Yamaha YSR45FX Owner's Manual

The engine exhaust from this product

contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

YAMAHA LIT-CALIF-65-01

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 crafts-

manship and reliability that have made Yamaha a leader in these fields.

This manual will provide you with a good basic understanding of the features and operation of this vehicle. 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.

IIF! ViVl,_1-'t_II_[e-!

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 fea- tures. Regular inspections and careful maintenance, along with good operating tech-

niques, 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 SE- RIOUS INJURY OR DEATH.

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

,/_ This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

_lr!VAVl:1:l_,ll_,[t, ll A WARNING indicates a hazardous situation which, if not avoided, I

could result in death or serious injury.

NOTICE A NOTICE indicates special precautions that must be taken to I

avoid damage to the vehicle or other property.

TIP A TIP provides key information to make procedures easier or clearer. I

*Product and specifications are subject to change without notice.

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 acci-

dent 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

U.S.A.

1st edition, July 2007

permission of

Yamaha Motor Corporation,

U.S.A. is expressly prohibited.

Printed in U.S.A.

PIN LIT-11626-21-21

CONTENTS

U LOCATION OF THE WARNING

AND SPECIFICATION LABELS ....... 1-1

N lU H

SAFETY INFORMATION .................. 2-1

DESCRIPTION ................................. 3-1

INSTRUMENT AND CONTROL

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 -

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

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

KNOW YOUR VEHICLE ................. 7-1

Driver requirements ........................ 7-2

Passenger requirements ................. 7-3

Occupant protection system ............ 7-4

Protective structu re.......................... 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

ADJUSTMENT .................................. 8-1

Owner's 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 .................... 3-30

Cleaning the spark arrester ........... 3-31

Carburetor adjustment ................... 3-32

Idle speed adjustment .................... 3-33

Valve clearance ............................. 3-33

Brakes ............................................ 3-34

Front brake pad check ................... 3-34

Rear brake pad check .................... 3-35

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

A. Cleaning ...................................... 9-1

B. Storage ....................................... 9-2

SPECIFICATIONS .......................... 10-1

CONSUMER INFORMATION ........ 11-1

Identification number records ........ 11-1

NOISE REGULATION ................... 11-4

MAINTENANCE RECORD ........... 11-5

YAMAHA MOTOR

CORPORATION, U.S.A. SIDE x SIDE VEHICLE LIMITED

WARRANTY ................................ 11-6

YAMAHA EXTENDED SERVICE

(Y.E.S.) ........................................ 11-7

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 re- placement label is available from your Yamaha dealer.

Any part d your body (arms, legs,

or head) outside of the vehicle can be

crushed by the cage/frame.

If you think or feel

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.

Any part of your body (arms, legs, or head) outside of

the vehicle can be crushed by the

cage/frame.

If you think or feel

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.

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

YAMAHA 5B4-K7762-00

• _A 5B4-K7761-00 _

1-2

® ®

ImpropertirepressureoroverloadingtheRhinomay causesevereinjuryordeathfromlossofcontrolor

rollover.

OPERATINGTIREPRESSURE:Set withtirescold. RECOMMENDED:

FRONT:70kPa,(.70kgf/cm2),10psi REAR: 98kPa,(.98kgf/cm2),14psi

MINIMUM: FRONT:63kPa,(.63kgf/cm2),9psi

REAR:91kPa,(.91kgf/cm2),13psi

Neversetorallowtirepressureto bebelowthe minimum.Tiremaydislodgefromrim.

GrossVehicleWeightRating:907kg(2000Ib) maximumincludingvehicle,weightofoperator, passenger,accessories,cargo,and(if applicable)

trailertongueweight.

YAMAHA 5B4-F1696-00

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-O0

1-3

Improperuse ofcargobed or cage/framecan resultin

severeinjury or deathfromlossofcontrol, overturnor

otheraccidents.

• Do notcarrypassengersincargobed.

• Maximumload in cargobed: 181kg (400Ib).

• Loador trailermay affect handlingand stability:

• Securecargoso that itwill not shift- a looseload couldchangehandlingunexpectedlyor bethrown

forwardand strikeoccupants.

• Keepweight inthecargobedcenteredsideto side, andas lowand asfarforwardaspossible.Top-

heavyloadsincreasethe risk of overturn.

• Donottow or pullobjectsfromany pointotherthan the trailerhitch bracketor winch(if installed).

• Whenloadedwith cargoor towingatrailer:

• Reducespeedand allowmore roomto stop.

• Turngraduallyandgo slowly.

• Avoidhillsand roughterrain.

• ReadOwner'sManualbeforeloading,towing,or pullin! objects.

' YAMAHA 5B4-F4897-O0 ,,

1-4

k,,..,YAMAHA

_1MAX7.3INCH

-I (185MM).,

5UG-F151J-O0 ,j

® ®

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 Ib) tongue weight on the towing bracket.

Do not tow more than 550 kg (1212 Ib) rolling weight

(trailer plus cargo). Tow or pull only from hitch

bracket. Read Owner s Manual before loading, towing, or

pulling objects.

' YAMAHA 5B4-F151 K-00'

1-5

Head Body

Hands

/ Feet

,YAMAHA

Helmet and eye protection. Seatbelt and protective clothing.

