Yamaha Rhino YXR66FW, Owner'S Manual

Page 1: ...5UG F8199 14 LIT 11626 20 64 READ THIS MANUAL CAREFULLY It contains important safety information YXR66FW OWNER S MANUAL DIC2342 ...

Page 2: ...EBU00776 ...

Page 3: ... of the features and operation of this vehicle It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your vehicle please consult a Yamaha dealer WARNING Please read this manual carefully before operating this vehicle Do not attempt to operate this vehicle until you have attained adequate knowledge of its controls and operat...

Page 4: ...o alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death WARNING A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury NOTICE A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property TIP A TIP provides key information to make ...

Page 5: ... for on road use Check the laws and regulations in force before choosing where to operate this vehicle It is illegal to operate this vehicle on public lands where vehicles its size are prohibited This vehicle complies with almost all state off highway noise level and spark arrester laws and regulations YXR66FW OWNER S MANUAL 2007 by Yamaha Motor Corporation U S A 1st edition July 2007 All rights r...

Page 6: ...lerator pedal 4 9 Brake pedal 4 9 Parking brake lever 4 10 1 2 3 4 Seat belts 4 14 Glove compartment 4 14 Cargo bed 4 15 Front and rear shock absorber adjustment 4 17 Trailer hitch bracket and receiver 4 18 Auxiliary DC jack 4 19 FOR YOUR SAFETY PRE OPERATION CHECKS 5 1 Front and rear brakes 5 3 Fuel 5 4 Engine oil 5 6 Coolant 5 7 Final gear oil 5 7 Differential gear oil 5 7 Accelerator pedal 5 8 ...

Page 7: ...BASIC GUIDE FOR SAFE USE 7 1 KNOW YOUR VEHICLE 7 1 Doors 7 9 Passenger handholds 7 9 Seat and hip restraints 7 10 Floorboard 7 11 Steering wheel 7 11 LEARNING TO OPERATE YOUR VEHICLE 7 12 Personal protective equipment 7 12 Practice for new Rhino users 7 13 Getting ready to ride 7 14 Turning 7 15 Accelerating 7 16 Braking 7 16 Engine braking 7 16 Leaving the vehicle 7 17 Parking on a flat area 7 17...

Page 8: ...tridge 8 10 Final gear oil 8 15 Drive select lever box check hose 8 29 V belt cooling duct check hose 8 30 V belt case drain plug 8 30 Cleaning the spark arrester 8 31 Carburetor adjustment 8 32 Idle speed adjustment 8 33 Valve clearance 8 34 Brakes 8 34 Front brake pad check 8 34 Rear brake pad check 8 35 Checking the brake fluid level 8 36 Brake fluid replacement 8 37 Checking the brake pedal 8 ...

Page 9: ...ight bulb 8 51 Headlight beam adjustment 8 54 Tail brake light bulb replacement 8 54 Troubleshooting 8 56 Troubleshooting charts 8 58 CLEANING AND STORAGE 9 1 A Cleaning 9 1 B Storage 9 2 MAINTENANCE RECORD 11 5 YAMAHA MOTOR CORPORATION U S A SIDE SIDE VEHICLE LIMITED WARRANTY 11 6 YAMAHA EXTENDED SERVICE Y E S 11 7 9 EE book Page 4 Friday August 3 2007 4 52 PM ...

Page 10: ...EVU00060 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS 5 8 7 6 5 1 3 2 3 4 EE book Page 1 Friday August 3 2007 4 52 PM ...

Page 11: ...e crushed by the cage frame If you think or feel that the vehicle may tip or roll brace your feet on the floorboards and keep your hands on the WARNING Any part of your body arms legs or head outside of the vehicle can be crushed by the cage frame If you think or feel that the vehicle may tip or roll brace your feet on the floorboards and keep your hands on the WARNING YAMAHA 5B4 K8483 00 Do not r...

Page 12: ...REAR 91kPa 91kgf cm2 13psi Never set or allow tire pressure to be below the minimum Tire may dislodge from rim Gross Vehicle Weight Rating 907 kg 2000 lb maximum including vehicle weight of operator passenger accessories cargo and if applicable trailer tongue weight WARNING Keep hands body and other people away from pinch points when lowering bed Do not hold the cage frame while closing bed YAMAHA...

Page 13: ...oose load could change handling unexpectedly or be thrown forward and strike occupants Keep weight in the cargo bed centered side to side and as low and as far forward as possible Top heavy loads increase the risk of overturn Do not tow or pull objects from any point other than the trailer hitch bracket or winch if installed When loaded with cargo or towing a trailer Reduce speed and allow more ro...

Page 14: ...Checklist ü Head Helmet and eye protection ü Body Seatbelt and protective clothing ü Hands Inside vehicle and holding the handholds or steering wheel ü Feet On floorboard ready to brace and door closed EE book Page 5 Monday August 6 2007 6 58 PM ...

Page 15: ... Rhino may tip or roll Brace yourself by pressing your feet firmly on the floorboards and keep a firm grip on the steering wheel or handholds Do not put your hands or feet outside of the vehicle for any reason Be Qualified and Responsible This vehicle is intended for use only by an operator 16 or older with a valid motor vehicle license Read the Owner s Manual To reduce risk of accidents and injur...

Page 16: ...he labels on the vehicle to instruct new operators and passengers Do not allow anyone else to operate your vehicle or ride as a passenger if you are unsure that he she is willing and able to follow these instructions Get to know your vehicle This off road vehicle will handle and maneuver differently from cars ATVs go carts golf cars and grounds keeping vehicles Follow these instructions to reduce ...

Page 17: ...seat belts properly Both driver and passenger must be able to put both feet flat on the floorboard while seated upright with their backs against the seat backs Passenger must be able to reach and hold the handholds within the cage frame Both driver and passenger should wear an approved motorcycle helmet that fits properly Both driver and passenger should also wear eye protection goggles or a face ...

Page 18: ...ing objects can affect handling stability and risk of overturn or other accidents Read Chapter 6 before loading towing or pulling objects Do not overload the vehicle or trailer Refer to label in cargo bed for cargo bed load limit Re fer to label next to hitch for tongue weight and trailer load limits Keep weight in the cargo bed centered side to side and as low and as far forward as pos sible Secu...

Page 19: ...ruck by objects your vehicle is passing or crushed by the vehicle cage frame in a rollover accident Watch for branches brush or other hazards that could enter the vehicle Abrupt maneuvers or aggressive driving even on flat open areas can cause loss of control including rollovers The Rhino has higher ground clearance and other features to handle rug ged terrain and as a result can overturn in situa...

Page 20: ...an result in a rollover Avoid sideways sliding skidding or fishtailing and never do donuts Slow down before entering a turn and avoid hard braking in a turn When making tight turns from a stop or at slow speeds avoid sudden or hard accelera tion EE book Page 5 Friday August 3 2007 4 52 PM ...

