Rhino 660 repair manual free download

The tires listed below have been approved by Yamaha Motor Manufacturing corporation of America. Recommended lubricant Yamaha chain and cable lube or engine oil NOTE: Hold the cable end up and apply several drops of lubricant to the cable. Lubricate the pivoting parts. Recommended lubricant Lithium-soap-based grease 3 - Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.

Connect a charger and ammeter to the battery and start charging. Turn off the ignition. Install a new fuse of the proper amperage. Turn on switches to verify operation of the related electrical devices.

Turning in Headlight beam raised. Turning out Headlight beam lowered. Close the hood. Water pump inlet hose Disconnect. Coolant outlet hose Disconnect. Oil inlet hose Disconnect. For installation, reverse the removal pro- cedure. Dowel pin For installation, reverse the removal pro- cedure. Turn the crankshaft counterclockwise with a wrench. ACC Yamaha bond No.

Measure the outside diameter b of the rocker arm shafts. Rocker arm shaft outside diame- Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Removing the screwdriver and slowly release the timing chain tensioner rod. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough move- ment, replace the timing chain tensioner.

NOTE: To ensure an even surface rotate the cylinder head several times. Temporarily install the camshaft sprocket on the camshaft. Do not install the bolts. Then, install the timing chain on the cam- shaft sprocket. NOTE: Make sure the small holes 3 on the camshaft face upward.

With the screwdriver still inserted into the timing chain tensioner, install the timing chain tensioner and gasket onto the cylin- der block. Then, tighten the timing chain tensioner bolts to the specified torque. Stem-to-guide clearance Intake 0.

Margin thickness Intake 0. Valve seat width Intake 0. Install the valve into the cylinder head. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound. NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.

NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance Standard Limit Measure the piston pin outside diameter a. If out of specification, replace the piston pin. MAG- A. Dowel pin Stator lead holder Pickup coil Page Removing The A. Straighten the lock washer tabs. Secondary sliding sheave O-ring Secondary fixed sheave Weight outside diameter 30 mm 1.

One-way clutch bearing Clutch carrier assembly For installation, reverse the removal pro Remove them after all of them are loosened. If not, the one-way clutch assembly is faulty. Replace it.

Remove the crankcase bolts. Rotor cover Shaft Inner rotor Outer rotor Oil pump housing For assembly, reverse the disassembly procedure.

Crank width Pull out the guide bar from the right crank- case. Slide the shift fork assembly and remove the shift fork followers from the shift drum grooves. Remove the circlips 1. Place the universal joint in a press. With a suitable diameter pipe 2 beneath the yoke 3, press the bearing 4 into the pipe as shown. Clean the outside of the bearing housing assembly. Place the bearing housing assembly onto a hydraulic press.

To loosen the retainer, turn it clockwise. Press each bearing into the universal joint using a suitable socket. NOTE: The bearing must be inserted far enough into the universal joint so that the circlip can be installed. Install the circlips 2 into the groove of each bearing. Temporary install the left crankcase. Wrap a rag 1 around a screwdriver 2, and then insert it into the installation hole 3 of the right crankcase speed sensor to hold the middle driven gear.

Apply compressed air to the rear of the radi- ator. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver.

Coolant outlet joint breather hose Water pump inlet hose Water pump outlet hose Apply compressed air to the rear of the oil cooler. Place a container under the end of the fuel hose 1.

Crankcase breather hose Disconnect. NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. Throttle stop screw Vacuum chamber cover Spring Pilot jet Starter jet Carburetor heater For assembly, reverse the disassembly procedure.

Insert the piston valve into the carburetor body, and check for free movement. Fuel level 4. Bearing damage. Improper gear lash. This must not be con- C. If a test ride following reassembly indicates this condition, stop riding immediately to minimize gear dam- age. Elevate and spin both wheels. Feel for wheel bearing damage. NO Torque to specification. Double off-set joint Circlip Ball bearing Apply molybdenum disulfide grease into the dust boots.

