Yamaha RHINO 660 Owner's Manual
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It contains important safety information.


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Summary of Contents for Yamaha RHINO 660

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YXR660FAT LIT-11626-18-46 5UG-F8199-11...
  • 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 EVU00020 I MPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe WARNING...
  • Page 5 This vehicle complies with almost all state off-highway noise level and spark arrester laws and regulations. EVU00040 YXR660FAT OWNER’S MANUAL ©2004 by Yamaha Motor Corporation, AFFIX DEALER U.S.A. 1st edition, July 2004 LABEL HERE All rights reserved. Any reprinting or...
  • Page 6: Table Of Contents

    EVU00050 Fuel level check window ....4-14 CONTENTS Starter (choke) .......4-14 Seats ..........4-15 LOCATION OF THE WARNING Seat belts ........4-16 AND SPECIFICATION LABELS..1-1 Glove compartment .......4-18 Cargo bed ........4-18 SAFETY INFORMATION....2-1 Front and rear shock absorber adjustment ........4-21 DESCRIPTION AND VEHICLE Trailer hitch bracket .......4-23 IDENTIFICATION ......
  • Page 7 Switches.......... 5-8 Going downhill ......... 7-9 Tires ..........5-8 Crossing through shallow water ..7-11 How to measure tire pressure..5-10 Riding over rough terrain....7-13 Tire wear limit........ 5-11 Riding in brush or wooded areas..........7-14 OPERATION........6-1 Encountering obstacles on the Starting a cold engine .....
  • Page 8 Cleaning the air filter elements..8-22 Battery..........8-42 V-belt cooling duct check hose ..8-27 Battery maintenance......8-43 V-belt case drain plug....8-28 Fuse replacement ......8-44 Spark arrester cleaning ....8-29 Replacing a headlight bulb ....8-46 Carburetor adjustment....8-30 Headlight beam adjustment...8-47 Idle speed adjustment ....
  • Page 10: Location Of The Warning And Specification Labels

  • Page 11 LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR a replacement label is available from your DEATH. Yamaha dealer. OPERATING TIRE PRESSURE: Set with tires cold. RECOMMENDED: FRONT: 70kPa, {.70kgf/cm}, 10psi REAR: 98kPa, {.98kgf/cm}, 14psi MINIMUM: FRONT: 63kPa, {.63kgf/cm}, 9psi...
  • Page 12 Do not operate the vehicle Maximum Load in Cargo Bed:181kg. (400lb). with bed up. YAMAHA 5UG-K7764-00 Never carry passengers in cargo bed. Cargo can affect handling and stability. Read Owner’s Manual before loading or towing.
  • Page 13 MAX 7.3 INCH load more than 50kg (110 lbs) tongue weight on the towing (185MM) bracket. Do not tow more than YAMAHA 5UG-F151J-00 550kg (1212 lbs) rolling weight (trailer plus cargo). Operate in low-range gears only, allow for increased braking distance, and use extreme caution when operating on inclines.
  • Page 14 Passenger and cargo can affect vehicle handling. over or go out of control. NEVER USE WITH DRUGS OR ALCOHOL LOCATE AND READ THE OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. YAMAHA 5UG-F1568-01...
  • Page 15: Safety Information

    EVU00070 SAFETY INFORMATION This off-highway utility vehicle handles differently from other vehicles including cars and ATVs. SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described. This vehicle is designed to carry the driver and one passenger.
  • Page 16 Always inspect your vehicle each time you use it to be sure it is in safe operating condition. Al- ways follow the inspection and maintenance procedures and schedules described in this man- ual. Always keep both hands, arms, feet, and legs inside the vehicle at all times during operation. Keep your feet on the floorboard.
  • Page 17 Never operate on hills that are slippery or ones where you will not be able to see far enough ahead of you. Never go over the top of a hill at speed if you cannot see what is on the other side.
  • Page 18 WARNING When transporting the vehicle in anoth- er vehicle, be sure it is kept in an upright POTENTIAL HAZARD position. Otherwise, fuel may leak out of Improper handling of gasoline. the carburetor or fuel tank. WHAT CAN HAPPEN WHAT CAN HAPPEN Gasoline can catch fire and you could Gasoline is poisonous and can cause be burned.
  • Page 19 WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your vehicle in an area with adequate ventilation.
  • Page 20: Description And Vehicle Identification

    EVU00080 D ESCRIPTION AND VEHICLE IDENTIFICATION 1. Headlights 13. Spark arrester 2. Front shock absorber assembly adjusting ring 14. Passenger seat belt 3. Brake fluid reservoir 15. Passenger seat 4. Air filter element (Engine and air intake duct) 16. Oil filter cartridge 5.
  • Page 21 24. Light switch 25. Steering wheel 26. Starter (choke) 27. Main switch 28. On-Command four-wheel drive and differential gear lock switches 29. Indicator and warning lights 30. Auxiliary DC jack 31. Drive select lever 32. Parking brake lever 33. Accelerator pedal 34.
  • Page 22: Identification Number Records

