2004-2008 Yamaha Rhino 660 YXR660 Service Manual and Owners Manual 04-08 YXR 660 ATV Workshop Shop Repair Manual
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ATV 2006 Genuine Parts & Accessories
> LEISURE ATV ACCESSORIES YFZ 450 22 YFM 350R 32 YFM 660R 34 YFM 700R 40 GENERIC 44 > APPAREL, NOVELTIES APPAREL 48 NOVELTIES 56 > UTILITY ATV ACCESSORIES PROTECTION 4 FAIRINGS, FENDERS & WINDSHIELDS 7 RACKS & LUGGAGE 8 HUNTING 12 LIGHTS & METERS 14 SECURITY 15 WARN WINCHES & PLOWS 16 APPLICATION CHART 18 CONTENTS > GENUINE PARTS CHAIN KITS 60 BRAKE PADS & SHOES 61 AIR & OIL FILTERS 62 BATTERIES 64 TYRES 65 PLASTICS 66 YFM 660R PARTS 68 CROSS JOINTS 69 CARRIERS 70 SPARK PLUGS 71 GO FOR IT! We have a full line of Yamaha Genuine Accessories designed specially for your Utility and/or Leisure ATV to enhance its aggressive style and leading edge performance. It has never been easier to outfit your ATV for whatever you want to do. What is more, we have exclusive Yamaha Riding Gear and casual wear, so you'll be well dressed for your four- wheel adventure. Yamaha is dedicated to helping you get the most from your ATV's. Just turn the pages to see all that's available through your local Yamaha ATV dealer. ATV 2006 Genuine Parts & Accessories
5 4 Utility ATV Front Brush Guards Help protect the headlights and front fenders. Black powder-coated steel for durability. ’02-’06 Grizzly ABA-5KM58-00-00 ’03-’06 Kodiak ABA-5ND58-W0-00 Front Bumper Super heavy-duty protection for your front end. Powder-coated steel construction. Trail lights sold separately. ’02-’06 Grizzly ABA-5KM58-2W-00 ’03-’04 Kodiak ABA-5ND58-2W-00 Grab Bar Shields Help protect the front of your ATV. Powder-coated steel construction. Trail lights sold separately. Smooth Finish: ’00-’02 Kodiak ABA-5GH58-10-00 Wrinkle Finish: ’03-’04 Kodiak ABA-5GH58-1W-00 Front Skid Plate ‘03-’04 Kodiak & ‘03-’06 Bruin ABA-5ND34-40-00 Engine Skid Plate ‘03-’06 Kodiak & ‘03-’06 Bruin ABA-5ND34-20-00 BASH PLATE This lightweight, heavy-duty brushed silver aluminium plate provides added protection. Front ‘02-’06 Grizzly ABA-5KM34-40-00 ‘00-’02 Kodiak ABA-5GH34-30-01 Rear ‘02-’06 Grizzly 660 ABA-5KM34-50-00 Frame Skid Plate Each kit features a sturdy bash plate constructed of heavy-duty thick plate aluminium, coupled with Ultra High Molecular Weight (UHMW). Ribbed plastic skid plate. ‘98-’01 Grizzly ABA-4WV34-30-00 ‘99 Kodiak & ‘97-’99 Big Bear ABB-4KB34-30-00 Aluminium Skid Plate (not shown) ‘99 Kodiak & ‘98-’99 Big Bear ABB-4KB34-20-00 Protection
6 7 G Utility ATV A-ARM GUARD This lightweight, heavy-duty brushed silver aluminium plate provides added protection ‘02-’06 Grizzly Front ABA-5KM34-10-00 Rear ABA-5KM34-20-00 Kevlar Boot Guard (4 Pcs) Reinforced with extra tough. Para-Aramid fibers. Installs over the rubber CV boots for extra protection. Fits all 4WD models. ABA-2HR95-00-00 Rear Differential Skid Plate Brushed finish, heavy-duty 6061 T6 aluminium. Bolts quickly and easily to rear differential for maximum protection. Fits all solid-axle shaft-drive models. ‘03-’04 Kodiak & Bruin ABB-4KB34-10-00 Front A-Arm Skid Plate Constructed of special brushed-finish silver 5052 H32 aluminium plate for appearance, durability