2005 YAMAHA RHINO 660 brake

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

Brake pedal and accelerator pedal
lubrication ....................................... 8-101
Rear knuckle upper and lower pivot
lubrication ....................................... 8-101
Steering shaft lubrication .................. 8-103
Wheel removal ................................. 8-103
Wheel installation ............................. 8-105
Battery .............................................. 8-107
Battery maintenance ........................ 8-111
Fuse replacement............................. 8-113
Replacing a headlight bulb ............... 8-119
Headlight beam adjustment.............. 8-123
Tail/brake light bulb replacement ..... 8-125
Troubleshooting................................ 8-131
Troubleshooting charts ..................... 8-133
CLEANING AND STORAGE ................... 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................ 10-1
910U5UG61.book Page 3 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

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

3-2
3
23. Light switch
24. Steering wheel
25. Starter (choke)
26. Main switch
27. On-Command four-wheel drive and differential gear lock switches
28. Multi-function meter unit
29. Auxiliary DC jack
30. Horn switch
31. Drive select lever
32. Parking brake lever
33. Accelerator pedal
34. Brake pedalNOTE:_ The vehicle you have purchased may differ slightly
from those shown in the figures of this manual. _ U5UG61.book Page 2 Monday, September 6, 2004 9:00 AM

4-5
1. Differential gear lock indicator light “DIFF. LOCK”
2. Low-range indicator light “L”3. High-range indicator light “H”
4. Neutral indicator light “N”5. Reverse indicator light “R”
6. Parking brake indicator light “P”
7. Four-wheel-drive indicator “”/“”
8. Coolant temperature warning light “”
1. Témoin de blocage du différentiel “DIFF. LOCK”
2. Témoin de la gamme basse “L”3. Témoin de la gamme haute “H”
4. Témoin de point mort “N”5. Témoin de la marche arrière “R”
6. Témoin du frein de stationnement “P”
7. Indicateur quatre roues motrices “”/“”
8. Témoin d’alerte de la température du liquide de refroidissement “”
1. Luz indicadora del bloqueo del diferencial “DIFF. LOCK”
2. Luz indicadora de marcha corta “L”
3. Luz indicadora de marcha larga “H”
4. Luz indicadora de punto muerto “N”
5. Luz indicadora de marcha atrás “R”
6. Luz indicadora del freno de estacionamiento “P”
7. Luz indicadora de tracción integral “”/“”
8. Luz de aviso de la temperatura del líquido refrigerante “”
DIFF.
LOCKDIFF.
LOCK
DIFF.
LOCK
EVU00150
Indicator and warning lights
EVU01130
Differential gear lock indicator light “DIFF.
LOCK”
This indicator light and the differential gear lock in-
dicator in the display come on when the differential
gear lock switch is set to the “4WD-LOCK” posi-
tion.NOTE:_ When the switch is set to “LOCK”, the differential
gear lock indicator light will flash until the differen-
tial gear is locked. _
EVU01140
Low-range indicator light “L”
This indicator light comes on when the drive select
lever is in the “L” position.
EVU01150
High-range indicator light “H”
This indicator light comes on when the drive select
lever is in the “H” position.
U5UG61.book Page 5 Monday, September 6, 2004 9:00 AM

4-7
1. Differential gear lock indicator light “DIFF. LOCK”
2. Low-range indicator light “L”3. High-range indicator light “H”
4. Neutral indicator light “N”5. Reverse indicator light “R”
6. Parking brake indicator light “P”
7. Four-wheel-drive indicator “”/“”
8. Coolant temperature warning light “”
1. Témoin de blocage du différentiel “DIFF. LOCK”
2. Témoin de la gamme basse “L”3. Témoin de la gamme haute “H”
4. Témoin de point mort “N”5. Témoin de la marche arrière “R”
6. Témoin du frein de stationnement “P”
7. Indicateur quatre roues motrices “”/“”
8. Témoin d’alerte de la température du liquide de refroidissement “”
1. Luz indicadora del bloqueo del diferencial “DIFF. LOCK”
2. Luz indicadora de marcha corta “L”
3. Luz indicadora de marcha larga “H”
4. Luz indicadora de punto muerto “N”
5. Luz indicadora de marcha atrás “R”
6. Luz indicadora del freno de estacionamiento “P”
7. Luz indicadora de tracción integral “”/“”
8. Luz de aviso de la temperatura del líquido refrigerante “”
DIFF.
LOCKDIFF.
LOCK
DIFF.
LOCK
EVU00170
Neutral indicator light “N”
This indicator light comes on when the drive select
lever is in the “N” position.
EVU00160
Reverse indicator light “R”
This indicator light comes on when the drive select
lever is in the “R” reverse position. NOTE:_ If the indicator light flashes while riding, have a
Yamaha dealer check the speed sensor circuit._
EVU00210
Parking brake indicator light “P”
This indicator light comes on when the parking
brake is applied.
U5UG61.book Page 7 Monday, September 6, 2004 9:00 AM