Yamaha 2004 Rhino 660 YXR660FAS Manuals

Manuals and User Guides for Yamaha 2004 Rhino 660 YXR660FAS. We have 1 Yamaha 2004 Rhino 660 YXR660FAS manual available for free PDF download: Service Manual

Yamaha 2004 Rhino 660 YXR660FAS Service Manual

Yamaha 2004 Rhino 660 YXR660FAS Service Manual (421 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 19.84 MB
Table of contents
Specifications3................................................................................................................................................................
Periodic Checks And5................................................................................................................................................................
Table Of Contents7................................................................................................................................................................
Vehicle Identification18................................................................................................................................................................
Features19................................................................................................................................................................
Important Information22................................................................................................................................................................
Lock Washers/plates And Cotter Pins23................................................................................................................................................................
Checking Of Connections24................................................................................................................................................................
Special Tools25................................................................................................................................................................
General Specifications30................................................................................................................................................................
Engine Specifications33................................................................................................................................................................
Chassis Specifications41................................................................................................................................................................
Electrical Specifications43................................................................................................................................................................
Tightening Torques45................................................................................................................................................................
Chassis Tightening Torques48................................................................................................................................................................
How To Use The Conversion Table51................................................................................................................................................................
Lubrication Points And Lubricant Types52................................................................................................................................................................
Coolant Flow Diagrams53................................................................................................................................................................
Oil Flow Diagrams56................................................................................................................................................................
Cable Routing61................................................................................................................................................................
Introduction78................................................................................................................................................................
Engine80................................................................................................................................................................
Adjusting The Timing Chain83................................................................................................................................................................
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................................................................................................................................................................
Cleaning The Spark Arrester102................................................................................................................................................................
Chassis103................................................................................................................................................................
Adjusting The Parking Brake104................................................................................................................................................................
Checking The Brake Fluid Level105................................................................................................................................................................
Checking The Front Brake Pads106................................................................................................................................................................
Bleeding The Hydraulic Brake System107................................................................................................................................................................
Adjusting The Select Lever Shift Rod109................................................................................................................................................................
Checking The Final Gear Oil Level110................................................................................................................................................................
Changing The Final Gear Oil111................................................................................................................................................................
Changing The Differential Gear Oil112................................................................................................................................................................
Checking The Constant Velocity Joint Dust Boots113................................................................................................................................................................
Checking The Steering System114................................................................................................................................................................
Adjusting The Front Shock Absorbers116................................................................................................................................................................
Checking The Tires117................................................................................................................................................................
Checking The Wheels119................................................................................................................................................................
Lubricating The Pedal, Etc120................................................................................................................................................................
Electrical121................................................................................................................................................................
Checking And Charging The Battery122................................................................................................................................................................
Checking The Fuses126................................................................................................................................................................
Adjusting The Headlight Beam128................................................................................................................................................................
Changing The Tail/brake Light Bulb129................................................................................................................................................................
Engine Removal131................................................................................................................................................................
Select Lever Unit And Coolant Reservoir133................................................................................................................................................................
Hoses And Leads134................................................................................................................................................................
Engine Mounting Bolts136................................................................................................................................................................
Installing The Engine138................................................................................................................................................................
Cylinder Head Cover139................................................................................................................................................................
Removing The Cylinder Head Cover141................................................................................................................................................................
Installing The Cylinder Head Cover142................................................................................................................................................................
Rocker Arms143................................................................................................................................................................
Removing The Rocker Arms145................................................................................................................................................................
Installing The Rocker Arms146................................................................................................................................................................
Camshaft And Cylinder Head147................................................................................................................................................................
Removing The Camshaft And Cylinder Head149................................................................................................................................................................
Checking The Camshaft Sprocket150................................................................................................................................................................
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 Piston Rings166................................................................................................................................................................
Checking The Piston Pin167................................................................................................................................................................
Installing The Cylinder169................................................................................................................................................................
Engine Cooling Fan And A.c. Magneto170................................................................................................................................................................
Removing The A.c. Magneto173................................................................................................................................................................
Checking The Starter Clutch174................................................................................................................................................................
Checking The Engine Cooling Fan175................................................................................................................................................................
Balancer Gears And Oil Pump Gears178................................................................................................................................................................
Removing 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................................................................................................................................................................
Checking The Primary Sheave187................................................................................................................................................................
Assembling The Primary Sheave188................................................................................................................................................................
Installing The Primary And Secondary Sheaves190................................................................................................................................................................
Clutch191................................................................................................................................................................
Removing The Clutch193................................................................................................................................................................
Installing The Clutch194................................................................................................................................................................
Crankcase196................................................................................................................................................................
Crankcase Bearings199................................................................................................................................................................
Separating The Crankcase200................................................................................................................................................................
Checking The Relief Valve201................................................................................................................................................................
Installing The Shift Levers202................................................................................................................................................................
Crankshaft And Oil Pump203................................................................................................................................................................
Oil Pump204................................................................................................................................................................
Removing The Crankshaft205................................................................................................................................................................
Checking The Crankshaft207................................................................................................................................................................
Installing The Crankshaft And Balancer208................................................................................................................................................................
Transmission209................................................................................................................................................................
Drive Axle Assembly210................................................................................................................................................................
Removing The Transmission211................................................................................................................................................................
Checking The Shift Drum212................................................................................................................................................................
Checking The Secondary Shaft And Driven Sprocket213................................................................................................................................................................
Assembling The Shift Fork Assembly214................................................................................................................................................................
Middle Gear215................................................................................................................................................................
Middle Driven Shaft216................................................................................................................................................................
