2005 YAMAHA RHINO 660 check engine

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

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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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.
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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

4-33 1. Accelerator pedal
1. Pédale d’accélérateur
1. Pedal del acelerador
EVU01290
Accelerator pedal
Press the accelerator pedal down to increase en-
gine speed. Spring pressure returns the pedal to
the rest position when released. Always check that
the accelerator pedal returns normally before start-
ing the engine.
Before starting the engine, check the accelerator
pedal to be sure it is operating smoothly. Make
sure the accelerator pedal fully returns to the idle
position as soon as it is released.
WARNING
Malfunction of the accelerator pedal could
make it difficult to speed up or slow down
when you need to. This could cause an acci-
dent. Check the operation of the accelerator
pedal before you start the engine. If the accel-
erator pedal does not work smoothly, check
for the cause. Correct the problem before oper-
ating the vehicle or consult a Yamaha dealer.
U5UG61.book Page 33 Monday, September 6, 2004 9:00 AM

4-41 1. Fuel level check window
1. Hublot de contrôle du niveau de carburant
1. Mirilla de control del nivel de gasolina
A. Starter (choke) “”1. Fully open
2. Half open 3. Closed
A. Starter (enrichisseur) “”1. Ouverture maximale
2. Ouverture moyenne 3. Fermé
A. Estárter (estrangulador) “”1. Completamente abierto
2. Medio abierto 3. Cerrado
EVU00310
Fuel level check window
The amount of fuel in the fuel tank can be checked
through the fuel level check window. If the fuel lev-
el is low, refuel as soon as possible.
EVU00320
Starter (choke) “”
Starting a cold engine requires a richer air-fuel
mixture. A separate starter circuit supplies this
mixture.
Move in direction
a to turn on the starter (choke).
Move in direction
b to turn off the starter (choke).
Refer to “Starting a cold engine” for proper opera-
tion. (See pages 6-3–6-7.)
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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
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5-17
EVU01370
Coolant
Check the coolant level in the coolant reservoir
when the engine is cold. (The coolant level will
vary with engine temperature.) The coolant level is
satisfactory if it is between the minimum and max-
imum level marks on the coolant reservoir. If the
coolant level is at or below the minimum level
mark, add additional coolant to bring the level up to
maximum level mark. If coolant is not available,
add distilled water. Change the coolant every two
years. (See pages 8-47–8-49 for details.)CAUTION:_ Hard water or salt water is harmful to the en-
gine. You may use soft water if you cannot get
distilled water. _
Coolant reservoir capacity
(up to the maximum level mark):
0.35 L (0.31 Imp qt, 0.37 US qt)
U5UG61.book Page 17 Monday, September 6, 2004 9:00 AM