    This number can be used for ordering a new when ordering spare parts from a Yamaha key. dealer or for reference in case the vehicle is stolen.
  • Page 23: Vehicle Identification Number

    Record the information on this la- bel in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Vehicle identification number NOTE: The vehicle identification number is used to identify your vehicle.
  • Page 24: Control Functions

    EVU00130 C ONTROL FUNCTIONS Functions of the respective switch positions are as follows: EVU00140 All electrical circuits are supplied with power, Main switch and the headlights and taillights come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position.
  • Page 25 CAUTION: Do not operate the electric starter continuously for more than 5 sec- onds, or starter damage could occur. Wait at least 5 seconds between each operation of the electric starter to let it cool. Do not turn the key to the “START” position with the engine running, or damage to the electric starter can re- sult.
  • Page 26: Indicator And Warning Lights

    This indicator light comes on when the drive select lever is in the “R” reverse position. NOTE: If the indicator light flashes while riding, have a Yamaha dealer check the speed sensor cir- 1. Parking brake indicator light “P” cuit. 2. Reverse indicator light “R”...
  • Page 27 EVU00200 EVU00180 Four-wheel-drive indicator light “ ” Coolant temperature warning light “ ” This indicator light comes on when the “2WD/ When the coolant temperature reaches a 4WD” switch is in the “4WD” position. specified level, this light comes on to warn that the coolant temperature is too hot.
  • Page 28 Coolant temperature 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 29: Switches

    EVU00230 Switches CAUTION: Do not use the headlights with the engine 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. 1.
  • Page 30 EVU00250 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 when the differ- ential gear is locked (“DIFF.LOCK”).
  • Page 31 On-Command four-wheel drive switch WARNING “2WD”/“4WD” POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 4WD-LOCK (“DIFF.LOCK”), or vice-versa while the vehicle is moving. WHAT CAN HAPPEN The vehicle handles differently in 2WD than in 4WD and in 4WD-LOCK in some circumstances.
  • Page 32 Differential gear lock switch “LOCK”/ WARNING “4WD” POTENTIAL HAZARD Riding too fast while the vehicle is in 4WD-LOCK. WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked, so it takes more effort to turn the vehicle. The amount of effort required is greater the faster you go.
  • Page 33: Accelerator Pedal

    EVU00260 Accelerator pedal NOTE: If the differential gear lock is not engag- Press the accelerator pedal down to increase ing properly, turn the steering wheel back engine speed. Spring pressure returns the and forth to help it engage. pedal to the rest position when released. Al- Riding before the differential gear lock is ways check that the accelerator pedal returns properly engaged will cause the engine...
  • Page 34: Brake Pedal

    Check the operation of the accelerator pedal before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before oper- ating the vehicle. Consult a Yamaha dealer if you can’t find or solve the prob- lem yourself. 4-11...
  • Page 35: 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 hold 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 36: Drive Select Lever

    EVU00290 EVU00300 Drive select lever Fuel tank cap The drive select lever is used to shift your ve- Remove the fuel tank cap by turning it coun- hicle into the low, high, neutral and reverse terclockwise. positions. (Refer to pages 6-5–6-7 for the drive select lever operation.) 1.
  • Page 37: Fuel Level Check Window

    EVU00310 EVU00320 Fuel level check window Starter (choke) “ ” 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 If the fuel level is low, refuel as soon as possi- mixture.
  • Page 38: 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 39: Seat Belts

    EVU00340 Seat belts To wear the seat belt properly, do the follow- This vehicle is equipped with three-point seat ing: belts for both the operator and passenger. Al- 1. Hold the latch plate as you pull the belt ways wear the seat belt while riding in the ve- across your lap and chest.
  • Page 40 3. Put the lap portion of the belt low on your WARNING hips. Push down on the buckle end of the POTENTIAL HAZARD belt as you pull up on the shoulder part so Not wearing the seat belt. the belt is snug across your hips. Wearing the seat belt improperly.
  • Page 41: Glove Compartment

    EVU01191 EVU00350 Glove compartment Cargo bed CAUTION: To protect from damage, do not put metal products, like tools or sharply edged prod- ucts directly in the glove compartment. If they must be stored, wrap them in appro- priate cushion material. 1.
  • Page 42 Opening and closing the tailgate Lifting and lowering the cargo bed 1. Tailgate 2. Latch (× 2) 1. Cargo bed release lever To open To lift Unhook the latches, and then lower the tail- Push the cargo bed release lever down, and gate.
  • Page 43 WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Pinch points. Overloading the cargo bed WHAT CAN HAPPEN WHAT CAN HAPPEN You or someone else could be pinched Could cause changes in vehicle han- between the cargo bed and the frame dling which could lead to an accident. when the bed is being lowered.
  • Page 44: Front And Rear Shock Absorber Adjustment

