2005 YAMAHA RHINO 660 boot

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
U5UG61.book Page 2 Monday, September 6, 2004 9:00 AM

2-3

Watch carefully for other vehicles when operat-
ing on unpaved public streets or roads. Make
sure you know your country’s laws and regula-
tions before you ride on unpaved public streets
or roads.


Never operate this vehicle without wearing an
approved motorcycle helmet that fits properly.
You should also wear eye protection (goggles
or a face shield), gloves, over-the-ankle boots,
long-sleeved shirt or jacket, and long pants.


Never consume alcohol or drugs before or
while operating this vehicle.


Never operate at speeds too fast for your skills
or the conditions. Always go at a speed that is
proper for the terrain, visibility, operating condi-
tions, and your experience.


Never attempt jumps or other stunts.


Always inspect your vehicle each time you use
it to be sure it is in safe operating condition. Al-
ways follow the inspection and maintenance
procedures and schedules described in this
manual.
U5UG61.book Page 3 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

7-5
WARNING


Never exceed the stated maximum load ca-
pacity for this vehicle.


Cargo should be properly distributed and
securely attached.


Reduce speed when carrying cargo or tow-
ing a trailer. Allow greater distance for
braking.


Always follow the instructions in your
Owner’s Manual for carrying cargo or tow-
ing a trailer.
The driver and passenger must always wear a
seat belt and an approved motorcycle helmet. Also
wear eye protection and protective clothing, in-
cluding over-the-ankle boots, gloves, a long-
sleeved shirt or jacket, and long pants. Keep
hands and feet inside the vehicle at all times.
U5UG61.book Page 5 Monday, September 6, 2004 9:00 AM

7-7 1. Protective clothing 2. Goggles
3. Gloves 4. Boots
5. Helmet
1. Vêtements de protection 2. Lunettes
3. Gants 4. Bottes
5. Casque
1. Ropa protectora 2. Gafas de seguridad
3. Guantes 4. Botas
5. Casco
Always wear an approved helmet that fits properly.
You should also wear:
eye protection
(goggles or face shield)
gloves
boots
long-sleeved shirt or jacket
long pants
WARNING
Never operate this vehicle without wearing an
approved motorcycle helmet, eye protection
and protective clothing. Operating without an
approved motorcycle helmet increases your
chances of a severe head injury or death in the
event of an accident. Operating without eye
protection can result in an accident and in-
creases your chances of a severe injury in the
event of an accident.
U5UG61.book Page 7 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

8-21 1. Console
1. Console
1. Consola
EVU00691
Console
To remove
1. Remove the seats. (See page 4-43 for seat
removal and installation procedures.)
2. Remove the parking brake lever boot.
3. Pull the console upward (the drive select le-
ver boot will come loose).
To install
1. Place the console in its original position.
2. Install the parking brake lever boot.
3. Install the seats.CAUTION:_

When installing the console, be sure not to
pinch the cables or wires.


Make sure that the groove at the bottom of
the parking brake lever boot and the drive
select lever boot fits securely around the
edge of the hole in the console.
_
U5UG61.book Page 21 Monday, September 6, 2004 9:00 AM

8-51 1. Front axle boot (× 2 each side)
1. Soufflet d’essieu avant (× 2 de chaque côté)
1. Funda del eje delantero (× 2 a cada lado)
1. Rear axle boot (× 2 each side)
1. Soufflet d’essieu arrière (× 2 de chaque côté)
1. Funda del eje trasero (× 2 a cada lado)
EVU00740
Axle boots
Check the protective boots for holes or tears. If any
damage is found, have them replaced by a
Yamaha dealer.
U5UG61.book Page 51 Monday, September 6, 2004 9:00 AM