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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Technical Safety Notice
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This official OEM document is intended for professional technicians and skilled operators. Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

Yamaha Models Covered & Key Technical Specifications

Models: 2004 Yamaha YXR660FAS (Rhino 660)
Sub-models / Variants: 2WD, 4WD
Trade Names: Rhino 660
Build Years: 2004
Technical Data:

  • Engine: Liquid-cooled 4-stroke, SOHC single cylinder
  • Engine Displacement: 660 cc
  • Transmission: V-belt automatic
  • Ignition System: DC C.D.I.
  • Battery: 12 V, 28 AH
  • Fuel Tank Capacity: 30 L (7.93 US gal)
Technical Specifications
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Document Number / Seller:
27037 / Laura Robinson
File Size:
18.92 MB
File Type:
PDF
Language:
English
Pages:
421
Printable:
Yes
Category:
UTV
Last updated / verified
Jul 19, 2025

Yamaha Manual Features & Content Preview

2004 Yamaha YXR660FAS Rhino 660 Official Workshop Manual

  • 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
  • Accessible from your device as soon as the order is placed
  • Suitable for printing individual sections for shop-floor use
  • 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. 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. 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.

Manual FAQ, Purchase & Download Details

Can I find edition and publication date information for the 2004 Yamaha Rhino 660 UTV service manual? keyboard_arrow_down

Document identification page lists the material as a First Edition published in July 2003. This publication information is located near the front of the manual alongside the official copyright details.

Which publication number corresponds to this specific Rhino 660 service manual? keyboard_arrow_down

Manual is identified by the publication number LIT-11616-17-23.

What information do the exploded diagrams provide for component identification? keyboard_arrow_down

These diagrams contain visual breakdowns of parts and assembly orders, which are supplemented by job instruction charts for clarity. They serve to show how components are grouped within the mechanical sections of the document.

Does the manual include sections for periodic checks and maintenance tasks? keyboard_arrow_down

Table of Contents lists Chapter 3 as the designated section for periodic checks and adjustments, which covers various engine and chassis systems.

Are there wiring diagrams and electrical system references included in the document? keyboard_arrow_down

Chapter 9 of the manual contains electrical system coverage including dedicated circuit diagrams. These sections reference electrical components, signaling systems, and various lighting systems. The manual provides these reference materials to show the layout and connections for the electrical framework.

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