Molybdenum disulfide grease 40 g 1. Connect two C size batteries to the gear motor terminal 2 to operate the pinion gear 3. Operate the pinion gear until the paint mark 4 on the gear is aligned with the paint mark 5 on the gear motor case. Insert the double off-set joint into the differ- ential gear, and turn the gear back and forth. Otherwise, the ring gear will be dam- aged.

Select the suitable shims using the following chart. Too little gear Reduce right shim lash thickness. Measure the starting torque of the front wheel i. Bolt Final drive pinion gear shim Drive shaft coupling After all the bolts are loosened, remove them. Oil seal Bearing O-ring Ring gear bearing housing For assembly, reverse the disassembly procedure. Clean the outside surface of the final drive pinion gear. Final drive pinion gear shim 0.

In the example above, the calculated num- ber is 0. The chart instructs you to round off 8 to 10 at the hundredth place. Thus, the shim thickness is 0. Remove the final gear case assembly. Measure the thrust clearance. Do not reuse the oil seal. Secure the gear case in a vise or another supporting device. Place a folded rag 1. Secure the drive shaft coupling edge in the vise. Wheel runout limit Radial 2: 2.

If wheel runout is within the limits, replace the brake disc. Wheel runout limit Radial: 2. Connect a suitable hose 1 tightly to the brake caliper bleed screw 2. Brake pad wear limit 1. Install the brake pad holding bolts, the brake caliper, and the brake caliper mounting bolts.

Brake pad holding bolt 17 Nm 1. Brake fluid Drain. Brake pad holding bolt Brake pad Pad spring Caliper bracket Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body. Always clean up spilled brake fluid immediately. NOTE: The wear pattern on the rack and pinion gear teeth should be uniform. An uneven wear pat- tern may indicate improper adjustment or lack of lubrication.

NOTE: Do not tap or damage the top of the ball joint. Hold the body 3 in place while turning in the long bolt 4 to install the new ball joint B into the steering knuckle C. Install the new oil seals. If side play is noticeable, check the bush- ings. Apply lithium-soap base grease to the new ball joint A. Install a new rubber boot and new circlip. NOTE: Always use a new ball joint set. Install the front upper arm 1 and front lower arm 2.

Install the rear upper arm 1 and rear lower arm 2. If the continuity is faulty at any point, replace the switch. All manuals should have a table of contents. Some manuals may also include an index. A good manual will also have a general information section near the beginning that describes service rules, safety precautions, and any symbols and abbreviations used in the manual. In this section the manual will also describe specifications for the SxS; torque values; lubrication and seal points; cable and harness routing; and the emission control systems.

The manual may contain a schedule for routine maintenance in the general information section or this information might be contained in its own section.

After the general information section, the manual will be divided into sections or chapters for different areas or systems within the SxS. For example, the first section might cover general information on the frame and body.

Other sections will cover the engine, including the drive train and electrical system; the chassis, including the driving mechanism, suspension, and steering; and the frame and electrical system associated with it, such as the battery.

The manual may also contain a section with wiring diagrams. If the manual covers more than one variation of the model of SxS, the wiring diagrams for each variation should be included. Within each section or chapter for a system of the Yamaha Rhino SxS will be found detailed information on that system.

For example, some of the subsections in the chapter on the engine will be for the ignition system, the fuel system, the electric starter, the transmission, and the crankcase and crankshaft. Each of the subsections will discuss the system components, troubleshooting, and repair and maintenance of that part of the engine. In this way, it is simple for a person to drill down to find the information needed to maintain and repair their SxS. A well-written Yamaha Rhino SxS manual is an invaluable aid to anyone who wants to save money by doing the maintenance on their own SxS.

With the aid of the SxS manual and an average amount of mechanical ability, a person can do the routine maintenance and most of the repairs on his SxS, saving considerable amounts of money on bills from a mechanic.