Yamaha 2004 Rhino 660 YXR660FAS Manuals

Manuals and User Guides for Yamaha 2004 Rhino 660 YXR660FAS. We have 2 Yamaha 2004 Rhino 660 YXR660FAS manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha 2004 Rhino 660 YXR660FAS Service Manual (421 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 19.84 MB

Specifications
3
- Periodic Checks and
  5
- Table of Contents
  8
Chapter 1 General Information

18
Vehicle Identification

18
- Vehicle Identification Number
  18
- Model Label
  18
Features

19
- Self-Adjusting Parking Brake Mechanism
  19
Important Information

22
- Preparation for Removal Procedures
  22
- Replacement Parts
  22
- Gaskets, Oil Seals and O-Rings
  22
- Lock Washers/Plates and Cotter Pins
  23
- Bearings and Oil Seals
  23
- Circlips
  23
Checking of Connections

24
Special Tools

25
Chapter 2 Specifications

30
General Specifications

30
Engine Specifications

33
Chassis Specifications

41
Electrical Specifications

43
Tightening Torques

45
- Engine Tightening Torques
  45
- Chassis Tightening Torques
  48
How to Use the Conversion Table

51
General Tightening Torque Specifications

51
Lubrication Points and Lubricant Types

52
- Engine
  52
Coolant Flow Diagrams

53
Oil Flow Diagrams

56
Cable Routing

61
Chapter 3 Periodic Checks and Adjustments

78
Introduction

78
Periodic Maintenance/Lubrication

78
Engine

80
- Adjusting the Valve Clearance
  80
- Adjusting the Timing Chain
  83
- Adjusting the Idling Speed
  83
- Adjusting the Throttle Cable
  84
- Adjusting the Starter Cable
  85
- Checking the Spark Plug
  86
- Checking the Ignition Timing
  87
- Measuring the Compression Pressure
  88
- Checking the Engine Oil Level
  90
- Changing the Engine Oil
  91
- Cleaning the Air Filter
  93
- Checking the Coolant Level
  95
- Changing the Coolant
  96
- Checking the Coolant Temperature Warning Light
  100
- Checking the V-Belt
  101
- Cleaning the Spark Arrester
  102
Chassis

103
- Adjusting the Brake Pedal
  103
- Adjusting the Parking Brake
  104
- Checking the Brake Fluid Level
  105
- Checking the Front Brake Pads
  106
- Checking the Rear Brake Pads
  106
- Checking the Brake Hoses and Brake Pipes
  107
- Bleeding the Hydraulic Brake System
  107
- Adjusting the Select Lever Shift Rod
  109
- Adjusting the Brake Light Switch
  109
- Checking the Final Gear Oil Level
  110
- Changing the Final Gear Oil
  111
- Checking the Differential Gear Oil
  111
- Changing the Differential Gear Oil
  112
- Checking the Constant Velocity Joint Dust Boots
  113
- Checking the Steering System
  114
- Adjusting the Toe-In
  114
- Adjusting the Front Shock Absorbers
  116
- Adjusting the Rear Shock Absorbers
  116
- Checking the Tires
  117
- Checking the Wheels
  119
- Checking and Lubricating the Cables
  119
- Lubricating the Pedal, Etc
  120
Electrical

121
- Checking and Charging the Battery
  121
- Checking the Fuses
  126
- Adjusting the Headlight Beam
  128
- Changing the Headlight Bulb
  128
- Changing the Tail/Brake Light Bulb
  129
Chapter 4 Engine

131
Engine Removal

131
- Air Ducts, Muffler and Exhaust Pipe
  131
- Select Lever Unit and Coolant Reservoir
  133
- Hoses and Leads
  134
- Engine Mounting Bolts
  136
- Installing the Engine
  138
Cylinder Head Cover

139
- Removing the Cylinder Head Cover
  141
- Checking the Cylinder Head Cover
  141
- Checking the Tappet Covers
  141
- Installing the Cylinder Head Cover
  142
Rocker Arms

143
- Removing the Rocker Arms
  145
- Checking the Rocker Arms
  145
- Installing the Rocker Arms
  146
Camshaft and Cylinder Head

147
Valves and Valve Springs

155
Cylinder and Piston

163
- Removing the Piston
  164
- Checking the Cylinder and Piston
  164
- Checking the Piston Rings
  166
- Checking the Piston Pin
  167
- Installing the Piston
  167
- Installing the Cylinder
  169
Engine Cooling Fan and A.C. Magneto

