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User Manual: Yamaha Rhino-450-Owners-Manual

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2P5-F8199-12LIT-11626-21-21

READ THIS MANUAL CAREFULLY!

It contains important safety information.

YXR45FX

OWNER’S MANUAL

DIC2342

EBU00776

EVU00010

INTRODUCTION

Congratulations on your purchase of the Yamaha YXR45FX. 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 crafts-

manship and reliability that have made Yamaha a leader in these fields.

This manual will provide you with a good basic understanding of the features and operation of this

vehicle. It also includes basic maintenance and inspection procedures. If you have any questions

regarding the operation or maintenance of your vehicle, please consult a Yamaha dealer.

WARNING

Please read this manual carefully before operating 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 maintenance, along with good operating tech-

niques, will help ensure that you safely enjoy the capabilities and reliability of this vehicle.

EE.book Page 1 Friday, August 3, 2007 11:59 AM

EVU00021

IMPORTANT MANUAL INFORMATION

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SE-

RIOUS INJURY OR DEATH.

Particularly important information is distinguished in this manual by the following notations:

subject to change without notice.

This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this

symbol to avoid possible injury or death.

WARNING A WARNING indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

EA NOTICE indicates special precautions that must be taken to

avoid damage to the vehicle or other property.

TIP A TIP provides key information to make procedures easier or clearer.

EE.book Page 1 Friday, August 3, 2007 11:59 AM

EVU00030

IMPORTANT NOTE ABOUT USE

●This vehicle is designed and manufactured for off-road use only. Use on public streets,

roads, or highways is not only illegal in most areas, it also increases the risk of an acci-

dent involving other vehicles. This vehicle does not meet federal motor vehicle safety

standards for on-road use.

●Check the laws and regulations in force before choosing where to operate this vehicle.

It is illegal to operate this vehicle on public lands where vehicles its size are prohibited.

●This vehicle complies with almost all state off-highway noise level and spark arrester

laws and regulations.

YXR45FX

OWNER’S MANUAL

U.S.A.

1st edition, July 2007

authorized use without the written

permission of

Yamaha Motor Corporation,

U.S.A. is expressly prohibited.

Printed in U.S.A.

P/N LIT-11626-21-21

EE.book Page 2 Friday, August 3, 2007 11:59 AM

EVU00050

CONTENTS

LOCATION OF THE WARNING

AND SPECIFICATION LABELS....... 1-1

SAFETY INFORMATION.................. 2-1

DESCRIPTION ................................. 3-1

INSTRUMENT AND CONTROL

FUNCTIONS ..................................... 4-1

Main switch...................................... 4-1

Indicator and warning lights ............ 4-2

Indicator and warning lights

(Special Edition models) ............... 4-5

Multi-function meter unit

(Special Edition models) ............... 4-7

Switches ........................................ 4-10

................ 4-12

Brake pedal ................................... 4-12

Parking brake lever ....................... 4-13

Drive select lever........................... 4-14

Fuel tank cap................................. 4-14

Fuel level check window................4-15

Starter (choke) ..............................4-15

Doors..............................................4-16

Seats..............................................4-16

Seat belts .......................................4-17

Glove compartment .......................4-18

Cargo bed ......................................4-18

Front and rear shock absorber

adjustment ...................................4-20

Trailer hitch bracket and

receiver ........................................4-22

Auxiliary DC jack............................4-22

FOR YOUR SAFETY –

PRE-OPERATION CHECKS ............5-1

Front and rear brakes ......................5-3

Fuel ..................................................5-4

Engine oil .........................................5-6

Coolant.............................................5-7

Final gear oil ....................................5-7

Differential gear oil...........................5-7

Accelerator pedal.............................5-8

Seat belts .........................................5-8

EE.book Page 1 Friday, August 3, 2007 11:59 AM

Steering........................................... 5-8

Fittings and fasteners...................... 5-8

Lights............................................... 5-9

Switches.......................................... 5-9

Control cables ................................. 5-9

Tires ................................................ 5-9

OPERATION..................................... 6-1

Engine break-in............................... 6-1

Starting a cold engine ..................... 6-2

Starting a warm engine................... 6-5

Warming up..................................... 6-5

Drive select lever operation and

reverse driving............................... 6-6

On-Command four-wheel-drive

switch and differential gear lock

switch ............................................ 6-8

Parking .......................................... 6-10

................ 6-11

BASIC GUIDE FOR SAFE USE....... 7-1

KNOW YOUR VEHICLE................. 7-1

Driver requirements ........................ 7-2

Passenger requirements .................7-3

Occupant protection system............7-4

Protective structure..........................7-5

Seat belts.........................................7-6

Doors ............................................... 7-8

Passenger handholds......................7-9

Seat and hip restraints ..................7-10

Floorboard .....................................7-10

Steering wheel...............................7-11

LEARNING TO OPERATE

YOUR VEHICLE..........................7-12

Personal protective equipment......7-12

Practice for new Rhino users ........7-13

Getting ready to ride......................7-14

Turning...........................................7-14

Accelerating...................................7-15

Braking...........................................7-16

Engine braking...............................7-16

Leaving the vehicle........................7-16

Parking on a flat area ....................7-17

Parking on a slope.........................7-17

Loading..........................................7-17

EE.book Page 2 Friday, August 3, 2007 11:59 AM

Operation on different surfaces

and terrains.................................. 7-18

Hills................................................ 7-19

Uphill.............................................. 7-19

Downhill ......................................... 7-20

Rough terrain................................. 7-21

Pavement ...................................... 7-21

Water ............................................. 7-22

Loose terrain/slippery terrain......... 7-23

Brush or wooded areas ................. 7-23

Encountering obstacles................. 7-24

PERIODIC MAINTENANCE AND

ADJUSTMENT.................................. 8-1

Owner’s manual and tool kit............ 8-2

Periodic maintenance chart for the

emission control system................ 8-4

General maintenance and

................. 8-5

Hood ................................................ 8-7

Console ........................................... 8-9

Engine oil and oil filter cartridge .... 8-10

Final gear oil.................................. 8-15

Differential gear oil.........................8-17

Coolant...........................................8-19

Axle boots ......................................8-20

Spark plug inspection ....................8-21

Cleaning the air filter elements ......8-24

Drive select lever box check

hose .............................................8-29

V-belt cooling duct check hoses....8-29

V-belt case drain plug ....................8-30

Cleaning the spark arrester ...........8-31

Carburetor adjustment ...................8-32

Idle speed adjustment....................8-33

Valve clearance .............................8-33

Brakes............................................8-34

Front brake pad check...................8-34

Rear brake pad check....................8-35

Checking the brake fluid level........8-35

Brake fluid replacement.................8-36

Checking the brake pedal..............8-37

Parking brake lever free play

adjustment ...................................8-37

Brake light switch adjustment ........8-39

Cable inspection and lubrication....8-40

EE.book Page 3 Friday, August 3, 2007 11:59 AM

Brake pedal and accelerator

pedal lubrication.......................... 8-40

Rear knuckle upper and lower

pivot lubrication ........................... 8-41

Steering shaft lubrication .............. 8-41

Wheel removal .............................. 8-42

Tire replacement ........................... 8-42

Wheel installation.......................... 8-43

Battery........................................... 8-45

Battery maintenance..................... 8-46

Jump-starting ................................ 8-47

Fuse replacement ......................... 8-49

Replacing a headlight bulb ........... 8-51

Headlight beam adjustment.......... 8-53

Tail/brake light bulb

replacement ................................ 8-54

Troubleshooting ............................ 8-56

Troubleshooting charts ................. 8-57

CLEANING AND STORAGE............ 9-1

A. Cleaning...................................... 9-1

B. Storage ....................................... 9-2

SPECIFICATIONS ..........................10-1

CONSUMER INFORMATION ........11-1

Identification number records........11-1

NOISE REGULATION...................11-4

MAINTENANCE RECORD ...........11-5

YAMAHA MOTOR

CORPORATION, U.S.A.

SIDE × SIDE VEHICLE LIMITED

WARRANTY................................11-6

YAMAHA EXTENDED SERVICE

(Y.E.S.) ........................................11-7

EE.book Page 4 Friday, August 3, 2007 11:59 AM

1-1

EVU00060

LOCATION OF THE WARNING AND

SPECIFICATION LABELS

EE.book Page 1 Friday, August 3, 2007 11:59 AM

1-2

Read and understand all of the labels on your vehicle. They contain important information for safe

and proper operation of your vehicle.

Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a re-

placement label is available from your Yamaha dealer.

12 3

Any part of your

body (arms, legs,

or head) outside of

the vehicle can be

crushed by the

cage/frame.

If you think or feel

that the vehicle

may tip or roll,

brace your feet on

the floorboards,

and keep your

the

steering wheel.

Do not try to stop a

vehicle tipover

using your arm or

leg.

5B4-K7761-00

WARNING

Any part of your

body (arms, legs,

or head) outside of

the vehicle can be

crushed by the

cage/frame.

If you think or feel

that the vehicle

may tip or roll,

brace your feet on

the floorboards,

and keep your

handholds.

Do not try to stop a

vehicle tipover

using your arm or

leg.

5B4-K7762-00

WARNING

YAMAHA 5B4-K8483-00

Do not rest hands on door or hip restraint

bar. To avoid injury, keep hands completely

inside the vehicle by holding the steering

wheel or handholds.

WARNING

EE.book Page 2 Friday, August 3, 2007 11:59 AM

1-3

YAMAHA 5B4-F1696-00

WARNING

Keep hands, body, and other

people away from pinch points

when lowering bed. Do not hold

the cage/frame while closing bed.

YAMAHA 5B4-K7764-00

WARNING

EE.book Page 3 Friday, August 3, 2007 11:59 AM

1-4

YAMAHA 5B4-F4897-00

WARNING

YAMAHA 5UG-F151J-00

MAX 7.3 INCH

(185MM)

EE.book Page 4 Friday, August 3, 2007 11:59 AM

1-5

Secure load to prevent it

from shifting.

Never load more than 50 kg

(110 lb) tongue weight on

the towing bracket.

Do not tow more than 550

kg (1212 lb) rolling weight

(trailer plus cargo).

Tow or pull only from hitch

bracket.

Read Owner s Manual

pulling objects.

Improperly loading a trailer

or pulling an object can

affect handling, stability, and

risk of overturn or other

accidents.

YAMAHA 5B4-F151K-00

WARNING

YAMAHA 5B4-F1558-00

Head Helmet and eye protection.

Body Seatbelt and protective clothing.

Hands Inside vehicle and holding the

handholds or steering wheel.

Feet On floorboard, ready to brace,

and door closed.

EE.book Page 5 Friday, August 3, 2007 11:59 AM

1-6

•

DRIVER

UNDER

YAMAHA 5B4-F1568-01

WARNING

EE.book Page 6 Friday, August 3, 2007 11:59 AM

2-1

SAFETY INFORMATION

EVU00070

Be a responsible owner

As the vehicle’s owner, you are responsible for the safe and proper operation of your Rhino.

While understanding all parts of this manual are important for vehicle ownership, be sure to read

this chapter and the instructions in Chapter 7 before operating the Rhino. Also use these two

chapters and the labels on the vehicle to instruct new operators and passengers. Do not allow

anyone else to operate your vehicle or ride as a passenger if you are unsure that he/she is willing

and able to follow these instructions.

Get to know your vehicle

This off-road vehicle will handle and maneuver differently from cars, ATVs, go-carts, golf-cars and

grounds-keeping vehicles. Follow these instructions to reduce your risk of an accident and to re-

duce the risk of serious injury or death in the event of an accident.

EE.book Page 1 Friday, August 3, 2007 11:59 AM

2-2

Before you operate the Rhino

●Prepare yourself and your passenger:

•This vehicle is intended for use only by an operator 16 or older with a valid motor vehicle li-

cense.

•This vehicle is designed to carry the driver and one passenger. Never carry passengers in

the cargo bed.

•Both driver and passenger should wear seat belts properly.

•Both driver and passenger must be able to put both feet flat on the floorboard while seated

upright with their backs against the seat backs. Passenger must be able to reach and hold

the handholds within the cage/frame.

•Both driver and passenger should wear an approved motorcycle helmet that fits properly.

Both driver and passenger should also wear eye protection (goggles or a face shield),

ots, long-sleeved shirt or jacket, and long pants.

•Do not drive or ride as passenger after using drugs or alcohol.

DRIVER

UNDER

EE.book Page 2 Friday, August 3, 2007 11:59 AM

2-3

Prepare your vehicle

Perform the pre-operation checks each time you use the vehicle to make sure it is in safe operat-

ing condition. Failure to inspect or maintain the vehicle properly increases the possibility of an ac-

cident or equipment damage. See pages 5-1–5-2 for a list of pre-operation checks.

Prepare your load or trailer

Carrying loads, towing a trailer, or pulling objects can affect handling, stability, and risk of overturn

or other accidents.

•Read Chapter 6 before loading, towing, or pulling objects.

•Do not overload the vehicle or trailer. Refer to label in cargo bed for cargo bed load limit. Re-

fer to label next to hitch for tongue weight and trailer load limits.

•Keep weight in the cargo bed centered side to side, and as low and as far forward as pos-

sible.

•Secure cargo so that it will not shift – a loose load could change handling unexpectedly or be

thrown forward and strike occupants.

EE.book Page 3 Friday, August 3, 2007 11:59 AM

2-4

While using the Rhino

●Keep your body completely inside the vehicle at all times. Keep both hands on the steering

wheel. Be sure passenger is seated, belted, and holding onto the handholds. Close doors be-

fore driving. Any part of your body (arms, legs, and head) outside the vehicle can be struck by

objects your vehicle is passing or crushed by the vehicle cage/frame in a rollover accident.

●Watch for branches, brush, or other hazards that could enter the vehicle.

●Abrupt maneuvers or aggressive driving, even on flat, open areas, can cause loss of control,

including rollovers. The Rhino has higher ground clearance and other features to handle rug-

ged terrain, and, as a result, can overturn in situations where some other vehicles may not.

EE.book Page 4 Friday, August 3, 2007 11:59 AM

2-5

●Avoid rollovers:

•Use care when turning:

•Turning the steering wheel too far or too fast can result in a rollover.

•Avoid sideways sliding, skidding, or fishtailing, and never do donuts.

•Slow down before entering a turn and avoid hard braking in a turn.

•When making tight turns from a stop or at slow speeds, avoid sudden or hard accelera-

tion.

EE.book Page 5 Friday, August 3, 2007 11:59 AM

2-6

•Drive straight up and down inclines, not across them. If crossing a hill is unavoidable, drive

slowly and turn downhill immediately if you feel the vehicle may tip.

•Avoid paved surfaces. Turn gradually and go slowly if you must drive on pavement. This ve-

hicle is designed for off-road use only.

●If you think or feel that the vehicle may tip or roll, keep your body completely inside the protec-

tive structure of the vehicle:

•Brace yourself by pressing your feet firmly on the floorboards and keep a firm grip on the

steering wheel or handholds.

•Do not put your hands or feet outside of the vehicle for any reason. Your arm or leg could be

crushed.

•Do not try to stop a vehicle tipover using your arm or leg.

●Do not operate this vehicle on any public street, road, or highway, even if dirt or gravel.

●Do not operate the vehicle in fast-flowing water or water deeper than 33 cm (13 in). If you must

cross shallow, slow-moving water, choose your path carefully to avoid sharp drop-offs, large

rocks, or slippery surfaces. Operating this vehicle through deep or fast-flowing water can lead

to loss of control or overturn. To reduce your risk of drowning or other injuries, use care when

crossing through water.

EE.book Page 6 Friday, August 3, 2007 11:59 AM

2-7

●When loaded with cargo or towing a trailer:

•Reduce speed, operate in low gear only, and allow more room to stop.

•Avoid hills and rough terrain. Use extreme caution when towing or carrying a load on in-

clines.

•Load trailer properly and use extra care when towing or pulling.

●Do not tow or pull objects from any part of the vehicle other than the trailer hitch bracket or

winch (if installed).

EE.book Page 7 Friday, August 3, 2007 11:59 AM

2-8

Avoid carbon monoxide poisoning

All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can

cause headaches, dizziness, drowsiness, nausea, confusion, and eventually death.

Carbon monoxide is a colorless, odorless, tasteless gas which may be present even if you do not

see or smell any engine exhaust. Deadly levels of carbon monoxide can collect rapidly and you

can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide

can linger for hours or days in enclosed or poorly-ventilated areas. If you experience any symp-

toms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDI-

CAL TREATMENT.

●Do not run engine indoors. Even if you try to ventilate engine exhaust with fans or open win-

dows and doors, carbon monoxide can rapidly reach dangerous levels.

●Do not run engine in poorly ventilated or partially enclosed areas such as barns, garages, or

carports.

●Do not run engine outdoors where engine exhaust can be drawn into a building through open-

ings such as windows and doors.

EE.book Page 8 Friday, August 3, 2007 11:59 AM

2-9

Genuine Yamaha Accessories

Choosing accessories for your Rhino is an important decision. Genuine Yamaha Accessories,

which are available only from a Yamaha dealer, have been designed, tested, and approved by

Yamaha for use on your Rhino.

