READ THIS MANUAL CAREFULLY! It contains important safety information.
EBU00776
EE.book Page 1 Friday, August 3, 2007 11:59 AM EVU00010 INTRODUCTION Congratulations on your purchase of the Yamaha YXR45FX. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing vehicles. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
EE.book Page 1 Friday, August 3, 2007 11:59 AM EVU00021 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: 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.
EE.book Page 2 Friday, August 3, 2007 11:59 AM EVU00030 IMPORTANT NOTE ABOUT USE ● ● ● This vehicle is designed and manufactured for off-road use only. Use on public streets, roads, or highways is not only illegal in most areas, it also increases the risk of an accident 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.
EE.book Page 1 Friday, August 3, 2007 11:59 AM EVU00050 Fuel level check window ................4-15 Starter (choke) ..............................4-15 Doors..............................................4-16 Seats ..............................................4-16 Seat belts .......................................4-17 Glove compartment .......................4-18 Cargo bed ......................................4-18 Front and rear shock absorber adjustment ...................................
EE.book Page 2 Friday, August 3, 2007 11:59 AM Steering........................................... 5-8 Fittings and fasteners...................... 5-8 Lights............................................... 5-9 Switches.......................................... 5-9 Control cables ................................. 5-9 Tires ................................................ 5-9 6 OPERATION..................................... 6-1 Engine break-in............................... 6-1 Starting a cold engine ......
EE.book Page 3 Friday, August 3, 2007 11:59 AM Operation on different surfaces and terrains.................................. 7-18 Hills ................................................ 7-19 Uphill.............................................. 7-19 Downhill ......................................... 7-20 Rough terrain................................. 7-21 Pavement ...................................... 7-21 Water ............................................. 7-22 Loose terrain/slippery terrain.........
EE.book Page 4 Friday, August 3, 2007 11:59 AM Brake pedal and accelerator pedal lubrication .......................... 8-40 Rear knuckle upper and lower pivot lubrication ........................... 8-41 Steering shaft lubrication .............. 8-41 Wheel removal .............................. 8-42 Tire replacement ........................... 8-42 Wheel installation .......................... 8-43 Battery ........................................... 8-45 Battery maintenance .....................
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EE.book Page 2 Friday, August 3, 2007 11:59 AM 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 replacement label is available from your Yamaha dealer. 1 2 3 ! WARNING ! WARNING ! Any part of your body (arms, legs, or head) outside of the vehicle can be crushed by the cage/frame.
EE.book Page 3 Friday, August 3, 2007 11:59 AM 4 5 ! WARNING ! Keep hands, body, and other people away from pinch points when lowering bed. Do not hold the cage/frame while closing bed. Improper tire pressure or overloading the Rhino may cause severe injury or death from loss of control or rollover. OPERATING TIRE PRESSURE: Set with tires cold. RECOMMENDED: FRONT: 70kPa, (.70kgf/cm2), 10psi REAR: MINIMUM: 98kPa, (.98kgf/cm2), 14psi FRONT: 63kPa, (.63kgf/cm2), 9psi REAR: 91kPa, (.
EE.book Page 4 Friday, August 3, 2007 11:59 AM 6 7 ! WARNING Improper use of cargo bed or cage/frame can result in severe injury or death from loss of control, overturn or other accidents. Do not carry passengers in cargo bed. MAX 7.3 INCH (185MM) Maximum load in cargo bed: 181 kg (400 lb). Load or trailer may affect handling and stability: 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 5 Friday, August 3, 2007 11:59 AM 8 9 ! Head to Toe Safety Checklist WARNING Improperly loading a trailer or pulling an object can affect handling, stability, and risk of overturn or other accidents. Secure load to prevent it from shifting. Never load more than 50 kg (110 lb) tongue weight on the towing bracket. Do not tow more than 550 kg (1212 lb) rolling weight (trailer plus cargo). Tow or pull only from hitch bracket.
EE.book Page 6 Friday, August 3, 2007 11:59 AM 0 ! WARNING To reduce risk of accidents and injury or death: Be Prepared • Avoid Rollovers and Crushing Injuries • Wear seat belt, motorcycle helmet, eye protection and protective gear. • Use care when turning: o Turning the steering wheel too far or too fast can result in a rollover or loss of control. Keep your body completely inside the vehicle at all times. Keep both o Slow down before entering a turn. hands on the steering wheel.
