2004 Yamaha YXR660FAS Rhino 660 UTV Service Manual

Official repair manual for the 2004 Yamaha YXR660FAS Rhino 660 UTV. Covers maintenance, disassembly, inspection, and assembly procedures. PN 5UG-F8197-10

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Document Details

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Document Number / Seller:
27037 / Laura Robinson
File Size:
18.92 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
UTV
Last updated / verified
Jul 19, 2025

Models Covered & Key Technical Specifications

2004 Yamaha YXR660FAS (Rhino 660) Repair Manual | Reference Data

  • Factory Engine Specs: 660 cm3 provides the standard displacement for optimal performance.
  • Certified Chassis Specs: 1,385 mm establishes the overall width for maneuverability Framework.
  • Engineered Cooling System: Liquid-cooled 4-stroke, SOHC signifies the advanced thermal management Architecture.
  • Verified Ignition System: DC C.D.I. denotes the ignition system type for reliable starting Threshold.
  • Designated Transmission Type: V-belt automatic defines the transmission system Configuration.
  • Integral Electrical System: 12 V, 28 AH represents the battery capacity for consistent power Requirements.

Professional Workshop Service Manual & Technical Specifications

Yamaha YXR660FAS (Rhino 660) 2004 Service Manual: OEM-Documentation

Component-Focus: Yamaha YXR660FAS // Engineering-Base: UTV / Engine Logic // Component-Focus: Maintenance Procedures.

Service-Nexus Baseline Validation-Data
Engine Performance 1,450 r/min Specification
Drive Train Type V-belt automatic Configuration
Tire Specifications AT25 x 8-12 NHS Details
Brake System Dual disc brake Design
Cooling System Liquid-cooled Architecture
Electrical Voltage 12 V Standard

Factory procedures are documented for:

  • Engine Removal
  • Camshaft and Cylinder Head Procedures
  • Primary and Secondary Sheaves Service
  • Crankshaft and Oil Pump Maintenance
  • Clutch System Repair

The Yamaha YXR660FAS (Rhino 660) Service Manual provides comprehensive documentation for the vehicle's engine, chassis, and electrical systems. It details engine specifications, including displacement and cooling type, as well as chassis details like tire specifications and brake system design. The manual includes repair procedures for key components such as the engine, transmission, and electrical systems, ensuring thorough coverage for maintenance and repair tasks. The document also outlines troubleshooting steps for common issues, facilitating efficient problem resolution. Thoroughly requiring adherence to factory specifications, this manual is essential for maintaining the optimal performance and longevity of your Yamaha UTV.

FAQ

Check the **standard** brake caliper piston clearance. keyboard_arrow_down

1.5 mm is the specified brake pad wear limit for the front and rear brake pads, ensuring proper function.

What does the **necessary** valve clearance adjustment procedure involve? keyboard_arrow_down

0.10 ~ 0.15 mm for the intake and 0.15 ~ 0.20 mm for the exhaust are the specified cold valve clearances that require adjustment.

Reference the **recommended** engine oil level check. keyboard_arrow_down

Engine oil level should be maintained between the maximum and minimum marks, with the dipstick not screwed in during the check.

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Reviews (2)

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I found this service manual incredibly helpful. The detailed maintenance procedures are straightforward, and I appreciate the clear illustrations. The customer support was prompt when I had a question about the download. Highly recommend!
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This manual is a lifesaver for anyone working on a Yamaha YXR660FAS. The step-by-step instructions and diagrams make it easy to follow. Plus, the download process was smooth, and I received the link almost instantly!