DOWNLOAD PDF Yamaha YFM660FS 5KM2-AE3 SUPPLEMENTARY SERVICE MANUAL

YFM660FS 5KM2-AE3

SUPPLEMENTARY SERVICE MANUAL

FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YFM660FS. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.

YFM660F(P) 2002 SERVICE MANUAL: 5KM2-AE1 YFM660FR SUPPLEMENTARY SERVICE MANUAL: 5KM2-AE2

YFM660FS SUPPLEMENTARY SERVICE MANUAL ©2003 by Yamaha Motor Co., Ltd. First edition, April 2003 All rights reserved.

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 significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

NOTE: 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! WARNING

CAUTION: NOTE:

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 damage to the machine.

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

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 accompanied 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 4 is provided for removal and disassembly jobs.

2. Numbers 5 are 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 7 accompanies 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 8 are given in addition to the exploded diagram and the job instruction chart.

1

EB003000

2

GEN INFO

ILLUSTRATED SYMBOLS Illustrated symbols 1 to 0 are printed on the top right of each page and indicate the subject of each chapter.

SPEC

3

4

CHK ADJ

1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetion 7 Drive train 8 Chassis 9 Electrical 0 Troubleshooting

ENG

5

6

COOL

CARB

7

8

DRIV

CHAS

9

0

ELEC –

TRBL SHTG

+

A

Illustrated symbols A to H are used to identify the specifications appearing in the text.

B

C

D

E

F

A Can be serviced with engine mounted B Filling fluid C Lubricant D Special tool E Torque F Wear limit, clearance G Engine speed H Ω, V, A

T.

R.

G

H

I

J

Illustrated symbols I to N in the exploded diagrams indicate the types of lubricants and lubrication points.

K

G

E L

M

M B

N M

LS

O

P

LT

New

I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply lightweight lithium-soap-based grease N Apply molybdenum disulfide grease

Illustrated symbols O to P in the exploded diagrams indicate where to apply a locking agent O and when to install a new part P. O Apply the locking agent (LOCTITE) P Replace

CONTENTS GENERAL INFORMATION ..............................................................................1 FEATURES ...............................................................................................1 OVERRIDE SWITCH (DEACTIVATING THE SPEED LIMITER WHEN THE DIFFERENTIAL IS LOCKED) ...........................................1 SPECIFICATIONS ............................................................................................3 GENERAL SPECIFICATIONS ..................................................................3 MAINTENANCE SPECIFICATIONS .........................................................4 ENGINE ................................................................................................4 CHASSIS ..............................................................................................5 ELECTRICAL ........................................................................................5 CHASSIS ..........................................................................................................6 STEERING SYSTEM ................................................................................6 INSTALLING THE REAR BRAKE LEVER ............................................6 ELECTRICAL ...................................................................................................7 CHECKING THE SWITCH ........................................................................7 CHECKING THE SWITCH CONTINUITY .............................................7 SIGNAL SYSTEM .....................................................................................9 CIRCUIT DIAGRAM ..............................................................................9 YFM660FS WIRING DIAGRAM

GEN INFO

FEATURES

GENERAL INFORMATION FEATURES OVERRIDE SWITCH (DEACTIVATING THE SPEED LIMITER WHEN THE DIFFERENTIAL IS LOCKED) This model is equipped with a speed limiter system (35 km/h [22 mph]) that operates when the differential is locked and the ATV is traveling forward. If additional engine power is required (e.g., to free the ATV from mud) when the ATV is traveling forward and the differential is locked, the speed limiter can be temporarily deactivated by pressing the override switch.

NOTE: The speed limiter is deactivated only while the override switch is being pressed.

1 Override switch

When the override switch is pressed, the segments of the speedometer digits are displayed as follows.

OFF LOCK

ODOTRIP AB

F km/h F F CLOCKHOUR E

0.2s

0.2s

0.2s

0.2s 0.2s

0.2s

NOTE: ● When the front differential gear is locked and the drive select lever is in the “L”, “H”, “N”, or “P” position, the display changes when the override switch is pressed. (The speedometer display is not displayed at this time.) ● When the front differential gear is not locked or the drive select lever is in the “R” position, the display does not change even if the override switch is pressed.

