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2004-2007 Yamaha Rhino 660 UTV service manual

Models covered in this manual:

Rhino 660 / Yamaha Motor Company

YXR660FAS

  • 2004 Yamaha Rhino 660
  • 2005 Yamaha Rhino 660
  • 2006 Yamaha Rhino 660
  • 2007 Yamaha Rhino 660

Engine: 660cc, 4-Stroke Single, Liquid Cooled w/Fan, 5-Valve SOHC, 100 mm x 84 mm, 9.1:1

File specifications

File size: 14.89 MB
File type: PDF
Language: English

Printable: Yes
Estimated download time: 0.3 Minutes
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Product Information

Table of Contents

  1. General Information
    • Scooter Identification
    • Vehicle Identification Number
    • Engine Serial Number
    • Important Information
      • All Replacement Parts
      • Gaskets, Oil Seals, and O-Rings
      • Lock Washers/Plates and Cotter Pins
      • Bearings and Oil Seals
      • Circlips
    • Special Tools
      • For the Engine Service
      • For the Power Train Service
      • Measuring Tools
  2. Specifications
    • General Specifications
    • Maintenance Specifications
      • Power Unit
      • Lower Unit
      • Electrical
      • Dimensions
    • Tightening Torques
      • Specified Torques
      • General Torques
  3. Periodic Checks and Adjustments
    • Maintenance Interval Chart
    • General
      • Checking the Anodes
      • Lubrication Points
  4. Engine
    • Camshaft and Valves
      • Removing/Installing the Camshaft and Valves
      • Replacing the Valve Guides
      • Installing the Valves
    • Power Unit
      • Camshaft and Valves
      • Removing/Installing the Camshaft and Valves
      • Replacing the Valve Guides
      • Installing the Valves
  5. Cooling System
    • Cooling System General
    • Water Pump
      • Removing/Installing the Water Pump
      • Checking the Impeller and Impeller Housing Cup
  6. Fuel System
    • Fuel System General
    • Carburetor
      • Disassembling/Assembling the Carburetor
      • Checking the Carburetor Components
  7. Drive Train
    • Drive Shaft
      • Removing/Installing the Drive Shaft
      • Removing the Pinion
      • Removing the Drive Shaft Bearing
      • Disassembling the Forward Gear Assembly
    • Lower Case Assembly
      • Disassembling/Assembling the Lower Case Assembly
      • Checking the Drive Shaft Sleeve
  8. Chassis
    • Frame
      • Checking and Adjusting the Frame
      • Removing/Installing the Frame
  9. Electrical
    • Electrical Components
      • Fore and Aft Views
      • Port and Starboard Views
    • Electrical Components Analysis
      • Measuring the Peak Voltage
    • Ignition System
      • Checking the Charge Coil
      • Checking the Pulser Coil
      • Checking the CDI Unit
  10. Troubleshooting
    • Troubleshooting Chart
    • Engine Troubleshooting
      • Engine Will Not Start
      • Engine Starts But Runs Only at Idle Speed
      • Engine Overheats
    • Electrical Troubleshooting
      • No Spark
      • Weak Spark

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