Page 21: ...eering wheel or handholds Do not put your hands or feet outside of the vehicle for any reason Your arm or leg could be crushed Do not try to stop a vehicle tipover using your arm or leg Do not operate this vehicle on any public street road or highway even if dirt or gravel Do not operate the vehicle in fast flowing water or water deeper than 33 cm 13 in If you must cross shallow slow moving water ...

Page 22: ...oid hills and rough terrain Use extreme caution when towing or carrying a load on in clines Load trailer properly and use extra care when towing or pulling Do not tow or pull objects from any part of the vehicle other than the trailer hitch bracket or winch if installed EE book Page 7 Friday August 3 2007 4 52 PM ...

Page 23: ...levels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas If you experience any symp toms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDI CAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open win dows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine ...

Page 24: ...sold by Yamaha or modifications not specifically recommended by Yamaha even if sold and installed by a Yamaha dealer Aftermarket parts accessories and modifications While you may find aftermarket products similar in design and quality to genuine Yamaha Acces sories recognize that some aftermarket accessories or modifications are not suitable because of potential safety hazards to you or others Ins...

Page 25: ...he performance capabili ties and to provide the best combination of handling braking and comfort Other tires rims sizes and combinations may not be appropriate Refer to pages 8 42 8 45 for tire specifications and more information on replacing your tires EE book Page 10 Friday August 3 2007 4 52 PM ...

Page 26: ...eservoir 4 Air filter elements engine and air intake duct 5 V belt case 6 Driver seat 7 Driver seat belt C 14 Spark arrester 15 Passenger seat belt 16 Passenger seat 17 Oil filter cartridge 18 Passenger handhold 19 Engine oil filler cap 20 Battery I H E J K L M C N D F G EE book Page 1 Friday August 3 2007 4 52 PM ...

Page 27: ...drive and differential gear lock switches 30 Multi function meter unit 31 Auxiliary DC jack 32 Drive select lever 33 Parking brake lever 34 Accelerator pedal The vehicle you have purchased may differ slightly from those shown in the figures of this manual O P Q R S T U Y X W V H EE book Page 2 Friday August 3 2007 4 52 PM ...

Page 28: ...plied with power and the headlights and tail lights come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this posi tion START The electric starter is engaged by turning and holding the key in this po sition Release the key when the en gine starts OFF O N S T A R T OFF ON START EE book Page 1 Friday August 3 2007 4 52 PM ...

Page 29: ...U01131 On Command differential gear lock indica tor light DIFF LOCK This indicator light and the On Command dif ferential gear lock indicator in the display come on when the On Command differential gear lock switch is set to the LOCK position When the switch is set to LOCK the On Command differential gear lock indicator light will flash until the differential gear is locked EVU01140 Low range indi...

Page 30: ...er check the speed sensor circuit EVU00210 EVU01161 On Command four wheel drive differential gear lock indicator The On Command four wheel drive indicator comes on when the On Command four wheel drive switch is set to the 4WD posi tion The On Command differential gear lock indi cator in the On Command four wheel drive indicator also comes on when the On Command differential gear lock switch is set...

Page 31: ...engine may overheat if the vehicle is overloaded If this happens reduce the load to specification After restarting make sure that the light is out Continuous use while the light is on may cause damage to the engine EVU01630 Multi function meter unit 1 Speedometer 2 Fuel meter 3 H button 4 M button 5 Clock Hour meter 6 Odometer Tripmeter A Tripmeter B 7 TRIP ODO button 8 Clock Hour button The multi...

Page 32: ...meter modes A and B in the fol lowing order ODO TRIP A TRIP B ODO To reset a tripmeter select it by pushing the TRIP ODO button and then hold the TRIP ODO button for at least three seconds The tripmeters can be used to estimate the dis tance that can be traveled with a full tank of fu el This information will enable you to plan future fuel stops Holding in the TRIP ODO button and then turning the ...

Page 33: ...hing the H button 4 Set the minutes by pushing the M but ton 5 Push the button and then re lease it to start the clock Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear from F full towards E empty as the fuel level decreases When the E segment disappears and the fuel level warning indicator flashes refuel as soon as possible 1 ...

Page 34: ... to to turn on the high beam and the taillights NOTICE Do not use the headlights with the engine turned off for an extended period of time The battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it L H L H L H EE book Page 7 Friday August 3 2007 4 52 PM ...

Page 35: ...WD and a differential gear lock switch 4WD LOCK Select the appropriate drive accord ing to terrain and conditions Four wheel drive 4WD Power is sup plied to the rear and front wheels Four wheel drive with the differential gear locked 4WD LOCK Power is supplied to the rear and front wheels with the differ ential gear locked Unlike the 4WD mode all wheels turn at the same speed regard less of tracti...

Page 36: ...ressure returns the pedal to the rest position when released Al ways check that the accelerator pedal returns normally before starting the engine 1 Accelerator pedal EVU00270 Brake pedal Press the brake pedal to slow or stop the ve hicle 1 Brake pedal EE book Page 9 Friday August 3 2007 4 52 PM ...

Page 37: ... moving while parked To set the parking brake pull the lever up completely To release the parking brake pull up on the lever press the release button and then push the lever all the way down Spring pressure helps return the lever to the released position 1 Parking brake lever 2 Release button EE book Page 10 Friday August 3 2007 4 52 PM ...

Page 38: ...i cle into the low high neutral and reverse po sitions Refer to pages 6 6 6 7 for the drive select lever operation 1 Drive select lever EVU00300 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap EE book Page 11 Friday August 3 2007 4 52 PM ...

Page 39: ...r choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op eration See pages 6 2 6 5 Doors To open a door simply pull the latch outward To close a door push or pull the door inward until it is securely latched Be sure the door is SECURELY LATCHED AFTER CLOSING IT 1 Latch 2 Door 1 2 EE book Page 12 Friday August 3 2007 4 52 PM ...

Page 40: ...ssenger seat 3 Seat lock lever 2 To install a seat insert the projections on the rear of the seat into the seat holders and push down on the seat at the front Make sure the seats are securely latched WARNING A loose seat could cause the operator to lose control or cause the operator or pas senger to fall EE book Page 13 Friday August 3 2007 4 52 PM ...

Page 41: ...while riding in the vehicle See pages 7 6 7 8 for more information EVU01191 Glove compartment NOTICE To protect from damage do not put metal products like tools or sharply edged prod ucts directly in the glove compartment If they must be stored wrap them in appro priate cushioning material a Unlock b Open EE book Page 14 Friday August 3 2007 4 52 PM ...