and light weight. Includes a stamped in Yamaha Bear Logo for added distinction. ‘03-’06 Kodiak ABA-5ND34-10-00 Overfenders Custom-formed design helps to deflect trail debris. Set of front and rear overfenders. Bruin ATV-5UH04-FN-DR -’04 Kodiak ABA-5GHFE-ND-00 ’05-’06 Kodiak IRS-1D9 ATV-1D966-00-00 ’02-’06 Grizzly 660 ABB-5KM66-00-00 Fairing Black (ABS) Helps deflect wind, flying objects and brush. Universal ”break-away” mounts allow you to remove and store fairing when not in use. ABA-FAIRN-00-BK Windshield with Bear Logo Installs in minutes. Constructed of durable, clear polycarbonate. ABA-UXX03-00-00 ATV Cover Black Helps protect your ATV while in storage. Storage bag included. Fits all ATV’s (except Grizzly) ATV-COVER-01-00 Fits Grizzly ATV-COVER-02-00 Protection Fairing, Fenders & Windshields
Utility ATV 9 8 Front Rack Extension Wrinkle Finish Powder-coated steel construction for durability, with special wrinkle finish to match stock rack. Helps keep rack loads in place. ’02-’06 Grizzly ABA-5KM53-10-00 Rear Rack Extension Smooth Finish Smooth powder-coated finish, Helps keep rack loads in place. ’98-’01 Grizzly, ’96-’02 Kodiak, ’97-’03 Big Bear ABB-4SH51-10-00 Rear Rack Extension Wrinkle Finish Powder-coated steel construction for durability, with special wrinkle finish to match stock rack. Helps keep rack loads in place. ’02-’06 Grizzly ABA-5KM51-10-00 ’03-’04 Kodiak ABA-5ND51-1W-00 Anti Skid Rubber Packs Grizzly Special aluminium and rubber construction. Fits front or rear rack (one pair per rack). ABA-5KM34-90-00 Standard Front Rack Bag Soft-sided design includes a full-length zipper for easy access, and outside straps for additional attachments. Fits all ATV’s with racks ABB-4SH53-30-00 Rear Rack Bag Features: Shoulder carrying strap. Rubber carry handle. Inside cargo dividers. Heavy-duty zipper and zipper flap. Approx. 80 litres storage capacity. Fits all ATV’s with racks ABA-4SH51-31-BK Standard Rear Rack Bag Soft-sided design includes a full-length zipper for easy access, and outside straps for additional attachments. Fits all ATV’s with racks. ABA-4SH51-30-00 Front Rack Bag FEATURES: Shoulder carrying strap. Snap-on pocket. Rubber carry handle. Inside cargo dividers. Heavy-duty zipper and zipper flap. Approx. 40 litres storage capacity. Approx. 74cm wide bag. ABA-30W53-30-BK Fender Bag Soft-sided design includes a full-length zipper for easy access, and outside straps for additional attachments. Fits all ATV’s. ABA-FENDB-AG-BK ATV Box Sturdy PE ATV box with quick release/ fastening system. Storage space for chain saw. Green ATV-W0754-00-00 Black ATV-W0754-03-00 Mounting Kit ATV Box (not shown) Needed for installation of ATV Box on Big Bear, Kodiak, Grizzly and Bruin. ATV-W0754-BR-01 Racks & Luggage
Utility ATV 11
