Yamaha Rhino YXR66FW Owner's Manual
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Yamaha Rhino YXR66FW Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S MANUAL
YXR66FW
LIT-11626-20-64
5UG-F8199-14

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Summary of Contents for Yamaha Rhino YXR66FW

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YXR66FW LIT-11626-20-64 5UG-F8199-14...
  • Page 2 EBU00776...
  • Page 3 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.

  • Page 4: Important Manual Information

    EVU00021 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. YXR66FW OWNER’S MANUAL ©2007 by Yamaha Motor Corporation, U.S.A. 1st edition, July 2007 All rights reserved. Any reprinting or unauthorized use without the written...

  • Page 6: Table Of Contents

    EVU00050 Seat belts ........4-14 CONTENTS Glove compartment .......4-14 Cargo bed ........4-15 LOCATION OF THE WARNING Front and rear shock absorber AND SPECIFICATION LABELS..1-1 adjustment ........4-17 Trailer hitch bracket and SAFETY INFORMATION....2-1 receiver ........4-18 Auxiliary DC jack......4-19 DESCRIPTION ......... 3-1 FOR YOUR SAFETY –...
  • Page 7 Control cables ......... 5-9 Doors ..........7-9 Tires ..........5-9 Passenger handholds...... 7-9 Seat and hip restraints ....7-10 OPERATION........6-1 Floorboard ........7-11 Engine break-in....... 6-1 Steering wheel....... 7-11 Starting a cold engine ..... 6-2 LEARNING TO OPERATE Starting a warm engine....6-5 YOUR VEHICLE......
  • Page 8 Rough terrain......... 7-22 Drive select lever box check Pavement ........7-22 hose ..........8-29 Water ..........7-22 V-belt cooling duct check hose..8-30 Loose terrain/slippery terrain..7-23 V-belt case drain plug ....8-30 Brush or wooded areas ....7-24 Cleaning the spark arrester ...8-31 Encountering obstacles....
  • Page 9 SIDE × SIDE VEHICLE LIMITED Battery ........... 8-45 Battery maintenance ..... 8-46 WARRANTY........ 11-6 Jump-starting ........ 8-47 YAMAHA EXTENDED SERVICE Fuse replacement ......8-49 (Y.E.S.) ........11-7 Replacing a headlight bulb ... 8-51 Headlight beam adjustment ..8-54 Tail/brake light bulb replacement ........

  • Page 10: Location Of The Warning And Specification Labels

    EVU00060 L OCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 11 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 re- placement label is available from your Yamaha dealer. WARNING WARNING...
  • Page 12 WARNING WARNING Keep hands, body, and other people away from pinch points when lowering bed. Do not hold the cage/frame while closing bed. YAMAHA 5B4-K7764-00 YAMAHA 5B4-F1696-00...
  • Page 13 WARNING MAX 7.3 INCH (185MM) YAMAHA 5UG-F151J-00 YAMAHA 5B4-F4897-00...
  • Page 14 ü Head Helmet and eye protection. ü Body Seatbelt and protective clothing. ü Hands Inside vehicle and holding the handholds or steering wheel. ü Feet On floorboard, ready to brace, and door closed. YAMAHA 5B4-F1558-00...
  • Page 15 WARNING • • • • DRIVER • UNDER • • • • • YAMAHA 5B4-F1568-01...

  • Page 16: Safety Information

    EVU00070 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 operating the Rhino. Also use these two chapters and the labels on the vehicle to instruct new operators and passengers.
  • 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. DRIVER UNDER • This vehicle is designed to carry the driver and one passenger. Never carry passengers in 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. See pages 5-1–5-2 for a list of pre-operation checks. Prepare your load or trailer Carrying loads, towing a trailer, or pulling objects can affect handling, stability, and risk of overturn or other accidents.
  • 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 in a rollover accident.
  • 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 can 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 Many companies with no connection to Yamaha manufacture parts and accessories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these af- termarket companies produce. Therefore, Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha, even if sold and installed by a Yamaha dealer.
  • 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 8-42–8-45 for tire specifications and more information on replacing your tires.

  • Page 26: Description

    EVU00080 D ESCRIPTION J K L 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.
  • Page 27 The vehicle you have purchased may differ slightly from those shown in the figures of this Q R S manual. Y X W 25. Light switch 26. Steering wheel 27. Starter (choke) 28. Main switch 29. On-Command four-wheel-drive and differential gear lock switches 30.

  • Page 28: Instrument And Control Functions

    EVU00130 I NSTRUMENT AND CONTROL Functions of the respective switch positions FUNCTIONS are as follows: EVU00140 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. The key can be removed in this posi- tion.

