Yamaha RHINO 450, RHINO User Manual

READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YXR45FX
2P5-F8199-12LIT-11626-21-21
EBU00776
EVU00010

INTRODUCTION

Congratulations on your purchase of the Yamaha YXR45FX. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing vehicles. With the purchase of this Yamaha, you can now appreciate the high degree of crafts­manship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this vehicle. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your vehicle, please consult a Yamaha dealer.
WARNING
Please read this manual carefully before operating this vehicle. Do not attempt to operate this vehicle until you have attained adequate knowledge of its controls and operating fea­tures. Regular inspections and careful maintenance, along with good operating tech­niques, will help ensure that you safely enjoy the capabilities and reliability of this vehicle.
EVU00021

IMPORTANT MANUAL INFORMATION

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SE­RIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations:
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
WARNING
NOTICE
TIP
*Product and specifications are subject to change without notice.
A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
EVU00030

IMPORTANT NOTE ABOUT USE

This vehicle is designed and manufactured for off-road use only. Use on public streets,
roads, or highways is not only illegal in most areas, it also increases the risk of an acci­dent involving other vehicles. This vehicle does not meet federal motor vehicle safety standards for on-road use.
Check the laws and regulations in force before choosing where to operate this vehicle.
It is illegal to operate this vehicle on public lands where vehicles its size are prohibited.
This vehicle complies with almost all state off-highway noise level and spark arrester
laws and regulations.
YXR45FX
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
permission of
Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11626-21-21
EVU00050