12 13 Utility ATV A Front Rack Bag Realtree® Hardwoods™ Camouflage FEATURES: Shoulder carrying strap. Snap-on pocket. Rubber carry handle. Inside cargo dividers. Heavy-duty zipper and zipper flap. Kodiak and Bruin Approx. 74cm wide bag. ABA-UXX53-29-HD Grizzly, Big Bear Approx. 80cm wide bag. ABA-UXX53-30-HD Rear Rack Bag Realtree® Hardwoods™ Camouflage FEATURES: Shoulder carrying strap. Snap-on pocket. Rubber carry handle. Inside cargo dividers. Heavy-duty zipper and zipper flap. Approx. 3.0 cubic feet storage capacity. Fits all ATV’s with racks ABA-UXX51-30-HD Fender Cover Realtree® Hardwoods™ Camouflage for Grizzly 660 Form-fitting design fits tightly over the fenders. ABA-5KMCM-CV-HD Seat Cover Realtree® Hardwoods™ Camouflage for Grizzly 660 Easy-to-use, slip-on design. ABA-5KM24-00-HD ATV Cover Realtree® Hardwoods™ Camouflage Helps protect your ATV during storage. Fits all ATV’s (except Grizzly) ABA-5ND43-00-HD Fits Grizzly ABA-5KM43-00-HD Hunting Gun Boot Mount Heavy-duty steel construction for durability. Special powder-coated paint adds corrosion resistance and durability, and is finished to match the rear rack of the ATV. Grizzly 660 ABA-5KM67-40-00 Gun Boot Includes a heavy-duty, impact resistant Yamaha gun boot with thick pile lining. ABB-4SH67-10-00 Deluxe Gun Boot Includes a heavy-duty, impact resistant Yamaha gun boot shell, and a convenient transport bag for your rifle. ABA-UXX67-10-00 Gun Boot Cover Realtree® Hardwoods™ Camouflage. Installs easily into Yamaha’s gun boots. ATV-COVER-GN-HD
14 15 Utility ATV A ATV Lock Medium C-1000 SPECIFICATIONS: Specially designed for securing Yamaha vehicles such as ATV’s to a fixed object. Shackle lock fits ATV’s drive axle up to ø 50 mm Genuine U-lock with good resistance against many types of manual attacks. Ice spray tested. Special hardened hexagonal steel chain. Loop system Chain including Textile webbing for easy use, transport and protection. U-Lock shackle internal length: ø 100 mm U-Lock shackle internal width: ø 52 mm U-Lock shackle diameter: ø 11 mm Chain Link Section: hex. 9 mm Loop ring: hex. 11 mm Length of chain: 1050 mm Gross Weight of combination: ca. 2800 gr. YMD-L0CK4-50-00 ATV Lock Strong C-2000 SPECIFICATIONS: Specially designed for securing Yamaha ATV’s to fixed objects. Total configuration offers high level of security. Special steel hexagonal Chain. Double ball bearing locking for high tensile and torsion strength. Hardened shackle to resist bolt cutters, hack saws, hammers, etc. Double loop ring system to reduce Chain length and weight. Abus Plus Key® locking mechanism, with two keys and separate key number. Loop system Chain including Textile webbing for easy use, transport and protection against scratching. Ice spray tested. Lock Class 3 according EN 12320 Lock - cylinder: Plus Key® System Locking system: Double locking Lock shackle: ø 11 mm Chain Link Section: hex. 11 mm Loopring: hex. 14 mm Length of chain: 1400 mm Gross Weight of combination: ca. 3200 gr. YMD-L0CK4-60-00 Black Bear ATV Immobilizer SPECIFICATIONS: Transponder operated immobiliser system for Yamaha ATV’s. No electric power consumption when activated - saves battery life. Immobilises Ignition and Electric starter. Also handstart not possible when immobiliser is activated. Compact and waterproof design. Easy to install due to wiring with Yamaha couplers. CE approved. YMD-1PCA0-70-MC Transponder ATV Immobilizer YMD-1PCA0-70-MC Antenna ATV Immobilizer YMD-1PCA0-70-MC LED Assy YMD-1PCA0-70-MC Light & Meters Security Light Kit FEATURES: 70.000-candlepower sealed-beam bulb, durable and weather-resistant rubber housing, a