2004-2008 Yamaha Rhino 660 YXR660 Service Manual Download + Owners Manual 04-08 YXR 660 ATV Workshop Shop Repair Manual

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LANGUAGE:ENGLISH
PAGES:600+
DOWNLOADABLE:YES
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2004-2008 YAMAHA RHINO 660 YXR660 SERVICE MANUAL DOWNLOAD + OWNERS MANUAL 04-08 YXR 660 ATV WORKSHOP SHOP REPAIR MANUAL:

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DESCRIPTION:

2004-2008 Yamaha Rhino 660 YXR660 Service Manual Download and Owners Manual 04-08 YXR 660 ATV Workshop Shop Repair Manual

• This Supplementary Service Manual has been prepared to introduce new service and data for the YXR66FW/YXR66FSPW. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.
• 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 significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

INTRODUCTION:

Yamaha YXR660FA. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing vehicles. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this vehicle. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your vehicle, please consult a Yamaha dealer.

TABLE OF CONTENTS:

2004-2008 Yamaha Rhino 660 YXR660 Service Manual Download and Owners Manual 04-08 YXR 660 ATV Workshop Shop Repair Manual

YXR66FW YXR66FSPW Supplementary Service Manual...............................  1
	Contents
................................................................  7
	How to use this Manual...................................................  5
	SPECIFICATIONS...........................................................  8
		GENERAL SPECIFICATIONS...............................................  8
		CHASSIS SPECIFICATIONS...............................................  9
		ELECTRICAL SPECIFICATIONS............................................ 10
		TIGHTENING TORQUES................................................... 10
		CABLE ROUTING........................................................ 11
	PERIODIC CHECKS AND ADJUSTMENTS..........................................  7
		CHASSIS.............................................................. 23
		ELECTRICAL........................................................... 28
	FUEL SYSTEM..............................................................  7
		FUEL PUMP AND FUEL TANK.............................................. 30
	CHASSIS..................................................................  7
		SEATS, ENCLOSURE, HOOD AND CARGO BED................................. 32
		FRONT AND REAR BRAKES................................................ 34
	ELECTRICAL...............................................................  7
		ELECTRICAL COMPONENTS................................................ 35
		SIGNALING SYSTEM..................................................... 38
	YXR66FW/YXR66FSPW 2007 WIRING DIAGRAM.................................... 45
YXR660FAV Supplementary Service Manual....................................... 46
	How to use this Manual................................................... 49
	Contents................................................................. 51
	Specifications........................................................... 52
		General Specifications............................................... 52
		Chassis Specifications............................................... 53
		Electrical Specifications............................................ 54
		Tightening Torques................................................... 54
		Cable Routing........................................................ 55
	Periodic Checks and Adjustments.......................................... 72
		Electrical........................................................... 72
	Engine................................................................... 74
		Engine Cooling Fan and AC Magneto.................................... 74
	Cooling System........................................................... 77
		Oil Cooler........................................................... 77
	Chassis.................................................................. 79
		Seats, Enclosures, Hood and Cargo Bed................................ 79
		Front Wheels and Brake Discs......................................... 86
		Rear Wheels and Brake Disc........................................... 88
		Front Arms and Front Shock Absorbers................................. 89
		Rear Knuckle and Stabilizer.......................................... 91
	Electrical............................................................... 92
		Electrical Components................................................ 92
		Lighting System...................................................... 94
		Signaling System..................................................... 97
	Wiring Diagram...........................................................101
YXR660FAT Supplementary Service Manual.......................................104
	How to use this Manual...................................................107
	Contents.................................................................109
	Specifications...........................................................110
		General Specifications...............................................110
		Engine Specifications................................................111
		Chassis Specifications...............................................111
		Electrical Specifications............................................111
		Tightening Torques...................................................112
		Cable Routing........................................................113
	Periodic Checks and Adjustments..........................................129
		Introduction.........................................................129
		Periodic Maintenance/Lubrication.....................................129
		Engine...............................................................131
		Chassis..............................................................134
	Engine...................................................................135
		Engine Removal.......................................................135
	Fuel System..............................................................137
		Carburetor...........................................................137
	Chassis..................................................................140
		Seats, Enclosure, Hood and Cargo Bed.................................140
	Wiring Diagram...........................................................145
YXR660FAS Service Manual.....................................................146
