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.
1. Remove the muffler and head pipes, to do this the head pipes must be loose in order to remove the muffler. YAMAHA RHINO 660 INSTALLATION head pipe 04 -UP RHINO 660 2. Remover the air filter box, 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. 3. Disconnect the vacuum. line from intake manifold and cap off. If you use a boost gauge this is a good place to connect. muffler carburetor vacuum line vacuum line to boost gauge air filer box intake manifold
4. Remove factory fuel pump. 5. Mount the exhaust manifold with the 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 shown. It would be best to use the oil return hose from turbo to locate position. for easy of drilling holes remove turbo, drill 4 holes and secure the pump with bolts included. factory fuel pump turbo ex. manifold 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 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. intake pipe drill a 2 inch hole turbo comp. intake
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 sealant to seal up the area. intake pipe 2 inch hole 8 turbo rubber carburetor adapter 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 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. L bracket air filter box air filter box L bracket
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. blow-by hose air filter box and intake hose 14. Install oil supply line by removing the 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 compressor and secure to oil inlet fitting on the turbo. See photo for proper location of line. oil line to turbo oil fitting adapter right angle oil fitting the line over the top of the compressor and secure to oil inlet fitting on the turbo
15. Install the oil return fitting included into 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 return hose from oil pump oil check oil return fitting 16. Install the turbo oil outlet on the turbo and heat resistant oil return hose to turbo oil outlet and to inlet of oil pump as shown and secure with hose clamps. oil hose to oil return fitting 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 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. 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. charge pipe #2 charge pipe #1 30 A relay
19. Install the charge piping as shown using the black rubber coupler included on to rhino intake manifold. The engine cover will need to be notched to go over the charge piping The engine engine cover cover will need to be notched 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. Remove the wire tie holder from the rear hanger 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 hole and attach hanger. rear hanger front 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