Yamaha Rhino 660: Common Problems & Issues

Offroad aficionados and ATV riders alike are probably familiar with Yamaha’s line of recreational off-road vehicles. But if you’re interested in them at all, you should know what the common associated problems are – especially if you’re thinking about the Yamaha Rhino 660. 

Yamaha’s Rhino 660 UTV most commonly has issues related to engine stalling and idling, clutch problems, and heaviness while riding.

To learn more about the most common problems with the Yamaha Rhino 660 ATV, keep reading this guide. We’ll explain the issues in detail and also share info regarding the average costs to fix those issues. Without further ado, let’s get into the details!

Table of Contents

Common Yamaha Rhino 660 Problems

According to the information we collected by scouring Yamaha UTV forums and Reddit threads about the Rhino 660, the following are some of the most common issues riders faced with their UTV:

  • Engine Idling and Shutdown
  • Problems with Clutch
  • Bulky/Heavy Riding 
  • Engine Damage from Dust

Engine Idling and Shutdown

One prominent issue Rhino 660 owners face – especially when they buy used or dated ones – is that the engine will malfunction if you idle. 

Although it may seem at first like the idling is not a problem, after several minutes, it will lead to the engine suddenly cutting off. What’s more is that the problem is often accompanied by difficulty restarting the engine afterwards.

Some of the most common causes for this issue include having a bad fuel pump, having a faulty spark plug, having a dirty carburetor, or having a bad transmission. 

Average Cost to Fix

Depending on what’s wrong with your Rhino 660 UTV, the cost of repairs could vary:

  • Average Rhino 660 fuel pump replacement cost – as little as $15-$20 for parts and about $100/hour for labor 
  • Average Rhino 660 spark plug replacement cost – roughly $10 for parts and about $100/hour for labor
  • Average Rhino 660 carburetor cleaning cost – about $50-$100
  • Average Rhino 660 transmission replacement cost – between $5-$250 for parts (depending on the part) and about $100/hour for labor 

Problems with Clutch

Another issue with the Rhino 660 is that users may experience a clutch out of place, which causes it to not work properly. This displacement sometimes occurs in aged Yamaha Rhino 660 vehicles, as it’s a natural change over time. 

Although it may seem like a huge problem, as a bad clutch can keep the UTV from engaging and driving, it’s not that hard to fix. All you really need to do is to have a mechanic reposition the clutch and secure it so that it doesn’t keep tipping over.

However, if the clutch isn’t working or is jerking when you move it, it could be due to the part being in need of replacement. This is a more costly issue to fix. 

Average Cost to Fix

If you have a bad clutch that you need to replace, it’s going to cost you somewhere in the ballpark of $600 for an entire clutch kit. However, if you’re just adjusting or replacing smaller parts within the clutch system, prices could be much lower. 

Otherwise, your clutch may simply need to be cleaned and re-lubricated to get it back to working order. You may even be able to save some money by doing this work on your own. 

Bulky/Heavy Riding

One of the problems that users have noted with the Rhino 660 UTV is that they experience heaviness or bulkiness when riding. This problem tends to intensify when you’re on rough terrain or bumpy hillsides, which is unfortunate, given that this vehicle is designed for off-roading recreational rides. 

Average Cost to Fix

Unfortunately, there isn’t a lot you can do to change this aspect of the Rhino 660 UTV. Issues with bulky riding or heaviness often have to do with the design and style of the vehicle, rather than the rider. 

One possible remedy to this problem is increasing the size of your UTV tires. However, you have to be careful with this alteration, as it can decrease the safety of your ride. 

Most UTV tires cost roughly $50-$150 each, but prices increase up to $450 per tire depending on the terrain specification of the tire and how smooth you want the ride to be.

Engine Damage from Dust

Because the air filter in this vehicle isn’t very high-quality, it doesn’t work well in terms of keeping out dirt, dust, and other debris from the engine. As a result, dirt gets sucked into the vehicle’s interior and collects on certain parts of the engine system. 

This leads to damage – which is sometimes severe – to parts like the cylinder walls, engine valves, pistons, or other internal engine parts. And when this damage occurs, it can cost a lot of money to repair or replace the parts. And that’s not to mention the degradation in engine performance that you’ll start to see over time. 

Average Cost to Fix

Depending on the parts affected by dirt penetrating the UTV’s air filter, the cost to make fixes could vary:

  • Average Rhino 660 cylinder replacement cost – $80 for parts and $100/hour for labor
  • Average Rhino 660 air filter replacement cost – $15 for parts and $100/hour for labor
  • Average Rhino 660 engine valve replacement cost – $75 for parts and $100/hour for labor 
  • Average Rhino 660 piston replacement cost – $40 for parts and $100/hour for labor 

Final Thoughts

Our guide to the Yamaha Rhino 660’s common issues is meant to give potential owners of this UTV some important insights. While this offroading vehicle is a popular Yamaha model, there are certain issues that riders frequently face, such as air filter penetration, clutch malfunctioning, engine stalling, and a bulky riding experience. 

Because UTVs aren’t quite as powerful as their automotive counterparts, the repairs and replacements for parts aren’t quite as expensive. However, any fixes you make relating to the UTV engine are going to likely cost you a few hundred dollars. 

Be sure to speak to a qualified UTV mechanic about any repairs you think you might need for your Rhino 660. 

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