deluxe RAM® mounting system, 10' coiled cable, and a 12V-plug/receptacle system. ABA-2HR35-10-00 Light Kit ATV Back Up Halogen YMD-62017-00-00 Light Kit ATV Trail Halogen FEATURES: two halogen lamps, a universal mounting bracket, high-grade mounting hardware, full electrical wiring system, and a water-resistant control switch. YMD-62018-00-00 PIAA 004X Series 35W=60W super white performance. FEATURES: High-performance 60mm (2.4”). Diameter round light kit. Includes lamps, wiring, and switch. Long range beam ABA-73462-00-00 PIAA 510 Series 35W=60W super white performance. FEATURES: High-performance 100mm (3.9”). Diameter round light kit. Includes lamps, wiring, and switch. Long range beam ABA-73514-00-00 Wide beam ABA-73510-00-00 Hour Meter Includes pre-programmed service intervals for 4-cycle ATV’s. ENG-METER-4C-01
16 17 Warn Winches & Plows Yamaha Warn Winch CE 1.5 Ci Yamaha Warn Winch CE 2.5 Ci Yamaha Warn Winch CE 3,0 Ci YMD-70245-00-00 YMD-64501-00-00 YMD-70240-00-00 Model Model code Year mounting kit mounting kit mounting kit Beartracker 2X4 5XG ‘98-’04 4XE-W0769-20-BT 4XE-W0769-20-BT 4XE-W0769-20-BT Bruin 250 2X4 1P0 ‘05-’06 TBA TBA N.A. Bruin 2X4 5WH ‘04-’06 YMD-68366-00 YMD-68366-00 YMD-68366-00 Bruin 4X4 5UH ‘04-’06 YMD-68366-00 YMD-68366-00 YMD-68366-00 Big Bear Professional 4X4 4SH ‘00-’06 N.A. 5GH-W0769-20-K0 5GH-W0769-20-K0 Kodiak 400 Automatic 4X4 5GA ‘00-’02 5GH-W0769-20-K0 5GH-W0769-20-K0 5GH-W0769-20-K0 Kodiak 400 Automatic 2X4 5ND ‘03-’04 YMD-63945-00 YMD-63945-00 YMD-63945-00 Kodiak 400 Automatic 4X4 5ND ‘03-’04 YMD-63945-00 YMD-63945-00 YMD-63945-00 Kodiak 450 Automatic 4X4 5ND ‘03-’04 YMD-63945-00 YMD-63945-00 YMD-63945-00 Kodiak 450 Auto/IRS 4X4 1D9 ‘05-’06 N.A. YMD-69480-00 N.A. Grizzly 600 4X4 5KM ‘98-’01 5GT-W0769-00-GR 5GT-W0769-00-GR 5GT-W0769-00-GR Grizzly 660 Automatic 4X4 5KM ‘02-’06 YMD-65098-01 YMD-65098-01 YMD-65098-01 YFM 660 5LP -’05 YMD-69062-00 N.A. N.A. YFM 700 1S3 ‘06 TBA N.A. N.A. Winching Accessory Kit INCLUDES: Snatch block: assists in double lined and angled pulls. Shackle for rigging attachments. Tree trunk protector: load strap to protect a tree trunk and other objects from the damage a wire rope might cause. YMD-63350-00-00 Winching Gloves Essential for safe handling of wire rope. Material: leather & cotton. YMD-14042-00-00 Remote Control Remote control upgrade for CE 2.5 Ci winch YMD-64259-00-00 Roller Fairlead all models 4.48”/113.7mm. Helps “guide” the cable into and out of the winch YMD-W0769-10-00 Choker Chain (not shown) YMD-26083-00-00 YAMAHA - WARN PLOW CONFIGURATION LIST Warn Winches & Plows YAMAHA - WINCH CONFIGURATION LIST Description Yamaha # Plow Blade kit 54’’ YMD-70954-00-00 Plow Base YMD-62100-00-00 ATV Plow Actuator YMD-67650-00-00 Plow Manual Lift YMD-65510-00-00 Plow Accessories Plow Markers YMD-67679-00-00 Snow Control Flap YMD-67870-00-00 Blade Side Wall YMD-67957-00-00 Plastic Wear Bar YMD-67861-00-00 Plow Ag Adapter YMD-62344-00-00 A B C D E F Model Model Code Year Plow Mounting Kit ATV Plow Actuator Plow Manual Lift Big Bear Professional 4X4 4SH ‘00-’06 YMD-37840-00-00 YMD-67650-00-00 YMD-65510-00-00 Bruin 2X4 5WH ‘04-’06 YMD-64670-00-00 YMD-67650-00-00 YMD-65510-00-00 Bruin 