Name: Yamaha 2004 Rhino 660 YXR660FAS
Brand: Yamaha
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LIT-11616-17-23 5UG-F8197-10

YXR660FAS

SERVICE MANUAL

Default Chapter3
- Specifications3
  - Periodic Checks and5
  - Table of Contents8
Chapter 1 General Information18
Vehicle Identification18
- Vehicle Identification Number18
- Model Label18
Features19
- Self-Adjusting Parking Brake Mechanism19
Important Information22
- Preparation for Removal Procedures22
- Replacement Parts22
- Gaskets, Oil Seals and O-Rings22
- Lock Washers/Plates and Cotter Pins23
- Bearings and Oil Seals23
- Circlips23
Checking of Connections24
Special Tools25
Chapter 2 Specifications30
General Specifications30
Engine Specifications33
Chassis Specifications41
Electrical Specifications43
Tightening Torques45
- Engine Tightening Torques45
- Chassis Tightening Torques48
How to Use the Conversion Table51
General Tightening Torque Specifications51
Lubrication Points and Lubricant Types52
- Engine52
Coolant Flow Diagrams53
Oil Flow Diagrams56
Cable Routing61
Chapter 3 Periodic Checks and Adjustments78
Introduction78
Periodic Maintenance/Lubrication78
Engine80
- Adjusting the Valve Clearance80
- Adjusting the Timing Chain83
- Adjusting the Idling Speed83
- Adjusting the Throttle Cable84
- Adjusting the Starter Cable85
- Checking the Spark Plug86
- Checking the Ignition Timing87
- Measuring the Compression Pressure88
- Checking the Engine Oil Level90
- Changing the Engine Oil91
- Cleaning the Air Filter93
- Checking the Coolant Level95
- Changing the Coolant96
- Checking the Coolant Temperature Warning Light100
- Checking the V-Belt101
- Cleaning the Spark Arrester102
Chassis103
- Adjusting the Brake Pedal103
- Adjusting the Parking Brake104
- Checking the Brake Fluid Level105
- Checking the Front Brake Pads106
- Checking the Rear Brake Pads106
- Checking the Brake Hoses and Brake Pipes107
- Bleeding the Hydraulic Brake System107
- Adjusting the Select Lever Shift Rod109
- Adjusting the Brake Light Switch109
- Checking the Final Gear Oil Level110
- Changing the Final Gear Oil111
- Checking the Differential Gear Oil111
- Changing the Differential Gear Oil112
- Checking the Constant Velocity Joint Dust Boots113
- Checking the Steering System114
- Adjusting the Toe-In114
- Adjusting the Front Shock Absorbers116
- Adjusting the Rear Shock Absorbers116
- Checking the Tires117
- Checking the Wheels119
- Checking and Lubricating the Cables119
- Lubricating the Pedal, Etc120
Electrical121
- Checking and Charging the Battery121
- Checking the Fuses126
- Adjusting the Headlight Beam128
- Changing the Headlight Bulb128
- Changing the Tail/Brake Light Bulb129
Chapter 4 Engine131
Engine Removal131
- Air Ducts, Muffler and Exhaust Pipe131
- Select Lever Unit and Coolant Reservoir133
- Hoses and Leads134
- Engine Mounting Bolts136
- Installing the Engine138
Cylinder Head Cover139
- Removing the Cylinder Head Cover141
- Checking the Cylinder Head Cover141
- Checking the Tappet Covers141
- Installing the Cylinder Head Cover142
Rocker Arms143
- Removing the Rocker Arms145
- Checking the Rocker Arms145
- Installing the Rocker Arms146
Camshaft and Cylinder Head147
- Removing the Camshaft and Cylinder Head149
- Checking the Camshaft149
- Checking the Camshaft Sprocket150
- Checking the Decompression System150
- Checking the Timing Chain Guide (Exhaust Side)150
- Checking the Timing Chain Tensioner150
- Checking the Cylinder Head151
- Installing the Camshaft and Cylinder Head152
Valves and Valve Springs155
- Removing the Valves and Valve Springs156
- Checking the Valves and Valve Springs157
- Installing the Valves and Valve Springs161
Cylinder and Piston163
- Removing the Piston164
- Checking the Cylinder and Piston164
- Checking the Piston Rings166
- Checking the Piston Pin167
- Installing the Piston167
- Installing the Cylinder169
Engine Cooling Fan and A.C. Magneto170