–1–

FEATURES

GEN INFO

CAUTION: If the segments of the speedometer digits show the override display when the override switch is not pressed, the speed limiter system is malfunctioning. Check the override switch and ignition system, and then repair if necessary.

–2–

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS GENERAL SPECIFICATIONS Item

Standard

Model code:

Transmission: Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Single speed automatic Sub transmission ratio Reverse gear

5KMJ/5KMR (for CDN) 5KMK/5KMS (for Europe) 5KML (for Oceania)

low high

V-belt Shaft drive 41/21 × 24/18 × 33/9 (9.544) V-belt automatic Left hand operation 2.45 ~ 0.70 : 1 35/17 (2.058) 26/21 (1.238) 25/17 (1.471)

–3–

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS ENGINE Item Carburetor: I. D. mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot air jet Pilot outlet Pilot jet Pilot screw Bypass 1 Bypass 2 Bypass 3 Valve seat size Starter jet Starter jet Throttle valve size Float height Fuel level Engine idle speed Intake vacuum

Standard

(M.J) (M.A.J) (J.N) (N.J) (P.A.J.1) (P.A.J.2) (P.O) (P.J) (P.S) (B.P.1) (B.P.2) (B.P.3) (V.S) (G.S.1) (G.S.2) (Th.V) (F.H) (F.L)

5KMA 10 #153.8 #70 6JPH9-53-2 O-0M #60 1.5 1.1 #40 3 turns out 0.8 0.8 0.8 3.0 #55 0.8 #105 13 mm (0.51 in) 4.5 mm (0.18 in) 1,450 ~ 1,550 r/min 30.7 ~ 33.3 kPa (230 ~ 250 mmHg, 9.07 ~ 9.83 inHg)

–4–

Limit ----------------------------------------------------------------

MAINTENANCE SPECIFICATIONS

SPEC

CHASSIS Item

Standard

Front suspension: Shock absorber travel Fork spring free length

Spring fitting length Spring rate

86 mm (3.39 in) 296.5 mm (11.67 in) (for CDN)

(K1)

Stroke Optional spring Rear suspension: Shock absorber travel Spring free length

Spring fitting length Spring rate

(K1)

(K1)

Stroke Optional spring

(K1)

307.0 mm (12.09 in) (for Europe and Oceania) 237 mm (9.33 in) 20 N/mm (2.04 kg/mm, 114.2 lb/in) 0 ~ 86 mm (0 ~ 3.39 in) No 95 mm (3.74 in) 278.5 mm (10.96 in) (for CDN) 285.5 mm (11.24 in) (for Europe and Oceania) 237 mm (9.33 in) 36.4 N/mm (3.71 kg/mm, 207.84 lb/in) 0 ~ 95 mm (0 ~ 3.74 in) No

Limit ---290.6 mm (11.44 in) 300.9 mm (11.85 in) ----------------------------------

ELECTRICAL Item C.D.I.: Magneto model/manufacturer Pickup coil resistance/color Rotor rotation direction sensing coil resistance/color C.D.I. unit model/manufacturer Charging system: Type Model/manufacturer Nominal output Charging coil resistance/color

Standard

Limit

F4T469/MITSUBISHI 459 ~ 561 Ω at 20 °C (68 °F)/ White/Red – White/Green 0.063 ~ 0.077 Ω at 20 °C (68 °F)/ Red – White/Blue F8T40372/MITSUBISHI

-------

A.C. magneto generator F4T469/MITSUBISHI 14 V 21 A at 5,000 r/min 0.32 ~ 0.43 Ω at 20 °C (68 °F)/ White – White

-------------

–5–

-------

STEERING SYSTEM

CHAS

CHASSIS STEERING SYSTEM INSTALLING THE REAR BRAKE LEVER 1.Install: ● Handlebar switch 1 ● Rear brake lever ● Lever bracket 2 NOTE: Install the lever bracket as shown. a 74.5 mm (2.9 in)

–6–

CHECKING THE SWITCH

ELEC –

+

ELECTRICAL CHECKING THE SWITCH CHECKING THE SWITCH CONTINUITY Refer to “CHECKING THE SWITCH” in CHAPTER 9 (Manual No.: 5KM2-AE1) and check for continuity between lead terminals.