Page 42: ...ng information see pages 6 11 6 13 Opening and closing the tailgate 1 Tailgate 2 Latch 2 To open Unhook the latches and then lower the tail gate To close Place the tailgate in the original position and Maximum load limit 181 kg 400 lb EE book Page 15 Friday August 3 2007 4 52 PM ...

Page 43: ...y lift up the cargo bed until it stops To lower With hands and fingers clear of pinch points lower the cargo bed slowly to its original posi tion and be sure it is locked into place WARNING Keep hands body and other people away from pinch points when low ering bed Do not hold onto the cage frame while closing the bed EE book Page 16 Friday August 3 2007 4 52 PM ...

Page 44: ...right sides to the same setting Un even adjustment can cause poor handling and loss of stability which could lead to an accident NOTICE Frequent or severe bottoming can cause increased wear or damage to the vehicle Adjust the spring preload as follows To increase the spring preload turn the ad justing ring in direction a To decrease the spring preload turn the ad justing ring in direction b 1 Spri...

Page 45: ...vehicle is equipped with a trailer hitch bracket and a 5 cm 2 in receiver for a stan dard trailer hitch Trailer towing equipment can be obtained at a Yamaha dealer See pages 6 11 6 13 for precaution information 1 Trailer hitch bracket 2 Receiver Standard position B A Minimum soft E Maximum hard 2 1 EE book Page 18 Friday August 3 2007 4 52 PM ...

Page 46: ...ork lights radios etc The auxiliary DC jack should only be used when the engine is running 1 Auxiliary DC jack cap 1 Set the light switch to OFF 1 Auxiliary DC jack 4 When the auxiliary DC jack is not being used cover it with the cap Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A EE book Page 19 Friday August 3 2007 4 52 PM ...

Page 47: ...d cause the fuse to blow If accessories are used without the en gine running the battery will lose its charge and engine starting may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged EE book Page 20 Friday August 3 2007 4 52 PM ...

Page 48: ...ment damage Do not operate the vehicle if you find any problem If a problem cannot be corrected by the procedures provided in this manual have the vehicle inspect ed by a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Brakes Check operation free play fluid level and fluid leakage Fill with DOT 4 brake fluid if necessary 5 3 8 34 8 37 8 39 8 40 Parking brake Ch...

Page 49: ...heck for proper operation and belt wear 5 8 Steering Check for proper operation 5 8 Fittings and fasteners Check all fittings and fasteners 5 8 Lights and switches Check for proper operation 5 9 8 51 8 56 Wheels and tires Check tire pressure and for wear and damage 5 9 5 11 8 42 8 45 Axle boots Check for damage 8 20 ITEM ROUTINE PAGE EE book Page 2 Friday August 3 2007 4 52 PM ...

Page 50: ... neces sary See pages 8 36 8 37 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir Ap ply the brakes firmly for one minute If there is any leakage have the vehicle inspected by a Yamaha dealer Brake operation Check the operation of the brakes at the start of every ride Test the brakes at slow speed after starting out to make sure they...

Page 51: ...n flames or oth er sources of ignition such as the pilot lights of water heaters and clothes dry ers 2 Do not overfill the fuel tank Because fuel 4 Be sure the fuel tank cap is closed se curely WARNING Gasoline is poisonous and can cause inju ry or death Handle gasoline with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoli...

Page 52: ...Yamaha because it may cause fuel system damage or vehicle performance problems Portable gas containers If you carry a portable gas can in the bed of the Rhino be sure to secure it with the cap tightened before driving the vehicle Always place a portable gas container on the ground before filling it Before removing the container cap touch the container with the gas dispenser nozzle Keep gas dispens...

Page 53: ...o not mix any chemical addi tives with oil Do not use oils with a die sel specification of CD or oils of a higher quality than specified In addi tion do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase 1 CD specification 2 ENERGY CONSERVING II Recommended engine oil type and quantity See page 10 2 1 2 EE book Page 6 Friday August 3 2007 4...

Page 54: ... 8 19 8 20 for details NOTICE Hard water or salt water is harmful to the engine You may use soft water if you can not get distilled water EVU00430 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 15 8 16 for details If desired an SAE 80W90 hypoid gear oil may be used for all conditions TIP TIP GL 4 is a quality and additive rating GL 5 or GL 6 ...

Page 55: ... off any dirt or mud that could af fect operation Have a Yamaha dealer repair as necessary for proper operation A crash can damage the restraint systems in your vehicle A damaged restraint system may not properly protect the person using it resulting in serious injury or death in a crash To help make sure your restraint systems are working properly after a crash have them in spected and any necess...

Page 56: ... and you could be unable to control the vehicle EVU00500 Tires Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage EVU00510 Tire pressure Use the tire pressure gauge to check and ad just tire pressures when the tires are cold Tire pressures must be equal on both sides WARNING Operation of this vehicle with improper tire pressure may cau...

Page 57: ...e the second reading Dust or dirt in the gauge could cause the first reading to be incorrect 1 Tire pressure gauge Recommended pressure Minimum Maximum Front 70 kPa 0 70 kgf cm2 10 psi 63 kPa 0 63 kgf cm2 9 psi 77 kPa 0 77 kgf cm2 11 psi Rear 98 kPa 0 98 kgf cm2 14 psi 91 kPa 0 91 kgf cm2 13 psi 105 kPa 1 05 kgf cm2 15 psi EE book Page 10 Friday August 3 2007 4 52 PM ...

Page 58: ...EVU00520 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit EE book Page 11 Friday August 3 2007 4 52 PM ...

Page 59: ...life of your vehicle than the period between zero and 20 hours For this reason we ask that you read the fol lowing material carefully Because the engine is brand new you must not put an excessive load on it for the first several hours of opera tion During the first 20 hours the various parts in the engine wear and polish them selves to achieve the correct operating clear ances During this period p...

Page 60: ...ehicle from time to time Do not operate it at one set throttle position 10 20 hours Avoid prolonged operation above three quar ter throttle EVU00540 Starting a cold engine 1 Apply the brake pedal 2 Shift the drive select lever into the neutral position When the drive select lever is in the neutral position the neutral indicator light should come on If the neutral in dicator light does not come on ...

Page 61: ... ambient temperature at 0 C 30 F 30 C 90 F and warming up position Position 3 Cold engine start ambient temperature above 25 C 80 F and warm engine start position a Starter choke 1 Fully open 2 Half open 3 Closed 4 With your foot off the accelerator pedal start the engine by turning the key to START EE book Page 3 Friday August 3 2007 4 52 PM ...

Page 62: ... may result WARNING The speed of a cold engine may increase enough as it warms up to cause the vehi cle to move on its own while the choke is being used Do not get out of the vehicle while the engine is running and the drive select lever is in any gear Unwanted vehicle movement can cause serious injury or death and it may be dan gerous to try to stop the vehicle The park ing brake may not keep the...