  • Page 29: Indicator And Warning Lights

    EVU00150 EVU01131 Indicator and warning lights On-Command differential gear lock indica- tor light “DIFF. LOCK” This indicator light and the On-Command dif- ferential gear lock indicator in the display come on when the On-Command differential gear lock switch is set to the “LOCK” position. When the switch is set to “LOCK”, the On- Command differential gear lock indicator light will flash until the differential gear is locked.
  • Page 30 If the indicator light flashes under any other circumstances or the speedometer does not 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.

  • Page 31: Multi-Function Meter Unit

    EVU00181 EVU01630 Coolant temperature warning light “ ” Multi-function meter unit 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 32 two tripmeters (which show the distance Odometer and tripmeter modes traveled since they were last set to zero) Pushing the “TRIP/ODO” button switches the a clock display between the odometer mode “ODO” an hour meter (which shows the total time and the tripmeter modes “A”...
  • Page 33 Clock mode Fuel meter Pushing the “ ” button switches the dis- The fuel meter indicates the amount of fuel in play between the clock mode “CLOCK” and the fuel tank. The display segments of the fuel the hour meter mode “HOUR” in the following meter disappear from “F”...

  • Page 34: Switches

    EVU00230 Switches NOTICE EVU00240 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 the starter motor will not operate properly. If this should happen, remove the battery and recharge it.
  • Page 35 EVU01183 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 36: Accelerator Pedal

    EVU00260 EVU00270 Accelerator pedal Brake pedal Press the accelerator pedal down to increase Press the brake pedal to slow or stop the ve- engine speed. Spring pressure returns the hicle. pedal to the rest position when released. Al- ways check that the accelerator pedal returns normally before starting the engine.

  • Page 37: Parking Brake Lever

    EVU00280 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 38: Drive Select Lever

    EVU00290 EVU00300 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- cle into the low, high, neutral, and reverse po- terclockwise. sitions. (Refer to pages 6-6–6-7 for the drive select lever operation.) 1.

  • Page 39: Starter (Choke)

    EVU00320 Starter (choke) “ ” Doors Starting a cold engine requires a richer air-fuel To open a door, simply pull the latch outward. mixture. A separate starter circuit supplies this To close a door, push or pull the door inward mixture.

  • Page 40: Seats

    EVU00330 Seats To install a seat, insert the projections on the To remove a seat, pull its seat lock lever up- rear of the seat into the seat holders and push ward, lift the front of the seat, and then slide down on the seat at the front.

  • Page 41: Seat Belts

    EVU00340 EVU01191 Seat belts Glove compartment This vehicle is equipped with three-point seat NOTICE belts for both the operator and the passenger. To protect from damage, do not put metal Always wear the seat belts properly while products, like tools or sharply edged prod- riding in the vehicle.

  • Page 42: Cargo Bed

    EVU00351 Cargo bed Opening and closing the tailgate 1. Cargo bed 2. Tailgate 1. Tailgate 2. Latch (× 2) 3. Cargo hook (× 4) To open Unhook the latches, and then lower the tail- Maximum load limit: 181 kg (400 lb) gate.
  • Page 43 Lifting and lowering the cargo bed To lower With hands and fingers clear of pinch points, lower the cargo bed slowly to its original posi- tion and be sure it is locked into place. WARNING! Keep hands, body, and other people away from pinch points when low- ering bed.

  • Page 44: Front And Rear Shock Absorber Adjustment

    EVU00360 Front and rear shock absorber adjustment Adjust the spring preload as follows: The spring preload can be adjusted to suit the To increase the spring preload, turn the ad- justing ring in direction a. operating conditions. You can reduce preload for a softer ride, or increase preload if frequent To decrease the spring preload, turn the ad- justing ring in direction b.

  • Page 45: Trailer Hitch Bracket And Receiver

    5 cm (2 in) receiver for a stan- Standard position: B dard trailer hitch. Trailer towing equipment A- Minimum (soft) can be obtained at a Yamaha dealer. (See E- Maximum (hard) pages 6-11–6-13 for precaution information.) 1. Trailer hitch bracket 2.

  • Page 46: Auxiliary Dc Jack

    EVU00380 Auxiliary DC jack The auxiliary DC jack is located at the right side of the front panel. The auxiliary DC jack can be used for suitable work lights, radios, etc. The auxiliary DC jack should only be used when the engine is running. 1.
  • Page 47 NOTICE Do not use accessories requiring more than the maximum capacity stated above. This may overload the circuit and cause the fuse to blow. If accessories are used without the en- gine running, the battery will lose its charge and engine starting may become difficult.