Poor connection, no continuity → Correct or replace.

The coupler locations are circled.

*

1

2 Br L Y G

4

3 L/B B

R/W R/B

Lg B

PUSH

Br Y L L/B G B

PUSH

5

R/B R/W Lg

C L/B L/G L/R Sb Br Gy G/R B

2WD

L/R L/G

G/R Gy

4WD

Sb L/B

B

LOCK

(BLACK)

(GRAY)

Br

6 R Br/L Br ON OFF

R Br/L Br

7

Br Y (BLACK)

8

B

B

(BLACK)

9

0

B

A P Br

B

B

OFF ON

P

Br

L

B

Gy W

P

–7–

CHECKING THE SWITCH 1 Light switch 2 Engine stop switch 3 Start switch 4 Override switch 5 On-command four-wheel drive switch and differential gear lock switch 6 Main switch 7 Rear brake light switch 8 Front brake light switch 9 Rear brake switch 0 Horn switch (for Europe and Oceania) A Gear position switch B Reverse switch C Fuse

–8–

ELEC –

+

–9–

n

m

OFF ON

k

R

Br

P

B

B

Br

B

(BLACK)

(BLACK)

o

Y Br

Y Br

(BLACK)

(BLACK)

i

j

Y

Br

Br

Br/L

B

Y L

B

G Y

B

Y G

f

b

a R/Y

R/Y

`

B

B

Y G

Br/L

R

B

Y G

c

B

G Y

B

Y G

f

PUSH

d

R/W

4

R/W R/B

R/W

]

Br Br/L R

R

L Y G

Br/L

R Br/L Br

(BLACK)

R

W

B

W

2

W

Br/L Br

R

g

ON OFF

3

W W W

B B

Y

Br

B

Br

W W W

W/G

Br Y

B

B

1

h

l

P

Br

W

W W

W

W/R W/G

W W

R W/G

W/L W/R

W/G R

R

W/G W/R

L/B

B

B

Lg

R

R

R/W R/B

Lg

R/B R/W

Lg

B

\

P

P

Br/L

L/B

L/W

[

L Y R/Y B G L/B

7

Br Sb L/B R/B Br/B B/Y

B

L/B Sb Br B/Y Br/B R/B

P

B

G W/B

(GRAY)

(BLACK)

2WD 4WD LOCK

Br/R Br/R

O

Z B

B

A

B

B

W/B B/R

A A

B/Y

W/B B/R

B/Y Br/B B B/R W/B

Br/B B Br/B

B

L/R B

Br/R Br/R

(BLACK)

Br/B B/R L/B Sb Br B/Y W/B

B B B

Sb L/B Br B/Y B

B (GRAY)

B/Y Br/R Br/R B L/R

W

G/R Gy

Br/B

Sb Br

L/R L/G

L/G B

L/B

B

9

G/W

G/W

(BLACK)

Y/B Gy

L/B B Br Sb

B

Br

L/G L/R L/B Sb

Gy G/R

(GRAY)

O (GRAY)

C

WIRE HARNESS IGNITION COIL LEAD

Br/B Br/R Br/R B L/G

V

Y

X

Y/B Gy Br/R L/R

G/R Gy B Br

Br/R L/R

(BLACK)

L/R L/G Sb L/B

Br/R

U

Br/L

WIRE HARNESS SUB-WIRE HARNESS

L/W L/B 6 (BLACK)

R R

Br Y L L/B G B

8

B

B

R

R

B

R

R

OFF PUSH

e

B

5

R/G

B

B/R

B/R WIRE HARNESS SUB-WIRE HARNESS

W/B B

A W/B B

B

L

L

R/B

B

T

S

R/B L

B

B/Y

B/Y

L

B

B

B B/Y

L

B

B

B

W

G/W W/B Sb G/R (BLACK)

