Yamaha RHINO 660 Manual

READ THIS MANUAL CAREFULLY!

It contains important safety information.

OWNER’S MANUAL

YXR660FAT

LIT-11626-18-46

5UG-F8199-11

INTRODUCTION

Congratulations on your purchase of the Yamaha YXR660FA. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing vehicles. With the purchase of this Yamaha, you can now appreciate the high degree of 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.

IMPORTANT MANUAL INFORMATION

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

	WARNING	Failure to follow WARNING instructions could result in severe
		injury or death to the vehicle operator, a bystander or a person
		inspecting or repairing the vehicle.
	CAUTION:	A CAUTION indicates special precautions that must be taken to
		avoid damage to the vehicle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

IMPORTANT NOTICE

●This vehicle is designed and manufactured for off-road use only. It is illegal to operate this vehicle on any public street, road, or highway. Such use is prohibited by law.

●Check the laws and regulations in force before choosing where to operate this vehicle. It is illegal to operate this vehicle on public lands where vehicles its size are prohibited.

●This vehicle complies with almost all state off-highway noise level and spark arrester laws and regulations.

AFFIX DEALER

LABEL HERE

YXR660FAT

OWNER’S MANUAL

©2004 by Yamaha Motor Corporation, U.S.A.

1st edition, July 2004

All rights reserved. Any reprinting or unauthorized use without the written permission of

Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A.

P/N LIT-11626-18-46

		CONTENTS
	1	LOCATION OF THE WARNING
		AND SPECIFICATION LABELS	1-1
	2	SAFETY INFORMATION..................	2-1
	3	DESCRIPTION AND VEHICLE
		IDENTIFICATION	3-1
		Identification number records..........	3-3
		Key identification number................	3-3
		Vehicle identification number ..........	3-4
		Model label ......................................	3-4
	4	CONTROL FUNCTIONS ..................	4-1
		Main switch	4-1
		Indicator and warning lights ............	4-3
		Switches ..........................................	4-6
		Accelerator pedal ..........................	4-10
		Brake pedal ...................................	4-11
		Parking brake lever .......................	4-12
		Drive select lever...........................	4-13
		Fuel tank cap.................................	4-13

Fuel level check window................	4-14
Starter (choke) ...............................	4-14
Seats..............................................	4-15
Seat belts .......................................	4-16
Glove compartment .......................	4-18
Cargo bed ......................................	4-18
Front and rear shock absorber
adjustment ...................................	4-21
Trailer hitch bracket .......................	4-23
Auxiliary DC jack............................	4-24

	5	PRE-OPERATION CHECKS ............	5-1
		Front and rear brakes	5-2
		Fuel ..................................................	5-4
		Engine oil .........................................	5-5
		Coolant.............................................	5-6
		Final gear oil ....................................	5-7
		Differential gear oil ...........................	5-7
		Accelerator pedal.............................	5-7
		Seat belts .........................................	5-7
		Steering............................................	5-8
		Fittings and fasteners ......................	5-8
		Lights................................................	5-8

Switches..........................................	5-8
Tires ................................................	5-8
How to measure tire pressure.......	5-10
Tire wear limit................................	5-11

	6	OPERATION.....................................	6-1
		Starting a cold engine	6-1
		Starting a warm engine...................	6-3
		Jump-starting ..................................	6-3
		Warming up.....................................	6-5
		Drive select lever operation and
		reverse driving...............................	6-5
		Engine break-in...............................	6-7
		Parking ............................................	6-9
		Parking on a slope ..........................	6-9
		Accessories and loading...............	6-11
	7	DRIVING YOUR VEHICLE...............	7-1
		Getting to know your vehicle	7-1
		Learning to operate your vehicle ....	7-5
		Turning your vehicle........................	7-6
		Braking ............................................	7-7
		Going uphill .....................................	7-7

Going downhill.................................	7-9
Crossing through shallow water ....	7-11
Riding over rough terrain...............	7-13
Riding in brush or wooded
areas............................................	7-14
Encountering obstacles on the
trail ...............................................	7-15

	8	PERIODIC MAINTENANCE AND
		ADJUSTMENT	8-1
		Owner’s manual and tool kit............	8-1
		Periodic maintenance/
		lubrication ......................................	8-4
		Hood ................................................	8-6
		Console............................................	8-8
		Engine oil and oil filter cartridge ......	8-9
		Final gear oil ..................................	8-13
		Differential gear oil.........................	8-15
		Coolant ..........................................	8-17
		Axle boots......................................	8-19
		Spark plug inspection ....................	8-20