CONTENTS

LOCATION OF THE WARNING
1
AND SPECIFICATION LABELS....... 1-1
SAFETY INFORMATION.................. 2-1
2
DESCRIPTION .................................3-1
3
INSTRUMENT AND CONTROL
4
FUNCTIONS .....................................4-1
Main switch...................................... 4-1
Indicator and warning lights ............ 4-2
Indicator and warning lights
(Special Edition models) ............... 4-5
Multi-function meter unit
(Special Edition models) ............... 4-7
Switches ........................................ 4-10
Accelerator pedal .......................... 4-12
Brake pedal ................................... 4-12
Parking brake lever ....................... 4-13
Drive select lever........................... 4-14
Fuel tank cap................................. 4-14
Fuel level check window................4-15
Starter (choke) ..............................4-15
Doors..............................................4-16
Seats..............................................4-16
Seat belts .......................................4-17
Glove compartment .......................4-18
Cargo bed ......................................4-18
Front and rear shock absorber
adjustment ...................................4-20
Trailer hitch bracket and
receiver ........................................4-22
Auxiliary DC jack............................4-22
FOR YOUR SAFETY –
5
PRE-OPERATION CHECKS ............5-1
Front and rear brakes ......................5-3
Fuel ..................................................5-4
Engine oil .........................................5-6
Coolant.............................................5-7
Final gear oil ....................................5-7
Differential gear oil...........................5-7
Accelerator pedal.............................5-8
Seat belts .........................................5-8
Steering........................................... 5-8
Fittings and fasteners...................... 5-8
Lights............................................... 5-9
Switches.......................................... 5-9
Control cables ................................. 5-9
Tires ................................................ 5-9
OPERATION..................................... 6-1
6
Engine break-in............................... 6-1
Starting a cold engine ..................... 6-2
Starting a warm engine................... 6-5
Warming up..................................... 6-5
Drive select lever operation and
reverse driving............................... 6-6
On-Command four-wheel-drive
switch and differential gear lock
switch ............................................ 6-8
Parking .......................................... 6-10
Loading ......................................... 6-11
BASIC GUIDE FOR SAFE USE....... 7-1
7
KNOW YOUR VEHICLE................. 7-1
Driver requirements ........................ 7-2
Passenger requirements .................7-3
Occupant protection system............7-4
Protective structure..........................7-5
Seat belts.........................................7-6
Doors ...............................................7-8
Passenger handholds......................7-9
Seat and hip restraints ..................7-10
Floorboard .....................................7-10
Steering wheel...............................7-11
LEARNING TO OPERATE
YOUR VEHICLE..........................7-12
Personal protective equipment......7-12
Practice for new Rhino users ........ 7-13
Getting ready to ride......................7-14
Turning...........................................7-14
Accelerating...................................7-15
Braking...........................................7-16
Engine braking...............................7-16
Leaving the vehicle........................7-16
Parking on a flat area ....................7-17
Parking on a slope.........................7-17
Loading..........................................7-17
Operation on different surfaces
and terrains.................................. 7-18
Hills................................................ 7-19
Uphill.............................................. 7-19
Downhill ......................................... 7-20
Rough terrain................................. 7-21
Pavement ......................................7-21
Water ............................................. 7-22
Loose terrain/slippery terrain.........7-23
Brush or wooded areas ................. 7-23
Encountering obstacles................. 7-24
PERIODIC MAINTENANCE AND
8
ADJUSTMENT.................................. 8-1
Owners manual and tool kit............ 8-2
Periodic maintenance chart for the
emission control system................ 8-4
General maintenance and
lubrication chart............................. 8-5
Hood ................................................ 8-7
Console ...........................................8-9
Engine oil and oil filter cartridge.... 8-10
Final gear oil..................................8-15
Differential gear oil.........................8-17
Coolant...........................................8-19
Axle boots ......................................8-20
Spark plug inspection ....................8-21
Cleaning the air filter elements ......8-24
Drive select lever box check
hose .............................................8-29
V-belt cooling duct check hoses....8-29
V-belt case drain plug ....................8-30
Cleaning the spark arrester ...........8-31
Carburetor adjustment...................8-32
Idle speed adjustment....................8-33
Valve clearance .............................8-33
Brakes............................................8-34
Front brake pad check...................8-34
Rear brake pad check....................8-35
Checking the brake fluid level........8-35
Brake fluid replacement.................8-36
Checking the brake pedal..............8-37
Parking brake lever free play
adjustment ...................................8-37
Brake light switch adjustment ........8-39
Cable inspection and lubrication....8-40
Brake pedal and accelerator
pedal lubrication.......................... 8-40
Rear knuckle upper and lower
pivot lubrication ........................... 8-41
Steering shaft lubrication .............. 8-41
Wheel removal .............................. 8-42