EE.book Page 1 Friday, August 3, 2007 11:59 AM EVU00070 SAFETY INFORMATION 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.
EE.book Page 2 Friday, August 3, 2007 11:59 AM 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 license. 1 2 3 DRIVER UNDER 16 • 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.
EE.book Page 3 Friday, August 3, 2007 11:59 AM Prepare your vehicle Perform the pre-operation checks each time you use the vehicle to make sure it is in safe operating condition. Failure to inspect or maintain the vehicle properly increases the possibility of an accident 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.
EE.book Page 4 Friday, August 3, 2007 11:59 AM 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 before 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.
EE.book Page 5 Friday, August 3, 2007 11:59 AM ● 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 acceleration.
EE.book Page 6 Friday, August 3, 2007 11:59 AM ● ● ● • 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 vehicle is designed for off-road use only.
EE.book Page 7 Friday, August 3, 2007 11:59 AM ● ● 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 inclines. • Load trailer properly and use extra care when towing or pulling. Do not tow or pull objects from any part of the vehicle other than the trailer hitch bracket or winch (if installed).
EE.book Page 8 Friday, August 3, 2007 11:59 AM 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.
EE.book Page 9 Friday, August 3, 2007 11:59 AM 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 aftermarket companies produce.
EE.book Page 10 Friday, August 3, 2007 11:59 AM Aftermarket tires and rims The tires and rims that came with your Rhino were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Refer to pages 8-42–8-44 for tire specifications and more information on replacing your tires.
EE.book Page 1 Friday, August 3, 2007 11:59 AM EVU00080 DESCRIPTION 1- E F G H IJ K L D C 1. Headlights 2. Front shock absorber assembly spring preload adjusting ring 3. Brake fluid reservoir 4. Air filter elements (engine and air intake duct) 5. V-belt case O 14. Spark arrester 15. Passenger seat belt 16. Passenger seat 17. Oil filter cartridge 18. Passenger handhold 19. Engine oil filler cap 20.
EE.book Page 2 Friday, August 3, 2007 11:59 AM P Q R S T UV W The vehicle you have purchased may differ slightly from those shown in the figures of this manual. X 1 2 3 4 5 6 7 [ Z Y H 26. Light switch 27. Steering wheel 28. Starter (choke) 29. Main switch 30. On-Command four-wheel-drive and differential gear lock switches 31. Indicator and warning lights 32. Multi-function meter unit (Special Edition models) 33. Auxiliary DC jack 34.
EE.book Page 1 Friday, August 3, 2007 11:59 AM EVU00130 INSTRUMENT AND CONTROL FUNCTIONS 1- EVU00140 Main switch OFF ON OFF O N START 1. Main switch START Functions of the respective switch positions are as follows: ON: All electrical circuits are supplied with power, and the headlights and taillights come on when the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position.
EE.book Page 2 Friday, August 3, 2007 11:59 AM EVU00210 Indicator and warning lights Parking brake indicator light “P” This indicator light comes on when the parking brake is applied. 1 2 EVU00161 1. 2. 3. 4. 5. 6. Parking brake indicator light “P” Reverse indicator light “R” Neutral indicator light “N” On-Command four-wheel-drive indicator light “ ” On-Command differential gear lock indicator light “ Coolant temperature warning light “ ” DIFF.
EE.book Page 3 Friday, August 3, 2007 11:59 AM EVU00181 On-Command four-wheel-drive indicator light “ ” This indicator light comes on when the On-Command four-wheel-drive switch is in the “4WD” position. Due to the synchronizing mechanism in the differential gear case, the light may not come on until the vehicle starts moving. On-Command differential gear lock indicator light “ ” This indicator light comes on when the On-Command differential gear lock switch is set to the “LOCK” position. DIFF.
EE.book Page 4 Friday, August 3, 2007 11:59 AM Coolant temperature warning light checking method Turn the main switch to “ON”. Coolant temperature warning light does not come on. Coolant temperature warning light comes on. Turn the main switch to “START” with the transmission in the neutral position. Coolant temperature warning light comes on momentarily. Coolant temperature and electrical circuit are OK. Coolant temperature warning light does not come on.