    EVU00360 Front and rear shock absorber adjustment WARNING The spring preload can be adjusted to suit the POTENTIAL HAZARD operating conditions. Carrying a passenger in the cargo bed You can reduce preload for a softer ride, or in- WHAT CAN HAPPEN crease preload if frequent bottoming occurs.
  • Page 45 1. Spring preload adjusting ring 1. Special wrench 2. Position indicator NOTE: A special wrench can be obtained at a Yamaha dealer to make this adjustment. Standard position: B A- Minimum (soft) E- Maximum (hard) 4-22...
  • Page 46: Trailer Hitch Bracket

    Improper shock absorber adjustment. Trailer towing equipment can be obtained at a WHAT CAN HAPPEN Yamaha dealer. (See pages 6-12–6-13 for Uneven adjustment can cause poor precaution information.) handling and loss of stability, which could lead to an accident.
  • Page 47: 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 48 4. When the auxiliary DC jack is not being used, cover it with the cap. CAUTION: Do not use accessories requiring more than the above maximum capac- ity. This may overload the circuit and cause the fuse to blow. If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine starting may be-...
  • Page 49: Pre-Operation Checks

    EVU01200 P RE-OPERATION CHECKS Before using this vehicle, check the following points: ITEM ROUTINE PAGE • Check operation, free play, fluid level and fluid leakage. Brakes 5-2–5-3, 8-32–8-35 • Fill with DOT 4 brake fluid if necessary. Parking brake • Check for proper operation, condition and free play. 8-36–8-37 •...
  • Page 50: Front And Rear Brakes

    Increases the possibility of an accident firm feeling when the brakes are applied. If or equipment damage. not, have the vehicle inspected by a Yamaha HOW TO AVOID THE HAZARD dealer. Always inspect your vehicle each time...
  • Page 51 If there is brakes. any leakage, have the vehicle inspected by a WHAT CAN HAPPEN Yamaha dealer. You could lose braking ability, which could lead to an accident. Brake operation HOW TO AVOID THE HAZARD...
  • Page 52: Fuel

    Gasohol containing ethanol can be used if and piston rings, as well as to the exhaust ethanol content does not exceed 10%. Gaso- system. hol containing methanol is not recommended by Yamaha because it may cause fuel system damage or vehicle performance problems.
  • Page 53: Engine Oil

    EVU00410 Engine oil WARNING Make sure the engine oil is at the specified POTENTIAL HAZARD level. Add oil as necessary. (See pages 8-9– Improper care when refueling. 8-12.) WHAT CAN HAPPEN CAUTION: Fuel can spill, which can cause a fire and severe injury.
  • Page 54: Coolant

    EVU00420 Coolant WARNING Check the coolant level in the coolant reser- POTENTIAL HAZARD voir when the engine is cold. (The coolant lev- Removing the radiator cap when the en- el will vary with engine temperature.) The gine and radiator are still hot. coolant level is satisfactory if it is between the WHAT CAN HAPPEN minimum and maximum level marks on the...
  • Page 55: Final Gear Oil

    It must operate smoothly and 8-14 for details.) fully spring back to the idle position when re- leased. Have a Yamaha dealer repair as nec- Recommended oil: essary for proper operation. SAE 80 API GL-4 Hypoid gear oil...
  • Page 56: Steering

    Take the vehicle or uneven tire pressure, may cause loss to a Yamaha dealer or refer to the Service of control, increasing your risk of acci- Manual for correct tightening torque.
  • Page 57 2. The tires should be set to the rec- 4. Use no more than the following ommended pressure: pressures when seating the tire Recommended tire pressure beads. Front 70 kPa (0.70 kgf/cm , 10 psi) Front 250 kPa (2.5 kgf/cm , 36 psi) Rear 98 kPa (0.98 kgf/cm , 14 psi)
  • Page 58: How To Measure Tire Pressure

    EVU00510 How to measure tire pressure Use the tire pressure gauge. NOTE: The tire pressure gauge is included as stan- dard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.
  • Page 59: Tire Wear Limit