Removing The Middle Drive 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................................................................................................................................................................
Radiator And Coolant Reservoir229................................................................................................................................................................
Checking The Radiator231................................................................................................................................................................
Installing The Radiator232................................................................................................................................................................
Water Pump233................................................................................................................................................................
Disassembling The Water Pump235................................................................................................................................................................
Assembling The Water Pump236................................................................................................................................................................
Oil Cooler238................................................................................................................................................................
Checking The Oil Cooler240................................................................................................................................................................
Fuel Pump And Fuel Tank241................................................................................................................................................................
Checking The Fuel Pump Operation243................................................................................................................................................................
Carburetor244................................................................................................................................................................
Disassembling The Carburetor248................................................................................................................................................................
Assembling The Carburetor250................................................................................................................................................................
Adjusting The Fuel Level251................................................................................................................................................................
Troubleshooting252................................................................................................................................................................
Front Constant Velocity Joints, Differential Gear And Drive Shaft255................................................................................................................................................................
Disassembling The Universal Joint260................................................................................................................................................................
Checking The Constant Velocity Joints261................................................................................................................................................................
Checking The Gear Motor262................................................................................................................................................................
Assembling The Differential Gear263................................................................................................................................................................
Assembling The Universal Joint265................................................................................................................................................................
Checking The Differential Gear Operation267................................................................................................................................................................
And Drive Shaft269................................................................................................................................................................
Assembling The Rear Constant Velocity Joints275................................................................................................................................................................
Removing The Final Drive Roller Bearings276................................................................................................................................................................
Installing The Final Drive Roller Bearings277................................................................................................................................................................
Checking The Drive Shaft282................................................................................................................................................................
Measuring And Adjusting The Final Gear Lash283................................................................................................................................................................
Assembling The Final Gear Case284................................................................................................................................................................
Seats, Enclosure, Hood And Cargo Bed287................................................................................................................................................................
Seats, Console And Instrument Panels288................................................................................................................................................................
Panels And Footrest Cover290................................................................................................................................................................
Cargo Bed292................................................................................................................................................................
Skid Plates294................................................................................................................................................................
Enclosure And Seat Belts295................................................................................................................................................................
Front Wheels And Brake Discs296................................................................................................................................................................
Checking The Front Wheel298................................................................................................................................................................
Checking The Front Brake Disc299................................................................................................................................................................
Rear Wheels And Brake Disc300................................................................................................................................................................
Rear Brake Disc301................................................................................................................................................................
Checking The Rear Wheel302................................................................................................................................................................
Installing The Rear Wheel Hub303................................................................................................................................................................
Front And Rear Brakes304................................................................................................................................................................
Rear Brake Pads305................................................................................................................................................................
Replacing The Front Brake Pads306................................................................................................................................................................
Replacing The Rear Brake Pads307................................................................................................................................................................
Brake Master Cylinder310................................................................................................................................................................
Checking The Master Cylinder312................................................................................................................................................................
Installing The Brake Master Cylinder313................................................................................................................................................................
Front Brake Caliper315................................................................................................................................................................
Rear Brake Caliper317................................................................................................................................................................
Disassembling The Front Brake Calipers321................................................................................................................................................................
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................................................................................................................................................................
Disassembling The Steering Assembly334................................................................................................................................................................
Assembling The Steering Assembly335................................................................................................................................................................
Installing The Steering System336................................................................................................................................................................
Tie-rod And Steering Knuckle337................................................................................................................................................................
Removing The Steering Knuckles338................................................................................................................................................................
Front Arms And Front Shock Absorber342................................................................................................................................................................
Removing The Front Arms344................................................................................................................................................................
Checking The Front Shock Absorber346................................................................................................................................................................
Installing The Front Arms And Front Shock Absorber347................................................................................................................................................................
Rear Knuckle And Stabilizer348................................................................................................................................................................
Checking The Rear Knuckle349................................................................................................................................................................
Rear Arms And Rear Shock Absorber350................................................................................................................................................................
Checking The Rear Arms351................................................................................................................................................................
Installing The Rear Arms And Rear Shock Absorber352................................................................................................................................................................
Electrical Components353................................................................................................................................................................
Checking The Switch355................................................................................................................................................................
Checking The Switch Continuity356................................................................................................................................................................
Checking The Bulbs And Bulb Sockets358................................................................................................................................................................
Checking The Condition Of The Bulb Sockets360................................................................................................................................................................
Ignition System361................................................................................................................................................................
Electric Starting System367................................................................................................................................................................
Starting Circuit Operation368................................................................................................................................................................
Starter Motor372................................................................................................................................................................
Checking The Starter Motor373................................................................................................................................................................
Assembling The Starter Motor374................................................................................................................................................................
Charging System375................................................................................................................................................................
Lighting System378................................................................................................................................................................
Checking The Lighting System381................................................................................................................................................................
Signaling System384................................................................................................................................................................
Checking The Signal System388................................................................................................................................................................
Cooling System398................................................................................................................................................................
Wd/4wd Selecting System403................................................................................................................................................................
Carburetor Heating System408................................................................................................................................................................
Starting Failure/hard Starting412................................................................................................................................................................
Compression System413................................................................................................................................................................
Faulty Drive Train414................................................................................................................................................................
Faulty Gear Shifting415................................................................................................................................................................
Poor Speed Performance416................................................................................................................................................................
Unstable Handling417................................................................................................................................................................

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