Yamaha Yamaha Rhino 660 User manual

5UG-F8199-11LIT-11626-18-46
READ THIS MANUAL CAREFULLY!
It contains important safety information.
YXR660FAT
OWNER’S MANUAL
PRINTED IN USA
2004.08-2.8×1 CR
(E)
YAMAHA MOTOR CO., LTD.

EVU00010
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INTRODUCTION
Congratulations on your purchase of the Yamaha YXR660FA. It represents the result of many
years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing
vehicles. With the purchase of this Yamaha, you can now appreciate the high degree of crafts-
manship and reliability that have made Yamaha a leader in these fields.
This manual will provide you with a good basic understanding 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 operating fea-
tures. Regular inspections and careful maintenance, along with good operating tech-
niques, will help ensure that you safely enjoy the capabilities and reliability of this vehicle.
_
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EVU00020
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IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN
SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe
injury or death to the vehicle operator, a bystander or a person
inspecting or repairing the vehicle.
CAUTION:
A CAUTION indicates special precautions that must be taken to
avoid damage to the vehicle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
EE.book Page 1 Tuesday, July 27, 2004 5:17 PM

AFFIX DEALER
LABEL HERE
EVU00030
2-
IMPORTANT NOTICE
●This vehicle is designed and manufactured for off-road use only. It is illegal to operate
this vehicle on any public street, road, or highway. Such use is prohibited by law.
●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.
EVU00040
YXR660FAT
OWNER’S MANUAL
©2004 by Yamaha Motor Corporation,
U.S.A.
1st edition, July 2004
All rights reserved. Any reprinting or
unauthorized use without the written
permission of
Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11626-18-46
EE.book Page 2 Tuesday, July 27, 2004 5:17 PM

EVU00050
CONTENTS
LOCATION OF THE WARNING
AND SPECIFICATION LABELS....... 1-1
SAFETY INFORMATION.................. 2-1
DESCRIPTION AND VEHICLE
IDENTIFICATION ............................. 3-1
Identification number records.......... 3-3
Key identification number................ 3-3
Vehicle identification number .......... 3-4
Model label ...................................... 3-4
CONTROL FUNCTIONS .................. 4-1
Main switch...................................... 4-1
Indicator and warning lights ............ 4-3
Switches .......................................... 4-6
Accelerator pedal .......................... 4-10
Brake pedal ................................... 4-11
Parking brake lever ....................... 4-12
Drive select lever........................... 4-13
Fuel tank cap................................. 4-13
1
2
3
4
Fuel level check window................4-14
Starter (choke) ...............................4-14
Seats..............................................4-15
Seat belts .......................................4-16
Glove compartment .......................4-18
Cargo bed ......................................4-18
Front and rear shock absorber
adjustment ...................................4-21
Trailer hitch bracket .......................4-23
Auxiliary DC jack............................4-24
PRE-OPERATION CHECKS ............5-1
Front and rear brakes ......................5-2
Fuel ..................................................5-4
Engine oil .........................................5-5
Coolant.............................................5-6
Final gear oil ....................................5-7
Differential gear oil ...........................5-7
Accelerator pedal.............................5-7
Seat belts .........................................5-7
Steering............................................5-8
Fittings and fasteners ......................5-8
