Yamaha YXR70FX RHINO FUEL INJECTION 700FI OWNER'S MANUAL User To The Bfc3955e 4717 45de 8fae 8badd43b74de

User Manual: Yamaha YXR70FX to the manual

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RHINO FUEL INJECTION 700FI YXR70FX OWNER'S MANUAL

5B4-F8199-10LIT-11626-21-58

READ THIS MANUAL CAREFULLY!

It contains important safety information.

YXR70FX

OWNER’S MANUAL

DIC2342

EBU00776

EVU00010

INTRODUCTION

Congratulations on your purchase of the Yamaha YXR70FX. 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 Thursday, September 6, 2007 4:28 PM

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:

*Product and specifications are 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.

NOTICE A 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 Thursday, September 6, 2007 4:28 PM

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.

YXR70FX

OWNER’S MANUAL

U.S.A.

1st edition, August 2007

unauthorized use without the written

permission of

Yamaha Motor Corporation,

U.S.A. is expressly prohibited.

Printed in U.S.A.

P/N LIT-11626-21-58

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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

Multi-function meter unit.................. 4-5

Switches ........................................ 4-11

Accelerator pedal .......................... 4-13

Brake pedal ................................... 4-13

Parking brake lever ....................... 4-14

Drive select lever........................... 4-15

Fuel tank cap................................. 4-15

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

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

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

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

Cup holders....................................4-18

Cargo bed ......................................4-19

Front and rear shock absorber

adjustment ...................................4-21

Trailer hitch bracket and

receiver ........................................4-23

Auxiliary DC jack............................4-23

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

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

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

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

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

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

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

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

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

Starting the engine.......................... 6-2

Drive select lever operation and

reverse driving............................... 6-4

On-Command four-wheel-drive

switch and differential gear lock

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

Parking ............................................ 6-8

Loading ........................................... 6-9

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

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

Driver requirements ........................ 7-3

Passenger requirements................. 7-4

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

Protective structure ......................... 7-6

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

Doors............................................... 7-9

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

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

Floorboard .....................................7-11

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

Accelerating...................................7-16

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

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

Leaving the vehicle........................7-17

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

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

Loading..........................................7-18

Operation on different surfaces

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

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

Uphill..............................................7-20

Downhill .........................................7-21

Rough terrain.................................7-22

Pavement ......................................7-22

EE.book Page 2 Thursday, September 6, 2007 4:28 PM

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

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

Brush or wooded areas ................. 7-24

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

lubrication chart ............................. 8-5

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

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

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

Final gear oil.................................. 8-16

Differential gear oil......................... 8-19

Coolant .......................................... 8-21

Axle boots...................................... 8-23

Spark plug inspection.................... 8-24

Cleaning the air filter element ....... 8-26

Drive select lever box check

hose............................................. 8-31

V-belt cooling duct check hose......8-32

V-belt case drain plug ....................8-32

Cleaning the spark arrester ...........8-33

Valve clearance .............................8-34

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

Checking the front and rear brake

pads .............................................8-34

Checking the parking brake

pads .............................................8-35

Checking the brake fluid level........8-36

Brake fluid replacement.................8-37

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

Parking brake lever free play

adjustment ...................................8-38

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

Cable inspection and lubrication....8-40

Brake pedal and accelerator

pedal lubrication...........................8-41

Rear knuckle upper and lower

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

Steering shaft lubrication ...............8-43

Wheel removal...............................8-43

Tire replacement............................8-44

EE.book Page 3 Thursday, September 6, 2007 4:28 PM

Wheel installation.......................... 8-45

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

Battery maintenance..................... 8-47

Jump-starting ................................ 8-48

Fuse replacement ......................... 8-51

Replacing a headlight bulb ........... 8-53

Headlight beam adjustment.......... 8-55

Tail/brake light bulb

replacement ................................ 8-56

Troubleshooting ............................ 8-58

Troubleshooting charts ................. 8-59

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

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1-1

EVU00060

LOCATION OF THE WARNING AND

SPECIFICATION LABELS

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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

hands on the

handholds.

Do not try to stop a

vehicle tipover

using your arm or

leg.

5B4-K7762-00

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

hands on the

steering wheel.

Do not try to stop a

vehicle tipover

using your arm or

leg.

5B4-K7761-00

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

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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

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1-4

YAMAHA 5UG-F151J-00

MAX 7.3 INCH

(185MM)

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1-5

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 Thursday, September 6, 2007 4:28 PM

1-6

•

DRIVER

UNDER

YAMAHA 5B4-F1568-01

WARNING

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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.

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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),

gloves, over-the-ankle boots, long-sleeved shirt or jacket, and long pants.

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

DRIVER

UNDER

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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 Thursday, September 6, 2007 4:28 PM

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.

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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.

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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.

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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).

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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.

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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.

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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 8-43–8-46 for tire specifications and

more information on replacing your tires.