Cleaning the air filter elements......	8-22
V-belt cooling duct check hose .....	8-27
V-belt case drain plug....................	8-28
Spark arrester cleaning .................	8-29
Carburetor adjustment...................	8-30
Idle speed adjustment ...................	8-31
Valve clearance adjustment ..........	8-31
Front brake pad check ..................	8-32
Rear brake pad check ...................	8-33
Checking the brake fluid level .......	8-33
Brake fluid replacement.................	8-34
Checking the brake pedal .............	8-35
Parking brake lever free play
adjustment...................................	8-36
Brake light switch adjustment........	8-37
Cable inspection and lubrication ...	8-38
Brake pedal and accelerator
pedal lubrication ..........................	8-39
Rear knuckle upper and lower
pivot lubrication............................	8-39
Steering shaft lubrication...............	8-40
Wheel removal ..............................	8-40
Wheel installation ..........................	8-41

Battery............................................	8-42
Battery maintenance......................	8-43
Fuse replacement ..........................	8-44
Replacing a headlight bulb ............	8-46
Headlight beam adjustment...........	8-47
Tail/brake light bulb
replacement .................................	8-48
Troubleshooting .............................	8-50
Troubleshooting charts ..................	8-51

	9	CLEANING AND STORAGE	............9-1
		A. Cleaning	9-1
		B. Storage ........................................	9-3
	10	SPECIFICATIONS .........................	10-1
	11	NOISE REGULATION.....................	11-1
	12	MAINTENANCE RECORD .............	12-1

	13	YAMAHA MOTOR CORPORATION,
		U.S.A. SIDE × SIDE VEHICLE

LIMITED WARRANTY ...................

13-1

	14	YAMAHA EXTENDED SERVICE
		(Y.E.S.)	14-1

LOCATION OF THE WARNING AND

SPECIFICATION LABELS

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.

1

WARNING

The enclosure cannot protect occupants in all foreseeable accidents, including rollover.

YAMAHA

5UG-K8483-00

2

WARNING 1

IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL.

LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH.

OPERATING TIRE PRESSURE: Set with tires cold. RECOMMENDED: FRONT: 70kPa, {.70kgf/cm}, 10psi

REAR: 98kPa, {.98kgf/cm}, 14psi MINIMUM: FRONT: 63kPa, {.63kgf/cm}, 9psi REAR: 91kPa, {.91kgf/cm}, 13psi

Never set tire pressure below minimum. Tire may dislodge from rim.

Gross Vehicle Weight Rating: 907 kg (2000lb) maximum including weight of operator, passenger, accessories, cargo, and

(if applicable) trailer tongue weight.

YAMAHA

5UG-F1696-01

1-2

3

	WARNING
	Keep hands, body, other
	persons away when closing bed.
	Do not operate the vehicle
	with bed up.
YAMAHA	5UG-K7764-00

4

WARNING

Severe INJURY or DEATH can result if you ignore the following:

Maximum Load in Cargo Bed:181kg. (400lb).

Never carry passengers in cargo bed.

Cargo can affect handling and stability. Read Owner’s Manual before loading or towing.

When loading with cargo or towing a trailer: Reduce speed and allow more room to stop. Avoid hills and rough terrain.

Be sure cargo is secured - a loose load could change handling unexpectedly. Keep weight in the cargo bed centered, and as low and far forward as possible. Top-heavy loads increase the risk of overturn.

YAMAHA

5UG-F4897-00

1-3

5

MAX 7.3 INCH

(185MM)

YAMAHA

5UG-F151J-00

6

WARNING

Improperly loading a trailer and failure to use extra care when pulling trailer can cause an accident or injury. Never load more than 50kg (110 lbs) tongue weight on the towing bracket. Do not tow more than 550kg (1212 lbs) rolling weight (trailer plus cargo). Operate in low-range gears only, allow for increased braking distance, and use extreme caution when operating on inclines. Read carefully the loading information and trailer hitch sections in the owner’s manual.

YAMAHA 5UG-F151K-02

1-4

7

WARNING

Turning the off road vehicle in 4WD-LOCK (“DIFF.LOCK”) takes more effort.

Operate at a slow speed and allow extra time and distance for maneuvers to avoid loss of control.