Many companies with no connection to Yamaha manufacture parts and accessories or offer other

modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these af-

termarket companies produce. Therefore, Yamaha can neither endorse nor recommend the use

of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha,

even if sold and installed by a Yamaha dealer.

Aftermarket parts, accessories, and modifications

While you may find aftermarket products similar in design and quality to genuine Yamaha Acces-

sories, recognize that some aftermarket accessories or modifications are not suitable because of

potential safety hazards to you or others. Installing aftermarket products or having other modifica-

tions performed to your Rhino that change any of the vehicle’s design or operation characteristics

can put you and others at greater risk of serious injury or death. You are responsible for injuries

related to changes in the vehicle.

EE.book Page 9 Friday, August 3, 2007 11:59 AM

2-10

Aftermarket tires and rims

The tires and rims that came with your Rhino were designed to match the performance capabili-

ties and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes,

and combinations may not be appropriate. Refer to pages 8-42–8-44 for tire specifications and

more information on replacing your tires.

EE.book Page 10 Friday, August 3, 2007 11:59 AM

3-1

EVU00080

DESCRIPTION

1. Headlights

2. Front shock absorber assembly spring preload adjusting ring

3. Brake fluid reservoir

4. Air filter elements (engine and air intake duct)

5. V-belt case

8. Cargo bed

9. Tail/brake lights

10. Rear shock absorber assembly spring preload adjusting ring

11. Cargo bed release levers

12. Spark plug

13. Door

14. Spark arrester

15. Passenger seat belt

16. Passenger seat

17. Oil filter cartridge

18. Passenger handhold

19. Engine oil filler cap

20. Battery

21. Fuses

22. Coolant reservoir

23. Radiator cap

24. Fuel level check window

25. Fuel tank cap

IHEJKLM

NCO

EE.book Page 1 Friday, August 3, 2007 11:59 AM

3-2

26. Light switch

27. Steering wheel

28. Starter (choke)

29. Main switch

30. On-Command four-wheel-drive and differential gear lock switches

31. Indicator and warning lights

32. Multi-function meter unit (Special Edition models)

33. Auxiliary DC jack

34. Drive select lever

36. Accelerator pedal

37. Brake pedal

The vehicle you have purchased may differ

slightly from those shown in the figures of this

manual.

[Z Y H

PQ RST UV W X

EE.book Page 2 Friday, August 3, 2007 11:59 AM

4-1

EVU00130

INSTRUMENT AND CONTROL

FUNCTIONS

EVU00140

Main switch

1. Main switch

Functions of the respective switch positions

are as follows:

ON:

All electrical circuits are supplied with

power, and the headlights and tail-

lights come on when the light switch is

on.

OFF:

All electrical circuits are switched off.

The key can be removed in this posi-

tion.

START:

The electric starter is engaged by

turning and holding the key in this po-

sition. Release the key when the en-

gine starts.

OFF

START

EE.book Page 1 Friday, August 3, 2007 11:59 AM

4-2

Indicator and warning lights

1. Parking brake indicator light “P”

2. Reverse indicator light “R”

3. Neutral indicator light “N”

4. On-Command four-wheel-drive indicator light “”

5. On-Command differential gear lock indicator light “”

6. Coolant temperature warning light “”

EVU00210

Parking brake indicator light “P”

This indicator light comes on when the park-

ing brake is applied.

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.

If the indicator light flashes under any other

circumstances, have a Yamaha dealer check

the speed sensor circuit.

EVU00170

Neutral indicator light “N”

This indicator light comes on when the drive

select lever is in the “N” position.

DIFF.

LOCK

EE.book Page 2 Friday, August 3, 2007 11:59 AM

4-3

On-Command four-wheel-drive indicator

light “”

This indicator light comes on when the

On-Command four-wheel-drive switch is in

the “4WD” position.

Due to the synchronizing mechanism in the

differential gear case, the light may not come

on until the vehicle starts moving.

On-Command differential gear lock indica-

tor light “”

This indicator light comes on when the

On-Command differential gear lock switch is

set to the “LOCK” position.

EVU00181

Coolant temperature warning light “”

If the coolant temperature reaches a specified

level, this light comes on to warn that the cool-

ant 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 8-58.)

NOTICE

●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.

DIFF.

LOCK

EE.book Page 3 Friday, August 3, 2007 11:59 AM

4-4

Coolant temperature warning light checking method

Turn the main switch to “ON”.

Coolant temperature warning

light does not come on.

Coolant temperature

warning light comes on.

Coolant temperature

warning light does not

come on.

Coolant temperature and

electrical circuit are OK.

Turn the main switch to “START” with

the transmission in the neutral position.

Ask a Yamaha dealer to

inspect the electrical circuit.

Coolant temperature

warning light comes on

momentarily.

EE.book Page 4 Friday, August 3, 2007 11:59 AM

4-5

EVU00150

Indicator and warning lights

(Special Edition models)

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

8. Coolant temperature warning light “”

EVU01131

On-Command differential gear lock indica-

tor light “DIFF. LOCK”

This indicator light and the On-Command dif-

ferential gear lock indicator in the display

come on when the On-Command differential

gear lock switch is set to the “LOCK” position.

When the switch is set to “LOCK”, the On-

Command differential gear lock indicator light

will flash until the differential 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.

EE.book Page 5 Friday, August 3, 2007 11:59 AM

4-6

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.

If the indicator light flashes under any other

circumstances or the speedometer does not

show the speed while riding, have a Yamaha

dealer check the speed sensor circuit.

EVU00210

“P”

This indicator light comes on when the park-

ing brake is applied.

EVU01161

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” posi-

tion.

The On-Command differential gear lock indi-

cator “” in the On-Command four-wheel-

drive indicator also comes on when the On-

Command differential gear lock switch is set

to the “LOCK” position.

●Due to the synchronizing mechanism in the

differential gear case, the four-wheel-drive

indicator 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 6 Friday, August 3, 2007 11:59 AM

4-7

EVU00181

Coolant temperature warning light “”

If the coolant temperature reaches a specified

level, this light comes on to warn that the cool-

ant 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 8-58.)

●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.

EVU01630

Multi-function meter unit

(Special Edition models)

1. Speedometer 2. Fuel meter

3. “H” button 4. “M” button

5. Clock/Hour meter

6. Odometer/Tripmeter A/Tripmeter B

7. “TRIP/ODO” button 8. Clock/Hour button “/”

The multi-function meter unit is equipped with

the following:

●a speedometer (which shows the riding

speed)

●an odometer (which shows the total dis-

tance traveled)

EE.book Page 7 Friday, August 3, 2007 11:59 AM

4-8

●two tripmeters (which show the distance

traveled since they were last set to zero)

●a clock

●an hour meter (which shows the total time

the key has been turned to “ON”)

●a fuel meter

Odometer and tripmeter modes

Pushing the “TRIP/ODO” button switches the

display between the odometer mode “ODO”

and the tripmeter modes “A” and “B” in the fol-

lowing order:

ODO → TRIP A → TRIP B → ODO

To reset a tripmeter, select it by pushing the

“TRIP/ODO” button, and then hold the “TRIP/

ODO” button for at least three seconds. The

tripmeters can be used to estimate the dis-

tance that can be traveled with a full tank of fu-

el. This information will enable you to plan

future fuel stops.

Holding in the “TRIP/ODO” button and then

turning the key to “ON” switches the display

between “mph” and “km/h”.

EE.book Page 8 Friday, August 3, 2007 11:59 AM

4-9

Clock mode

Pushing the “/” button switches the dis-

play between the clock mode “CLOCK” and

the hour meter mode “HOUR” in the following

order:

CLOCK → HOUR → CLOCK

To set the clock

1. Set the display to the clock.

2. Push the “/” button until the clock

starts flashing.

3. Set the hours by pushing the “H” button.

4. Set the minutes by pushing the “M” but-

ton.

5. Push the “/” button, and then re-

lease it to start the clock.

Fuel meter

The fuel meter indicates the amount of fuel in

the fuel tank. The display segments of the fuel

meter disappear from “F” (full) towards “E”

(empty) as the fuel level decreases. When the

“E” segment disappears and the fuel level

warning indicator flashes, refuel as soon as

possible.

1. Fuel level warning indicator

2. Fuel meter 3. “E” segment

EE.book Page 9 Friday, August 3, 2007 11:59 AM

4-10

EVU00230

Switches

EVU00240

Light switch “OFF/ / ”

1. Light switch “OFF/ / ”

Set the switch to “” to turn on the low beam

and the taillights.

Set the switch to “” to turn on the high

beam and the taillights.

off all the lights.

Do not use the headlights with the engine

turned off for an extended period of time.

The battery may discharge to the point

that the starter motor will not operate

properly. If this should happen, remove

the battery and recharge it.

EE.book Page 10 Friday, August 3, 2007 11:59 AM

4-11

EVU01183

On-Command four-wheel-drive and differ-

ential gear lock switches

1. On-Command four-wheel-drive switch “2WD”/“4WD”

2. On-Command differential gear lock switch “4WD”/“LOCK”

This vehicle is equipped with an On-Com-

mand four-wheel-drive switch “2WD”/“4WD”

and a differential gear lock switch “4WD”/

“LOCK”. Select the appropriate drive accord-

●Two-wheel drive (“2WD”): Power is sup-

plied to the rear wheels only.

●Four-wheel drive (“4WD”): Power is sup-

plied 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 with the differ-

ential gear locked. Unlike the 4WD mode,

all wheels turn at the same speed regard-

less of traction.

EE.book Page 11 Friday, August 3, 2007 11:59 AM

4-12

EVU00260

Accelerator pedal

Press the accelerator pedal down to increase

engine speed. Spring pressure returns the

pedal to the rest position when released. Al-

ways check that the accelerator pedal returns

normally before starting the engine.

1. Accelerator pedal

EVU00270

Brake pedal

Press the brake pedal to slow or stop the ve-

hicle.

1. Brake pedal

EE.book Page 12 Friday, August 3, 2007 11:59 AM

4-13

EVU00280

Parking brake lever

The parking brake lever is located at the right

side of the driver’s seat. It will help keep the

vehicle from moving while parked.

To set the parking brake, pull the lever up

completely.

To release the parking brake, pull up on the

lever, press the release button, and then push

the lever all the way down.

Spring pressure helps return the lever to the

released position. 1. Parking brake lever 2. Release button

EE.book Page 13 Friday, August 3, 2007 11:59 AM

4-14

EVU00290

Drive select lever

The drive select lever is used to shift the vehi-

cle into the low, high, neutral, and reverse po-

sitions. (Refer to pages 6-6–6-7 for the drive

select lever operation.)

1. Drive select lever

EVU00300

Fuel tank cap

Remove the fuel tank cap by turning it coun-

terclockwise.

1. Fuel tank cap

EE.book Page 14 Friday, August 3, 2007 11:59 AM

4-15

Fuel level check window

The amount of fuel in the fuel tank can be

checked through the fuel level check window.

If the fuel level is low, refuel as soon as possi-

ble.

1. Fuel level check window

EVU00320

Starter (choke) “”

Starting a cold engine requires a richer air-fuel

mixture. A separate starter circuit supplies this

mixture.

Move in direction a to turn on the starter

(choke).

Move in direction b to turn off the starter

(choke).

Refer to “Starting a cold engine” for proper op-

eration. (See pages 6-2–6-5.)

A. Starter (choke) “” 1. Fully open

2. Half open 3. Closed

EE.book Page 15 Friday, August 3, 2007 11:59 AM

4-16

Doors

To open a door, simply pull the latch outward.

To close a door, push or pull the door inward

until it is securely latched. Be sure the door is

SECURELY LATCHED AFTER CLOSING IT.

1. Latch 2. Door

EVU00330

Seats

To remove a seat, pull its seat lock lever up-

ward, lift the front of the seat, and then slide

the seat forward and up.

1. Driver seat 2. Passenger seat

3. Seat lock lever (× 2)

EE.book Page 16 Friday, August 3, 2007 11:59 AM

4-17

To install a seat, insert the projections on the

rear of the seat into the seat holders and push

down on the seat at the front. Make sure the

seats are securely latched. WARNING! A

loose seat could cause the operator to

lose control, or cause the operator or pas-

senger to fall.

EVU00340

Seat belts

This vehicle is equipped with three-point seat

belts for both the operator and the passenger.

Always wear the seat belts properly while

riding in the vehicle. See pages 7-6–7-8 for

more information.

EE.book Page 17 Friday, August 3, 2007 11:59 AM

4-18

EVU01191

Glove compartment

NOTICE

To protect from damage, do not put metal

products, like tools or sharply edged prod-

ucts, directly in the glove compartment. If

they must be stored, wrap them in appro-

priate cushioning material.

EVU00351

Cargo bed

1. Cargo bed 2. Tailgate

3. Cargo hook (× 4)

For additional loading information, see pages

6-11–6-13.

Maximum load limit: 181 kg (400 lb)

EE.book Page 18 Friday, August 3, 2007 11:59 AM

4-19

Opening and closing the tailgate

1. Tailgate 2. Latch (× 2)

To open

Unhook the latches, and then lower the tail-

gate.

To close

Place the tailgate in the original position, and

Lifting and lowering the cargo bed

1. Cargo bed release lever

To lift

Push down the cargo bed release lever on the

left or right side of the vehicle, and then slowly

lift up the cargo bed until it stops.

EE.book Page 19 Friday, August 3, 2007 11:59 AM

4-20

To lower

With hands and fingers clear of pinch points,

lower the cargo bed slowly to its original posi-

tion and be sure it is locked into place.

WARNING! Keep hands, body, and other

people away from pinch points when low-

ering bed. Do not hold onto the cage/frame

while closing the bed.

EVU00360

Front and rear shock absorber adjustment

The spring preload can be adjusted to suit the

operating conditions. You can reduce preload

for a softer ride, or increase preload if frequent

bottoming occurs or when carrying loads.

WARNING

Always adjust the shock absorbers on the

left and right sides to the same setting. Un-

even adjustment can cause poor handling

and loss of stability, which could lead to

an accident.

NOTICE

Frequent or severe bottoming can cause

increased wear or damage to the vehicle.

EE.book Page 20 Friday, August 3, 2007 11:59 AM

4-21

Adjust the spring preload as follows:

To increase the spring preload, turn the ad-

justing ring in direction a.

To decrease the spring preload, turn the ad-

justing ring in direction b.

1. Spring preload adjusting ring

2. Position indicator

A special wrench can be obtained at a

Yamaha dealer to make this adjustment.

1. Special wrench

Standard position: B

A- Minimum (soft)

E- Maximum (hard)

EE.book Page 21 Friday, August 3, 2007 11:59 AM

4-22

EVU00370

Trailer hitch bracket and receiver

This vehicle is equipped with a trailer hitch

bracket and a 5 cm (2 in) receiver for a stan-

dard trailer hitch. Trailer towing equipment

can be obtained at a Yamaha dealer. (See

pages 6-11–6-13 for precaution information.)

1. Trailer hitch bracket 2. Receiver

EVU00380

Auxiliary DC jack

The auxiliary DC jack is located at the right

side of the front panel. The auxiliary DC jack

can be used for suitable work lights, radios,

etc. The auxiliary DC jack should only be used

when the engine is running.

1. Auxiliary DC jack cap

1. Set the light switch to “OFF”.

2. Start the engine. (See pages 6-2–6-5.)

3. Open the auxiliary DC jack cap, and then

insert the accessory power plug into the

jack.

EE.book Page 22 Friday, August 3, 2007 11:59 AM

4-23

1. Auxiliary DC jack

4. When the auxiliary DC jack is not being

used, cover it with the cap.

●Do not use accessories requiring more

than the maximum capacity stated

above. This may overload the circuit

and cause the fuse to blow.

●If accessories are used without the en-

gine running, the battery will lose its

charge and engine starting may become

difficult.

●Do not use an automotive cigarette

lighter or other accessories with a plug

that gets hot, because the jack can be

damaged.

Maximum rated capacity for the auxiliary

DC jack:

DC 12 V, 120 W (10 A)

EE.book Page 23 Friday, August 3, 2007 11:59 AM

5-1

EVU01200

FOR YOUR SAFETY – PRE-OPERATION CHECKS

Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in the Own-

er’s Manual.

WARNING

Failure to inspect or maintain the vehicle properly increases the possibility of an accident

or equipment damage. Do not operate the vehicle if you find any problem. If a problem

cannot be corrected by the procedures provided in this manual, have the vehicle inspect-

ed by a Yamaha dealer.

Before using this vehicle, check the following points:

ITEM ROUTINE PAGE

Brakes •Check operation, free play, fluid level, and fluid leakage.

•Fill with DOT 4 brake fluid if necessary. 5-3, 8-34–8-37, 8-39

Parking brake •Check for proper operation, condition, and free play. 8-37–8-38

Fuel •Check fuel level.

h fuel if necessary. 5-4–5-5

Engine oil •Check oil level.

