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Troubleshooting

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   Summary of Contents for Yamaha YSR45FX

  • Page 2

    State of California to cause cancer, birth defects other reproductive harm. YAMAHA LIT-CALIF-65-01...

  • Page 3

    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.

  • Page 4

    IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SE- RIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

  • Page 5

    • This vehicle complies with almost all state off-highway noise level and spark arrester laws and regulations. YXR45FX OWNER'S MANUAL ©2007 by Yamaha Motor Corporation, U.S.A. 1st edition, July 2007 All rights reserved. Any reprinting unauthorized use without the written...

  • Page 6: Table Of Contents

    CONTENTS Fuel level check window ....4-15 Starter (choke) ......4-15 Doors ..........4-16 LOCATION OF THE WARNING Seats ..........4-16 AND SPECIFICATION LABELS ..1-1 Seat belts ........4-17 SAFETY INFORMATION ....2-1 Glove compartment ....... 4-18 Cargo bed ........4-18 Front and rear shock absorber DESCRIPTION...

  • Page 7

    Steering ........... Passenger requirements ....7-3 Fittings and fasteners ...... Occupant protection system .... 7-4 Protective structu re ......Lights ..........Switches .......... Seat belts ......... Control cables ......... Doors ..........Tires ..........Passenger handholds ...... Seat and hip restraints ....

  • Page 8

    Operation on different surfaces Differential gear oil ......8-17 and terrains ........7-18 Coolant ........... 8-19 Hills ..........7-19 Axle boots ........8-20 Uphill ..........7-19 Spark plug inspection ....8-21 Downhill ......... 7-20 Cleaning the air filter elements ..8-24 Drive select lever box check Rough terrain .........

  • Page 9

    ......8-41 NOISE REGULATION ....11-4 Steering shaft lubrication ....8-41 Wheel removal ......8-42 MAINTENANCE RECORD ... 11-5 YAMAHA MOTOR Tire replacement ......8-42 Wheel installation ......8-43 CORPORATION, U.S.A. SIDE x SIDE VEHICLE LIMITED Battery ........... 8-45 WARRANTY ........

  • Page 10: Labels

    LOCATION OF THE WARNING AND SPECIFICATION LABELS...

  • Page 11

    Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a re- placement label is available from your Yamaha dealer. © Do not rest hands on door or hip restraint bar. To avoid injury, keep hands completely inside the vehicle by holding the steering wheel or handholds.

  • Page 12

    Improper tire pressureor overloading the Rhinomay people away from pinch points causesevereinjuryor deathfrom loss ofcontrolor when lowering bed. Do not hold rollover. the cage/frame while closing bed. OPERATING TIREPRESSURE: S et withtires cold. YAMAHA 5B4-K7764-O0 RECOMMENDED: FRONT:70kPa,(.70kgf/cm2), 10psi REAR: 98kPa,(.98kgf/cm2), 14psi MINIMUM: FRONT:63kPa,(.63kgf/cm2),9psi REAR: 91kPa,(.91kgf/cm2),13psi...

  • Page 13

    (if installed). • When loaded with cargo or towing a trailer: • Reducespeed and allowmore roomto stop. • Turn graduallyandgo slowly. • Avoid hills and rough terrain. • Read Owner's Manualbefore loading, towing,or pullin! objects. ' YAMAHA 5B4-F4897-O0...

  • Page 14

    (110 Ib) tongue weight on the towing bracket. Do not tow more than 550 kg (1212 Ib) rolling weight (trailer plus cargo). Tow or pull only from hitch bracket. Read Owner s Manual before loading, towing, or pulling objects. ' YAMAHA 5B4-F151 K-00'...

  • Page 15

    If crossing a hill is unavoidable, drive slowly only by an operator 16 or older \'_ 1 _-_NYi and turn downhill immediately if you feel the Genuine Yamaha Doors and with a valid motor vehicle license. "_ vehicle may tip.

  • Page 16

    SAFETY INFORMATION Be a responsible owner As the vehicle's owner, you are responsible for the safe and proper operation of your Rhino. While understanding all parts of this manual are important for vehicle ownership, be sure to read this chapter and the instructions in Chapter 7 before...

  • Page 17

    Before you operate the Rhino • Prepare yourself and your passenger: • This vehicle is intended for use only by an operator 16 or older with a valid motor vehicle li- cense. • This vehicle is designed to carry the driver and one passenger. Never carry passengers the cargo bed.

  • Page 18

    Prepare your vehicle Perform the pre-operation checks each time you use the vehicle to make sure it is in safe operat- ing condition. Failure to inspect or maintain the vehicle properly increases the possibility of an ac- cident or equipment damage.

  • Page 19

    While using the Rhino • Keep your body completely inside the vehicle at all times. Keep both hands on the steering wheel. Be sure passenger is seated, belted, and holding onto the handholds. Close doors be- fore driving. Any part of your body (arms, legs, and head) outside the vehicle can be struck by objects your vehicle is passing or crushed by the vehicle cage/frame...

  • Page 20

    Avoid rollovers: • Use care when turning: • Turning the steering wheel too far or too fast can 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. •...

  • Page 21

    • Drive straight up and down inclines, not across them. If crossing a hill is unavoidable, drive slowly and turn downhill immediately if you feel the vehicle may tip. • Avoid paved surfaces. Turn gradually and go slowly if you must drive on pavement. This ve- hicle is designed for off-road use only.

  • Page 22

    • When loaded with cargo or towing a trailer: • Reduce speed, operate in low gear only, and allow more room to stop. • Avoid hills and rough terrain. Use extreme caution when towing or carrying a load on in- clines.

