Yamaha 2004 YXR660 Service Manual Manual pdf 289 page image
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Yamaha 2004 YXR660 Service Manual

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Contents
  1. SPECIFICATIONS
  2. Table Of Contents
  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. VEHICLE IDENTIFICATION
  14. FEATURES
  15. IMPORTANT INFORMATION
  16. LOCK WASHERS/PLATES AND COTTER PINS
  17. CHECKING OF CONNECTIONS
  18. SPECIAL TOOLS
  19. GENERAL SPECIFICATIONS
  20. ENGINE SPECIFICATIONS
  21. CHASSIS SPECIFICATIONS
  22. ELECTRICAL SPECIFICATIONS
  23. TIGHTENING TORQUES
  24. CHASSIS TIGHTENING TORQUES
  25. HOW TO USE THE CONVERSION TABLE
  26. LUBRICATION POINTS AND LUBRICANT TYPES
  27. COOLANT FLOW DIAGRAMS
  28. OIL FLOW DIAGRAMS
  29. CABLE ROUTING
  30. PERIODIC CHECKS AND
  31. ENGINE
  32. ADJUSTING THE TIMING CHAIN
  33. ADJUSTING THE THROTTLE CABLE
  34. ADJUSTING THE STARTER CABLE
  35. CHECKING THE SPARK PLUG
  36. CHECKING THE IGNITION TIMING
  37. MEASURING THE COMPRESSION PRESSURE
  38. CHECKING THE ENGINE OIL LEVEL
  39. CHANGING THE ENGINE OIL
  40. CLEANING THE AIR FILTER
  41. CHECKING THE COOLANT LEVEL
  42. CHANGING THE COOLANT
  43. COOLING SYSTEM
  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 THE FUSES
  63. ADJUSTING THE HEADLIGHT BEAM
  64. CHANGING THE TAIL/BRAKE LIGHT BULB
  65. ENGINE REMOVAL
  66. SELECT LEVER UNIT AND COOLANT RESERVOIR
  67. HOSES AND LEADS
  68. ENGINE MOUNTING BOLTS
  69. INSTALLING THE ENGINE
  70. CYLINDER HEAD COVER
  71. REMOVING THE CYLINDER HEAD COVER
  72. INSTALLING THE CYLINDER HEAD COVER
  73. ROCKER ARMS
  74. REMOVING THE ROCKER ARMS
  75. INSTALLING THE ROCKER ARMS
  76. CAMSHAFT AND CYLINDER HEAD
  77. REMOVING THE CAMSHAFT AND CYLINDER HEAD
  78. CHECKING THE CAMSHAFT SPROCKET
  79. CHECKING THE CYLINDER HEAD
  80. INSTALLING THE CAMSHAFT AND CYLINDER HEAD
  81. VALVES AND VALVE SPRINGS
  82. REMOVING THE VALVES AND VALVE SPRINGS
  83. CHECKING THE VALVES AND VALVE SPRINGS
  84. INSTALLING THE VALVES AND VALVE SPRINGS
  85. CYLINDER AND PISTON
  86. REMOVING THE PISTON
  87. CHECKING THE PISTON RINGS
  88. CHECKING THE PISTON PIN
  89. INSTALLING THE CYLINDER
  90. ENGINE COOLING FAN AND A.C. MAGNETO
  91. REMOVING THE A.C. MAGNETO
  92. CHECKING THE STARTER CLUTCH
  93. CHECKING THE ENGINE COOLING FAN
  94. BALANCER GEARS AND OIL PUMP GEARS
  95. REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR
  96. INSTALLING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR
  97. PRIMARY AND SECONDARY SHEAVES
  98. PRIMARY SHEAVE
  99. SECONDARY SHEAVE
  100. REMOVING THE PRIMARY AND SECONDARY SHEAVES
  101. CHECKING THE PRIMARY SHEAVE
  102. ASSEMBLING THE PRIMARY SHEAVE
  103. INSTALLING THE PRIMARY AND SECONDARY SHEAVES
  104. CLUTCH
  105. REMOVING THE CLUTCH
  106. INSTALLING THE CLUTCH
  107. 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
  117. CHECKING THE CRANKSHAFT
  118. INSTALLING THE CRANKSHAFT AND BALANCER
  119. TRANSMISSION
  120. DRIVE AXLE ASSEMBLY
  121. REMOVING THE TRANSMISSION
  122. CHECKING THE SHIFT DRUM
  123. CHECKING THE SECONDARY SHAFT AND DRIVEN SPROCKET
  124. ASSEMBLING THE SHIFT FORK ASSEMBLY
  125. MIDDLE GEAR
  126. MIDDLE DRIVEN SHAFT
  127. REMOVING THE MIDDLE DRIVE SHAFT
  128. CHECKING THE PINION GEARS
  129. SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS
  130. INSTALLING THE MIDDLE DRIVEN SHAFT
  131. INSTALLING THE MIDDLE DRIVE SHAFT
  132. MEASURING THE MIDDLE GEAR BACKLASH
  133. RADIATOR AND COOLANT RESERVOIR
  134. CHECKING THE RADIATOR
  135. INSTALLING THE RADIATOR
  136. WATER PUMP
  137. DISASSEMBLING THE WATER PUMP
  138. ASSEMBLING THE WATER PUMP
  139. OIL COOLER
  140. CHECKING THE OIL COOLER
  141. FUEL SYSTEM
  142. CHECKING THE FUEL PUMP OPERATION