•Fill with oil to proper level if necessary. 5-6, 8-10–8-14

Coolant reservoir •Check coolant level.

•Fill with coolant if necessary. 5-7, 8-19–8-20

EE.book Page 1 Friday, August 3, 2007 11:59 AM

5-2

Final gear oil/

Differential gear oil •Check for leakage. 5-7, 8-15–8-18

Accelerator pedal •Check for proper accelerator pedal operation. 5-8

Seat belts •Check for proper operation and belt wear. 5-8

Steering •Check for proper operation. 5-8

Fittings and fasteners •Check all fittings and fasteners. 5-8

Lights and switches •Check for proper operation. 5-8, 8-51–8-55

Wheels and tires •Check tire pressure and for wear and damage. 5-9–5-11, 8-42–8-44

Axle boots •Check for damage. 8-20–8-21

ITEM ROUTINE PAGE

EE.book Page 2 Friday, August 3, 2007 11:59 AM

5-3

EVU00390

Front and rear brakes

Brake pedal

Check for correct brake pedal free play. If the

brake pedal free play is incorrect, have a

Yamaha dealer adjust it. (See page 8-37.)

Check the operation of the brake pedal. It

should move smoothly and there should be a

firm feeling when the brakes are applied. If

not, have the vehicle inspected by a Yamaha

dealer.

Brake fluid level

Check the brake fluid level. Add fluid if neces-

sary. (See pages 8-35–8-36.)

Brake fluid leakage

Check to see if any brake fluid is leaking out of

the pipe joints or the brake fluid reservoir. Ap-

ply the brakes firmly for one minute. If there is

any leakage, have the vehicle inspected by a

Yamaha dealer.

Brake operation

Check the operation of the brakes at the start

of every ride. Test the brakes at slow speed

after starting out to make sure they are work-

ing properly. If the brakes do not provide prop-

er braking performance, inspect the brake

system. (See pages 8-34–8-35, 8-37–8-39.)

Recommended brake fluid: DOT 4

EE.book Page 3 Friday, August 3, 2007 11:59 AM

5-4

EVU00400

Fuel

Make sure there is sufficient gasoline in the

tank.

WARNING

Gasoline and gasoline vapors are ex-

tremely flammable. To avoid fires and ex-

plosions and to reduce the risk of injury

when refueling, follow these instructions.

1. Before refueling, turn off the engine and

be sure that driver and passenger are

outside the vehicle.

Never refuel while smoking, or while in

the vicinity of sparks, open flames, or oth-

er sources of ignition such as the pilot

lights of water heaters and clothes dry-

ers.

. Because fuel

expands when it heats up, heat from the

engine or the sun can cause fuel to spill

out of the fuel tank.

3. Wipe up any spilled fuel immediately.

4. Be sure the fuel tank cap is closed se-

curely.

WARNING

Gasoline is poisonous and can cause inju-

ry or death. Handle gasoline with care.

Never siphon gasoline by mouth. If you

should swallow some gasoline or inhale a

lot of gasoline vapor, or get some gasoline

in your eyes, see your doctor immediately.

If gasoline spills on your skin, wash with

soap and water. If gasoline spills on your

clothing, change your clothes.

EE.book Page 4 Friday, August 3, 2007 11:59 AM

5-5

Your Yamaha engine has been designed to

use regular unleaded gasoline with a pump

octane number ([R+M]/2) of 86 or higher, or

research octane number of 91 or higher. If

knocking or pinging occurs, use a different

brand of gasoline or premium unleaded fuel.

Unleaded fuel will give you longer spark plug

life and reduced maintenance cost.

Gasohol

There are two types of gasohol: gasohol con-

taining ethanol and that containing methanol.

Gasohol containing ethanol can be used if

ethanol content does not exceed 10%. Gaso-

hol containing methanol is not recommended

by Yamaha because it may cause fuel system

damage or vehicle performance problems.

Portable gas containers

If you carry a portable gas can in the bed of

the Rhino, be sure to secure it with the cap

tightened before driving the vehicle.

Always place a portable gas container on the

ground before filling it. Before removing the

container cap, touch the container with the

gas dispenser nozzle. Keep gas dispenser

nozzle in contact with container inlet when fill-

ing. WARNING! Never refill a fuel container

in the bed of any vehicle. Fire may result

from a build-up of static electricity. The

discharge of this build-up while refueling

can cause a spark and ignite the gasoline.

Recommended fuel:

Unleaded gasoline only

Fuel tank capacity:

30.0 L (6.60 Imp gal, 7.93 US gal)

EE.book Page 5 Friday, August 3, 2007 11:59 AM

5-6

EVU00410

Engine oil

Make sure the engine oil is at the specified

level. Add oil as necessary. (See pages 8-10–

8-14.)

NOTICE

●In order to prevent clutch slippage

(since the engine oil also lubricates the

clutch), do not mix any chemical addi-

tives with oil. Do not use oils with a die-

sel specification of “CD” or oils of a

higher quality than specified. In addi-

tion, do not use oils labeled “ENERGY

CONSERVING II” or higher.

●Make sure that no foreign material en-

ters the crankcase.

1. “CD” specification 2. “ENERGY CONSERVING II”

Recommended engine oil type and

quantity:

See page 10-2.

EE.book Page 6 Friday, August 3, 2007 11:59 AM

5-7

EVU00420

Coolant

Check the coolant level in the coolant reser-

voir when the engine is cold (the coolant level

will vary with engine temperature).

The coolant level is satisfactory if it is between

the minimum and maximum level marks on

the coolant reservoir. If the coolant level is at

or below the minimum level mark, add addi-

tional coolant to bring the level up to maxi-

mum level mark. If coolant is not available,

add distilled water. Change the coolant every

two years. (See pages 8-19–8-20 for details.)

Hard water or salt water is harmful to the

engine. You may use soft water if you can-

not get distilled water.

EVU00430

Final gear oil

Make sure the final gear oil is at the specified

level. Add oil as necessary. (See pages 8-15–

8-16 for details.)

If desired, an SAE 80W90 hypoid gear oil may

be used for all conditions.

TIP

GL-4 is a quality and additive rating; GL-5 or

GL-6 rated hypoid gear oils may also be used.

EVU00440

Differential gear oil

Make sure the differential gear oil is at the

specified level. Add oil as necessary. (See

pages 8-17–8-18 for details.)

Coolant reservoir capacity

(up to the maximum level mark):

0.35 L (0.31 Imp qt, 0.37 US qt)

Recommended oil:

SAE 80 API GL-4 Hypoid gear oil

Recommended oil:

SAE 80 API GL-5 Hypoid gear oil

EE.book Page 7 Friday, August 3, 2007 11:59 AM

5-8

EVU00450

Accelerator pedal

Check to see that the accelerator pedal oper-

ates correctly. It must operate smoothly and

spring back to the idle position fully when re-

leased. Have a Yamaha dealer repair as nec-

essary for proper operation.

EVU00460

Seat belts

Make sure that the seat belts are not frayed,

torn, stretched, or damaged. Each seat belt

must move smoothly when pulled out and re-

tract on its own when released. It must also

lock up when quickly pulled out. The latch

plate should click securely into the buckle and

release when the release button is pushed

firmly. Wash off any dirt or mud that could af-

fect operation. Have a Yamaha dealer repair

as necessary for proper operation.

A crash can damage the restraint systems in

your vehicle. A damaged restraint system

may not properly protect the person using it,

resulting in serious injury or death in a crash.

To help make sure your restraint systems are

working properly after a crash, have them in-

spected and any necessary replacements

made as soon as possible.

EVU01230

Steering

Park on level ground. Turn the steering wheel

right and left. Check for excessive free play,

abnormal noises, or a rough feeling. Have a

Yamaha dealer repair as necessary for proper

operation.

EVU00470

Fittings and fasteners

Always check the tightness of chassis fittings

and fasteners before a ride. Take the vehicle

to a Yamaha dealer or refer to the Service

Manual for correct tightening torque.

EE.book Page 8 Friday, August 3, 2007 11:59 AM

5-9

EVU00480

Lights

Check the headlights and tail/brake lights to

make sure they are in working condition. Re-

pair as necessary for proper operation.

EVU00490

Switches

Check the operation of all switches. Have a

Yamaha dealer repair as necessary for proper

operation.

Control cables

When riding in cold weather, always make

sure all control cables work smoothly before

you begin riding. WARNING! Control cables

can freeze in cold weather and you could

be unable to control the vehicle.

EVU00500

Tires

Check tire pressure regularly to make sure it

is at the recommended specifications. Also

check for wear and damage.

EVU00510

Tire pressure

Use the tire pressure gauge to check and ad-

just tire pressures when the tires are cold. Tire

pressures must be equal on both sides.

WARNING! Operation of this vehicle with

improper tire pressure may cause severe

injury or death from loss of control or roll-

over. Tire pressure below the minimum

specified could also cause the tire to dis-

lodge from the rim under severe riding

conditions.

EE.book Page 9 Friday, August 3, 2007 11:59 AM

5-10

Set tire pressures to the following specifica-

tions:

ACE-02E

The tire pressure gauge is included as stan-

dard equipment. Make two measurements of

the tire pressure and use the second reading.

Dust or dirt in the gauge could cause the first

reading to be incorrect.

1. Tire pressure gauge

Recommended

pressure Minimum Maximum

Front

70 kPa

(0.70 kgf/cm2,

10 psi)

63 kPa

(0.63 kgf/cm2,

9 psi)

77 kPa

(0.77 kgf/cm2,

11 psi)

Rear

98 kPa

(0.98 kgf/cm2,

14 psi)

91 kPa

(0.91 kgf/cm2,

13 psi)

105 kPa

(1.05 kgf/cm2,

15 psi)

EE.book Page 10 Friday, August 3, 2007 11:59 AM

5-11

EVU00520

Tire wear limit

When the tire groove decreases to 3 mm

(0.12 in) due to wear, replace the tire.

a. Tire wear limit

EE.book Page 11 Friday, August 3, 2007 11:59 AM

6-1

EVU00530

OPERATION

Read the Owner’s Manual carefully to be-

come familiar with all controls. If there is a

control or function you do not understand, ask

your Yamaha dealer.

WARNING

Failure to familiarize yourself with the con-

trols can lead to loss of control, which

could cause an accident or injury.

Engine break-in

There is never a more important period in the

life of your vehicle than the period between

zero and 20 hours.

For this reason, we ask that you read the fol-

lowing material carefully. Because the engine

is brand new, you must not put an excessive

load on it for the first several hours of opera-

tion. During the first 20 hours, the various

parts in the engine wear and polish them-

selves to achieve the correct operating clear-

ances.

During this period, prolonged full-throttle oper-

ation or any condition that might result in ex-

cessive engine heating must be avoided.

However, momentary (2–3 seconds maxi-

mum) full-throttle operation under load does

not harm the engine.

EE.book Page 1 Friday, August 3, 2007 11:59 AM

6-2

Each full-throttle acceleration sequence

should be followed with a substantial rest pe-

riod for the engine, by cruising at lower r/min

so the engine can rid itself of the temporary

build-up of heat. If any abnormality is noticed

during this period, consult a Yamaha dealer.

0–10 hours:

Avoid continuous operation above half-throt-

tle. Allow a cooling-off period of five to ten

minutes after every hour of operation. Vary

the speed of the vehicle from time to time. Do

not operate it at one set throttle position.

10–20 hours:

Avoid prolonged operation above three-quar-

ter throttle.

The vehicle may now be operated normally.

EVU00540

Starting a cold engine

1. Apply the brake pedal.

2. Shift the drive select lever into the neutral

position.

●When the drive select lever is in the

neutral position, the neutral indicator

light should come on. If the neutral in-

dicator light does not come on, ask a

Yamaha dealer to inspect the electric

circuit.

●The engine can be started in any gear

if the brake is applied. However, it is

recommended to shift into neutral be-

fore starting the engine.

EE.book Page 2 Friday, August 3, 2007 11:59 AM

6-3

3. Use the starter (choke) in reference to

the figure:

Position 1: Cold engine start – ambient

temperature below 5 °C

(40 °F).

Position 2: Cold engine start – ambient

temperature at 0 °C (30

°F)–30 °C (90 °F) and

warming up position.

Position 3: Cold engine start – ambient

temperature above 25 °C

(80 °F) and warm engine

start position.

a. Starter (choke) 1. Fully open

2. Half open 3. Closed

4. With your foot off the accelerator pedal,

start the engine by turning the key to

“START”.

EE.book Page 3 Friday, August 3, 2007 11:59 AM

6-4

If the engine fails to start, release the key, and

then try starting it again. Wait a few seconds

before the next attempt. Each attempt should

be as short as possible, to preserve battery

energy. NOTICE: Do not crank the engine

more than 5 seconds on each attempt, or

starter damage could occur. Wait at least 5

seconds between each operation of the

electric starter to let it cool.

Do not turn the key to the “START” position

with the engine running, or damage to the

electric starter may result.

WARNING

The speed of a cold engine may increase

enough as it warms up to cause the vehi-

cle to move on its own while the choke is

being used. Do not get out of the vehicle

while the engine is running and the drive

select lever is in any gear.

Unwanted vehicle movement can cause

serious injury or death, and it may be dan-

gerous to try to stop the vehicle. The park-

ing brake may not keep the vehicle from

accelerating.

5. If the engine is started with the starter

(choke) in position 1, the starter (choke)

should be returned to position 2 to warm

up the engine. If the engine is started with

the starter (choke) in position 2, keep

the starter (choke) in this position to

warm up the engine.

EE.book Page 4 Friday, August 3, 2007 11:59 AM

6-5

6. With the vehicle still in neutral, continue

warming up the engine until it idles

smoothly, and return the starter (choke)

to position 3 before riding. Failure to do

so may result in poor performance and

premature wearing of the rear brake and

V-belt.

EVU00550

Starting a warm engine

To start a warm engine, refer to the “Starting a

cold engine” section. The starter (choke)

should not be used. Press the accelerator

pedal slightly.

EVU00561

Warming up

To get maximum engine life, always warm up

the engine before starting off. To see whether

or not the engine is warm, check for smooth

throttle response with the vehicle in neutral

and the starter (choke) turned off.

Never accelerate hard with a cold engine!

EE.book Page 5 Friday, August 3, 2007 11:59 AM

6-6

Drive select lever operation and reverse

driving

Do not shift without coming to a complete

stop and waiting for the engine to return to

normal idle speed. Damage to the engine

or drive train may occur.

Shifting: neutral to high and high to low

1. Stop the vehicle. Take your foot off the

accelerator pedal.

2. Apply the brake pedal, then shift by mov-

ing the drive select lever along the shift

guide. Make sure that the drive select le-

ver is completely shifted into position.

1. Drive select lever

3. Release the brake pedal and press the

accelerator pedal gradually.

EE.book Page 6 Friday, August 3, 2007 11:59 AM

6-7

Shifting: neutral to reverse

WARNING

Before you shift into reverse, make sure

there are no obstacles or people behind

you. When it is safe to proceed, go slowly.

Hitting an obstacle or person could result

in serious injury or death.

1. Stop the vehicle. Take your foot off the

accelerator pedal and check behind you.

2. Apply the brake pedal.

3. Shift from neutral to reverse or vice versa

by moving the drive select lever along the

shift guide.

●When in reverse, the reverse indicator

light should be on. Due to the synchro-

nizing mechanism in the engine, the

ntil the vehicle

starts moving.

●If the light does not come on, ask a

Yamaha dealer to inspect the reverse

indicator light electrical circuit.

1. Drive select lever

4. Check behind the vehicle for people or

obstacles, and then release the brake

pedal.

5. Press the accelerator pedal gradually

and continue to watch to the rear while

backing.

EE.book Page 7 Friday, August 3, 2007 11:59 AM

6-8

EVU01183

On-Command four-wheel-drive switch and

differential gear lock switch

You may notice that the vehicle handles dif-

ferently in 2WD, 4WD, and 4WD-LOCK

(“DIFF. LOCK”). For example, you should ex-

pect that the vehicle will require more effort to

turn in 4WD-LOCK (“DIFF. LOCK”). Always

stop the vehicle before changing between

2WD and 4WD or 4WD and 4WD-LOCK

(“DIFF-LOCK”).

1. Differential gear lock lever

2. On-Command four-wheel-drive switch “2WD”/“4WD”

“2WD”/“4WD”

To change from 2WD to 4WD, stop the vehi-

cle, and then set the switch to “4WD”. When

the vehicle is in 4WD, the four-wheel-drive in-

dicator light “” or, for Special Edition models,

the four-wheel-drive indicator “” will come

on in the multi-function display. To change

from 4WD to 2WD, stop the vehicle, be sure

the differential gear lock lever is set to

position a, and then set the switch to “2WD”.