Lights................................................5-8
5
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Switches.......................................... 5-8
Tires ................................................ 5-8
How to measure tire pressure....... 5-10
Tire wear limit................................ 5-11
OPERATION..................................... 6-1
Starting a cold engine ..................... 6-1
Starting a warm engine................... 6-3
Jump-starting .................................. 6-3
Warming up..................................... 6-5
Drive select lever operation and
reverse driving............................... 6-5
Engine break-in............................... 6-7
Parking ............................................ 6-9
Parking on a slope .......................... 6-9
Accessories and loading............... 6-11
DRIVING YOUR VEHICLE............... 7-1
Getting to know your vehicle........... 7-1
Learning to operate your vehicle .... 7-5
Turning your vehicle........................ 7-6
Braking ............................................ 7-7
Going uphill ..................................... 7-7
Going downhill ................................. 7-9
Crossing through shallow water .... 7-11
Riding over rough terrain...............7-13
Riding in brush or wooded
areas............................................ 7-14
Encountering obstacles on the
trail ............................................... 7-15
PERIODIC MAINTENANCE AND
ADJUSTMENT .................................. 8-1
Owner’s manual and tool kit............ 8-1
Periodic maintenance/
lubrication ...................................... 8-4
Hood ................................................ 8-6
Console............................................ 8-8
Engine oil and oil filter cartridge ...... 8-9
Final gear oil .................................. 8-13
Differential gear oil......................... 8-15
Coolant .......................................... 8-17
Axle boots...................................... 8-19
Spark plug inspection .................... 8-20
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7
8
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Cleaning the air filter elements...... 8-22
V-belt cooling duct check hose ..... 8-27
V-belt case drain plug.................... 8-28
Spark arrester cleaning ................. 8-29
Carburetor adjustment................... 8-30
Idle speed adjustment ................... 8-31
Valve clearance adjustment.......... 8-31
Front brake pad check .................. 8-32
Rear brake pad check ................... 8-33
Checking the brake fluid level ....... 8-33
Brake fluid replacement................. 8-34
Checking the brake pedal ............. 8-35
Parking brake lever free play
adjustment................................... 8-36
Brake light switch adjustment........ 8-37
Cable inspection and lubrication ... 8-38
Brake pedal and accelerator
pedal lubrication .......................... 8-39
Rear knuckle upper and lower
pivot lubrication............................ 8-39
Steering shaft lubrication............... 8-40
Wheel removal .............................. 8-40
Wheel installation .......................... 8-41
Battery............................................8-42
Battery maintenance......................8-43
Fuse replacement ..........................8-44
Replacing a headlight bulb ............8-46
Headlight beam adjustment...........8-47
Tail/brake light bulb
replacement .................................8-48
Troubleshooting .............................8-50
Troubleshooting charts ..................8-51
CLEANING AND STORAGE ............9-1
A. Cleaning ......................................9-1
B. Storage ........................................9-3
SPECIFICATIONS .........................10-1
NOISE REGULATION.....................11-1
MAINTENANCE RECORD .............12-1
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10
11
12
EE.book Page 3 Tuesday, July 27, 2004 5:17 PM

