check engine YAMAHA YFM660R 2005 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 lever ............................ 4-23
Shift pedal ......................................... 4-27
Reverse knob .................................... 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............................................... 5-15
Chain ................................................. 5-17
Throttle lever ...................................... 5-19
Fittings and fasteners......................... 5-19
Lights ................................................. 5-19
Switches............................................. 5-19
Tires .................................................. 5-21
How to measure tire pressure ........... 5-25
Tire wear limit .................................... 5-27
5
U5LP64.book Page 1 Thursday, April 1, 2004 4:53 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 ....................6-33
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 ................................7-41
Climbing uphill.....................................7-47
Riding downhill ....................................7-57
Crossing a slope .................................7-61
Crossing through shallow water ..........7-65
Riding over rough terrain ....................7-69
Sliding and skidding ............................7-71
What to do if .......................................7-75
What to do ..........................................7-75
67
PERIODIC MAINTENANCE AND
ADJUSTMENT ........................................ 8-1
Owner’s manual and tool kit ................. 8-3
Periodic maintenance/lubrication.......... 8-7
Panel removal and installation ........... 8-17
Engine oil and oil filter cartridge ......... 8-19
Cooling system ................................... 8-35
Changing the coolant.......................... 8-39
Spark plug inspection ......................... 8-47
Air filter element cleaning ................... 8-53
Carburetor adjustment ........................ 8-59
Idle speed adjustment ........................ 8-61
Throttle lever adjustment ................... 8-63
Valve clearance adjustment .............. 8-65
Front and rear brake pad inspection... 8-67
Brake fluid level inspection ................. 8-69
Brake fluid replacement ...................... 8-73
Front brake lever free play.................. 8-75
Brake pedal height adjustment ........... 8-77
Parking brake adjustment ................... 8-79
Adjusting the rear brake light switch ... 8-83
Clutch lever free play adjustment ...... 8-85
Drive chain slack check ...................... 8-87
Drive chain slack adjustment .............. 8-89
Lubricating the drive chain ................. 8-91
Cable inspection and lubrication ........ 8-95
8
U5LP64.book Page 2 Thursday, April 1, 2004 4:53 PM

4-5 1. Reverse indicator light “R”
2. Neutral indicator light “N”
3. Coolant temperature warning light “”
1. Témoin de marche arrière “R”
2. Témoin de point mort “N”
3. Témoin d’avertissement de la température du liquide de
refroidissement “”
1. Luz de control de marcha atrás “R”
2. Luz de control de punto muerto “N”
3. Luz de aviso de la temperatura del refrigerante “”
EBU00713
Coolant temperature warning light “”
When the coolant temperature reaches a specified
level, this light comes on to warn that the coolant
temperature is too hot. If the light comes on during
operation, stop the engine as soon as it is safe to
do so and allow the engine to cool down for about
10 minutes.
The coolant temperature warning light circuit can
be checked according to the procedure on page
4-7.CAUTION:

The engine may overheat if the ATV is
overloaded. If this happens, reduce the
load to specification.


Restart after making sure that the light is
out. Continuous use while the light is on
may cause damage to the engine.
U5LP64.book Page 5 Thursday, April 1, 2004 4:53 PM

4-7
EBU00714
Coolant temperature warning light checking method
ACB-09E
Turn the main switch to “ON” and
the engine stop switch to “”.
Coolant temperature warning
light does not come on.
Coolant temperature
warning light comes on.
Coolant temperature
warning light does not
come on.
Coolant temperature and
electrical circuit are OK. Go
ahead with riding.
Push the start switch with the
transmission in the neutral position.
Ask a Yamaha dealer to
inspect the electrical circuit.
Coolant temperature
warning light comes on
momentarily.
U5LP64.book Page 7 Thursday, April 1, 2004 4:53 PM

4-15 1. Throttle lever
1. Levier d’accélération
1. Palanca de aceleración
EBU00063
Throttle lever
Once the engine is running, movement of the
throttle lever will increase the engine speed.
Regulate the speed of the machine by varying the
throttle position. Because the throttle is spring-
loaded, the machine will decelerate, and the en-
gine will return to an idle any time the hand is re-
moved from the throttle lever.
Before starting the engine, check the throttle to be
sure it is operating smoothly. Make sure it returns
to the idle position as soon as the lever is released.
WARNING
Malfunction of the throttle could make it diffi-
cult to speed up or slow down when you need
to. This could cause an accident. Check the
operation of the throttle lever before you start
the engine. If the throttle does not work
smoothly, check for the cause. Correct the
problem before riding the ATV or consult a
Yamaha dealer.
U5LP64.book Page 15 Thursday, April 1, 2004 4:53 PM

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, lever free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-67–8-75
Rear brakeCheck operation, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-67–8-73, 8-77
ClutchCheck operation, condition and lever free play. 8-85
Parking brakeCheck operation, condition and cable length. 8-79–8-81
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13, 8-19–8-33
Coolant reservoirCheck coolant level in reservoir.
Fill with coolant if necessary.5-15–5-17,
8-35–8-45
Drive chainCheck chain slack and condition.
Adjust if necessary.5-17, 8-87–8-93
ThrottleCheck for proper throttle cable operation and free play. 5-19, 8-63
Wheels and tiresCheck tire pressure, wear and damage.5-21–5-27,
8-103–8-105
Fittings and fastenersCheck all fittings and fasteners. 5-19
Lights and switchesCheck for proper operation.5-19, 8-83,
8-115–8-125
U5LP64.book Page 1 Thursday, April 1, 2004 4:53 PM

5-15
EBU13160
Coolant
Check the coolant level in the coolant reservoir
when the engine is cold. (The coolant level will
vary with engine temperature.) The coolant level is
satisfactory if it is between the minimum and max-
imum level marks on the coolant reservoir. If the
coolant level is at or below the minimum level
mark, add distilled water to bring the level up to the
maximum level mark. Change the coolant every
two years. (See pages 8-35–8-45 for details.)CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use soft water if you cannot get
distilled water. _
Coolant reservoir capacity
(up to the maximum level mark):
0.29 L
U5LP64.book Page 15 Thursday, April 1, 2004 4:53 PM

5-17
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. _
EBU00498
Chain
Check the general condition of the chain and
check the chain slack before every ride. Lubricate
and adjust the chain as necessary. (See pages
8-87–8-93 for details.)
U5LP64.book Page 17 Thursday, April 1, 2004 4:53 PM

6-9
EBU00180
Starting a warm engine
To start a warm engine, refer to the “Starting a cold
engine” section. The starter (choke) should not be
used. The throttle should be opened slightly.
EBU01820
Warming up
To get maximum engine life, always warm up the
engine before starting off. Never accelerate hard
with a cold engine! To see whether or not the en-
gine is warm, check if it responds to the throttle
normally with the starter (choke) turned off.
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8-7
EBU02621
PERIODIC MAINTENANCE/LUBRICATION
NOTE:_

For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.


For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance in-
tervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month mainte-
nance intervals should be followed.
_
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
Valves*Check valve clearance.
Adjust if necessary.
Cooling systemCheck coolant leakage.
Repair if necessary.
Replace coolant every 24 months.Spark plugCheck condition.
Adjust gap and clean.
Replace if necessary.Air filter elementClean.
Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*Check starter (choke) operation.
Adjust engine idling speed.Crankcase breather
system*Check breather hose for cracks or damage.
Replace if necessary.Exhaust system*Check for leakage.
Tighten if necessary.
Replace gasket if necessary.Fuel line*Check fuel hose for cracks or damage.
Replace if necessary.U5LP64.book Page 7 Thursday, April 1, 2004 4:53 PM