2005 YAMAHA RHINO 660 brake fluid

Tire wear limit......................................5-35
OPERATION ............................................6-1
Starting a cold engine ...........................6-3
Starting a warm engine .........................6-9
Jump-starting ........................................6-9
Warming up.........................................6-13
Drive select lever operation and
reverse driving ..................................6-15
Engine break-in ...................................6-21
Parking ................................................6-25
Parking on a slope ..............................6-25
Accessories and loading .....................6-29
DRIVING YOUR VEHICLE .......................7-1
Getting to know your vehicle .................7-1
Learning to operate your vehicle...........7-9
Turning your vehicle............................7-13
Braking ................................................7-15
Going uphill .........................................7-17
Going downhill ....................................7-21
Crossing through shallow water ..........7-27
Riding over rough terrain ....................7-33
Riding in brush or wooded areas ........7-35
Encountering obstacles on the trail .....7-37
67
PERIODIC MAINTENANCE AND
ADJUSTMENT ......................................... 8-1
Owner’s manual and tool kit ................. 8-3
periodic maintenance/lubrication .......... 8-7
Hood ................................................... 8-17
Console .............................................. 8-21
Engine oil and oil filter cartridge ......... 8-23
Final gear oil ....................................... 8-35
Differential gear oil.............................. 8-41
Coolant ............................................... 8-47
Axle boots ........................................... 8-51
Spark plug inspection ......................... 8-53
Cleaning the air filter elements ........... 8-61
V-belt cooling duct check hose ........... 8-73
V-belt case drain plug ......................... 8-75
Carburetor adjustment ........................ 8-77
Idle speed adjustment ........................ 8-79
Valve clearance adjustment ............... 8-81
Front brake pad check ........................ 8-83
Rear brake pad check ........................ 8-85
Checking the brake fluid level............. 8-85
Brake fluid replacement ...................... 8-89
Checking the brake pedal ................... 8-91
Parking brake lever free play
adjustment ........................................ 8-93
Brake light switch adjustment ............. 8-97
Cable inspection and lubrication......... 8-99
8
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3-1
EVU00080
1-DESCRIPTION AND VEHICLE IDENTIFICATION
1. Headlights
2. Front shock absorber assembly 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. Spark plug
9. Cargo bed
10. Tail/brake lights
11. Rear shock absorber assembly adjusting ring
12. Cargo bed release lever
13. Passenger seat belt
14. Passenger seat
15. Oil filter cartridge
16. Engine oil dipstick
17. Battery
18. Fuses
19. Coolant reservoir
20. Radiator cap
21. Fuel level check window
22. Fuel tank cap
U5UG61.book Page 1 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

8-8
Engine oil filter cartridge
Replace.Final gear oil
Check oil level/oil leakage.
Replace.Differential gear oil
Front brake*Check operation/brake pad wear/fluid leakage/see NOTE page
8-9.
Correct if necessary. Replace pads if worn to the limit.Rear brake*Check operation/brake pad wear/fluid leakage/see NOTE page
8-9.
Correct if necessary. Replace pads if worn to the limit.Accelerator pedal*
Check operation and free play.V-belt*Check operation.
Check for wear, cracks, or damage.Wheels*Check balance/damage/runout.
Repair if necessary.Wheel bearings*Check bearing assemblies for looseness/damage.
Replace if damaged.Front and rear
suspension*Check operation and for leakage.
Correct if necessary.Steering system*Check operation and for looseness/Replace if damaged.
Check toe-in/Adjust if necessary.Rear upper and lower
knuckle pivots*Lubricate with lithium-soap-based grease.Drive shaft universal joint*
Lubricate with lithium-soap-based grease.Engine mount*Check for cracks or damage.
Check bolt tightness.Front and rear axle boots*Check operation.
Replace if damaged.Stabilizer bushings*
Check for cracks or damage.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
U5UG61.book Page 8 Monday, September 6, 2004 9:00 AM

8-9
* Since these items require special tools, data and technical skills have a Yamaha dealer perform the service.NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
On the inner parts of the master cylinder and caliper, replace the oil seals every two years.
Replace the brake hoses every four years, or if cracked or damaged.
Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
U5UG61.book Page 9 Monday, September 6, 2004 9:00 AM

8-85 1. Brake pad wear indicator groove
1. Rainure d’indication d’usure de plaquette de frein
1. Ranura indicadora de desgaste de la pastilla de freno
1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
EVU00840
Rear brake pad check
Each brake pad is provided with wear indicator
grooves, which allow you to check the brake pad
wear without having to disassemble the brake. To
check the brake pad wear, check the wear indica-
tor grooves. If a brake pad has worn to the point
that the wear indicator grooves have almost disap-
peared, have a Yamaha dealer replace the brake
pads as a set.
EVU00850
Checking the brake fluid level
Insufficient brake fluid may let air enter the brake
system, possibly causing the brakes to become in-
effective.
Before riding, check that the brake fluid is above
the minimum level mark and replenish if neces-
sary. A low brake fluid level may indicate worn
brake pads and/or brake system leakage. If the
brake fluid level is low, be sure to check the brake
pads for wear and the brake system for leakage.
U5UG61.book Page 85 Monday, September 6, 2004 9:00 AM