2005 YAMAHA RHINO 660 maintenance

EVU00010
1-INTRODUCTION
Congratulations on your purchase of the Yamaha
YXR660FA. It represents the result of many years
of Yamaha experience in the production of fine
sporting, touring, and pace-setting racing vehicles.
With the purchase of this Yamaha, you can now
appreciate the high degree of craftsmanship and
reliability that have made Yamaha a leader in
these fields.
This manual will provide you with a good basic un-
derstanding of the features and operation of this
vehicle. It also includes basic maintenance and in-
spection procedures. If you have any questions re-
garding the operation or maintenance of your
vehicle, please consult a Yamaha dealer.
WARNING
_ Please read this manual carefully before oper-
ating this vehicle. Do not attempt to operate
this vehicle until you have attained adequate
knowledge of its controls and operating fea-
tures. Regular inspections and careful mainte-
nance, along with good operating techniques,
will help ensure that you safely enjoy the capa-
bilities and reliability of this vehicle. _
U5UG61.book Page 4 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

2-3

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

5-2
5
WARNING
Always inspect your vehicle each time you use it to make sure it is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Own-
er’s Manual. Failure to inspect increases the possibility of an accident or equipment damage.U5UG61.book Page 2 Monday, September 6, 2004 9:00 AM

8-1
EVU01450
1-PERIODIC MAINTENANCE AND
ADJUSTMENTPeriodic inspection, adjustment and lubrication will
keep your vehicle in the safest and most efficient
condition possible. Safety is an obligation of the
vehicle owner. The most important points of vehi-
cle inspection, adjustment and lubrication are ex-
plained on the following pages.
WARNING
Never service an engine while it is running.
Moving parts can catch clothing or parts of the
body, causing injury. Electrical components
can cause shocks or can start fires. Turn off
the engine when performing maintenance un-
less otherwise specified. Have a Yamaha deal-
er perform service if you are not familiar with
vehicle service.
U5UG61.book Page 1 Monday, September 6, 2004 9:00 AM

8-3 1. Owner’s manual
1. Manuel du propriétaire
1. Manual del propietario
1. Owner’s tool kit 2. Tire pressure gauge
1. Trousse de réparation 2. Manomètre pour pneus
1. Juego de herramientas 2. Manómetro para neumáticos
EVU01460
Owner’s manual and tool kit
You are recommended to put this owner’s manual
in the vinyl bag and always carry it on the bottom
of the driver seat as shown. Put the owner’s tool kit
and tire pressure gauge in the space beside the
battery.
The service information included in this manual is
intended to provide you, the owner, with the nec-
essary information for completing your own pre-
ventive maintenance and minor repairs. The tools
provided in the Owner’s tool kit are sufficient for
this purpose, except that a torque wrench is also
necessary to properly tighten nuts and bolts.NOTE:_ If you do not have a torque wrench available dur-
ing a service operation requiring one, take your ve-
hicle to a Yamaha dealer to check the torque
settings and adjust them as necessary. _
U5UG61.book Page 3 Monday, September 6, 2004 9:00 AM

8-7
EVU00670
PERIODIC MAINTENANCE/LUBRICATION
NOTE:

For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals.


For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance in-
tervals. However, keep in mind that if the vehicle isn’t used for a long period of time, the month main-
tenance intervals should be followed.
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
Valves*Check valve clearance.
Adjust if necessary.
Cooling systemCheck coolant leakage.
Repair if necessary.
Replace coolant every 24 months.Spark plugCheck condition.
Adjust gap and clean.
Replace if necessary.Air filter elements
(Engine and air intake duct)Clean.
Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*Check idle speed/starter operation.
Adjust if necessary.Crankcase breather
system*Check breather hose for cracks or damage.
Replace if necessary.Exhaust system*Check for leakage.
Tighten if necessary.
Replace gasket(s) if necessary.Fuel line*Check fuel hose for cracks or damage.
Replace if necessary.Engine oil
Replace (warm engine before draining).U5UG61.book Page 7 Monday, September 6, 2004 9:00 AM