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3-1

EVU00080

DESCRIPTION

1. Headlights

2. Front shock absorber assembly

3. Brake fluid reservoir

4. Air filter element

5. V-belt case

6. Driver seat

7. Driver seat belt

8. Cargo bed

9. Tail/brake lights

10. Rear shock absorber assembly

11. Cargo bed release levers

12. Spark plug

13. Door

CBA 0

14. Spark arrester

15. Passenger seat belt

16. Passenger seat

17. Passenger handhold

18. Engine oil dipstick

19. Battery

20. Fuses

21. Coolant reservoir

22. Radiator cap

23. Oil filter cartridge

24. Fuel tank cap

HGFEIJKL

ACMN

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3-2

25. Light switch

26. Steering wheel

27. Main switch

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

29. Multi-function meter unit

30. Auxiliary DC jack

31. Drive select lever

32. Parking brake lever

33. Accelerator pedal

34. Brake pedal

The vehicle you have purchased may differ

slightly from those shown in the figures of this

manual.

OPST

WX G

EE.book Page 2 Thursday, September 6, 2007 4:28 PM

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

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4-2

EVU00150

Indicator and warning lights

1. On-Command differential gear lock indicator light

“DIFF. LOCK”

2. Low-range indicator light “L”

3. High-range indicator light “H”

4. Neutral indicator light “N”

5. Reverse indicator light “R”

6. Parking brake indicator light “P”

7. On-Command four-wheel-drive/differential gear lock

indicator “”/“”

8. Coolant temperature warning light “”

9. Engine trouble 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.

DIFF.

LOCK

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4-3

EVU00170

Neutral indicator light “N”

This indicator light comes on when the drive

select lever is in the “N” position.

5B410001

Reverse indicator light “R”

This indicator light comes on when the drive

select lever is in the “R” reverse position.

EVU00210

Parking brake indicator light “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 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

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4-4

5B410002

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 8-60.)

The electrical circuit of the warning light can

be checked by turning the key to “ON”. If the

warning light does not come on, have a

Yamaha dealer check the electrical circuit.

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.

5B410003

Engine trouble warning light “”

This warning light comes on or flashes when

an electrical circuit monitoring the engine is

defective. When this occurs, have a Yamaha

dealer check the self-diagnosis system. (See

page 4-10 for an explanation of the self-diag-

nosis device.)

The electrical circuit of the warning light can

be checked by turning the key to “ON”. If the

warning light does not come on, then go off,

have a Yamaha dealer check the electrical

circuit.

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4-5

5B410004

Multi-function meter unit

1. Speedometer 2. Fuel meter

3. “H” button 4. “M” button

5. Clock/Hour meter/Voltage display

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)

●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 voltage display (which shows the battery

voltage)

●a fuel meter

●a self-diagnosis device

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4-6

Odometer and tripmeter modes

1. Odometer/Tripmeter A/Tripmeter B

2. “TRIP/ODO” button

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.

To switch the display between “mph” and

“km/h”, push and hold the “TRIP/ODO” button

while turning the key to “ON”.

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4-7

Clock, hour meter and voltage display

modes

1. Clock/Hour button “/”

2. “H” button 3. “M” button

4. Clock/Hour meter/Voltage display

Pushing the “/” button switches the dis-

play between the clock mode “CLOCK”, the

hour meter mode “HOUR”, and the voltage

display mode “btry” in the following order:

CLOCK → HOUR → btry → 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.

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4-8

Voltage display mode

This display shows the battery voltage.

“btry” appears for 1 second when the voltage

display mode is first selected, and then the

battery voltage is shown.

If the battery voltage is less than 10 volts, “LO”

is displayed and if the voltage is above 16

volts, “HI” is displayed.

OTICE

If the voltage display indicates “LO” or

“HI”, there may be trouble with the battery

charging circuit or the battery may be

faulty. If “LO” or “HI” appears in the dis-

play, have a Yamaha dealer check or repair

the vehicle.

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4-9

Fuel meter

1. Fuel level warning indicator

2. Fuel meter 3. “E” segment

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.

TIP

This fuel meter is equipped with a self-diagno-

sis system. If the electrical circuit is defective,

all the display segments and fuel level warn-

ing indicator will start flashing. If this occurs,

have a Yamaha dealer check the electrical

circuit.

EE.book Page 9 Thursday, September 6, 2007 4:28 PM

4-10

Self-diagnosis device

1. Error code display

This model is equipped with a self-diagnosis

device for various electrical circuits.

If any of those circuits are defective, the en-

gine trouble warning light will come on or

flash, and then the multi-function display will

indicate a two-digit error code.

If the multi-function display indicates such an

error code, note the code number, and then

have a Yamaha dealer check the vehicle.

OTICE

If the multi-function display indicates an

error code, the vehicle should be checked

as soon as possible in order to avoid en-

gine damage.

EE.book Page 10 Thursday, September 6, 2007 4:28 PM

4-11

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.

Set the switch to “OFF” to turn off all the lights.

NOTICE

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 11 Thursday, September 6, 2007 4:28 PM

4-12

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-

ing to terrain and conditions.

●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 12 Thursday, September 6, 2007 4:28 PM

4-13

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 13 Thursday, September 6, 2007 4:28 PM

4-14

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 14 Thursday, September 6, 2007 4:28 PM

4-15

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 6-4–6-5 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 15 Thursday, September 6, 2007 4:28 PM

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 Thursday, September 6, 2007 4:28 PM

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 Thursday, September 6, 2007 4:28 PM

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.

a. Unlock. b. Open.