    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 60: Operation

    Read the Owner’s Manual carefully. If make sure all control cables work there is a control or function you do not smoothly before you begin riding. understand, ask your Yamaha dealer. 1. Apply the brake. 2. Shift the drive select lever into the neutral position.
  • Page 61 25 °C (80 °F) and warm engine should come on. If the neutral indicator start position. light does not come on, ask a Yamaha dealer to inspect the electric circuit. The engine can be started in any gear if the brake is applied. However, it is rec- ommended to shift into neutral before starting the engine.
  • Page 62: Starting A Warm Engine

    EVU00550 Starting a warm engine NOTE: If the engine fails to start, release the key, and To start a warm engine, refer to the “Starting a then try starting again. Wait a few seconds cold engine” section. The starter (choke) before the next attempt.
  • Page 63 4. Using a charged 12 V battery, connect WARNING the positive lead of the jumper cable to Do not connect the negative lead of the the positive terminal of the battery in the jumper cable to the negative terminal of vehicle and the other end of the positive the battery in the vehicle.
  • Page 64: Warming Up

    EVU00570 Warming up 2. Apply the brakes, then shift by moving To get maximum engine life, always warm up the drive select lever along the shift the engine before starting off. Never acceler- guide. ate hard with a cold engine! To see whether or NOTE: not the engine is warm, check if it responds to Make sure that the drive select lever is com-...
  • Page 65 1. Drive select lever NOTE: When in reverse, the reverse indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect the reverse indicator light electrical cir- cuit. Due to the synchronizing mechanism in the engine, the light may not come on un- til the vehicle starts moving.
  • Page 66: Engine Break-In

    EVU00590 5. Press the accelerator pedal gradually Engine break-in and continue to watch to the rear while There is never a more important period in the backing. life of your vehicle than the period between zero and 20 hours. WARNING For this reason, we ask that you carefully read POTENTIAL HAZARD the following material.
  • Page 67 If any abnormality is noticed during this period, consult a Yamaha dealer. After break-in: The vehicle can now be operated normally. 0–10 hours: Avoid continuous operation above half throt- tle.
  • Page 68: Parking

    EVU01210 EVU00600 Parking Parking on a slope When parking, stop the engine and shift the WARNING drive select lever into the neutral position. Ap- POTENTIAL HAZARD ply the parking brake to help prevent the vehi- Parking on a hill or other incline. cle from rolling.
  • Page 69 1. Bring the vehicle to a stop by applying the brakes. 2. Stop the engine. 3. With the brakes applied, set the parking brake. NOTE: Like many other vehicles, the parking brake acts on the rear wheels. For the parking brake to have the effect of braking all four wheels, shift to 4WD before stopping the engine.
  • Page 70: Accessories And Loading

    Examples include (but are not limited Choose only accessories designed for your to) an object that limits your ability to turn vehicle. Your Yamaha dealer has a variety the steering wheel or one that limits your of genuine Yamaha accessories. Other ac- view.
  • Page 71 EVU00630 Loading Choose a trailer hitch drawbar designed for Cargo or a trailer can change the stability and use with a 5 cm (2 in) receiver. (See page handling of a vehicle. 4-23 for more information.) You must use common sense and good judg- Do not exceed the maximum tongue ment when carrying cargo or towing a trailer.
  • Page 72 Make sure the load does not interfere with WARNING controls or your ability to see where you are POTENTIAL HAZARD going. Overloading this vehicle or carrying or Drive more slowly than you would without a towing cargo improperly. load. The more weight you carry, the slow- WHAT CAN HAPPEN er you should go.
  • Page 73: Driving Your Vehicle

    EVU00640 D RIVING YOUR VEHICLE WARNING POTENTIAL HAZARD GETTING TO KNOW YOUR VEHICLE Not wearing the seat belt. This off-highway utility vehicle will handle and Wearing the seat belt improperly. maneuver differently from an ordinary pas- senger car or other vehicle. WHAT CAN HAPPEN Before you begin to use your vehicle, be sure There is increased risk of being killed or...
  • Page 74 The total weight of operator, passenger, ac- WARNING cessories, cargo, trailer tongue weight, and POTENTIAL HAZARD the vehicle itself must not exceed 907 kg Carrying a passenger in the cargo bed. (2,000 lb). (See “Loading” on page 6-12.) Car- WHAT CAN HAPPEN rying a passenger and cargo can affect vehi- The passenger could fall or be struck by cle handling.
  • Page 75 The driver and passenger must always wear a WARNING seat belt and an approved motorcycle helmet. POTENTIAL HAZARD Also wear eye protection and protective cloth- Overloading this vehicle or carrying or ing, including over-the-ankle boots, gloves, a towing cargo improperly. long-sleeved shirt or jacket, and long pants.
  • Page 76 WARNING HOW TO AVOID THE HAZARD Always wear an approved motorcycle POTENTIAL HAZARD helmet that fits properly. You should Operating this vehicle without wearing also wear: an approved motorcycle helmet, eye eye protection protection, and protective clothing. (goggles or face shield) WHAT CAN HAPPEN gloves Operating...
  • Page 77: Learning To Operate Your Vehicle

