2004-2007 Yamaha Rhino 660 ATV Service Manual

2004–2007 Yamaha Rhino 660 Service Information

• Built for owners and professional technicians servicing the 2004–2007 Yamaha Rhino 660 with the 660 cm³ SOHC engine and automatic transmission
• Official OEM publication P/N 5UG-28197-00, original 2004 edition
• Contains 506 pages of technical documentation, including 40+ system-specific exploded-view diagrams and comprehensive torque-specification tables
• Downloads to your account within seconds of checkout
• File link appears in your order confirmation straight away
• Laid out for standard letter and A4 printing
• Full-text search finds any part number in seconds
• Reference only — always consult a certified technician before performing service on this equipment.

Technical Scope and Documentation

The 2004–2007 Yamaha Rhino 660 service manual provides extensive details for vehicle maintenance and component rebuilding. Chapters delineate procedures for engine top-end work, including valve clearance adjustment, camshaft inspection, and cylinder assembly. Drivetrain documentation covers the V-belt transmission, middle gear backlash measurement, and differential gear service. Chassis sections describe the independent double-wishbone suspension, rack-and-pinion steering, and dual disc braking systems. Electrical troubleshooting tables assist in diagnosing ignition, charging, and cooling system faults.

Specification Highlights

Engine cooling system capacity is documented at 2.5 liters in the cooling specifications table. Intake valve clearance for the Yamaha Rhino 660 is specified at 0.10–0.15 mm. The primary sheave assembly nut torque is listed at 120 Nm in the engine tightening specifications section.

An official 506-page Yamaha OEM workshop manual covering the 2004–2007 Yamaha Rhino 660, documenting engine, chassis, electrical, and drivetrain specifications for the 5UG1 model variant.