all YAMAHA RHINO 660 2005 Owners Manual

EVU01250
3-IMPORTANT NOTICE


This vehicle is designed and manufactured for
use on UNPAVED surfaces only. It is unsafe to
operate this vehicle on any paved surface,
paved street, paved road or motorway.


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.
EVU01100
YXR660FAT
OWNER’S MANUAL
©2004 by Yamaha Motor Co., Ltd.
1st Edition, August 2004
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in U.S.A.
U5UG61.book Page 1 Monday, September 6, 2004 9:00 AM

FVU01250
REMARQUE IMPORTANTE


Ce véhicule est conçu et fabriqué pour une utilisation
sur surfaces non revêtues uniquement. La conduite de
ce véhicule sur les surfaces ou les routes revêtues est
dangereuse.


Prendre connaissance des lois et réglementations en
vigueur avant de décider de l’endroit où circuler dans
ce véhicule.
L’utilisation de ce véhicule sur les espaces publics
dont l’accès est interdit aux véhicules de cette taille
est illicite.
FVU01100
YXR660FAT
MANUEL DU PROPRIÉTAIRE
© 2004 par la Yamaha Motor Co., Ltd.
1re édition, août 2004
Tous droits réservés
Toute réimpression ou utilisation
sans la permission écrite
de la Yamaha Motor Co., Ltd.
est formellement interdite.
Imprimé aux États-Unis
SVU01250
AVISO IMPORTANTE


Este vehículo está diseñado y fabricado única-
mente para uso en superficies NO PAVIMENTA-
DAS. No es seguro utilizar este vehículo en vías
pavimentadas como calles, carreteras o auto-
vías.


Consulte las leyes y reglamentos vigentes antes
de decidir el lugar donde vaya a utilizar este vehí-
culo.
Es ilegal utilizar este vehículo en vías públicas en
las que esté prohibida la circulación de vehículos
de este tamaño.
SVU01100
YXR660FAT
MANUAL DEL PROPIETARIO
©2004 por Yamaha Motor Co., Ltd.
1ª edición, agosto 2004
Todos los derechos reservados.
Toda reimpresión o
uso no autorizado sin el consentimiento
por escrito de Yamaha Motor Co., Ltd.
quedan expresamente prohibidos.
Impreso en EEUU.
U5UG61.book Page 2 Monday, September 6, 2004 9:00 AM

Tire wear limit......................................5-35
OPERATION ............................................6-1
Starting a cold engine ...........................6-3
Starting a warm engine .........................6-9
Jump-starting ........................................6-9
Warming up.........................................6-13
Drive select lever operation and
reverse driving ..................................6-15
Engine break-in ...................................6-21
Parking ................................................6-25
Parking on a slope ..............................6-25
Accessories and loading .....................6-29
DRIVING YOUR VEHICLE .......................7-1
Getting to know your vehicle .................7-1
Learning to operate your vehicle...........7-9
Turning your vehicle............................7-13
Braking ................................................7-15
Going uphill .........................................7-17
Going downhill ....................................7-21
Crossing through shallow water ..........7-27
Riding over rough terrain ....................7-33
Riding in brush or wooded areas ........7-35
Encountering obstacles on the trail .....7-37
67
PERIODIC MAINTENANCE AND
ADJUSTMENT ......................................... 8-1
Owner’s manual and tool kit ................. 8-3
periodic maintenance/lubrication .......... 8-7
Hood ................................................... 8-17
Console .............................................. 8-21
Engine oil and oil filter cartridge ......... 8-23
Final gear oil ....................................... 8-35
Differential gear oil.............................. 8-41
Coolant ............................................... 8-47
Axle boots ........................................... 8-51
Spark plug inspection ......................... 8-53
Cleaning the air filter elements ........... 8-61
V-belt cooling duct check hose ........... 8-73
V-belt case drain plug ......................... 8-75
Carburetor adjustment ........................ 8-77
Idle speed adjustment ........................ 8-79
Valve clearance adjustment ............... 8-81
Front brake pad check ........................ 8-83
Rear brake pad check ........................ 8-85
Checking the brake fluid level............. 8-85
Brake fluid replacement ...................... 8-89
Checking the brake pedal ................... 8-91
Parking brake lever free play
adjustment ........................................ 8-93
Brake light switch adjustment ............. 8-97
Cable inspection and lubrication......... 8-99
8
U5UG61.book Page 2 Monday, September 6, 2004 9:00 AM

Brake pedal and accelerator pedal
lubrication ....................................... 8-101
Rear knuckle upper and lower pivot
lubrication ....................................... 8-101
Steering shaft lubrication .................. 8-103
Wheel removal ................................. 8-103
Wheel installation ............................. 8-105
Battery .............................................. 8-107
Battery maintenance ........................ 8-111
Fuse replacement............................. 8-113
Replacing a headlight bulb ............... 8-119
Headlight beam adjustment.............. 8-123
Tail/brake light bulb replacement ..... 8-125
Troubleshooting................................ 8-131
Troubleshooting charts ..................... 8-133
CLEANING AND STORAGE ................... 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................ 10-1
910U5UG61.book Page 3 Monday, September 6, 2004 9:00 AM

