2004-2007 Yamaha Rhino (YXR660FAS) Service & Repair Manual

LIT-11616-17-23 5UG-F8197-10 YXR660FAS SERVICE MANUAL

EBS00001 YXR660FAS SERVICE MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. First Edition, July 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-17-23

EBS00002 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 vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle 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. NOTE: _ Designs and specifications are subject to change without notice. EBS00003 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 vehicle operator, passenger, a bystander, or a person checking or repairing the vehicle. A CAUTION indicates special precautions that must be taken to avoid dam- age to the vehicle. A NOTE provides key information to make procedures easier or clearer. WARNING CAUTION: NOTE:

EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “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 4 is provided for removal and disassembly jobs. 2. Numbers 5 are 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 7 accompanies 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 8 are given in addition to the exploded diagram and the job instruction chart.

EBS00006 SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 0 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Fuel system 7 Drive train 8 Chassis 9 Electrical 0 Troubleshooting Symbols A to H indicate the following. A Can be serviced with engine mounted B Filling fluid C Lubricant D Special tool E Torque F Wear limit, clearance G Engine speed H Electrical data (Ω, V, A) Symbols I to N in the exploded diagrams indicate the types of lubricants and lubrication points. I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply lithium-soap-based grease N Apply molybdenum disulfide grease Symbols O to P in the exploded diagrams indicate where to apply a locking agent O and when to install a new part P. O Apply the locking agent (LOCTITE ® ) P Replace 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P GEN INFO SPEC CHK ADJ ENG COOL FUEL DRIV CHAS – + ELEC TRBL SHTG T R . . E G M B LS M LT New

EBS00008 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 FUEL SYSTEM FUEL 6 DRIVE TRAIN DRIV 7 CHASSIS CHAS 8 ELECTRICAL ELEC 9 TROUBLESHOOTING TRBL SHTG 10 – +

CONTENTS CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION............................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1 MODEL LABEL.......................................................................................... 1-1 FEATURES ...................................................................................................... 1-2 SELF-ADJUSTING PARKING BRAKE MECHANISM............................... 1-2 IMPORTANT INFORMATION ......................................................................... 1-5 PREPARATION FOR REMOVAL PROCEDURES ................................... 1-5 REPLACEMENT PARTS........................................................................... 1-5 GASKETS, OIL SEALS AND O-RINGS .................................................... 1-5 LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-6 BEARINGS AND OIL SEALS .................................................................... 1-6 CIRCLIPS .................................................................................................. 1-6 CHECKING OF CONNECTIONS .................................................................... 1-7 SPECIAL TOOLS ............................................................................................ 1-8 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ........................................................................ 2-1 ENGINE SPECIFICATIONS ............................................................................ 2-4 CHASSIS SPECIFICATIONS ........................................................................ 2-12 ELECTRICAL SPECIFICATIONS ................................................................. 2-14 TIGHTENING TORQUES .............................................................................. 2-16 ENGINE TIGHTENING TORQUES ......................................................... 2-16 CHASSIS TIGHTENING TORQUES ....................................................... 2-19 HOW TO USE THE CONVERSION TABLE.................................................. 2-22 GENERAL TIGHTENING TORQUE SPECIFICATIONS ............................... 2-22

LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-23 ENGINE ................................................................................................... 2-23 COOLANT FLOW DIAGRAMS ..................................................................... 2-24 OIL FLOW DIAGRAMS ................................................................................. 2-27 CABLE ROUTING ......................................................................................... 2-32 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION.............................................................................................. 3-1 PERIODIC MAINTENANCE/LUBRICATION .................................................. 3-1 ENGINE ........................................................................................................... 3-3 ADJUSTING THE VALVE CLEARANCE .................................................. 3-3 ADJUSTING THE TIMING CHAIN ............................................................ 3-6 ADJUSTING THE IDLING SPEED ............................................................ 3-6 ADJUSTING THE THROTTLE CABLE ..................................................... 3-7 ADJUSTING THE STARTER CABLE ....................................................... 3-8 CHECKING THE SPARK PLUG ............................................................... 3-9 CHECKING THE IGNITION TIMING ....................................................... 3-10 MEASURING THE COMPRESSION PRESSURE .................................. 3-11 CHECKING THE ENGINE OIL LEVEL.................................................... 3-13 CHANGING THE ENGINE OIL ............................................................... 3-14 CLEANING THE AIR FILTER.................................................................. 3-16 CHECKING THE COOLANT LEVEL ....................................................... 3-18 CHANGING THE COOLANT................................................................... 3-19 CHECKING THE COOLANT TEMPERATURE WARNING LIGHT ......... 3-23 CHECKING THE V-BELT ........................................................................ 3-23 CLEANING THE SPARK ARRESTER .................................................... 3-25 CHASSIS ....................................................................................................... 3-26 ADJUSTING THE BRAKE PEDAL .......................................................... 3-26 ADJUSTING THE PARKING BRAKE...................................................... 3-27 CHECKING THE BRAKE FLUID LEVEL................................................. 3-28 CHECKING THE FRONT BRAKE PADS ................................................ 3-29 CHECKING THE REAR BRAKE PADS .................................................. 3-29 CHECKING THE BRAKE HOSES AND BRAKE PIPES ......................... 3-29 BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-30 ADJUSTING THE SELECT LEVER SHIFT ROD .................................... 3-32 ADJUSTING THE BRAKE LIGHT SWITCH ............................................ 3-32 CHECKING THE FINAL GEAR OIL LEVEL ............................................ 3-33 CHANGING THE FINAL GEAR OIL ........................................................ 3-34 CHECKING THE DIFFERENTIAL GEAR OIL ......................................... 3-34

