warning YAMAHA YFM660R 2002 Repair Manual

8-87
EBU00570
Cable inspection and lubrication
WARNING
Inspect cables frequently and replace if dam-
aged. Corrosion can result when the outer cov-
ering of control cables becomes damaged.
Cables can also become frayed or kinked. Op-
eration of controls could be restricted, which
could cause an accident or injury.Lubricate the inner cables and the cable ends. If
the cables do not operate smoothly, ask a Yamaha
dealer to replace them.
EBU00737
Brake and shift pedal/brake and clutch lever
lubrication
Lubricate the pivoting parts of each lever and ped-
al.Recommended lubricant:
Engine oil
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5LP61.book Page 87 Monday, August 27, 2001 3:49 PM

8-101
WARNING
Battery electrolyte is poisonous and danger-
ous, causing severe burns, etc. It contains sul-
furic acid. Avoid contact with skin, eyes or
clothing.
Antidote:

EXTERNAL: Flush with water.


INTERNAL: Drink large quantities of water
or milk. Follow with milk of magnesia, beat-
en egg or vegetable oil. Call a physician
immediately.


EYES: Flush with water for 15 minutes and
get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes or other sources of
ignition away. Ventilate when charging or us-
ing in an enclosed space. Always shield your
eyes when working near batteries. KEEP OUT
OF REACH OF CHILDREN.
U5LP61.book Page 101 Monday, August 27, 2001 3:49 PM

8-105 1. Fuse 2. Spare fuse
1. Fusible 2. Fusible de rechange
1. Fusible 2. Fusible de repuesto
EBU00391
Fuse replacement
1. The fuse case is located under the seat.
2. If the fuse is blown, turn off the main switch
and install a new fuse of the specified amper-
age. Then turn on the switches. If the fuse im-
mediately blows again, consult a Yamaha
dealer.
WARNING
Always use a fuse of the specified rating. Nev-
er use a material in place of the proper fuse. An
improper fuse can cause damage to the electri-
cal system which could lead to a fire. CAUTION:
To prevent accidental short-circuiting, turn off
the main switch when checking or replacing a
fuse. Specified fuse: 20 A
U5LP61.book Page 105 Monday, August 27, 2001 3:49 PM

8-113 1. Headlight bulb holder
1. Fixation d’ampoule de phare
1. Portabombillas del faro
1. Headlight bulb 2. Headlight bulb holder
1. Ampoule de phare 2. Fixation d’ampoule
1. Bonbilla del faro 2. Portabombillas del faro
7. Push the headlight bulb holder inward, turn it
counterclockwise and remove the defective
bulb.
WARNING
_ A headlight bulb is hot when it is on and imme-
diately after it is turned off. Wait for the bulb to
cool down before touching or removing it. You
can be burned, or a fire could start if the bulb
touches something flammable. _8. Put a new headlight bulb into position and se-
cure it in place with the bulb holder.
9. Install the headlight bulb holder cover.CAUTION:_ Make sure the headlight bulb holder cover is
securely fitted over the bulb holder and seated
against the reflector. _10. Align the projections with the holders, install
the headlight unit into the case, and install the
screw.
11. Install the headlight cover in the original posi-
tion, and then install the screw.
U5LP61.book Page 113 Monday, August 27, 2001 3:49 PM

8-119
EBU00413
Troubleshooting
Although Yamaha machines receive a rigid in-
spection before shipment from the factory, trouble
may occur during operation.
Any problem in the fuel, compression, or ignition
systems can cause poor starting and loss of pow-
er. The troubleshooting chart describes a quick,
easy procedure for making checks. If your ma-
chine requires any repair, take it to a Yamaha
dealer.
The skilled technicians at a Yamaha dealership
have the tools, experience, and know-how to prop-
erly service your machine. Use only genuine
Yamaha parts on your machine. Imitation parts
may look like Yamaha parts, but they are often in-
ferior. Consequently, they have a shorter service
life and can lead to expensive repair bills.
WARNING
Do not smoke when checking the fuel system.
Fuel can ignite or explode, causing severe in-
jury or property damage. Make sure there are
no open flames or sparks in the area, including
pilot lights from water heaters or furnaces.
U5LP61.book Page 119 Monday, August 27, 2001 3:49 PM

8-122
Engine overheatingNOTE:If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is
changed to the recommended coolant as soon as possible.
WARNING
Wait for the engine and radiator to cool before removing the radiator cap. You could be burned by
hot fluid and steam blown out under pressure. Always put a thick rag over the cap when opening.
Allow any remaining pressure to escape before completely removing the cap. Wait until the
engine has cooled.
Check the coolant level in the
reservoir tank and/or radiator.
Level is OK.Level is low, check the
cooling system for leakage.
No
leakage.Leakage.
Ask a Yamaha dealer to inspect
and repair the cooling system.Add coolant. (See NOTE.)
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and/or repair the cooling system.
U5LP61.book Page 122 Monday, August 27, 2001 3:49 PM

9-5
8. Automotive type wax may be applied to all
painted and chrome plated surfaces. Avoid
combination cleaner-waxes. Many contain
abrasives which may mar the paint or protec-
tive finish. When finished, start the engine
and let it idle for several minutes.
WARNING
Wet brakes may have reduced stopping ability,
increasing the chance of an accident. Test the
brakes after washing. Apply the brakes several
times at slow speeds to let friction dry out the
linings.
U5LP61.book Page 5 Monday, August 27, 2001 3:49 PM

10-5
Wheel travel:
Front
Rear230 mm
220 mm
Electrical:
Ignition system
Generator system
Battery type/voltage capacityDC-C.D.I.
A.C. Magneto
YTX14-BS/12 V, 12 Ah
Headlight type Krypton bulb
Bulb voltage, wattage
× quantity:
Headlight
Tail/brake light
Indicator/warning lights:
Neutral
Reverse
Coolant temperature12 V, 30 W/30 W
× 2
12 V, 5 W/21 W
× 1
12 V, 1.7 W
× 1
12 V, 1.7 W
× 1
12 V, 1.7 W
× 1
Fuse 20 AMODEL YFM660R
U5LP61.book Page 5 Monday, August 27, 2001 3:49 PM