Inside vehicle and holding the handholds or steering wheel. On floorboard, ready to brace,

and door closed.

5B4-F1558-00,

To reduce risk of accidents and injury or death: ,_\

Be Prepared _ Avoid Rollovers and Crushing Injuries

• Wear seat belt, motorcycle helmet, _ ° Use care when tuming:

eye protection and protecbve gear. _!,_DI!I o Turning the steering wheel toofar or too fast

• Keep your body completely inside ]_, _ can result in a rollover or loss of control. thevehicle at all times. Keep both '_ o Slow down before entering a turn.

hands on the steering wheel. Be _ o When making tight turns froma stop or at slow sure passenger is seated, belted, _ ib speeds, avoid sudden or hard acceleration. Abrupt maneuvers or

and holding ontothe handholds, o Avoid sideways sliding, skidding, or fishtailing, aggressive driving have

and never do donuts, caused rollovers - even on

Be Qualified and Responsible • Drive straight up and down inclines, not across flat, open areas.

• This vehicleis intended for use /[ u_u_ )} them. If crossing a hill is unavoidable, drive slowly only by anoperator 16 or older \'_ 1 _-_NYi and turn downhill immediately if you feel the

with a valid motor vehicle license. "_ vehicle maytip.

• Passenger and driver must be able to • Avoid paved surfaces. Turn gradually and go place both feet flat onthe floorboard while slowly if you must drive on pavement. This vehicle

seated upright with their backs against the is designed for off-road use only. seat backs. If you think or feel the Rhino may tip or roll:

• Do notdrive or ride as passenger after • Brace yourself by pressing your feet firmly onthe using drugs or alcohol, floorboards and keep a firm grip on the steering

• Do notoperate on public roads, wheel or handholds.

--/- Read the Owner's Manual YAMAHA

Genuine Yamaha Doors and a Handhold/Strap are

available for free installation or replacement. Yamaha

recommends these features to help keep occupants from sticking arms or legsout of the

vehicle during a rollover.

• Do not putyour hands or feet outside of the vehicle for any reason. [-_ntact your dealer or visit [----

I www.yamaha-motor.com/rhino

5B4-F1568-01

1-6

SAFETY INFORMATION

Be a responsible owner

As the vehicle's owner, you are responsible for the safe and proper operation of your Rhino. While understanding all parts of this manual are important for vehicle ownership, be sure to read

this chapter and the instructions in Chapter 7 before operating the Rhino. Also use these two chapters and the labels on the vehicle to instruct new operators and passengers. 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 re-

duce 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 li- cense.

• 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

Prepare your vehicle

Perform the pre-operation checks each time you use the vehicle to make sure it is in safe operat-

ing condition. Failure to inspect or maintain the vehicle properly increases the possibility of an ac- cident or equipment damage. See pages 5-1-5-2 for a list of pre-operation checks.

Prepare your load or trailer Carrying loads, towing a trailer, or pulling objects can affect handling, stability, and risk of overturn or other accidents.

• 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 pos- sible.

• 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 be-

fore driving. Any part of your body (arms, legs, and head) outside the vehicle can be struck by objects your vehicle is passing or crushed by the vehicle cage/frame in a rollover accident.

• 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 rug-

ged 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 ve- hicle 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 symp-

toms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDI- CAL 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 af-

termarket companies produce. Therefore, Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha,

even if sold and installed by a Yamaha dealer.

Aftermarket parts, accessories, and modifications

While you may find aftermarket products similar in design and quality to genuine Yamaha Acces- sories, recognize that some aftermarket accessories or modifications are not suitable because of

potential safety hazards to you or others. Installing aftermarket products or having other modifica- tions performed to your Rhino that change any of the vehicle's 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 capabili-

ties and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Refer to pages 8-42-8-44 for tire specifications and

more information on replacing your tires.

2-10

DESCRIPTION

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

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

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

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

manual.

3-2

INSTRUMENT AND CONTROL

FUNCTIONS

Main switch

;TART

1. Main switch

Functions of the respective switch positions

are as follows: ON:

All electrical circuits are supplied with power, and the headlights and tail-

lights come on when the light switch is

on.

OFF:

All electrical circuits are switched off. The key can be removed in this posi-

tion.

START:

The electric starter is engaged by turning and holding the key in this po- sition. Release the key when the en- gine starts.

4-1

Indicator and warning lights

O FFLOCK

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 "=,_E"

Parking brake indicator light "P" This indicator light comes on when the park-

ing brake is applied.

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.

Neutral indicator light "N" This indicator light comes on when the drive

select lever is in the "N" position.

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.

On-Command differential gear lock indica- tor light" _ "

This indicator light comes on when the On-Command differential gear lock switch is

set to the "LOCK" position.

Coolant temperature warning light "_"

If the coolant temperature reaches a specified

level, this light comes on to warn that the cool- ant temperature is too hot. If the light comes

on during operation, stop the engine as soon as it is safe to do so and allow the engine to

cool down for about 10 minutes. (See page 8-58.)

NOTICE

• 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

+ 145 hidden pages

Yamaha YSR45FX Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual