Yamaha Yamaha Rhino 660 Owner's manual

INSTRUCTION SUPPLEMENT FOR
2004-Later Yamaha Rhino 660
Removing stock carburetor and cables
1. Remove engine cover and tunnel
(center of floor board).
2. Remove throttle cable from throttle
pedal and chassis. See fig 1.
3. Remove choke cable from dash.
See figure 2.
Figure 1. Throttle cable
Figure 2. Choke cable
4. Remove stock carburetor, cables
and all vent hoses attached to
carburetor. NOTE: Carburetor can
be removed without disconnecting
cables. Unplug black and yellow
wires from carb and tape ends with
electrical tape as they will not be
used with the Edelbrock carburetor.
5. Stuff a dry, clean rag into the
intake manifold to keep debris from
entering engine.
6. Remove oil line directly above oil
filter. See fig 3. Disconnect rubber
hose at bottom where it connects
to hard tube. See fig 4.
NOTE: Clean oil and dirt off of flange and
case before removing oil line.
Figure 3.
Figure 4.
7. Remove stock fuel line from fuel
pump. Save insulating material as
it will be reused on new fuel line.
Installing the Edelbrock Carburetor
1. Attach new fuel line to fuel pump
reusing stock clamp and insulating
material.
2. Install new throttle cable into bracket
and throttle pedal. Do not route
throttle cable in stock position. Cable
will need to be routed to passenger
side of vehicle. See figure 5 for cable
routing.
NOTE: Apply a small amount of grease to
O-ring on pedal end of cable for easier
installation into throttle pedal.
Figure 5.

3. Remove the hex pipe plug from the
carb cap using a 11mm or 7/16 wrench.
Do not discard plug, as it will be
needed later. Install the metering
adjustment tool included in the
hardware kit. Do not over-tighten as
damage may occur to cap.
4. Attach fuel line onto fuel inlet banjo
and secure with stock pinch clamp.
Fuel line may need to be trimmed to
proper length.
5. Place Edelbrock carburetor into
manifold. Do not tighten clamp yet.
6. Remove the cable bracket end from
cable bracket using #2 phillips.
7. Insert cable end into cable wheel in the
8:00 o’clock position. Place elbow into
bottom slot of cable bracket and secure
by reinstalling cables bracket end and
screw. See figure 6.
Figure 6.
8. Align carburetor as close to vertical as
possible and tighten manifold clamp.
9. Adjust cable until wide-open throttle is
achieved.
10. Secure clamp around air boot onto
back of carburetor.
11. Use supplied vacuum cap to cover
elbow on right side (passenger side) of
air boot. Secure with supplied zip tie.
12. Carefully remove O-ring from stock oil
line flange and place it onto new oil line
flange as shown in figure 7.
Figure 7.
13. Wrap the threaded portion of the elbow
with Teflon tape and thread into billet
oil block until the barb is 90 degrees to
the two holes as shown in figure 8. Do
not tighten completely as bolts need
too be installed.
Figure 8.
14. Install block onto engine with the elbow
and plug facing up. Secure to motor
with two M6X1X30 bolts (supplied). Be
sure no to over tighten as damage
can occur to engine case. See
manual for recommended torque
specs.
15. Once bolts have been tightened, use a
wrench to turn the elbow ¼forward to
tighten as shown in figure 9.
Figure 9.

NOTE: Turn elbow until it is just below three
o’clock position as shown in picture above.
16. Install hose clamps on each end of
supplied 3/8 hose (blue). Lube the
inside of both ends of hose with a light
oil (WD-40 or similar). Push hose onto
oil fitting on engine and the opposite
end onto the factory hard tube coming
from the front of vehicle. See figures
10 and 11.
Figure 10.
Figure 11.
17. After each end of hose has been
installed tighten clamps.
18. Engage starter without opening
throttle. NOTE:The stock fuel pump is
vacuum operated, so it is
recommended that the starter be
engaged for at least 10 seconds.
19. After fuel has entered float bowl, pump
the throttle 3-5 times to prime the
accelerator pump.
20. Once pump is primed, start engine.
NOTE: The Edelbrock carburetor
does not have a choke system. Cold
starts will require 2-3 pumps of the
throttle pedal to activate the
accelerator pump.
For any questions regarding
tuning or installation of Edelbrock
products, please call our toll free
tech line M-F 8:00am-12: 30pm,
1:30pm-5:00pm PST.
877-888-7504 ext.2.
Edelbrock #3119 Yamaha
Rhino 660 Carburetor
Specifications
Bore Size: 40mm round
Needle: 18E @ 14 clicks
Accelerator Pump Bypass: 1.5
turns out.
Alternate Needles: 16E, 20E
Main Jet: 74
Alternate Jets: 72, 76
Replacement Throttle Cables:
#9353