  • Page 23

    Avoid carbon monoxide poisoning All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide cause headaches, dizziness, drowsiness, nausea, confusion, and eventually death. Carbon monoxide is a colorless, odorless, tasteless gas which may be present even if you do not see or smell any engine exhaust.

  • Page 24

    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.

  • Page 25

    Aftermarket tires and rims The tires and rims that came with your Rhino were designed to match the 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 8-42-8-44 for tire specifications more information...

  • Page 26: Description

    DESCRIPTION 1. Headlights 14. Spark arrester 2. Front shock absorber assembly spring preload adjusting ring 15. Passenger seat belt 3. Brake fluid reservoir 16. Passenger seat 4. Air filter elements (engine and air intake duct) 17. Oil filter cartridge 5. V-belt case 18.

  • Page 27

    The vehicle you have purchased may differ slightly from those shown in the figures of this manual. 26. Light switch 27. Steering wheel 28. Starter (choke) 29. Main switch 30. On-Command four-wheel-drive and differential gear lock switches 31. Indicator and warning lights 32.

  • Page 28: Instrument Functions

    INSTRUMENT AND CONTROL Functions of the respective switch positions FUNCTIONS are as follows: All electrical circuits are supplied with Main switch power, and the headlights and tail- lights come on when the light switch is OFF: All electrical circuits are switched off.

  • Page 29: Indicator And Warning Lights

    If the indicator light flashes under any other 1. Parking brake indicator light "P" circumstances, have a Yamaha dealer check 2. Reverse indicator light"R" the speed sensor circuit. 3, Neutral indicator light "N" 4. On-Command four-wheel-drive indicator light "_"...

  • Page 30

    On-Command four-wheel-drive indicator Coolant temperature warning light "_" light "_" If the coolant temperature reaches a specified This indicator light comes when level, this light comes on to warn that the cool- On-Command four-wheel-drive switch is in ant temperature is too hot. If the light comes the "4WD"...

  • Page 31

    Coolant temperatu re Coolant temperature warning light comes on warning light does not momentarily. come on. Coolant temperature and electrical circuit are OK. Ask a Yamaha dealer to Go ahead with riding. inspect the electrical circuit.

  • Page 32: Indicator And Warning Lights (special Edition Models)

    Indicator and warning lights On-Command differential gear lock indica- (Special Edition models) 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",...

  • Page 33

    • Due to the synchronizing mechanism in the show the speed while riding, have a Yamaha differential gear case, the four-wheel-drive dealer check the speed sensor circuit. indicator may not come on until the vehicle starts moving.

  • Page 34: Multi-function Meter Unit

    Multi-function meter unit Coolant temperature warning light "_" (Special Edition models) If the coolant temperature reaches a specified level, this light comes on to warn that the cool- ant temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.

  • Page 35

    • two tripmeters (which show the distance Odometer and tripmeter modes traveled since they were last set to zero) Pushing the "TRIP/ODO" button switches • a clock display between the odometer mode "ODO" • an hour meter (which shows the total time and the tripmeter modes "A"...

  • Page 36

    Clock mode Fuel meter The fuel meter indicates the amount of fuel in Pushing the" _ / [_" button switches the dis- play between the clock mode "CLOCK" the fuel tank. The display segments of the fuel the hour meter mode "HOUR" in the following meter disappear from "F"...

  • Page 37: Switches

    Switches NOTICE Do not use the headlights with the engine Light switch "OFF/©_/®-" turned off for an extended period of time. The battery may discharge to the point that starter motor will not operate properly. If this should happen, remove the battery and recharge ®- 1.

  • Page 38

    On-Command four-wheel-drive and differ- • Four-wheel drive ("4WD"): Power is sup- ential gear lock switches 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.

  • Page 39: Accelerator Pedal

    Accelerator pedal Brake pedal Press the accelerator pedal down to increase Press the brake pedal to slow or stop the ve- hicle. engine speed. Spring pressure returns pedal to the rest position when released. ways check that the accelerator pedal returns normally before starting the engine.

  • Page 40: Parking Brake Lever

    Parking brake lever The parking brake lever is located at the right side of the driver's seat. It will help keep the vehicle from 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.

  • Page 41: Drive Select Lever

    Drive select lever Fuel tank cap The drive select lever is used to shift the vehi- Remove the fuel tank cap by turning it coun- terclockwise. cle into the low, high, neutral, and reverse po- sitions. (Refer to pages 6-6-6-7 for the drive select lever operation.) 1.

  • Page 42: Fuel Level Check Window

    Fuel level check window Starter (choke) "I_1" The amount of fuel in the fuel tank can be Starting a cold engine requires a richer air-fuel checked through the fuel level check window. mixture. A separate starter circuit supplies this mixture. If the fuel level is low, refuel as soon as possi- ble.

  • Page 43: Doors

    Doors Seats To open a door, simply pull the latch outward. To remove a seat, pull its seat lock lever up- ward, lift the front of the seat, and then slide To close a door, push or pull the door inward the seat forward and up.

  • Page 44: Seat Belts

    Seat belts To install a seat, insert the projections on the rear of the seat into the seat holders and push This vehicle is equipped with three-point seat down on the seat at the front. Make sure the belts for both the operator and the passenger. seats are securely latched.

  • Page 45: Glove Compartment

    Glove compartment Cargo bed NOTICE To protect from damage, do not put metal products, like tools or sharply edged prod- ucts, directly in the glove compartment. they must be stored, wrap them in appro- priate cushioning material. 1. Cargo bed 2.

  • Page 46

    Opening and closing the tailgate Lifting and lowering the cargo bed _¥( "" \\\_\ ,_3 b" \v_J "/j 1. Tailgate 2. Latch (x2) 1. Cargo bed release lever To lift To open Unhook the latches, and then lower the tail- Push down the cargo bed release lever on the gate.

