2004 – 2007 Yamaha YXR660F Rhino Side X Side Service Manual


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SKU: LIT-11616-RH-68 Category:


This 2004 – 2007 Yamaha YXR66F Rhino Side X Side Service Manual provides repair and maintenance information for 2004 – 2007 Yamaha YXR66F Rhino Side X Sides.

This manual shows 2007 on cover, but contains two supplements and a base manual to fully cover 2004 2005 2006 2007.


2004 Yamaha YXR660FAS Rhino
2005 Yamaha YXR660FAT Rhino
2006 Yamaha YXR660FAV Rhino
2007 Yamaha YXR660FW Rhino
2007 Yamaha YXR660FSPW Rhino

Table of Contents

General Information
Periodic Checks And Adjustments
Cooling System
Fuel System
Drive Train

Index of Topics

Chapter 1 General Information
Vehicle Identification
Vehicle Identification Number
Model Label
Self-adjusting Parking Brake Mechanism
Important Information
Preparation For Removal Procedures
Replacement Parts
Gaskets, Oil Seals And O-rings
Lock Washers/plates And Cotter Pins
Bearings And Oil Seals
Checking Of Connections
Special Tools

Chapter 2 Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Tightening Torques
Engine Tightening Torques
Chassis Tightening Torques
How To Use The Conversion Table
General Tightening Torque Specifications
Lubrication Points And Lubricant Types
Coolant Flow Diagrams
Oil Flow Diagrams
Cable Routing

Chapter 3 Periodic Checks And Adjustments
Periodic Maintenance/lubrication
Adjusting The Valve Clearance
Adjusting The Timing Chain
Adjusting The Idling Speed
Adjusting The Throttle Cable
Adjusting The Starter Cable
Checking The Spark Plug
Checking The Ignition Timing
Measuring The Compression Pressure
Checking The Engine Oil Level
Changing The Engine Oil
Cleaning The Air Filter
Checking The Coolant Level
Changing The Coolant
Checking The Coolant Temperature Warning Light
Checking The V-belt
Cleaning The Spark Arrester
Adjusting The Brake Pedal
Adjusting The Parking Brake
Checking The Brake Fluid Level
Checking The Front Brake Pads
Checking The Rear Brake Pads
Checking The Brake Hoses And Brake Pipes
Bleeding The Hydraulic Brake System
Adjusting The Select Lever Shift Rod
Adjusting The Brake Light Switch
Checking The Final Gear Oil Level
Changing The Final Gear Oil
Checking The Differential Gear Oil
Changing The Differential Gear Oil
Checking The Constant Velocity Joint Dust Boots
Checking The Steering System
Adjusting The Toe-in
Adjusting The Front Shock Absorbers
Adjusting The Rear Shock Absorbers
Checking The Tires
Checking The Wheels
Checking And Lubricating The Cables
Lubricating The Pedal, Etc
Checking And Charging The Battery
Checking The Fuses
Adjusting The Headlight Beam
Changing The Headlight Bulb
Changing The Tail/brake Light Bulb

Chapter 4 Engine
Engine Removal
Air Ducts, Muffler And Exhaust Pipe
Select Lever Unit And Coolant Reservoir
Hoses And Leads
Engine Mounting Bolts
Installing The Engine
Cylinder Head Cover
Removing The Cylinder Head Cover
Checking The Cylinder Head Cover
Checking The Tappet Covers
Installing The Cylinder Head Cover
Rocker Arms
Removing The Rocker Arms
Checking The Rocker Arms
Installing The Rocker Arms
Camshaft And Cylinder Head
Removing The Camshaft And Cylinder Head
Checking The Camshaft
Checking The Camshaft Sprocket
Checking The Decompression System
Checking The Timing Chain Guide (exhaust Side)
Checking The Timing Chain Tensioner
Checking The Cylinder Head
Installing The Camshaft And Cylinder Head
Valves And Valve Springs
Removing The Valves And Valve Springs
Checking The Valves And Valve Springs
Installing The Valves And Valve Springs
Cylinder And Piston
Removing The Piston
Checking The Cylinder And Piston
Checking The Piston Rings
Checking The Piston Pin
Installing The Piston
Installing The Cylinder
Engine Cooling Fan And Ac Magneto
Removing The Ac Magneto
Checking The Ac Magneto
Checking The Starter Clutch
Checking The Engine Cooling Fan
Installing The Ac Magneto
Balancer Gears And Oil Pump Gears
Removing The Balancer Drive Gear
And Balancer Driven Gear
Checking The Oil Pump Drive Gear
And Oil Pump Driven Gear
Checking The Balancer Drive Gear
And Balancer Driven Gear
Installing The Balancer Drive Gear
And Balancer Driven Gear
Primary And Secondary Sheaves
Primary Sheave
Secondary Sheave
Removing The Primary And Secondary Sheaves
Disassembling The Secondary Sheave
Checking The Primary Sheave
Checking The Secondary Sheave
Assembling The Primary Sheave
Assembling The Secondary Sheave
Installing The Primary And Secondary Sheaves
Removing The Clutch
Checking The Clutch
Installing The Clutch
Starter Motor, Timing Chain And Oil Filter
Crankcase Bearings
Separating The Crankcase
Checking The Timing Chain And Guides
Checking The Oil Delivery Pipe
Checking The Relief Valve
Checking The Crankcase
Checking The Bearings
Assembling The Crankcase
Installing The Shift Levers
Crankshaft And Oil Pump
Oil Pump
Removing The Crankshaft
Checking The Oil Pump
Checking The Relief Valve
Checking The Oil Strainer
Assembling The Oil Pump
Checking The Crankshaft
Installing The Crankshaft And Balancer
Drive Axle Assembly
Removing The Transmission
Checking The Shift Forks
Checking The Shift Drum
Checking The Drive Axle
Checking The High Wheel Gear And Middle Drive Gear Checking The Secondary Shaft And Driven Sprocket
Checking The Chain
Assembling The Shift Fork Assembly
Installing The Transmission
Middle Gear
Middle Drive Shaft
Middle Driven Shaft
Removing The Middle Drive Shaft
Removing The Middle Driven Shaft
Checking The Pinion Gears
Selecting The Middle Drive And Driven Gear Shims
Installing The Middle Driven Shaft
Installing The Middle Drive Shaft
Measuring The Middle Gear Backlash

