air filter YAMAHA RHINO 660 2007 Owners Manual

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
Cleaning the spark arrester ................ 8-77
Carburetor adjustment ........................ 8-81
Idle speed adjustment ........................ 8-83
Valve clearance .................................. 8-85
Front brake pad check ........................ 8-87
Rear brake pad check ........................ 8-89
Checking the brake fluid level............. 8-89
Brake fluid replacement ...................... 8-93
Checking the brake pedal ................... 8-95
Parking brake lever free play
adjustment ........................................ 8-97
Brake light switch adjustment ........... 8-101
8
EE.book Page 2 Friday, August 4, 2006 12:02 PM

3-1
EVU00080
1-DESCRIPTION AND VEHICLE IDENTIFICATION
1. Headlights
2. Front shock absorber assembly adjusting ring
3. Brake fluid reservoir
4. Air filter elements (engine and air intake duct)
5. V-belt case
6. Driver seat
7. Driver seat belt
8. Spark plug
9. Cargo bed
10. Tail/brake lights
11. Rear shock absorber assembly adjusting ring
12. Cargo bed release levers
13. Spark arrester
14. Passenger seat belt
15. Passenger seat
16. Oil filter cartridge
17. Engine oil dipstick
18. Battery
19. Fuses
20. Coolant reservoir
21. Radiator cap
22. Fuel tank cap
EE.book Page 1 Friday, August 4, 2006 12:02 PM

7-29 1. Air filter case check hose
1. Tube de vidange du boîtier de filtre à air
1. Tubo de vaciado de la caja del filtro de aire
1. V-belt cooling duct check hose
1. Tube de vidange du conduit de refroidissement de la courroie trapé-
zoïdale
1. Tubo de vaciado del conducto de refrigeración de la correa tra-
pezoidal
CAUTION:_ After riding your vehicle in water, be sure to
drain the trapped water by removing the check
hose at the bottom of the air filter case, the V-
belt cooling duct check hose, the drive select
lever box check hose and the V-belt case drain
plug. Wash the vehicle in fresh water if it has
been operated in salt water or muddy condi-
tions. _
EE.book Page 29 Friday, August 4, 2006 12:02 PM

8-7
EVU00671
PERIODIC MAINTENANCE/LUBRICATION
NOTE:

For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals.


For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals.
However, keep in mind that if the vehicle isn’t used for a long period of time, the month maintenance intervals
should be followed.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
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
Valves*Check valve clearance.
Adjust if necessary.
Cooling systemCheck coolant leakage.
Repair if necessary.
Replace coolant every 24 months.Spark plugCheck condition.
Adjust gap and clean.
Replace if necessary.Air filter elements
(engine and air intake duct)Clean.
Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*Check idle speed/starter operation.
Adjust if necessary.Crankcase breather
system*Check breather hose for cracks or damage.
Replace if necessary.Exhaust system*Check for leakage.
Tighten if necessary.
Replace gasket(s) if necessary.Spark arresterClean.EE.book Page 7 Friday, August 4, 2006 12:02 PM

8-8
Fuel line*Check fuel hose for cracks or damage.
Replace if necessary.Engine oilReplace (warm engine before draining).Engine oil filter cartridgeReplace.Final gear oil
Check oil level/oil leakage.
Replace.Differential gear oil
Front brake*Check operation/brake pad wear/fluid leakage/see NOTE page
8-9.
Correct if necessary. Replace pads if worn to the limit.Rear brake*Check operation/brake pad wear/fluid leakage/see NOTE page
8-9.
Correct if necessary. Replace pads if worn to the limit.Accelerator pedal*Check operation and free play.V-belt*Check operation.
Check for wear, cracks, or damage.Wheels*Check balance/damage/runout.
Repair if necessary.Wheel bearings*Check bearing assemblies for looseness/damage.
Replace if damaged.Front and rear
suspension*Check operation and for leakage.
Correct if necessary.Steering system*Check operation and for looseness/Replace if damaged.
Check toe-in/Adjust if necessary.Rear upper and lower
knuckle pivots*Lubricate with lithium-soap-based grease.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.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
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
EE.book Page 8 Friday, August 4, 2006 12:02 PM

8-61 1. Quick fastener screw (× 4) 2. Air intake duct grill
1. Vis à serrage rapide (× 4) 2. Grille du conduit d’air
1. Tornillo de fijación rápida (× 4)
2. Rejilla del conducto de admisión de aire
1. Air filter element 2. Air intake duct grill
1.Élément du filtre à air 2. Grille du conduit d’air
1. Filtro de aire
2. Rejilla del conducto de admisión de aire
EVU01473
Cleaning the air filter elements
Cleaning the intake duct air filter element
1. Remove the air intake duct grill by removing
the quick fastener screws.
2. Remove the air filter element from the air in-
take duct grill by pulling it out as shown.
3. Remove any large particles from the air filter
element by hand.
EE.book Page 61 Friday, August 4, 2006 12:02 PM

8-63 1. Air filter element
1.Élément du filtre à air
1. Filtro de aire
1. Air filter case check hose
1. Tube de vidange du boîtier de filtre à air
1. Tubo de vaciado de la caja del filtro de aire
4. Tap the air filter element to remove most of
the dust and dirt, and then blow the remain-
ing dirt out with compressed air.
5. Install the air filter element into the air intake
duct grill.
6. Install the air intake duct grill by installing the
quick fastener screws.
Cleaning the engine air filter elementNOTE:_ 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 fil-
ter case. _1. Remove the seats. (See page 4-45 for seat
removal and installation procedures.)
2. Remove the console. (See page 8-21 for
console removal and installation proce-
dures.)
EE.book Page 63 Friday, August 4, 2006 12:02 PM

8-65 1. Holder (× 4) 2. Air filter case cover
1. Support (× 4) 2. Couvercle du boîtier de filtre à air
1. Soporte (× 4) 2. Cubierta de la caja del filtro de aire
1. Air filter element
1.Élément du filtre à air
1. Filtro de aire
3. Remove the air filter case cover by unhook-
ing the holders.
4. Remove the air filter element.
EE.book Page 65 Friday, August 4, 2006 12:02 PM

8-67 1. Air filter frame 2. Sponge material
3. Element retaining plate
1. Armature de filtre à air 2.Élément en mousse
3. Plaque de retenue de l’élément
1. Bastidor del filtro de aire 2. Material esponjoso
3. Placa de retención del filtro
5. Remove the sponge material from its frame.
6. Wash the sponge material gently but thor-
oughly in solvent.
WARNING
Always use parts cleaning solvent to clean the
sponge material. Never use low flash point sol-
vents or gasoline to clean the sponge material
because the engine could catch fire or ex-
plode.7. Squeeze the excess solvent out of the
sponge material and let it dry.CAUTION:_ Do not twist the sponge material when squeez-
ing it. _
EE.book Page 67 Friday, August 4, 2006 12:02 PM

8-69 1. Crankcase breather hose
1. Durite de mise à l’air du carter moteur
1. Tubo respiradero del cárter
8. Check the sponge material and replace it if
damaged.
9. Thoroughly apply Yamaha foam air filter oil or
other quality liquid foam air filter oil (not spray
type) to the sponge material.NOTE:_ The sponge material should be wet but not drip-
ping. _10. Pull the sponge material over its frame.
11. Install the air filter element.
12. Install the air filter case cover and be sure the
crankcase breather hose is connected.
13. Install the console.
14. Install the seats.
EE.book Page 69 Friday, August 4, 2006 12:02 PM