5UG-F1558-00

8

WARNING

Improper use can result in Severe INJURY or DEATH.

This off-highway utility vehicle will handle and maneuver differently from an ordinary passenger car or other vehicle.

Vehicle capacity: 1 operator and 1 passenger. Passenger must be able to reach and hold the handgrip inside enclosure.

This vehicle is recommended only for operators 16 and older with a valid motor vehicle license. Adults must supervise use by minors. Check state laws for minimum age requirements.

Gross Vehicle Weight Rating: 2000 lb (907 kg) maximum including operator, passenger, accessories, cargo and trailer tongue weight.

Passenger and cargo can affect vehicle handling.

ALWAYS

wear a seat belt when riding in the vehicle.

keep your hands and feet inside the vehicle at all times-watch for branches, brush, or other hazards that could enter the vehicle.

drive straight up and down inclines-driving across the side of an incline increase the risk of overturn.

NEVER

operate through water deeper than 13” (33cm) or fast flowing water-if you must cross shallow, slow moving water, choose your path carefully to avoid sharp drop-offs, large rocks, or slippery surfaces that could cause the vehicle to overturn.

make sharp, high-speed turns-the vehicle could roll over or go out of control.

ALWAYS USE AN APPROVED HELMET

AND PROTECTIVE GEAR

NEVER USE ON PUBLIC ROADS OR PAVEMENT

NEVER USE WITH DRUGS OR ALCOHOL

LOCATE AND READ THE OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

YAMAHA

5UG-F1568-01

1-5

SAFETY INFORMATION

2

This off-highway utility vehicle handles differently from other vehicles including cars and ATVs. SEVERE INJURY OR DEATH can result if you do not follow these instructions:

●Read this manual and all labels carefully and follow the operating procedures described.

●This vehicle is designed to carry the driver and one passenger. Never carry passengers in the cargo bed.

●Always be sure the driver and passenger are wearing seat belts.

●Never give a ride to a passenger who is too small to reach and hold the handgrip on the enclosure.

●Always avoid operating the vehicle on any paved surfaces, including sidewalks, driveways, parking lots, and streets.

●Never operate this vehicle on any public street, road, or highway, even a dirt or gravel one.

●Never operate this vehicle without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or a face shield), gloves, over-the-ankle boots, long-sleeved shirt or jacket, and long pants.

●Never consume alcohol or drugs before or while operating this vehicle.

●Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience.

●Never attempt jumps or other stunts.

2-1

●Always inspect your vehicle each time you use it to be sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

●Always keep both hands, arms, feet, and legs inside the vehicle at all times during operation. Keep your feet on the floorboard. Never hold onto the enclosure except when using the handgrip inside the enclosure. Otherwise, your hand could be injured if it is caught between the enclosure and an obstacle outside the vehicle.

●Always keep both hands on the steering wheel when driving.

●Never wrap your thumbs and fingers around the steering wheel. This is particularly important when driving in rough terrain. The front wheels will move right and left as they respond to the terrain, and this movement will be felt in the steering wheel. A sudden jolt could wrench the steering wheel around, and your thumbs or fingers could be injured if they are in the way of the steering wheel spokes.

●Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when driving the vehicle.

●Never operate on excessively rough, slippery, or loose terrain until you have learned and practiced the skills necessary to control the vehicle on such terrain. Always be especially cautious on these kinds of terrain.

●Never turn at excessive speed. Practice turning at slow speeds before attempting to turn at faster speeds. Do not attempt turns on steep inclines.

●Never operate the vehicle on hills that are too steep for it or for your abilities. Go straight up and down hills where possible. Maximum slope angle: 15°

2-2

●Never operate on hills that are slippery or ones where you will not be able to see far enough ahead of you. Never go over the top of a hill at speed if you cannot see what is on the other side.

●Always follow proper procedures for going uphill. If you lose momentum and cannot continue up a hill, back down the hill with the engine in reverse gear. Use engine braking to help you go slowly. If necessary, use the brakes gradually to help you go slowly.

●Always check terrain carefully before going down hills. Go as slowly as possible. Never go down a hill at high speed.

●Always check for obstacles before operating in a new area.

●Never operate the vehicle in fast flowing water or water deeper than the floorboards on this model. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.

●Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. Do not brake abruptly when carrying loads in the cargo bed.

●Always use the size and type of tires specified in this manual.

●Always maintain proper tire pressure as described in this manual.