Page 63: ... warm engine To start a warm engine refer to the Starting a cold engine section The starter choke should not be used Press the accelerator pedal slightly EVU00561 Warming up To get maximum engine life always warm up the engine before starting off To see whether or not the engine is warm check for smooth throttle response with the vehicle in neutral and the starter choke turned off Never accelerate...

Page 64: ...ccur Shifting neutral to high and high to low 1 Stop the vehicle Take your foot off the accelerator pedal 2 Apply the brake pedal then shift by mov ing the drive select lever along the shift guide Make sure that the drive select le ver is completely shifted into position 1 Drive select lever 3 Release the brake pedal and press the accelerator pedal gradually EE book Page 6 Friday August 3 2007 4 5...

Page 65: ... Apply the brake pedal 3 Shift from neutral to reverse or vice versa by moving the drive select lever along the shift guide When in reverse the reverse indicator light should be on Due to the synchro nizing mechanism in the engine the light may not come on until the vehicle 1 Drive select lever 4 Check behind the vehicle for people or obstacles and then release the brake pedal 5 Press the accelera...

Page 66: ...FF LOCK Always stop the vehicle before changing between 2WD and 4WD or 4WD and 4WD LOCK DIFF LOCK 2WD 4WD To change from 2WD to 4WD stop the vehi cle and then set the switch to 4WD When the vehicle is in 4WD the four wheel drive in dicator will come on in the multi function display To change from 4WD to 2WD stop the vehicle be sure the differential gear lock lever is set to position a and then set...

Page 67: ...r is locked the differential gear lock indicator light DIFF LOCK will come on along with the differential gear lock indica tor in the multi function display To re lease the differential gear lock stop the vehicle and set the switch to 4WD When the switch is set to LOCK the dif ferential gear lock indicator and indicator light will flash until the differential gear is locked When the indicator and ...

Page 68: ... speed to be limited until en gagement is complete EVU01210 Parking When parking stop the engine and shift the drive select lever into the neutral position Ap ply the parking brake to help prevent the vehi cle from rolling See pages 7 17 7 18 for more information on parking and parking on a slope EE book Page 10 Friday August 3 2007 4 52 PM ...

Page 69: ...r accident Do not exceed the Maximum Loading Limits for the vehicle see box or vehi cle labeling Keep weight in the cargo bed centered side to side and as low and as far for ward as possible Top heavy loads in Do not exceed the maximum tongue weight Make sure the load does not interfere with your control or ability to see where you are going Tie down cargo in the trailer securely Make sure cargo i...

Page 70: ... load in the trailer if necessary to reduce the weight on hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum vehicle load limit MAXIMUM LOADING LIMIT Vehicle loading limit total weight of cargo operator passenger and accessories and tongue weight 393 kg 866 lb Cargo bed 181 kg 400 lb Trailer hitch Pulling load total weight of trailer and cargo 550 kg 1 21...

Page 71: ...kes longer to stop Avoid hills and rough terrain Choose Pulling something other than a trailer Yamaha recommends that loads be transport ed in the bed or in a trailer If you need to move an object a short distance use a winch and follow the winch manufacturer s instruc tions If you choose to use something other than a winch use extreme caution follow the manu facturer s instructions for that produ...

Page 72: ...low these instructions to reduce your risk of an accident and to reduce the risk of serious injury or death in the event of an accident KNOW YOUR VEHICLE This off road vehicle will handle and maneu ver differently from cars ATVs go carts golf cars and grounds keeping vehicles The Rhino has higher ground clearance and other features to handle rugged terrain and as a result can overturn in situation...

Page 73: ... inju ries or death to drivers or passengers As the owner operator it is your responsibility to protect yourself and your passenger from accidents including rollovers The Rhino has many features including a protective struc ture and seat belts to help protect occupants but the best way to avoid injuries is to avoid accidents There is a risk of injury or death in any accident even with these safety...

Page 74: ... when the vehicle is not in use to prevent unauthorized use of the machine Parents Many states have implemented new motor vehicle licensing requirements for young driv ers These requirements are in response to the disproportionately high rate of crashes in volving youthful drivers As with automobiles to promote safe driving behaviors you should supervise drivers and consider setting rules and putt...

Page 75: ...ace both feet on the floorboard while seated upright with his her back against the seat back Allow only one passenger in the vehicle and only in the passenger seat Do not car ry any other passengers Do not carry pas sengers in the cargo bed Do not allow someone to ride as a passen ger who has been using drugs or alcohol Occupant protection system 1 Passenger handhold 2 Seat belt 3 Door 1 2 2 3 1 E...

Page 76: ...s injury or death You are re sponsible for any such changes to the ve hicle The Rhino comes with a variety of features to help reduce the risk of driver and passenger injury These features work together and when properly used these features will help protect the occupants in the event of an acci dent If these features are not used properly they can cause injury 1 EE book Page 5 Friday August 3 200...

Page 77: ... or hip restraint bar Wear your seat belt and helmet If you think or feel that the vehicle may tip or roll do not put your hands or feet outside the vehicle for any reason You will not be able to Seat belts Seat belts should be worn by both driver and passenger Driver must be sure that the pas senger is belted before driving Be sure the seat belt is not twisted is close fitting across the hips and...

Page 78: ...nt systems in your vehicle A damaged restraint system may not properly protect the person using it resulting in serious injury or death in a crash To help make sure your restraint systems are working properly after a crash have them in spected and any necessary replacements made as soon as possible 1 Seat belt 2 2 Latch plate 2 3 Buckle 2 To wear the seat belt properly do the follow ing 1 Hold the...

Page 79: ...il it clicks Pull up on the latch plate to make sure it is secure 4 Put the lap portion of the belt low on your hips Pull up on the shoulder part so the belt is snug across your hips 5 Position the shoulder belt over your shoulder and across your chest The shoulder belt should fit against your chest If it is loose pull the belt out all the way and then let it retract 6 To release the buckle firmly...

Page 80: ...crushed against outside objects or the ground during a rollover Passenger handholds Handholds are provided to grip during opera tion to maintain proper position and balance Holding onto the handholds helps to reduce the likelihood that the passenger puts a hand outside the vehicle if the vehicle begins to tip There are two handholds on the protective structure and two handholds on the passen ger s...

Page 81: ... designed to help keep you in the vehicle Do not hold onto hip restraint bar when the vehicle is moving Your hand or arm may be struck by objects or crushed against outside objects or the ground during a rollover EE book Page 10 Friday August 3 2007 4 52 PM ...

Page 82: ...your palms on the out side of the steering wheel Similar to other off road vehicles if the Rhino hits a deep rut or large obstacle the steering wheel could brief ly jerk in one direction or back and forth as the tires and vehicle respond to the obstacle This quick motion could injure your thumbs or wrist if your thumbs or hand s are inside the steer ing wheel Grip the steering wheel so that your t...