  • Page 48: For Your Safety - Pre-Operation Checks

    Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspect- ed by a Yamaha dealer. Before using this vehicle, check the following points:...
  • Page 49 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 50: Front And Rear Brakes

    Brake operation firm feeling when the brakes are applied. If Check the operation of the brakes at the start not, have the vehicle inspected by a Yamaha of every ride. Test the brakes at slow speed dealer. after starting out to make sure they are work- ing properly.

  • Page 51: Fuel

    EVU00400 Fuel 4. Be sure the fuel tank cap is closed se- Make sure there is sufficient gasoline in the curely. tank. WARNING WARNING Gasoline is poisonous and can cause inju- Gasoline and gasoline vapors are ex- ry or death. Handle gasoline with care. tremely flammable.
  • Page 52 WARNING! Never refill a fuel container by Yamaha because it may cause fuel system in the bed of any vehicle. Fire may result damage or vehicle performance problems.

  • Page 53: Engine Oil

    EVU00410 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-10– 8-14.) NOTICE In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical addi- tives with oil.

  • Page 54: Coolant

    EVU00420 EVU00430 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).

  • Page 55: Accelerator Pedal

    Have a Yamaha dealer repair Always check the tightness of chassis fittings as necessary for proper operation. and fasteners before a ride. Take the vehicle to a Yamaha dealer or refer to the Service Manual for correct tightening torque.

  • Page 56: Lights

    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 be equal on both sides.
  • Page 57 Set tire pressures to the following specifica- tions: ACE-02E Recommended Minimum Maximum pressure 70 kPa 63 kPa 77 kPa Front (0.70 kgf/cm (0.63 kgf/cm (0.77 kgf/cm 10 psi) 9 psi) 11 psi) 98 kPa 91 kPa 105 kPa Rear (0.98 kgf/cm (0.91 kgf/cm (1.05 kgf/cm 14 psi)
  • Page 58 EVU00520 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. Tire wear limit 5-11...

  • Page 59: Operation

    If there is a zero and 20 hours. control or function you do not understand, ask your Yamaha dealer. For this reason, we ask that you read the fol- lowing material carefully. Because the engine...

  • Page 60: Starting A Cold Engine

    If any abnormality is noticed When the drive select lever is in the during this period, consult a Yamaha dealer. neutral position, the neutral indicator light should come on. If the neutral in- 0–10 hours:...
  • Page 61 3. Use the starter (choke) in reference to the figure: Position 1: Cold engine start – ambient temperature below 5 °C (40 °F). Position 2: Cold engine start – ambient temperature at 0 °C (30 °F)–30 °C (90 °F) warming up position. Position 3: Cold engine start –...
  • Page 62 If the engine fails to start, release the key, and WARNING 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 cle to move on its own while the choke is energy.

  • Page 63: Starting A Warm Engine

    EVU00561 6. With the vehicle still in neutral, continue Warming up 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 3 before riding.

  • Page 64: Drive Select Lever Operation And Reverse Driving

    Drive select lever operation and reverse 2. 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 idle speed.
  • Page 65 Due to the synchro- backing. nizing mechanism in the engine, the 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 66: On-Command Four-Wheel-Drive Switch And Differential Gear Lock Switch

    EVU01183 On-Command four-wheel-drive switch and “2WD”/“4WD” differential gear lock switch To change from 2WD to 4WD, stop the vehi- You may notice that the vehicle handles dif- cle, and then set the switch to “4WD”. When ferently in 2WD, 4WD, and 4WD-LOCK the vehicle is in 4WD, the four-wheel-drive in- (“DIFF.
  • Page 67 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 b, and then set the switch to “LOCK”. When the dif- ferential gear is locked, the differential gear lock indicator light (“DIFF.

  • Page 68: Parking

    EVU01210 Driving before the differential gear lock is Parking properly engaged (e.g., when the indicator When parking, stop the engine and shift the and indicator light are flashing) will cause drive select lever into the neutral position. Ap- the engine speed to be limited until en- ply the parking brake to help prevent the vehi- gagement is complete.

  • Page 69: Loading

    EVU00630 Loading Do not exceed the maximum tongue Take extra precautions when driving with a weight. load or trailer. Follow these instructions and Make sure the load does not interfere always use common sense and good judg- with your control or ability to see ment when carrying cargo or towing a trailer.
  • Page 70 Use the hooks equipped on the cargo bed to MAXIMUM LOADING LIMIT tie down loads. Vehicle loading limit (total weight of cargo, operator, passenger and Choose a trailer hitch drawbar designed for accessories and tongue weight): use with a 5 cm (2 in) receiver. (See page 393 kg (866 lb) 4-18 for more information.) Cargo bed: 181 kg (400 lb)
  • Page 71 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 a ed in the bed or in a trailer. If you need to load.