EE.book Page 5 Friday, August 3, 2007 11:59 AM EVU00150 EVU01131 Indicator and warning lights (Special Edition models) On-Command differential gear lock indicator light “DIFF. LOCK” This indicator light and the On-Command differential 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 OnCommand differential gear lock indicator light will flash until the differential gear is locked. EVU01140 1.
EE.book Page 6 Friday, August 3, 2007 11:59 AM EVU00170 EVU01161 Neutral indicator light “N” This indicator light comes on when the drive select lever is in the “N” position. On-Command four-wheel-drive/differential gear lock indicator “ ”/“ ” The On-Command four-wheel-drive indicator “ ” comes on when the On-Command fourwheel-drive switch is set to the “4WD” position. EVU00161 Reverse indicator light “R” This indicator light comes on when the drive select lever is in the “R” reverse position.
EE.book Page 7 Friday, August 3, 2007 11:59 AM EVU00181 EVU01630 Coolant temperature warning light “ ” If the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes. (See page 8-58.) Multi-function meter unit (Special Edition models) NOTICE ● ● The engine may overheat if the vehicle is overloaded.
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EE.book Page 9 Friday, August 3, 2007 11:59 AM Clock mode Pushing the “ / ” button switches the display between the clock mode “CLOCK” and the hour meter mode “HOUR” in the following order: CLOCK → HOUR → CLOCK To set the clock 1. Set the display to the clock. 2. Push the “ / ” button until the clock starts flashing. 3. Set the hours by pushing the “H” button. 4. Set the minutes by pushing the “M” button. 5. Push the “ / ” button, and then release it to start the clock.
EE.book Page 10 Friday, August 3, 2007 11:59 AM EVU00230 Switches NOTICE EVU00240 Light switch “OFF/ 1. Light switch “OFF/ L / H / L H ” ” Set the switch to “ L ” to turn on the low beam and the taillights. Set the switch to “ H ” to turn on the high beam and the taillights. 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.
EE.book Page 11 Friday, August 3, 2007 11:59 AM EVU01183 On-Command four-wheel-drive and differential 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-Command four-wheel-drive switch “2WD”/“4WD” and a differential gear lock switch “4WD”/ “LOCK”. Select the appropriate drive accord- Four-wheel drive (“4WD”): Power is supplied to the rear and front wheels.
EE.book Page 12 Friday, August 3, 2007 11:59 AM EVU00260 EVU00270 Accelerator pedal Press the accelerator pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the accelerator pedal returns normally before starting the engine. Brake pedal Press the brake pedal to slow or stop the vehicle. 1. Brake pedal 1.
EE.book Page 13 Friday, August 3, 2007 11:59 AM 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.
EE.book Page 14 Friday, August 3, 2007 11:59 AM EVU00290 EVU00300 Drive select lever The drive select lever is used to shift the vehicle into the low, high, neutral, and reverse positions. (Refer to pages 6-6–6-7 for the drive select lever operation.) Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 1. Fuel tank cap 1.
EE.book Page 15 Friday, August 3, 2007 11:59 AM EVU00320 Fuel level check window The amount of fuel in the fuel tank can be checked through the fuel level check window. If the fuel level is low, refuel as soon as possible. 1. Fuel level check window Starter (choke) “ ” Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke).
EE.book Page 16 Friday, August 3, 2007 11:59 AM EVU00330 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. Seats To remove a seat, pull its seat lock lever upward, lift the front of the seat, and then slide the seat forward and up. 1 2 1. Latch 2. Door 1. Driver seat 3. Seat lock lever (× 2) 2.
EE.book Page 17 Friday, August 3, 2007 11:59 AM EVU00340 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 passenger to fall. 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.
EE.book Page 18 Friday, August 3, 2007 11:59 AM EVU01191 EVU00351 Glove compartment Cargo bed NOTICE To protect from damage, do not put metal products, like tools or sharply edged products, directly in the glove compartment. If they must be stored, wrap them in appropriate cushioning material. 1. Cargo bed 3. Cargo hook (× 4) 2. Tailgate Maximum load limit: 181 kg (400 lb) For additional loading information, see pages 6-11–6-13.
