2001-2005 Yamaha Raptor 660 YFM660RN YFM660RNC Service Manual

For Yamaha Raptor 660 (2001-2005) models: diagnostics, service, and parts for engine, chassis, electrical, and more. Includes part number LIT-11616-14-21.

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Document Details

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Document Number / Seller:
27035 / Kevin Johnson
File Size:
36.02 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
ATV
Last updated / verified
May 22, 2025

Models Covered & Key Technical Specifications

2001-2005 Yamaha Raptor 660 (YFM660RN, YFM660RNC) Service Manual

For Yamaha Raptor 660 (2001-2005) models: diagnostics, service, and parts for engine, chassis, electrical, and more. Includes part number LIT-11616-14-21. | Official Publication Division.

  • Technical Resolution Data: 1200 dpi establishes the maximum print output Architecture.
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  • Essential Power Rating: 450 W -- signifies the active printing consumption Threshold.
  • Advanced Memory Capacity: The formatter board requires 64 MB for standard operation Logic.
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Professional Workshop Service Manual & Technical Specifications

Applied Technical Electrical Manual: Yamaha Raptor 660, YFM660RN, YFM660RNC ATV Manual (2001-2005) - Comprehensive Repair & Troubleshooting Guide Transmission-Guide

Serial-Range: 2001-2005 // Equipment-Series: Raptor 660R, Raptor 660 // Serial-Range: YFM660RN, YFM660RNC.

Yamaha Raptor 660 (2001-2005) Service Manual: Overview

Assessment-Parameter Baseline Framework
Engine Type 4-stroke, SOHC Liquid-cooled
Displacement 660 cc N/A
Bore x Stroke 100.0 x 84.0 mm N/A
Compression Ratio 9.2:1 N/A
Fuel Type Unleaded N/A

Technical content addresses engine service, chassis maintenance, electrical system troubleshooting, and periodic checks and adjustments. Key specifications for components like the clutch, transmission, and brakes are provided, along with detailed diagrams. Procedures for disassembly, assembly, and repair are outlined for all major systems, including lubrication points and types. Maintenance intervals are specified for routine care.

Engine Systems

This section details engine removal, cylinder head cover servicing, rocker arms, camshaft and cylinder head procedures, valves and valve springs, cylinder and piston, AC magneto, clutch, oil pump, shift shaft, crankcase, crankshaft and balancer, and transmission. It includes checks for wear, damage, and proper function, along with replacement recommendations and installation procedures.

Chassis Components

The chassis section covers front and rear wheels, wheel axles, hubs, brakes, steering system, front arms, front shock absorbers, rear shock absorbers, relay arms, swingarms, and drive chains. It provides instructions for removal, installation, checking, and adjustment of these critical components.

Electrical Systems

This part of the manual addresses the electrical components, including the ignition system, electric starting system, charging system, lighting system, signal system, and troubleshooting for these areas. Circuit diagrams and diagnostic procedures are included.

Troubleshooting Guide

Comprehensive troubleshooting steps are provided for common issues such as starting problems, poor engine performance, faulty gear shifting, clutch slipping, overheating, faulty brakes, and lighting system malfunctions. It offers solutions based on symptom analysis.

Maintenance specifications include detailed information on engine components, chassis measurements, electrical system ratings, and tightening torques for various fasteners. The manual specifies recommended lubricants and their application points. Torque specifications are provided for engine, chassis, and electrical components to ensure proper assembly and function. This documentation ensures adherence to manufacturer specifications for optimal performance and longevity.

FAQ

What **tools** are designated for valve clearance adjustment procedures? keyboard_arrow_down

14 Nm (1.4 m•kg, 10 ft•lb) locknuts are used for the tappet adjusting tool (P/N. YM-08035, 90890-01311) during valve clearance adjustments.

Identify the **critical** pressure specifications for the tires. keyboard_arrow_down

Front and rear tires have a standard recommended pressure of 27.5 kPa (0.275 kg/cm2, 4.0 psi) when cold.

What **procedures** are required for the steering stem bearing retainer adjustment? keyboard_arrow_down

40 Nm (4.0 m•kg, 29 ft•lb) is the specified torque for tightening the bearing retainer (steering stem), using a damper rod holder (P/N. YM-01327, 90890-01327) for the adjustment.

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The exploded diagrams are great! I had a smooth experience with the download process and appreciated the quick response from support. Highly recommend!
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The service manual is comprehensive and easy to understand. I appreciated the prompt email with the download link—smooth process!
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I found all the maintenance guidelines very practical. The support team responded quickly to my questions, which was fantastic!
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This manual has been a lifesaver for my Yamaha ATV. The detailed diagrams make repairs straightforward, and the troubleshooting section is incredibly helpful!
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This manual covers everything you need to know. The download was hassle-free, and I received helpful assistance when needed. Very satisfied!