5B410005

Cup holders

Be sure to tightly close the cap of any plastic

bottle before placing it in a cup holder.

Some plastic bottles may not fit into the cup

holders depending on their size and shape.

WARNING

●While the vehicle is moving, do not

place any open or glass containers in

the cup holders; otherwise, the con-

tents may spill and the glass contain-

ers may break.

●Do not place any items, other than

cups or plastic bottles, in the cup

holders; otherwise, they may be

thrown about and possibly injure peo-

ple in the vehicle during sudden brak-

ing or an accident.

EE.book Page 18 Thursday, September 6, 2007 4:28 PM

4-19

1. Storage/cup holder (× 1) 2. Cup holder (× 2)

EVU00351

Cargo bed

1. Cargo bed 2. Tailgate

3. Cargo hook (× 4)

For additional loading information, see pages

6-9–6-11.

Maximum load limit: 181 kg (400 lb)

EE.book Page 19 Thursday, September 6, 2007 4:28 PM

4-20

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

then hook the latches.

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 20 Thursday, September 6, 2007 4:28 PM

4-21

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.

5B410006

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.

The rear wheels need to be removed to adjust

the rear shock absorber assemblies. (See

pages 8-43–8-46 for wheel removal and in-

stallation procedures.)

EE.book Page 21 Thursday, September 6, 2007 4:28 PM

4-22

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 22 Thursday, September 6, 2007 4:28 PM

4-23

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 6-9–6-11 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 6-2–6-3.)

3. Open the auxiliary DC jack cap, and then

insert the accessory power plug into the

jack.

EE.book Page 23 Thursday, September 6, 2007 4:28 PM

4-24

1. Auxiliary DC jack

4. When the auxiliary DC jack is not being

used, cover it with the cap.

OTICE

●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 24 Thursday, September 6, 2007 4:28 PM

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,

8-39–8-40

Parking brake •Check for proper operation, condition, and free play. 8-38–8-39

Fuel •Check fuel level.

•Fill with fuel if necessary. 5-4–5-5

Engine oil •Check oil level.

•Fill with oil to proper level if necessary. 5-6, 8-10–8-15

Coolant reservoir •Check coolant level.

•Fill with coolant if necessary. 5-7, 8-21–8-22

EE.book Page 1 Thursday, September 6, 2007 4:28 PM

5-2

Final gear oil/

Differential gear oil •Check for leakage. 5-7, 8-16–8-21

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. 5-9, 8-53–8-57

Wheels and tires •Check tire pressure and for wear and damage. 5-9–5-11, 8-43–8-46

Axle boots •Check for damage. 8-23

ITEM ROUTINE PAGE

EE.book Page 2 Thursday, September 6, 2007 4:28 PM

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 8-36–8-37.)

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, 8-37–8-40.)

Recommended brake fluid: DOT 4

EE.book Page 3 Thursday, September 6, 2007 4:28 PM

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.

2. Do not overfill the fuel tank. 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.

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.

EE.book Page 4 Thursday, September 6, 2007 4:28 PM

5-5

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 Thursday, September 6, 2007 4:28 PM

5-6

EVU00410

Engine oil

Make sure the engine oil is at the specified

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

8-15.)

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 Thursday, September 6, 2007 4:28 PM

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 8-21–8-22 for details.)

NOTICE

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 8-16–

8-18 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 8-19–8-21 for details.)

Coolant reservoir capacity

(up to the maximum level mark):

0.32 L (0.28 Imp qt, 0.34 US qt)

Recommended oil:

SAE 80 API GL-4 Hypoid gear oil

Recommended oil:

SAE 80 API GL-4 Hypoid gear oil

EE.book Page 7 Thursday, September 6, 2007 4:28 PM

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. The 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 Thursday, September 6, 2007 4:28 PM

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 Thursday, September 6, 2007 4:28 PM

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 Thursday, September 6, 2007 4:28 PM

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 Thursday, September 6, 2007 4:28 PM

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 Thursday, September 6, 2007 4:28 PM

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.

After break-in:

The vehicle may now be operated normally.

5B410007

Starting the engine

1. Turn the main switch to “ON”.

NOTICE

The coolant temperature warning light and

engine trouble warning light should come

on, then go off.

If a warning light does not go off, see page

4-4 for the corresponding warning light

circuit check.

2. Apply the brake pedal.

3. 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.

EE.book Page 2 Thursday, September 6, 2007 4:28 PM

6-3

●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.

4. With your foot off the accelerator pedal,

start the engine by turning the key to

“START”.

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.

TIP

For maximum engine life, never accelerate

hard when the engine is cold!

EE.book Page 3 Thursday, September 6, 2007 4:28 PM

6-4

Drive select lever operation and reverse

driving

NOTICE

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 4 Thursday, September 6, 2007 4:28 PM

6-5

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

light may not come on until 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 5 Thursday, September 6, 2007 4:28 PM

6-6

5B410009

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 “” 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 6 Thursday, September 6, 2007 4:28 PM

6-7

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 (“DIFF. LOCK”) will come

on along with the differential gear lock indica-

tor “” in the multi-function display. To re-

lease the differential gear lock, stop the

vehicle and set the switch to “4WD”.