Chapter 5 Cooling System
Radiator And Coolant Reservoir
Checking The Radiator
Installing The Radiator
Water Pump
Disassembling The Water Pump
Checking The Water Pump
Assembling The Water Pump
Oil Cooler
Checking The Oil Cooler

Chapter 6 Fuel System
Fuel Pump And Fuel Tank
Checking The Fuel Pump Operation
Disassembling The Carburetor
Checking The Carburetor
Assembling The Carburetor
Adjusting The Fuel Level

Chapter 7 Drive Train
Front Constant Velocity Joints, Differential Gear And Drive Shaft
Disassembling The Universal Joint
Removing The Differential Gear Assembly
Checking The Constant Velocity Joints
Checking The Differential Gear
Checking The Gear Motor
Assembling The Front Constant Velocity Joints
Assembling The Differential Gear
Assembling The Universal Joint
Measuring And Adjusting The Differential Gear Lash Checking The Differential Gear Operation
Rear Constant Velocity Joints, Final Drive Gear
And Drive Shaft
Assembling The Rear Constant Velocity Joints
Disassembling The Final Gear Case
Removing The Final Drive Roller Bearings
Installing The Final Drive Roller Bearings
Positioning The Final Drive Pinion Gear And Ring Gear
Checking The Drive Shaft
Checking The Final Gear Case
Measuring And Adjusting The Final Gear Lash
Assembling The Final Gear Case

Chapter 8 Chassis
Seats, Enclosure, Hood And Cargo Bed
Front Bumper And Hood
Seats, Console And Instrument Panels
Panels And Footrest Cover
Cargo Bed
Skid Plates
Enclosure And Seat Belts
Front Wheels And Brake Discs
Checking The Front Wheel
Checking The Front Wheel Hub
Checking The Front Brake Disc
Installing The Front Wheel Hub
Installing The Front Wheel
Rear Wheels And Brake Disc
Rear Wheels
Rear Brake Disc
Checking The Rear Wheel
Checking The Rear Wheel Hub
Checking The Rear Brake Disc
Installing The Rear Wheel Hub
Installing The Rear Wheel
Front And Rear Brakes
Front Brake Pads
Rear Brake Pads
Replacing The Front Brake Pads
Replacing The Rear Brake Pads
Brake Master Cylinder
Checking The Master Cylinder
Assembling The Brake Master Cylinder
Installing The Brake Master Cylinder
Front Brake Caliper
Rear Brake Caliper
Disassembling The Front Brake Calipers
Disassembling The Rear Brake Caliper
Checking The Front And Rear Brake Calipers
Assembling The Front Brake Calipers
Assembling The Rear Brake Caliper
Installing The Front Brake Calipers
Installing The Rear Brake Caliper
Pedal Assembly
Steering System
Steering Column And Steering Assembly
Disassembling The Steering Assembly
Checking The Steering Joint
Checking The Steering Assembly
Assembling The Steering Assembly
Installing The Steering System
Tie-rod And Steering Knuckle
Removing The Steering Knuckles
Checking The Tie-rods
Checking The Steering Knuckles
Front Arms And Front Shock Absorber
Removing The Front Arms
Checking The Front Arms
Checking The Front Shock Absorber
Installing The Front Arms And Front Shock Absorber
Rear Knuckle And Stabilizer
Checking The Rear Knuckle
Checking The Stabilizer
Rear Arms And Rear Shock Absorber
Checking The Rear Arms
Checking The Rear Shock Absorber
Installing The Rear Arms And Rear Shock Absorber

Chapter 9 Electrical
Electrical Components
Checking The Switch
Checking The Switch
Checking A Switch Shown In The Manual
Checking The Switch Continuity
Checking The Bulbs And Bulb Sockets
Types Of Bulbs
Checking The Condition Of The Bulbs
Checking The Condition Of The Bulb Sockets
Ignition System
Circuit Diagram
Electric Starting System
Circuit Diagram
Starting Circuit Operation
Starter Motor
Checking The Starter Motor
Assembling The Starter Motor
Charging System
Circuit Diagram
Lighting System
Circuit Diagram
Checking The Lighting System
Signaling System
Circuit Diagram
Checking The Signal System
Cooling System
Circuit Diagram
2wd/4wd Selecting System
Circuit Diagram
Carburetor Heating System
Circuit Diagram

Chapter 10 Troubleshooting
Starting Failure/hard Starting
Fuel System
Electrical System
Compression System
Poor Idle Speed Performance
Poor Idle Speed Performance
Poor Medium And High-speed Performance
Poor Medium And High-speed Performance
Faulty Drive Train
Faulty Gear Shifting
Hard Shifting
Shift Lever Does Not Move
Jumps Out Of Gear
Faulty Clutch Performance
Engine Operates But Vehicle Will Not Move
Clutch Slipping
Poor Starting Performance
Poor Speed Performance
Faulty Brake
Poor Braking Effect
Shock Absorber Malfunction
Unstable Handling
Unstable Handling
Lighting System
Headlight Does Not Come On
Bulb Burnt Out

Additional information

Weight 3 lbs
Dimensions 11 × 9 × 1.5 in

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