- Removing the A.C. Magneto173
- Checking the A.C. Magneto173
- Checking the Starter Clutch174
- Checking the Engine Cooling Fan175
- Installing the A.C. Magneto175
Balancer Gears and Oil Pump Gears178
- Removing the Balancer Drive Gear and Balancer Driven Gear180
- Checking the Oil Pump Drive Gear and Oil Pump Driven Gear180
- Checking the Balancer Drive Gear and Balancer Driven Gear180
- Installing the Balancer Drive Gear and Balancer Driven Gear181
Primary and Secondary Sheaves182
- Primary Sheave184
- Secondary Sheave185
- Removing the Primary and Secondary Sheaves186
- Disassembling the Secondary Sheave186
- Checking the Primary Sheave187
- Checking the Secondary Sheave187
- Assembling the Primary Sheave188
- Assembling the Secondary Sheave188
- Installing the Primary and Secondary Sheaves190
Clutch191
- Removing the Clutch193
- Checking the Clutch193
- Installing the Clutch194
Crankcase196
- Starter Motor, Timing Chain and Oil Filter196
- Crankcase197
- Crankcase Bearings199
- Separating the Crankcase200
- Checking the Timing Chain and Guides200
- Checking the Oil Delivery Pipe200
- Checking the Relief Valve201
- Checking the Crankcase201
- Checking the Bearings201
- Assembling the Crankcase201
- Installing the Shift Levers202
Crankshaft and Oil Pump203
- Oil Pump204
- Removing the Crankshaft205
- Checking the Oil Pump205
- Checking the Relief Valve206
- Checking the Oil Strainer206
- Assembling the Oil Pump206
- Checking the Crankshaft207
- Installing the Crankshaft and Balancer208
Transmission209
- Drive Axle Assembly210
- Removing the Transmission211
- Checking the Shift Forks211
- Checking the Shift Drum212
- Checking the Drive Axle212
- Checking the High Wheel Gear and Middle Drive Gear212
- Checking the Secondary Shaft and Driven Sprocket213
- Checking the Chain213
- Assembling the Shift Fork Assembly214
- Installing the Transmission214
Middle Gear215
- Middle Drive Shaft215
- Middle Driven Shaft216
- Removing the Middle Drive Shaft218
- Removing the Middle Driven Shaft218
- Checking the Pinion Gears221
- Selecting the Middle Drive and Driven Gear Shims222
- Installing the Middle Driven Shaft225
- Installing the Middle Drive Shaft227
- Measuring the Middle Gear Backlash228
Chapter 5 Cooling System229
Radiator and Coolant Reservoir229
- Checking the Radiator231
- Installing the Radiator232
Water Pump233
- Disassembling the Water Pump235
- Checking the Water Pump235
- Assembling the Water Pump236
Oil Cooler238
- Checking the Oil Cooler240
Chapter 6 Fuel System241
Fuel Pump and Fuel Tank241
- Checking the Fuel Pump Operation243
Carburetor244
- Disassembling the Carburetor248
- Checking the Carburetor248
- Assembling the Carburetor250
- Adjusting the Fuel Level251
Chapter 7 Drive Train252
Troubleshooting252
Front Constant Velocity Joints, Differential Gear and Drive Shaft255
- Disassembling the Universal Joint260
- Removing the Differential Gear Assembly260
- Checking the Constant Velocity Joints261
- Checking the Differential Gear261
- Checking the Gear Motor262
- Assembling the Front Constant Velocity Joints262
- Assembling the Differential Gear263
- Assembling the Universal Joint265
- Measuring and Adjusting the Differential Gear Lash265
- Checking the Differential Gear Operation267
Rear Constant Velocity Joints, Final Drive Gear and Drive Shaft269
- Assembling the Rear Constant Velocity Joints275
- Disassembling the Final Gear Case275
- Removing the Final Drive Roller Bearings276
- Installing the Final Drive Roller Bearings277
- Positioning the Final Drive Pinion Gear and Ring Gear277
- Checking the Drive Shaft282
- Checking the Final Gear Case282
- Measuring and Adjusting the Final Gear Lash283
- Assembling the Final Gear Case284
Chapter 8287
- Front Bumper and Hood287
- Seats, Console and Instrument Panels288
- Panels and Footrest Cover290
- Cargo Bed292
- Skid Plates294
- Enclosure and Seat Belts295
