Yamaha 2004 Rhino 660 YXR660FAS Service Manual Manual pdf 378 page image
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Yamaha 2004 Rhino 660 YXR660FAS Service Manual

Also see for 2004 Rhino 660 YXR660FAS: Owner's manual

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Contents
  1. SPECIFICATIONS
  2. PERIODIC CHECKS AND
  3. Table Of Contents
  4. Table Of Contents
  5. Table Of Contents
  6. Table Of Contents
  7. Table Of Contents
  8. Table Of Contents
  9. Table Of Contents
  10. Table Of Contents
  11. Table Of Contents
  12. Table Of Contents
  13. Table Of Contents
  14. VEHICLE IDENTIFICATION
  15. FEATURES
  16. IMPORTANT INFORMATION
  17. LOCK WASHERS/PLATES AND COTTER PINS
  18. CHECKING OF CONNECTIONS
  19. SPECIAL TOOLS
  20. GENERAL SPECIFICATIONS
  21. ENGINE SPECIFICATIONS
  22. CHASSIS SPECIFICATIONS
  23. ELECTRICAL SPECIFICATIONS
  24. TIGHTENING TORQUES
  25. CHASSIS TIGHTENING TORQUES
  26. HOW TO USE THE CONVERSION TABLE
  27. LUBRICATION POINTS AND LUBRICANT TYPES
  28. COOLANT FLOW DIAGRAMS
  29. OIL FLOW DIAGRAMS
  30. CABLE ROUTING
  31. INTRODUCTION
  32. ENGINE
  33. ADJUSTING THE TIMING CHAIN
  34. ADJUSTING THE THROTTLE CABLE
  35. ADJUSTING THE STARTER CABLE
  36. CHECKING THE SPARK PLUG
  37. CHECKING THE IGNITION TIMING
  38. MEASURING THE COMPRESSION PRESSURE
  39. CHECKING THE ENGINE OIL LEVEL
  40. CHANGING THE ENGINE OIL
  41. CLEANING THE AIR FILTER
  42. CHECKING THE COOLANT LEVEL
  43. CHANGING THE COOLANT
  44. CHECKING THE COOLANT TEMPERATURE WARNING LIGHT
  45. CLEANING THE SPARK ARRESTER
  46. CHASSIS
  47. ADJUSTING THE PARKING BRAKE
  48. CHECKING THE BRAKE FLUID LEVEL
  49. CHECKING THE FRONT BRAKE PADS
  50. BLEEDING THE HYDRAULIC BRAKE SYSTEM
  51. ADJUSTING THE SELECT LEVER SHIFT ROD
  52. CHECKING THE FINAL GEAR OIL LEVEL
  53. CHANGING THE FINAL GEAR OIL
  54. CHANGING THE DIFFERENTIAL GEAR OIL
  55. CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS
  56. CHECKING THE STEERING SYSTEM
  57. ADJUSTING THE FRONT SHOCK ABSORBERS
  58. CHECKING THE TIRES
  59. CHECKING THE WHEELS
  60. LUBRICATING THE PEDAL, ETC
  61. ELECTRICAL
  62. checking and charging the battery
  63. CHECKING THE FUSES
  64. ADJUSTING THE HEADLIGHT BEAM
  65. CHANGING THE TAIL/BRAKE LIGHT BULB
  66. ENGINE REMOVAL
  67. SELECT LEVER UNIT AND COOLANT RESERVOIR
  68. HOSES AND LEADS
  69. ENGINE MOUNTING BOLTS
  70. INSTALLING THE ENGINE
  71. CYLINDER HEAD COVER
  72. REMOVING THE CYLINDER HEAD COVER
  73. INSTALLING THE CYLINDER HEAD COVER
  74. ROCKER ARMS
  75. REMOVING THE ROCKER ARMS
  76. INSTALLING THE ROCKER ARMS
  77. CAMSHAFT AND CYLINDER HEAD
  78. REMOVING THE CAMSHAFT AND CYLINDER HEAD
  79. CHECKING THE CAMSHAFT SPROCKET