4X4 5UH ‘04-’06 YMD-64670-00-00 YMD-67650-00-00 YMD-65510-00-00 Kodiak 400 Automatic 4X4 5GA ‘00-’02 YMD-60013-00-00 YMD-67650-00-00 YMD-65510-00-00 Kodiak 400 Automatic 2X4 5ND ‘03-’04 YMD-64670-00-00 YMD-67650-00-00 YMD-65510-00-00 Kodiak 400 Automatic 4X4 5ND ‘03-’04 YMD-64670-00-00 YMD-67650-00-00 YMD-65510-00-00 Kodiak 450 Automatic 4X4 5ND ‘03-’04 YMD-64670-00-00 YMD-67650-00-00 YMD-65510-00-00 Kodiak 450 Auto/IRS 4X4 1D9 ‘05-’06 YMD-64670-00-00 YMD-67650-00-00 YMD-65510-00-00 Grizzly 600 4X4 5KM ‘98 YMD-37841-00-00 YMD-67650-00-00 YMD-65510-00-00 Grizzly 600 4X4 5KM ‘99-’01 YMD-39553-00-00 YMD-67650-00-00 YMD-65510-00-00 Grizzly 660 Automatic 4X4 5KM ‘02-’06 YMD-64669-00-00 YMD-67650-00-00 YMD-65510-00-00 CONFIGURATION OPTIONS Step 1: • Order Plow Blade (YMD-70954-00-00) and Base (YMD-62100-00-00) Step 2: • Order Mounting Kit for your ATV (column D) Step 3: • Plow operated by Winch - No further items needed • Plow operated by Manual Lift - Order Manual Lift (YMD-65510-00-00) • Plow operated by Actuator - Order Actuator (YMD-67650-00-00) 1.5ci 2.5ci 3.0ci Part Number: YMD-70245-00-00 YMD-64501-00-00 YMD-69492-00-00 Rated Line Pull: 680kgs (1500 lbs.) single line 1134 kgs. (2500 lbs.) single-line 1360 kgs. (3000 lbs.) single-line Wire Rope 15m, 4mm diameter 15m, 5mm diameter 15m, 5mm diameter Weight 5.2 kgs. 7.0 kgs. 8.6kgs. Motor: 12V DC, .04hp permanent magnet 12V DC, .9hp (.7kW) permanent magnet 12V DC, .9hp (.7kW) permanent magnet Control Handlebar mounted Mini-rocker switch Handlebar mounted Mini-rocker switch Remote Control, 3.0m lead, Handlebar mounted Mini-rocker switch Geartrain 3-Stage Planetary 3-Stage Planetary 3-Stage Planetary Gear ratio 103:01 136:01 136:01 Brake Mechanical brake standard Mechanical brake standard Mechanical brake standard Drum Diameter/Length: 38mm/76mm 51mm/75mm 51mm/75mm Fairlead Hawse Hawse Roller Battery leads 10 gauge 6 gauge 6 gauge Finish Grey Grey Argent grey powder coat Use for Sports ATV’s Mid range Utility Heavy Utility / mud and water environment YAMAHA - WINCH SPECIFICATION LIST
This is a comprehensive workshop service manual for the 04-08 Yamaha RHINO 660 YXR 660 YFM80, covering the years 2004-2008. It includes the complete operations and owners manual, detailing all normal maintenance procedures and ATV functions.
The YXR660 RHINO SERVICE MANUAL consists of hundreds of pages with detailed pictures, diagrams, and procedures that cover the RAPTOR 80 ATV from bumper to bumper. Additionally, it includes individual service supplements for all years of the 04-08 Yamaha RHINO 660.
This RHINO Repair Manual is fully indexed and bookmarked by topic, allowing for quick searches to find the needed information. It is of perfect quality and can be printed entirely or selectively by page. The manual also allows zooming in on diagrams or pictures for easy part identification.
Rest assured, this manual provides the correct and updated information for all years, making it an essential resource for professional mechanics and DIY enthusiasts alike.
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2004-2008 Yamaha Rhino 660 YXR660 Service Manual and Owners Manual 04-08 YXR 660 ATV Workshop Shop Repair Manual