Tire replacement........................... 8-42
Wheel installation.......................... 8-43
Battery........................................... 8-45
Battery maintenance..................... 8-46
Jump-starting ................................ 8-47
Fuse replacement ......................... 8-49
Replacing a headlight bulb ........... 8-51
Headlight beam adjustment.......... 8-53
Tail/brake light bulb
replacement ................................ 8-54
Troubleshooting ............................ 8-56
Troubleshooting charts ................. 8-57
CLEANING AND STORAGE............ 9-1
9
A. Cleaning...................................... 9-1
B. Storage ....................................... 9-2
SPECIFICATIONS ..........................10-1
10
CONSUMER INFORMATION ........ 11-1
11
Identification number records........11-1
NOISE REGULATION...................11-4
MAINTENANCE RECORD ...........11-5
YAMAHA MOTOR
CORPORATION, U.S.A. SIDE × SIDE VEHICLE LIMITED
WARRANTY................................11-6
YAMAHA EXTENDED SERVICE
(Y.E.S.) ........................................11-7
EVU00060
1
3
1-
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
2
3
4
5
8
65
7
1-1
Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a re­placement label is available from your Yamaha dealer.
12 3
!
WARNING
Any part of your body (arms, legs, or head) outside of the vehicle can be crushed by the cage/frame.
If you think or fe el that the vehicle may tip or roll, brace your feet on the floorboards, and keep your hands on the handholds.
Do not try to stop a vehicle tipover using your arm or leg.
!
WARNING
Any part of your body (arms, legs, or head) outside of the vehicle can be crushed by the cage/frame.
If you think or fe el that the vehicle may tip or roll, brace your feet on the floorboards, and keep your hands on the steering wheel.
Do not try to stop a vehicle tipover using your arm or leg.
!
WARNING
Do not rest hands on door or hip restraint bar. To avoid injury, keep hands completely inside the vehicle by holding the steering wheel or handholds.
YAMAHA 5B4-K8483-00
1
2
3
4
5
6
7
8
9
10
11
12
13
14
5B4-K7762-00
5B4-K7761-00
1-2
45
!
WARNING
Improper tire pressure or overloading the Rhino may cause severe injury or death from loss of control or rollover.
OPERATING TIRE PRESSURE: Set with tires cold. RECOMMENDED:
2
FRONT: 70kPa, (.70kgf/cm REAR: 98kPa, (.98kgf/cm
MINIMUM: FRONT: 63kPa, (.63kgf/cm
REAR: 91kPa, (.91kgf/cm
), 10psi
2
), 14psi
2
), 9psi
2
), 13psi
Never set or allow tire pressure to be below the minimum. Tire may dislodge from rim.
Gross Vehicle Weight Rating: 907 kg (2000 lb) maximum including vehicle, weight of operator, passenger, accessories, cargo, and (if applicable)
trailer tongue weight.
YAMAHA 5B4-F1696-00
!
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
1-3
67
!
WARNING
Improper use of cargo bed or cage/frame can result in severe injury or death from loss of control, overturn or other accidents.
Do not carry passengers in cargo bed. Maximum load in cargo bed: 181 kg (400 lb). Load or trailer may affect handling and stability:
Secure cargo so that it will not shift a loose load
could change handling unexpectedly or be thrown forward and strike occupants.
Keep weight in the cargo bed centered side to side,
and as low and as far forward as possible. Top- heavy loads increase the risk of overturn.
Do not tow or pull objects from any point other than
the trailer hitch bracket or winch (if installed).
When loaded with cargo or towing a trailer:
Reduce speed and allow more room to stop. Turn gradually and go slowly. Avoid hills and rough terrain.
Read Owners Manual before loading, towing, or pulling objects.
YAMAHA 5UG-F151J-00
MAX 7.3 INCH
(185MM)
YAMAHA 5B4-F4897-00
1-4
89
!
WARNING
Improperly loading a trailer or pulling an object can affect handling, stability, and risk of overturn or other accidents.
Secure load to prevent it from shifting. Never load more than 50 kg (110 lb) tongue weight on the towing bracket. Do not tow more than 550 kg (1212 lb) rolling weight (trailer plus cargo). Tow or pull only from hitch bracket. Read Owner s Manual before loading, towing, or pulling objects.
YAMAHA 5B4-F151K-00
Head to Toe
Safety Checklist
ü
Head Helmet and eye protection.
ü
Body Seatbelt and protective clothing.
ü
Hands Inside vehicle and holding the
ü
Feet On floorboard, ready to brace,
YAMAHA 5B4-F1558-00
handholds or steering wheel. and door closed.
1-5
0
!
WARNING
Be Prepared
Wear seat belt, motorcycle helmet, eye protectionand protective gear.
Keep your body completely inside the vehicleat all times. Keep both hands on the steering wheel. Be sure passengeris seated, belted, and holdingonto the handholds.
Be Qualified and Responsible
This vehicleis intended for use only byan operator 16 or older with a valid motor vehicle license.
Passenger and drivermust be able to
place both feet flat on the floorboard while seated uprightwith their backs against the seat backs.
Do not drive or ride as passenger after using drugsor alcohol.
Do not operate on publicroads.
YAMAHA 5B4-F1568-01
To reduce risk of accidents and injury or death:
Avoid Rollovers and Crushing Injuries
DRIVER
UNDER
16
If you think or feel the Rhino may tip or roll:
Read the Owners Manual
Use carewhen turning:
o Turning the steering wheel too far or too fast
can resultin a rolloveror loss of control. o Slow down before entering a turn. o When making tight turns froma stop or at slow
speeds, avoidsudden or hard acceleration. o Avoid sideways sliding, skidding, or fishtailing,
and never do donuts.
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 pavedsurfaces. Turn gradually and go slowly if you must drive on pavement. This vehicle is designedfor off-road use only.
Brace yourselfby pressing your feet firmlyon the floorboards and keep a firm grip on the steering wheel orhandholds.
Do not put your handsor feet outsideof the vehicle for any reason.
Abrupt maneuvers or aggressive driving have caused rollovers even on flat, openareas.
Genuine Yamaha Doors and a Handhold/Strap are available for free installation or replacement.
recommends these features to help keepoccupants from sticking arms or legs out of the vehicle during a rollover.
Contact yourdealer or visit
www.yamaha-motor.com/rhino
Yamaha
1-6
EVU00070

