Yamaha Rhino 660 UTV Service Manual Set, 2004–2007 (P/N 5UG-F8197-10)

Use the base manual for the main repair procedures and the supplements for model-specific changes. The YXR66FAV supplement refers back to both earlier publications for some procedures.

For a 2007 vehicle, verify the model code before buying. The final supplement’s wiring sheets identify the YXR66FAV 2006, and the file has no separate 2007 supplement.

PDF Search, Bookmarks, and Wiring Diagrams

Search and wiring detail: Searchable text and embedded bookmarks help you find chapters and wiring diagrams. Zoom in to read the small wire color codes and connector labels on the full wiring diagrams.

The download is one printable English PDF with 506 pages. That total includes six introductory pages on manual organization and symbols, two within each publication’s page count.

Engine, Driveline, and Electrical Service

This selection of workshop topics includes examples from the base manual and supplements. The set also covers brake light switch adjustment and cable lubrication.

• Engine overhaul: Engine removal and installation, camshaft and valve inspection, piston and ring checks, crankcase separation, crankshaft and balancer work, and internal transmission service.

• V-belt and shaft drive: Primary and secondary sheave service, wet centrifugal clutch inspection, middle-gear backlash, CV joints, differential and final-drive setup, and 2WD/4WD gear-motor checks.

• Brakes, steering, and suspension: Hydraulic bleeding, caliper and master cylinder overhaul, self-adjusting parking brake service, rack-and-pinion steering, double-wishbone arms, shocks, and stabilizer work.

• Cooling and fuel: Radiator and reservoir checks, water pump disassembly and reassembly, oil cooler inspection, fuel pump testing, and Mikuni BSR42 carburetor overhaul and fuel level adjustment.

• Electrical diagnosis: Circuit tests and fault-isolation charts for ignition, starting, charging, lighting, signaling, radiator fan control, 2WD/4WD selection, and carburetor heating.

The set is suited to technicians and experienced owners equipped for bench repairs. Major procedures use pullers, holding fixtures, a press, a dial indicator, and electrical test equipment.

Engine and Driveline Repair Depth

Periodic service includes valve clearance and timing chain adjustment, ignition timing and compression checks, V-belt inspection, toe-in adjustment, and battery charging. The engine teardown covers the decompression mechanism, valve seats and guides, timing chain tensioner, starter clutch, A.C. magneto, oil pump and relief valve, shift forks, shift drum, and drive axle.

Exploded views and ordered job charts identify parts and disassembly order. Tightening tables, wear limits, lubrication points, and coolant and oil flow diagrams support inspection and reassembly.

The driveline procedures cover universal joints, pinion and bearing inspection, shim selection, and front and rear gear lash. The manual treats the front differential as a factory-assembled unit and warns that splitting it can cause malfunction. It also explains how gear-motor and shift-fork indexing affects the indicator and engagement of 2WD and differential lock.

Supplement Changes and Fault Finding

The YXR660FAT supplement revises transmission and carburetor specifications, chassis and electrical data, tightening values, and cable routing. It also covers revised air filter, parking brake, exhaust and air duct, carburetor joint, body panel, cargo bed, and seat belt procedures.

The YXR66FAV supplement distinguishes standard and special-edition indicator displays, steel and cast wheels, and lighting circuits. Its service updates cover hub hardware, front arms, the rear stabilizer, the front guard and skid plates, the engine cooling fan and A.C. magneto, and oil cooler removal.

Model-specific wiring diagrams complement the individual circuit tests. The troubleshooting chapter traces hard starting through fuel, electrical, and compression checks and addresses shifting, clutch, overheating, braking, shock absorber, handling, and lighting faults.

Special Tools and Workshop Setup

The tool index pairs US and Canadian tool numbers with international equivalents. Examples include the sheave spring compressor (YM-04134 / 90890-04134), gear lash measurement tool (YM-01467 / 90890-01467), bearing retainer wrench (YM-04128 / 90890-04128), and pulse ignition spark checker (YM-34487 / 90890-06754). The sheave, engine removal, and driveline procedures identify where holding tools or lifting support are needed.

Sample Valve Clearance, Sheave Torque, and Gear Lash

For the YXR660FAS, the valve adjustment procedure specifies cold valve clearance of 0.10–0.15 mm at the intake and 0.15–0.20 mm at the exhaust.

The same base manual lists 120 Nm for the primary sheave nut during sheave installation. The middle-gear procedure specifies 0.1–0.3 mm of backlash for the dial indicator check used to assess shim selection.