	How to use this Manual...................................................149
	Table of Contents........................................................151
	Chapter 1 General Information............................................162
		Vehicle Identification...............................................162
		Features.............................................................163
		Important Information................................................166
		Checking of Connections..............................................168
		Special Tools........................................................169
	Chapter 2 Specifications.................................................174
		General Specifications...............................................174
		Engine Specifications................................................177
		Chassis Specifications...............................................185
		Electrical Specifications............................................187
		Tightening Torques...................................................189
		How to Use the Conversion Chart......................................195
		General Tightening Torque Specifications.............................195
		Lubrication Points and Lubricant Types...............................196
		Coolant Flow Diagrams................................................197
		Oil Flow Diagrams....................................................200
		Cable Routing........................................................205
	Chapter 3 Periodic Checks and Adjustments................................222
		Introduction.........................................................222
		Peirodic Maintenance/Lubrication.....................................222
		Engine...............................................................224
		Chassis..............................................................247
		Electrical...........................................................265
	Chapter 4 Engine.........................................................275
		Engine Removal.......................................................275
		Cylinder Head Cover..................................................283
		Rocker Arms..........................................................287
		Camshaft and Cylinder Head...........................................291
		Valves and Valve Springs.............................................299
		Cylinder and Piston..................................................307
		Engine Cooling Fan and A.C. Magneto..................................314
		Balancer Gears and Oil Pump Gears....................................322
		Primary and Secondary Sheaves........................................326
		Clutch...............................................................335
		Crankcase............................................................340
		Crankshaft and Oil Pump..............................................347
		Transmission.........................................................353
		Middle Gear..........................................................359
	Chapter 5 Cooling System.................................................373
		Radiator and Coolant Reservoir.......................................373
		Water Pump...........................................................377
		Oil Cooler...........................................................382
	Chapter 6 Fuel System....................................................385
		Fuel Pump and Fuel Tank..............................................385
		Carburetor...........................................................388
	Chapter 7 Drive Train....................................................396
		Troubleshooting......................................................396
		Front Constant Velocity Joints, Differential Gear and Drive Shaft....399
		Rear Constant Velocity Joints, Final Drive Gear and Drive Shaft......413
	Chapter 8 Chassis........................................................431
		Seats, Enclosure, Hood and Cargo Bed.................................431
		Front Wheels and Brake Discs ........................................440
		Rear Wheels and Brake Disc...........................................444
		Front and Rear Brakes................................................448
		Pedal Assembly.......................................................473
		Steering System......................................................475
		Front Arms and Front Shock Absorber..................................486
		Rear Knuckle and Stabilizer..........................................492
		Rear Arms and Rear Shock Absorber....................................494
	Chapter 9 Electrical.....................................................497
		Electrical Components................................................497
		Checking the Switch..................................................499
		Checking the Bulbs and Bulb Sockets..................................502
		Ignition System......................................................505
		Electrical Starting System...........................................511
		Charging System......................................................519
		Lighting System......................................................522
		Signaling System.....................................................527
		Cooling System.......................................................541
		2WD/4WD Selecting System.............................................546
		Carburetor Heating System............................................551
	Chapter 10 Troubleshooting...............................................555
		Starting Failure/Hard Starting.......................................555
		Poor Idle Speed Performance..........................................556
		Poor Medium and High-Speed Performance...............................556
		Faulty Drive Train...................................................557
		Faulty Gear Shifting.................................................558
		Faulty Clutch Performance............................................558
		Overheating..........................................................559
		Faulty Brake.........................................................559
		Shock Absorber Malfunction...........................................559
		Unstable Handling....................................................560
		Lighting System......................................................560
	YXR660FAS Wiring Diagram.................................................561

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]