YAMAHA RHINO 660

YAMAHA RHINO 660
YAMAHA RHINO 660
INSTALLATION INSTRUCTIONS
PLEASE READ THE ENTIRE INSTRUCTIONS
BEFORE STARTING THE INSTALLATION.
THIS KIT INCLUDES ALL NECESSARY PARTS WHICH INCLUDES
A GIBSON PERFORMANCE MUFFLER AND A GARRETT T20 TURBO.
THE FACTORY CARBURETOR AND AIR BOX ARE USED
IN THE INSTALLATION AND THE FUEL PUMP IS REPLACED
WITH AN ELECTRIC PUMP.
THIS IS A DRAW THROUGH THE CARBURETOR SYSTEM SO
THERE MAY BE SOME TURBO LAG TYPICAL WITH THIS TYPE OF
INSTALLATION.
NOTE: WITH ANY PERFORMANCE ENHANCING PRODUCTS
THERE IS THE RISK OF DAMAGING THE ENGINE AND
OR DRIVE TRAIN. THE RHINO HAS MANY AFTERMARKET
PRODUCTS AVAILABLE TO HELP PREVENT SUCH DAMAGE.
PARTS AVAILABLE ARE UPGRADED CLUCH SYSTEM, PISTONS,
RODS AND ALSO A REV LIMITER MODIFCATION SO THE ENGINE
CAN RUN AT HIGHER RPMS. WE RECOMMEND USING RACING
GAS AND IF ANY PING IS HEARD IT WILL BE NECESSARY TO RUN
RACING GAS.
TO START OUT REMOVE THE SEATS, ENGINE COVER, DRIVER
SIDE PLASTIC COVER UNDER THE SEAT AND DUMP BED.
WHEN REMOVING THE DUMP BED IT IS NECESSARY TO
DISCONNECT THE TAIL LIGHTS.
YAMAHA RHINO 660
INSTALLATION
04’-UP RHINO 660
1. Remove the muffler and head pipes,
to do this the head pipes must be loose
in order to remove the muffler.
head pipe
muffler
2. Remover the air filter box, carburetor,
carburetor
and the rubber carburetor mount.
be careful when disconnecting the throttle
cable and choke cable as there are loose
parts that need to be saved for
reinstallation. It will be necessary to
replace the main fuel jet and modify the
needle, please see instructions from
DYNOJET and make these modifications.
we recommend the DJ 200 and to put one
extra washer on the needle.
vacuum line
3. Disconnect the vacuum. line from intake
manifold and cap off. If you use a boost
gauge this is a good place to connect.
vacuum line to
boost gauge
intake manifold
air filer box
4. Remove factory fuel pump.
5. Mount the exhaust manifold with the
factory fuel pump
4 lock washers and nuts included.
For a stronger installation you may
want to change the manifold studs
with grade ‘8’ studs.
Install the oil return fitting on to turbo
and temporarily install the turbo in place.
then locate the proper location for the
oil scavenging pump under the turbo as
turbo
shown.
It would be best to use the oil return
hose from turbo to locate position.
for easy of drilling holes remove turbo,
ex. manifold
drill 4 holes and secure the pump with
bolts included.
ex. manifold
turbo
6. Install turbo on to the exhaust manifold as
shown. It may be easier to install right
angle charge coupler to turbo before
mounting.
turbo
ex. manifold
right angle charge coupler
intake pipe
7. Locate the air intake pipe which goes
between the carburetor and turbo
compressor intake. Line up the pipe with
the turbo inlet and plastic panel which is
under the front driver side seat. See
photos of this and location of carburetor
and air filter box. Drill a 2 inch hole
through the plastic so you can insert the
air intake pipe.
drill a 2 inch hole
turbo comp. intake
intake pipe
8. Install the intake pipe onto the turbo.
Using the hanger included slip it over
the intake pipe and mark the location
where the hole needs to be drilled for
the supporting intake pipe bracket.
TIP: to limit the dirt/sand from entering
the new carburetor area you can take
a piece of fuel hose and slit it longwise
and fit it into the hole cut for the
intake pipe. then slide the intake pipe
into place and you can now use silicone
2 inch hole
sealant to seal up the area.
rubber carburetor
adapter
8
turbo
support
bracket
9. Drill appropriate hole and secure the
intake pipe with the support bracket
and install the rubber carburetor
adapter onto the end of intake pipe.
Be sure to use the adapter which
has the protuberance in the rubber to
match the grove in carburetor.
carburetor
10. Install the carburetor into the adaptor
and throttle and choke cables to
carburetor and reconnect.
carburetor
choke cable
throttle cable
“L” bracket
air filter box
11. Temporality install the “L” brackets
onto the air filter box as shown and
connect the air box to the carburetor.
Mark the seat frame in the proper place
remove the air box and drill two holes
for sheet metal screws.
12. Remove the “L” brackets from the air
box and install them onto the seat
frame.
air filter box
“L” bracket
blow-by hose
air filter box
and intake hose
13. Reinstall the air filter box onto the
carburet and secure the air box to
the “L” brackets. using the hose
included reconnect the breather
outlet to the air box.