  • Page 72: Basic Guide For Safe Use

    5UG14004 BASIC GUIDE FOR SAFE KNOW YOUR VEHICLE 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 and grounds-keeping vehicles. The safe and proper operation of this vehicle. Rhino has higher ground clearance and other Read this chapter and review the safety in- features to handle rugged terrain, and, as a...
  • Page 73 Doing things with a Rhino that some people do for thrills in other vehicles (such as side- ways sliding, skidding, fishtailing, or donuts) have led to side rollovers. These rollovers can result in crushed limbs and other serious inju- ries or death to drivers or passengers. As the owner/operator, it is your responsibility to protect yourself and your passenger from accidents, including rollovers.

  • Page 74: Driver Requirements

    Driver requirements Parents: This vehicle is intended for use only by an Many states have implemented new motor operator 16 or older with a valid motor vehi- vehicle licensing requirements for young driv- cle license. ers. These requirements are in response to the disproportionately high rate of crashes in- volving youthful drivers.

  • Page 75: Passenger Requirements

    Passenger requirements Occupant protection system This vehicle is designed for the operator and one passenger. Carrying passengers improp- erly can lead to serious injury or death. As the operator, you are responsible for your pas- senger. Your passenger must be able to place both feet on the floorboard while seated upright with his/her back against the seat back.
  • Page 76 WARNING Do not make changes to the occupant pro- tection system. If you install aftermarket products or have your vehicle modified, you may put yourself and others at greater risk of serious injury or death. You are re- sponsible for any such changes to the ve- hicle.

  • Page 77: Protective Structure

    Protective structure Seat belts The vehicle cage/frame provides a protective Seat belts should be worn by both driver and structure that helps limit intrusions by branch- passenger. Driver must be sure that the pas- es or other objects and may reduce your risk senger is belted before driving.
  • Page 78 An unbelted occupant may strike the interior of the vehicle, the protective structure, or oth- er objects in an accident or during operation. You may also fall completely out or be partial- ly ejected from the vehicle, which may lead to being crushed between the ground and the vehicle.
  • Page 79 2. If the latch plate is not positioned in the 4. Put the lap portion of the belt low on your correct location along the seat belt, hips. Pull up on the shoulder part so the squeeze the latch plate ends together belt is snug across your hips.

  • Page 80: Doors

    Doors Passenger handholds The doors are designed to reduce the likeli- Handholds are provided to grip during opera- hood that you will stick your leg out to stop the tion to maintain proper position and balance. vehicle from tipping over or for any other rea- Holding onto the handholds helps to reduce son in a rollover.

  • Page 81: Seat And Hip Restraints

    Seat and hip restraints The seat and hip restraints are designed to help keep you in the vehicle. Do not hold onto hip restraint bar when the vehicle is moving. Your hand or arm may be struck by objects or crushed against outside objects or the ground during a rollover.

  • Page 82: Floorboard

    Floorboard Steering wheel The floorboard allows you to brace your feet, Keep both hands on the steering wheel. Do which helps you keep your body in the vehicle not hold the steering wheel with your thumbs in the event of an accident or rollover. Keep inside the rim.

  • Page 83: Learning To Operate Your Vehicle

    LEARNING TO OPERATE YOUR VEHICLE CORRECT GRIP EXAMPLE Personal protective equipment INCORRECT GRIP EXAMPLE 1. Approved motorcycle helmet 2. Eye protection 3. Long-sleeved shirt or jacket 4. Gloves 5. Long pants 6. Over-the-ankle boots 7-12...

  • Page 84: Practice For New Rhino Users

    Both driver and passenger should wear the Wear eye protection when operating or riding following to reduce risk of injury in an acci- the vehicle to reduce the risk of a serious ac- dent: cident or injury. Eye protection, such as a face Approved motorcycle helmet that fits prop- shield or goggles, may reduce the risk of for- erly...

  • Page 85: Getting Ready To Ride

    Getting ready to ride Perform the Pre-Operation Checks on pages 5-1–5-11. Follow the instructions starting on page 6-2 to start the engine. Once it has warmed up and you have turned the choke off, you are ready to begin driving your vehi- cle.

  • Page 86: Turning

    Turning If you think or feel that the vehicle may tip or Use care in turns – turning the steering wheel roll, keep your body completely inside the pro- too far or too fast can result in loss of control tective structure of the vehicle: or a rollover.

  • Page 87: Accelerating

    Accelerating Braking With the engine idling in neutral and your foot When slowing down or stopping, take your on the brake, shift the drive select lever into foot off the accelerator pedal and press the low or high. NOTICE: Do not shift from low brake pedal smoothly.

  • Page 88: Leaving The Vehicle

    Leaving the vehicle Parking on a flat area Do not get out of the vehicle while the engine When parking on a flat area, stop the engine is running and the drive select lever is in any and shift the drive select lever into the neutral gear.