  • Page 47: Front And Rear Shock Absorber Adjustment

    To lower Front and rear shock absorber adjustment With hands and fingers clear of pinch points, The spring preload can be adjusted to suit the lower the cargo bed slowly to its original posi- operating conditions. You can reduce preload tion be sure it is locked...

  • Page 48

    Adjust the spring preload as follows: A special wrench obtained To increase the spring preload, turn the ad- Yamaha dealer to make this adjustment. justing ring in direction (_. Standard position: To decrease the spring preload, turn the ad- A- Minimum (soft) justing ring in direction @.

  • Page 49: Trailer Hitch Bracket And Receiver

    Trailer towing equipment can be obtained at a Yamaha dealer. (See etc. The auxiliary DC jack should only be used pages 6-11-6-13 for precaution information.) when the engine is running. 1. Trailer hitch bracket 2.

  • Page 50: Auxiliary Dc Jack

    NOTICE • Do not use accessories requiring more than maximum capacity stated above. This overload circuit and cause the fuse to blow. • If accessories are used without the en- gine running, the battery will lose charge and engine starting may become difficult.

  • Page 51: For Your Safety

    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 •...

  • Page 52

    ITEM ROUTINE PAGE Final gear oil/ • Check for leakage. 5-7, 8-15-8-18 Differential gear oil Accelerator pedal ° Check for proper accelerator pedal operation. Seat belts ° Check for proper operation and belt wear. Steering ° Check for proper operation. Fittings and fasteners °...

  • Page 53: Front And Rear Brakes

    Test the brakes at slow speed not, have the vehicle inspected by a Yamaha dealer. after starting out to make sure they are work- ing properly. If the brakes do not provide prop-...

  • Page 54: Fuel

    Fuel Be sure the fuel tank cap is closed Make sure there is sufficient gasoline in the curely. tank. IIV! _l,VAVl_,'! --'t _ , I I_[e-I IJV!'ykVAVl_,'! --t_, I I#[e-I Gasoline is poisonous and can cause inju- Gasoline gasoline vapors ry or death.

  • Page 55

    Your Yamaha engine has been designed Recommended fuel: use regular unleaded gasoline with a pump Unleaded gasoline only octane number ([R+M]/2) of 86 or higher, Fuel tank capacity: research octane number of 91 or higher. 30.0 L (6.60 Imp gal, 7.93 US gal)

  • Page 56: Engine Oil

    Engine Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-10- 8-14.) NOTICE • In order prevent clutch slippage (since the engine oil also lubricates clutch), do not mix any chemical addi- tives with oil. Do not use oils with a die- specification "CD"...

  • Page 57: Coolant

    Coolant Final gear oil Check the coolant level in the coolant reser- Make sure the final gear oil is at the specified voir when the engine is cold (the coolant level level. Add oil as necessary. (See pages 8-15- will vary with engine temperature). 8-16 for details.) Recommended oil:...

  • Page 58: Steering

    Have a Yamaha dealer repair as nec- To help make sure your restraint systems are essary for proper operation.

  • Page 59: Lights

    Switches Tire pressure Check the operation of all switches. Have a Use the tire pressure gauge to check and ad- Yamaha dealer repair as necessary for proper just tire pressures when the tires are cold. Tire operation. pressures must equal both sides.

  • Page 60

    Set tire pressures to the following specifica- tions: Recommended pressure Minimum Maximum 70 kPa 63 kPa 77 kPa Front (0.70 kgficm 2, (0.63 kgficm 2, (0.77 kgficm 2, 10 psi) 9 psi) 11 psi) 98 kPa 91 kPa 105 kPa Rear (0.98 kgficm 2, (0.91 kgficm 2,...

  • Page 61

    Tire wear limit When the tire groove decreases (0.12 in) due to wear, replace the tire. a. Tire wear limit 5-11...

  • Page 62: Operation

    If there is a zero and 20 hours. control or function you do not understand, your Yamaha dealer. For this reason, we ask that you read the fol- lowing material carefully. Because the engine _IV.v _kVAVl:! t,] _, I I_[el...

  • Page 63: Starting A Cold Engine

    • When the drive select lever is in the build-up of heat. If any abnormality is noticed during this period, consult a Yamaha dealer. neutral position, the neutral indicator light should come on. If the neutral in- 0-10 hours:...

  • Page 64

    Use the starter (choke) in reference AMBIENT TEMP./STARTER (CHOKE) POSITION the figure: 0 ° 10 ° 20 ° 30 ° °C Position Q: Cold engine start - ambient temperature below 5 °C (40 °F). Position (_: Cold engine start - ambient temperature 0°C °F)-30...

  • Page 65

    If the engine fails to start, release the key, and then try starting it again. Wait a few seconds The speed of a cold engine may increase before the next attempt. Each attempt should enough as it warms up to cause the vehi- be as short as possible, to preserve battery...

  • Page 66: Starting A Warm Engine

    With the vehicle still in neutral, continue Warming warming up the engine until it idles To get maximum engine life, always warm up smoothly, and return the starter (choke) the engine before starting off. To see whether to position Q before riding. Failure to do or not the engine is warm, check for smooth so may result in poor performance...

  • Page 67: Drive Select Lever Operation And

    Drive select lever operation and reverse Apply the brake pedal, then shift by mov- driving ing the drive select lever along the shift guide. Make sure that the drive select le- NOTICE ver is completely shifted into position. Do not shift without coming to a complete stop and waiting for the engine to return to normal...

  • Page 68

    Due to the synchro- backing. nizing mechanism in the engine, light may not come on until the vehicle starts moving. • If the light does not come on, ask a Yamaha dealer to inspect the reverse indicator light electrical circuit.

