DOWNLOAD PDF Yamaha 2002 YFM660F(P) 5KM2-AE1 Service Manual

2002

YFM660F(P) 5KM2-AE1

SERVICEMANUAL

YFM660F(P) 2002 SERVICE MANUAL © 2001 by Yamaha Motor Co., Ltd. First edition, May 2001 All rights reserved.

Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

NOTICE

NOTE:

IMPORTANT INFORMATION

WARNING

CAUTION: NOTE:

HOW TO USE THIS MANUAL MANUAL ORGANIZATION

EXPLODED DIAGRAMS

ILLUSTRATED SYMBOLS

GEN INFO

SPEC

CHK ADJ

ENG

COOL

CARB

DRIV

CHAS

ELEC –

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GEN INFO

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SPEC

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CHK ADJ

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CHK ADJ CHAPTER 3.

PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ........................................................................................... 3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS .......................... 3-1 SEAT, CARRIERS, FENDERS AND FUEL TANK ...................................... 3-3 SEAT AND SIDE PANELS .................................................................... 3-3 FRONT CARRIER, FRONT BUMPER AND FRONT GRILL ................. 3-4 HANDLEBAR COVER, FUEL TANK COVER AND FRONT FENDER . 3-5 REAR CARRIER AND REAR FENDER ................................................ 3-7 ENGINE SKID PLATE (CENTER) AND ENGINE SKID PLATE (REAR) .............................................................................................. 3-9 FUEL TANK ......................................................................................... 3-10 FOOTREST BOARDS ................................................................................ 3-12 ENGINE ...................................................................................................... 3-13 ADJUSTING THE VALVE CLEARANCE ............................................ 3-13 ADJUSTING THE TIMING CHAIN ...................................................... 3-16 ADJUSTING THE IDLING SPEED ...................................................... 3-16 ADJUSTING THE THROTTLE LEVER FREE PLAY .......................... 3-17 ADJUSTING THE SPEED LIMITER ................................................... 3-19 ADJUSTING THE STARTER CABLE ................................................. 3-21 CHECKING THE SPARK PLUG ......................................................... 3-22 CHECKING THE IGNITION TIMING ................................................... 3-23 MEASURING THE COMPRESSION PRESSURE .............................. 3-24 CHECKING THE ENGINE OIL LEVEL ............................................... 3-26 CHANGING THE ENGINE OIL ........................................................... 3-27 CLEANING THE AIR FILTER ............................................................. 3-29 CHECKING THE COOLANT LEVEL ................................................... 3-31 CHANGING THE COOLANT .............................................................. 3-32 CHECKING THE V-BELT .................................................................... 3-36 CLEANING THE SPARK ARRESTER ................................................ 3-37

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CHECKING THE V-BELT

CHK ADJ

CHECKING THE V-BELT 1.Remove: ● Right footrest board ● Crankcase cover (right) Refer to “PRIMARY AND SECONDARY SHEAVES” in CHAPTER 4.

2.Check: ● V-belt 1 Cracks/wear/scaling/chipping → Replace.

Oil/grease → Check primary sheave and secondary sheave.

3.Measure: ● V-belt width 2 Out of specification → Replace.

V-belt width: 33.2 mm (1.31 in) <Limit:> 29.9 mm (1.18 in)

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CHECKING THE CONSTANT VELOCITY JOINT DUST BOOT/CHECKING THE STEERING SYSTEM/ADJUSTING THE TOE-IN

CHK ADJ

CHECKING THE CONSTANT VELOCITY JOINT DUST BOOT 1.Check: ● Dust boots 1 Damage → Replace.

Refer to “FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR” in CHAPTER 7.

CHECKING THE STEERING SYSTEM 1.Place the machine on a level surface.

2.Check: ● Steering assembly bushings Move the handlebar up and down, and/or back and forth.

Excessive play → Replace the steering stem bushings.

3.Check: ● Tie-rod ends Turn the handlebar to the left and/or right until it stops completely, then move the handlebar from the left to the right slightly. Tierod end has any vertical play → Replace the tie-rod end(s).

4.Raise the front end of the machine so that there is no weight on the front wheels.

5.Check: ● Ball joints and/or wheel bearings Move the wheels laterally back and forth.

Excessive free play → Replace the front arms (upper and lower) and/or wheel bearings.

ADJUSTING THE TOE-IN 1.Place the machine on a level surface.

2.Measure: ● Toe-in Out of specification → Adjust.

Toe-in: 0 ~ 10 mm (0.00 ~ 0.39 in) (with tire touching the ground)

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ADJUSTING THE TOE-IN

CHK ADJ

***************************************************** Measurement steps: NOTE: Before measuring the toe-in, make sure that the tire pressure is correct. ● Mark both front tire tread centers. ● Face the handlebar straight ahead. ● Measure the width È between the marks. ● Rotate the front tires 180° until the marks are

exactly opposite one another. ● Measure the width É between the marks. ● Calculate the toe-in using the formula given below.

Toe-in = É – È ● If the toe-in is incorrect, adjust it.

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3.Adjust: ● Toe-in

WARNING Be sure that both tie-rods are turned the same amount. If not, the machine will drift right or left even though the handlebar is positioned straight. This may lead to mishandling and an accident. ● After setting the toe-in to specification, run the machine slowly for some distance with both hands lightly holding the handlebar and check that the handlebar responds correctly. If not, turn either the right or left tierod within the toe-in specification. ●

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ROCKER ARMS

ENG

ROCKER ARMS

Order

1 2 3 4 5 6 7 8 9

Job name/Part name Removing the rocker arm Cylinder head cover Plug/O-ring Bolt Rocker arm shaft 2 Rocker arm 3 Rocker arm shaft 3/O-ring Rocker arm 4 Rocker arm shaft 1/O-ring Rocker arm 1 Rocker arm 2

Q’ty

1/1 2 1 1 1/1 1 1/1 1 1

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Remarks Remove the parts in the order below.

Refer to “CYLINDER HEAD COVER”.

Refer to “REMOVING/INSTALLING THE ROCKER ARM”.

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