  • Page 89: Loading

    4. With the brake pedal applied, set the Operation on different surfaces and parking brake. terrains 5. Block the front and rear wheels with Go slowly and proceed with caution when op- rocks or other objects. erating on an unfamiliar surface or terrain. This vehicle may handle differently in certain Loading types of terrains or on certain surfaces.

  • Page 90: Hills

    Hills Choose carefully which hills you attempt to climb or descend. Avoid hills with slippery sur- faces or those where you will not be able to see far enough ahead of you. Use common sense and remember that some hills are too steep for you to climb or descend.

  • Page 91: Uphill

    Uphill Slow down when you reach the crest of the hill Do not attempt to climb hills until you have if you cannot see clearly what is on the other mastered basic maneuvers on flat ground. side – there could be another person, an ob- Drive straight up hills, and avoid crossing the stacle, or a sharp drop-off.

  • Page 92: Downhill

    Downhill If you are sliding or skidding, try to steer in the Check the terrain carefully before going direction the vehicle is sliding, to regain con- downhill. When possible, choose a path that trol. For example, if you feel the back of the lets you drive your vehicle straight downhill.

  • Page 93: Rough Terrain

    Rough terrain Water Operation over rough terrain should be done If you must cross shallow, slow-moving water with caution. up to the depth of the vehicle’s floorboards, Look for and avoid obstacles that could choose your path carefully to avoid sharp cause damage to the vehicle or could lead drop-offs, large rocks, or slippery surfaces to a rollover or accident.

  • Page 94: Loose Terrain/Slippery Terrain

    Loose terrain/slippery terrain NOTICE When driving on slippery terrain, including After driving your vehicle in water, be sure wet, muddy, or icy conditions, as well as loose to drain the trapped water by removing the gravel, be aware that you could begin skid- check hose at the bottom of the air filter ding or sliding.

  • Page 95: Brush Or Wooded Areas

    Brush or wooded areas Encountering obstacles When operating in areas with brush or trees, If you cannot go around an obstacle, such as watch carefully on both sides and above the a fallen tree or a ditch, stop the vehicle where vehicle for obstacles such as branches that it is safe to do so.

  • Page 96: Periodic Maintenance And Adjustment

    If you are not familiar with vehicle service, have a Yamaha dealer perform service.

  • Page 97: Owner's Manual And Tool Kit

    EVU00660 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.
  • Page 98 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 99: Periodic Maintenance Chart For The Emission Control System

    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 spe- cial tools, data and technical skills.

  • Page 100: General Maintenance And Lubrication Chart

    EVU01650 General maintenance and lubrication chart INITIAL EVERY month Whichever 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 •...
  • Page 101 INITIAL EVERY month Whichever 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. •...

  • Page 102: Hood

    EVU00680 Hood To open Unhook the hood latches, and then slowly tilt the hood up until it stops. 1. Hood 1. Latch (× 2)
  • Page 103 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 1 on the rear of the hood into slots 2 Do not drive the vehicle with the hood on the back of the instrument panel.

  • Page 104: Console

    EVU00691 Console To install 1. Place the console in its original position. To remove 2. Install the parking brake lever boot. 1. Remove the seats. (See page 4-13 for 3. Install the seats. seat removal and installation proce- NOTICE dures.) When installing the console, be sure not 2.

  • Page 105: Engine Oil And Oil Filter Cartridge

    EVU00701 Engine oil and oil filter cartridge 5. 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.
  • Page 106 7. 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) 8. Reinstall the console. 1. Remove the console. (See page 8-9 for console removal and installation proce- dures.) 2.
  • Page 107 Make sure the O-ring is seated properly. 5. Remove the oil filter cartridge with an oil filter wrench. An oil filter wrench is avail- able from a Yamaha dealer. 1. O-ring 7. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the 1.
  • Page 108 9. 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 the engine and exhaust system have cooled down. Recommended engine oil: See page 10-2.
  • Page 109 10. Start the engine, and then let it idle for NOTICE several minutes while checking it for oil In order to prevent clutch slippage leakage. If oil is leaking, immediately turn (since the engine oil also lubricates the the engine off and check for the cause. clutch), do not mix any chemical addi- 11.

  • Page 110: Final Gear Oil

    EVU00710 Final gear oil 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended Checking the final gear oil level type to raise it to the correct level. 1. Park the vehicle on a level surface. NOTICE: Be sure no foreign material 2.
  • Page 111 Changing the final gear oil 5. Add the recommended final gear oil up to 1. Park the vehicle on a level surface. the brim of the filler hole. NOTICE: Be 2. Place a container under the final gear sure no foreign material enters the fi- case to collect the used oil.