  • Page 69: On-command Four-wheel-drive

    On-Command four-wheel-drive switch and "2WD"/"4WD" differential gear lock switch To change from 2WD to 4WD, stop the vehi- cle, and then set the switch to "4WD". When You may notice that the vehicle handles dif- ferently 2WD, 4WD, 4WD-LOCK the vehicle is in 4WD, the four-wheel-drive ("DIFF.

  • Page 70

    On-Command differential gear lock switch To lock the differential gear in 4WD, stop the "4WD'/"LOCK" vehicle, make sure the On-Command four- wheel-drive switch is set to "4WD", move the differential gear lock lever to position @, and then set the switch to "LOCK". When the dif- ferential gear is locked,...

  • Page 71: Parking

    For Special Edition models: Parking • When the switch is set to "LOCK", the dif- When parking, stop the engine and shift the ferential gear lock indicator and indicator drive select lever into the neutral position. Ap- light will flash until the differential gear is ply the parking brake to help prevent the vehi- locked.

  • Page 72: Loading

    Loading • Do not exceed the maximum tongue Take extra precautions when driving with a weight. load or trailer. Follow these instructions • Make sure the load does not interfere with your control or ability always use common sense and good judg- ment when carrying cargo or towing a trailer.

  • Page 73

    Use the hooks equipped on the cargo bed to MAXIMUM LOADING LIMIT tie down loads. • Vehicle loading limit (total weight of cargo, operator, passenger Choose a trailer hitch drawbar designed accessories and tongue weight): use with a 5 cm (2 in) receiver. (See page 398 kg (877 Ib) 4-22 for more information.)

  • Page 74

    Operating when loaded with cargo or tow- Pulling something other than a trailer ing a trailer Yamaha recommends that loads be transport- Drive more slowly than you would without ed in the bed or in a trailer. If you need to...

  • Page 75: Basic Guide For Safe Use

    KNOW YOUR VEHICLE BASIC GUIDE FOR SAFE This off-road vehicle will handle and maneu- ver differently from cars, ATVs, go-carts, golf- As a Rhino owner you are responsible for the cars grounds-keeping vehicles. safe proper operation of this vehicle. Rhino has higher ground clearance and other Read this chapter and review the safety in-...

  • Page 76: Driver Requirements

    Driver requirements Doing things with a Rhino that some people do for thrills in other vehicles (such as side- • This vehicle is intended for use only by an ways sliding, skidding, fishtailing, or donuts) operator 16 or older with a valid motor vehi- have led to side rollovers.

  • Page 77: Passenger Requirements

    Parents: Passenger requirements Many states have implemented motor This vehicle is designed for the operator vehicle licensing requirements for young driv- one passenger. Carrying passengers improp- ers. These requirements are in response erly can lead to serious injury or death. As the the disproportionately high rate of crashes operator,...

  • Page 78: Occupant Protection System

    Occupant protection system 1, Passenger handhold 1. Passenger handhold 2. Seat belt 3. Door 1, Door...

  • Page 79: Protective Structure

    Protective structure The vehicle cage/frame provides a protective Do not make changes to the occupant pro- structure that helps limit intrusions by branch- tection system. If you install aftermarket es or other objects and may reduce your risk products or have your vehicle modified, of injury in accidents.

  • Page 80: Seat Belts

    Seat belts An unbelted occupant may strike the interior Seat belts should be worn by both driver and of the vehicle, the protective structure, or oth- passenger. Driver must be sure that the pas- er objects in an accident or during operation. senger is belted before driving.

  • Page 81

    If the latch plate is not positioned in the correct location along seat belt, squeeze the latch plate ends together along its long edges in order to more eas- ily adjust its location up or down along the length of the belt. Push the latch plate into the buckle until it clicks.

  • Page 82: Doors

    Doors Put the lap portion of the belt low on your hips. Pull up on the shoulder part so the The doors are designed to reduce the likeli- belt is snug across your hips. hood that you will stick your leg out to stop the vehicle from tipping over or for any other rea- Position shoulder...

  • Page 83: Passenger Handholds

    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...

  • Page 84: Seat And Hip Restraints

    Floorboard Seat and hip restraints The seat and hip restraints are designed The floorboard allows you to brace your feet, help keep you in the vehicle. Do not hold onto which helps you keep your body in the vehicle in the event of an accident or rollover.

  • Page 85: Steering Wheel

    Steering wheel CORRECT GRIP EXAMPLE Keep both hands on the steering wheel. not hold the steering wheel with your thumbs inside the rim. Keep 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...

  • Page 86: Learning To Operate

    LEARNING TO OPERATE YOUR VEHICLE Both driver and passenger should wear the following to reduce risk of injury in an acci- dent: Personal protective equipment • Approved motorcycle helmet that fits prop- erly • protection (goggles, helmet face shield, or protective eyewear) •...

  • Page 87: Practice For New Rhino Users

    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.

  • Page 88: Getting Readyto Ride

    Getting readyto ride Turning Performthe Pre-Operation Checkson pages Usecarein turns- turningthesteeringwheel too far or too fastcan resultin lossof control 5-1-5-11. Followthe instructions startingon page 6-2 to start the engine. Once it has or a rollover. S lowdownbeforeenteringturns. warmedup and you haveturnedthe choke Whenmakingtightturnsfroma standstill o r at off, you are readyto begindrivingyourvehi- slowspeeds,avoidsuddenor hardaccelera-...

  • Page 89: Accelerating

    If you think or feel that the vehicle may tip or Accelerating roll, keep your body completely inside the pro- With the engine idling in neutral and your foot tective structure of the vehicle: on the brake, shift the drive select lever into •...

  • Page 90: Braking

    Braking Leaving the vehicle When slowing down or stopping, take your Do not get out of the vehicle while the engine foot off the accelerator pedal and press the is running and the drive select lever is in any brake pedal smoothly.

