2004-2007 Yamaha Rhino 660 ATV Service Manual

Shop manual for the Yamaha Rhino 660 with drive train, chassis, and electrical system coverage. PN 5UG-27700-00-00

4.3starstarstarstarstar_border(3)
visibility Preview Available
Yamaha 2004-2007 Yamaha Rhino 660 ATV Service Manual manual page preview - page 1 of 506

Sample pages from the 2004-2007 Yamaha Rhino 660 ATV Service Manual manual

Yamaha 2004-2007 Yamaha Rhino 660 ATV Service Manual manual preview page 3 - thumbnail
Yamaha 2004-2007 Yamaha Rhino 660 ATV Service Manual manual preview page 4 - thumbnail
Yamaha 2004-2007 Yamaha Rhino 660 ATV Service Manual manual preview page 5 - thumbnail
info_outline Click thumbnails to preview different pages
$17.78 (incl. VAT) Instant Download / No Shipping Fees
2 copies sold
OR BUY NOW
verified_user
Lifetime Access
Re-download anytime
flash_on
Instant Download
Get it immediately
lock
Secure Payment
PayPal

Document Details

keyboard_arrow_down
Document Number / Seller:
27163 / David Phillips
File Size:
23.12 MB
File Type:
PDF
Language:
English
Pages:
506
Printable:
Yes
Category:
ATV
Last updated / verified
Aug 3, 2025

Models Covered & Key Technical Specifications

Certified Service Calibration Manual: ATV Yamaha Rhino 660 Service & Repair Manual (2004-2007) - Comprehensive Repair and Maintenance Guide System-Standards Assembly-Group: 506 pages // Performance-Values: 23.117 MB file size / Operational-Framework: English Manual-File

Service procedures are grouped by:

  • Removal procedures are documented for engine components.
  • Technical specifications are provided for chassis and electrical systems.
  • Factory specifications are documented for engine, cooling system, and fuel system.
  • Engine rebuild procedures are documented for internal engine components.
  • Drivetrain specifications are addressed in the transmission and drive axle sections.
  • General tightening torque specifications are listed for all fasteners.

Manual Description & Preview

Yamaha Rhino 660 Service & Repair Manual (2004-2007)

General Specifications: 506 pages // Category: ATV / System: Logic // Technical-details: All specifications in SI and Metric units.

Identifier Baseline Calibration-Data
Overall Length 2,885 mm 113.6 in
Overall Width 1,385 mm 54.5 in
Engine Displacement 660 cm³ 40.3 cu in
Fuel Tank Capacity 30 L 7.93 US gal
Front Wheel Travel 185 mm 7.28 in

Service procedures are documented for engine, cooling system, fuel system, drive train, chassis, electrical system, and troubleshooting. Technical specifications are provided for engine type, displacement, bore x stroke, and compression ratio. Factory specifications are documented for general dimensions, weight, tire specifications, and suspension components. Engine rebuild procedures are documented for cylinder head, camshaft, valves, and pistons. Drivetrain specifications are addressed in the transmission, differential gear, and clutch sections.

The manual provides detailed information on periodic checks and adjustments, including valve clearance, idle speed, throttle cable, and starter cable. It also covers maintenance procedures such as changing engine oil, cleaning the air filter, and checking coolant levels.

Torque specifications for various components are included to ensure proper assembly and structural misalignment prevention.

FAQ

Determine the **specific** torque specifications for the cylinder head bolts. keyboard_arrow_down

38 N·m (3.8 m·kg, 27 ft·lb) is the specified torque for the cylinder head bolts (M9: 1-6) as detailed in the manual.

What **designated** safety precautions should be followed when working with the battery? keyboard_arrow_down

Always wear protective eye gear, charge batteries in a well-ventilated area, and keep them away from sparks or open flames to avoid severe burns or eye injury.

Check the **critical** lubrication requirements for the starter idle gear shaft. keyboard_arrow_down

The starter idle gear shaft requires grease (M) as indicated in the lubrication points section of the manual.

What does the **required** testing parameters indicate for the piston pin bore? keyboard_arrow_down

22.004 ~ 22.015 mm (0.8663 ~ 0.8667 in) is the standard piston pin bore inside diameter, with a limit of 22.045 mm (0.8679 in) for acceptable piston-to-cylinder clearance.

Customer Reviews

Read what our customers say about this Yamaha ATV manual and share your own experience.