2005 YAMAHA RHINO 660 differential

4-29
NOTE:_

When the switch is set to “LOCK”, the differ-
ential gear lock indicator light will flash until
the differential gear is locked.


When the indicator light is flashing, turning
the steering wheel back and forth will help the
differential gear lock to engage.


Riding before the differential gear lock is
properly engaged (e.g., when the indicator
light is flashing) will cause the engine speed
to be limited until engagement is complete.
_
U5UG61.book Page 29 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

5-21
EVU00430
Final gear oil
Make sure the final gear oil is at the specified level.
Add oil as necessary. (See pages 8-35–8-39 for
details.)
If desired, an SAE 80W90 hypoid gear oil may be
used for all conditions.NOTE:_ GL-4 is a quality and additive rating, GL-5 or GL-6
rated hypoid gear oils may also be used. _
EVU00440
Differential gear oil
Make sure the differential gear oil is at the speci-
fied level. Add oil as necessary. (See pages 8-41–
8-45 for details.)Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
U5UG61.book Page 21 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

7-13
CAUTION:_ Do not shift from low to high or vice versa with-
out coming to a complete stop and waiting for
the engine to return to normal idle speed. Dam-
age to the engine or drive train may occur. _TURNING YOUR VEHICLE
The vehicle is easier to steer in two-wheel drive
(2WD) than four-wheel drive (4WD). Steering
takes the most effort in 4WD with the differential
locked (DIFF. LOCK).
It is possible for the vehicle to roll over or go out of
control if you attempt sharp, high-speed turns. You
should also be careful making sharp turns on
rough terrain. Do not attempt to turn around or
make abrupt maneuvers on slopes.
U5UG61.book Page 13 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

8-41 1. Differential gear oil filler bolt
2. Proper oil level 3. Differential gear oil
1. Vis de remplissage de l’huile de différentiel
2. Niveau d’huile correct 3. Huile de différentiel
1. Perno de llenado de aceite del diferencial
2. Nivel correcto de aceite 3. Aceite del diferencial
EVU00721
Differential gear oil
Checking the differential gear oil level
1. Place the vehicle on a level surface.
2. Remove the differential gear oil filler bolt and
check the oil level. It should be up to the brim
of the filler hole. If the level is low, add suffi-
cient oil of the recommended type to raise it
to the specified level.CAUTION:_ Be sure no foreign material enters the differen-
tial gear case. _3. Install the differential gear oil filler bolt, and
then tighten it to the specified torque.
Tightening torque:
Differential gear oil filler bolt:
23 Nm (2.3 m·kgf, 16 ft·lbf)
U5UG61.book Page 41 Monday, September 6, 2004 9:00 AM

8-43 1. Differential gear oil drain bolt
1. Vis de vidange de l’huile de différentiel
1. Perno de vaciado de aceite del diferencial
Changing the differential gear oil
1. Place the vehicle on a level surface.
2. Place a container under the differential gear
case to collect the used oil.
3. Remove the differential gear oil filler bolt and
differential gear oil drain bolt to drain the oil.
4. Install the differential gear oil drain bolt, and
tighten it to the specified torque.
5. Fill the differential gear case with the recom-
mended oil. Tightening torque:
Differential gear oil drain bolt:
9.8 Nm (0.98 m·kgf, 7.1 ft·lbf)
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
Oil quantity:
0.32 L (0.28 Imp qt, 0.34 US qt)
U5UG61.book Page 43 Monday, September 6, 2004 9:00 AM