    LEARNING TO OPERATE YOUR VEHICLE Perform the Pre-Operation Checks on pages You should become familiar with the perfor- 5-1–5-11. Set the parking brake, shift to neu- mance characteristics of the vehicle in a large, tral, and follow the instructions on page 6-1 to flat area that is free of obstacles and other ve- start the engine.
  • Page 78: Turning Your Vehicle

    Position your hands on the steering wheel so CAUTION: that your thumbs and fingers do not wrap Do not shift from low to high or vice versa around the wheel. This is particularly impor- without coming to a complete stop and tant when driving in rough terrain.
  • Page 79: Braking

    BRAKING Braking ability is affected by the type of ter- rain. In most cases, gradually application of the brakes is more effective than abrupt brak- ing, particularly on loose surfaces like gravel. Always allow for greater braking distance on rough, loose, or slippery surfaces. GOING UPHILL Do not attempt to climb hills until you have mastered basic maneuvers on flat ground.
  • Page 80 Before climbing the hill, first be sure you are WARNING operating in low range 4WD or, if necessary, POTENTIAL HAZARD with 4WD Diff. Lock. To climb a hill, you need Operating on excessively steep hills. traction, momentum, and steady throttle. WHAT CAN HAPPEN Travel fast enough to keep your momentum The vehicle can overturn more easily on...
  • Page 81: Going Downhill

    If you start to lose traction or momentum GOING DOWNHILL when climbing, and you decide you will be un- Check the terrain carefully before going down able to continue, use the brakes to come to a a hill. When possible, choose a path that lets stop.
  • Page 82 Before starting down hill, make sure the vehi- WARNING cle is in low-range 4WD. On most slopes, this POTENTIAL HAZARD will let you use engine braking to help you go Going down a hill improperly. downhill slowly. Go as slowly as possible. If WHAT CAN HAPPEN you are starting to go too fast, apply the Could cause loss of control or cause the...
  • Page 83: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER WARNING If you must cross shallow, slow moving water POTENTIAL HAZARD up to the depth of the vehicle’s floorboards, Operating this vehicle through deep or choose your path carefully to avoid sharp fast-flowing water. drop-offs, large rocks, or slippery surfaces WHAT CAN HAPPEN that could cause the vehicle to overturn.
  • Page 84 CAUTION: After riding your vehicle in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the V-belt cooling duct check hose, the drive select lever box check hose and the V-belt case drain plug.
  • Page 85: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN Operating over rough terrain should be done with caution. Look for obstacles that could cause damage to the vehicle or could lead to a rollover or accident. Avoid jumping the vehi- cle as injury, loss of control, and damage to the vehicle could occur.
  • Page 86: Riding In Brush Or Wooded Areas

    RIDING IN BRUSH OR WOODED AREAS When operating in areas with brush or trees, watch carefully on both sides and above the vehicle for obstacles such as branches that the vehicle might hit, causing an accident, or for brush that might enter the vehicle as you pass and strike the driver or passenger.
  • Page 87: Encountering Obstacles On The Trail

    ENCOUNTERING OBSTACLES ON THE WARNING TRAIL POTENTIAL HAZARD If you cannot go around an obstacle such as a Improperly operating over obstacles fallen tree trunk or a ditch, stop the vehicle WHAT CAN HAPPEN where it is safe to do so. Set the parking brake Could cause loss of control or a colli- and get out to inspect the area thoroughly.
  • Page 88: Periodic Maintenance And Adjustment

    EVU00650 P ERIODIC MAINTENANCE AND Have a Yamaha dealer perform service if ADJUSTMENT you are not familiar with vehicle service. Periodic inspection, adjustment and lubrica- tion will keep your vehicle in the safest and EVU00660 most efficient condition possible. Safety is an Owner’s manual and tool kit...
  • Page 89 If you do not have a torque wrench available 1. Owner’s tool kit 2. Tire pressure gauge during a service operation requiring one, take your vehicle to a Yamaha dealer to check the torque settings and adjust them as necessary.
  • Page 90 Never modify this vehicle through im- proper installation or use of accesso- ries. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this vehicle and should be in- stalled and used according to instruc- tions.
  • Page 91: Periodic Maintenance/Lubrication