SAFETY INFORMATION

Be a responsible owner
As the vehicles 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. Do not allow anyone else to operate your vehicle or ride as a passenger if you are unsure that he/she is willing and able to follow these instructions.
Get to know your vehicle
This off-road vehicle will handle and maneuver differently from cars, ATVs, go-carts, golf-cars and grounds-keeping vehicles. Follow these instructions to reduce your risk of an accident and to re­duce the risk of serious injury or death in the event of an accident.
2-1
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 li­cense.
1
2
3
DRIVER UNDER
16
This vehicle is designed to carry the driver and one passenger. Never carry passengers in the cargo bed.
Both driver and passenger should wear seat belts properly.
Both driver and passenger must be able to put both feet flat on the floorboard while seated
upright with their backs against the seat backs. Passenger must be able to reach and hold the handholds within the cage/frame.
Both driver and passenger should wear an approved motorcycle helmet that fits properly. Both driver and passenger should also wear eye protection (goggles or a face shield), gloves, over-the-ankle boots, long-sleeved shirt or jacket, and long pants.
Do not drive or ride as passenger after using drugs or alcohol.
2-2
4
5
6
7
8
9
10
11
12
13
14
Prepare your vehicle
Perform the pre-operation checks each time you use the vehicle to make sure it is in safe operat­ing condition. Failure to inspect or maintain the vehicle properly increases the possibility of an ac­cident 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.
Read Chapter 6 before loading, towing, or pulling objects.
Do not overload the vehicle or trailer. Refer to label in cargo bed for cargo bed load limit. Re-
fer to label next to hitch for tongue weight and trailer load limits.
Keep weight in the cargo bed centered side to side, and as low and as far forward as pos­sible.
Secure cargo so that it will not shift – a loose load could change handling unexpectedly or be thrown forward and strike occupants.
2-3
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 be­fore 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.
Watch for branches, brush, or other hazards that could enter the vehicle.
Abrupt maneuvers or aggressive driving, even on flat, open areas, can cause loss of control,
including rollovers. The Rhino has higher ground clearance and other features to handle rug­ged terrain, and, as a result, can overturn in situations where some other vehicles may not.
2-4
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.
When making tight turns from a stop or at slow speeds, avoid sudden or hard accelera-
tion.
2-5
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 ve­hicle is designed for off-road use only.
If you think or feel that the vehicle may tip or roll, keep your body completely inside the protec-
tive structure of the vehicle:
Brace yourself by pressing your feet firmly on the floorboards and keep a firm grip on the steering wheel or handholds.
Do not put your hands or feet outside of the vehicle for any reason. Your arm or leg could be crushed.
Do not try to stop a vehicle tipover using your arm or leg.
Do not operate this vehicle on any public street, road, or highway, even if dirt or gravel.
Do not operate the vehicle in fast-flowing water or water deeper than 33 cm (13 in). If you must
cross shallow, slow-moving water, choose your path carefully to avoid sharp drop-offs, large rocks, or slippery surfaces. Operating this vehicle through deep or fast-flowing water can lead to loss of control or overturn. To reduce your risk of drowning or other injuries, use care when crossing through water.
2-6
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.
Load trailer properly and use extra care when towing or pulling.
Do not tow or pull objects from any part of the vehicle other than the trailer hitch bracket or
winch (if installed).
2-7
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. Deadly levels of carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly-ventilated areas. If you experience any symp­toms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDI­CAL TREATMENT.
Do not run engine indoors. Even if you try to ventilate engine exhaust with fans or open win-
dows and doors, carbon monoxide can rapidly reach dangerous levels.
Do not run engine in poorly ventilated or partially enclosed areas such as barns, garages, or
carports.
Do not run engine outdoors where engine exhaust can be drawn into a building through open-
ings such as windows and doors.
2-8
Genuine Yamaha Accessories
Choosing accessories for your Rhino is an important decision. Genuine Yamaha Accessories, which are available only from a Yamaha dealer, have been designed, tested, and approved by
Yamaha for use on your Rhino.
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 af­termarket 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.
Aftermarket parts, accessories, and modifications
While you may find aftermarket products similar in design and quality to genuine Yamaha Acces­sories, recognize that some aftermarket accessories or modifications are not suitable because of potential safety hazards to you or others. Installing aftermarket products or having other modifica­tions performed to your Rhino that change any of the vehicles design or operation characteristics can put you and others at greater risk of serious injury or death. You are responsible for injuries related to changes in the vehicle.
2-9
Aftermarket tires and rims
The tires and rims that came with your Rhino were designed to match the performance capabili­ties and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Refer to pages 8-42–8-44 for tire specifications and more information on replacing your tires.
2-10
EVU00080
1-

