2007 YAMAHA RHINO 660 engine

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

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.
EE.book Page 9 Friday, August 4, 2006 12:02 PM

2-13
WARNING


Always turn off the engine when refueling.


Do not refuel right after the engine has
been running and is still very hot.


Do not spill gasoline on the engine or ex-
haust pipe/muffler when refueling. Never
refuel while smoking, or while in the vicini-
ty of sparks, open flames, or other sources
of ignition such as the pilot lights of water
heaters and clothes dryers. Gasoline can
catch fire and you could be burned.


When transporting the vehicle in another
vehicle, be sure it is kept in an upright po-
sition. Otherwise, fuel may leak out of the
carburetor or fuel tank.


Gasoline is poisonous. If you should swal-
low some gasoline or inhale a lot of gaso-
line vapor, or get some gasoline in your
eyes, see your doctor immediately. If gaso-
line spills on your skin, wash with soap
and water. If gasoline spills on your cloth-
ing, change your clothes.
EE.book Page 13 Friday, August 4, 2006 12:02 PM

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 levers
13. Spark arrester
14. Passenger seat belt
15. Passenger seat
16. Oil filter cartridge
17. Engine oil dipstick
18. Battery
19. Fuses
20. Coolant reservoir
21. Radiator cap
22. Fuel tank cap
EE.book Page 1 Friday, August 4, 2006 12:02 PM

4-1 1. Main switch a. OFF b. ON c. START
1. Contacteur à cléa. OFF (arrêt)
b. ON (marche) c. START (mise en marche)
1. Interruptor principal a. OFF (desconectado)
b. ON (contacto) c. START (arranque)
EVU00130
1-CONTROL FUNCTIONS
EVU00140
Main switch
Functions of the respective switch positions are as
follows:
ON:
All electrical circuits are supplied with power, and
the headlights and taillights come on when the
light switch is on.
OFF:
All electrical circuits are switched off. The key can
be removed in this position.
START:
The electric starter is engaged by turning and
holding the key in this position. Release the key
when the engine starts.
EE.book Page 1 Friday, August 4, 2006 12:02 PM

4-3
CAUTION:_

Do not operate the electric starter continu-
ously for more than 5 seconds, or starter
damage could occur. Wait at least 5 sec-
onds between each operation of the elec-
tric starter to let it cool.


Do not turn the key to the “START” posi-
tion with the engine running, or damage to
the electric starter can result.


See starting instructions prior to starting
the engine. (See pages 6-3–6-7 for details.)
_
EE.book Page 3 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