EE.book Page 19 Friday, August 3, 2007 11:59 AM Opening and closing the tailgate Lifting and lowering the cargo bed 1. Tailgate 1. Cargo bed release lever 2. Latch (× 2) To open Unhook the latches, and then lower the tailgate. To close Place the tailgate in the original position, and 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 Friday, August 3, 2007 11:59 AM EVU00360 To lower With hands and fingers clear of pinch points, lower the cargo bed slowly to its original position and be sure it is locked into place. WARNING! Keep hands, body, and other people away from pinch points when lowering bed. Do not hold onto the cage/frame while closing the bed. Front and rear shock absorber adjustment The spring preload can be adjusted to suit the operating conditions.
EE.book Page 21 Friday, August 3, 2007 11:59 AM Adjust the spring preload as follows: To increase the spring preload, turn the adjusting ring in direction a. To decrease the spring preload, turn the adjusting ring in direction b. A special wrench can be obtained at a Yamaha dealer to make this adjustment. Standard position: B A- Minimum (soft) E- Maximum (hard) 1. Spring preload adjusting ring 2. Position indicator 1.
EE.book Page 22 Friday, August 3, 2007 11:59 AM EVU00370 EVU00380 Trailer hitch bracket and receiver This vehicle is equipped with a trailer hitch bracket and a 5 cm (2 in) receiver for a standard trailer hitch. Trailer towing equipment can be obtained at a Yamaha dealer. (See pages 6-11–6-13 for precaution information.) 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.
EE.book Page 23 Friday, August 3, 2007 11:59 AM NOTICE ● ● 1. Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack: DC 12 V, 120 W (10 A) 4. When the auxiliary DC jack is not being used, cover it with the cap. ● Do not use accessories requiring more than the maximum capacity stated above. This may overload the circuit and cause the fuse to blow. If accessories are used without the engine running, the battery will lose its charge and engine starting may become difficult.
EE.book Page 1 Friday, August 3, 2007 11:59 AM EVU01200 FOR YOUR SAFETY – PRE-OPERATION CHECKS 1- 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 Owner’s Manual. 1 2 3 4 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.
EE.book Page 2 Friday, August 3, 2007 11:59 AM ITEM ROUTINE PAGE Final gear oil/ Differential gear oil • Check for leakage. 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. Wheels and tires • Check tire pressure and for wear and damage.
EE.book Page 3 Friday, August 3, 2007 11:59 AM 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 necessary. (See pages 8-35–8-36.
EE.book Page 4 Friday, August 3, 2007 11:59 AM EVU00400 Fuel Make sure there is sufficient gasoline in the tank. WARNING Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions 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.
EE.book Page 5 Friday, August 3, 2007 11:59 AM Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost. Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol.
EE.book Page 6 Friday, August 3, 2007 11:59 AM EVU00410 Engine oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 8-10– 8-14.) 1 NOTICE ● ● In order to prevent clutch slippage (since the engine 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 quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher.
EE.book Page 7 Friday, August 3, 2007 11:59 AM EVU00420 EVU00430 Coolant Check the coolant level in the coolant reservoir when the engine is cold (the coolant level will vary with engine temperature). Final gear oil Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 8-15– 8-16 for details.) The coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir.
EE.book Page 8 Friday, August 3, 2007 11:59 AM EVU00450 Accelerator pedal Check to see that the accelerator pedal operates correctly. It must operate smoothly and spring back to the idle position fully when released. Have a Yamaha dealer repair as necessary for proper operation. EVU00460 Seat belts Make sure that the seat belts are not frayed, torn, stretched, or damaged. Each seat belt must move smoothly when pulled out and retract on its own when released. It must also lock up when quickly pulled out.
EE.book Page 9 Friday, August 3, 2007 11:59 AM EVU00480 EVU00500 Lights Check the headlights and tail/brake lights to make sure they are in working condition. Repair as necessary for proper operation. Tires Check tire pressure regularly to make sure it is at the recommended specifications. Also check for wear and damage. EVU00490 EVU00510 Switches Check the operation of all switches. Have a Yamaha dealer repair as necessary for proper operation.
EE.book Page 10 Friday, August 3, 2007 11:59 AM Set tire pressures to the following specifications: ACE-02E 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) The tire pressure gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading.
EE.book Page 11 Friday, August 3, 2007 11:59 AM EVU00520 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a.
