Yamaha Raptor 660R Repair Manual 2001-2005

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Features

Features
This repair and service manual covers Yamaha Raptor 660R ATVs, 2001-2005.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE | GENERAL INFORMATION
Manual organization*Warnings, cautions and notes*Safety*Basic service methods*Serial numbers*Fasteners*Shop supplies*Basic tools*Precision measuring tools*Storage*Specifications

CHAPTER TWO | TROUBLESHOOTING
Operating requirements*Starting the engine*Engine spark test*Engine performance*Electrical testing*Electrical component replacement*Engine starting system*Engine noise*Machine noise*Engine leakdown test*Clutch*Gear shift linkage and transmission*Brakes*Steering and handling

CHAPTER THREE | LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride inspection*Engine break-in*Tune-up and service intervals*Battery*Fuel and lubricants*Periodic lubrication*Maintenance and inspection*Engine tune-up*Spark plug*Specifications

CHAPTER FOUR | ENGINE TOP END
Shop cleanliness*Exhaust system*Cylinder head cover*Camshaft and cam chain tensioner*Cylinder head*Valves*Cylinder*Piston and piston rings*Specifications

CHAPTER FIVE | ENGINE LOWER END
Shop cleanliness*Engine*Cam chain and rear guide*Crankcase*Seal replacement*Crankcase bearing replacement*Engine balancer*Oil strainer*Crankshaft*Specifications

CHAPTER SIX | CLUTCH, GEARSHIFT LINKAGE AND LUBRICATION SYSTEM
Right crankcase cover*Clutch*Oil pump*Balancer shaft driven gear*Primary drive gears*Speed sensor*Shift lever*External gearshift linkage*Clutch cable replacement*Specifications

CHAPTER SEVEN | TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation*Service notes*Early and late transmission differences*Input shaft*Output shaft*Transmission inspection*Reverse shaft and lockout assemblies*Shift drum and forks*Specifications

CHAPTER EIGHT | FUEL SYSTEM
Carburetors*Carburetor cleaning and inspection*Float adjustment*Carburetor synchronization*Carburetor systems*Fuel valve*Throttle cable replacement*Specifications

CHAPTER NINE | ELECTRICAL SYSTEM
Resistance testing guidelines*Continuity testing guidelines*Basic ignition and charging system operation*Upper idle gear cover*Left crankcase cover*Lower idle gear*Stator and pickup coil*Rotor and starter clutch*Starter*Starting system switches*Ignition system*Charging system*Fan system*Water temperature warning circuit*Indicator circuits*Headlight*Taillight*Left handlebar switches*Specifications

CHAPTER TEN | COOLING SYSTEM
Safety precautions*Thermostat*Water temperature sending unit*Radiator and fan*Fan sending unit*Water pump*Specifications

CHAPTER ELEVEN | FRONT SUSPENSION AND STEERING
Front wheel*Front hub*Tie rods*Steering knuckle*Control arms*Shock absorbers*Steering shaft*Handlebar*Tires and wheels*Specifications

CHAPTER TWELVE | REAR SUSPENSION
Rear wheel*Rear wheel hub*Rear axle*Rear axle hub*Sprockets*Drive chain*Shock absorber*Rear suspension adjustment*Shock linkage*Swing arm*Specifications

CHAPTER THIRTEEN | BRAKES
Disc brake fundamentals*Front brake pads*Front brake calipers*Front master cylinder*Rear brake pads*Rear brake caliper*Rear master cylinder*Rear brake pedal*Brake system draining*Brake system bleeding*Brake disc*Specifications

CHAPTER FOURTEEN | BODY
Seat*Front panel*Headlight assembly*Fuel tank top panel*Front fender*Rear fender*Fuel tank*Fuel tank protectors*Footguard assembly*Skid plates

WIRING DIAGRAM

Clymer ATV repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

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