EE.book Page 8 Friday, August 3, 2007 11:59 AM

6-9

On-Command differential gear lock switch

“4WD”/“LOCK”

1. On-Command differential gear lock switch “4WD”/“LOCK”

2. Differential gear lock lever

To lock the differential gear in 4WD, stop the

vehicle, make sure the On-Command four-

wheel-drive switch is set to “4WD”, move the

differential gear lock lever to position b, and

then set the switch to “LOCK”. When the dif-

ferential gear is locked, the differential gear

lock indicator light “” or, for special edition

modes, the differential gear lock indicator light

(“DIFF. LOCK”) will come on along with the

differential gear lock indicator “” in the

multi-function display. To release the differen-

tial gear lock, stop the vehicle and set the

switch to “4WD”.

●If the differential gear lock is not engaging

properly, turn the steering wheel back and

forth to help it engage.

●Driving before the differential gear lock is

properly engaged will cause the engine

speed to be limited until engagement is

complete.

DIFF.

LOCK

DIFF.

LOCK

EE.book Page 9 Friday, August 3, 2007 11:59 AM

6-10

For Special Edition models:

●When the switch is set to “LOCK”, the dif-

ferential gear lock indicator and indicator

light will flash until the differential gear is

locked.

●When the indicator and indicator light are

flashing, turning the steering wheel back

and forth will help the differential gear lock

to engage.

●Driving before the differential gear lock is

properly engaged (e.g., when the indicator

and indicator light are flashing) will cause

the engine speed to be limited until en-

gagement is complete.

EVU01210

Parking

When parking, stop the engine and shift the

drive select lever into the neutral position. Ap-

ply the parking brake to help prevent the vehi-

cle from rolling. See page 7-17 for more

information on parking and parking on a

slope.

EE.book Page 10 Friday, August 3, 2007 11:59 AM

6-11

EVU00630

Take extra precautions when driving with a

load or trailer. Follow these instructions and

always use common sense and good judg-

ment when carrying cargo or towing a trailer.

Prepare your load or trailer

WARNING

Improper loading or towing can increase

the risk of loss of control, an overturn, or

other accident:

●Do not exceed the Maximum Loading

Limits for the vehicle (see box or vehi-

cle labeling).

●Keep weight in the cargo bed centered

side to side, and as low and as far for-

ward as possible. Top-heavy loads in-

urn. Be sure

cargo is secured – a loose load could

change handling unexpectedly or

strike occupants.

●Do not exceed the maximum tongue

weight.

●Make sure the load does not interfere

with your control or ability to see

where you are going.

●Tie down cargo in the trailer securely.

Make sure cargo in the trailer cannot

move around. A shifting load can

cause an accident.

EE.book Page 11 Friday, August 3, 2007 11:59 AM

6-12

Use the hooks equipped on the cargo bed to

tie down loads.

Choose a trailer hitch drawbar designed for

use with a 5 cm (2 in) receiver. (See page

4-22 for more information.)

You can measure tongue weight with a bath-

room scale. Put the tongue of the loaded trail-

er on the scale with the tongue at hitch height.

Adjust the load in the trailer, if necessary, to

reduce the weight on hitch. If you are carrying

cargo and towing a trailer, include the tongue

weight in the maximum vehicle load limit.

MAXIMUM LOADING LIMIT

●Vehicle loading limit (total weight of

cargo, operator, passenger and

accessories and tongue weight):

398 kg (877 lb)

●Cargo bed: 181 kg (400 lb)

●Trailer hitch:

Pulling load (total weight of trailer and

cargo): 550 kg (1,212 lb)

Tongue weight (vertical weight on trailer

hitch point): 50 kg (110 lb)

EE.book Page 12 Friday, August 3, 2007 11:59 AM

6-13

Operating when loaded with cargo or tow-

ing a trailer

Drive more slowly than you would without a

load. The more weight you carry, the slower

you should go. Although conditions vary, it is

good practice to keep the vehicle in low gear

whenever you are carrying heavier loads or

when towing a trailer.

WARNING

Carrying loads or towing a trailer can in-

crease the risk of loss of control, an over-

turn, or other accident. To reduce the risk

of an accident:

●Reduce speed, operate in low gear

only, and allow more room to stop. A

heavier vehicle takes longer to stop.

●Avoid hills and rough terrain. Choose

reme caution

when towing or carrying a load on in-

clines.

●Turn gradually and go slowly.

Pulling something other than a trailer

Yamaha recommends that loads be transport-

ed in the bed or in a trailer. If you need to

move an object a short distance use a winch

and follow the winch manufacturer’s instruc-

tions.

If you choose to use something other than a

winch use extreme caution, follow the manu-

facturer’s instructions for that product, and

only attach to the hitch or hitch bracket of the

Rhino. WARNING! Improperly pulling can

cause serious injury or death. Never ex-

ceed the Pulling Load limit of the Rhino.

Avoid pulling on inclines.

Pulling objects on the ground can be more

hazardous than pulling a trailer. It may be dif-

ficult to predict how the load will affect vehicle

operation. That effect could also change de-

pending upon terrain or what obstacles might

be in the object’s path.

EE.book Page 13 Friday, August 3, 2007 11:59 AM

7-1

BASIC GUIDE FOR SAFE

USE

As a Rhino owner you are responsible for the

safe and proper operation of this vehicle.

Read this chapter and review the safety in-

structions in Chapter 2 before operating the

vehicle. Use these chapters and the labels on

the vehicle to instruct new operators and pas-

sengers. Do not allow anyone else to operate

the vehicle or ride as a passenger if you are

unsure that he/she is willing and able to follow

these instructions.

WARNING

Follow these instructions to reduce your

risk of an accident and to reduce the risk

of serious injury or death in the event of an

KNOW YOUR VEHICLE

This off-road vehicle will handle and maneu-

ver differently from cars, ATVs, go-carts, golf-

cars and grounds-keeping vehicles. The

Rhino has higher ground clearance and other

features to handle rugged terrain, and, as a

result, can overturn in situations where some

vehicles may not. This would include vehicles

made primarily for pavement, roads, im-

proved paths, or grounds-keeping. If you do

not use care in maneuvering the Rhino, you

can cause it to roll over even on flat, open ar-

eas.

EE.book Page 1 Friday, August 3, 2007 11:59 AM

7-2

Doing things with a Rhino that some people

do for thrills in other vehicles (such as side-

ways sliding, skidding, fishtailing, or donuts)

have led to side rollovers. These rollovers can

result in crushed limbs and other serious inju-

ries or death to drivers or passengers.

As the owner/operator, it is your responsibility

to protect yourself and your passenger from

accidents, including rollovers. The Rhino has

many features, including a protective struc-

ture and seat belts, to help protect occupants,

but the best way to avoid injuries is to avoid

accidents. There is a risk of injury or death in

any accident, even with these safety features.

Driver requirements

●This vehicle is intended for use only by an

operator 16 or older with a valid motor vehi-

cle license.

●The driver must be able to place both feet

flat on the floorboard while seated upright

with his/her back against the seat back.

●Do not drive after using drugs or alcohol.

Remove the ignition key when the vehicle is

not in use to prevent unauthorized use of the

machine.

DRIVER

UNDER

EE.book Page 2 Friday, August 3, 2007 11:59 AM

7-3

Parents:

Many states have implemented new motor

vehicle licensing requirements for young driv-

ers. These requirements are in response to

the disproportionately high rate of crashes in-

volving youthful drivers. As with automobiles,

to promote safe driving behaviors, you should

supervise drivers and consider setting rules

and putting limits on how, when, and where

the Rhino can be used.

Passenger requirements

This vehicle is designed for the operator and

one passenger. Carrying passengers improp-

erly can lead to serious injury or death. As the

operator, you are responsible for your pas-

senger.

●Your passenger must be able to place both

feet on the floorboard while seated upright

with his/her back against the seat back.

●Allow only one passenger in the vehicle

and only in the passenger seat. Do not car-

ry any other passengers. Do not carry pas-

sengers in the cargo bed.

●Do not allow someone to ride as a passen-

ger who has been using drugs or alcohol.

EE.book Page 3 Friday, August 3, 2007 11:59 AM

7-4

Occupant protection system

1. Passenger handhold 2. Seat belt

3. Door

1. Door

1. Passenger handhold

EE.book Page 4 Friday, August 3, 2007 11:59 AM

7-5

WARNING

Do not make changes to the occupant pro-

tection system. If you install aftermarket

products or have your vehicle modified,

you may put yourself and others at greater

risk of serious injury or death. You are re-

sponsible for any such changes to the ve-

hicle.

The Rhino comes with a variety of features to

help reduce the risk of driver and passenger

injury. These features work together, and

when properly used, these features will help

protect the occupants in the event of an acci-

dent. If these features are not used properly,

they can cause injury.

Protective structure

The vehicle cage/frame provides a protective

structure that helps limit intrusions by branch-

es or other objects and may reduce your risk

of injury in accidents. The protective structure

will not protect occupants in all rollovers or ac-

cidents.

Body parts outside of vehicle can be struck by

passing objects or crushed during vehicle roll-

over. Do not put your hands or feet outside of

the vehicle for any reason. Do not hold onto

the door, cage/frame or hip restraint bar.

Wear your seat belt and helmet.

If you think or feel that the vehicle may tip or

roll, do not put your hands or feet outside the

vehicle for any reason. You will not be able to

stop the vehicle from tipping over using your

body. Any part of your body (arms, legs, or

head) outside of the vehicle can be crushed

by the vehicle cage/frame.

EE.book Page 5 Friday, August 3, 2007 11:59 AM

7-6

Seat belts

Seat belts should be worn by both driver and

passenger. Driver must be sure that the pas-

senger is belted before driving.

●Be sure the seat belt is not twisted, is

close-fitting across the hips and chest,

and is latched securely.

●Do not wear the lap belt across the abdo-

men or stomach.

●Do not put the shoulder belt behind the

back.

Failure to use seat belts properly may lead to

an increased likelihood and severity of injury.

An unbelted occupant may strike the interior

of the vehicle, the protective structure, or oth-

er objects in an accident or during operation.

You may also fall completely out or be partial-

ly ejected from the vehicle, which may lead to

being crushed between the ground and the

vehicle. Wearing the seat belt helps you re-

main in the vehicle – the doors and handholds

are not a substitute for using a seat belt.

A crash can damage the restraint systems in

your vehicle. A damaged restraint system

may not properly protect the person using it,

resulting in serious injury or death in a crash.

To help make sure your restraint systems are

working properly after a crash, have them in-

spected and any necessary replacements

made as soon as possible.

EE.book Page 6 Friday, August 3, 2007 11:59 AM

7-7

1. Seat belt (× 2) 2. Latch plate (× 2)

3. Buckle (× 2)

To wear the seat belt properly, do the follow-

ing:

1. Hold the latch plate as you pull the belt

across your lap and chest. Make sure the

belt is not twisted and is not caught on

any portion of the vehicle, your clothing,

carrying.

2. If the latch plate is not positioned in the

correct location along the seat belt,

squeeze the latch plate ends together

along its long edges in order to more eas-

ily adjust its location up or down along the

length of the belt.

3. Push the latch plate into the buckle until it

clicks. Pull up on the latch plate to make

sure it is secure.

1. Buckle 2. Latch plate

EE.book Page 7 Friday, August 3, 2007 11:59 AM

7-8

4. Put the lap portion of the belt low on your

hips. Pull up on the shoulder part so the

belt is snug across your hips.

5. Position the shoulder belt over your

shoulder and across your chest. The

shoulder belt should fit against your

chest. If it is loose, pull the belt out all the

way and then let it retract.

6. To release the buckle, firmly press the re-

lease button.

Doors

The doors are designed to reduce the likeli-

hood that you will stick your leg out to stop the

vehicle from tipping over or for any other rea-

son in a rollover. The doors may also reduce

intrusion of objects into the occupant area.

Make sure the doors are securely latched be-

fore operation. Do not place your arm or hand

on the door during operation. Your hand or

arm may be struck by objects or crushed

against outside objects or the ground during a

rollover.

EE.book Page 8 Friday, August 3, 2007 11:59 AM

7-9

Passenger handholds

Handholds are provided to grip during opera-

tion to maintain proper position and balance.

Holding onto the handholds helps to reduce

the likelihood that the passenger puts a hand

outside the vehicle if the vehicle begins to tip.

There are two handholds on the protective

structure and two handholds on the passen-

ger’s left side, for the right and left hands.

The driver should make sure the passenger is

holding onto the handholds with both hands

before operating the vehicle.

EE.book Page 9 Friday, August 3, 2007 11:59 AM

7-10

Seat and hip restraints

The seat and hip restraints are designed to

help keep you in the vehicle. Do not hold onto

hip restraint bar when the vehicle is moving.

Your hand or arm may be struck by objects or

crushed against outside objects or the ground

during a rollover.

Floorboard

The floorboard allows you to brace your feet,

which helps you keep your body in the vehicle

in the event of an accident or rollover. Keep

your feet on the floorboard during operation.

EE.book Page 10 Friday, August 3, 2007 11:59 AM

7-11

Steering wheel

Keep both hands on the steering wheel. Do

not hold the steering wheel with your thumbs

inside the rim. Keep your palms on the out-

side of the steering wheel. Similar to other off-

road vehicles, if the Rhino hits a deep rut or

large obstacle, the steering wheel could brief-

ly jerk in one direction or back and forth as the

tires and vehicle respond to the obstacle. This

quick motion could injure your thumbs or wrist

if your thumbs or hand(s) are inside the steer-

ing wheel. Grip the steering wheel so that

your thumbs will not be hit by the spokes. As

an example, see the illustration.

CORRECT GRIP EXAMPLE

INCORRECT GRIP EXAMPLE

EE.book Page 11 Friday, August 3, 2007 11:59 AM

7-12

LEARNING TO OPERATE YOUR VEHICLE

Personal protective equipment

1. Approved motorcycle helmet

2. Eye protection 3. Long-sleeved shirt or jacket

4. Gloves 5. Long pants

6. Over-the-ankle boots

Both driver and passenger should wear the

following to reduce risk of injury in an acci-

dent:

●Approved motorcycle helmet that fits prop-

erly

●Eye protection (goggles, helmet face

shield, or protective eyewear)

●Over-the-ankle boots, gloves, long-sleeved

shirt or jacket, and long pants

An approved helmet and other personal pro-

tective equipment can help in a variety of

ways, including:

●Reduce the severity of injuries if any part of

you is outside the vehicle cage/frame pro-

tective structure during a rollover.

●Help protect you if outside objects intrude

inside the vehicle during operation.

●Help protect you in the event of vehicle im-

pact with an obstacle.

EE.book Page 12 Friday, August 3, 2007 11:59 AM

7-13

Wear eye protection when operating or riding

the vehicle to reduce the risk of a serious ac-

cident or injury. Eye protection, such as a face

shield or goggles, may reduce the risk of for-

eign material getting in your eyes and help

prevent loss of vision.

Practice for new Rhino users

You should become familiar with the perfor-

mance characteristics of the vehicle in a large,

flat area that is free of obstacles and other ve-

hicles. Practice controlling the accelerator

pedal, brakes, steering, and drive select lever.

Drive at slow speeds with gradual accelera-

tion and turning. Practice smooth throttle ap-

plication. Practice slowing down before

turning. Practice maintaining a steady throttle

through the turn. Avoid higher speeds until

h the operation

of your vehicle. Remember, driving aggres-

sively or making abrupt maneuvers even on

flat, open areas can cause side rollovers.

Become familiar with the way the vehicle feels

in low and high ranges, first in two-wheel drive

(2WD) and then in four-wheel drive (4WD)

and four-wheel drive with the differential

locked (DIFF. LOCK). Steering may take

more effort in 4WD with the differential locked

(DIFF. LOCK). Also practice driving in re-

verse.

Take the time to learn basic operation of the

vehicle before attempting more difficult ma-

neuvers.

EE.book Page 13 Friday, August 3, 2007 11:59 AM

7-14

Getting ready to ride

Perform the Pre-Operation Checks on pages

5-1–5-11. Follow the instructions starting on

page 6-2 to start the engine. Once it has

warmed up and you have turned the choke

off, you are ready to begin driving your vehi-

cle.

Turning

Use care in turns – turning the steering wheel

too far or too fast can result in loss of control

or a rollover. Slow down before entering turns.

When making tight turns from a standstill or at

slow speeds, avoid sudden or hard accelera-

tion. Driving aggressively or making abrupt

maneuvers even on flat, open areas can

cause side rollovers. Avoid sideways sliding,

skidding, or fishtailing, and never do donuts. If

you feel the Rhino begin to slide sideways or

fishtail during a turn, steer into the direction of

the slide, if possible, and gradually let off the

accelerator pedal to regain directional control

and avoid rollover. For example, if you feel the

back of the vehicle start to slide to your right,

steer to the right.

EE.book Page 14 Friday, August 3, 2007 11:59 AM

7-15

If you think or feel that the vehicle may tip or

roll, keep your body completely inside the pro-

tective structure of the vehicle:

●Brace yourself by pressing your feet firmly

on the floorboards and keep a firm grip on

the steering wheel or handholds.

●Do not put your hands or feet outside of the

vehicle for any reason. Do not try to stop a

tipover using your arm or leg.

