spur gear

Primary reduction ratio 71/34 (2.088)

Secondary reduction system Chain drive

Secondary reduction ratio 40/13 (3.076)

Transmission type Constant mesh, 5-speed/forward.

1-speed/reverse

Operation Left foot operation

Gear ratio

1st gear 31/12 (2.583)

2nd gear 30/18 (1.667)

3rd gear 27/21 (1.286)

4th gear 22/21 (1.047)

5th gear 19/21 (0.904)

Reverse gear 33/25 ×25/18 (1.833)

GENERAL SPECIFICATIONS

–2 –

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Cylinder head:

Warp limit ---- 0.03 mm

(0.001 in)

Timing chain:

Timing chain type/No. of links 82RH2015/126 ----

Timing chain adjustment method Automatic ----

Rocker arm/rocker arm shaft:

Bearing inside diameter 12.000 ~ 12.018 mm

(0.4724 ~ 0.4731 in)

----

Shaft outside diameter 11.976 ~ 11.991 mm

(0.4715 ~ 0.4721 in)

----

Arm-to-shaft clearance 0.009 ~ 0.042 mm

(0.0004 ~ 0.0017 in)

----

Valve, valve seat, valve guide:

Valve clearance (cold) IN 0.10 ~ 0.15 mm

(0.0039 ~ 0.0059 in)

----

EX 0.15 ~ 0.20 mm

(0.0059 ~ 0.0079 in)

----

Valve dimensions

“A”head diameter IN 29.9 ~ 30.1 mm

(1.1772 ~ 1.1850 in)

----

EX 31.9 ~ 32.1 mm

(1.2559 ~ 1.2638 in)

----

“B”face width IN 2.25 mm (0.0886 in) ----

EX 2.26 mm (0.0890 in) ----

“C”seat width IN 1.1 ~ 1.3 mm

(0.0433 ~ 0.0512 in)

1.6 mm

(0.0630 in)

EX 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

1.6 mm

(0.0630 in)

“D”margin thickness IN 0.85 ~ 1.15 mm

(0.0335 ~ 0.0453 in)

----

EX 0.85 ~ 1.15 mm

(0.0335 ~ 0.0453 in)

----

Head Diameter Face Width Seat Width Margin Thickness

MAINTENANCE SPECIFICATIONS

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