2007 YAMAHA RHINO 660 differential

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 ............................................. 4-21
Accelerator pedal ............................... 4-35
Brake pedal ........................................ 4-37
Parking brake lever ............................ 4-39
Drive select lever ................................ 4-41
Fuel tank cap ...................................... 4-41
Starter (choke).................................... 4-43
Seats .................................................. 4-45
1234
Seat belts ........................................... 4-47
Glove compartment............................ 4-51
Cargo bed .......................................... 4-53
Front and rear shock absorber
adjustment ....................................... 4-59
Trailer hitch bracket ........................... 4-63
Auxiliary DC jack ................................ 4-65
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
Tire wear limit..................................... 5-35
5
EE.book Page 1 Friday, August 4, 2006 12:02 PM

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
Cleaning the spark arrester ................ 8-77
Carburetor adjustment ........................ 8-81
Idle speed adjustment ........................ 8-83
Valve clearance .................................. 8-85
Front brake pad check ........................ 8-87
Rear brake pad check ........................ 8-89
Checking the brake fluid level............. 8-89
Brake fluid replacement ...................... 8-93
Checking the brake pedal ................... 8-95
Parking brake lever free play
adjustment ........................................ 8-97
Brake light switch adjustment ........... 8-101
8
EE.book Page 2 Friday, August 4, 2006 12:02 PM

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. _ EE.book Page 2 Friday, August 4, 2006 12:02 PM

4-5
1.
On-Command 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. On-Command four-wheel-drive/differential gear lock indicator
“”/“”
8. Coolant temperature warning light “”
1. Témoin de commande 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 de commande de transmission quatre roues motrices/blocage
du différentiel “”/“”
8. Témoin d’alerte de la température du liquide de refroidissement “”
1. Luz indicadora del interruptor manual de 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. Indicador de interruptor manual de tracción en las cuatro ruedas/
bloqueo del diferencial “”/“”
8. Luz de aviso de la temperatura del líquido refrigerante “”
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
EVU00150
Indicator and warning lights
EVU01131
On-Command four-wheel-drive/differential
gear lock indicator “”/“”
The On-Command four-wheel-drive indicator “”
comes on when the On-Command four-wheel-
drive switch is set to the “4WD” position.
The On-Command differential gear lock indicator
“” in the On-Command four-wheel-drive indica-
tor also comes on when the On-Command differ-
ential gear lock switch is set to the “LOCK”
position.NOTE:

Due to the synchronizing mechanism in the dif-
ferential gear case, the four-wheel-drive indica-
tor may not come on until the vehicle starts
moving.


When the On-Command differential gear lock
switch is set to “LOCK”, the indicator “” will
flash until the differential gear is locked.
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
EE.book Page 5 Friday, August 4, 2006 12:02 PM

4-7
1.
On-Command 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. On-Command four-wheel-drive/differential gear lock indicator
“”/“”
8. Coolant temperature warning light “”
1. Témoin de commande 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 de commande de transmission quatre roues motrices/blocage
du différentiel “”/“”
8. Témoin d’alerte de la température du liquide de refroidissement “”
1. Luz indicadora del interruptor manual de 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. Indicador de interruptor manual de tracción en las cuatro ruedas/
bloqueo del diferencial “”/“”
8. Luz de aviso de la temperatura del líquido refrigerante “”
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
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.
EVU00170
Neutral indicator light “N”
This indicator light comes on when the drive select
lever is in the “N” position.
EVU00161
Reverse indicator light “R”
This indicator light comes on when the drive select
lever is in the “R” reverse position.
Furthermore, this indicator light flashes when the
engine is being raced for 10 seconds or more.NOTE:_ If the indicator light flashes under any other cir-
cumstances or the speedometer does not show
the speed while riding, have a Yamaha dealer
check the speed sensor circuit._
EE.book Page 7 Friday, August 4, 2006 12:02 PM

4-9
1.
On-Command 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. On-Command four-wheel-drive/differential gear lock indicator
“”/“”
8. Coolant temperature warning light “”
1. Témoin de commande 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 de commande de transmission quatre roues motrices/blocage
du différentiel “”/“”
8. Témoin d’alerte de la température du liquide de refroidissement “”
1. Luz indicadora del interruptor manual de 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. Indicador de interruptor manual de tracción en las cuatro ruedas/
bloqueo del diferencial “”/“”
8. Luz de aviso de la temperatura del líquido refrigerante “”
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
EVU00210
Parking brake indicator light “P”
This indicator light comes on when the parking
brake is applied.
EVU01161
On-Command differential gear lock indicator
light “DIFF. LOCK”
This indicator light and the On-Command differen-
tial gear lock indicator in the display come on when
the On-Command differential gear lock switch is
set to the “LOCK” position.NOTE:When the switch is set to “LOCK”, the On-Com-
mand differential gear lock indicator light will flash
until the differential gear is locked.
EE.book Page 9 Friday, August 4, 2006 12:02 PM

4-11
1.
On-Command 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. On-Command four-wheel-drive/differential gear lock indicator
“”/“”
8. Coolant temperature warning light “”
1. Témoin de commande 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 de commande de transmission quatre roues motrices/blocage
du différentiel “”/“”
8. Témoin d’alerte de la température du liquide de refroidissement “”
1. Luz indicadora del interruptor manual de 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. Indicador de interruptor manual de tracción en las cuatro ruedas/
bloqueo del diferencial “”/“”
8. Luz de aviso de la temperatura del líquido refrigerante “”
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
EVU00181
Coolant temperature warning light “”
When the coolant temperature reaches a specified
level, this light comes on to warn that the coolant
temperature is too hot. If the light comes on during
operation, stop the engine as soon as it is safe to
do so and allow the engine to cool down for about
10 minutes. (See page 8-140.)CAUTION:_

The engine may overheat if the vehicle is
overloaded. If this happens, reduce the
load to specification.


After restarting, make sure that the light is
out. Continuous use while the light is on
may cause damage to the engine.
_
EE.book Page 11 Friday, August 4, 2006 12:02 PM

4-23 1. On-Command four-wheel-drive switch “2WD”/“4WD”
2. On-Command differential gear lock switch “4WD”/”LOCK”
1. Contacteur de commande du mode de traction “2WD”/“4WD”
2. Commutateur de blocage du différentiel “4WD”/”LOCK”
1. Selector de tracción integral “2WD”/“4WD”
2. Interruptor manual de bloqueo del diferencial “4WD”/”LOCK”
EVU01273
On-Command four-wheel-drive and differential
gear lock switches
This vehicle is equipped with an On-Command
four-wheel-drive switch “2WD”/“4WD” and a differ-
ential gear lock switch “4WD”/“LOCK”. Select the
appropriate drive according to terrain and the con-
ditions.

Two-wheel drive (“2WD”): Power is supplied to
the rear wheels only.


Four-wheel drive (“4WD”): Power is supplied to
the rear and front wheels.


Four-wheel drive with the differential gear
locked (“4WD-LOCK”): Power is supplied to the
rear and front wheels when the differential gear
is locked (“DIFF.LOCK”). Unlike the 4WD
mode, all wheels turn at the same speed re-
gardless of traction.
EE.book Page 23 Friday, August 4, 2006 12:02 PM