Accelerating

With the engine idling in neutral and your foot

on the brake, shift the drive select lever into

low or high. NOTICE: Do not shift from low

to high or vice versa without coming to a

complete stop and waiting for the engine

to return to normal idle speed – damage to

the engine or drive train may occur. Then

release the parking brake. Press the accel-

erator pedal slowly and smoothly. The centrif-

ugal clutch will engage and the vehicle will

begin to accelerate.

Avoid higher speeds and sudden or hard ac-

celeration until you are thoroughly familiar

with the operation of your vehicle. Avoid sud-

den or hard acceleration in any turn.

EE.book Page 15 Friday, August 3, 2007 11:59 AM

7-16

Braking

When slowing down or stopping, take your

foot off the accelerator pedal and press the

brake pedal smoothly. Improper use of the

brakes can cause the tires to lose traction, re-

ducing control of the vehicle and increasing

the possibility of an accident.

Braking ability is affected by type of terrain. In

most cases, gradual application of the brakes

is more effective than abrupt braking, particu-

larly on loose surfaces, such as gravel. Al-

ways allow for greater braking distance on

rough, loose, or slippery surfaces.

Engine braking

Engine compression braking is designed to

assist you when operating your Rhino off-

ine helps slow

the vehicle down after you take your foot off

the accelerator. Engine braking is more no-

ticeable in 4WD. Application of vehicle brakes

provides additional stopping power.

Leaving the vehicle

Do not get out of the vehicle while the engine

is running and the drive select lever is in any

gear. There is a risk of injury because:

●The speed of a cold engine may increase

enough as it warms up to cause the vehicle

to move on its own while the choke is being

used.

●Children or others may accidentally press

the accelerator pedal.

●Objects tossed into the vehicle may strike

the accelerator pedal.

●The parking brake may not keep the vehi-

cle from accelerating.

Unwanted vehicle movement can cause seri-

ous injury or death, and it may be dangerous

to try to stop the vehicle.

EE.book Page 16 Friday, August 3, 2007 11:59 AM

7-17

Parking on a flat area

When parking on a flat area, stop the engine

and shift the drive select lever into the neutral

position. Apply the parking brake to help pre-

vent the vehicle from rolling.

Parking on a slope

The parking brake acts only on the rear

wheels when in 2WD. For the parking brake to

take effect on all four wheels, shift to 4WD

Diff. Lock before stopping the engine.

If you park on a hill that is too steep the vehi-

cle may roll out of control. Never park on hills

that are so steep you cannot walk up them

easily. If you must park on an incline follow

these instructions:

1. Bring the vehicle to a stop by applying the

2. Put the vehicle in 4WD Diff. Lock.

3. Turn the engine off.

4. With the brake pedal applied, set the

parking brake.

5. Block the front and rear wheels with

rocks or other objects.

The total weight of operator, passenger, ac-

cessories, cargo, trailer tongue weight, and

the vehicle itself must not exceed 907 kg

(2,000 lb). Vehicle loading can affect han-

dling. See “Loading” on pages 6-11–6-13.

EE.book Page 17 Friday, August 3, 2007 11:59 AM

7-18

Operation on different surfaces and

terrains

Go slowly and proceed with caution when op-

erating on an unfamiliar surface or terrain.

This vehicle may handle differently in certain

types of terrains or on certain surfaces. You

may come upon hidden rocks, bumps, or

holes without enough time to react. To avoid

loss of control or rollover, always be alert to

changing surfaces or terrain when operating

the vehicle.

The Rhino has higher ground clearance and

other features to handle rugged terrain, and

as a result, can overturn in situations where

some vehicles may not. Abrupt maneuvers or

aggressive driving can cause loss of control,

including rollovers – even on flat, open areas.

crushed limbs

and other serious injuries or death to drivers

or passengers.

EE.book Page 18 Friday, August 3, 2007 11:59 AM

7-19

Hills

Choose carefully which hills you attempt to

climb or descend. Avoid hills with slippery sur-

faces or those where you will not be able to

see far enough ahead of you. Use common

sense and remember that some hills are too

steep for you to climb or descend. Use proper

driving techniques to avoid rearward, forward,

or sideways rollovers on hills and slopes.

Drive straight up and down inclines, not

across them. If crossing a hill is unavoidable,

drive slowly. Turn downhill immediately if you

feel the vehicle may tip.

If you think or feel the Rhino may tip or

roll:

●Brace yourself by pressing your feet firmly

p a firm grip on

the steering wheel or handholds.

●Do not put your hands or feet outside of the

vehicle for any reason.

Uphill

Do not attempt to climb hills until you have

mastered basic maneuvers on flat ground.

Drive straight up hills, and avoid crossing the

side of a hill, which increases your risk of roll-

over. Practice first on gentle slopes before at-

tempting steeper hills. Always check the

terrain carefully before attempting any hill.

To climb a hill, you need traction, momentum,

and steady throttle. For more traction and

control for climbing steeper and/or rougher

slopes, shift into low gear and select 4WD or

4WD Diff. Lock. Travel fast enough to main-

tain momentum, but not so fast that you can-

not react to changes in the terrain as you

climb.

EE.book Page 19 Friday, August 3, 2007 11:59 AM

7-20

Slow down when you reach the crest of the hill

if you cannot see clearly what is on the other

side – there could be another person, an ob-

stacle, or a sharp drop-off.

If you start to lose traction or momentum

when climbing, and decide you will be unable

to continue, use the brakes to stop. Do not at-

tempt to turn the vehicle around. With your

foot on the brake pedal, look behind you and

plan your descent. Shift the drive select lever

into reverse so you can use engine braking to

slow your descent. Release the brake and be-

gin to coast down the hill. Use engine braking

as much as possible, gently applying the

brakes when necessary.

Downhill

Check the terrain carefully before going

downhill. When possible, choose a path that

lets you drive your vehicle straight downhill.

Choose your path carefully and drive slowly

enough to be able to react to obstacles that

you encounter.

For more traction and control, before going

down steeper and/or rougher slopes, shift into

low gear and select 4WD or 4WD Diff. Lock.

Engine braking will help you go downhill slow-

ly. Go as slowly as possible. If you begin to go

too fast, apply the brakes gently. Avoid hard

application of the brakes, which could cause

the vehicle to slide.

EE.book Page 20 Friday, August 3, 2007 11:59 AM

7-21

If you are sliding or skidding, try to steer in the

direction the vehicle is sliding, to regain con-

trol. For example, if you feel the back of the

vehicle start to slide to your right, steer to the

right.

If you must turn on the hill to avoid an obsta-

cle, do so slowly and carefully. If the vehicle

starts to tip, immediately steer in the downhill

direction if there are no obstacles in your path.

As you regain proper balance, gradually steer

again in the direction you want to go.

Rough terrain

Operation over rough terrain should be done

with caution.

●Look for and avoid obstacles that could

cause damage to the vehicle or could lead

to a rollover or accident.

●Do not drive in a way that will get the Rhino

airborne, as injury, loss of control, and

damage to the vehicle could occur.

Pavement

This vehicle is designed for off-road use only.

Avoid paved surfaces. Turn gradually and go

slowly if you must drive on pavement.

EE.book Page 21 Friday, August 3, 2007 11:59 AM

7-22

Water

If you must cross shallow, slow-moving water

up to the depth of the vehicle’s floorboards,

choose your path carefully to avoid sharp

drop-offs, large rocks, or slippery surfaces

that could cause the vehicle to overturn. Nev-

er operate through water deeper than 33 cm

(13 in) or fast-flowing water. Choose a path

where both your entrance into and exit point

from the water is a gradual incline. Determine

the water depth and currents before crossing.

Operating this vehicle through deep or fast-

flowing water can lead to loss of control or

overturn. To reduce your risk of drowning or

other injuries, use care when crossing

through water.

effectiveness.

After leaving the water, test your brakes. If

necessary, apply the brakes several times to

let friction dry out the linings.

After driving your vehicle in water, be sure

to drain the trapped water by removing the

check hose at the bottom of the air filter

case, the V-belt cooling duct check hoses,

the drive select lever box check hose and

the V-belt case drain plug. Wash the vehi-

cle in fresh water if it has been operated in

salt water or muddy conditions.

EE.book Page 22 Friday, August 3, 2007 11:59 AM

7-23

Loose terrain/slippery terrain

When driving on slippery terrain, including

wet, muddy, or icy conditions, as well as loose

gravel, be aware that you could begin skid-

ding or sliding. To avoid loss of control, slow

down and put the Rhino in 4WD before driving

on a slippery surface and plan your path to

avoid making abrupt maneuvers.

If you feel the Rhino begin to slide sideways or

fishtail during a turn, steer into the direction of

the slide if possible, to regain directional con-

trol. For example, if you feel the back of the

vehicle start to slide to your right, steer to the

right.

Brush or wooded areas

When operating in areas with brush or trees,

watch carefully on both sides and above the

vehicle for obstacles such as branches that

the vehicle might hit, causing an accident.

Watch for brush that might enter the vehicle

as you pass and strike you or the passenger.

Never hold onto the cage/frame. The passen-

ger should always hold onto the handholds

with both hands.

The muffler and other engine parts become

extremely hot during operation and remain

hot after the engine has stopped. To reduce

the risk of fire during operation or after leaving

the vehicle, do not let brush, grass and other

materials collect under the vehicle, near the

muffler or exhaust pipe, or next to other hot

parts. Check under the vehicle after operating

in areas where combustible materials may

have collected. Do not idle or park the vehicle

in long dry grass or other dry ground cover.

EE.book Page 23 Friday, August 3, 2007 11:59 AM

7-24

Encountering obstacles

If you cannot go around an obstacle, such as

a fallen tree or a ditch, stop the vehicle where

it is safe to do so. Set the parking brake and

get out to inspect the area thoroughly. Look

from both your approach side and exit side. If

you believe you can continue safely, choose

the path that will allow you to get over the ob-

stacle and at as close to a right angle as pos-

sible to minimize vehicle tipping. Go only fast

enough to maintain your momentum but still

give yourself plenty of time to react to chang-

es in conditions.

If there is any question about your ability to

maneuver safely over the obstacle, you

should turn around if the ground is flat and you

have the room or back up until you find a less

EE.book Page 24 Friday, August 3, 2007 11:59 AM

8-1

EVU00650

PERIODIC MAINTENANCE AND

ADJUSTMENT

Periodic inspection, adjustment, and lubrica-

tion will keep your vehicle in the safest and

most efficient condition possible.

Safety is an obligation of the vehicle owner/

operator. The most important points of vehicle

inspection, adjustment, and lubrication are ex-

plained on the following pages.

WARNING

Failure to properly maintain the vehicle or

performing maintenance activities incor-

rectly may increase your risk of injury or

death during service or while using the ve-

hicle. If you are not familiar with vehicle

service, have a Yamaha dealer perform

WARNING

Turn off the engine when performing main-

tenance unless otherwise specified.

●A running engine has moving parts

that can catch on body parts or cloth-

ing and electrical parts that can cause

shocks or fires.

●Running the engine while servicing

can lead to eye injury, burns, fire, or

carbon monoxide poisoning – possi-

bly leading to death. See page 2-8 for

more information about carbon mon-

oxide.

EE.book Page 1 Friday, August 3, 2007 11:59 AM

8-2

EVU00660

Owner’s manual and tool kit

You are recommended to put this owner’s

manual in the vinyl bag and always carry it un-

derneath the driver seat as shown. Put the

owner’s tool kit and tire pressure gauge in the

space beside the battery.

1. Owner’s manual

1. Owner’s tool kit 2. Tire pressure gauge

The service information included in this man-

ual is intended to provide you, the owner, with

the necessary information for completing your

own preventive maintenance and minor re-

pairs.

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.

EE.book Page 2 Friday, August 3, 2007 11:59 AM

8-3

If you do not have a torque wrench available

during a service operation requiring one, take

your vehicle to a Yamaha dealer to check the

torque settings and adjust them as necessary.

EE.book Page 3 Friday, August 3, 2007 11:59 AM

8-4

EVU01640

Periodic maintenance chart for the emission control system

●For vehicles not equipped with an odometer or hour meter, follow the month maintenance in-

tervals.

●For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours mainte-

nance intervals. However, keep in mind that if the vehicle isn’t used for a long period of time,

the month maintenance intervals should be followed.

●Items marked with an asterisk should be performed by a Yamaha dealer as they require spe-

cial tools, data and technical skills.

ITEM ROUTINE

Whichever

comes first

INITIAL EVERY

month136612

(mi)

320

(200)

1,200

(750)

2,400

(1,500)

2,400

(1,500)

4,800

(3,000)

hours 20 75 150 150 300

Fuel line* •Check fuel hose for cracks or damage.

•Replace if necessary.

Valves* •Check valve clearance.

•Adjust if necessary.

Spark plug

•Check condition.

•Adjust gap and clean.

•Replace if necessary.

Carburetor* •Check idle speed/starter operation.

•Adjust if necessary.

er hose for cracks or damage.

essary.

Exhaust system*

•Check for leakage.

•Tighten if necessary.

•Replace gasket(s) if necessary.

Spark arrester •Clean.

EE.book Page 4 Friday, August 3, 2007 11:59 AM

8-5

EVU01650

General maintenance and lubrication chart

ITEM ROUTINE

Whichever

comes first

INITIAL EVERY

month136612

(mi)

320

(200)

1,200

(750)

2,400

(1,500)

2,400

(1,500)

4,800

(3,000)

hours 20 75 150 150 300

Cooling system

•Check coolant leakage.

•Repair if necessary.

•Replace coolant every 24 months.

Air filter elements

(engine and air intake duct)

•Clean.

•Replace if necessary.

Every 20–40 hours

(More often in wet or dusty areas.)

Engine oil •Replace (warm engine before draining).

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 page 8-6.

•Correct if necessary. Replace pads if worn to the limit.

Rear brake* •Check operation/brake pad wear/fluid leakage/see page 8-6.

•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.

tion and for leakage.

essary.

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.

EE.book Page 5 Friday, August 3, 2007 11:59 AM

8-6

Recommended brake fluid: DOT 4

Brake fluid replacement:

●Replace the brake fluid when disassembling the master cylinder or caliper.

●Check the brake fluid level regularly and add fluid as required.

●Replace the oil seals on the inner parts of the master cylinder and caliper every two years.

●Replace the brake hoses every four years, or if cracked or damaged.

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.

Fittings and fasteners* •Check all chassis fittings and fasteners.

•Correct if necessary.

ITEM ROUTINE

Whichever

comes first

INITIAL EVERY

month136612

(mi)

320

(200)

1,200

(750)

2,400

(1,500)

2,400

(1,500)

4,800

(3,000)

hours 20 75 150 150 300

EE.book Page 6 Friday, August 3, 2007 11:59 AM

8-7

EVU00680

Hood

To open

Unhook the hood latches, and then slowly tilt

the hood up until it stops.

1. Latch (× 2)

1. Hood

EE.book Page 7 Friday, August 3, 2007 11:59 AM

8-8

To close

Lower the hood slowly to its original position,

and then hook the hood latches. Secure pro-

jections 1 on the rear of the hood into slots 2

on the back of the instrument panel. Secure

slots 3 on the side of the hood around

projections 4 on the frame.

1. Projection (× 2) 2. Slot (× 2)

n (× 2)

●Make sure that all cables and wires are

in place when closing the hood.

●Do not drive the vehicle with the hood

open, unlatched, or removed.

EE.book Page 8 Friday, August 3, 2007 11:59 AM

8-9

EVU00691

Console

To remove

1. Remove the seats. (See pages 4-16–

4-17 for seat removal and installation

procedures.)

2. Remove the parking brake lever boot.

3. Pull the console upward (the drive select

lever boot will come loose).

1. Console

To install

1. Place the console in its original position.

2. Install the parking brake lever boot.

3. Install the seats.

NOTICE

●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 con-

sole.

EE.book Page 9 Friday, August 3, 2007 11:59 AM

8-10

EVU00701

Engine oil and oil filter cartridge

Check engine oil level before each operation.

In addition, change the oil and the oil filter car-

tridge at the intervals specified in the periodic

maintenance and lubrication chart.

To check the engine oil level

1. Park the vehicle on a level surface.

2. Remove the console. (See page 8-9 for

console removal and installation proce-

dures.)

3. Check the engine oil level on a cold en-

gine. If the engine was started before

checking the oil level, be sure to warm up

the engine sufficiently, and then wait at

least ten minutes until the oil settles for

an accurate reading.

4. Remove the engine oil filler cap and wipe

n rag.

5. Insert the dipstick in the oil filler hole

(without screwing it in), and then remove

it again to check the oil level. The engine

oil should be between the minimum and

maximum level marks.

1. Maximum level mark 2. Minimum level mark

3. Dipstick 4. Engine oil filler cap

6. If the engine oil is at or below the mini-

mum level mark, add sufficient oil of the

recommended type to raise it to the cor-

rect level.

EE.book Page 10 Friday, August 3, 2007 11:59 AM

8-11

7. Insert the dipstick into the oil filler hole,

and then tighten the oil filler cap.