  • Page 91: Parking On A Flat Area

    Parking on a flat area 4. With the brake pedal applied,set the Whenparkingon a flat area,stop the engine parkingbrake. andshiftthe driveselectleverintothe neutral 5. Block the front and rear wheels with rocksor otherobjects. position.Applythe parkingbraketo help pre- vent the vehiclefromrolling. Loading Parking on a slope The total weight of operator,passenger, a c- The parking brake acts only on the rear...

  • Page 92: Operation On Different Surfaces

    Operation on different surfaces terrains Go slowly and proceed with caution when op- erating on an unfamiliar surface or terrain. This vehicle may handle differently in certain types of terrains or on certain surfaces. come upon hidden rocks, bumps, holes without enough time to react.

  • Page 93: Hills

    Hills Uphill Choose carefully which hills you attempt Do not attempt to climb hills until you have climb or descend. Avoid hills with slippery sur- mastered basic maneuvers on flat ground. faces or those where you will not be able to Drive straight up hills, and avoid crossing see far enough...

  • Page 94: Downhill

    Downhill Slowdownwhenyou reachthe crestofthehill if you cannotsee clearlywhat is on the other Check the terrain carefully before going side- there couldbe anotherperson,an ob- downhill.When possible,choosea path that stacle,or a sharpdrop-off. lets you drive your vehiclestraightdownhill. Chooseyour path carefullyand drive slowly If you start to lose traction or momentum enoughto be able to reactto obstaclesthat whenclimbing, a nddecideyou will be unable...

  • Page 95: Rough Terrain

    If you are sliding or skidding, try to steer in the Rough terrain direction the vehicle is sliding, to regain con- Operation over rough terrain should be done with caution. trol. For example, if you feel the back of the •...

  • Page 96: Water

    Water NOTICE If you must cross shallow, slow-moving water After driving your vehicle in water, be sure up to the depth of the vehicle's floorboards, to drain the trapped water by removing choose your path carefully to avoid sharp check hose at the bottom of the air filter drop-offs,...

  • Page 97: Loose Terrain/slippery Terrain

    Brush or wooded areas Loose terrain/slippery terrain When driving on slippery terrain, including When operating in areas with brush or trees, wet, muddy, or icy conditions, as well as loose watch carefully on both sides and above the vehicle for obstacles such as branches that gravel,...

  • Page 98: Encountering Obstacles

    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.

  • Page 99: Periodic Maintenance

    Failure to properly maintain the vehicle oxide. performing maintenance activities 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.

  • Page 100: Owner's Manual And Tool Kit

    Owner's manual and tool kit You are recommended to put this owner's manual in the vinyl bag and always carry it un- derneath the driver seat as shown. Put the owner's tool kit and tire pressure gauge in the space beside the battery. 1, Owner's tool kit 2.

  • Page 101

    If you do not 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.

  • Page 102: Periodic Maintenance Chart For The

    • Items marked with an asterisk should be performed by a Yamaha dealer as they require spe- cial tools, data and technical skills. INITIAL EVERY...

  • Page 103: General Maintenance And Lubrication Chart

    General maintenance and lubrication chart INITIAL EVERY Whichever month ITEM ROUTINE comes first 1,200 2,400 2,400 4,800 (mi) (200) (750) (1,500) (1,500) (3,000) hours Check coolant leakage. Cooling system Repair if necessary. Replace coolant every 24 months. Air filter elements Clean.

  • Page 104

    INITIAL EVERY Whichever month ITEM ROUTINE comes first 1,200 2,400 2,400 4,800 _> (mi) (200) (750) (1,500) (1,500) (3,000) hours Drive shaft universal joint* • Lubricate with lithium-soap-based grease. • Check for cracks or damage. © © Engine mount* • Check bolt tightness. Front and rear axle boots* •...

  • Page 105: Hood

    Hood To open Unhook the hood latches, and then slowly tilt the hood up until it stops. 1, Hood 1, Latch (× 2)

  • Page 106

    To close NOTICE Lower the hood slowly to its original position, • Make sure that all cables and wires are and then hook the hood latches. Secure pro- in place when closing the hood. jections Q on the rear of the hood into slots (_ •...

  • Page 107: Console

    Console To install 1. Place the console in its original position. To remove Install the parking brake lever boot. Install the seats. 1. Remove the seats. (See pages 4-16- 4-17 for seat removal installation NOTICE procedures.) • When installing the console, be sure not Remove the parking...

  • Page 108: Engine Oil And Oil Filter Cartridge

    Engine oil and oil filter cartridge Insert the dipstick in the oil filler hole Check engine oil level before each operation. (without screwing it in), and then remove In addition, change the oil and the oil filter car- it again to check the oil level. The engine oil should be between the minimum...

  • Page 109

    Insert the dipstick into the oil filler hole, To change the engine oil (with or without and then tighten the oil filler cap. oil filter cartridge replacement) Reinstall the console. 1. Remove the console. (See page 8-9 for console removal and installation proce- dures.)

  • Page 110

    Remove the oil filter cartridge with an oil filter wrench. An oil filter wrench is avail- able from a Yamaha dealer. 1, O-ring Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the 2.

  • Page 111

    Add the specified amount of recommend- ed engine oil, and then reinstall the en- gine oil filler cap and tighten it. NOTICE: Be sure to wipe off spilled oil on any parts after engine exhaust system have cooled down. Recommended engine oil: See page 10-2.

  • Page 112

    10. Start the engine, and then let it idle for NOTICE several minutes while checking it for oil • In order prevent clutch slippage leakage. If oil is leaking, immediately turn (since the engine oil also lubricates the engine off and check for the cause. clutch), do not mix any chemical addi-...