●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.

DIFF.

LOCK

EE.book Page 7 Thursday, September 6, 2007 4:28 PM

6-8

●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 pages 7-17–7-18 for

more information on parking and parking on a

slope.

EE.book Page 8 Thursday, September 6, 2007 4:28 PM

6-9

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-

crease the risk of overturn. 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 9 Thursday, September 6, 2007 4:28 PM

6-10

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

4-23 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):

367 kg (809 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 10 Thursday, September 6, 2007 4:28 PM

6-11

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

terrain carefully. Use extreme 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 11 Thursday, September 6, 2007 4:28 PM

7-1

5B410010

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

accident.

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 Thursday, September 6, 2007 4:28 PM

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.

EE.book Page 2 Thursday, September 6, 2007 4:28 PM

7-3

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.

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 younger drivers and consider set-

ting rules and putting limits on how, when, and

where the Rhino can be used.

DRIVER

UNDER

EE.book Page 3 Friday, September 7, 2007 3:50 PM

7-4

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.

Occupant protection system

1. Passenger handhold 2. Seat belt

3. Door

1. Door

EE.book Page 4 Thursday, September 6, 2007 4:28 PM

7-5

1. Passenger handhold

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.

EE.book Page 5 Thursday, September 6, 2007 4:28 PM

7-6

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.

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.

EE.book Page 6 Thursday, September 6, 2007 4:28 PM

7-7

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.

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,

or any equipment you are carrying.

EE.book Page 7 Thursday, September 6, 2007 4:28 PM

7-8

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

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.

EE.book Page 8 Thursday, September 6, 2007 4:28 PM

7-9

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 door is securely latched before

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 roll-

over.

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 Thursday, September 6, 2007 4:28 PM

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.

EE.book Page 10 Thursday, September 6, 2007 4:28 PM

7-11

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.

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.

EE.book Page 11 Thursday, September 6, 2007 4:28 PM

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

CORRECT GRIP EXAMPLE

INCORRECT GRIP EXAMPLE

EE.book Page 12 Thursday, September 6, 2007 4:28 PM

7-13

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.

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

you are thoroughly familiar with the operation

of your vehicle. Remember, driving aggres-

sively or making abrupt maneuvers even on

flat, open areas can cause side rollovers.

EE.book Page 13 Thursday, September 6, 2007 4:28 PM

7-14

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.

Getting ready to ride

Perform the Pre-Operation Checks on pages

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

pages 6-2–6-3 to start the engine.

EE.book Page 14 Thursday, September 6, 2007 4:28 PM

7-15

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.

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.

EE.book Page 15 Thursday, September 6, 2007 4:28 PM

7-16

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.

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-

road. With this feature, the engine 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.

EE.book Page 16 Thursday, September 6, 2007 4:28 PM

7-17

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:

●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.

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

brakes.

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

3. Turn the engine off.

EE.book Page 17 Thursday, September 6, 2007 4:28 PM

7-18

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 6-9–6-11.

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.

These rollovers can result in crushed limbs

and other serious injuries or death to drivers

or passengers.

EE.book Page 18 Thursday, September 6, 2007 4:28 PM

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

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.

EE.book Page 19 Thursday, September 6, 2007 4:28 PM

7-20

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.

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.

EE.book Page 20 Thursday, September 6, 2007 4:28 PM

7-21

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.

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.

EE.book Page 21 Thursday, September 6, 2007 4:28 PM

7-22

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.

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.

Wet brakes may have reduced effectiveness.

After leaving the water, test your brakes. If

necessary, apply the brakes several times to

let friction dry out the linings.

EE.book Page 22 Thursday, September 6, 2007 4:28 PM

7-23

NOTICE

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 hose,

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.

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.

EE.book Page 23 Thursday, September 6, 2007 4:28 PM

7-24

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.

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

difficult path.

EE.book Page 24 Thursday, September 6, 2007 4:28 PM

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

service.

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 Thursday, September 6, 2007 4:28 PM

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 Thursday, September 6, 2007 4:28 PM

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 Thursday, September 6, 2007 4:28 PM

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.

Crankcase breather

system*

•Check breather hose for cracks or damage.

•Replace if necessary.

Exhaust system*

•Check for leakage.

•Tighten if necessary.

•Replace gasket(s) if necessary.

Spark arrester •Clean.

EE.book Page 4 Thursday, September 6, 2007 4:28 PM

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 element •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.

Parking brake* •Check operation and free play/brake pad wear.

•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.

Front and rear

suspension*

•Check operation and for leakage.

•Correct if necessary.

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 Thursday, September 6, 2007 4:28 PM

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 Thursday, September 6, 2007 4:28 PM

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 Thursday, September 6, 2007 4:28 PM

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)

3. Slot (× 2) 4. Projection (× 2)

OTICE

●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 Thursday, September 6, 2007 4:28 PM

8-9

5B410011

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 forward and upward (the

drive select lever boot will come loose).

To ease removal of the console, shift the

drive select lever into the low gear “L” po-

sition.

1. Console

To install

1. Place the console in its original position.

2. Install the parking brake lever boot.

3. Install the seats.

NOTICE

●Be sure to position the seat belt buckles

to the outside of the console.

●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 Thursday, September 6, 2007 4:28 PM

8-10

5B410012

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 dipstick, and then wipe it off

with a clean rag.

1. Dipstick

EE.book Page 10 Thursday, September 6, 2007 4:28 PM

8-11

5. Insert the dipstick completely into the oil

filler hole, 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

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.

7. Insert the dipstick completely into the oil

filler hole.

8. Reinstall the console.

EE.book Page 11 Thursday, September 6, 2007 4:28 PM

8-12

To change the engine oil (with or without

oil filter cartridge replacement)

1. Park the vehicle on a level surface.

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

console removal and installation proce-

dures.)

3. Start the engine, warm it up for several

minutes, and then turn it off.

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

lect the used oil, and then remove the

dipstick.

5. Remove the engine oil drain bolt to drain

the oil from the crankcase.

1. Engine oil drain bolt

Skip steps 6–10 if the oil filter cartridge is not

being replaced.

6. Lift the cargo bed up. (See pages 4-20–

4-21 for cargo bed lifting and lowering

procedures.)

EE.book Page 12 Thursday, September 6, 2007 4:28 PM

8-13

7. Remove the oil filter cartridge with an oil

filter wrench. An oil filter wrench is avail-

able from a Yamaha dealer. Make sure

that the O-ring is removed together with

the oil filter cartridge. If the O-ring re-

mains attached to the crankcase, oil leak-

age may occur.

1. Oil filter cartridge 2. Oil filter wrench

8. 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

9. 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 13 Thursday, September 6, 2007 4:28 PM

8-14

1. Oil filter cartridge 2. Torque wrench

10. Lower the cargo bed.

11. Reinstall the engine oil drain bolt, and

then tighten it to the specified torque.

12. Refill with the specified amount of recom-

mended engine oil, and then insert the

dipstick completely into the oil filler hole.

NOTICE: Be sure to wipe off spilled oil

on any parts after the engine and ex-

haust system have cooled down.

Tightening torque:

Engine oil drain bolt:

30 Nm (3.0 m·kgf, 22 ft·lbf)

Recommended engine oil:

See page 10-2.

Oil quantity:

Without oil filter cartridge replacement:

2.00 L (1.76 Imp qt, 2.11 US qt)

With oil filter cartridge replacement:

2.10 L (1.85 Imp qt, 2.22 US qt)

EE.book Page 14 Thursday, September 6, 2007 4:28 PM

8-15

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”

13. 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.

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

utes, and then check the oil level and cor-

rect it if necessary.

15. Reinstall the console.

EE.book Page 15 Thursday, September 6, 2007 4:28 PM

8-16

5B410013

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.

1. Final gear oil filler bolt 2. Final gear 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 16 Thursday, September 6, 2007 4:28 PM

8-17

Changing the final gear oil

1. Park the vehicle on a level surface.

2. Remove the final gear case guard by re-

moving the bolts and the collars.

1. Final gear case guard 2. Bolt and collar (× 7)

3. Place a container under the final gear

case to collect the used oil.

4. Remove the oil filler bolt and the drain

bolt to drain the oil.

1. Final gear oil drain bolt

5. Reinstall the drain bolt, and then tighten it

to the specified torque.

Tightening torque:

Final gear oil drain bolt:

20 Nm (2.0 m·kgf, 14 ft·lbf)

EE.book Page 17 Thursday, September 6, 2007 4:28 PM

8-18

6. Refill with the recommended final gear oil

up to the brim of the filler hole. NOTICE:

Be sure no foreign material enters the

final gear case.

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

en it to the specified torque.

8. Check for oil leakage. If oil leakage is

found, check for the cause.

9. Install the final gear case guard by install-

ing the bolts and the collars, and then

tightening the bolts to the specified

torque.

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)

Tightening torque:

Final gear case guard bolt:

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

EE.book Page 18 Thursday, September 6, 2007 4:28 PM

8-19

5B410014

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. Remove the differential gear case guard

by removing the bolts and the collars.

1. Differential gear case guard

2. Bolt and collar (× 7)

Tightening torque:

Differential gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

EE.book Page 19 Thursday, September 6, 2007 4:28 PM

8-20

3. Place a container under the differential

gear case to collect the used oil.

4. Remove the differential gear oil filler bolt

and differential gear oil drain bolt to drain

the oil.

1. Differential gear oil drain bolt

5. Reinstall the differential gear oil drain

bolt, and tighten it to the specified torque.

6. Refill the differential gear case with the

recommended oil. NOTICE: Be sure no

foreign material enters the differential

gear case.

7. Reinstall the differential gear oil filler bolt,

and then tighten it to the specified torque.

8. 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-4 Hypoid gear oil

Oil quantity:

0.18 L (0.16 Imp qt, 0.19 US qt)

Tightening torque:

Differential gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

EE.book Page 20 Thursday, September 6, 2007 4:28 PM

8-21

9. Install the differential gear case guard by

installing the bolts and the collars, and

then tightening the bolts to the specified

torque.

