brake YAMAHA YFM660R 2002 Owners Manual

EBU00015
1-CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ...................... 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION AND MACHINE
IDENTIFICATION ................................... 3-1
Identification number records .............. 3-3
Key identification number .................... 3-5
Vehicle identification number .............. 3-5
Model label .......................................... 3-7
CONTROL FUNCTIONS ........................ 4-1
Main switch........................................... 4-1
Indicator and warning lights ................. 4-3
Handlebar switches ........................... 4-11
Throttle lever ..................................... 4-15
Speed limiter ..................................... 4-17
Clutch lever ....................................... 4-19
Brake lever ......................................... 4-19
Brake pedal ........................................ 4-21
Parking brake .................................... 4-23
Shift pedal ......................................... 4-27
Reverse knob “REV”.......................... 4-27
1234
Fuel tank cap .................................... 4-29
Fuel cock ........................................... 4-29
Starter (choke) .................................. 4-31
Seat.................................................... 4-33
Front shock absorber adjustment ...... 4-35
Rear shock absorber adjustment ....... 4-37
PRE-OPERATION CHECKS .................. 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil ........................................... 5-13
Coolant .............................................. 5-17
Chain ................................................. 5-19
Throttle lever ..................................... 5-21
Fittings and Fasteners ...................... 5-21
Lights ................................................. 5-21
Switches............................................. 5-21
Tires .................................................. 5-23
How to measure tire pressure ........... 5-27
Tire wear limit .................................... 5-29
5
U5LP61.book Page 1 Monday, August 27, 2001 3:49 PM

OPERATION ...........................................6-1
Starting a cold engine ..........................6-3
Starting a warm engine ........................6-9
Warming up ..........................................6-9
Reverse knob operation and
reverse driving .................................6-11
Shifting ................................................6-15
To start out and accelerate ................6-17
To decelerate .....................................6-21
Engine break-in ..................................6-23
Parking ...............................................6-27
Parking on a slope ..............................6-29
Accessories and loading ....................6-31
Accessories ........................................6-31
Loading ..............................................6-33
RIDING YOUR ATV..................................7-1
Getting to know your ATV .....................7-3
Ride with care and good judgement .....7-5
Be careful where you ride ...................7-27
Turning your ATV ................................7-39
Climbing uphill.....................................7-45
Riding downhill ....................................7-55
Crossing a slope .................................7-59
Crossing through shallow water ..........7-63
Riding over rough terrain ....................7-67
Sliding and skidding ............................7-69
67
What to do if ... ................................... 7-73
What to do ... ...................................... 7-73
PERIODIC MAINTENANCE AND
ADJUSTMENT ........................................ 8-1
Owner’s manual and tool kit ................ 8-3
Periodic maintenance/lubrication ......... 8-7
Panel removal and installation ........... 8-15
Engine oil and oil filter cartridge ......... 8-17
Cooling system ................................... 8-31
Changing the coolant.......................... 8-33
Spark plug inspection ......................... 8-41
Air filter element cleaning .................. 8-45
Carburetor adjustment ....................... 8-51
Idle speed adjustment ....................... 8-53
Throttle lever adjustment ................... 8-55
Valve clearance adjustment .............. 8-57
Front and rear brake pad inspection... 8-59
Inspecting the brake fluid level ........... 8-61
Brake fluid replacement ...................... 8-65
Front brake adjustment ...................... 8-67
Rear brake adjustment ....................... 8-69
Parking brake adjustment ................... 8-71
Adjusting the rear brake light switch ... 8-75
Clutch lever free play adjustment ...... 8-77
Drive chain slack check ..................... 8-79
Drive chain slack adjustment .............. 8-81
8
U5LP61.book Page 2 Monday, August 27, 2001 3:49 PM

Lubricating the drive chain ................ 8-83
Cable inspection and lubrication ....... 8-87
Brake and shift pedal/brake and
clutch lever lubrication ..................... 8-87
Front upper and lower arm pivot
lubrication ......................................... 8-89
Rear arm pivot lubrication .................. 8-91
Wheel removal .................................. 8-95
Wheel installation .............................. 8-97
Battery ............................................... 8-99
Battery maintenance ....................... 8-103
Fuse replacement ............................ 8-105
Replacing a headlight bulb ............... 8-107
Tail/brake light bulb replacement ..... 8-117
Troubleshooting ............................... 8-119
Troubleshooting chart ...................... 8-121
CLEANING AND STORAGE .................. 9-1
A. CLEANING ...................................... 9-1
B. STORAGE ...................................... 9-7
9
SPECIFICATIONS ................................ 10-1
CONVERSION TABLE .......................... 11-1
1011
U5LP61.book Page 3 Monday, August 27, 2001 3:49 PM

2-13

Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth
terrain. On extremely slippery surfaces, such
as ice, go slowly and be very cautious in order
to reduce the chance of skidding or sliding out
of control.