  • Page 113: Final Gear Oil

    Final gear oil If the oil is below the brim of the filler hole, add sufficient oil of the recommended Checking the final gear oil level type raise it to correct level. 1. Park the vehicle on a level surface. NOTICE: Be sure no foreign...

  • Page 114

    Changing the final gear oil Add the recommended final gear oil up to 1. Park the vehicle on a level surface. the brim of the filler hole. NOTICE: Place a container under the final gear sure no foreign material enters the fi- case to collect the used oil.

  • Page 115: Differential Gear Oil

    Differential gear oil Reinstall the differential gear oil filler bolt, and then tighten it to the specified torque. Checking the differential gear oil level Tightening torque: 1. Park the vehicle on a level surface. Differential gear oil filler bolt: Remove the differential gear oil filler bolt 23 Nm (2.3 m.kgf, 17 ft.lbf)

  • Page 116

    Recommended oil: SAE 80 API GL-5 Hypoid gear oil Oil quantity: 0.32 L (0.28 Imp qt, 0.34 US qt) Reinstall the differential gear oil filler bolt, and then tighten it to the specified torque. Tightening torque: Differential gear oil filler bolt: 1, Differential gear oil d rain b olt 23 Nm (2.3 m.kgf, 17 ft.lbf)

  • Page 117: Coolant

    Coolant The coolant level should be checked before each ride. Checking the coolant level 1. Park the vehicle on a level surface. Open the hood. (See pages 8-7-8-8 hood opening and closing procedures.) Check the coolant level in the coolant reservoir when the engine is cold as the...

  • Page 118: Axle Boots

    If water used instead of coolant, have a Yamaha deal- er check the antifreeze content of the coolant as soon as possible. The radiator fan is automatically switched or off according to the coolant temperature the radiator.

  • Page 119: Spark Plug Inspection

    Spark plug inspection Removal 1. Remove the console. (See page 8-9 for console removal and installation proce- dures.) Remove the spark plug cap. 1. Rear axle boot (x 2 each side) 1. Spark plug cap Use the spark plug wrench in the tool kit to remove the spark plug as shown.

  • Page 120

    Inspection The spark plug is an important engine compo- nent and is easy to inspect. The condition the spark plug can indicate the condition the engine. ideal color of the porcelain insulator around the center electrode is a medium-to- light tan for a vehicle that is being ridden nor- mally.

  • Page 121

    Installation Install the spark plug and tighten it to the 1. Measure the electrode gap with a wire specified torque. If a torque wrench is not thickness gauge and, if necessary, adjust available when installing the gap to specification. spark plug, a good estimate of the correct torque is one-quarter to one-half...

  • Page 122: Cleaning The Air Filter Elements

    Remove the air filter element from the air Cleaning the air filter elements intake duct grill by pulling it out as shown. Cleaning the intake duct air filter element 1. Remove the air intake duct grill by remov- ing the quick fastener screws.

  • Page 123

    Reinstall the air filter element into the air Cleaning the engine air filter element There is a check hose at the bottom of the air intake duct grill. filter case. If dust or water collects in this Reinstall the air intake duct grill by install- ing the quick fastener screws.

  • Page 124

    Remove the air filter element. Remove the air filter case cover by un- hooking the holders. 1. Air filter element 1. Air filter case cover holder (× 5) 2, Air filter case cover 8-26...

  • Page 125

    5. Remove the sponge material from Wash sponge material gently frame. thoroughly 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 serious injury.

  • Page 126

    Tighten all fittings securely to avoid the 11. Thoroughly apply Yamaha foam air filter possibility of unfiltered air entering the engine. oil or other quality liquid foam air filter oil NOTICE (not spray type) to the sponge material.

  • Page 127: Drive Select Lever Box Check Hose

    Drive select lever box check hose V-belt cooling duct check hoses The drive select lever box check hose is locat- The V-belt cooling duct check hoses are lo- ed under the console. (See page 8-9 for con- cated under the console and cargo bed. (See sole removal and installation procedures.)

  • Page 128: V-belt Case Drain Plug

    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, as the water may affect 1, V-belt cooling duct check hose other engine parts.

  • Page 129: Cleaning The Spark Arrester

    Cleaning the spark arrester Remove the tailpipe by pulling it out of the muffler. IF! ViVl,_! -'t_II _[e-I Tap the tailpipe lightly, and then use a Hot exhaust system may cause burns. To wire brush to remove any carbon depos- avoid burns or fires, make sure that the en- its from the spark arrester portion of the...

  • Page 130: Carburetor Adjustment

    Tailpipe bolt: requires very sophisticated adjustment. Most 9.5 Nm (0.95 m.kgf, 6.9 ft.lbf) adjusting should be left to a Yamaha dealer who has the professional knowledge and ex- perience to do so. However, the idling speed adjustment...

  • Page 131: Idle Speed Adjustment

    To prevent this, the valve clear- tion @ to decrease the engine speed. ance must be adjusted regularly. This adjust- ment however, should be left to a professional Yamaha service technician. 8-33...

  • Page 132: Brakes

    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. 8-34...

  • Page 133: Rear Brake Pad Check

    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. 1. Minimum level mark Insufficient brake fluid may allow air to enter...

  • Page 134: Brake Fluid Replacement

    Yamaha service personnel. performance. Have a Yamaha dealer replace the following components during periodic maintenance Recommended brakefluid:DOT4 when they are damaged or leaking. • Replace the oil seals every two years.

  • Page 135: Checking The Brake Pedal

    Checking the brake pedal Parking brake lever free play adjustment Have a Yamaha dealer check the brakes at Periodically check the parking brake lever free the intervals specified in the periodic mainte- play and adjust it if necessary. nance and lubrication chart.