8. Reinstall the console.

To change the engine oil (with or without

oil filter cartridge replacement)

1. Remove the console. (See page 8-9 for

console removal and installation proce-

dures.)

2. Start the engine, warm it up for several

minutes, and then turn it off.

3. Place an oil pan under the engine to col-

lect the used oil, and then remove the en-

gine oil filler cap.

4. Remove the engine oil drain bolt to drain

the oil from the crankcase.

1. Engine oil drain bolt

EE.book Page 11 Friday, August 3, 2007 11:59 AM

8-12

Skip steps 5–7 if the oil filter cartridge is not

being replaced.

5. Remove the oil filter cartridge with an oil

filter wrench. An oil filter wrench is avail-

able from a Yamaha dealer.

1. Oil filter cartridge 2. Oil filter wrench

6. Apply a light coat of clean engine oil to

the O-ring of the new oil filter cartridge.

Make sure the O-ring is seated properly.

1. O-ring

7. Install the new oil filter cartridge with an

oil filter wrench, and then tighten it to the

specified torque with a torque wrench.

Tightening torque:

Oil filter cartridge:

17 Nm (1.7 m·kgf, 12 ft·lbf)

EE.book Page 12 Friday, August 3, 2007 11:59 AM

8-13

1. Oil filter cartridge 2. Torque wrench

8. Reinstall the engine oil drain bolt, and

then tighten it to the specified torque.

9. Add the specified amount of recommend-

ed engine oil, and then reinstall the en-

gine oil filler cap and tighten it. NOTICE:

Be sure to wipe off spilled oil on any

parts after the engine and exhaust

system have cooled down.

Tightening torque:

Engine oil drain bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

Recommended engine oil:

See page 10-2.

Oil quantity:

Without oil filter cartridge replacement:

2.50 L (2.20 Imp qt, 2.64 US qt)

With oil filter cartridge replacement:

2.60 L (2.29 Imp qt, 2.75 US qt)

EE.book Page 13 Friday, August 3, 2007 11:59 AM

8-14

●In order to prevent clutch slippage

(since the engine oil also lubricates the

clutch), do not mix any chemical addi-

tives with oil. Do not use oils with a die-

sel specification of “CD” or oils of a

higher quality than specified. In addi-

tion, do not use oils labeled “ENERGY

CONSERVING II” or higher.

●Make sure that no foreign material en-

ters the crankcase.

1. “CD” specification 2. “ENERGY CONSERVING II”

10. Start the engine, and then let it idle for

several minutes while checking it for oil

leakage. If oil is leaking, immediately turn

the engine off and check for the cause.

11. Turn the engine off, wait at least ten min-

utes, and then check the oil level and cor-

rect it if necessary.

12. Reinstall the console.

EE.book Page 14 Friday, August 3, 2007 11:59 AM

8-15

EVU00710

Final gear oil

Checking the final gear oil level

1. Park the vehicle on a level surface.

2. Remove the oil filler bolt, and then check

the oil level in the final gear case. The oil

level should be at the brim of the filler

hole.

ear oil

3. Correct oil level

3. If the oil is below the brim of the filler hole,

add sufficient oil of the recommended

type to raise it to the correct level.

NOTICE: Be sure no foreign material

enters the final gear case.

4. Reinstall the oil filler bolt, and then tight-

en it to the specified torque.

Tightening torque:

Final gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

EE.book Page 15 Friday, August 3, 2007 11:59 AM

8-16

Changing the final gear oil

1. Park the vehicle on a level surface.

2. Place a container under the final gear

case to collect the used oil.

3. Remove the oil filler bolt and the drain

bolt to drain the oil.

1. Final gear oil drain bolt

4. Reinstall the drain bolt, and then tighten it

5. Add the recommended final gear oil up to

the brim of the filler hole. NOTICE: Be

sure no foreign material enters the fi-

nal gear case.

6. Reinstall the oil filler bolt, and then tight-

en it to the specified torque.

7. Check for oil leakage. If oil leakage is

found, check for the cause.

Tightening torque:

Final gear oil drain bolt:

20 Nm (2.0 m·kgf, 14 ft·lbf)

Recommended oil:

SAE 80 API GL-4 Hypoid gear oil

Oil quantity:

0.25 L (0.22 Imp qt, 0.26 US qt)

Tightening torque:

Final gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

EE.book Page 16 Friday, August 3, 2007 11:59 AM

8-17

EVU00721

Differential gear oil

Checking the differential gear oil level

1. Park the vehicle on a level surface.

2. Remove the differential gear oil filler bolt

and check the oil level. It should be up to

the brim of the filler hole. If the level is

low, add sufficient oil of the recommend-

ed type to raise it to the specified level.

NOTICE: Be sure no foreign material

enters the differential gear case.

1. Differential gear oil filler bolt

2. Correct oil level 3. Differential gear oil

3. Reinstall the differential gear oil filler bolt,

and then tighten it to the specified torque.

Changing the differential gear oil

1. Park the vehicle on a level surface.

2. Place a container under the differential

gear case to collect the used oil.

3. Remove the differential gear oil filler bolt

and differential gear oil drain bolt to drain

the oil.

Tightening torque:

Differential gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

EE.book Page 17 Friday, August 3, 2007 11:59 AM

8-18

1. Differential gear oil drain bolt

4. Reinstall the differential gear oil drain

bolt, and tighten it to the specified torque.

5. Fill the differential gear case with the rec-

e sure no for-

eign material enters the differential

gear case.

6. Reinstall the differential gear oil filler bolt,

and then tighten it to the specified torque.

7. Check for oil leakage. If oil leakage is

found, check for the cause.

Tightening torque:

Differential gear oil drain bolt:

9.8 Nm (0.98 m·kgf, 7.1 ft·lbf)

Recommended oil:

SAE 80 API GL-5 Hypoid gear oil

Oil quantity:

0.32 L (0.28 Imp qt, 0.34 US qt)

Tightening torque:

Differential gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

EE.book Page 18 Friday, August 3, 2007 6:35 PM

8-19

EVU00732

Coolant

The coolant level should be checked before

each ride.

Checking the coolant level

1. Park the vehicle on a level surface.

2. Open the hood. (See pages 8-7–8-8 for

hood opening and closing procedures.)

3. Check the coolant level in the coolant

reservoir when the engine is cold as the

coolant level varies with engine tempera-

ture. The coolant should be between the

minimum and maximum level marks.

1. Coolant reservoir cap

2. Maximum level mark 3. Minimum level mark

4. If the coolant is at or below the minimum

level mark, remove the reservoir cap,

add coolant to the maximum level mark,

reinstall the reservoir cap, and then close

the hood.

Coolant reservoir capacity

(up to the maximum level mark):

0.35 L (0.31 Imp qt, 0.37 US qt)

EE.book Page 19 Friday, August 3, 2007 11:59 AM

8-20

Changing the coolant

The coolant must be changed by a Yamaha

dealer at the intervals specified in the periodic

maintenance and lubrication chart.

Adding water instead of coolant lowers the

antifreeze content of the coolant. If water is

used instead of coolant, have a Yamaha deal-

er check the antifreeze content of the coolant

as soon as possible.

The radiator fan is automatically switched on

or off according to the coolant temperature in

the radiator.

Mix antifreeze with distilled water only.

However, if distilled water is not available,

soft water may be used for refilling.

If your vehicle overheats, see page 8-58 for

EVU00740

Axle boots

Check the protective boots for holes or tears.

If any damage is found, have them replaced

by a Yamaha dealer.

1. Front axle boot (× 2 each side)

EE.book Page 20 Friday, August 3, 2007 11:59 AM

8-21

1. Rear axle boot (× 2 each side)

EVU00750

Spark plug inspection

Removal

1. Remove the console. (See page 8-9 for

console removal and installation proce-

dures.)

2. Remove the spark plug cap.

1. Spark plug cap

3. Use the spark plug wrench in the tool kit

to remove the spark plug as shown.

EE.book Page 21 Friday, August 3, 2007 11:59 AM

8-22

1. Spark plug wrench

Inspection

The spark plug is an important engine compo-

nent and is easy to inspect. The condition of

the spark plug can indicate the condition of

the engine.

The ideal color of the porcelain insulator

around the center electrode is a medium-to-

light tan for a vehicle that is being ridden nor-

mally.

You should periodically remove and inspect

the spark plug because heat and deposits will

cause the spark plug to slowly break down

and erode. If electrode erosion becomes ex-

cessive, or if carbon and other deposits are

excessive, you should replace the spark plug

with the specified plug.

Specified spark plug:

DR8EA (NGK)

EE.book Page 22 Friday, August 3, 2007 11:59 AM

8-23

Installation

1. Measure the electrode gap with a wire

thickness gauge and, if necessary, adjust

the gap to specification.

2. Clean the surface of the spark plug gas-

ket and its mating surface, and then wipe

off any grime from the spark plug

threads.

3. Install the spark plug and tighten it to the

specified torque. If a torque wrench is not

available when you are installing the

spark plug, a good estimate of the correct

torque is one-quarter to one-half turn

past finger tight. Have the spark plug

tightened to the specified torque as soon

as possible.

4. Install the spark plug cap.

5. Reinstall the console.

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Tightening torque:

Spark plug:

17.5 Nm (1.75 m·kgf, 12.7 ft·lbf)

EE.book Page 23 Friday, August 3, 2007 11:59 AM

8-24

EVU00763

Cleaning the air filter elements

Cleaning the intake duct air filter element

1. Remove the air intake duct grill by remov-

ing the quick fastener screws.

1. Quick fastener screw (× 4)

2. Air intake duct grill

2. Remove the air filter element from the air

intake duct grill by pulling it out as shown.

1. Air filter element 2. Air intake duct grill

3. Remove any large particles from the air

filter element by hand.

4. Tap the air filter element to remove as

much dust and dirt as possible.

EE.book Page 24 Friday, August 3, 2007 11:59 AM

8-25

5. Reinstall the air filter element into the air

intake duct grill.

6. Reinstall the air intake duct grill by install-

ing the quick fastener screws.

Cleaning the engine air filter element

There is a check hose at the bottom of the air

filter case. If dust or water collects in this

hose, empty the hose and clean the air filter

element and air filter case.

1. Air filter case check hose

1. Remove the seats. (See pages 4-16–

4-17 for seat removal and installation

procedures.)

2. Remove the console. (See page 8-9 for

console removal and installation proce-

dures.)

EE.book Page 25 Friday, August 3, 2007 11:59 AM

8-26

3. Remove the air filter case cover by un-

hooking the holders.

1. Air filter case cover holder (× 5)

2. Air filter case cover

4. Remove the air filter element.

1. Air filter element

EE.book Page 26 Friday, August 3, 2007 11:59 AM

8-27

5. Remove the sponge material from its

frame.

1. Air filter frame 2. Sponge material

3. Element retaining plate

6. Wash the sponge material gently but

thoroughly in parts cleaning solvent.

WARNING! Using gasoline or other

flammable solvents to clean the air fil-

ter element can cause a fire or explo-

sion, which could lead to serious

injury.

7. Squeeze the excess solvent out of the

sponge material. NOTICE: Do not twist

the sponge material when squeezing

it.

EE.book Page 27 Friday, August 3, 2007 11:59 AM

8-28

8. Wash the sponge material in warm soapy

water to remove remaining solvent, then

rinse thoroughly with plain warm water.

9. Squeeze excess water out of the sponge

material. NOTICE: Do not twist the

sponge material when squeezing it.

10. Allow the sponge material to dry thor-

oughly. Inspect the sponge material and

replace it if damaged.

11. Thoroughly apply Yamaha foam air filter

oil or other quality liquid foam air filter oil

(not spray type) to the sponge material.

The sponge material should be wet but

not dripping.

12. Pull the sponge material over its frame.

13. Reinstall the air filter element.

14. Reinstall the air filter case cover by hook-

ing the holders onto the air filter case.

16. Install the seats.

The air filter element should be cleaned every

20–40 hours. It should be cleaned and lubri-

cated more often if the vehicle is operated in

extremely dusty areas. Each time air filter ele-

ment maintenance is performed, check the air

inlet to the air filter case for obstructions.

Check the air filter element rubber joint to the

carburetor and manifold fittings for an airtight

seal. Tighten all fittings securely to avoid the

possibility of unfiltered air entering the engine.

Never operate the engine with the air filter

element removed. This will allow unfiltered

air to enter, causing rapid engine wear and

possible engine damage. Additionally, op-

eration without the air filter element will af-

fect carburetor jetting with subsequent

poor performance and possible engine

overheating.

EE.book Page 28 Friday, August 3, 2007 11:59 AM

8-29

2P512001

Drive select lever box check hose

The drive select lever box check hose is locat-

ed under the console. (See page 8-9 for con-

sole removal and installation procedures.) If

dust or water collects in the drive select lever

box check hose, remove the hose and clean

it.

1. Drive select lever box check hose

EVU00770

V-belt cooling duct check hoses

The V-belt cooling duct check hoses are lo-

cated under the console and cargo bed. (See

page 8-9 for console removal and installation

procedures.) If dust or water collects in the V-

belt cooling duct check hose, remove the

hose and clean it.

1. V-belt cooling duct check hose

EE.book Page 29 Friday, August 3, 2007 11:59 AM

8-30

1. V-belt cooling duct check hose

EVU00780

V-belt case drain plug

The V-belt case drain plug is located under

the driver seat. (See pages 4-16–4-17 for seat

removal and installation procedures.)

After riding in water deep enough to allow wa-

ter to enter the V-belt case, remove the drain

plug to drain any water from the case.

If water drains from the V-belt case after re-

moving the drain plug, have a Yamaha dealer

inspect the vehicle, as the water may affect

other engine parts.

1. V-belt case drain plug

EE.book Page 30 Friday, August 3, 2007 11:59 AM

8-31

EVU00792

Cleaning the spark arrester

WARNING

Hot exhaust system may cause burns. To

avoid burns or fires, make sure that the en-

gine is stopped and the exhaust system is

cool before cleaning spark arrester. Do not

start the engine while cleaning the exhaust

system.

1. Remove the bolts.

1. Bolt (× 3)

2. Remove the tailpipe by pulling it out of

the muffler.

3. Tap the tailpipe lightly, and then use a

wire brush to remove any carbon depos-

its from the spark arrester portion of the

tailpipe and inside of the tailpipe housing.

1. Tailpipe 2. Spark arrester

4. Insert the tailpipe into the muffler and

align the bolt holes.

5. Install the tailpipe by installing the bolts,

and then tighten the bolts to the specified

torque.

EE.book Page 31 Friday, August 3, 2007 11:59 AM

8-32

EVU00800

Carburetor adjustment

The carburetor is a vital part of the engine and

requires very sophisticated adjustment. Most

adjusting should be left to a Yamaha dealer

who has the professional knowledge and ex-

perience to do so. However, the idling speed

adjustment may be performed by the owner

as a part of the usual maintenance routine.

NOTICE

The carburetor was set at the Yamaha fac-

tory after many tests. If the settings are

disturbed by someone without sufficient

technical knowledge, poor engine perfor-

mance and damage may result.

Tightening torque:

Tailpipe bolt:

9.5 Nm (0.95 m·kgf, 6.9 ft·lbf)

EE.book Page 32 Friday, August 3, 2007 11:59 AM

8-33

EVU00810

Idle speed adjustment

A diagnostic tachometer must be used for this

procedure.

1. Start the engine and warm it up for a few

minutes at approximately 1,000 to

2,000 r/min. Occasionally rev the engine

to 4,000 to 5,000 r/min. The engine is

warm when it responds quickly to the

throttle with the choke off.

2. Remove the seats. (See pages 4-16–

4-17 for seat removal and installation

procedures.)

3. Remove the console. (See page 8-9 for

console removal and installation proce-

dures.)

4. Connect the tachometer to the spark plug

lead, and then set the idle to the specified

idling speed by adjusting the throttle stop

direction a to

increase the engine speed, and in direc-

tion b to decrease the engine speed.

1. Throttle stop screw

5. Reinstall the console.

6. Reinstall the seats.

Valve clearance

The correct valve clearance changes with

use, resulting in improper fuel/air supply or

engine noise. To prevent this, the valve clear-

ance must be adjusted regularly. This adjust-

ment however, should be left to a professional

Yamaha service technician.

Specified idle speed:

1,450–1,550 r/min

EE.book Page 33 Friday, August 3, 2007 11:59 AM

8-34

Brakes

Replacement of brake components requires

professional knowledge. Brake service should

be performed by a Yamaha dealer.

WARNING

Operating with improperly serviced or ad-

justed brakes could lead to a loss in brak-

ing ability and an accident.

EVU00830

Front brake pad check

Each brake pad is provided with wear indica-

tor grooves, which allow you to check the

brake pad wear without having to disassem-

ble the brake. To check the brake pad wear,

check the wear indicator grooves. If a brake

pad has worn to the point that the wear indica-

eared, have a

Yamaha dealer replace the brake pads as a

set.

The wheels need to be removed to check the

brake pads. (See pages 8-42–8-44 for wheel

removal and installation procedures.)