●Never exceed the stated load capacity. Cargo should be as far forward in the bed as possible, and distributed evenly from side to side. Be sure cargo is secured so that it cannot move around during operation. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.

2-3

WARNING

POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN

Gasoline can catch fire and you could be burned.

HOW TO AVOID THE HAZARD

Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot. Do not spill gasoline on the engine or exhaust pipe/muffler when refueling. Never refuel while smoking, or while in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers.

When transporting the vehicle in another vehicle, be sure it is kept in an upright position. Otherwise, fuel may leak out of the carburetor or fuel tank.

WHAT CAN HAPPEN

Gasoline is poisonous and can cause injuries.

HOW TO AVOID THE HAZARD

If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

2-4

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.

2-5

DESCRIPTION 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.	V-belt case	17.	Engine oil dipstick
6.	Driver seat	18.	Battery
7.	Driver seat belt	19.	Fuses
8.	Spark plug	20.	Coolant reservoir
9.	Cargo bed	21.	Radiator cap
10.	Tail/brake lights	22.	Fuel level check window
11.	Rear shock absorber assembly adjusting ring	23.	Fuel tank cap
12.	Cargo bed release lever

3-1

3

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.Brake pedal

NOTE:

The vehicle you have purchased may differ slightly from those shown in the figures of this manual.

3-2

Identification number records

Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen.

1.KEY IDENTIFICATION NUMBER:

2.VEHICLE IDENTIFICATION NUMBER:

3.MODEL LABEL INFORMATION:

Key identification number

The key identification number is stamped on the key as shown in the following illustration. This number can be used for ordering a new key.

1. Key identification number

3-3

Vehicle identification number			Model label
The vehicle identification number is stamped			The model label is affixed to the location in the
into the frame.			illustration. 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.

1. Model label

3-4

CONTROL FUNCTIONS

Main switch

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

CAUTION:

● Do not operate the electric starter continuously for more than 5 seconds, or starter damage could occur.

Wait at least 5 seconds between each

4

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 result.

●See starting instructions prior to starting the engine. (See pages 6-1–6-3 for details.)

4-2

Indicator and warning lights

1.	Parking brake indicator light “P”
2.	Reverse indicator light “R”
3.	Neutral indicator light “N”
4.	Four-wheel-drive indicator light “		”		”
5.	Differential gear lock indicator light “			LOCK
				DIFF.
6.	Coolant temperature warning light “				”

Parking brake indicator light “P”

This indicator light comes on when the parking brake is applied.

Reverse indicator light “R”

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 circuit.

Neutral indicator light “N”

This indicator light comes on when the drive select lever is in the “N” position.

4-3

Four-wheel-drive indicator light “ ”

This indicator light comes on when the “2WD/ 4WD” switch is in the “4WD” position.

NOTE:

Due to the synchronizing mechanism in the differential gear case, the light may not come on until the vehicle starts moving.

Differential gear lock indicator light “ DIFF. ”

LOCK

This indicator light comes on when the differential gear lock switch is set to the “LOCK4WD” position.

Coolant temperature warning light “”

When 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.

CAUTION:

●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.

4-4

Coolant temperature warning light checking method

Turn the main switch to “ON”.

Coolant temperature warning			Coolant temperature
light does not come on.			warning light comes on.

Turn the main switch to “START” with the transmission in the neutral position.

Coolant temperature warning light comes on momentarily.

Coolant temperature warning light does not come on.

Coolant temperature and electrical circuit are OK. Go ahead with riding.

Ask a Yamaha dealer to inspect the electrical circuit.

4-5

Switches

1. Light switch “OFF/ L / H ”

Light switch “OFF/ L / H ”

Set the switch to “ L ” to turn on the low beam and the taillights.

Set the switch to “ H ” to turn on the high beam and the taillights.

Set the switch to “OFF” to turn off all the lights.

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.

4-6

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”). Unlike
		the 4WD mode, all wheels turn at the same
		speed regardless of traction.

1.On-Command four-wheel drive switch “2WD”/“4WD”

2.Differential gear lock switch “LOCK”/“4WD”

This vehicle is equipped with an On-Com- mand four-wheel drive switch “2WD”/“4WD” and a differential gear lock switch “LOCK”/ “4WD”. Select the appropriate drive according to terrain and the conditions.

●Two-wheel drive (“2WD”): Power is supplied to the rear wheels only.

4-7