Page 83: ...LEARNING TO OPERATE YOUR VEHICLE Personal protective equipment CORRECT GRIP EXAMPLE INCORRECT GRIP EXAMPLE 1 2 3 4 5 6 EE book Page 12 Friday August 3 2007 4 52 PM ...

Page 84: ...ation Wear eye protection when operating or riding the vehicle to reduce the risk of a serious ac cident or injury Eye protection such as a face shield or goggles may reduce the risk of for eign material getting in your eyes and help prevent loss of vision Practice for new Rhino users You should become familiar with the perfor mance characteristics of the vehicle in a large flat area that is free ...

Page 85: ...Steering may take more effort in 4WD with the differential locked DIFF LOCK Also practice driving in re verse Getting ready to ride Perform the Pre Operation Checks on pages 5 1 5 11 Follow the instructions starting on page 6 2 to start the engine Once it has warmed up and you have turned the choke off you are ready to begin driving your vehi cle EE book Page 14 Friday August 3 2007 4 52 PM ...

Page 86: ...l during a turn steer into the direction of the slide if possible and gradually let off the accelerator pedal to regain directional control and avoid rollover For example if you feel the back of the vehicle start to slide to your right steer to the right If you think or feel that the vehicle may tip or roll keep your body completely inside the pro tective structure of the vehicle Brace yourself by...

Page 87: ...miliar with the operation of your vehicle Avoid sud den or hard acceleration in any turn Braking When slowing down or stopping take your foot off the accelerator pedal and press the brake pedal smoothly Improper use of the brakes can cause the tires to lose traction re ducing control of the vehicle and increasing the possibility of an accident Braking ability is affected by type of terrain In most...

Page 88: ... or death and it may be dangerous to try to stop the vehicle Parking on a flat area When parking on a flat area stop the engine and shift the drive select lever into the neutral position Apply the parking brake to help pre vent the vehicle from rolling Parking on a slope The parking brake acts only on the rear wheels when in 2WD For the parking brake to take effect on all four wheels shift to 4WD ...

Page 89: ...ng on an unfamiliar surface or terrain This vehicle may handle differently in certain types of terrains or on certain surfaces You may come upon hidden rocks bumps or holes without enough time to react To avoid loss of control or rollover always be alert to changing surfaces or terrain when operating the vehicle The Rhino has higher ground clearance and other features to handle rugged terrain and ...

Page 90: ... steep for you to climb or descend Use proper driving techniques to avoid rearward forward or sideways rollovers on hills and slopes Drive straight up and down inclines not across them If crossing a hill is unavoidable drive slowly Turn downhill immediately if you feel the vehicle may tip If you think or feel the Rhino may tip or roll Brace yourself by pressing your feet firmly EE book Page 19 Fri...

Page 91: ...m but not so fast that you can not react to changes in the terrain as you climb Slow down when you reach the crest of the hill if you cannot see clearly what is on the other side there could be another person an ob stacle or a sharp drop off If you start to lose traction or momentum when climbing and decide you will be unable to continue use the brakes to stop Do not at tempt to turn the vehicle a...

Page 92: ... If you begin to go too fast apply the brakes gently Avoid hard application of the brakes which could cause the vehicle to slide If you are sliding or skidding try to steer in the direction the vehicle is sliding to regain con trol For example if you feel the back of the vehicle start to slide to your right steer to the right If you must turn on the hill to avoid an obsta cle do so slowly and care...

Page 93: ...oss shallow slow moving water up to the depth of the vehicle s floorboards choose your path carefully to avoid sharp drop offs large rocks or slippery surfaces that could cause the vehicle to overturn Nev er operate through water deeper than 33 cm 13 in or fast flowing water Choose a path where both your entrance into and exit point from the water is a gradual incline Determine the water depth and...

Page 94: ...ing on slippery terrain including wet muddy or icy conditions as well as loose gravel be aware that you could begin skid ding or sliding To avoid loss of control slow down and put the Rhino in 4WD before driving on a slippery surface and plan your path to avoid making abrupt maneuvers If you feel the Rhino begin to slide sideways or fishtail during a turn steer into the direction of the slide if p...

Page 95: ...the vehicle near the muffler or exhaust pipe or next to other hot Encountering obstacles If you cannot go around an obstacle such as a fallen tree or a ditch stop the vehicle where it is safe to do so Set the parking brake and get out to inspect the area thoroughly Look from both your approach side and exit side If you believe you can continue safely choose the path that will allow you to get over...

Page 96: ...ies incor rectly may increase your risk of injury or death during service or while using the ve hicle If you are not familiar with vehicle service have a Yamaha dealer perform service WARNING Turn off the engine when performing main tenance unless otherwise specified A running engine has moving parts that can catch on body parts or cloth ing and electrical parts that can cause shocks or fires Runn...

Page 97: ...ace beside the battery 1 Owner s manual 1 Owner s tool kit 2 Tire pressure gauge The service information included in this man ual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor re pairs The tools provided in the owner s tool kit are sufficient for this purpose except that a torque wrench is also necessary to properly tig...

Page 98: ...ot have a torque wrench available during a service operation requiring one take your vehicle to a Yamaha dealer to check the torque settings and adjust them as necessary EE book Page 3 Friday August 3 2007 4 52 PM ...

Page 99: ... should be performed by a Yamaha dealer as they require spe cial tools data and technical skills ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Fuel line Check fuel hose for cracks or damage Replace if necessary Valves Check valve clearance Adjust if necessary Spark plug Check condition Adjust ga...

Page 100: ... Replace Final gear oil Check oil level oil leakage Replace Differential gear oil Front brake Check operation brake pad wear fluid leakage see page 8 6 Correct if necessary Replace pads if worn to the limit Rear brake Check operation brake pad wear fluid leakage see page 8 6 Correct if necessary Replace pads if worn to the limit Accelerator pedal Check operation and free play V belt Check operatio...

Page 101: ...racked or damaged Drive shaft universal joint Lubricate with lithium soap based grease Engine mount Check for cracks or damage Check bolt tightness Front and rear axle boots Check operation Replace if damaged Stabilizer bushings Check for cracks or damage Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 ...

Page 102: ...EVU00680 Hood To open Unhook the hood latches and then slowly tilt the hood up until it stops 1 Latch 2 1 Hood EE book Page 7 Friday August 3 2007 4 52 PM ...

Page 103: ...2 on the back of the instrument panel Secure slots 3 on the side of the hood around projections 4 on the frame 1 Projection 2 2 Slot 2 3 Slot 2 4 Projection 2 NOTICE Make sure that all cables and wires are in place when closing the hood Do not drive the vehicle with the hood open unlatched or removed EE book Page 8 Friday August 3 2007 4 52 PM ...

