Yamaha YXR660FAS Rhino 660 UTV 2004 Service Manual (P/N LIT-11616-17–23)

• Covers 2004 Yamaha YXR660FAS Rhino 660 UTV models, including 2WD and 4WD configurations
• Official Yamaha publication P/N LIT-11616-17-23, first edition July 2003
• Contains 56 exploded-view diagrams and 32 cable routing illustrations
• Indexed PDF search covers every chapter and appendix
• Details teardown and inspection procedures for the steering knuckles, brake master cylinder, primary and secondary sheaves, constant velocity joints, and water pump
• Features essential wiring diagrams, circuit diagrams, coolant flow diagrams, oil flow diagrams, and job instruction charts
• This 421-page factory service manual is the official reference used by authorized dealers for the 2004 Rhino 660 launch build

Documentation Walkthrough

The 2004 Yamaha YXR660FAS Rhino 660 service manual provides a structured overview of vehicle systems. The chapters document general information, detailed specifications, and periodic maintenance intervals for the engine, cooling, fuel, drive train, chassis, and electrical systems. By delivering exact factory tolerances and clearance specifications, this resource streamlines daily shop routines and accelerates diagnostic workflows. For mechanics aiming to bypass expensive dealership labor rates, the guide offers step-by-step repair instructions for complex tasks, including bleeding the hydraulic brake system, adjusting the valve clearance, overhauling the transmission, and setting the differential gear lash. The publication also includes comprehensive troubleshooting charts for identifying issues related to starting performance, idle speed, gear shifting, clutch operation, engine cooling, and vehicle handling.

Engine and Chassis Specifications

This factory manual provides precise technical data for maintenance and engine overhauls. Standard engine compression pressure is documented at 1,324 kPa (188.31 psi) at 850 r/min. The 660 cc engine requires 2.20 L of oil during a filter replacement, while the final gear case capacity is listed at 0.25 L. Valve clearance for the intake is listed at 0.10–0.15 mm in the cylinder head specification table. The fuel system uses a MIKUNI BSR42 carburetor with a float height of 13 mm. Final gear backlash is specified at 0.1–0.3 mm throughout the drive train data sections.

When servicing the drive train on these early Rhino 660 models, technicians must be aware of specific mechanical pitfalls. The middle driven shaft bearing retainer utilizes left-hand threads; attempting to loosen it with standard counterclockwise force will severely damage the housing. Furthermore, applying a hydraulic press directly to the middle driven pinion gear end without the proper adapter socket will permanently crush the gear threads. All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work. This official 421-page Yamaha OEM manual documents the 2004 YXR660FAS Rhino 660, covering engine, chassis, electrical, and cooling specifications for this model year.