  80. CHECKING THE CYLINDER HEAD
  81. INSTALLING THE CAMSHAFT AND CYLINDER HEAD
  82. VALVES AND VALVE SPRINGS
  83. REMOVING THE VALVES AND VALVE SPRINGS
  84. CHECKING THE VALVES AND VALVE SPRINGS
  85. INSTALLING THE VALVES AND VALVE SPRINGS
  86. CYLINDER AND PISTON
  87. REMOVING THE PISTON
  88. CHECKING THE PISTON RINGS
  89. CHECKING THE PISTON PIN
  90. INSTALLING THE CYLINDER
  91. ENGINE COOLING FAN AND A.C. MAGNETO
  92. REMOVING THE A.C. MAGNETO
  93. CHECKING THE STARTER CLUTCH
  94. CHECKING THE ENGINE COOLING FAN
  95. BALANCER GEARS AND OIL PUMP GEARS
  96. REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR
  97. INSTALLING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR
  98. PRIMARY AND SECONDARY SHEAVES
  99. PRIMARY SHEAVE
  100. SECONDARY SHEAVE
  101. REMOVING THE PRIMARY AND SECONDARY SHEAVES
  102. CHECKING THE PRIMARY SHEAVE
  103. ASSEMBLING THE PRIMARY SHEAVE
  104. INSTALLING THE PRIMARY AND SECONDARY SHEAVES
  105. CLUTCH
  106. REMOVING THE CLUTCH
  107. INSTALLING THE CLUTCH
  108. CRANKCASE
  109. CRANKCASE BEARINGS
  110. SEPARATING THE CRANKCASE
  111. CHECKING THE RELIEF VALVE
  112. INSTALLING THE SHIFT LEVERS
  113. CRANKSHAFT AND OIL PUMP
  114. OIL PUMP
  115. REMOVING THE CRANKSHAFT
  116. CHECKING THE CRANKSHAFT
  117. INSTALLING THE CRANKSHAFT AND BALANCER
  118. TRANSMISSION
  119. DRIVE AXLE ASSEMBLY
  120. REMOVING THE TRANSMISSION
  121. CHECKING THE SHIFT DRUM
  122. CHECKING THE SECONDARY SHAFT AND DRIVEN SPROCKET
  123. ASSEMBLING THE SHIFT FORK ASSEMBLY
  124. MIDDLE GEAR
  125. MIDDLE DRIVEN SHAFT
  126. REMOVING THE MIDDLE DRIVE SHAFT
  127. CHECKING THE PINION GEARS
  128. SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS
  129. INSTALLING THE MIDDLE DRIVEN SHAFT
  130. INSTALLING THE MIDDLE DRIVE SHAFT
  131. MEASURING THE MIDDLE GEAR BACKLASH
  132. RADIATOR AND COOLANT RESERVOIR
  133. CHECKING THE RADIATOR
  134. INSTALLING THE RADIATOR
  135. WATER PUMP
  136. DISASSEMBLING THE WATER PUMP
  137. ASSEMBLING THE WATER PUMP
  138. OIL COOLER
  139. CHECKING THE OIL COOLER
  140. FUEL PUMP AND FUEL TANK
  141. CHECKING THE FUEL PUMP OPERATION
  142. CARBURETOR
  143. DISASSEMBLING THE CARBURETOR
  144. ASSEMBLING THE CARBURETOR
  145. ADJUSTING THE FUEL LEVEL
  146. TROUBLESHOOTING
  147. FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT
  148. DISASSEMBLING THE UNIVERSAL JOINT
  149. CHECKING THE CONSTANT VELOCITY JOINTS
  150. CHECKING THE GEAR MOTOR
  151. ASSEMBLING THE DIFFERENTIAL GEAR
  152. ASSEMBLING THE UNIVERSAL JOINT
  153. CHECKING THE DIFFERENTIAL GEAR OPERATION
  154. AND DRIVE SHAFT
  155. ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS
  156. REMOVING THE FINAL DRIVE ROLLER BEARINGS