Never operate an ATV in fast flowing water or
in water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.


Always be sure there are no obstacles or peo-
ple behind you when you operate in reverse.
When it is safe to proceed in reverse, go slowly.


Always use the size and type tires specified in
this manual.


Always maintain proper tire pressure as de-
scribed in this manual.
U5LP61.book Page 13 Monday, August 27, 2001 3:49 PM

3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Seat
2. Fuel tank cap
3. Engine oil tank
4. Brake pedal
5. Headlight
6. Fuel cock
7. Throttle stop screw
8. Coolant reservoir
9. Tail/brake light10. Shift pedal
11. Clutch lever
12. Handlebar switches
13. Parking brake
14. Main switch
15. Reverse knob
16. Throttle lever
17. Brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5LP61.book Page 1 Monday, August 27, 2001 3:49 PM

4-19 1. Clutch lever
1. Levier d’embrayage
1. Palanca de embrague
1. Brake lever
1. Levier de frein
1. Palanca del freno
EBU00069
Clutch lever
The clutch lever is located on the left handlebar
and the ignition circuit cut-off system is incorporat-
ed in the clutch lever holder. Pull the clutch lever to
the handlebar to disengage the clutch, and release
the lever to engage the clutch. The lever should be
pulled rapidly and released slowly for smooth
clutch operation. (Refer to “Starting a cold engine”
for a description of the ignition circuit cut-off sys-
tem.)
EBU00988
Brake lever
The brake lever is located on the right handlebar.
Pull it toward the handlebar to apply the front
brake.
U5LP61.book Page 19 Monday, August 27, 2001 3:49 PM

4-21 1. Brake pedal
1. Pédale de frein
1. Pedal del freno
EBU00989
Brake pedal
The brake pedal is located on the right side of the
machine. Push down on the pedal to apply the rear
brake.
U5LP61.book Page 21 Monday, August 27, 2001 3:49 PM

4-23 1. Button 2. Lock plate
1. Bouton 2. Verrou
1. Botón 2. Placa de bloqueo
1. Locked position
1. Position verrou bloqué
1. Posición bloqueada
EBU00081
Parking brake
Use the parking brake when you have to start the
engine or park the machine, especially on a slope.
Squeeze the clutch lever while pushing the button,
then push in the lock plate to apply the parking
brake. Squeeze the clutch lever to release the
parking brake.NOTE:When the parking brake is used, engine speed is
limited to 2,300 r/min. Be sure the parking brake is
released before moving the throttle lever. Other-
wise, the engine will misfire, preventing normal op-
eration.
U5LP61.book Page 23 Monday, August 27, 2001 3:49 PM

4-25
WARNING


Always set the parking brake before start-
ing the engine. The ATV could start mov-
ing unexpectedly if the parking brake is not
applied. This could cause loss of control or
a collision.


Always be sure you have released the
parking brake before you begin to ride. The
brake could overheat if you ride the ATV
without releasing the parking brake. You
could lose braking performance which
could cause an accident. You could also
wear out the brakes prematurely.
U5LP61.book Page 25 Monday, August 27, 2001 3:49 PM

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5 ~ 5-7,
8-59 ~ 8-67
Rear brakeCheck operation, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5 ~ 5-7,
8-59 ~ 8-65, 8-69
ClutchCheck operation, condition and lever free play. 8-77
Parking brakeCheck operation, condition and cable free play. 8-71 ~ 8-73
FuelCheck fuel level.
Fill with fuel if necessary.5-9 ~ 5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13 ~ 5-15,
8-17 ~ 8-29
Coolant reservoirCheck coolant level.
Fill with coolant if necessary.5-17 ~ 5-19,
8-31 ~ 8-39
Drive chainCheck chain slack and condition.
Adjust if necessary.5-19, 8-77 ~ 8-83
ThrottleCheck for proper throttle cable operation and free play. 5-21, 8-55
Wheels and tiresCheck tire pressure, wear and damage.5-23 ~ 5-29,
8-95 ~ 8-97
Fittings and fastenersCheck all fittings and fasteners. 5-21
LightsCheck for proper operation. 5-21, 8-107 ~ 8-117
U5LP61.book Page 1 Monday, August 27, 2001 3:49 PM