Yamaha Raptor 660R Repair Manual 2001-2005

The shift lever pivots on the left footpeg and is clamped to the transmission shift shaft. The following procedure provides steps for partial and complete removal of the linkage and pedal from the machine.

1. Completely remove the linkage bolt (Figure 59), then remove the linkage from the shaft.



2. To install the linkage onto the shift shaft, install the linkage so the gap is aligned level with the center of the shift shaft (Figure 60).



3. Torque the bolt to 10 N.m (88 in.-lb.).

1. Remove the bolts securing the left footpeg to the footguard.



2. Remove the bolts securing the footpeg to the frame.



3. Remove the shift lever linkage as described in Step 1.



4. Disassemble, clean and lubricate the pivot as described in this section.



5. Reverse these steps to install the shift lever assembly.



6. Check pedal height adjustment (Chapter Three).

The machine is equipped with tubeless, low-pressure tires. The tires are designed for off-road use.

Rapid wear will occur if the machine is ridden on paved surfaces.

If a puncture occurs, a tire plug may be used temporarily. A tire plug is not suitable as a permanent repair. Repair the tire as soon as possible.

The procedures in this section detail how to remove a tire from the rim and how to make a permanent cold patch tire repair.

• General Information
• Troubleshooting
• Lubrication, Maintenance and Tune-up
• Engine
• Clutch and External Gearshift Linkage
• Transmission and Internal Shift Mechanism
• Fuel and Emission Systems
• Exhaust System
• Electrical System
• Wheels, Tires and Drivetrain
• Front Suspension and Steering
• Rear Suspension
• Brakes
• Body and Frame
• Wiring Diagrams