170
- Removing the A.C. Magneto
  173
- Checking the A.C. Magneto
  173
- Checking the Starter Clutch
  174
- Checking the Engine Cooling Fan
  175
- Installing the A.C. Magneto
  175
Balancer Gears and Oil Pump Gears

178
Primary and Secondary Sheaves

182
- Primary Sheave
  184
- Secondary Sheave
  185
- Removing the Primary and Secondary Sheaves
  186
- Disassembling the Secondary Sheave
  186
- Checking the Primary Sheave
  187
- Checking the Secondary Sheave
  187
- Assembling the Primary Sheave
  188
- Assembling the Secondary Sheave
  188
- Installing the Primary and Secondary Sheaves
  190
Clutch

191
- Removing the Clutch
  193
- Checking the Clutch
  193
- Installing the Clutch
  194
Crankcase

196
- Starter Motor, Timing Chain and Oil Filter
  196
- Crankcase
  197
- Crankcase Bearings
  199
- Separating the Crankcase
  200
- Checking the Timing Chain and Guides
  200
- Checking the Oil Delivery Pipe
  200
- Checking the Relief Valve
  201
- Checking the Crankcase
  201
- Checking the Bearings
  201
- Assembling the Crankcase
  201
- Installing the Shift Levers
  202
Crankshaft and Oil Pump

203
- Oil Pump
  204
- Removing the Crankshaft
  205
- Checking the Oil Pump
  205
- Checking the Relief Valve
  206
- Checking the Oil Strainer
  206
- Assembling the Oil Pump
  206
- Checking the Crankshaft
  207
- Installing the Crankshaft and Balancer
  208
Transmission

209
- Drive Axle Assembly
  210
- Removing the Transmission
  211
- Checking the Shift Forks
  211
- Checking the Shift Drum
  212
- Checking the Drive Axle
  212
- Checking the High Wheel Gear and Middle Drive Gear
  212
- Checking the Secondary Shaft and Driven Sprocket
  213
- Checking the Chain
  213
- Assembling the Shift Fork Assembly
  214
- Installing the Transmission
  214
Middle Gear

215
- Middle Drive Shaft
  215
- Middle Driven Shaft
  216
- Removing the Middle Drive Shaft
  218
- Removing the Middle Driven Shaft
  218
- Checking the Pinion Gears
  221
- Selecting the Middle Drive and Driven Gear Shims
  222
- Installing the Middle Driven Shaft
  225
- Installing the Middle Drive Shaft
  227
- Measuring the Middle Gear Backlash
  228
Chapter 5 Cooling System

229
Radiator and Coolant Reservoir

229
- Checking the Radiator
  231
- Installing the Radiator
  232
Water Pump

233
- Disassembling the Water Pump
  235
- Checking the Water Pump
  235
- Assembling the Water Pump
  236
Oil Cooler

238
- Checking the Oil Cooler
  240
Chapter 6 Fuel System

241
Fuel Pump and Fuel Tank

241
- Checking the Fuel Pump Operation
  243
Carburetor

244
- Disassembling the Carburetor
  248
- Checking the Carburetor
  248
- Assembling the Carburetor
  250
- Adjusting the Fuel Level
  251
Chapter 7 Drive Train

252
Troubleshooting

252
Front Constant Velocity Joints, Differential Gear and Drive Shaft

255
Rear Constant Velocity Joints, Final Drive Gear and Drive Shaft

269
Chapter 8

287
- Front Bumper and Hood
  287
- Seats, Console and Instrument Panels
  288
- Panels and Footrest Cover
  290
- Cargo Bed
  292
- Skid Plates
  294
- Enclosure and Seat Belts
  295
Seats, Enclosure, Hood and Cargo Bed

287
Front Wheels and Brake Discs

296
- Checking the Front Wheel
  298
- Checking the Front Wheel Hub
  298
- Checking the Front Brake Disc
  299
- Installing the Front Wheel Hub
  299
- Installing the Front Wheel
  299
Rear Wheels and Brake Disc

300
- Rear Wheels
  300
- Rear Brake Disc
  301
- Checking the Rear Wheel
  302
- Checking the Rear Wheel Hub
  302
- Checking the Rear Brake Disc
  302
- Installing the Rear Wheel Hub
  303
- Installing the Rear Wheel
  303
Front and Rear Brakes