  • Page 112: Differential Gear Oil

    EVU00721 Differential gear oil 3. 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: 2.
  • Page 113 Recommended oil: SAE 80 API GL-5 Hypoid gear oil Oil quantity: 0.32 L (0.28 Imp qt, 0.34 US qt) 6. Reinstall the differential gear oil filler bolt, and then tighten it to the specified torque. Tightening torque: Differential gear oil filler bolt: 1.

  • Page 114: Coolant

    EVU00732 Coolant The coolant level should be checked before each ride. Checking the coolant level 1. Park the vehicle on a level surface. 2. Open the hood. (See pages 8-7–8-8 for hood opening and closing procedures.) 3. Check the coolant level in the coolant reservoir when the engine is cold as the 1.

  • Page 115: Axle Boots

    EVU00740 Changing the coolant Axle boots The coolant must be changed by a Yamaha Check the protective boots for holes or tears. dealer at the intervals specified in the periodic If any damage is found, have them replaced maintenance and lubrication chart.

  • Page 116: Spark Plug Inspection

    5UG14001 Spark plug inspection Removal 1. Lift the cargo bed up. (See pages 4-15– 4-16 for cargo bed lifting and lowering procedures.) 2. Remove the spark plug cap. 1. Rear axle boot (× 2 each side) 1. Spark plug cap 3.
  • Page 117 Inspection The spark plug is an important engine compo- nent and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. The 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 118 Installation 3. 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 you are installing the the gap to specification. spark plug, a good estimate of the correct torque is one-quarter to one-half turn Spark plug gap:...

  • Page 119: Cleaning The Air Filter Elements

    5UG14002 Cleaning the air filter elements 2. Remove the air filter element from the air 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 120 5. Reinstall the air filter element into the air Cleaning the engine air filter element intake duct grill. There is a check hose at the bottom of the air 6. Reinstall the air intake duct grill by install- filter case. If dust or water collects in this ing the quick fastener screws.
  • Page 121 3. Remove the air filter case cover by un- 4. Remove the air filter element. hooking the holders. 1. Air filter element 1. Air filter case cover holder (× 4) 2. Air filter case cover 8-26...
  • Page 122 5. Remove the sponge material from its 6. Wash the sponge material gently but frame. thoroughly in parts cleaning solvent. WARNING! Using gasoline or other flammable solvents to clean the air fil- ter element can cause a fire or explo- sion, which could lead to serious injury.
  • Page 123 10. Allow the sponge material to dry thor- oughly. Inspect the sponge material and replace it if damaged. 11. Thoroughly apply Yamaha foam air filter 1. Crankcase breather hose oil or other quality liquid foam air filter oil 15. Install the console.

  • Page 124: Drive Select Lever Box Check Hose

    2P512001 The air filter element should be cleaned every Drive select lever box check hose 20–40 hours. It should be cleaned and lubri- The drive select lever box check hose is locat- cated more often if the vehicle is operated in ed under the console.

  • Page 125: V-Belt Cooling Duct Check Hose

    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 other engine parts.

  • Page 126: Cleaning The Spark Arrester

    EVU00792 Cleaning the spark arrester 2. Remove the tailpipe by pulling it out of the muffler. WARNING 3. 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 gine is stopped and the exhaust system is...

  • Page 127: 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 may be performed by the owner as a part of the usual maintenance routine.

  • Page 128: Idle Speed Adjustment

    EVU00810 Idle speed adjustment Specified idle speed: A diagnostic tachometer must be used for this 1,450–1,550 r/min procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min.

  • Page 129: Valve Clearance

    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 130: 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. Brake pad wear indicator groove 1.

  • Page 131: Checking The Brake Fluid Level

    EVU00850 Checking the brake fluid level The brake fluid reservoir is located under the hood. (See pages 8-7–8-8 for hood opening and closing procedures.) Observe these precautions: When checking the fluid level, make sure the top of the brake fluid reservoir is level. Use only the recommended quality brake fluid.

  • Page 132: Brake Fluid Replacement

    Brake fluid may deteriorate painted surfac- Checking the brake pedal es or plastic parts. Always clean up spilled Have a Yamaha dealer check the brakes at fluid immediately. the intervals specified in the periodic mainte- Have a Yamaha dealer inspect the brake nance and lubrication chart.

  • Page 133: Parking Brake Lever Free Play Adjustment

    EVU00870 Parking brake lever free play adjustment Periodically check the parking brake lever free play and adjust it if necessary. 1. Shift the drive select lever into low gear “L”. 2. Remove the seats. (See page 4-13 for seat removal and installation proce- dures.) 3.