  143. CARBURETOR
  144. DISASSEMBLING THE CARBURETOR
  145. ASSEMBLING THE CARBURETOR
  146. ADJUSTING THE FUEL LEVEL
  147. DRIVE TRAIN
  148. FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT
  149. DISASSEMBLING THE UNIVERSAL JOINT
  150. CHECKING THE CONSTANT VELOCITY JOINTS
  151. CHECKING THE GEAR MOTOR
  152. ASSEMBLING THE DIFFERENTIAL GEAR
  153. ASSEMBLING THE UNIVERSAL JOINT
  154. CHECKING THE DIFFERENTIAL GEAR OPERATION
  155. AND DRIVE SHAFT
  156. ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS
  157. REMOVING THE FINAL DRIVE ROLLER BEARINGS
  158. INSTALLING THE FINAL DRIVE ROLLER BEARINGS
  159. CHECKING THE DRIVE SHAFT
  160. MEASURING AND ADJUSTING THE FINAL GEAR LASH
  161. ASSEMBLING THE FINAL GEAR CASE
  163. SEATS, CONSOLE AND INSTRUMENT PANELS
  164. PANELS AND FOOTREST COVER
  165. CARGO BED
  166. SKID PLATES
  167. ENCLOSURE AND SEAT BELTS
  168. FRONT WHEELS AND BRAKE DISCS
  169. CHECKING THE FRONT WHEEL
  170. CHECKING THE FRONT BRAKE DISC
  171. REAR WHEELS AND BRAKE DISC
  172. REAR BRAKE DISC
  173. CHECKING THE REAR WHEEL
  174. INSTALLING THE REAR WHEEL HUB
  175. FRONT AND REAR BRAKES
  176. REAR BRAKE PADS
  177. REPLACING THE FRONT BRAKE PADS
  178. REPLACING THE REAR BRAKE PADS
  179. BRAKE MASTER CYLINDER
  180. CHECKING THE MASTER CYLINDER
  181. INSTALLING THE BRAKE MASTER CYLINDER
  182. FRONT BRAKE CALIPER
  183. REAR BRAKE CALIPER
  184. DISASSEMBLING THE FRONT BRAKE CALIPERS
  185. CHECKING THE FRONT AND REAR BRAKE CALIPERS
  186. ASSEMBLING THE FRONT BRAKE CALIPERS
  187. ASSEMBLING THE REAR BRAKE CALIPER
  188. INSTALLING THE FRONT BRAKE CALIPERS
  189. INSTALLING THE REAR BRAKE CALIPER
  190. PEDAL ASSEMBLY
  191. STEERING SYSTEM
  192. DISASSEMBLING THE STEERING ASSEMBLY
  193. ASSEMBLING THE STEERING ASSEMBLY
  194. INSTALLING THE STEERING SYSTEM
  195. TIE-ROD AND STEERING KNUCKLE
  196. REMOVING THE STEERING KNUCKLES
  197. FRONT ARMS AND FRONT SHOCK ABSORBER
  198. REMOVING THE FRONT ARMS
  199. CHECKING THE FRONT SHOCK ABSORBER
  200. INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER
  201. REAR KNUCKLE AND STABILIZER
  202. CHECKING THE REAR KNUCKLE
  203. REAR ARMS AND REAR SHOCK ABSORBER
  204. CHECKING THE REAR ARMS
  205. INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER
  207. CHECKING THE SWITCH
  208. CHECKING THE SWITCH CONTINUITY
  209. CHECKING THE BULBS AND BULB SOCKETS
  210. CHECKING THE CONDITION OF THE BULB SOCKETS
  211. IGNITION SYSTEM
  212. TROUBLESHOOTING
  213. ELECTRIC STARTING SYSTEM
  214. STARTING CIRCUIT OPERATION
  216. STARTER MOTOR
  217. CHECKING THE STARTER MOTOR
  218. ASSEMBLING THE STARTER MOTOR
  219. CHARGING SYSTEM
  221. LIGHTING SYSTEM
  223. CHECKING THE LIGHTING SYSTEM
  224. SIGNALING SYSTEM
  225. CIRCUIT DIAGRAM
  232. STARTING FAILURE/HARD STARTING
  233. COMPRESSION SYSTEM
  234. FAULTY DRIVE TRAIN
  235. FAULTY GEAR SHIFTING
  236. POOR SPEED PERFORMANCE
  237. UNSTABLE HANDLING
  238. periodic checks and adjustments
  239. CHECKING THE SIGNAL SYSTEM
Yamaha 2004 YXR660 Service Manual Manual pdf 289 page image
8 - 7CHAS5542143673 (9)(12)(12)(9)TR..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R. .11 Nm (1.1 m • kg, 8.0 ft • Ib)T R..26 Nm (2.6 m • kg, 19 ft • Ib)Order Job/Part Q’ty RemarksDisassembling the cargo bed Remove the parts in the order listed.1 Hinge cover 22 Tailgate 13 Cargo bed panel 24 Tail/brake light bulb holder 25 Mud guard 26 Cargo bed release lever 17 Cargo bed 1For assembly, reverse the disassemblyprocedure.SEATS, ENCLOSURE, HOOD AND CARGO BEDwww.midwestmanuals.com
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This manual is suitable for:
2004 YXR660Rhino 2004Rhino 2005Rhino 2006Rhino 2007YXR660FAS
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