    EVU00670 PERIODIC MAINTENANCE/LUBRICATION NOTE: G For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals. G For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the vehicle isn’t used for a long period of time, the month maintenance intervals should be followed.
  • Page 92 • Check all chassis fittings and fasteners. Fittings and fasteners* • Correct if necessary. * Since these items require special tools, data and technical skills have a Yamaha dealer perform the service. NOTE: G Recommended brake fluid: DOT 4 G Brake fluid replacement: •...
  • Page 93: 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 94 To close CAUTION: Lower the hood slowly to its original position, Make sure that all cables and wires and then hook the hood latches. are in place when closing the hood. Secure projections 1 on the underside of the Do not drive the vehicle with the hood hood into slots 2 on the back of the instru- open, unlatched, or removed.
  • Page 95: Console

    EVU00690 Console To install To remove 1. Place the console in its original position. 1. Remove the seats. (See page 4-15 for 2. Install the parking brake lever boot. seat removal and installation proce- 3. Install the drive select lever boot correct- dures.) 2.
  • Page 96: To Check Engine Oil Level

    EVU00700 Engine oil and oil filter cartridge NOTE: The engine oil should be between the mini- The engine oil level should be checked before mum and maximum level marks. each operation. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic mainte- nance and lubrication chart.
  • Page 97 4. Remove the engine oil drain bolt to drain the oil from the crankcase. 1. Oil filter cartridge 2. Oil filter wrench NOTE: An oil filter wrench is available at a nearby Yamaha dealer. 1. Engine oil drain bolt 8-10...
  • Page 98 6. Apply a light coat of engine oil to the O-ring of the new oil filter cartridge. NOTE: Make sure the O-ring is seated properly. 1. Oil filter cartridge 2. Torque wrench 8. Install the engine oil drain bolt, and then tighten it to the specified torque.
  • Page 99 10. Start the engine and warm it up for seve- Recommended engine oil: ral minutes. While warming up, check for See page 10-2. oil leakage. If oil leakage is found, turn Oil quantity: the engine off immediately and check for Without oil filter cartridge replacement: the cause.
  • Page 100: Final Gear Oil

    EVU00710 Final gear oil 3. If the oil is below the brim of the filler hole, Checking the final gear oil level add sufficient oil of the recommended 1. Place the vehicle on a level surface. type to raise it to the correct level. 2.
  • Page 101 Changing the final gear oil 5. Add the recommended final gear oil up to 1. Place the vehicle on a level surface. the brim of the filler hole. 2. Place a container under the final gear Recommended oil: case to collect the used oil. SAE 80 API GL-4 Hypoid gear oil 3.
  • Page 102: Checking/Changing Differential Gear Oil

    EVU00720 Differential gear oil CAUTION: Checking the differential gear oil Be sure no foreign material enters the dif- 1. Place the vehicle on a level surface. ferential gear case. 2. Remove the differential gear oil filler bolt and check the oil level. It should be up to 3.
  • Page 103 Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.32 L (0.28 Imp qt, 0.34 US qt) CAUTION: Be sure no foreign material enters the dif- ferential gear case. 6. Install the differential gear oil filler bolt, 1. Differential gear oil drain bolt and then tighten it to the specified torque.
  • Page 104: Coolant

    EVU00730 Coolant The coolant level should be checked before each ride. Checking the coolant level 1. Place the vehicle on a level surface. 2. Open the hood. (See pages 8-6–8-7 for hood opening and closing procedures.) 3. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level varies with engine tempera- 1.
  • Page 105 Mix anti freeze with distilled water only. However, if distilled water is not available, soft water may be used for refilling. Changing the coolant The coolant must be changed by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. NOTE: Adding water instead of coolant lowers the antifreeze content of the coolant.
  • Page 106: Axle Boots

    EVU00740 Axle boots Check the protective boots for holes or tears. If any damage is found, have them replaced by a Yamaha dealer. 1. Rear axle boot (× 2 each side) 1. Front axle boot (× 2 each side) 8-19...
  • Page 107: Spark Plug Inspection

    EVU00750 Spark plug inspection Removal 1. Lift the cargo bed up. (See pages 4-18– 4-21 for cargo bed lifting and lowering procedures.) 2. Remove the spark plug cap. 1. Spark plug wrench 1. Spark plug cap 3. Use the spark plug wrench in the tool kit to remove the spark plug as shown.
  • Page 108 Do not attempt to diagnose such problems yourself. Instead, take the vehicle to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.
  • Page 109: Cleaning The Air Filter Elements