  • Page 134: Brake Light Switch Adjustment

    EVU00880 Brake light switch adjustment The brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. 1. Open the hood. (See pages 8-7–8-8 for hood opening and closing procedures.) 2.

  • Page 135: Cable Inspection And Lubrication

    Cables can also become frayed or kinked. 1. Brake light switch 2. Adjusting nut Lubricate the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to re- place them. Recommended lubricant: Lithium-soap-based grease 8-40...

  • Page 136: Brake Pedal And Accelerator Pedal Lubrication

    EVU00900 EVU00910 Brake pedal and accelerator pedal Rear knuckle upper and lower pivot lubrication lubrication Lubricate the pivoting parts. Lubricate the knuckle upper and lower pivots with a grease gun. Recommended lubricant: Lithium-soap-based grease Recommended lubricant: Lithium-soap-based grease 8-41...

  • Page 137: Steering Shaft Lubrication

    EVU00920 EVU00930 Steering shaft lubrication Wheel removal Lubricate the pivot points. 1. Loosen the wheel nuts. 2. Elevate the vehicle and place a suitable Recommended lubricant: stand under the frame. Lithium-soap-based grease 3. Remove the nuts from the wheel. 4. Remove the wheel. 1.

  • Page 138: Tire Replacement

    Tire replacement The tires listed below have been approved by Always use the same size and type of tires Yamaha Motor Manufacturing Corporation of recommended in this owner’s manual. The America for this model. tires that came with your Rhino were de-...

  • Page 139: Wheel Installation

    EVU00940 Wheel installation 1. Install the wheel and the nuts. The arrow mark on the tire must point toward the rotating direction of the wheel. Tapered nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel.

  • Page 140: Battery

    If the battery seems to have discharged, con- sult a Yamaha dealer. NOTICE Do not try to remove the sealing caps of the battery cells. You may damage the bat- tery.

  • Page 141: Battery Maintenance

    EVU00960 Battery maintenance WARNING 1. If the vehicle will not be used for a month Avoid battery contact with skin, eyes, or or longer, remove the battery and store it clothing. Shield eyes when working near in a cool, dark place. Completely re- batteries.

  • Page 142: Jump-Starting

    Jump-starting Jump-starting the vehicle should be avoided. The battery should be removed and charged instead. WARNING To avoid battery explosion and/or serious damage to the electrical system: Do not connect the negative lead of the jumper cable to the negative termi- 1.
  • Page 143 However, if the vehicle must be jump-started, proceed as follows. 1. Turn the key to “OFF”. 2. Open the hood. (See pages 8-7–8-8 for hood opening and closing procedures.) 3. Remove the battery compartment cover. 4. Using a charged 12-volt battery, connect the positive lead of the jumper cable to the positive terminal of the battery in the vehicle and the other end of the positive...

  • Page 144: Fuse Replacement

    EVU00970 6. Start the engine. (Refer to “Starting a Fuse replacement cold engine” on pages 6-2–6-5.) The main fuse and the fuse box are located 7. After the engine starts, disconnect the under the hood. (See pages 8-7–8-8 for hood negative lead of the jumper cable from opening and closing procedures.) the vehicle and charged battery, and...
  • Page 145 Turn the key to “OFF” and turn off the electri- cal circuit in question. NOTICE To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. WARNING! Always use a fuse of the 1.

  • Page 146: Replacing A Headlight Bulb

    3. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates. 4. If the fuse blows again immediately, have a Yamaha dealer check the electrical system. 1. Cover at the rear of the headlight 5. Reinstall the battery compartment cover.
  • Page 147 3. Remove the headlight bulb holder cover 4. Remove the headlight bulb holder by by pulling it off. pushing it in and turning it counterclock- wise. 1. Headlight bulb holder cover 1. Headlight bulb holder 8-52...
  • Page 148 5. Wait for the headlight bulb to cool before 7. Reinstall the bulb holder by pushing it in touching or removing it. Remove the bulb and turning it clockwise. by pulling it out. Reinstall the bulb holder cover and the 6.

  • Page 149: Headlight Beam Adjustment

    Tail/brake light bulb replacement If a tail/brake light bulb burns out, replace it as NOTICE follows: It is advisable to have a Yamaha dealer 1. Remove the quick fastener screws and make this adjustment. bolts from panel A (if replacing the left...
  • Page 150 2. Lift the cargo bed up. (See page 4-16 for cargo bed lifting and lowering proce- dures.) 3. Remove the panel. 4. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 1. Panel B 1. Tail/brake light bulb holder 5.