  157. INSTALLING THE FINAL DRIVE ROLLER BEARINGS
  158. CHECKING THE DRIVE SHAFT
  159. MEASURING AND ADJUSTING THE FINAL GEAR LASH
  160. ASSEMBLING THE FINAL GEAR CASE
  161. SEATS, ENCLOSURE, HOOD AND CARGO BED
  162. SEATS, CONSOLE AND INSTRUMENT PANELS
  163. PANELS AND FOOTREST COVER
  164. CARGO BED
  165. SKID PLATES
  166. ENCLOSURE AND SEAT BELTS
  167. FRONT WHEELS AND BRAKE DISCS
  168. CHECKING THE FRONT WHEEL
  169. CHECKING THE FRONT BRAKE DISC
  170. REAR WHEELS AND BRAKE DISC
  171. REAR BRAKE DISC
  172. CHECKING THE REAR WHEEL
  173. INSTALLING THE REAR WHEEL HUB
  174. FRONT AND REAR BRAKES
  175. REAR BRAKE PADS
  176. REPLACING THE FRONT BRAKE PADS
  177. REPLACING THE REAR BRAKE PADS
  178. BRAKE MASTER CYLINDER
  179. CHECKING THE MASTER CYLINDER
  180. INSTALLING THE BRAKE MASTER CYLINDER
  181. FRONT BRAKE CALIPER
  182. REAR BRAKE CALIPER
  183. DISASSEMBLING THE FRONT BRAKE CALIPERS
  184. CHECKING THE FRONT AND REAR BRAKE CALIPERS
  185. ASSEMBLING THE FRONT BRAKE CALIPERS
  186. ASSEMBLING THE REAR BRAKE CALIPER
  187. INSTALLING THE FRONT BRAKE CALIPERS
  188. INSTALLING THE REAR BRAKE CALIPER
  189. PEDAL ASSEMBLY
  190. STEERING SYSTEM
  191. DISASSEMBLING THE STEERING ASSEMBLY
  192. ASSEMBLING THE STEERING ASSEMBLY
  193. INSTALLING THE STEERING SYSTEM
  194. TIE-ROD AND STEERING KNUCKLE
  195. REMOVING THE STEERING KNUCKLES
  196. FRONT ARMS AND FRONT SHOCK ABSORBER
  197. REMOVING THE FRONT ARMS
  198. CHECKING THE FRONT SHOCK ABSORBER
  199. INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER
  200. REAR KNUCKLE AND STABILIZER
  201. CHECKING THE REAR KNUCKLE
  202. REAR ARMS AND REAR SHOCK ABSORBER
  203. CHECKING THE REAR ARMS
  204. INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER
  205. ELECTRICAL COMPONENTS
  206. CHECKING THE SWITCH
  207. CHECKING THE SWITCH CONTINUITY
  208. CHECKING THE BULBS AND BULB SOCKETS
  209. CHECKING THE CONDITION OF THE BULB SOCKETS
  210. IGNITION SYSTEM
  211. ELECTRIC STARTING SYSTEM
  212. STARTING CIRCUIT OPERATION
  213. STARTER MOTOR
  214. CHECKING THE STARTER MOTOR
  215. ASSEMBLING THE STARTER MOTOR
  216. CHARGING SYSTEM
  217. LIGHTING SYSTEM
  218. CHECKING THE LIGHTING SYSTEM
  219. SIGNALING SYSTEM
  220. CHECKING THE SIGNAL SYSTEM
  221. COOLING SYSTEM
  222. WD/4WD SELECTING SYSTEM
  223. CARBURETOR HEATING SYSTEM
  224. STARTING FAILURE/HARD STARTING
  225. COMPRESSION SYSTEM
  226. FAULTY DRIVE TRAIN
  227. FAULTY GEAR SHIFTING
  228. POOR SPEED PERFORMANCE
  229. UNSTABLE HANDLING
/ 421
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This manual is suitable for:
2004 Rhino 660 YXR660FAS
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