2004-2006 Yamaha Rhino 660 YXR66FAV UTV Service Manual

Technical reference for Rhino 660 UTV models. Documents troubleshooting, component replacement, and system diagnostics. Includes part number YXR66FAV.

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Document Details

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Document Number / Seller:
24021 / Robert Campbell
File Size:
22.49 MB
File Type:
ZIP
Language:
English
Pages:
521
Printable:
Yes
Category:
UTV
Last updated / verified
Feb 24, 2025

Models Covered & Key Technical Specifications

Full-Coverage Maintenance Safety Manual: Yamaha Rhino 660 YXR66FAV manual, 2004, 2005, 2006 Data-Compendium Rhino 660, YXR66FAV / Yamaha Motor Corp., Ltd (YXR66FAV) -- 2004, 2005, 2006. Expert Primer for Rhino 660 for Rhino 660 Dossier.

  • Verified Rotation Data: 1,385 mm establishes the overall width Measurement.
  • Key Shipping Weight: For standard load, 506 kg signifies the vehicle's basic weight Rating.
  • Prescribed Maximum Resolution: For optimal performance, 280 mm defines the minimum ground clearance Boundary.
  • Nominal Fluid Levels: The transmission requires 25/17 (1.471) for reverse gear Engagement.
  • Design Wattage Specs: Headlights utilize 12 V 30 W/30 W × 2 bulbs for illumination.
  • Designated Linear Velocity: The engine speed is rated at 1,450 ~ 1,550 r/min for idle operation.

Professional Workshop Service Manual & Technical Specifications

Full-Coverage Maintenance Safety Manual: Yamaha Rhino 660 YXR66FAV manual, 2004, 2005, 2006 Data-Compendium

Model-Designation: Rhino 660, YXR66FAV / Yamaha Motor Corp., Ltd // Technical-Domain: UTV / Power Sports Logic // Year-Coverage: 2004-2006. Service-Nexus Rating Calibration-Standards
General Specifications 2,885 mm (Overall Length) 1,385 mm (Overall Width)
Chassis Specifications 1,853 mm (Overall Height) 818 mm (Seat Height)
Engine Specifications 3,900 mm (Turning Radius) 510 kg (Basic Weight)
Electrical Specifications 660 cm³ (Displacement) 100 × 84 mm (Bore x Stroke)
Troubleshooting 9.1:1 (Compression Ratio) 1,324 kPa (Compression Pressure)
Wiring Diagrams 12 V (Voltage) 28 AH (Battery Capacity)

Repair procedures are structured around identifying and addressing specific vehicle systems. Effectively mandating the repair process, this manual delves into detailed sections covering everything from engine disassembly and component checks to electrical system diagnostics and chassis adjustments. Users will find comprehensive guidance for all major systems, ensuring a Reliable and thorough approach to vehicle maintenance.

Engine Repair Procedures

This section documents the process for engine removal, cylinder head cover servicing, and camshaft/cylinder head inspections. It provides detailed steps for working on the engine's core components, ensuring proper reassembly and function.

Chassis Maintenance and Adjustments

Guidance for chassis-related maintenance, including front and rear suspension adjustments, wheel checks, and brake system procedures, is thoroughly covered. This ensures the vehicle's structural integrity and safe operation.

Electrical System Diagnostics

Covering everything from basic component checks to detailed circuit diagrams, this section helps in troubleshooting and repairing all electrical systems, ensuring optimal functionality and safety.

Troubleshooting and Repair Guides

This manual provides detailed troubleshooting steps for common issues and guides for systematic repair processes, enabling efficient problem-solving and component replacement. This manual documents torque specifications for various components to ensure proper service interval reliability.

FAQ

What is the **required** fluid capacity for the engine oil? keyboard_arrow_down

2.10 L (1.85 Imp qt, 2.22 US qt) is the periodic oil change capacity, with 2.20 L (1.94 Imp qt, 2.33 US qt) when the oil filter is replaced.

Calculate the **specified** component identification for the main switch? keyboard_arrow_down

The main switch is identified as "Main switch" within the electrical system section, corresponding to item number 8 in the diagrams and listings.

What values are **essential** for spark plug gap adjustment? keyboard_arrow_down

0.8 ~ 0.9 mm (0.031 ~ 0.035 in) is the essential spark plug gap specification to ensure correct ignition timing and performance.

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