304
- Front Brake Pads
  304
- Rear Brake Pads
  305
- Replacing the Front Brake Pads
  306
- Replacing the Rear Brake Pads
  307
- Brake Master Cylinder
  310
- Checking the Master Cylinder
  312
- Assembling the Brake Master Cylinder
  312
- Installing the Brake Master Cylinder
  313
- Front Brake Caliper
  315
- Rear Brake Caliper
  317
- Disassembling the Front Brake Calipers
  321
- Disassembling the Rear Brake Caliper
  321
- Checking the Front and Rear Brake Calipers
  322
- Assembling the Front Brake Calipers
  323
- Assembling the Rear Brake Caliper
  324
- Installing the Front Brake Calipers
  326
- Installing the Rear Brake Caliper
  327
Pedal Assembly

329
Steering System

331
- Steering Column and Steering Assembly
  331
- Disassembling the Steering Assembly
  334
- Checking the Steering Joint
  334
- Checking the Steering Assembly
  334
- Assembling the Steering Assembly
  335
- Installing the Steering System
  336
- Tie-Rod and Steering Knuckle
  337
- Removing the Steering Knuckles
  338
- Checking the Tie-Rods
  338
- Checking the Steering Knuckles
  338
Front Arms and Front Shock Absorber

342
Rear Knuckle and Stabilizer

348
- Checking the Rear Knuckle
  349
- Checking the Stabilizer
  349
Rear Arms and Rear Shock Absorber

350
Chapter 9 Electrical

353
Electrical Components

354
Checking the Switch

355
- Checking a Switch Shown in the Manual
  355
- Checking the Switch Continuity
  356
Checking the Bulbs and Bulb Sockets

358
Ignition System

361
- Circuit Diagram
  361
- Troubleshooting
  362
Electric Starting System

367
- Circuit Diagram
  367
- Starting Circuit Operation
  368
- Troubleshooting
  369
- Starter Motor
  372
- Checking the Starter Motor
  373
- Assembling the Starter Motor
  374
Charging System

375
- Circuit Diagram
  375
- Troubleshooting
  376
Lighting System

378
- Circuit Diagram
  378
- Troubleshooting
  379
- Checking the Lighting System
  381
Signaling System

384
- Circuit Diagram
  384
- Troubleshooting
  386
- Checking the Signal System
  388
Cooling System

398
- Circuit Diagram
  398
- Troubleshooting
  399
2Wd/4Wd Selecting System

403
- Circuit Diagram
  403
- Troubleshooting
  404
Carburetor Heating System

408
- Circuit Diagram
  408
- Troubleshooting
  412
Chapter 10

412
- Fuel System
  412
- Electrical System
  412
- Compression System
  413
Starting Failure/Hard Starting

412
Poor Idle Speed Performance

413
Poor Medium and High-Speed Performance

413
Faulty Drive Train

414
Faulty Gear Shifting

415
- Hard Shifting
  415
- Shift Lever Does Not Move
  415
- Jumps out of Gear
  415
Faulty Clutch Performance

415
- Engine Operates but Vehicle will Not Move
  415
- Clutch Slipping
  415
- Poor Starting Performance
  415
- Poor Speed Performance
  416
Overheating

416
Faulty Brake

416
- Poor Braking Effect
  416
Shock Absorber Malfunction

416
- Malfunction
  416
Unstable Handling

417
Lighting System

417
- Headlight Does Not Come on
  417
- Bulb Burnt out
  417

Yamaha 2004 Rhino 660 YXR660FAS Owner's Manual (154 pages)