    EVU00761 3. Install the spark plug and tighten it to the Cleaning the air filter elements Cleaning the intake duct air filter element specified torque. 1. Remove the air intake duct grill by remov- Tightening torque: ing the quick fastener screws. Spark plug: 17.5 Nm (1.75 m·kgf, 12.7 ft·lbf) NOTE:...
  • Page 110 1. Air filter element 2. Air intake duct grill 1. Air filter element 3. Remove any large particles from the air 5. Install the air filter element into the air in- filter element by hand. take duct grill. 4. Tap the air filter element to remove most 6.
  • Page 111 Cleaning the engine air filter element 3. Remove the air filter case cover by un- hooking the holders. NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case.
  • Page 112 6. Wash the air filter element gently but thoroughly in solvent. WARNING POTENTIAL HAZARD Using low flash point solvents or gaso- line to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. 1.
  • Page 113 9. Thoroughly apply Yamaha foam air filter 13. Install the console. oil or other quality liquid foam air filter oil 14. Install the seats. (not spray type) to the air filter element. NOTE: The air filter element should be cleaned every...
  • Page 114: V-Belt Cooling Duct Check Hose

    EVU00770 V-belt cooling duct check hose CAUTION: The V-belt cooling duct check hose is located Never operate the engine with the air filter under the driver seat. (See page 4-15 for seat element removed. This will allow unfiltered removal and installation procedures.) air to enter, causing rapid engine wear and If dust or water collects in the V-belt cooling possible engine damage.
  • Page 115: V-Belt Case Drain Plug

    NOTE: If water drains from the V-belt case after re- moving the drain plug, have a Yamaha dealer 1. V-belt case drain plug inspect the vehicle as the water may affect other engine parts.
  • Page 116: Spark Arrester Cleaning

    EVU00790 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon depos- its from the spark arrester portion of the tailpipe.
  • Page 117: Carburetor Adjustment

    The carburetor is a vital part of the engine and POTENTIAL HAZARD requires very sophisticated adjustment. Most Improper cleaning of the spark arrester. adjusting should be left to a Yamaha dealer Hot exhaust system who has the professional knowledge and ex- WHAT CAN HAPPEN perience to do so.
  • Page 118: Idle Speed Adjustment

    To prevent this, the valve clear- increase the engine speed, and in direc- ance must be adjusted regularly. This adjust- tion b to decrease the engine speed. ment however, should be left to a professional Yamaha service technician. Specified idle speed: 1,450–1,550 r/min 8-31...
  • Page 119: Front 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...
  • Page 120: 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 let air enter the brake system, possibly causing the brakes to become ineffective.
  • Page 121: Brake Fluid Replacement

    Always clean up spilled and closing procedures.) fluid immediately. Observe these precautions: Have a Yamaha dealer inspect the brake When checking the fluid level, make sure system if the brake fluid level goes down. the top of the brake fluid reservoir is level.
  • Page 122: Checking The Brake Pedal

    EVU01220 Checking the brake pedal WARNING Have a Yamaha dealer check the brakes at POTENTIAL HAZARD the intervals specified in the periodic mainte- Operating with improperly serviced or nance and lubrication chart. There should be adjusted brakes. no free play in the brake pedal. The brakes...
  • Page 123: 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 4-15 for seat removal and installation proce- dures.) 3.
  • Page 124: 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 8-6–8-7 for hood opening and closing procedures.) 2.
  • Page 125: Cable Inspection And Lubrication

    Inspect cables frequently. Replace dam- aged cables. Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to replace them. Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil 8-38...
  • Page 126: 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 (all-purpose grease) Recommended lubricant: Lithium-soap-based grease 8-39...
  • Page 127: 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. (all purpose grease) 4.
  • Page 128: Wheel Installation

    EVU00940 Wheel installation 1. Install the wheel and the nuts. NOTE: 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 ta- pered side towards the wheel.
  • Page 129: Battery

    Keep out of reach of chil- tery. If the battery seems to have discharged, dren. consult a Yamaha dealer. Antidote: EXTERNAL: Flush with water. CAUTION: INTERNAL: Drink large quantities of wa- Do not try to remove the sealing caps of ter or milk.
  • Page 130: Battery Maintenance

    EVU00960 Battery maintenance 1. When the vehicle is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely re- charge the battery before reinstallation. CAUTION: A special battery charger (constant volt- age/ampere or constant voltage) is re- quired recharging...
  • Page 131: Fuse Replacement

    EVU00970 Fuse replacement CAUTION: The main fuse and the fuse box are located To prevent accidental short-circuiting, under the hood. (See pages 8-6–8-7 for hood turn off the main switch when checking or opening and closing procedures.) replacing a fuse. If a fuse is blown, turn off the main switch and install a new fuse of the specified amperage.
  • Page 132 4. Turn the key to “ON” and turn on the proper fuse. electrical circuit in question to check if the device operates. 5. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 6. Install the battery compartment cover. 7. Close the hood. 8-45...
  • Page 133: Replacing A Headlight Bulb

    EVU00980 Replacing a headlight bulb If a headlight bulb burns out, replace it as fol- lows. 1. Lift the hood up. (See pages 8-6–8-7 for hood opening and closing procedures.) 2. Remove the bulb holder cover at the rear of the headlight by pulling it off. 1.
  • Page 134: Headlight Beam Adjustment

