2005 YAMAHA RHINO 660 brakes

EVU00050
1-CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ....................... 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION AND VEHICLE
IDENTIFICATION .................................... 3-1
Identification number records ............... 3-7
Key identification number ..................... 3-9
Vehicle identification number ............. 3-11
Model label ......................................... 3-13
CONTROL FUNCTIONS ......................... 4-1
Main switch........................................... 4-1
Indicator and warning lights.................. 4-5
Multi-function meter unit ..................... 4-13
Switches ............................................. 4-19
Accelerator pedal ............................... 4-33
Brake pedal ........................................ 4-35
Parking brake lever ............................ 4-37
Drive select lever ................................ 4-39
Fuel tank cap ...................................... 4-39
Fuel level check window..................... 4-41
Starter (choke) ................................... 4-41
1234
Seats .................................................. 4-43
Seat belts ........................................... 4-45
Glove compartment............................ 4-49
Cargo bed .......................................... 4-51
Front and rear shock absorber
adjustment ....................................... 4-57
Trailer hitch bracket ........................... 4-61
Auxiliary DC jack ................................ 4-63
PRE-OPERATION CHECKS ................... 5-1
Front and rear brakes .......................... 5-7
Fuel .................................................... 5-11
Engine oil ........................................... 5-15
Coolant............................................... 5-17
Final gear oil ...................................... 5-21
Differential gear oil ............................. 5-21
Accelerator pedal ............................... 5-23
Seat belts ........................................... 5-23
Steering.............................................. 5-25
Fittings and fasteners......................... 5-25
Lights ................................................. 5-25
Switches............................................. 5-27
Tires ................................................... 5-29
How to measure tire pressure ............ 5-33
5
U5UG61.book Page 1 Monday, September 6, 2004 9:00 AM

2-9

Always follow proper procedures for going up-
hill. 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 gradu-
ally 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 peo-
ple 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.
U5UG61.book Page 9 Monday, September 6, 2004 9:00 AM

5-1
EVU01340
1-PRE-OPERATION CHECKS
Before using this vehicle, check the following points:
ITEM ROUTINE PAGE
BrakesCheck operation, free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-7–5-9,
8-83–8-91
Parking brakeCheck for proper operation, condition and free play. 8-93–8-95
FuelCheck fuel level.
Fill with fuel if necessary.5-11–5-13
Engine oilCheck oil level.
Fill with oil if necessary.5-15, 8-23–8-33
Coolant reservoirCheck coolant level.
Fill with coolant if necessary.5-17–5-19,
8-47–8-49
Final gear oil/
Differential gear oilCheck for leakage. 5-21, 8-35–8-45
Accelerator pedalCheck for proper accelerator pedal operation. 5-23
Seat beltsCheck for proper operation and belt wear. 5-23
SteeringCheck for proper operation. 5-25
Fittings and fastenersCheck all fittings and fasteners. 5-25
Lights and switchesCheck for proper operation.5-25–5-27,
8-119–8-129
Wheels and tiresCheck tire pressure, wear and damage.5-29–5-35,
8-103–8-105
Axle bootsCheck for damage. 8-51
U5UG61.book Page 1 Monday, September 6, 2004 9:00 AM

5-7
EVU01350
Front and rear brakes
Brake pedal
Check for correct brake pedal free play. If the
brake pedal free play is incorrect, have a Yamaha
dealer adjust it. (See page 8-91.)
Check the operation of the brake pedal. It should
move smoothly and there should be a firm feeling
when the brakes are applied. If not, have the vehi-
cle inspected by a Yamaha dealer.
Brake fluid level
Check the brake fluid level.
Add fluid if necessary. (See pages 8-85–8-89.)
Recommended brake fluid: DOT 4
U5UG61.book Page 7 Monday, September 6, 2004 9:00 AM

5-9
Brake fluid leakage
Check to see if any brake fluid is leaking out of the
pipe joints or the brake fluid reservoir. Apply the
brakes firmly for one minute. If there is any leak-
age, have the vehicle inspected by a Yamaha
dealer.
Brake operation
Test the brakes at slow speed after starting out to
make sure they are working properly. If the brakes
do not provide proper braking performance, in-
spect the brake system. (See pages 8-83–8-91.)
WARNING
Always check the brakes at the start of every
ride. Do not drive the vehicle if you find any
problem with the brakes or you could lose
braking ability, which could lead to an acci-
dent. If a problem cannot be corrected by the
adjustment procedures provided in this manu-
al, have the vehicle inspected by a Yamaha
dealer.
U5UG61.book Page 9 Monday, September 6, 2004 9:00 AM

6-15 1. Drive select lever a. L (Low)
b. H (High) c. N (Neutral) d. R (Reverse)
1. Sélecteur de marche a. L (gamme basse)
b. H (gamme haute) c. N (point mort)
d. R (marche arrière)
1. Palanca selectora de marcha a. L (Marcha corta)
b. H (Marcha larga) c. N (Punto muerto)
d. R (Marcha atrás)
EVU01410
Drive select lever operation and reverse
driving CAUTION:_ Before shifting, you must stop the vehicle and
take your foot off the accelerator pedal. Other-
wise, the transmission may be damaged. _ Shifting: Neutral to High and High to Low
1. Stop the vehicle. Keep your foot off the accel-
erator pedal.
2. Apply the brakes, then shift by moving the
drive select lever along the shift guide. NOTE:_ Make sure that the drive select lever is completely
shifted into position. _3. Release the brakes and press the accelera-
tor pedal gradually.
U5UG61.book Page 15 Monday, September 6, 2004 9:00 AM

6-27
1. Bring the vehicle to a stop by applying the
brakes.
2. Stop the engine.
3. With the brakes applied, set the parking
brake.NOTE:Like many other vehicles, the parking brake acts
on the rear wheels. For the parking brake to have
the effect of braking all four wheels, shift to 4WD
before stopping the engine.
U5UG61.book Page 27 Monday, September 6, 2004 9:00 AM

7-9
LEARNING TO OPERATE YOUR VEHICLE
You should become familiar with the performance
characteristics of the vehicle in a large, flat area
that is free of obstacles and other vehicles. Prac-
tice control of the accelerator pedal, brakes, steer-
ing, and drive select lever. Drive first at slow speed
and become comfortable at that speed before
gradually increasing your speed. Become familiar
with the way the vehicle feels in low and high rang-
es, first in two-wheel drive (2WD) and then in four-
wheel drive (4WD) and four-wheel drive with the
differential locked (DIFF. LOCK). Also practice
driving in reverse. Take the time to learn basic op-
eration before attempting more difficult maneu-
vers.
U5UG61.book Page 9 Monday, September 6, 2004 9:00 AM