  • Page 151: Troubleshooting

    If your vehicle Tightening torque: requires any repair, take it to a Yamaha deal- Panel bolt: 6.5 Nm (0.65 m·kgf, 4.7 ft·lbf) The skilled technicians at a Yamaha dealer- ship have the tools, experience, and know- how to properly service your vehicle.
  • Page 152 WARNING When checking the fuel system, do not smoke and make sure there are no open flames or sparks in the area, including pi- lot lights from water heaters or furnaces. Gasoline or gasoline vapors can ignite or explode, causing severe injury or property damage.

  • Page 153: Troubleshooting Charts

    There is fuel. No fuel. from the fuel pump. clogged. fuel flow. Check if there is fuel in the fuel tank. Ask a Yamaha dealer to Supply fuel. Restart the engine. No fuel. inspect. 2. Compression There is compression. Compression normal.
  • Page 154 Restart the engine. If the engine overheats again, ask a Level is OK. Yamaha dealer to inspect and/or repair the cooling system. If it is difficult to get the recommended coolant, tap water can be used temporarily, provided that it is changed to the recommended coolant as soon as possible.

  • Page 155: Cleaning And Storage

    EVU01030 C LEANING AND STORAGE 3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure A. Cleaning to do the job. WARNING! Test the Frequent, thorough cleaning of your vehicle brakes after washing. Apply the will not only enhance its appearance but will brakes several times at slow speeds improve its general performance and extend...

  • Page 156: Storage

    1. Fill the fuel tank with fresh fuel and add 6. Clean the seats with a vinyl upholstery the specified amount of Yamaha Fuel cleaner to keep the covers pliable and Stabilizer and Conditioner or equivalent glossy.
  • Page 157 5. Block up the frame to raise all wheels off nates the need to drain the fuel system. Con- the ground. sult a Yamaha dealer if the fuel system needs 6. Tie a plastic bag over the exhaust pipe to be drained.

  • Page 158: Specifications

    EVU01050 S PECIFICATIONS Model YXR66FW 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)
  • Page 159 Model YXR66FW Engine oil: Type: 110 130 ˚F YAMALUBE 4 (20W-50) or SAE 20W-50 YAMALUBE 4 (10W-40) or SAE 10W-40 YAMALUBE 4-CW (5W-30) or SAE 5W-30 50 ˚C Recommended engine oil classification API service SG type or higher, JASO standard MA...
  • Page 160 Model YXR66FW 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): 2.50 L (2.20 Imp qt, 2.64 US qt)
  • Page 161 Model YXR66FW Transmission: Primary reduction system V-belt Secondary reduction system Shaft drive 41/21 × 24/18 × 33/9 (9.544) Secondary reduction ratio Transmission type V-belt automatic Operation Right hand operation Reverse gear 25/17 (1.471) Sub transmission ratio 35/17 (2.058) high 28/19 (1.473)
  • Page 162 Model YXR66FW Brakes: System Front and rear unified Type front Dual disc brake rear Single disc brake Operation Foot operation Suspension: Front suspension Double wishbone Rear suspension Double wishbone Shock absorber: Front shock absorber Coil spring/oil damper Rear shock absorber...
  • Page 163 Model YXR66FW Bulb voltage, wattage × quantity: 12 V 30.0 W/30.0 W × 2 Headlight 12 V 5.0 W/21.0 W × 2 Tail/brake light Indicator lights: Neutral indicator light Reverse indicator light Coolant temperature warning light Parking brake indicator light...

  • Page 164: Consumer Information

    Record the key identification number, vehicle identification number, and model label infor- mation in the spaces provided for assistance when ordering spare parts from a Yamaha 2. VEHICLE IDENTIFICATION NUMBER: dealer or for reference, in case the vehicle is ACA-02E stolen.
  • Page 165 EVU00100 EVU00110 Key identification number Vehicle identification number The key identification number is stamped on The vehicle identification number is stamped the key, as shown in the following illustration. into the frame. This number can be used for ordering a new key.
  • Page 166 Model label 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 167: Noise Regulation

    EVU01060 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 to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 168: Maintenance Record

    EVU01070 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. It is not acceptable proof of maintenance work.

  • Page 169: Yamaha Motor Corporation, U.s.a. Side × Side Vehicle Limited Warranty

    EVU01081 YAMAHA MOTOR CORPORATION, U.S.A. SIDE × SIDE VEHICLE LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants THE CUSTOMER’S RESPONSIBILITY under this YAMAHA MOTOR CORPORATION, U.S.A. MAKES that new Yamaha Side × Side vehicles purchased NO OTHER WARRANTY OF ANY KIND, EXPRESSED warranty shall be to: from an authorized Yamaha Side ×...

  • Page 170: Yamaha Extended Service (Y.e.s.)

    EVU01090 YAMAHA EXTENDED SERVICE (Y.E.S.) 11-7...
  • Page 171 11-8...
  • Page 174 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2007.08-1.3×1 CR...

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