1. Brake pad wear indicator groove

EE.book Page 34 Friday, August 3, 2007 11:59 AM

8-35

EVU00840

Rear brake pad check

Each brake pad is provided with wear indica-

tor grooves, which allow you to check the

brake pad wear without having to disassem-

ble the brake. To check the brake pad wear,

check the wear indicator grooves. If a brake

pad has worn to the point that the wear indica-

tor grooves have almost disappeared, have a

Yamaha dealer replace the brake pads as a

set.

1. Brake pad wear indicator groove

EVU00850

Checking the brake fluid level

1. Minimum level mark

Insufficient brake fluid may allow air to enter

the brake system, possibly causing the

brakes to become ineffective.

Before riding, check that the brake fluid is

above the minimum level mark and replenish,

if necessary. A low brake fluid level may indi-

cate worn brake pads and/or brake system

leakage. If the brake fluid level is low, be sure

to check the brake pads for wear and the

brake system for leakage.

EE.book Page 35 Friday, August 3, 2007 11:59 AM

8-36

The brake fluid reservoir is located under the

hood. (See pages 8-7–8-8 for hood opening

and closing procedures.)

Observe these precautions:

●When checking the fluid level, make sure

the top of the brake fluid reservoir is level.

●Use only the recommended quality brake

fluid. Otherwise, the rubber seals may de-

teriorate, causing leakage and poor braking

performance.

●Refill with the same type of brake fluid. Mix-

ing fluids may result in a harmful chemical

reaction and lead to poor braking perfor-

mance.

●Be careful that water does not enter the

efilling. Water

will significantly lower the boiling point of

the fluid and may result in vapor lock.

●Brake fluid may deteriorate painted surfac-

es or plastic parts. Always clean up spilled

fluid immediately.

●Have a Yamaha dealer inspect the brake

system if the brake fluid level goes down.

EVU00860

Brake fluid replacement

Complete fluid replacement should be done

only by trained Yamaha service personnel.

Have a Yamaha dealer replace the following

components during periodic maintenance or

when they are damaged or leaking.

●Replace the oil seals every two years.

●Replace the brake hoses every four years.

Recommended brake fluid: DOT 4

EE.book Page 36 Friday, August 3, 2007 11:59 AM

8-37

EVU01220

Checking the brake pedal

Have a Yamaha dealer check the brakes at

the intervals specified in the periodic mainte-

nance and lubrication chart. There should be

no free play in the brake pedal. The brakes

should operate smoothly and there should be

no brake drag. If the brakes feel soft or

spongy, this could indicate air in the brake

system. Have a Yamaha dealer check the

brake system if necessary.

1. Brake pedal

EVU00870

Parking brake lever free play adjustment

Periodically check the parking brake lever free

play and adjust it if necessary.

1. Shift the drive select lever into low gear

“L”.

2. Remove the seats. (See pages 4-16–

4-17 for seat removal and installation

procedures.)

3. Remove the console. (See page 8-9 for

console removal and installation proce-

dures.)

4. Check the parking brake lever free play.

The maximum free play is equal to one

click of the parking brake lever. If neces-

sary, adjust the free play as follows.

EE.book Page 37 Friday, August 3, 2007 11:59 AM

8-38

a. Parking brake lever free play

5. The parking brake lever must be re-

leased when checking and adjusting the

parking brake lever free play.

6. Loosen the locknut.

1. Locknut 2. Adjusting nut

7. Turn the adjusting nut in direction a to

increase the free play or in direction b to

decrease the free play.

8. Tighten the locknut.

9. Reinstall the console.

10. Reinstall the seats.

EE.book Page 38 Friday, August 3, 2007 11:59 AM

8-39

EVU00880

Brake light switch adjustment

The brake light switch, which is activated by

the brake pedal, is properly adjusted when the

brake light comes on just before braking takes

effect. If necessary, adjust the brake light

switch as follows.

1. Open the hood. (See pages 8-7–8-8 for

hood opening and closing procedures.)

2. Turn the adjusting nut while holding the

brake light switch in place. To make the

brake light come on earlier, turn the ad-

justing nut in direction a. To make the

brake light come on later, turn the adjust-

ing nut in direction b.

3. Close the hood.

1. Brake light switch 2. Adjusting nut

EE.book Page 39 Friday, August 3, 2007 11:59 AM

8-40

EVU00890

Cable inspection and lubrication

WARNING

Damaged cables could restrict operation,

which may cause an accident or injury. In-

spect control cables frequently and re-

place damaged cables. Corrosion can

result when the outer covering of control

cables becomes damaged. Cables can

also become frayed or kinked.

Lubricate the cable ends. If the cables do not

operate smoothly, ask a Yamaha dealer to re-

place them.

EVU00900

Brake pedal and accelerator pedal

lubrication

Lubricate the pivoting parts.

Recommended lubricant:

Lithium-soap-based grease

Recommended lubricant:

Lithium-soap-based grease

EE.book Page 40 Friday, August 3, 2007 11:59 AM

8-41

EVU00910

Rear knuckle upper and lower pivot

lubrication

Lubricate the knuckle upper and lower pivots

with a grease gun.

EVU00920

Steering shaft lubrication

Lubricate the pivot points.

Recommended lubricant:

Lithium-soap-based grease

Recommended lubricant:

Lithium-soap-based grease

EE.book Page 41 Friday, August 3, 2007 11:59 AM

8-42

EVU00930

Wheel removal

1. Loosen the wheel nuts.

2. Elevate the vehicle and place a suitable

stand under the frame.

3. Remove the nuts from the wheel.

4. Remove the wheel.

1. Nut (× 4)

Tire replacement

Always use the same size and type of tires

recommended in this owner’s manual. The

tires that came with your Rhino were de-

signed to match the performance capabilities

and to provide the best combination of han-

dling, braking, and comfort. It is best to re-

place all four tires at the same time. If that is

not possible, you must replace the tires in

pairs (front or rear) with tires of the same size

and type as the originals. Never replace just

one tire.

WARNING

Installing improper tires on your Rhino

can affect handling and stability. This can

cause a loss of control.

EE.book Page 42 Friday, August 3, 2007 11:59 AM

8-43

The tires listed below have been approved by

Yamaha Motor Manufacturing Corporation of

America for this model.

EVU00940

Wheel installation

1. Install the wheel and the nuts.

●The arrow mark on the tire must

point toward the rotating direction of

the wheel.

●Tapered nuts are used for both the

front and rear wheels. Install the nut

with its tapered side towards the

wheel.

2. Lower the vehicle so that the wheel is on

the ground.

3. Tighten the wheel nuts to the specified

torque.

WARNING

Do not reverse the rims on the Rhino to

widen the track width. Installing wheels

improperly increases the risk of wheel fail-

ure and accidents.

Manufacturer Size Type

Front MAXXIS 25 × 8-12NHS M951Y

Rear MAXXIS 25 × 10-12NHS M952Y

EE.book Page 43 Friday, August 3, 2007 11:59 AM

8-44

1. Arrow mark

1. Tapered nut

Wheel nut torque:

Front: 55 Nm (5.5 m·kgf, 40 ft·lbf)

Rear: 55 Nm (5.5 m·kgf, 40 ft·lbf)

EE.book Page 44 Friday, August 3, 2007 11:59 AM

8-45

EVU00950

Battery

This vehicle is equipped with a sealed-type

battery. Therefore it is not necessary to check

the electrolyte or add distilled water in the bat-

tery.

If the battery seems to have discharged, con-

sult a Yamaha dealer.

Do not try to remove the sealing caps of

the battery cells. You may damage the bat-

tery.

WARNING

Avoid battery contact with skin, eyes, or

clothing. Shield eyes when working near

batteries. Keep out of reach of children.

You could be poisoned or severely burned

by the sulfuric acid in battery electrolyte.

In case of accidental contact with battery

electrolyte:

EXTERNAL: Flush with water.

INTERNAL: Drink large quantities of water

or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Get prompt

medical attention.

EYES: Flush with water for 15 minutes and

get prompt medical attention.

WARNING

Batteries may produce explosive gases.

Ventilate when charging or using in a

closed space. Keep batteries away from

sparks, flames, cigarettes, or other sourc-

es of ignition.

EE.book Page 45 Friday, August 3, 2007 11:59 AM

8-46

EVU00960

Battery maintenance

1. If the vehicle will not be used for a month

or longer, remove the battery and store it

in a cool, dark place. Completely re-

charge the battery before reinstallation.

A special battery charger (constant volt-

age/ampere or constant voltage) is re-

quired for recharging a sealed-type

battery. Using a conventional battery

charger may shorten the battery life.

2. Always make sure the connections are

correct when putting the battery back in

the vehicle.

1. Negative battery lead (black)

2. Positive battery lead (red)

EE.book Page 46 Friday, August 3, 2007 11:59 AM

8-47

Jump-starting

Jump-starting the vehicle should be avoided.

The battery should be removed and charged

instead.

WARNING

To avoid battery explosion and/or serious

damage to the electrical system:

●Do not connect the negative lead of

the jumper cable to the negative termi-

nal of the battery

●Do not touch the positive lead of the

jumper cable to the negative lead.

●Do not reverse the polarity of the

jumper cables when connecting to the

batteries.

However, if the vehicle must be jump-started,

proceed as follows.

1. Turn the key to “OFF”.

2. Open the hood. (See pages 8-7–8-8 for

hood opening and closing procedures.)

3. Remove the battery compartment cover.

4. Using a charged 12-volt battery, connect

the positive lead of the jumper cable to

the positive terminal of the battery in the

vehicle and the other end of the positive

lead to the positive terminal of the

charged battery.

EE.book Page 47 Friday, August 3, 2007 11:59 AM

8-48

1. Jumper cable positive lead

2. Jumper cable negative lead

5. Connect the negative lead of the jumper

cable to the negative terminal of the

charged battery and the other end of the

negative lead to an unpainted metal sur-

face of the vehicle to be started.

6. Start the engine. (Refer to “Starting a

cold engine” on pages 6-2–6-5.)

7. After the engine starts, disconnect the

negative lead of the jumper cable from

the vehicle and charged battery, and

then disconnect the positive lead of the

jumper cable from the charged battery

and the battery in the vehicle.

8. Reinstall the battery compartment cover.

9. Close the hood.

EE.book Page 48 Friday, August 3, 2007 11:59 AM

8-49

EVU00970

Fuse replacement

The main fuse and the fuse box are located

under the hood. (See pages 8-7–8-8 for hood

opening and closing procedures.)

If a fuse is blown, turn off the main switch and

install a new fuse of the specified amperage.

If a fuse is blown, replace it as follows.

1. Remove the battery compartment cover

by lifting it up and pulling it out.

1. Battery compartment cover

Turn the key to “OFF” and turn off the electri-

cal circuit in question.

To prevent accidental short-circuiting,

turn off the main switch when checking or

replacing a fuse.

2. Remove the blown fuse, and then install

a new fuse of the specified amperage.

WARNING! Always use a fuse of the

specified amperage. Never use any

material in place of the proper fuse.

Using an improper fuse can cause

damage to the electrical system and

may lead to a fire.

EE.book Page 49 Friday, August 3, 2007 11:59 AM

8-50

1. Main fuse 2. Spare main fuse

3. Headlight fuse 4. Ignition fuse

5. Auxiliary DC jack fuse 6. Four-wheel-drive motor fuse

7. Signaling system fuse

8. Backup fuse (for odometer and clock on Special Edition

models)

9. Carburetor warmer fuse 10. Spare fuse (× 3)

3. Turn the key to “ON” and turn on the

electrical circuit in question to check if the

device operates.

4. If the fuse blows again immediately, have

a Yamaha dealer check the electrical

system.

5. Reinstall the battery compartment cover.

6. Close the hood.

Specified fuses:

Main fuse: 30.0 A

Headlight fuse: 15.0 A

Ignition fuse: 10.0 A

Auxiliary DC jack fuse: 10.0 A

Signaling system fuse: 10.0 A

Carburetor warmer fuse: 10.0 A

Four-wheel-drive motor

fuse: 3.0 A

Backup fuse: 10.0 A

EE.book Page 50 Friday, August 3, 2007 11:59 AM

8-51

EVU01670

Replacing a headlight bulb

If a headlight bulb burns out, replace it as fol-

lows.

1. Lift the hood up. (See pages 8-7–8-8 for

hood opening and closing procedures.)

2. Remove the cover at the rear of the

headlight by pulling it off.

1. Cover at the rear of the headlight

3. Remove the headlight bulb holder cover

by pulling it off.

1. Headlight bulb holder cover

EE.book Page 51 Friday, August 3, 2007 11:59 AM

8-52

4. Remove the headlight bulb holder by

pushing it in and turning it counterclock-

wise.

1. Headlight bulb holder

5. Wait for the headlight bulb to cool before

touching or removing it. Remove the bulb

by pulling it out.

6. Insert a new headlight bulb into the bulb

holder by pushing it in.

1. Do not touch the glass part of the bulb.

EE.book Page 52 Friday, August 3, 2007 11:59 AM

8-53

7. Reinstall the bulb holder by pushing it in

and turning it clockwise.

Reinstall the bulb holder cover and the

cover at the rear of the headlight.

NOTICE: Make sure the headlight bulb

holder cover is securely fitted over the

bulb holder and seated properly.

8. Close the hood.

9. Adjust the headlight beam if necessary.

EVU00990

Headlight beam adjustment

NOTICE

It is advisable to have a Yamaha dealer

make this adjustment.

To raise the beam, turn the adjusting screw in

direction a.

To lower the beam, turn the adjusting screw in

direction b.

1. Headlight beam adjusting screw

EE.book Page 53 Friday, August 3, 2007 11:59 AM

8-54

EVU01000

Tail/brake light bulb replacement

If a tail/brake light bulb burns out, replace it as

follows:

1. Remove the quick fastener screws and

bolts from panel A (if replacing the left

tail/brake light bulb) or panel B (if replac-

ing the right tail/brake light bulb).

1. Panel A

1. Panel B

1. Quick fastener screw (× 8) 2. Bolt (× 2)

3. Panel A

EE.book Page 54 Friday, August 3, 2007 11:59 AM

8-55

2. Lift the cargo bed up. (See pages 4-19–

4-20 for cargo bed lifting and lowering

procedures.)

3. Remove the panel.

4. Remove the bulb holder (together with

the bulb) by turning it counterclockwise.

1. Tail/brake light bulb holder

5. Push the defective bulb in and turn it

ove it from the

bulb holder.

6. Push a new bulb in and turn it clockwise

to install in the bulb holder.

7. Reinstall the bulb holder (together with

the bulb) by turning it clockwise.

8. Install the panel.

9. Lower the cargo bed.

10. Reinstall the quick fastener screws and

bolts, and then tighten the bolts to the

specified torque.

Tightening torque:

Panel bolt:

6.5 Nm (0.65 m·kgf, 4.7 ft·lbf)

EE.book Page 55 Friday, August 3, 2007 11:59 AM

8-56

EVU01010

Troubleshooting

Although Yamaha vehicles receive an inspec-

tion before shipment from the factory, trouble

may occur during operation. Any problem in

the fuel, compression, or ignition systems can

cause poor starting and loss of power. The

troubleshooting chart describes a quick, easy

procedure for making checks. If your vehicle

requires any repair, take it to a Yamaha deal-

er.

The skilled technicians at a Yamaha dealer-

ship have the tools, experience, and know-

how to properly service your vehicle. Use only

genuine Yamaha parts on your vehicle. Imita-

tion parts may look like Yamaha parts, but

they are often inferior. Consequently, they

have a shorter service life and can lead to ex-

pensive repair bills.

WARNING

When checking the fuel system, do not

smoke and make sure there are no open

flames or sparks in the area, including pi-

lot lights from water heaters or furnaces.

Gasoline or gasoline vapors can ignite or

explode, causing severe injury or property

damage.

EE.book Page 56 Friday, August 3, 2007 11:59 AM

8-57

EVU01020

Troubleshooting charts

Starting problems or poor engine performance

1. Fuel

Check if there is fuel

in the fuel tank.

There is fuel. No fuel. Fuel pump is

clogged.

Restart the engine.

No fuel. Supply fuel.

2. Compression

Use the electric

starter to see if

there is compression.

There is compression. Compression normal.

No compression. Ask a Yamaha dealer to

inspect.

3. Ignition

Remove the

spark plug and

check the electrodes.

Wet Wipe clean with dry cloth.

Dry Attach spark plug cap and

ground to chassis.

Use the

electric starter.

Spark is good. Ignition system is

normal.

Spark is weak.

Adjust the spark plug gap

or replace the spark plug.

No spark.

Ask a Yamaha dealer to

inspect.

4. Battery Engine turns over

quickly. Battery is good.

Engine turns over

slowly.

Check the connections,

recharge.

Check the

fuel flow.

Remove the fuel hose

from the fuel pump.

Ask a Yamaha dealer to

inspect.