CHANGING THE DIFFERENTIAL GEAR OIL ........................................ 3-35 CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS .......... 3-36 CHECKING THE STEERING SYSTEM .................................................. 3-37 ADJUSTING THE TOE-IN ....................................................................... 3-37 ADJUSTING THE FRONT SHOCK ABSORBERS ................................. 3-39 ADJUSTING THE REAR SHOCK ABSORBERS .................................... 3-39 CHECKING THE TIRES .......................................................................... 3-40 CHECKING THE WHEELS ..................................................................... 3-42 CHECKING AND LUBRICATING THE CABLES .................................... 3-42 LUBRICATING THE PEDAL, ETC. ......................................................... 3-43 ELECTRICAL ................................................................................................ 3-44 CHECKING AND CHARGING THE BATTERY ....................................... 3-44 CHECKING THE FUSES ........................................................................ 3-49 ADJUSTING THE HEADLIGHT BEAM ................................................... 3-51 CHANGING THE HEADLIGHT BULB ..................................................... 3-51 CHANGING THE TAIL/BRAKE LIGHT BULB ......................................... 3-52 CHAPTER 4 ENGINE ENGINE REMOVAL ........................................................................................ 4-1 AIR DUCTS, MUFFLER AND EXHAUST PIPE ........................................ 4-1 SELECT LEVER UNIT AND COOLANT RESERVOIR ............................. 4-3 HOSES AND LEADS................................................................................. 4-4 ENGINE MOUNTING BOLTS ................................................................... 4-6 INSTALLING THE ENGINE....................................................................... 4-8 CYLINDER HEAD COVER .............................................................................. 4-9 REMOVING THE CYLINDER HEAD COVER ......................................... 4-11 CHECKING THE CYLINDER HEAD COVER ......................................... 4-11 CHECKING THE TAPPET COVERS ...................................................... 4-11 INSTALLING THE CYLINDER HEAD COVER ....................................... 4-12 ROCKER ARMS ............................................................................................ 4-13 REMOVING THE ROCKER ARMS ......................................................... 4-15 CHECKING THE ROCKER ARMS.......................................................... 4-15 INSTALLING THE ROCKER ARMS........................................................ 4-16 CAMSHAFT AND CYLINDER HEAD............................................................ 4-17 REMOVING THE CAMSHAFT AND CYLINDER HEAD ......................... 4-19 CHECKING THE CAMSHAFT................................................................. 4-19 CHECKING THE CAMSHAFT SPROCKET ............................................ 4-20 CHECKING THE DECOMPRESSION SYSTEM..................................... 4-20 CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) ................. 4-20 CHECKING THE TIMING CHAIN TENSIONER...................................... 4-20 CHECKING THE CYLINDER HEAD ....................................................... 4-21 INSTALLING THE CAMSHAFT AND CYLINDER HEAD ........................ 4-22

VALVES AND VALVE SPRINGS .................................................................. 4-25 REMOVING THE VALVES AND VALVE SPRINGS ............................... 4-26 CHECKING THE VALVES AND VALVE SPRINGS ................................ 4-27 INSTALLING THE VALVES AND VALVE SPRINGS .............................. 4-31 CYLINDER AND PISTON.............................................................................. 4-33 REMOVING THE PISTON ...................................................................... 4-34 CHECKING THE CYLINDER AND PISTON ........................................... 4-34 CHECKING THE PISTON RINGS........................................................... 4-36 CHECKING THE PISTON PIN ................................................................ 4-37 INSTALLING THE PISTON ..................................................................... 4-37 INSTALLING THE CYLINDER ................................................................ 4-39 ENGINE COOLING FAN AND A.C. MAGNETO ........................................... 4-40 REMOVING THE A.C. MAGNETO.......................................................... 4-43 CHECKING THE A.C. MAGNETO .......................................................... 4-43 CHECKING THE STARTER CLUTCH .................................................... 4-44 CHECKING THE ENGINE COOLING FAN ............................................. 4-45 INSTALLING THE A.C. MAGNETO ........................................................ 4-45 BALANCER GEARS AND OIL PUMP GEARS ............................................ 4-48 REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR ........................................................... 4-50 CHECKING THE OIL PUMP DRIVE GEAR AND OIL PUMP DRIVEN GEAR ............................................................. 4-50 CHECKING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR ........................................................... 4-50 INSTALLING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR ........................................................... 4-51 PRIMARY AND SECONDARY SHEAVES.................................................... 4-52 PRIMARY SHEAVE................................................................................. 4-54 SECONDARY SHEAVE .......................................................................... 4-55 REMOVING THE PRIMARY AND SECONDARY SHEAVES ................. 4-56 DISASSEMBLING THE SECONDARY SHEAVE.................................... 4-56 CHECKING THE PRIMARY SHEAVE .................................................... 4-57 CHECKING THE SECONDARY SHEAVE .............................................. 4-57 ASSEMBLING THE PRIMARY SHEAVE ................................................ 4-58 ASSEMBLING THE SECONDARY SHEAVE.......................................... 4-58 INSTALLING THE PRIMARY AND SECONDARY SHEAVES................ 4-60 CLUTCH ........................................................................................................ 4-61 REMOVING THE CLUTCH ..................................................................... 4-63 CHECKING THE CLUTCH ...................................................................... 4-63 INSTALLING THE CLUTCH .................................................................... 4-64

2004-2007 Yamaha Rhino (YXR660FAS) Service & Repair Manual

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