1-1
EVU00060
1-LOCATION OF THE WARNING
AND SPECIFICATION LABELSRead and understand all of the labels on your ve-
hicle. They contain important information for safe
and proper operation of your vehicle.
Never remove any labels from your vehicle. If a la-
bel becomes difficult to read or comes off, a re-
placement label is available from your Yamaha
dealer.
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1-3
1
YAMAHA 5UG-K8483-00
WARNING
The enclosure cannot protect occupants
in all foreseeable accidents, including
rollover.
2
YAMAHA 5UG-F1696-01
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE
LOSS OF CONTROL.LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR
DEATH.OPERATING TIRE PRESSURE: Set with tires cold.RECOMMENDED: FRONT: 70kPa, {.70kgf/cm}, 10psi
REAR: 98kPa, {.98kgf/cm}, 14psi
MINIMUM: FRONT: 63kPa, {.63kgf/cm}, 9psi
REAR: 91kPa, {.91kgf/cm}, 13psiNever set tire pressure below minimum. Tire may dislodge from rim.Gross Vehicle Weight Rating: 907 kg (2000lb) maximum including weight of operator, passenger, accessories, cargo, and (if applicable) trailer tongue weight.
U5UG61.book Page 3 Monday, September 6, 2004 9:00 AM

1-4
3
WARNING
YAMAHA 5UG-K7764-00
Keep hands, body, other
persons away when closing bed.
Do not operate the vehicle
with bed up.
4YAMAHA 5UG-F4897-00
WARNING
Severe INJURY or DEATH can result
if you ignore the following:
Maximum Load in Cargo Bed:181kg. (400lb). Never carry passengers in cargo bed. Cargo can affect handling and stability.
Read Owner’s Manual before loading or
towing.
When loading with cargo or towing a
trailer: Reduce speed and allow more
room to stop. Avoid hills and rough
terrain.
Be sure cargo is secured - a loose load
could change handling unexpectedly.
Keep weight in the cargo bed centered,
and as low and far forward as possible.
Top-heavy loads increase the risk of
overturn.
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1-5
5
YAMAHA 5UG-F151K-02Improperly loading a trailer
and failure to use extra care
when pulling trailer can cause
an accident or injury. Never
load more than 50kg (110 lbs)
tongue weight on the towing
bracket. Do not tow more than
550kg (1212 lbs) rolling weight
(trailer plus cargo). Operate
in low-range gears only, allow
for increased braking distance,
and use extreme caution when
operating on inclines. Read
carefully the loading information
and trailer hitch sections in the
owner’s manual.
WARNING
6
7
YAMAHA 5UG-F151J-00
MAX 7.3 INCH
(185MM)
5UG-F1558-00
Turning the off road vehicle in 4WD-LOCK
(“DIFF.LOCK”) takes more effort.
Operate at a slow speed and allow
extra time and distance for maneuvers
to avoid loss of control.
WARNING
U5UG61.book Page 5 Monday, September 6, 2004 9:00 AM

1-6
8
9
ALWAYS USE AN
APPROVED HELMET
AND PROTECTIVE GEAR
NEVER USE ON PUBLIC
ROADS OR PAVEMENT
NEVER USE WITH
DRUGS OR ALCOHOL
WARNING
This off-highway utility vehicle will handle andmaneuver differently from an ordinary passenger caror other vehicle. Vehicle capacity: 1 operator and 1 passenger. Passenger must be able to reach and hold the handgrip inside enclosure. This vehicle is recommended only for operators 16 and older with a valid motor vehicle license. Adults must supervise use by minors. Check state laws for minimum age requirements. Gross Vehicle Weight Rating: 2000 lb (907 kg) maximum including operator, passenger, accessories, cargo and trailer tongue weight. Passenger and cargo can affect vehicle handling.
ALWAYS wear a seat belt when riding in the vehicle. keep your hands and feet inside the vehicle at all times-watch for branches, brush, or other hazards that could enter the vehicle. drive straight up and down inclines-driving across the side of an incline increase the risk of overturn.NEVER operate through water deeper than 13” (33cm) or fast flowing water-if you must cross shallow, slow moving water, choose your path carefully to avoid sharp drop-offs, large rocks, or slippery surfaces that could cause the vehicle to overturn.
make sharp, high-speed turns-the vehicle could roll over or go out of control.
Improper use can result in Severe INJURY or DEATH.
LOCATE AND READ THE OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
YAMAHA5UG-F1568-01
U5UG61.book Page 6 Monday, September 6, 2004 9:00 AM

2-1
SAFETY INFORMATION
EVU01260
This off-highway utility vehicle handles differently
from other vehicles including cars and ATVs.
SEVERE INJURY OR DEATH can result if you do
not follow these instructions:

Read this manual and all labels carefully and
follow the operating procedures described.


This vehicle is designed to carry the driver and
one passenger. Never carry passengers in the
cargo bed.


Always be sure the driver and passenger are
wearing seat belts.


Never give a ride to a passenger who is too
small to reach and hold the handgrip on the en-
closure.


Always avoid operating the vehicle on any
paved surfaces, including sidewalks, drive-
ways, parking lots, and streets.


Never operate this vehicle on any paved street,
paved road, or motorway.
U5UG61.book Page 1 Monday, September 6, 2004 9:00 AM