EE.book Page 57 Friday, August 3, 2007 11:59 AM

8-58

Engine overheating

Wait for the engine to cool before removing the radiator cap. WARNING! If the engine is not

cool when removing the radiator cap, hot fluid and steam could blow out under pressure

and burn you. Place a thick rag over the cap and remove the cap slowly to allow any remaining

pressure to escape.

If it is difficult to get the recommended coolant, tap water can be used temporarily, provided that

it is changed to the recommended coolant as soon as possible.

Wait until the

engine has cooled.

Check the coolant level in the

coolant reservoir and/or radiator.

Level is OK.

Level is low, check the

cooling system for leakage.

leakage.

Leakage.

Ask a Yamaha dealer to inspect

and repair the cooling system.

Add coolant. (See the text below.)

Restart the engine. If the engine overheats again, ask a

Yamaha dealer to inspect and/or repair the cooling system.

EE.book Page 58 Friday, August 3, 2007 11:59 AM

9-1

EVU01030

CLEANING AND STORAGE

A. Cleaning

Frequent, thorough cleaning of your vehicle

will not only enhance its appearance but will

improve its general performance and extend

the useful life of many components.

1. Before cleaning the vehicle:

a. Block off the end of the exhaust pipe

to prevent water entry. A plastic bag

and strong rubber band may be used.

b. Make sure the spark plug and all filler

caps are properly installed.

2. If the engine case is excessively greasy,

apply degreaser with a paint brush. Do

not apply degreaser to the wheel axles.

3. Rinse the dirt and degreaser off with a

garden hose. Use only enough pressure

to do the job. WARNING! Test the

brakes after washing. Apply the

brakes several times at slow speeds

to let friction dry out the linings. Wet

brakes may have reduced stopping

ability, increasing the chance of an ac-

cident. NOTICE: Excessive water

pressure may cause water seepage

and deterioration of wheel bearings,

brakes, transmission seals and elec-

trical devices. Many expensive repair

bills have resulted from improper

high-pressure detergent applications,

such as those available in coin-oper-

ated car washers.

EE.book Page 1 Friday, August 3, 2007 11:59 AM

9-2

4. Once the majority of the dirt has been

hosed off, wash all surfaces with warm

water and mild, detergent-type soap. An

old toothbrush or bottle brush is handy for

hard-to-get-at places.

5. Rinse the vehicle off immediately with

clean water and dry all surfaces with a

clean chamois towel or soft, absorbent

cloth.

6. Clean the seats with a vinyl upholstery

cleaner to keep the covers pliable and

glossy.

7. Automotive-type wax may be applied to

all painted and chrome-plated surfaces.

Avoid combination cleaner-waxes. Many

contain abrasives which may scratch the

paint or protective finish. When finished,

start the engine and let it idle for several

EVU01041

B. Storage

Long term storage (60 days or more) of your

vehicle will require some preventive proce-

dures to guard against deterioration. Make

any necessary repairs before storing the vehi-

cle.

After thoroughly cleaning the vehicle, prepare

for storage as follows:

1. Fill the fuel tank with fresh fuel and add

the specified amount of Yamaha Fuel

Stabilizer and Conditioner or equivalent

product. Operate the vehicle for at least

5 minutes to distribute treated fuel

through the fuel system.

2. Drain the fuel from the carburetor float

chamber into a clean container by loos-

ening the drain bolt; this will help prevent

fuel deposits from building up. Pour the

drained fuel into the fuel tank.

Specified amount:

1 oz of stabilizer to each gallon of fuel (or

7.5 ml of stabilizer to each liter of fuel)

EE.book Page 2 Friday, August 3, 2007 11:59 AM

9-3

3. Remove the spark plug, pour about one

tablespoon of SAE 10W-40 or 20W-50

motor oil in the spark plug hole and rein-

stall the spark plug. Ground the spark

plug wire and turn the engine over sever-

al times to coat the cylinder wall with oil.

4. Lubricate all control cables.

5. Block up the frame to raise all wheels off

the ground.

6. Tie a plastic bag over the exhaust pipe

outlet to prevent moisture from entering.

7. If storing in a humid or salt-air atmo-

sphere, coat all exposed metal surfaces

with a light film of oil. Do not apply oil to

any rubber parts or the seat covers.

8. Remove the battery and charge it. Store

it in a dry place and recharge it once a

month. Do not store the battery in an ex-

cessively warm or cold place [less than

0°C (30 °F) or more than 30 °C (90 °F)].

Use of fuel stabilizer and conditioner elimi-

nates the need to drain the fuel system. Con-

sult a Yamaha dealer if the fuel system needs

to be drained.

EE.book Page 3 Friday, August 3, 2007 11:59 AM

10-1

EVU01050

SPECIFICATIONS

Model YXR45FX

Dimensions:

Overall length 2,885 mm (113.6 in)

Overall width 1,385 mm (54.5 in)

Overall height 1,853 mm (73.0 in)

Seat height 818 mm (32.2 in)

Wheelbase 1,910 mm (75.2 in)

Ground clearance 280 mm (11.0 in)

Minimum turning radius 3,900 mm (154 in)

Basic weight:

With oil and full fuel tank 509.0 kg (1,122 lb)

Engine:

Engine type Liquid cooled 4-stroke, SOHC

Cylinder arrangement Forward-inclined single cylinder

Displacement 421.0 cm3

Bore × stroke 84.5 × 75.0 mm (3.33 × 2.95 in)

10.00:1

Starting system Electric starter

Lubrication system Wet sump

EE.book Page 1 Friday, August 3, 2007 11:59 AM

10-2

Engine oil:

Type:

Recommended engine oil classification API service SG type or higher, JASO standard MA

Quantity:

placement 2.50 L (2.20 Imp qt, 2.64 US qt)

With oil filter cartridge replacement 2.60 L (2.29 Imp qt, 2.75 US qt)

Model YXR45FX

010 30 50 70 90 110 130 ˚F

-20 -10 0 10 20 30 40 50 ˚C

YAMALUBE 4 (10W-40) or SAE 10W-40

YAMALUBE 4-CW (5W-30) or SAE 5W-30

YAMALUBE 4 (20W-50) or SAE 20W-50

NOTICE

In order to prevent clutch slippage (since the en-

gine oil also lubricates the clutch), do not mix any

chemical additives with oil. Do not use oils with a

diesel specification of “CD” or oils of a higher qual-

ity than specified. In addition, do not use oils la-

beled “ENERGY CONSERVING II” or higher.

EE.book Page 2 Friday, August 3, 2007 11:59 AM

10-3

Final gear case oil:

Type SAE 80 API GL-4 Hypoid gear oil

Quantity 0.25 L (0.22 Imp qt, 0.26 US qt)

Differential gear case oil:

Type SAE 80 API GL-5 Hypoid gear oil

Quantity 0.32 L (0.28 Imp qt, 0.34 US qt)

Radiator capacity (including all routes): 2.70 L (2.38 Imp qt, 2.85 US qt)

Air filter:

Engine Wet element

Intake duct Dry element

Fuel:

Type Unleaded gasoline only

Fuel tank capacity 30.0 L (6.60 lmp gal, 7.93 US gal)

Carburetor:

Type/quantity BSR33/1

Manufacturer MIKUNI

Spark plug:

DR8EA/NGK

Spark plug gap 0.6–0.7 mm (0.024–0.028 in)

Clutch type: Wet, centrifugal automatic

Model YXR45FX

EE.book Page 3 Friday, August 3, 2007 11:59 AM

10-4

Transmission:

Primary reduction system V-belt

Secondary reduction system Shaft drive

Secondary reduction ratio 43/20 × 24/17 × 33/9 (11.129)

Transmission type V-belt automatic

Operation Right hand operation

Reverse gear 30/15 (2.000)

Sub transmission ratio low 43/18 (2.389)

high 39/22 (1.773)

Chassis:

Frame type Steel tube frame

Caster angle 5.0°

Trail 26.0 mm (1.02 in)

Tire:

Type Tubeless

Size front 25 × 8-12NHS

rear 25 × 10-12NHS

Model YXR45FX

EE.book Page 4 Friday, August 3, 2007 11:59 AM

10-5

Brakes:

System Front and rear unified

Type front Dual disc brake

rear Single disc brake

Operation Foot operation

Suspension:

Front suspension Double wishbone

Rear suspension Double wishbone

Shock absorber:

Front shock absorber Coil spring/oil damper

Rear shock absorber Coil spring/oil damper

Wheel travel:

Front wheel travel 185 mm (7.3 in)

Rear wheel travel 185 mm (7.3 in)

Electrical:

Ignition system DC CDI

Generator system AC magneto

U1L-11

Battery capacity 12 V 28.0 Ah

Headlight type: Krypton bulb

Model YXR45FX

EE.book Page 5 Friday, August 3, 2007 11:59 AM

10-6

Bulb voltage, wattage × quantity:

Headlight 12 V 30.0 W/30.0 W × 2

Tail/brake light 12 V 5.0 W/21.0 W × 2

Indicator lights:

Neutral indicator light 12 V 1.7 W × 1

LED (Special Edition models)

Reverse indicator light 12 V 1.7 W × 1

LED (Special Edition models)

Coolant temperature warning light 12 V 1.7 W × 1

LED (Special Edition models)

Parking brake indicator light 12 V 1.7 W × 1

LED (Special Edition models)

On-Command four-wheel-drive indicator light

(except Special Edition models)

12 V 1.7 W × 1

On-Command four-wheel-drive/differential gear

lock indicator (Special Edition models)

LCD

On-Command differential gear lock indicator light 12 V 1.7 W × 1

LED (Special Edition models)

cial Edition models) LED

Low-range indicator light (Special Edition models) LED

Model YXR45FX

EE.book Page 6 Friday, August 3, 2007 11:59 AM

10-7

Specified fuses:

Main fuse 30.0 A

Headlight fuse 15.0 A

Ignition fuse 10.0 A

Auxiliary DC jack fuse 10.0 A

Four-wheel-drive motor fuse 3.0 A

Carburetor warmer fuse 10.0 A

Signaling system fuse 10.0 A

Backup fuse 10.0 A

Model YXR45FX

EE.book Page 7 Friday, August 3, 2007 11:59 AM

11-1

CONSUMER INFORMATION

EVU00090

Identification number records

Record the key identification number, vehicle

identification number, and model label infor-

mation in the spaces provided for assistance

when ordering spare parts from a Yamaha

dealer or for reference, in case the vehicle is

stolen.

1. KEY IDENTIFICATION NUMBER:

ACA-02E

2. VEHICLE IDENTIFICATION NUMBER:

ACA-02E

3. MODEL LABEL INFORMATION:

ACA-01E

EE.book Page 1 Friday, August 3, 2007 11:59 AM

11-2

EVU00100

Key identification number

The key identification number is stamped on

the key, as shown in the following illustration.

This number can be used for ordering a new

key.

1. Key identification number

EVU00110

Vehicle identification number

The vehicle identification number is stamped

into the frame.

1. Vehicle identification number

The vehicle identification number is used to

identify your vehicle.

EE.book Page 2 Friday, August 3, 2007 11:59 AM

11-3

EVU00121

Model label

The model label is affixed to the frame under

the driver seat. Record the information on this

label in the space provided. This information

will be needed to order spare parts from your

Yamaha dealer.

1. Model label

EE.book Page 3 Friday, August 3, 2007 11:59 AM

11-4

EVU01060

NOISE REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop-

erative by any person other than for purposes of maintenance, repair, or replacement of any de-

vice or element of design incorporated into any new vehicle for the purpose of noise control prior

to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after

such device or element of design has been removed or rendered inoperative by any person.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED

BELOW.”

These acts include tampering with the following systems; i.e., modification, removal, etc.

Exhaust system

Muffler

Exhaust pipe

Silencer

Intake system

Air cleaner case

Air cleaner element

Intake duct

EE.book Page 4 Friday, August 3, 2007 11:59 AM

11-5

EVU01070

MAINTENANCE RECORD

Copies of work orders and/or receipts for parts you purchase and install will be required to docu-

ment maintenance done in accordance with the warranty. The chart below is printed only as a re-

minder to you that the maintenance work is required. It is not acceptable proof of maintenance

work.

MAINTENANCE

INTERVAL DATE OF

SERVICE MILEAGE SERVICING DEALER

NAME AND ADDRESS REMARKS

month km (mi) hours

1 320 (200) 20

3 1,200 (750) 75

6 2,400 (1,500) 150

12 4,800 (3,000) 300

18 7,200 (4,500) 450

24 9,600 (6,000) 600

30 12,000 (7,500) 750

36 14,400 (9,000) 900

42 16,800 (10,500) 1,050

48 19,200 (12,000) 1,200

60 24,000 (15,000) 1,500

EE.book Page 5 Friday, August 3, 2007 11:59 AM

11-6

EVU01081

YAMAHA MOTOR CORPORATION, U.S.A. SIDE × SIDE VEHICLE LIMITED WARRANTY

Yamaha Motor Corporation, U.S.A. hereby warrants

that new Yamaha Side × Side vehicles purchased

from an authorized Yamaha Side × Side Vehicle

dealer in the continental United States will be free

from defects in material and workmanship for the

period of time stated herein, subject to certain stated

limitations.

GENERAL EXCLUSIONS from this warranty shall

include any failures caused by:

Competition or racing use.

Installation of parts or accessories that are not

qualitatively equivalent to genuine Yamaha parts.

Abnormal strain, neglect, or abuse.

Lack of proper maintenance.

Modification to original parts.

Damage due to improper transportation.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES

NO OTHER WARRANTY OF ANY KIND, EXPRESSED

OR IMPLIED. ALL IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE WHICH EXCEED THE

OBLIGATIONS AND TIME LIMITS STATED IN THIS

WARRANTY ARE HEREBY DISCLAIMED BY

YAMAHA MOTOR CORPORATION, U.S.A. AND

EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON

HOW LONG AN IMPLIED WARRANTY LASTS, SO

THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

ALSO EXCLUDED FROM THIS WARRANTY ARE

ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES

INCLUDING LOSS OF USE. SOME STATES DO

NOT ALLOW THE EXCLUSION OR LIMITATION OF

INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO

THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL

RIGHTS, AND YOU MAY ALSO HAVE OTHER

RIGHTS WHICH VARY FROM STATE TO STATE.

THE PERIOD OF WARRANTY for YXR OR YXP

Yamaha Side × Side vehicles shall be six (6) months

from the date of purchase, with no mileage limitation.

MODELS EXCLUDED FROM WARRANTY include

those used for non-Yamaha-authorized renting,

leasing, or other commercial purposes.

DURING THE PERIOD OF WARRANTY any

authorized Yamaha Side × Side Vehicle dealer will for

free of charge, repair or replace, at Yamaha’s option,

any part adjudged defective by Yamaha due to faulty

workmanship or material from the factory. Parts used

in warranty repairs will be warranted for the balance

of the product’s warranty period. All parts replaced

under warranty become property of Yamaha Motor

Corporation, U.S.A.

SPECIFIC EXCLUSIONS from this warranty shall

include parts replaced due to normal wear or routine

maintenance; such as spark plugs, oil, oil filter, air

filter, and brake pads.

Operate and maintain the Side × Side vehicle as

specified in the appropriate Owner’s Manual, and

Give notice to an authorized Yamaha Side × Side

Vehicle dealer of any and all apparent defects

within ten (10) days after discovery, and make the

machine available at that time for inspection and

repairs at such dealer’s place of business.

THE CUSTOMER’S RESPONSIBILITY under this

warranty shall be to:

WARRANTY TRANSFER: To transfer the warranty

from the original purchaser to any subsequent

purchaser(s), it is imperative that the Side × Side

vehicle be inspected and registered for warranty by

an authorized Yamaha Side × Side Vehicle dealer. In

order for this warranty to remain in effect, this

inspection and registration must take place within ten

(10) days after transfer of ownership to the

subsequent purchaser. A reasonable dealer-imposed

fee may be charged for this inspection.

EMISSION CONTROL SYSTEM WARRANTY

Yamaha Motor Corporation, U.S.A. also warrants to

the ultimate purchaser and each subsequent

purchaser of each 2006 and later model Yamaha Side

× Side vehicle covered by this warranty that the

vehicle is designed, built, and equipped so as to

conform at the time of sale with all U.S. emissions

standards applicable at the time of manufacture and

that it is free from defects in materials and

workmanship which would cause it not to meet these

standards within the period listed immediately below.

Failures other than those resulting from defects in

material or workmanship which arise solely as a

result of owner abuse and/or lack of proper

maintenance are not covered by this

warranty.

ALL MODELS

Thirty (30) months from the original purchase date

EE.book Page 6 Friday, August 3, 2007 11:59 AM

11-7

EVU01090

YAMAHA EXTENDED SERVICE (Y.E.S.)

EE.book Page 7 Friday, August 3, 2007 11:59 AM

11-8

EE.book Page 8 Friday, August 3, 2007 11:59 AM

B6-yoko.fm Page 1 Wednesday, March 8, 2006 10:46 AM

PRINTED IN USA

2007.08-2.9×1 CR

(E)

DIC2342

YAMAHA MOTOR CO., LTD.

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