5B410015

Coolant

The coolant level should be checked before

each ride.

Checking the coolant level

1. Park the vehicle on a level surface.

2. 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

Tightening torque:

Differential gear case guard bolt:

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

EE.book Page 21 Thursday, September 6, 2007 4:28 PM

8-22

3. 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.

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.

OTICE

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 8-60 for

instructions.

Coolant reservoir capacity

(up to the maximum level mark):

0.32 L (0.28 Imp qt, 0.34 US qt)

EE.book Page 22 Thursday, September 6, 2007 4:28 PM

8-23

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)

1. Rear axle boot (× 2 each side)

EE.book Page 23 Thursday, September 6, 2007 4:28 PM

8-24

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.

1. Spark plug wrench

EE.book Page 24 Thursday, September 6, 2007 4:28 PM

8-25

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.

Installation

1. Measure the electrode gap with a wire

thickness gauge and, if necessary, adjust

the gap to specification.

a. Spark plug gap

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.

Specified spark plug:

CPR7EA-9 (NGK)

Spark plug gap:

0.8–0.9 mm (0.031–0.035 in)

EE.book Page 25 Thursday, September 6, 2007 4:28 PM

8-26

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.

5B410016

Cleaning the air filter element

There is a check hose at the bottom of the air

filter case and at the bottom of the air duct un-

der the case. If dust or water collects in a

check hose, empty the hose and clean the air

filter element and air filter case.

1. Air filter case check hose

Tightening torque:

Spark plug:

12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)

EE.book Page 26 Thursday, September 6, 2007 4:28 PM

8-27

1. Air filter case check hose

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

hood opening and closing procedures.)

2. Remove the air intake duct shroud by re-

moving the quick fastener screws.

1. Quick fastener screw (× 2)

2. Air intake duct shroud

EE.book Page 27 Thursday, September 6, 2007 4:28 PM

8-28

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 28 Thursday, September 6, 2007 4:28 PM

8-29

5. Remove the sponge material from its

frame.

1. Air filter frame 2. Sponge material

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 29 Thursday, September 6, 2007 4:28 PM

8-30

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. Insert the projections on the air filter case

cover into the holders on the air filter

case, and then install the air filter case

cover by hooking the holders onto the

cover.

15. Install the air intake duct shroud by in-

stalling the quick fastener screws.

16. Close the hood.

EE.book Page 30 Thursday, September 6, 2007 4:28 PM

8-31

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

throttle body and manifold fittings for an air-

tight seal. Tighten all fittings securely to avoid

the possibility of unfiltered air entering the en-

gine.

NOTICE

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 the fuel injection system with

subsequent poor performance and possi-

ble engine overheating.

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

EE.book Page 31 Thursday, September 6, 2007 4:28 PM

8-32

5B410017

V-belt cooling duct check hose

The V-belt cooling duct check hose is located

under the cargo bed. 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

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 32 Thursday, September 6, 2007 4:28 PM

8-33

5B410018

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, and then remove the gasket.

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 3. Gasket

4. Install the gasket, and then insert the

tailpipe into the muffler and align the bolt

holes.

5. Install the bolts and tighten them to the

specified torque.

EE.book Page 33 Thursday, September 6, 2007 4:28 PM

8-34

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.

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.

5B410019

Checking the front and rear brake pads

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.

Tightening torque:

Tailpipe bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

EE.book Page 34 Thursday, September 6, 2007 4:28 PM

8-35

The wheels need to be removed to check the

brake pads. (See pages 8-43–8-46 for wheel

removal and installation procedures.)

1. Brake pad wear indicator groove

5B410020

Checking the parking brake pads

Each brake pad is provided with two wear in-

dicator 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 a wear indicator

groove almost appears, have a Yamaha deal-

er replace the brake pads as a set.

1. Brake pad wear indicator groove

EE.book Page 35 Thursday, September 6, 2007 4:28 PM

8-36

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.

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

brake fluid reservoir when refilling. Water

will significantly lower the boiling point of

the fluid and may result in vapor lock.

Recommended brake fluid: DOT 4

EE.book Page 36 Thursday, September 6, 2007 4:28 PM

8-37

●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.

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

EE.book Page 37 Thursday, September 6, 2007 4:28 PM

8-38

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.

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.

EE.book Page 38 Thursday, September 6, 2007 4:28 PM

8-39

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.

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.

EE.book Page 39 Thursday, September 6, 2007 4:28 PM

8-40

1. Brake light switch 2. Adjusting nut

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.

Recommended lubricant:

Lithium-soap-based grease

EE.book Page 40 Thursday, September 6, 2007 4:28 PM

8-41

EVU00900

Brake pedal and accelerator pedal

lubrication

Lubricate the pivoting parts.

5B410021

Rear knuckle upper and lower pivot

lubrication

1. Remove the lower arm protector by re-

moving the bolts.