Page 104: ...ome loose To install 1 Place the console in its original position 2 Install the parking brake lever boot 3 Install the seats NOTICE When installing the console be sure not to pinch the cables or wires Make sure that the groove at the bottom of the parking brake lever boot and the drive select lever boot fits securely around the edge of the hole in the con sole EE book Page 9 Friday August 3 2007 4...

Page 105: ...ine If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil settles for an accurate reading 4 Remove the engine oil filler cap and wipe 5 Insert the dipstick in the oil filler hole without screwing it in and then remove it again to check the oil level The engine oil should be between the minimum and maximum...

Page 106: ...ment 1 Remove the console See page 8 9 for console removal and installation proce dures 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the engine to col lect the used oil and then remove the en gine oil filler cap 4 Remove the engine oil drain bolt to drain the oil from the crankcase EE book Page 11 Friday August 3 2007 4 52 PM ...

Page 107: ...ealer 1 Oil filter cartridge 2 Oil filter wrench 6 Apply a light coat of clean engine oil to the O ring of the new oil filter cartridge Make sure the O ring is seated properly 1 O ring 7 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench Tightening torque EE book Page 12 Friday August 3 2007 4 52 PM ...

Page 108: ...p and tighten it NOTICE Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down Tightening torque Engine oil drain bolt 30 Nm 3 0 m kgf 22 ft lbf Recommended engine oil See page 10 2 Oil quantity Without oil filter cartridge replacement 1 90 L 1 67 Imp qt 2 01 US qt With oil filter cartridge replacement 2 00 L 1 76 Imp qt 2 11 US qt EE book Page 13 Friday ...

Page 109: ...se oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase 10 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 11 Turn the engine off wait at least ten min utes and then check the oil level and cor rect it if necessary 12 Reinstall the co...

Page 110: ...ole 1 Final gear oil filler bolt 2 Final gear oil 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level NOTICE Be sure no foreign material enters the final gear case 4 Reinstall the oil filler bolt and then tight en it to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf EE book Page 1...

Page 111: ...d the recommended final gear oil up to the brim of the filler hole NOTICE Be sure no foreign material enters the fi nal gear case 6 Reinstall the oil filler bolt and then tight en it to the specified torque 7 Check for oil leakage If oil leakage is found check for the cause Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 25 L 0 22 Imp qt 0 26 US qt Tightening torque Final gear oil f...

Page 112: ...CE Be sure no foreign material enters the differential gear case 3 Reinstall the differential gear oil filler bolt and then tighten it to the specified torque Changing the differential gear oil 1 Park the vehicle on a level surface 2 Place a container under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and differential gear oil drain bolt to drai...

Page 113: ...er bolt and then tighten it to the specified torque 7 Check for oil leakage If oil leakage is found check for the cause Tightening torque Differential gear oil drain bolt 9 8 Nm 0 98 m kgf 7 1 ft lbf Recommended oil SAE 80 API GL 5 Hypoid gear oil Oil quantity 0 32 L 0 28 Imp qt 0 34 US qt Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf EE book Page 18 Friday August 3...

Page 114: ...rvoir when the engine is cold as the coolant level varies with engine tempera ture The coolant should be between the minimum and maximum level marks 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark 4 If the coolant is at or below the minimum level mark remove the reservoir cap add coolant to the maximum level mark reinstall the reservoir cap and then close the hood Coolant reservo...

Page 115: ... the coolant as soon as possible The radiator fan is automatically switched on or off according to the coolant temperature in the radiator NOTICE Mix antifreeze with distilled water only However if distilled water is not available soft water may be used for refilling If your vehicle overheats see page 8 59 for EVU00740 Axle boots Check the protective boots for holes or tears If any damage is found...

Page 116: ... side 5UG14001 Spark plug inspection Removal 1 Lift the cargo bed up See pages 4 15 4 16 for cargo bed lifting and lowering procedures 2 Remove the spark plug cap 1 Spark plug cap EE book Page 21 Friday August 3 2007 4 52 PM ...

Page 117: ...ectrode is a medium to light tan for a vehicle that is being ridden nor mally You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes ex cessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug Specified spark plug DPR8EA 9 NGK EE ...

Page 118: ...ch is not available when you are installing the spark plug a good estimate of the correct torque is one quarter to one half turn past finger tight Have the spark plug tightened to the specified torque as soon as possible 4 Install the spark plug cap 5 Lower the cargo bed Spark plug gap 0 8 0 9 mm 0 031 0 035 in Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf EE book Page 23 Friday Augu...

Page 119: ...Quick fastener screw 4 2 Air intake duct grill 2 Remove the air filter element from the air intake duct grill by pulling it out as shown 1 Air filter element 2 Air intake duct grill 3 Remove any large particles from the air filter element by hand 4 Tap the air filter element to remove as much dust and dirt as possible EE book Page 24 Friday August 3 2007 4 52 PM ...

Page 120: ...eaning the engine air filter element There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case 1 Air filter case check hose 1 Remove the seats See page 4 13 for seat removal and installation proce EE book Page 25 Friday August 3 2007 4 52 PM ...

Page 121: ...e the air filter case cover by un hooking the holders 1 Air filter case cover holder 4 2 Air filter case cover 4 Remove the air filter element 1 Air filter element EE book Page 26 Friday August 3 2007 4 52 PM ...

Page 122: ... thoroughly in parts cleaning solvent WARNING Using gasoline or other flammable solvents to clean the air fil ter element can cause a fire or explo sion which could lead to serious injury 7 Squeeze the excess solvent out of the sponge material NOTICE Do not twist the sponge material when squeezing it EE book Page 27 Friday August 3 2007 4 52 PM ...

Page 123: ... material and replace it if damaged 11 Thoroughly apply Yamaha foam air filter oil or other quality liquid foam air filter oil not spray type to the sponge material The sponge material should be wet but not dripping 12 Pull the sponge material over its frame 13 Reinstall the air filter element 14 Reinstall the air filter case cover and be sure the crankcase breather hose is con 1 Crankcase breathe...

Page 124: ...the engine NOTICE Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally op eration without the air filter element will af fect carburetor jetting with subsequent poor performance and possible engine 2P512001 Drive select lever box check hose The drive select lever box check hose is loca...

Page 125: ...ck hose EVU00780 V belt case drain plug The V belt case drain plug is located under the driver seat See page 4 13 for seat re moval and installation procedures After riding in water deep enough to allow wa ter to enter the V belt case remove the drain plug to drain any water from the case If water drains from the V belt case after re moving the drain plug have a Yamaha dealer inspect the vehicle a...

Page 126: ...ot start the engine while cleaning the exhaust system 1 Remove the bolts 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon depos its from the spark arrester portion of the tailpipe and inside of the tailpipe housing 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muffler and EE book Page 31 Friday August 3 20...