EE.book Page 1 Friday, August 3, 2007 11:59 AM EVU00530 OPERATION 1- Read the Owner’s Manual carefully to become 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 controls 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.
EE.book Page 2 Friday, August 3, 2007 11:59 AM EVU00540 Each full-throttle acceleration sequence should be followed with a substantial rest period 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-throttle. Allow a cooling-off period of five to ten minutes after every hour of operation.
EE.book Page 3 Friday, August 3, 2007 11:59 AM 3. Use the starter (choke) in reference to the figure: Position 1: Cold engine start – ambient temperature below 5 °C (40 °F). Position 2: Cold engine start – ambient temperature at 0 °C (30 °F)–30 °C (90 °F) and warming up position. Position 3: Cold engine start – ambient temperature above 25 °C (80 °F) and warm engine start position. a. Starter (choke) 2. Half open 1. Fully open 3. Closed 4.
EE.book Page 4 Friday, August 3, 2007 11:59 AM 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.
EE.book Page 5 Friday, August 3, 2007 11:59 AM EVU00561 6. With the vehicle still in neutral, continue warming up the engine until it idles smoothly, and return the starter (choke) to position 3 before riding. Failure to do so may result in poor performance and premature wearing of the rear brake and V-belt. EVU00550 Starting a warm engine To start a warm engine, refer to the “Starting a cold engine” section. The starter (choke) should not be used. Press the accelerator pedal slightly.
EE.book Page 6 Friday, August 3, 2007 11:59 AM 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. 2. Apply the brake pedal, then shift by moving the drive select lever along the shift guide. Make sure that the drive select lever is completely shifted into position. Shifting: neutral to high and high to low 1. Stop the vehicle.
EE.book Page 7 Friday, August 3, 2007 11:59 AM 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.
EE.book Page 8 Friday, August 3, 2007 11:59 AM EVU01183 On-Command four-wheel-drive switch and differential gear lock switch You may notice that the vehicle handles differently in 2WD, 4WD, and 4WD-LOCK (“DIFF. LOCK”). For example, you should expect 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”).
EE.book Page 9 Friday, August 3, 2007 11:59 AM On-Command differential gear lock switch “4WD”/“LOCK” To lock the differential gear in 4WD, stop the vehicle, make sure the On-Command fourwheel-drive switch is set to “4WD”, move the differential gear lock lever to position b, and then set the switch to “LOCK”. When the differential gear is locked, the differential gear lock indicator light “ ” or, for special edition modes, the differential gear lock indicator light (“DIFF.
EE.book Page 10 Friday, August 3, 2007 11:59 AM EVU01210 For Special Edition models: ● When the switch is set to “LOCK”, the differential gear lock indicator and indicator light will flash until the differential gear is locked. ● When the indicator and indicator light are flashing, turning the steering wheel back and forth will help the differential gear lock to engage. ● Driving before the differential gear lock is properly engaged (e.g.
EE.book Page 11 Friday, August 3, 2007 11:59 AM EVU00630 Loading Take extra precautions when driving with a load or trailer. Follow these instructions and always use common sense and good judgment 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 vehicle labeling).
EE.book Page 12 Friday, August 3, 2007 11:59 AM Use the hooks equipped on the cargo bed to tie down loads. Choose a trailer hitch drawbar designed for use with a 5 cm (2 in) receiver. (See page 4-22 for more information.) You can measure tongue weight with a bathroom scale. Put the tongue of the loaded trailer on the scale with the tongue at hitch height. Adjust the load in the trailer, if necessary, to reduce the weight on hitch.
EE.book Page 13 Friday, August 3, 2007 11:59 AM Operating when loaded with cargo or towing 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 increase the risk of loss of control, an overturn, or other accident.
EE.book Page 1 Friday, August 3, 2007 11:59 AM 1- BASIC GUIDE FOR SAFE USE As a Rhino owner you are responsible for the safe and proper operation of this vehicle. Read this chapter and review the safety instructions in Chapter 2 before operating the vehicle. Use these chapters and the labels on the vehicle to instruct new operators and passengers. 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.
