Yamaha 5KM2-AE1 User manual

YFM660F(P)

5KM2-AE1

SERVICEMANUAL

2002

YFM660F(P) 2002

SERVICE MANUAL

First edition, May 2001

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 sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

OTE:

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!

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 dam-

age to the machine.

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

WARNING

CAUTION:

NOTE:

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 accompa-

nied 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 4is provided for removal and disassembly jobs.

2. Numbers 5are 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 7accompanies 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 8are given in addition

to the exploded diagram and the job instruction chart.

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1to 0are printed on the

top right of each page and indicate the subject

of each chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Engine

5Cooling system

6Carburetion

7Drive train

8Chassis

9Electrical

0Troubleshooting

Illustrated symbols Ato Hare used to identify

the specifications appearing in the text.

ACan be serviced with engine mounted

BFilling fluid

CLubricant

DSpecial tool

ETorque

FWear limit, clearance

GEngine speed

HΩ, V, A

Illustrated symbols Ito Nin the exploded

diagrams indicate the types of lubricants and

lubrication points.

IApply engine oil

JApply gear oil

KApply molybdenum disulfide oil

LApply wheel bearing grease

MApply lightweight lithium-soap base grease

NApply molybdenum disulfide grease

Illustrated symbols Oto Pin the exploded

diagrams indicate where to apply a locking

agent Oand when to install a new part P.

OApply the locking agent (LOCTITE)

PReplace

IJK

LMN

GEN

INFO SPEC

CHK

ADJ ENG

COOL CARB

DRIV

CHAS

–+

ELEC TRBL

SHTG

EGM

BLS M

LT New

TABLE OF CONTENTS

GENERAL INFORMATION GEN

INFO 1

SPECIFICATIONS SPEC 2

PERIODIC CHECKS AND

ADJUSTMENTS CHK

ADJ 3

ENGINE ENG 4

COOLING SYSTEM COOL 5

CARBURETION CARB 6

DRIVE TRAIN DRIV 7

CHASSIS CHAS 8

ELECTRICAL ELEC 9

TROUBLESHOOTING TRBL

SHTG

–+

GEN

INFO 1

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

MACHINE IDENTIFICATION ........................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER ................................................. 1-1

MODEL LABEL ..................................................................................... 1-1

FEATURES ................................................................................................... 1-2

FRONT DIFFERENTIAL ....................................................................... 1-2

TRANSMISSION ................................................................................... 1-9

IMPORTANT INFORMATION .................................................................... 1-10

PREPARATION FOR REMOVAL PROCEDURES ............................. 1-10

REPLACEMENT PARTS .................................................................... 1-10

GASKETS, OIL SEALS AND O-RINGS .............................................. 1-10

LOCK WASHERS/PLATES AND COTTER PINS ............................... 1-11

BEARINGS AND OIL SEALS .............................................................. 1-11

CIRCLIPS ............................................................................................ 1-11

CHECKING OF CONNECTIONS ............................................................... 1-12

SPECIAL TOOLS ....................................................................................... 1-13

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