Brand: Yamaha | Category: Utility Vehicle | Size: 7.99 MB

Table of Contents
6
Location of the Warning and Specification Labels
10
Safety Information
15
Description and Vehicle Identification
20
- Identification Number Records
  22
- Key Identification Number
  22
- Vehicle Identification Number
  23
- Model Label
  23
Control Functions
24
- Main Switch
  24
- Indicator and Warning Lights
  25
- Coolant Temperature Warning Light Checking Method
  27
- Switches
  28
- Accelerator Pedal
  34
- Brake Pedal
  35
- Parking Brake Lever
  36
- Drive Select Lever
  37
- Fuel Tank Cap
  37
- Fuel Level Check Window
  38
- Starter (Choke)
  38
- Seats
  39
- Seat Belts
  40
- Cargo Bed
  42
- Front and Rear Shock Absorber Adjustment
  45
- Trailer Hitch Bracket
  47
- Auxiliary DC Jack
  47
Pre-Operation Checks
49
- Front and Rear Brakes
  50
- Fuel
  52
- Engine Oil
  53
- Coolant
  54
- Final Gear Oil
  55
- Differential Gear Oil
  55
- Accelerator Pedal
  55
- Seat Belts
  55
- Steering
  56
- Fittings and Fasteners
  56
- Lights
  56
- Switches
  56
- Tires
  56
- How to Measure Tire Pressure
  58
- Tire Wear Limit
  59
Operation
60
- Starting a Cold Engine
  60
- Starting a Warm Engine
  62
- Jump-Starting
  62
- Warming up
  64
- Drive Select Lever Operation and Reverse Driving
  64
- Engine Break-In
  66
- Parking
  68
- Parking on a Slope
  68
- Accessories and Loading
  70
Driving Your Vehicle
73
- Getting to Know Your Vehicle
  73
- Learning to Operate Your Vehicle
  77
- Turning Your Vehicle
  78
- Braking
  79
Going Uphill
79
Going Downhill
81
Crossing through Shallow Water
83
Riding over Rough Terrain
85
Riding in Brush or Wooded Areas
86
Encountering Obstacles on the Trail
87
Periodic Maintenance and Adjustment
88
Owner's Manual and Tool Kit
88
Periodic Maintenance/Lubrication
91
Hood
93
Console
95
Engine Oil and Oil Filter Cartridge
96
Final Gear Oil
100
Differential Gear Oil
102
Coolant
104
Axle Boots
106
Spark Plug Inspection
107
Air Filter Element Cleaning
109
V-Belt Cooling Duct Check Hose
113
V-Belt Case Drain Plug
113
Spark Arrester Cleaning
114
Carburetor Adjustment
116
Idle Speed Adjustment
116
Valve Clearance Adjustment
117
Front Brake Pad Check
117
Rear Brake Pad Check
118
Checking the Brake Fluid Level
119
Brake Fluid Replacement
120
Checking the Brake Pedal
120
Parking Brake Cable Free Play Adjustment
121
Brake Light Switch Adjustment
123
Cable Inspection and Lubrication
124
Brake Pedal and Accelerator Pedal Lubrication
124
Rear Knuckle Upper and Lower Pivot Lubrication
125
Steering Shaft Lubrication
125
Wheel Removal
126
Wheel Installation
126
Battery
128
- Battery Maintenance
  129
- Fuse Replacement
  130
- Replacing a Headlight Bulb
  132
- Headlight Beam Adjustment
  133
- Tail/Brake Light Bulb Replacement
  134
- Troubleshooting
  135
- Troubleshooting Charts
  137
Cleaning and Storage
139
- Cleaning
  139
- Storage
  141
Specifications
143
Noise Regulation
149
Maintenance Record
150
Yamaha Motor Corporation
151
Side × Side Vehicle Limited Warranty
151

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Yamaha 2004 Rhino 660 YXR660FAS Manuals

Yamaha 2004 Rhino 660 YXR660FAS Service Manual (421 pages)

Table of Contents

Chapter 1 General Information

Vehicle Identification

Features

Important Information

Checking of Connections

Special Tools

Chapter 2 Specifications

General Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Tightening Torques

How to Use the Conversion Table

General Tightening Torque Specifications

Lubrication Points and Lubricant Types

Coolant Flow Diagrams

Oil Flow Diagrams

Cable Routing

Chapter 3 Periodic Checks and Adjustments

Introduction

Periodic Maintenance/Lubrication

Engine

Chassis

Electrical

Chapter 4 Engine

Engine Removal

Cylinder Head Cover

Rocker Arms

Camshaft and Cylinder Head

Valves and Valve Springs

Cylinder and Piston

Engine Cooling Fan and A.C. Magneto

Balancer Gears and Oil Pump Gears

Primary and Secondary Sheaves

Clutch

Crankcase

Crankshaft and Oil Pump

Transmission

Middle Gear

Chapter 5 Cooling System

Radiator and Coolant Reservoir

Water Pump

Oil Cooler

Chapter 6 Fuel System

Fuel Pump and Fuel Tank

Carburetor

Chapter 7 Drive Train

Troubleshooting

Front Constant Velocity Joints, Differential Gear and Drive Shaft

Rear Constant Velocity Joints, Final Drive Gear and Drive Shaft

Chapter 8

Seats, Enclosure, Hood and Cargo Bed

Front Wheels and Brake Discs

Rear Wheels and Brake Disc

Front and Rear Brakes

Pedal Assembly

Steering System

Front Arms and Front Shock Absorber

Rear Knuckle and Stabilizer

Rear Arms and Rear Shock Absorber

Chapter 9 Electrical

Electrical Components

Checking the Switch

Checking the Bulbs and Bulb Sockets

Ignition System

Electric Starting System

Charging System

Lighting System

Signaling System

Cooling System

2Wd/4Wd Selecting System

Carburetor Heating System

Chapter 10

Starting Failure/Hard Starting

Poor Idle Speed Performance

Poor Medium and High-Speed Performance

Faulty Drive Train