EE.book Page 2 Friday, August 3, 2007 11:59 AM Doing things with a Rhino that some people do for thrills in other vehicles (such as sideways sliding, skidding, fishtailing, or donuts) have led to side rollovers. These rollovers can result in crushed limbs and other serious injuries or death to drivers or passengers. Driver requirements ● This vehicle is intended for use only by an operator 16 or older with a valid motor vehicle license.
EE.book Page 3 Friday, August 3, 2007 11:59 AM Parents: Many states have implemented new motor vehicle licensing requirements for young drivers. These requirements are in response to the disproportionately high rate of crashes involving youthful drivers. As with automobiles, to promote safe driving behaviors, you should supervise drivers and consider setting rules and putting limits on how, when, and where the Rhino can be used.
EE.book Page 4 Friday, August 3, 2007 11:59 AM Occupant protection system 1 2 2 3 1 1. Passenger handhold 1. Passenger handhold 3. Door 2.
EE.book Page 5 Friday, August 3, 2007 11:59 AM WARNING Do not make changes to the occupant protection 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 responsible for any such changes to the vehicle. The Rhino comes with a variety of features to help reduce the risk of driver and passenger injury.
EE.book Page 6 Friday, August 3, 2007 11:59 AM Seat belts Seat belts should be worn by both driver and passenger. Driver must be sure that the passenger 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 abdomen 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 7 Friday, August 3, 2007 11:59 AM 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 easily 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. Seat belt (× 2) 3. Buckle (× 2) 2. Latch plate (× 2) To wear the seat belt properly, do the following: 1.
EE.book Page 8 Friday, August 3, 2007 11:59 AM 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 release button.
EE.book Page 9 Friday, August 3, 2007 11:59 AM Passenger handholds Handholds are provided to grip during operation 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 passenger’s left side, for the right and left hands.
EE.book Page 10 Friday, August 3, 2007 11:59 AM Seat and hip restraints The seat and hip restraints are designed to help keep you in the vehicle. Do not hold onto hip restraint bar when the vehicle is moving. Your hand or arm may be struck by objects or crushed against outside objects or the ground during a rollover. Floorboard The floorboard allows you to brace your feet, which helps you keep your body in the vehicle in the event of an accident or rollover.
EE.book Page 11 Friday, August 3, 2007 11:59 AM 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 outside of the steering wheel. Similar to other offroad vehicles, if the Rhino hits a deep rut or large obstacle, the steering wheel could briefly jerk in one direction or back and forth as the tires and vehicle respond to the obstacle.
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EE.book Page 13 Friday, August 3, 2007 11:59 AM Wear eye protection when operating or riding the vehicle to reduce the risk of a serious accident or injury. Eye protection, such as a face shield or goggles, may reduce the risk of foreign material getting in your eyes and help prevent loss of vision. Practice for new Rhino users You should become familiar with the performance characteristics of the vehicle in a large, flat area that is free of obstacles and other vehicles.
EE.book Page 14 Friday, August 3, 2007 11:59 AM Getting ready to ride Perform the Pre-Operation Checks on pages 5-1–5-11. Follow the instructions starting on page 6-2 to start the engine. Once it has warmed up and you have turned the choke off, you are ready to begin driving your vehicle. 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.
EE.book Page 15 Friday, August 3, 2007 11:59 AM If you think or feel that the vehicle may tip or roll, keep your body completely inside the protective 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 16 Friday, August 3, 2007 11:59 AM 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, reducing 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, particularly on loose surfaces, such as gravel.
EE.book Page 17 Friday, August 3, 2007 11:59 AM 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 prevent 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 vehicle may roll out of control.
EE.book Page 18 Friday, August 3, 2007 11:59 AM Operation on different surfaces and terrains Go slowly and proceed with caution when operating 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.
EE.book Page 19 Friday, August 3, 2007 11:59 AM Hills Choose carefully which hills you attempt to climb or descend. Avoid hills with slippery surfaces 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.
EE.book Page 20 Friday, August 3, 2007 11:59 AM 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 obstacle, 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 attempt to turn the vehicle around. With your foot on the brake pedal, look behind you and plan your descent.
EE.book Page 21 Friday, August 3, 2007 11:59 AM If you are sliding or skidding, try to steer in the direction the vehicle is sliding, to regain control. 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 obstacle, 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.
EE.book Page 22 Friday, August 3, 2007 11:59 AM 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. Never 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.