W/L

W/L

L/Y

B

B

G/Y

G/Y W/L

P

B

L/Y W

F

W

B C B

O C O

Q

G/L

R/G R/W B/R W/B G/R

(BLACK)

W Y/B B/R Lg G/L

A

=

(DARK GRAY)

R

R/B

Br

W/R W/G L/W R/B G/W Y/B G/R Sb G/L W/B B/R Lg

R

(BLACK)

R/B L/W O B B/Y R W/R W/G

W/B Br L/Y W/R L/R G/Y (BLACK)

G/L Sb W W/L B/R L/W (GRAY)

(BLACK)

L/Y R/W W/B G/Y L/R W/R

Sb G/L

(GRAY)

L/W B/R W/L

W

B

L/Y W

G/Y B

B/Y

O

Sb

P

N

Gy W

L

L/R

L/R

B

G/R R/G (BLACK)

W/R

L/W L/R W/R

W/R L/W

L/R Sb

Sb

L/W

B

R/G G/R

(BLACK)

G H I J K L M

E

W L B

D

C

B

SIGNAL SYSTEM

ELEC –

EB806000

SIGNAL SYSTEM

CIRCUIT DIAGRAM

+

SIGNAL SYSTEM 3 Main switch 4 Backup fuse 5 Battery 6 Main fuse 9 Reverse switch 0 CDI unit D Speed sensor F Multi-function meter G Differential gear lock indicator light H Coolant temperature indicator light I Reverse indicator light J Neutral indicator light K Park indicator light L High-range indicator light M Low-range indicator light N Gear position switch P Fuel sender Q Thermo switch 1 Y On-command four-wheel drive switch and differential gear lock switch Z Gear motor ] Ignition fuse e Override switch g Signaling system fuse h Rear brake light switch i Front brake light switch j Tail/brake light k Horn switch l Horn È For Europe and Oceania

– 10 –

ELEC –

+

YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN

YFM660FS WIRING DIAGRAM A

B

W/B B

W/B B

B/R

B/R

C

Br Sb L/B R/B Br/B B/Y

O

L/B Sb Br B/Y Br/B R/B

WIRE HARNESS SUB-WIRE HARNESS

WIRE HARNESS SUB-WIRE HARNESS

B

B

O

(GRAY)

(GRAY)

R/B L/W O B B/Y R W/R W/G

W Y/B B/R Lg G/L

G/W W/B Sb G/R

(BLACK)

(BLACK)

(BLACK)

WIRE HARNESS IGNITION COIL LEAD

W/G R

R W/G

W/R W/G

W/L W/R

1

W

W

W W

W W

W/R W/G L/W R/B G/W Y/B G/R Sb G/L W/B B/R Lg

W/G

W W W

W W W

R

2

B

B W

R

R

R

G/W R R R

B

W

R

L/W L/B 6 (BLACK)

5

R

W

R

W

9

4 R

B

W L B

L/Y W B

L/Y

E

W

B

R/G

ON OFF

B

Br Br/L R

R Br/L Br

Sb G/L

L/Y R/W W/B

L/W B/R W/L

G/Y L/R W/R

B

(GRAY)

(BLACK)

(BLACK)

W

A B

3

D

B

8

B B

L/Y W

B/Y

B

R

C

=

B/Y

L/B

B

B

B C B

L/W

7

(BLACK)

G/W

B

O C O

R

R W/G W/R

B/Y

R/G G/R

G/L Sb W

W/B Br L/Y

G/R R/G

W/L B/R L/W (GRAY)

W/R L/R G/Y (BLACK)

(BLACK)

B

B

Br

k OFF ON

Br

Br

B

B

R/G R/W B/R W/B G/R

Br/L Br

P

F

G H I J K L M

B

P

B

B

G/L

Br/L

Br/L

B

l

]