DESCRIPTION

C
1. Headlights
2. Front shock absorber assembly spring preload adjusting ring
3. Brake fluid reservoir
4. Air filter elements (engine and air intake duct)
5. V-belt case
6. Driver seat
7. Driver seat belt
8. Cargo bed
9. Tail/brake lights
10. Rear shock absorber assembly spring preload adjusting ring
11. Cargo bed release levers
12. Spark plug
13. Door
D
14. Spark arrester
15. Passenger seat belt
16. Passenger seat
17. Oil filter cartridge
18. Passenger handhold
19. Engine oil filler cap
20. Battery
21. Fuses
22. Coolant reservoir
23. Radiator cap
24. Fuel level check window
25. Fuel tank cap
3-1
FG
IHEJKLM
NCO
PQ RST UV W X
The vehicle you have purchased may differ slightly from those shown in the figures of this manual.
1
2
3
4
5
6
7
[Z Y
26. Light switch
27. Steering wheel
28. Starter (choke)
29. Main switch
30. On-Command four-wheel-drive and differential gear lock switches
31. Indicator and warning lights
32. Multi-function meter unit (Special Edition models)
33. Auxiliary DC jack
34. Drive select lever
35. Parking brake lever
36. Accelerator pedal
37. Brake pedal
H
8
9
10
11
12
13
14
3-2
EVU00130
1-
INSTRUMENT AND CONTROL
FUNCTIONS
EVU00140

Main switch

OFF
ON
F
F
O
O
N
S
T
A
R
START
T
1. Main switch
Functions of the respective switch positions are as follows: ON:
All electrical circuits are supplied with power, 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.
START:
The electric starter is engaged by turning and holding the key in this po­sition. Release the key when the en­gine starts.
4-1

Indicator and warning lights

1. Parking brake indicator light “P”
2. Reverse indicator light “R”
3. Neutral indicator light “N”
4. On-Command four-wheel-drive indicator light “”
5. On-Command differential gear lock indicator light “”
6. Coolant temperature warning light “”
DIFF. LOCK
EVU00210
Parking brake indicator light “P
This indicator light comes on when the park­ing brake is applied.
EVU00161
Reverse indicator light “R”
This indicator light comes on when the drive select lever is in the “R” reverse position. Furthermore, this indicator light flashes when the engine is being raced for 10 seconds or more. If the indicator light flashes under any other circumstances, have a Yamaha dealer check the speed sensor circuit.
EVU00170
Neutral indicator light “N”
This indicator light comes on when the drive select lever is in the “N” position.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
4-2
On-Command four-wheel-drive indicator light “”
This indicator light comes on when the On-Command four-wheel-drive switch is in the 4WD position. Due to the synchronizing mechanism in the differential gear case, the light may not come on until the vehicle starts moving.
EVU00181
Coolant temperature warning light “”
If the coolant temperature reaches a specified level, this light comes on to warn that the cool­ant 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. (See page 8-58.)
On-Command differential gear lock indica-
DIFF.
tor light “”
LOCK
This indicator light comes on when the On-Command differential gear lock switch is set to the “LOCK” position.
The engine may overheat if the vehicle
is overloaded. If this happens, reduce the load to specification.
After restarting, make sure that the light
is out. Continuous use while the light is on may cause damage to the engine.
4-3
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