14. Install oil supply line by removing the oil line to turbo
fitting on the engine that goes to the
oil cooler. Insert between the factory
fitting and engine our adapter and
secure with screws included. Screw in
the right angle adapter fitting and
attach stainless oil line to fitting. Bring
line across engine to drivers side and
thread line towards rear of rhino. Now
bring the line over the top of the
oil fitting adapter
compressor and secure to oil inlet
fitting on the turbo. See photo for
proper location of line.
right angle oil fitting
the line over the top of the compressor
and secure to oil inlet fitting on the turbo
oil return hose
15. Install the oil return fitting included into from oil pump
the oil check/fill hole and secure.
Using the oil return hose included
thread hose around to oil return pump
and fasten hose to right angle fitting
of oil pump output.
Secure with clamps included.
oil check
oil return fitting
16. Install the turbo oil outlet on the turbo
oil hose to oil
and heat resistant oil return hose to
return fitting
turbo oil outlet and to inlet of oil pump
as shown and secure with hose clamps.
17. Mount the replacement fuel pump on
the side of the passenger seat frame
as shown. Drill holes in seat frame to
match holes in “L” shaped mounting
bracket. Secure with bolts included.
Run fuel line from gas tank to inlet of
fuel pump using the factory fuel filter.
you may wish to use a higher flow
aftermarket fuel filter.
From the output side of fuel pump
connect the included fuel line to
carburetor.
You may find that a fuel pressure
regulator is needed if gas wants to run
out of carburetor. Not included in kit.
oil pump
to carburetor
oil hose from
turbo oil outlet
from fuel tank
18. The fuel and oil pump require more
amps than are available in the engine
compartment so we need to add a relay.
Included in the kit is a 30 amp relay
which needs to be connected to the
battery. Open the front compartment
and remove the battery cover. relay
can be loose in the compartment. the
wires connect as noted red and
black with eyelet connect to battery.
Spade connector goes to one terminal
of the blue rectangular connector.
There are different models of Rhino and
some do not have the blue connector.
Use a test light to determine which one
is switched with ignition. Be careful which
one you choose as one goes off when you
put Rhino in gear and it will blow lots of
smoke out the exhaust. A safe place to
connect is on drivers side of Rhino is the
light switch, the wire going into the switch
charge pipe #2
turns on and off with the key.
Connect there and then thread the long
red wire under the hump in the floorboard
back to the fuel pump.
charge pipe #1
Find the proper length to
connect to fuel pump and cut the
wire connect that end to the fuel pump
and to the additional wire which then
connects to the oil pump. The black
wire on both pumps then need to be
grounded.
30 A relay
19. Install the charge piping as shown
using the black rubber coupler included The
engine
cover
engine
cover will need to be
on to rhino intake manifold.
notched go over the charge piping
The engine cover will need to be
notched to go over the charge piping
20.The last install is the muffler, remove
the original hangers for the stock
muffler. Install the outlet on turbo and
using the silvery donut gasket. Slip it
over the end of outlet and then attach
muffler with bolts and springs as
indicated. Do not tighten these bolts
Be sure to leave plenty of flex between
rear hanger
the muffler and the exhaust outlet but
tight enough so it will not leak.
There is a lot of movement between
engine and muffler.
front
The muffler is supported by 3 hangers
hanger
that will have to be installed. In the box
with the muffler are some photos that
show how the front mount is installed
and the photo shone hear indicates
rear hanger
where it mounts.
The muffler has 2 additional hangers.
rear hanger
rear hanger
Remove the wire tie holder from the
frame where the hanger lines up and
drill a hole through the bottom portion
of the frame the same size the zip tie hole.
Now secure the muffler hanger on
drivers side with rubber flex mount.
now connect the rubber flex mount on
passenger side to muffler bracket and
hanger. Line up the hole in hanger
with frame and locate the place to drill
for hanger bracket. Drill proper size
front hanger
hole and attach hanger.
NOTE: BE SURE THERE IS ENOUGH CLEARENCE
BETWEEN THE TAIL OF THE MUFFLER AND THE DUMP BED WHEN OPEN
BY ADDING WASHERS TO CLEAR AFTER THE BED IS REINSTALLED.
THE TURBO INSTALLATION SHOULD NOW BE COMPLETE, BEFORE
REINSTALLING THE STOCK RHINO PARTS START THE ENGINE AND
CHECK FOR OIL/ GAS LEAKS AND BE SURE ALL CONNECTIONS AND
BOLTS ARE TIGHT.IF YOU PLAN ON RUNNING YOUR RHINO HARD YOU
MAY WISH TO MAKE AN ADDITIONAL TURBO BRACE GOING FROM THE
TURBO TO THE ENGINE, THERE IS AN EYELET ON THE TOP OF
THE HEAD, A BRACE ALMOST STRAIGHT DOWN TO ONE OF THE OUTLET
BOLTS SHOULD BE SUFFICIENT.. IF JUMPING THIS COULD HELP
PREVENT THE TURBO FROM PULLING THE STUDS OUT OF THE HEAD.
NOW REINSTALL THE BED,UNDER SEAT COVER,
ENGINE COVER AND SEATS. INSTALLATION SHOULD NOW BE
COMPLETE.
IF YOU NEED ADDITIONAL HELP PLEASE CALL
888 9302424 FOR TECHNICAL ASSISTANCE.
ENJOY
TURBO SPECIALTIES
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