1. Bolt (× 3) 2. Lower arm protector

Recommended lubricant:

Lithium-soap-based grease 1

EE.book Page 41 Thursday, September 6, 2007 4:28 PM

8-42

2. Lubricate the knuckle upper and lower

pivots with a grease gun.

3. Install the lower arm protector by install-

ing the bolts and tightening them to the

specified torque.

Recommended lubricant:

Lithium-soap-based grease

Tightening torque:

Lower arm protector:

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

EE.book Page 42 Thursday, September 6, 2007 4:28 PM

8-43

EVU00920

Steering shaft lubrication

Lubricate the pivot points.

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)

Recommended lubricant:

Lithium-soap-based grease

EE.book Page 43 Thursday, September 6, 2007 4:28 PM

8-44

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.

The tires listed below have been approved by

Yamaha Motor Manufacturing Corporation of

America for this model.

Manufacturer Size Type

Front MAXXIS 25 × 8-12NHS M951Y

Rear MAXXIS 25 × 10-12NHS M952Y

EE.book Page 44 Thursday, September 6, 2007 4:28 PM

8-45

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 nuts

with their 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.

1. Arrow mark

1. Tapered nut

EE.book Page 45 Thursday, September 6, 2007 4:28 PM

8-46

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.

OTICE

Do not try to remove the sealing caps of

the battery cells. You may damage the bat-

tery.

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 46 Thursday, September 6, 2007 4:28 PM

8-47

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.

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.

NOTICE

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.

EE.book Page 47 Thursday, September 6, 2007 4:28 PM

8-48

1. Negative battery lead (black)

2. Positive battery lead (red)

5B410022

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.

EE.book Page 48 Thursday, September 6, 2007 4:28 PM

8-49

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.

(See pages 8-51–8-52 for battery com-

partment cover removal and installation

procedures.)

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

console removal and installation proce-

dures.)

5. 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.

1. Jumper cable positive lead

6. 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 crankcase to be started.

EE.book Page 49 Thursday, September 6, 2007 4:28 PM

8-50

1. Jumper cable negative lead

7. Start the engine. (Refer to “Starting the

engine” on pages 6-2–6-3.)

8. After the engine starts, disconnect the

negative lead of the jumper cable from

the crankcase and charged battery, and

then disconnect the positive lead of the

jumper cable from the charged battery

and the battery in the vehicle.

9. Reinstall the console.

10. Reinstall the battery compartment cover.

11. Close the hood.

EE.book Page 50 Thursday, September 6, 2007 4:28 PM

8-51

5B410023

Fuse replacement

The main fuse, the fuel injection system 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 quick fastener screws.

2. Remove the battery compartment cover

by lifting it up and pulling it out.

1. Quick fastener screw (× 2)

2. Battery compartment cover

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

cal circuit in question.

NOTICE

To prevent accidental short-circuiting,

turn off the main switch when checking or

replacing a fuse.

3. 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 51 Thursday, September 6, 2007 4:28 PM

8-52

1. Fuel injection system spare fuse

2. Fuel injection system fuse

3. Main fuse 4. Headlight fuse “HEAD”

5. Signaling system fuse “SIGNAL”

6. Auxiliary DC jack fuse “TERMINAL”

7. Four-wheel-drive motor fuse “DIFF”

8. Ignition fuse “IGNITION”

9. Backup fuse “BACK UP” (for odometer and clock)

10.Spare fuse (× 3) 11. Radiator fan fuse “FAN”

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

electrical circuit in question to check if the

device operates.

5. If the fuse blows again immediately, have

a Yamaha dealer check the electrical

system.

6. Reinstall the battery compartment cover

by installing the quick fastener screws.

7. Close the hood.

12 3 7

456 8

Specified fuses:

Main fuse: 40.0 A

Fuel injection system fuse: 10.0 A

Headlight fuse: 15.0 A

Ignition fuse: 10.0 A

Auxiliary DC jack fuse: 10.0 A

Signaling system fuse: 10.0 A

Four-wheel-drive motor

fuse: 10.0 A

Radiator fan fuse: 25.0 A

Backup fuse: 10.0 A

EE.book Page 52 Thursday, September 6, 2007 4:28 PM

8-53

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 53 Thursday, September 6, 2007 4:28 PM

8-54

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 54 Thursday, September 6, 2007 4:28 PM

8-55

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 55 Thursday, September 6, 2007 4:28 PM

8-56

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 56 Thursday, September 6, 2007 4:28 PM

8-57

2. Lift the cargo bed up. (See pages 4-20–

4-21 for cargo bed lifting and lowering

procedures.)

3. Remove the panel (panel A or B).

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

counterclockwise to remove 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:

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

EE.book Page 57 Thursday, September 6, 2007 4:28 PM

8-58

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 58 Thursday, September 6, 2007 4:28 PM

8-59

5B410024

Troubleshooting charts

Starting problems or poor engine performance

1. Fuel

Check if there is fuel

in the fuel tank.

There is fuel.

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

Use the electric starter.

Engine turns over

quickly. Battery is good.

Engine turns over

slowly.

Check the connections,

recharge.

Check the compression.

EE.book Page 59 Thursday, September 6, 2007 4:28 PM

8-60

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 60 Thursday, September 6, 2007 4:28 PM

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 Thursday, September 6, 2007 4:28 PM

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

minutes.

