Yamaha Raptor 660 ATV Manual Set: Service + 2004 Owner's Manual (P/N LIT-11616-14-21)

The RP supplement must be used with the RN/RNC service manual. The separate owner’s manual covers operation, preventive maintenance, and minor repairs.

Model fit: YFM660RT identifies the owner’s manual. The workshop publications cover RN/RNC and RP; this set does not include an RT-labeled service manual.

PDF Search, Bookmarks, and Wiring Detail

Search and diagram detail: Both PDFs have searchable main text and embedded section bookmarks. Some illustration labels and portions of the owner’s back matter are outside the searchable text. Small labels in the service wiring diagrams are readable when zoomed in.

The ZIP contains two printable PDFs: a combined service-and-supplement file and a separate owner’s manual, totaling 545 pages. This includes the supplement, original covers, unnumbered pages, back matter, and two registration-card pages.

Engine, Chassis, and Electrical Service

These selected coverage highlights outline the principal work documented in the publications. Oil-flow diagrams and reverse-control-cable adjustment are further examples of included material.

• Engine repair: Step-by-step procedures cover engine removal, cylinder-head and camshaft service, decompression checks, valve work, piston and cylinder inspection, and timing-component installation.

• Clutch and transmission: Clutch disassembly, oil-pump inspection, shift-shaft service, crankcase separation, crankshaft and balancer work, and transmission inspection and reassembly.

• Brakes and chassis: Master-cylinder and caliper service, hydraulic brake bleeding, wheel and rear-axle inspection, steering repair, suspension removal, and swingarm and drive-chain service.

• Cooling system: Radiator inspection, thermostat testing, and water-pump disassembly, seal inspection, and reassembly, supported by coolant-flow diagrams.

• Twin carburetors: Removal, separation, disassembly, diaphragm and jet inspection, reassembly, synchronization checks, and float-height and fuel-level adjustment.

• Electrical diagnosis: Circuit-based troubleshooting covers ignition, electric starting, charging, lighting, signal, and cooling-fan systems, with separate RN/RNC and RP wiring diagrams.

• Owner operation: Controls, pre-ride checks, starting, reverse use, shifting, break-in, suspension adjustment, riding techniques, routine maintenance, and troubleshooting charts.

Yamaha wrote the workshop publications primarily for its dealers and qualified mechanics; the owner’s volume addresses experienced ATV operators and owner-level preventive maintenance and minor repairs.

Workshop Procedures and RP Changes

Internal inspection: Exploded assemblies and ordered job charts accompany the repair procedures. Transmission coverage includes shaft runout, shift forks, shift-drum grooves, gear dogs, engagement, and assembly checks.

Periodic service extends to valve-clearance adjustment, compression testing, clutch and brake adjustment, steering inspection and toe-in, drive-chain alignment, battery checks, and headlight adjustment.

Supplement differences: The RP material revises transmission ratios, engine inspection specifications, cable routing, maintenance information, rear-shock settings, and relay-arm procedures. Swingarm, drive-chain, and AC-magneto sections document further changes.

Keeping these revisions separate from the base specifications helps a mechanic select the applicable inspection limits, tightening torques, and setup data.

Chassis Inspection and Repair Cautions

Wheel and suspension sections extend to rear hubs, the steering stem and tie-rods, front arms and shocks, and rear-shock and relay-arm inspection. Rear-shock coverage addresses removal, inspection, and replacement rather than internal damper rebuilding.

Direct hammering can damage the rear axle’s threads and splines or the crankcase mating faces. Other cautions address brake-seal damage from wrong or mixed fluid and O-ring chain damage from pressure washing, steam, gasoline, harsh solvents, or coarse brushes.

Brake hydraulics, the gas-charged rear shock, battery work, and internal engine repair should be handled with the safety precautions and skill level specified by Yamaha.

Electrical Fault Tracing and Shop References

The starting-circuit explanation and component tests help distinguish motor or relay faults from neutral-switch, clutch-switch, and wiring problems. Separate troubleshooting sections address hard starting, poor idle or high-speed performance, shift faults, clutch slip or drag, overheating, weak brakes, unstable handling, shock problems, and lighting failures.

Visual references include the RN/RNC and RP wiring diagrams, coolant-flow diagrams, cable-routing views, the electric-starting circuit diagram, and exploded brake-caliper views. Component-specific torque tables, lubrication points, approved fluids, capacities, wear limits, clearances, and electrical test values accompany the relevant work.

Special-tool listings provide U.S./Canada and corresponding 90890-series numbers. Examples include the crankcase separating tool YU-01135-A / 90890-01135, flywheel puller YU-33270 / 90890-01362, clutch holding tool YM-91042 / 90890-04086, and water-pump mechanical-seal installer YM-33221 / 90890-04078.

Owner Controls, Riding, and Maintenance

Control explanations cover the main switch, warning and indicator lights, handlebar switches, throttle and speed limiter, clutch and brake controls, parking brake, shift pedal, reverse knob, fuel cock, starter choke, seat, and suspension adjusters.

Pre-operation checks address brakes, fuel, engine oil, coolant, chain condition, throttle action, fasteners, lights, switches, and tires. Operating guidance covers cold and warm starts, acceleration and deceleration, parking, loading, hill and side-slope riding, shallow water, rough terrain, and recovery from sliding or stalling.

Maintenance instructions cover engine oil and filter service, coolant replacement, spark-plug and air-filter care, spark-arrester cleaning, brake and clutch checks, chain care, battery and fuse service, bulb replacement, cleaning, storage, and a maintenance record. Owner carburetor adjustment is limited principally to idle speed; more involved adjustment and valve-clearance work are assigned to qualified service personnel.

Selected Valve-Clearance and Carburetor Data

For RN/RNC engine service, cold valve-clearance specifications are 0.10–0.15 mm at the intake and 0.15–0.20 mm at the exhaust. The RP supplement lists the same clearance ranges.

The RN/RNC carburetor procedure specifies a fuel level 3–4 mm below the float-chamber mating surface. The RP specification table retains that range, alongside the carburetor setup data.