Seats, Enclosure, Hood and Cargo Bed287
Front Wheels and Brake Discs296
- Checking the Front Wheel298
- Checking the Front Wheel Hub298
- Checking the Front Brake Disc299
- Installing the Front Wheel Hub299
- Installing the Front Wheel299
Rear Wheels and Brake Disc300
- Rear Wheels300
- Rear Brake Disc301
- Checking the Rear Wheel302
- Checking the Rear Wheel Hub302
- Checking the Rear Brake Disc302
- Installing the Rear Wheel Hub303
- Installing the Rear Wheel303
Front and Rear Brakes304
- Front Brake Pads304
- Rear Brake Pads305
- Replacing the Front Brake Pads306
- Replacing the Rear Brake Pads307
- Brake Master Cylinder310
- Checking the Master Cylinder312
- Assembling the Brake Master Cylinder312
- Installing the Brake Master Cylinder313
- Front Brake Caliper315
- Rear Brake Caliper317
- Disassembling the Front Brake Calipers321
- Disassembling the Rear Brake Caliper321
- Checking the Front and Rear Brake Calipers322
- Assembling the Front Brake Calipers323
- Assembling the Rear Brake Caliper324
- Installing the Front Brake Calipers326
- Installing the Rear Brake Caliper327
Pedal Assembly329
Steering System331
- Steering Column and Steering Assembly331
- Disassembling the Steering Assembly334
- Checking the Steering Joint334
- Checking the Steering Assembly334
- Assembling the Steering Assembly335
- Installing the Steering System336
- Tie-Rod and Steering Knuckle337
- Removing the Steering Knuckles338
- Checking the Tie-Rods338
- Checking the Steering Knuckles338
Front Arms and Front Shock Absorber342
- Removing the Front Arms344
- Checking the Front Arms344
- Checking the Front Shock Absorber346
- Installing the Front Arms and Front Shock Absorber347
Rear Knuckle and Stabilizer348
- Checking the Rear Knuckle349
- Checking the Stabilizer349
Rear Arms and Rear Shock Absorber350
- Checking the Rear Arms351
- Checking the Rear Shock Absorber351
- Installing the Rear Arms and Rear Shock Absorber352
Chapter 9 Electrical353
Electrical Components354
Checking the Switch355
- Checking a Switch Shown in the Manual355
- Checking the Switch Continuity356
Checking the Bulbs and Bulb Sockets358
- Types of Bulbs358
- Checking the Condition of the Bulbs358
- Checking the Condition of the Bulb Sockets360
Ignition System361
- Circuit Diagram361
- Troubleshooting362
Electric Starting System367
- Circuit Diagram367
- Starting Circuit Operation368
- Troubleshooting369
- Starter Motor372
- Checking the Starter Motor373
- Assembling the Starter Motor374
Charging System375
- Circuit Diagram375
- Troubleshooting376
Lighting System378
- Circuit Diagram378
- Troubleshooting379
- Checking the Lighting System381
Signaling System384
- Circuit Diagram384
- Troubleshooting386
- Checking the Signal System388
Cooling System398
- Circuit Diagram398
- Troubleshooting399
2Wd/4Wd Selecting System403
- Circuit Diagram403
- Troubleshooting404
Carburetor Heating System408
- Circuit Diagram408
- Troubleshooting412
Chapter 10412
- Fuel System412
- Electrical System412
- Compression System413
Starting Failure/Hard Starting412
Poor Idle Speed Performance413
Poor Medium and High-Speed Performance413
Faulty Drive Train414
Faulty Gear Shifting415
- Hard Shifting415
- Shift Lever Does Not Move415
- Jumps out of Gear415
Faulty Clutch Performance415
- Engine Operates but Vehicle will Not Move415
- Clutch Slipping415
- Poor Starting Performance415
- Poor Speed Performance416
Overheating416
Faulty Brake416
- Poor Braking Effect416
Shock Absorber Malfunction416
- Malfunction416
Unstable Handling417
Lighting System417
- Headlight Does Not Come on417
- Bulb Burnt out417

Yamaha 2004 Rhino 660 YXR660FAS User Manual

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Yamaha 2004 Rhino 660 YXR660FAS Specifications

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Brand	Yamaha
Model	2004 Rhino 660 YXR660FAS
Category	Offroad Vehicle
Language	English