Page 127: ...to do so However the idling speed adjustment may be performed by the owner as a part of the usual maintenance routine NOTICE The carburetor was set at the Yamaha fac tory after many tests If the settings are disturbed by someone without sufficient technical knowledge poor engine perfor mance and damage may result Tightening torque Tailpipe bolt 9 5 Nm 0 95 m kgf 6 9 ft lbf EE book Page 32 Friday A...

Page 128: ... the throttle with the choke off 2 Remove the seats See page 4 13 for seat removal and installation proce dures 3 Remove the console See page 8 9 for console removal and installation proce dures 4 Connect the tachometer to the spark plug lead and then set the idle to the specified idling speed by adjusting the throttle stop 1 Throttle stop screw 5 Reinstall the console 6 Reinstall the seats Specif...

Page 129: ...rvice should be performed by a Yamaha dealer WARNING Operating with improperly serviced or ad justed brakes could lead to a loss in brak ing ability and an accident EVU00830 Front brake pad check Each brake pad is provided with wear indica tor grooves which allow you to check the brake pad wear without having to disassem ble the brake To check the brake pad wear check the wear indicator grooves If...

Page 130: ... brake pad is provided with wear indica tor grooves which allow you to check the brake pad wear without having to disassem ble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indica tor grooves have almost disappeared have a Yamaha dealer replace the brake pads as a set EE book Page 35 Friday August 3 2007 4 52 PM ...

Page 131: ...for hood opening and closing procedures Observe these precautions When checking the fluid level make sure the top of the brake fluid reservoir is level Use only the recommended quality brake fluid Otherwise the rubber seals may de teriorate causing leakage and poor braking performance Refill with the same type of brake fluid Mix ing fluids may result in a harmful chemical reaction and lead to poor...

Page 132: ... maintenance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every four years EVU01220 Checking the brake pedal Have a Yamaha dealer check the brakes at the intervals specified in the periodic mainte nance and lubrication chart There should be no free play in the brake pedal The brakes should operate smoothly and there should be no brake drag If th...

Page 133: ...dures 3 Remove the console See page 8 9 for console removal and installation proce dures 4 Check the parking brake lever free play The maximum free play is equal to one click of the parking brake lever If neces sary adjust the free play as follows a Parking brake lever free play 5 The parking brake lever must be re leased when checking and adjusting the parking brake lever free play 6 Loosen the l...

Page 134: ...al is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows 1 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the ad justing nut in direction a To make the brake light come on lat...

Page 135: ...pect control cables frequently and re place damaged cables Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Lubricate the cable ends If the cables do not operate smoothly ask a Yamaha dealer to re place them Recommended lubricant Lithium soap based grease EE book Page 40 Friday August 3 2007 4 52 PM ...

Page 136: ...voting parts EVU00910 Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease EE book Page 41 Friday August 3 2007 4 52 PM ...

Page 137: ...EVU00930 Wheel removal 1 Loosen the wheel nuts 2 Elevate the vehicle and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Nut 4 Recommended lubricant Lithium soap based grease EE book Page 42 Friday August 3 2007 4 52 PM ...

Page 138: ... If that is not possible you must replace the tires in pairs front or rear with tires of the same size and type as the originals Never replace just one tire WARNING Installing improper tires on your Rhino can affect handling and stability This can cause a loss of control The tires listed below have been approved by Yamaha Motor Manufacturing Corporation of America for this model Manufacturer Size ...

Page 139: ...the front and rear wheels Install the nut with its tapered side towards the wheel 2 Lower the vehicle so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque WARNING Do not reverse the rims on the Rhino to widen the track width Installing wheels improperly increases the risk of wheel fail 1 Arrow mark EE book Page 44 Friday August 3 2007 4 52 PM ...

Page 140: ...e or add distilled water in the bat tery If the battery seems to have discharged con sult a Yamaha dealer NOTICE Do not try to remove the sealing caps of the battery cells You may damage the bat tery Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf EE book Page 45 Friday August 3 2007 4 52 PM ...

Page 141: ...ush with water for 15 minutes and get prompt medical attention WARNING Batteries may produce explosive gases EVU00960 Battery maintenance 1 If the vehicle will not be used for a month or longer remove the battery and store it in a cool dark place Completely re charge the battery before reinstallation NOTICE _ A special battery charger constant volt age ampere or constant voltage is re quired for r...

Page 142: ...NING To avoid battery explosion and or serious damage to the electrical system Do not connect the negative lead of the jumper cable to the negative termi nal of the battery Do not touch the positive lead of the jumper cable to the negative lead Do not reverse the polarity of the jumper cables when connecting to the batteries EE book Page 47 Friday August 3 2007 4 52 PM ...

Page 143: ...of the jumper cable to the positive terminal of the battery in the vehicle and the other end of the positive lead to the positive terminal of the charged battery 1 Jumper cable positive lead 2 Jumper cable negative lead 5 Connect the negative lead of the jumper cable to the negative terminal of the charged battery and the other end of the negative lead to an unpainted metal sur face of the vehicle...

Page 144: ...ttery in the vehicle 8 Reinstall the battery compartment cover 9 Close the hood EVU00970 Fuse replacement The main fuse and the fuse box are located under the hood See pages 8 7 8 8 for hood opening and closing procedures If a fuse is blown turn off the main switch and install a new fuse of the specified amperage If a fuse is blown replace it as follows 1 Remove the battery compartment cover by li...

Page 145: ...ARNING Always use a fuse of the specified amperage Never use any material in place of the proper fuse Using an improper fuse can cause damage to the electrical system and may lead to a fire 1 Main fuse 2 Spare main fuse 3 Headlight fuse 4 Ignition fuse 5 Auxiliary DC jack fuse 6 Four wheel drive motor fuse 7 Signaling system fuse 8 Backup fuse for odometer and clock 9 Carburetor warmer fuse 10 Spa...

Page 146: ... bulb burns out replace it as fol lows 1 Lift the hood up See pages 8 7 8 8 for hood opening and closing procedures 2 Remove the cover at the rear of the headlight by pulling it off 1 Cover at the rear of the headlight Specified fuses Main fuse 30 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Signaling system fuse 10 0 A Carburetor warmer fuse 10 0 A Four wheel drive...

Page 147: ...ht bulb holder cover by pulling it off 1 Headlight bulb holder cover 4 Remove the headlight bulb holder by pushing it in and turning it counterclock wise 1 Headlight bulb holder EE book Page 52 Friday August 3 2007 4 52 PM ...

Page 148: ...h the glass part of the bulb 7 Reinstall the bulb holder by pushing it in and turning it clockwise Reinstall the bulb holder cover and the cover at the rear of the headlight NOTICE Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly 8 Close the hood 9 Adjust the headlight beam if necessary EE book Page 53 Friday August 3 2007 4 52 PM ...

