2P5-F8199-12LIT-11626-21-21
READ THIS MANUAL CAREFULLY!
It contains important safety information.
YXR45FX
OWNER’S MANUAL
DIC2342
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.
EE.book Page 1 Friday, August 3, 2007 11:59 AM
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
A WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
NOTICE
A NOTICE indicates special precautions that must be taken to
avoid damage to the vehicle or other property.
TIP
A TIP provides key information to make procedures easier or clearer.
EE.book Page 1 Friday, August 3, 2007 11:59 AM
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
EE.book Page 2 Friday, August 3, 2007 11:59 AM
EVU00050
CONTENTS
LOCATION OF THE WARNING
AND SPECIFICATION LABELS....... 1-1
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
1
2
3
4
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
5
EE.book Page 1 Friday, August 3, 2007 11:59 AM
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
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
6
EE.book Page 2 Friday, August 3, 2007 11:59 AM
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
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
8
EE.book Page 3 Friday, August 3, 2007 11:59 AM
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
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 × SIDE VEHICLE LIMITED
WARRANTY................................11-6
YAMAHA EXTENDED SERVICE
(Y.E.S.) ........................................11-7
10
11
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EVU00060
1-
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
5
8
7
65
1
3
2
3
4
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13
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
Any part of your
body (arms, legs,
or head) outside of
the vehicle can be
crushed by the
cage/frame.
If you think or f eel
that the vehicle
may tip or roll,
brace your feet on
the floorboards,
and keep your
hands on the
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 f eel
that the vehicle
may tip or roll,
brace your feet on
the floorboards,
and keep your
hands on the
WARNING
!
YAMAHA 5B4-K8483-00
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.
WARNING
!
EE.book Page 2 Friday, August 3, 2007 11:59 AM
45
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:
FRONT: 70kPa, (.70kgf/cm
2
), 10psi
REAR: 98kPa, (.98kgf/cm
2
), 14psi
MINIMUM: FRONT: 63kPa, (.63kgf/cm
2
), 9psi
REAR: 91kPa, (.91kgf/cm
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.
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
WARNING
!
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67
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.
WARNING
!
YAMAHA 5UG-F151J-00
MAX 7.3 INCH
(185MM)
EE.book Page 4 Friday, August 3, 2007 11:59 AM
89
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
Improperly loading a trailer
or pulling an object can
affect handling, stability, and
risk of overturn or other
accidents.
WARNING
!
YAMAHA 5B4-F1558-00
Head to Toe
Safety Checklist
ü
Head Helmet and eye protection.
ü
Body Seatbelt and protective clothing.
ü
Hands Inside vehicle and holding the
handholds or steering wheel.
ü
Feet On floorboard, ready to brace,
and door closed.
EE.book Page 5 Friday, August 3, 2007 11:59 AM
0
Passenger and driver must be able to
place both feet flat on the floorboard while
seated upright with their backs against the
seat backs.
•
Do not drive or ride as passenger after
using drugs or alcohol.
•
Do not operate on public roads.
Avoid Rollovers and Crushing Injuries
•
Use care when turning:
o Turning the steering wheel too far or too fast
can result in a rollover or loss of control.
o Slow down before entering a turn.
o When making tight turns from a stop or at slow
speeds, avoid sudden 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 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 the Rhino may tip or roll:
•
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.
Be Qualified and Responsible
•
This vehicle is intended for use
only by an operator 16 or older
with a valid motor vehicle license.
Read the Owners Manual
To reduce risk of accidents and injury or death:
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 legs out of the
vehicle during a rollover.
Contact your dealer or visit
www.yamaha-motor.com/rhino
Be Prepared
•
Wear seat belt, motorcycle helmet,
eye protection and protective gear.
•
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.
Abrupt maneuvers or
aggressive driving have
caused rollovers even on
flat, open areas.
DRIVER
UNDER
16
YAMAHA 5B4-F1568-01
WARNING
!
EE.book Page 6 Friday, August 3, 2007 11:59 AM
SAFETY INFORMATION
EVU00070
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 reduce the risk of serious injury or death in the event of an accident.
EE.book Page 1 Friday, August 3, 2007 11:59 AM
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13
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.
• 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.
DRIVER
UNDER
16
EE.book Page 2 Friday, August 3, 2007 11:59 AM
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.
EE.book Page 3 Friday, August 3, 2007 11:59 AM
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.
EE.book Page 4 Friday, August 3, 2007 11:59 AM
●
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.
EE.book Page 5 Friday, August 3, 2007 11:59 AM
• 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.
EE.book Page 6 Friday, August 3, 2007 11:59 AM
●
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).
EE.book Page 7 Friday, August 3, 2007 11:59 AM
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.
EE.book Page 8 Friday, August 3, 2007 11:59 AM
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 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.
EE.book Page 9 Friday, August 3, 2007 11:59 AM
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.
EE.book Page 10 Friday, August 3, 2007 11:59 AM
EVU00080
1-
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
C
14. Spark arrester
15. Passenger seat belt
16. Passenger seat
17. Oil filter cartridge
18. Passenger handhold
19. Engine oil filler cap
20. Battery
IHEJKLM
NCO
D
FG
EE.book Page 1 Friday, August 3, 2007 11:59 AM
1
2
3
4
5
6
7
8
9
10
11
12
13
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
The vehicle you have purchased may differ
slightly from those shown in the figures of this
manual.
[Z Y
H
PQ RST UV W X
EE.book Page 2 Friday, August 3, 2007 11:59 AM
EVU00130
1-
INSTRUMENT AND CONTROL
FUNCTIONS
EVU00140
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.
O
F
F
O
N
S
T
A
R
T
OFF
ON
START
EE.book Page 1 Friday, August 3, 2007 11:59 AM
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13
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 “”
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.
DIFF.
LOCK
EE.book Page 2 Friday, August 3, 2007 11:59 AM
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 indicator light “”
This indicator light comes on when the
On-Command differential gear lock switch is
set to the “LOCK” position.
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.)
● 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.
DIFF.
LOCK
EE.book Page 3 Friday, August 3, 2007 11:59 AM
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