  • Page 136

    ® a, Parking brake lever free play 1, Locknut 2, Adjusting nut Turn the adjusting nut in direction ® to 5. The parking brake lever must be re- increase the free play or in direction @ to leased when checking and adjusting parking brake lever free play.

  • Page 137: Brake Light Switch Adjustment

    Brake light switch adjustment The brake light switch, which is activated the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust brake light switch as follows. 1. Open the hood. (See pages 8-7-8-8 hood opening and closing procedures.) Turn the adjusting nut while...

  • Page 138: Cable Inspection And Lubrication

    Cables 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 Lithium-soap-based lubricant: grease 8140...

  • Page 139: Rear Knuckle Upper And Lower Pivot Lubrication

    Rear knuckle upper and lower pivot Steering shaft lubrication lubrication Lubricate the pivot points. Lubricate the knuckle upper and lower pivots Recommended lubricant: with a grease gun. Lithium-soap-based grease Recommended lubricant: Lithium-soap-based grease 8-41...

  • Page 140: Wheel Removal

    Wheel removal Tire replacement 1. Loosen the wheel nuts. Always use the same size and type of tires recommended in this owner's manual. Elevate the vehicle and place a suitable stand under the frame. tires that came with your Rhino were Remove the nuts from the wheel.

  • Page 141: Wheel Installation

    Wheel installation The tires listed below have been approved 1. Install the wheel and the nuts. Yamaha Motor Manufacturing Corporation America for this model. • The arrow mark L_ on the tire must point toward the rotating direction Manufacturer Size Type the wheel.

  • Page 142

    Wheel nut torque: Front: 55 Nm (5.5 m.kgf, 40 ft.lbf) Rear: 55 Nm (5.5 m.kgf, 40 ft.lbf) 1. Arrow m ark Tapered nut 8144...

  • Page 143: Battery

    You could be poisoned or severely burned If the battery seems to have discharged, con- by the sulfuric acid in battery electrolyte. sult a Yamaha dealer. In case of accidental contact with battery NOTICE electrolyte: Do not try to remove...

  • Page 144: Battery Maintenance

    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 charge the battery before reinstallation. NOTICE A special battery charger (constant volt- age/ampere or constant voltage) ----2...

  • Page 145: Jump-starting

    Jump-starting However, if the vehicle must be jump-started, Jump-starting the vehicle should be avoided. proceed as follows. The battery should be removed and charged 1. Turn the key to "OFF". instead. Open the hood. (See pages 8-7-8-8 hood opening and closing procedures.) _kVAVl_,y .-t _, i i _, [ e-w Remove...

  • Page 146

    Start the engine. (Refer to "Starting cold engine" on pages 6-2-6-5.) After the engine starts, disconnect negative lead of the jumper cable from vehicle charged battery, then disconnect the positive lead of the jumper cable from the charged battery and the battery in the vehicle. Reinstall the battery compartment cover.

  • Page 147: Fuse Replacement

    Fuse replacement Turn the key to "OFF" and turn off the electri- The main fuse and the fuse box are located cal circuit in question. under the hood. (See pages 8-7-8-8 for hood NOTICE opening and closing procedures.) prevent accidental short-circuiting, If a fuse is blown, turn off the main switch and turn off the main switch...

  • Page 148

    Backup fuse (for odometer and clock on Special Edition models) device operates. Carburetor warmer fuse 10, Spare fuse (× 3) If the fuse blows again immediately, have a Yamaha dealer check electrical system. Reinstall the battery compartment cover. Close the hood.

  • Page 149: Replacing A Headlight Bulb

    Replacing a headlight bulb Remove the headlight bulb holder cover If a headlight bulb burns out, replace it as fol- by pulling it off. lows. 1. Lift the hood up. (See pages 8-7-8-8 hood opening and closing procedures.) Remove the cover at the rear of the...

  • Page 150

    Wait for the headlight bulb to cool before Remove headlight bulb holder pushing it in and turning it counterclock- touching or removing it. Remove the bulb wise. by pulling it out. Insert a new headlight bulb into the bulb holder by pushing it in.

  • Page 151: Headlight Beam Adjustment

    Reinstall the bulb holder by pushing it in and turning it clockwise. NOTICE Reinstall the bulb holder cover and the It is advisable to have a Yamaha dealer cover rear headlight. make this adjustment. NOTICE: Make sure the headlight bulb...

  • Page 152: Tail/brake Light Bulb Replacement

    Tail/brake light bulb replacement If a tail/brake light bulb burns out, replace it as follows: 1. Remove the quick fastener screws bolts from panel A (if replacing the left tail/brake light bulb) or panel B (if replac- ing the right tail/brake light bulb).

  • Page 153

    Lift the cargo bed up. (See pages 4-19- Reinstall the bulb holder (together with 4-20 for cargo bed lifting and lowering the bulb) by turning it clockwise. procedures.) Install the panel. Remove the panel. Lower the cargo bed. Remove the bulb holder (together with 10.

  • Page 154: Troubleshooting

    Yamahadeal- The skilledtechniciansat a Yamahadealer- ship have the tools, experience,and know- howto properlyserviceyourvehicle.Useonly genuineYamahapartson yourvehicle.Imita- tion parts may look like Yamaha parts, but they are often inferior. Consequently, t hey havea shorterservicelifeandcanleadto ex- pensiverepairbills. 8156...

  • Page 155: Troubleshooting Charts

    Remove the fuel hose Check the No fuel. from the fuel pump. _"[ fuelflow. uel pump is clogged. Check if there is fuel in the fuel tank. Ask a Yamaha dealer to Nofuel. SupplyfueL Restart the engine. inspect. There is compression Compression normal.

  • Page 156

    Place a thick rag over the cap and remove the cap slowly to allow any remaining pressure to escape. Ask a Yamaha dealer to inspect " _ " I and repairthe cooling system.

  • Page 157: Cleaning And Storage

    CLEANING AND STORAGE Rinse the dirt and degreaser off with a garden hose. Use only enough pressure A. Cleaning do the job. WARNING! Test Frequent, thorough cleaning of your vehicle brakes after washing. Apply will not only enhance its appearance but will brakes several...

  • Page 158: Storage

    Fill the fuel tank with fresh fuel and add Clean the seats with a vinyl upholstery the specified amount of Yamaha Fuel cleaner to keep the covers pliable Stabilizer and Conditioner or equivalent glossy.

  • Page 159

    5. Blockupthe frameto raiseallwheelsoff nates the need to drain the fuel system. Con- the ground. sult a Yamaha dealer if the fuel system needs 6. Tie a plasticbag over the exhaustpipe to be drained. outletto preventmoisturefromentering. 7. If storing in a humid or salt-air atmo- sphere,coat all exposedmetalsurfaces with a lightfilm of oil.

  • Page 160: Specifications

    SPECIFICATIONS Model YXR45FX Dimensions: Overall length 2,885 mm (113.6 in) Overall width 1,385 mm (54.5 in) Overall height 1,853 mm (73.0 in) Seat height 818 mm (32.2 in) Wheelbase 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...

  • Page 161

    Model YXR45FX Engine oil: Type: 130 °F YAMALUBE 4 (20W-50) or SAE 20W-50 _'AMALLJBE 4 (16W-40) _ r SAE16W-40= i YAMALUBE 4-CW (5W-30)or SAE 5W-30 50 °C Recommended engine oil classification API service SG type or higher, JASO standard MA NOTICE In order to prevent clutch slippage (since the en- gine oil also lubricates the clutch), do not mix any...

  • Page 162

    Model YXR45FX Final gear case oil: Type SAE 80 API GL-4 Hypoid gear oil Quantity 0.25 L (0.22 Imp qt, 0.26 US qt) Differential gear case oil: Type SAE 80 API GL-5 Hypoid gear oil Quantity 0.32 L (0.28 Imp qt, 0.34 US qt) Radiator capacity (including all routes): 2.70 L (2.38 Imp qt, 2.85 US qt) Air filter:...

  • Page 163

    Model YXR45FX Transmission: V-belt Primary reduction system Shaft drive Secondary reduction system Secondary reduction ratio 43/20 × 24/17 × 33/9 (11.129) V-belt automatic Transmission type Operation Right hand operation Reverse gear 30/15 (2.000) Sub transmission ratio 43/18 (2.389) high 39/22 (1.773) Chassis: Steel tube frame Frame type...

  • Page 164

    Model YXR45FX Brakes: Front and rear unified System front Dual disc brake Type rear Single disc brake Operation Foot operation Suspension: Double wishbone Front suspension Double wishbone Rear suspension Shock absorber: Front shock absorber Coil spring!oil damper Rear shock absorber Coil spring/oil damper Wheel travel: Front wheel travel...

  • Page 165

    Model YXR45FX Bulb voltage, wattage x quantity: 12 V 30.0 W/30.O W x 2 Headlight 12 V 5.0 W/21.0 W x 2 Tail!brake light Indicator lights: 12V1.7Wx1 Neutral indicator light LED (Special Edition models 12V1.7Wx1 Reverse indicator light LED (Special Edition models 12V1.7Wx1 Coolant temperature warning light LED (Special Edition models...

  • Page 166

    Model YXR45FX Specified fuses: Main fuse 30.0 A 15.0A Headlight fuse 10.0A Ignition fuse 10.0A Auxiliary DC jack fuse Four-wheel-drive motor fuse 3.0A Carburetor warmer fuse 10.0A 10.0A Signaling system fuse 10.0A Backup fuse 10-7...

  • Page 167: Consumer Information

    Yamaha VEHICLE IDENTIFICATION NUMBER: dealer or for reference, in case the vehicle is stolen. MODEL LABEL INFORMATION: • I© 11-1...

  • Page 168

    Vehicle identification number Key identification number The key identification number is stamped The vehicle identification number is stamped into the frame. the key, as shown in the following illustration. This number can be used for ordering a new key. 1, Vehicle identification number The vehicle identification number...

  • Page 169

    The model label 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 11-3...

  • Page 170: Noise Regulation

    NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop- erative by any person other than for purposes of maintenance, repair, or replacement of any de- vice or element of design incorporated into any new vehicle for the purpose of noise control prior...

  • Page 171: Maintenance Record

    MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to docu- ment maintenance done in accordance with the warranty. The chart below is printed only as a re- minder to you that the maintenance work is required.

  • Page 172: Yamaha Motor Corporation

    FROM THIS WARRANTY. PERIOD OF WARRANTY for YXR OR YXP repairs at such dealer's place of business. Yamaha Side × Side vehicles shall be six (6) months SOME STATES DO NOT ALLOW LIMITATIONS from the date of purchase, with no mileage limitation.

  • Page 173: Yamaha Extended Service

    (Y.E.S.). (TRIP) is included at no extra cost. TRIP gives up to $150 reimbursement occurrence for any reasonable • Y.E.S. is designed administered by Yamaha Motor expenses incur because your Yamaha needs Corporation to provide maximum owner satisfaction. covered service:...

  • Page 174

    Y.E.S. costs less within the first 90 days after buy your Yamaha. See your dealer today! SERVICE YAMAHA EXTENDED A special note: If visiting your dealer isn't convenient, contact Yamaha with your Primary ID number (your frame number).

  • Page 175

    PRINTED INUSA 2007.08o2.9×1...

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