5B410025

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.

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 Thursday, September 6, 2007 4:28 PM

9-3

2. 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.

3. Lubricate all control cables.

4. Block up the frame to raise all wheels off

the ground.

5. Tie a plastic bag over the exhaust pipe

outlet to prevent moisture from entering.

6. 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.

7. 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 Thursday, September 6, 2007 4:28 PM

10-1

EVU01050

SPECIFICATIONS

Model YXR70FX

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)

1,901 mm (74.8 in) (Special Edition model)

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 540.0 kg (1,190 lb)

Engine:

Engine type Liquid cooled 4-stroke, SOHC

Cylinder arrangement Forward-inclined single cylinder

Displacement 686.0 cm3

Bore × stroke 102.0 × 84.0 mm (4.02 × 3.31 in)

Compression ratio 9.20:1

Starting system Electric starter

Lubrication system Wet sump

EE.book Page 1 Thursday, September 6, 2007 4:28 PM

10-2

Engine oil:

Type:

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

Quantity:

Without oil filter cartridge replacement 2.00 L (1.76 Imp qt, 2.11 US qt)

With oil filter cartridge replacement 2.10 L (1.85 Imp qt, 2.22 US qt)

Model YXR70FX

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 Thursday, September 6, 2007 4:28 PM

10-3

Final gear case oil:

Type SAE80 API GL-4 Hypoid gear oil

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

Differential gear case oil:

Type SAE80 API GL-4 Hypoid gear oil

Quantity 0.18 L (0.16 Imp qt, 0.19 US qt)

Radiator capacity (including all routes): 2.35 L (2.07 Imp qt, 2.48 US qt)

Air filter:

Air filter element Wet element

Fuel:

Type Unleaded gasoline only

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

Throttle body:

Type/quantity 41EHS/1

Manufacturer MIKUNI

Spark plug:

Type/manufacturer CPR7EA-9/NGK

Spark plug gap 0.8–0.9 mm (0.031–0.035 in)

Clutch type: Wet, centrifugal automatic

Model YXR70FX

EE.book Page 3 Thursday, September 6, 2007 4:28 PM

10-4

Transmission:

Primary reduction system V-belt

Secondary reduction system Shaft drive

Secondary reduction ratio 41/21 × 17/12 × 33/9 (10.142)

Transmission type V-belt automatic

Operation Right hand operation

Reverse gear 23/14 × 28/23 (2.000)

Sub transmission ratio low 31/16 (1.938)

high 31/21 (1.476)

Chassis:

Frame type Steel tube frame

Caster angle 5.0°

Trail 26.0 mm (1.02 in)

Tire:

Ty p e Tu b e l e s s

Size front 25 × 8-12NHS

rear 25 × 10-12NHS

Wheel:

Type Panel wheel

Cast wheel (Special Edition model)

Rim size front 12 × 6.0AT

rear 12 × 7.5AT

Model YXR70FX

EE.book Page 4 Thursday, September 6, 2007 4:28 PM

10-5

Brakes:

System Front and rear unified

Type front Dual disc brake

rear Dual 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 Transistorized coil ignition (digital)

Generator system AC magneto

Battery type U1L-11

Battery capacity 12 V 28.0 Ah

Headlight type: Krypton bulb

Model YXR70FX

EE.book Page 5 Thursday, September 6, 2007 4:28 PM

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 LED

Reverse indicator light LED

Coolant temperature warning light LED

Engine trouble warning light LED

Parking brake indicator light LED

On-Command four-wheel-drive/differential gear

lock indicator

LCD

On-Command differential gear lock indicator light LED

High-range indicator light LED

Low-range indicator light LED

Model YXR70FX

EE.book Page 6 Thursday, September 6, 2007 4:28 PM

10-7

Specified fuses:

Main fuse 40.0 A

Fuel injection system fuse 10.0 A

Headlight fuse 15.0 A

Ignition fuse 10.0 A

Auxiliary DC jack fuse 10.0 A

Four-wheel-drive motor fuse 10.0 A

Signaling system fuse 10.0 A

Backup fuse 10.0 A

Radiator fan fuse 25.0 A

Model YXR70FX

EE.book Page 7 Thursday, September 6, 2007 4:28 PM

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 Thursday, September 6, 2007 4:28 PM

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.

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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

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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 Thursday, September 6, 2007 4:28 PM

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

54 21,600 (13,500) 1,350

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

EE.book Page 5 Thursday, September 6, 2007 4:28 PM

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.

Accident or collision damage.

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

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EVU01090

YAMAHA EXTENDED SERVICE (Y.E.S.)

EE.book Page 7 Thursday, September 6, 2007 4:28 PM

11-8

EE.book Page 8 Thursday, September 6, 2007 4:28 PM

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

PRINTED IN USA

2007.09-6.5×1 CR

(E)

DIC2342

YAMAHA MOTOR CO., LTD.

Yamaha YXR70FX RHINO FUEL INJECTION 700FI OWNER'S MANUAL User To The Bfc3955e 4717 45de 8fae 8badd43b74de

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