    WARNING CAUTION: POTENTIAL HAZARD A headlight bulb is hot when it is on and It is advisable to have a Yamaha dealer immediately after it is turned off. make this adjustment. WHAT CAN HAPPEN To raise the beam, turn the adjusting screw in You can be burned, or a fire could start direction a.
  • Page 135: Tail/Brake Light Bulb Replacement

    EVU01000 Tail/brake light bulb replacement If a tail/brake light bulb burns out, replace it as follows: 1. Remove panel A (if replacing the left tail/ brake bulb) or panel B (if replacing the right tail/brake bulb) by removing the quick fasteners and bolts. 1.
  • Page 136 2. Remove the bulb holder (together with Tightening torque: the bulb) by turning it counterclockwise. Panel bolt: 6.5 N·m (0.65 m·kgf, 4.7 ft·lbf) 1. Tail/brake light bulb holder 3. Push the defective bulb in and turn it counterclockwise to remove it from the bulb holder.
  • Page 137: Troubleshooting

    Use only genuine Yamaha parts on your vehicle. Imita- tion parts may look like Yamaha parts, but they are often inferior. Consequently, they have a shorter service life and can lead to ex- pensive repair bills.
  • Page 138: Troubleshooting Charts

    There is fuel. No fuel. from the fuel pump. fuel flow. clogged. 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 139 Restart the engine. If the engine overheats again, ask a Level is OK. Yamaha dealer to inspect and/or repair the cooling system. NOTE: If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recommended coolant as soon as possible.
  • Page 140: Cleaning And Storage

    EVU01030 C LEANING AND STORAGE CAUTION: Excessive water pressure may cause wa- A. CLEANING ter seepage and deterioration of wheel Frequent, thorough cleaning of your vehicle bearings, brakes, transmission seals and will not only enhance its appearance but will electrical devices. Many expensive repair improve its general performance and extend bills have resulted from improper high the useful life of many components.
  • Page 141 6. Clean the seats with a vinyl upholstery WARNING cleaner to keep the cover pliable and POTENTIAL HAZARD glossy. Operation with wet brakes after wash- 7. Automotive type wax may be applied to ing. all painted and chrome plated surfaces. WHAT CAN HAPPEN Avoid combination cleaner-waxes.
  • Page 142: Storage

    Long term storage (60 days or more) of your nates the need to drain the fuel system. Con- vehicle will require some preventive proce- sult a Yamaha dealer if the fuel system needs dures to guard against deterioration. After to be drained instead.
  • Page 143 8. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an ex- cessively warm or cold place (less than 0 °C (30 °F) or more than 30 °C (90 °F)). NOTE: Make any necessary repairs before storing the vehicle.
  • Page 144: Specifications

    EVU01050 S PECIFICATIONS Model YXR660FA 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 273 mm (10.75 in) Minimum turning radius 3,900 mm (153.5 in) Basic weight:...
  • Page 145 Model YXR660FA Engine oil: 0° 10° 30° 50° 70° 90° 110° 130°F Type YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 -20° -10° 0° 10° 20° 30° 40° 50°C Recommended engine oil classification API Service SE, SF, SG type or higher CAUTION: In order to prevent clutch slippage (since the en- gine oil also lubricates the clutch), do not mix any...
  • Page 146 Model YXR660FA Final gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity: 0.25 L (0.22 Imp qt, 0.26 US qt) Differential gear case oil: Type SAE80 API GL-4 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) Air filter:...
  • Page 147 Model YXR660FA 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) Chassis: Frame type Steel tube frame...
  • Page 148 Model YXR660FA 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 Coil spring/oil damper Wheel travel: Front wheel travel...
  • Page 149 Model YXR660FA Bulb voltage, wattage × quantity: 12 V 30 W/30.0 W × 2 Headlight 12 V 5 W/21.0 W × 2 Tail/brake light Indicator lights: 12 V 1.7 W × 1 Neutral indicator light 12 V 1.7 W × 1 Reverse indicator light 12 V 1.7 W ×...
  • Page 150: Noise Regulation

    EVU01060 N OISE 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 151: Maintenance Record

    EVU01070 M AINTENANCE 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 152 Modification to original parts. EXCLUDED FROM THIS WARRANTY. THE PERIOD OF WARRANTY for YXR OR YXP Yamaha Side × Side vehicles shall be six (6) months Damage due to improper transportation. from the date of purchase, with no mileage limitation.
  • Page 153 EVU01090 YAMAHA EXTENDED SERVICE (Y.E.S.) 14-1...
  • Page 154 14-2...
  • Page 155 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2004.08-2.8×1 CR...

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