`

Br

Br/L

Br/L

Br/L

g

U

[

Br/B Br/R Br/R B L/G

B/Y Br/R Br/R B L/R

(BLACK)

(BLACK)

Br/R

G/Y W/L

Br

a R/Y

Br

h

i

Br Y

B B

(BLACK)

(BLACK) Y

R/W

R/W

R/W R/B

c

b

P L/B

Lg

d

e

PUSH

OFF PUSH

Y

Y Br

Y Br

(BLACK)

(BLACK)

Br/R Br/R

Br/R Br/R

R/B R/W

R/W R/B

Lg

Lg

Y/B Gy Br/R L/R

W Br/B

L/G B

L/R B

B/Y

Q

S

G/R Gy

Y G

j

Y G

f

R

f

Y G

Y G

B

B

G Y B

P

L/R L/G Sb L/B

G/R Gy B Br

(BLACK)

(GRAY)

L/G L/R L/B Sb

Gy G/R

(BLACK)

(GRAY)

Br

B

G Y B

N L/R Sb

R/B L

L

L/B

Sb Br

B

T

Br/B B Br/B

B

B

L Sb L/B Br B/Y B

B B B

Br/B B/R L/B Sb Br B/Y W/B

\

P

L

2WD 4WD LOCK

B B

L

Gy W

(DARK GRAY)

Y Y L

o

B

G/Y B

L/W L/R W/R

W/R L/W L/R L/G

m

P

B

R/B

B

Br

n

R/B

Y/B Gy

Br/R L/R

X L Y G

Sb G/Y

W/L

L Y R/Y B G L/B

W/R

L/R

W/L

R

V Br Y L L/B G B

L/W

O

Br B/Y

R/Y

L/R

Sb

B

B

L

W/B A W/B B/R A B/R

G W/B B/Y Br/B B B/R W/B B

P

Z

B

B

B

B B

L/B B Br Sb

A

B

1 AC magneto 2 Rectifier/regulator 3 Main switch 4 Backup fuse 5 Battery 6 Main fuse 7 Starter relay 8 Starter motor 9 Reverse switch 0 CDI unit A Rear brake switch B Ignition coil C Spark plug D Speed sensor E Meter assembly F Multi-function meter G Differential gear lock indicator light H Coolant temperature indicator light I Reverse indicator light J Neutral indicator light K Park indicator light L High-range indicator light M Low-range indicator light N Gear position switch O Diode P Fuel sender Q Thermo switch 1 R Circuit breaker (fan motor) S Thermo switch 2 T Fan motor U Four-wheel drive fuse V Four-wheel drive relay 1 W Four-wheel drive relay 2 X Four-wheel drive relay 3 Y On-command four-wheel drive switch and differential gear lock switch Z Gear motor [ Auxiliary DC jack fuse \ Auxiliary DC jack ] Ignition fuse ^ Headlight fuse a Handlebar switch (left) b Light switch c Engine stop switch d Start switch e Override switch f Headlight g Signaling system fuse h Rear brake light switch i Front brake light switch j Tail/brake light k Horn switch l Horn m Carburetor heater fuse n Thermoswitch o Carburetor heater È For Europe and Oceania É Option

COLOR CODE B ............ Black Br........... Brown G............ Green L ............ Blue Lg .......... Light green O............ Orange P ............ Pink R............ Red Sb .......... Sky blue

Gy..........Gray W ........... White Y ............Yellow B/R ........ Black/Red B/Y.........Black/Yellow Br/B ....... Brown/Black Br/L........ Brown/Blue Br/R ....... Brown/Red G/L.........Green/Blue

G/R ........Green/Red G/W .......Green/White G/Y ........Green/Yellow L/B .........Blue/Black L/G.........Blue/Green L/R .........Blue/Red L/W ........Blue/White L/Y .........Blue/Yellow R/B.........Red/Black

R/G ........Red/Green R/W........Red/White R/Y.........Red/Yellow W/B ........White/Black W/G .......White/Green W/L ........White/Blue W/R........White/Red Y/B .........Yellow/Black