Page 149: ...wer the beam turn the adjusting screw in direction b EVU01000 Tail brake light bulb replacement If a tail brake light bulb burns out replace it as follows 1 Remove the quick fastener screws and bolts from panel A if replacing the left tail brake light bulb or panel B if replac ing the right tail brake light bulb 1 Panel A EE book Page 54 Friday August 3 2007 4 52 PM ...

Page 150: ...rgo bed lifting and lowering proce dures 3 Remove the panel 4 Remove the bulb holder together with the bulb by turning it counterclockwise 1 Tail brake light bulb holder 5 Push the defective bulb in and turn it EE book Page 55 Friday August 3 2007 4 52 PM ...

Page 151: ...ms can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your vehicle requires any repair take it to a Yamaha deal er The skilled technicians at a Yamaha dealer ship have the tools experience and know how to properly service your vehicle Use only genuine Yamaha parts on your vehicle Imita tion parts may look like Yamaha parts but ...

Page 152: ... and make sure there are no open flames or sparks in the area including pi lot lights from water heaters or furnaces Gasoline or gasoline vapors can ignite or explode causing severe injury or property damage EE book Page 57 Friday August 3 2007 4 52 PM ...

Page 153: ...ession Ask a Yamaha dealer to inspect 3 Ignition Remove the spark plug and check the electrodes Wet Wipe clean with dry cloth Dry Attach spark plug cap and ground to chassis Use the electric starter Spark is good Ignition system is normal Spark is weak Adjust the spark plug gap or replace the spark plug No spark 4 Battery Use the electric starter Engine turns over quickly Battery is good Check the...

Page 154: ...ed coolant tap water can be used temporarily provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the coolant reservoir and or radiator Level is OK Level is low check the cooling system for leakage No leakage Leakage Ask a Yamaha dealer to inspect and repair the cooling system Add coolant See the text below Restart t...

Page 155: ...y degreaser with a paint brush Do not apply degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job WARNING Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings Wet brakes may have reduced stopping ability increasing the chance of an ac cident NOTICE Excessive water pressure...

Page 156: ...tive finish When finished start the engine and let it idle for several EVU01041 B Storage Long term storage 60 days or more of your vehicle will require some preventive proce dures to guard against deterioration Make any necessary repairs before storing the vehi cle After thoroughly cleaning the vehicle prepare for storage as follows 1 Fill the fuel tank with fresh fuel and add the specified amoun...

Page 157: ... prevent moisture from entering 7 If storing in a humid or salt air atmo sphere coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat covers 8 Remove the battery and charge it Store it in a dry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F Use of fuel st...

Page 158: ...ase 1 910 mm 75 2 in Ground clearance 280 mm 11 0 in Minimum turning radius 3 900 mm 154 in Basic weight With oil and full fuel tank 514 0 kg 1 133 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 660 0 cm3 Bore stroke 100 0 84 0 mm 3 94 3 31 in Compression ratio 9 10 1 EE book Page 1 Friday August 3 2007 4 52 PM ...

Page 159: ...40 or SAE 10W 40 YAMALUBE 4 CW 5W 30 or SAE 5W 30 YAMALUBE 4 20W 50 or SAE 20W 50 NOTICE In order to prevent clutch slippage since the en gine oil also lubricates the clutch do not mix any chemical additives with oil Do not use oils with a diesel specification of CD or oils of a higher qual ity than specified In addition do not use oils la beled ENERGY CONSERVING II or higher EE book Page 2 Friday...

Page 160: ...28 Imp qt 0 34 US qt Radiator capacity including all routes 2 50 L 2 20 Imp qt 2 64 US qt Air filter Engine Wet element Intake duct Dry element Fuel Type Unleaded gasoline only Fuel tank capacity 30 0 L 6 60 lmp gal 7 93 US gal Carburetor Type quantity BSR42 1 Manufacturer MIKUNI Spark plug Type manufacturer DPR8EA 9 NGK Model YXR66FW EE book Page 3 Friday August 3 2007 4 52 PM ...

Page 161: ...ransmission type V belt automatic Operation Right hand operation Reverse gear 25 17 1 471 Sub transmission ratio low 35 17 2 058 high 28 19 1 473 Chassis Frame type Steel tube frame Caster angle 5 0 Trail 26 0 mm 1 02 in Tire Type Tubeless Size front 25 8 12NHS rear 25 10 12NHS Model YXR66FW EE book Page 4 Friday August 3 2007 4 52 PM ...

Page 162: ...ne Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 185 mm 7 3 in Rear wheel travel 185 mm 7 3 in Electrical Ignition system DC CDI Generator system AC magneto Battery type U1L 11 Model YXR66FW EE book Page 5 Friday August 3 2007 4 52 PM ...

Page 163: ...arning light LED Parking brake indicator light LED On Command four wheel drive differential gear lock indicator LCD On Command differential gear lock indicator light LED High range indicator light LED Low range indicator light LED Specified fuses Main fuse 30 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Model YXR66FW EE book Page 6 Friday August 3 2007 4 52 PM ...

Page 164: ... number and model label infor mation in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER ACA 02E 2 VEHICLE IDENTIFICATION NUMBER ACA 02E 3 MODEL LABEL INFORMATION ACA 01E EE book Page 1 Friday August 3 2007 4 52 PM ...

Page 165: ...llowing illustration This number can be used for ordering a new key 1 Key identification number EVU00110 Vehicle identification number The vehicle identification number is stamped into the frame 1 Vehicle identification number The vehicle identification number is used to identify your vehicle EE book Page 2 Friday August 3 2007 4 52 PM ...

Page 166: ...is affixed to the frame under the driver seat Record the information on this label in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label EE book Page 3 Friday August 3 2007 4 52 PM ...

Page 167: ...pose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Mu...

Page 168: ...to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1 200 750 75 6 2 400 1 500 150 12 4 800 3 000 300 18 7 200 4 500 450 24 9 600 6 000 600 30 12 000 7 500 750 36 14 400 9 000 900 42 16 800 10 500 1 050 48 19 200 12 000 1 200 EE book Page 5...

Page 169: ...IOD OF WARRANTY any authorized Yamaha Side Side Vehicle dealer will for free of charge repair or replace at Yamaha s option any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corporation U S A O...

Page 170: ...EVU01090 YAMAHA EXTENDED SERVICE Y E S EE book Page 7 Friday August 3 2007 4 52 PM ...

Page 171: ...EE book Page 8 Friday August 3 2007 4 52 PM ...

Page 172: ...B6 yoko fm Page 1 Wednesday March 8 2006 10 46 AM ...

Page 173: ...B6 yoko fm Page 1 Wednesday March 8 2006 10 46 AM ...

Page 174: ...PRINTED IN USA 2007 08 1 3 1 CR E DIC2342 YAMAHA MOTOR CO LTD ...