YAMAHA MOTOR CORPORATION,
U.S.A. SIDE ×SIDE VEHICLE
LIMITED WARRANTY ................... 13-1
YAMAHA EXTENDED SERVICE
(Y.E.S.) .......................................... 14-1
13
14
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1-1
EVU00060
1-
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
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1-2
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Read and understand all of the labels on your
vehicle. They contain important information
for safe and proper operation of your vehicle.
Never remove any labels from your vehicle. If
a label becomes difficult to read or comes off,
a replacement label is available from your
Yamaha dealer.
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}, 13psi
Never 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.
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1-3
34
WARNING
YAMAHA 5UG-K7764-00
Keep hands, body, other
persons away when closing bed.
Do not operate the vehicle
with bed up.
YAMAHA 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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1-4
56
YAMAHA 5UG-F151J-00
MAX 7.3 INCH
(185MM)
YAMAHA 5UG-F151K-02
Improperly 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
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1-5
7
8
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
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 and
maneuver differently from an ordinary passenger car
or 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.
k eep 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.
YAMAHA 5UG-F1568-01
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2-1
1
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SAFETY INFORMATION
EVU00070
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 enclo-
sure.
●Always avoid operating the vehicle on any paved surfaces, including sidewalks, driveways,
parking lots, and streets.
●Never operate this vehicle on any public street, road, or highway, even a dirt or gravel one.
●Never operate this vehicle without wearing an approved motorcycle helmet that fits properly.
You should also wear eye protection (goggles or a face shield), gloves, over-the-ankle boots,
long-sleeved shirt or jacket, and long pants.
●Never consume alcohol or drugs before or while operating this vehicle.
●Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is
proper for the terrain, visibility, operating conditions, and your experience.
●Never attempt jumps or other stunts.
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2-2
●Always inspect your vehicle each time you use it to be sure it is in safe operating condition. Al-
ways follow the inspection and maintenance procedures and schedules described in this man-
ual.
●Always keep both hands, arms, feet, and legs inside the vehicle at all times during operation.
Keep your feet on the floorboard. Never hold onto the enclosure except when using the hand-
grip inside the enclosure. Otherwise, your hand could be injured if it is caught between the en-
closure and an obstacle outside the vehicle.
●Always keep both hands on the steering wheel when driving.
●Never wrap your thumbs and fingers around the steering wheel. This is particularly important
when driving in rough terrain. The front wheels will move right and left as they respond to the
terrain, and this movement will be felt in the steering wheel. A sudden jolt could wrench the
steering wheel around, and your thumbs or fingers could be injured if they are in the way of the
steering wheel spokes.
●Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when driving the vehicle.
●Never operate on excessively rough, slippery, or loose terrain until you have learned and prac-
ticed the skills necessary to control the vehicle on such terrain. Always be especially cautious
on these kinds of terrain.
●Never turn at excessive speed. Practice turning at slow speeds before attempting to turn at
faster speeds. Do not attempt turns on steep inclines.
●Never operate the vehicle on hills that are too steep for it or for your abilities. Go straight up and
down hills where possible. Maximum slope angle: 15°
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2-3
●Never operate on hills that are slippery or ones where you will not be able to see far enough
ahead of you. Never go over the top of a hill at speed if you cannot see what is on the other
side.
●Always follow proper procedures for going uphill. If you lose momentum and cannot continue
up a hill, back down the hill with the engine in reverse gear. Use engine braking to help you go
slowly. If necessary, use the brakes gradually to help you go slowly.
●Always check terrain carefully before going down hills. Go as slowly as possible. Never go
down a hill at high speed.
●Always check for obstacles before operating in a new area.
●Never operate the vehicle in fast flowing water or water deeper than the floorboards on this
model. Remember that wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several times to let friction dry out the linings.
●Always be sure there are no obstacles or people behind you when you operate in reverse.
When it is safe to proceed in reverse, go slowly. Do not brake abruptly when carrying loads in
the cargo bed.
●Always use the size and type of tires specified in this manual.
●Always maintain proper tire pressure as described in this manual.
●Never exceed the stated load capacity. Cargo should be as far forward in the bed as possible,
and distributed evenly from side to side. Be sure cargo is secured so that it cannot move
around during operation. Reduce speed and follow instructions in this manual for carrying car-
go or pulling a trailer. Allow greater distance for braking.
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2-4
WARNING
POTENTIAL HAZARD
Improper handling of gasoline.
WHAT CAN HAPPEN
Gasoline can catch fire and you could
be burned.
HOW TO AVOID THE HAZARD
Always turn off the engine when refuel-
ing. Do not refuel right after the engine
has been running and is still very hot.
Do not spill gasoline on the engine or
exhaust pipe/muffler when refueling.
Never refuel while smoking, or while in
the vicinity of sparks, open flames, or
other sources of ignition such as the pi-
lot lights of water heaters and clothes
dryers.
When transporting the vehicle in anoth-
er vehicle, be sure it is kept in an upright
position. Otherwise, fuel may leak out of
the carburetor or fuel tank.
WHAT CAN HAPPEN
Gasoline is poisonous and can cause
injuries.
HOW TO AVOID THE HAZARD
If you should swallow some gasoline or
inhale a lot of gasoline vapor, or get
some gasoline in your eyes, see your
doctor immediately. If gasoline spills on
your skin, wash with soap and water. If
gasoline spills on your clothing, change
your clothes.
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2-5
WARNING
POTENTIAL HAZARD
Starting or running the engine in a
closed area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death
within a short time.
HOW TO AVOID THE HAZARD
Always operate your vehicle in an area
with adequate ventilation.
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3-1
EVU00080
1-
DESCRIPTION AND VEHICLE IDENTIFICATION
1. Headlights
2. Front shock absorber assembly adjusting ring
3. Brake fluid reservoir
4. Air filter element (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 lever
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 level check window
23. Fuel tank cap
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