EE.book Page 23 Friday, August 3, 2007 11:59 AM 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 skidding 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.
EE.book Page 24 Friday, August 3, 2007 11:59 AM 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 obstacle and at as close to a right angle as possible to minimize vehicle tipping.
EE.book Page 1 Friday, August 3, 2007 11:59 AM EVU00650 PERIODIC MAINTENANCE AND ADJUSTMENT 1- Periodic inspection, adjustment, and lubrication 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 explained on the following pages.
EE.book Page 2 Friday, August 3, 2007 11:59 AM EVU00660 Owner’s manual and tool kit You are recommended to put this owner’s manual in the vinyl bag and always carry it underneath the driver seat as shown. Put the owner’s tool kit and tire pressure gauge in the space beside the battery. 1. Owner’s tool kit 1. Owner’s manual 2.
EE.book Page 3 Friday, August 3, 2007 11:59 AM 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 4 Friday, August 3, 2007 11:59 AM EVU01640 Periodic maintenance chart for the emission control system ● For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals. ● For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance 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.
EE.book Page 5 Friday, August 3, 2007 11:59 AM EVU01650 General maintenance and lubrication chart ITEM Cooling system Air filter elements (engine and air intake duct) Engine oil Engine oil filter cartridge Final gear oil Differential gear oil Front brake* Rear brake* Accelerator pedal* V-belt* Wheels* Wheel bearings* ROUTINE • • • • • • • • • • • • • • • • • • • • Whichever month comes first km (mi) hours Check coolant leakage. Repair if necessary. Replace coolant every 24 months. Clean.
EE.book Page 6 Friday, August 3, 2007 11:59 AM ITEM Drive shaft universal joint* Engine mount* Front and rear axle boots* Stabilizer bushings* Fittings and fasteners* ROUTINE • • • • • • • • Whichever month comes first km (mi) hours 1 320 (200) 20 INITIAL 3 1,200 (750) 75 6 2,400 (1,500) 150 EVERY 6 12 2,400 4,800 (1,500) (3,000) 150 300 Lubricate with lithium-soap-based grease. Check for cracks or damage. Check bolt tightness. Check operation. Replace if damaged. Check for cracks or damage.
EE.book Page 7 Friday, August 3, 2007 11:59 AM EVU00680 Hood To open Unhook the hood latches, and then slowly tilt the hood up until it stops. 1. Hood 1.
EE.book Page 8 Friday, August 3, 2007 11:59 AM To close Lower the hood slowly to its original position, and then hook the hood latches. Secure projections 1 on the rear of the hood into slots 2 on the back of the instrument panel. Secure slots 3 on the side of the hood around projections 4 on the frame. 1. Projection (× 2) 2. Slot (× 2) n (× 2) NOTICE ● ● 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 9 Friday, August 3, 2007 11:59 AM EVU00691 Console To remove 1. Remove the seats. (See pages 4-16– 4-17 for seat removal and installation procedures.) 2. Remove the parking brake lever boot. 3. Pull the console upward (the drive select lever boot will come loose). To install 1. Place the console in its original position. 2. Install the parking brake lever boot. 3. Install the seats. NOTICE ● ● When installing the console, be sure not to pinch the cables or wires.
EE.book Page 10 Friday, August 3, 2007 11:59 AM EVU00701 Engine oil and oil filter cartridge Check engine oil level before each operation. In addition, change the oil and the oil filter cartridge 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 procedures.) 3. Check the engine oil level on a cold engine.
EE.book Page 11 Friday, August 3, 2007 11:59 AM 7. Insert the dipstick into the oil filler hole, and then tighten the oil filler cap. 8. Reinstall the console. To change the engine oil (with or without oil filter cartridge replacement) 1. Remove the console. (See page 8-9 for console removal and installation procedures.) 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place an oil pan under the engine to collect the used oil, and then remove the engine oil filler cap. 4.
EE.book Page 12 Friday, August 3, 2007 11:59 AM Skip steps 5–7 if the oil filter cartridge is not being replaced. 6. Apply a light coat of clean engine oil to the O-ring of the new oil filter cartridge. Make sure the O-ring is seated properly. 5. Remove the oil filter cartridge with an oil filter wrench. An oil filter wrench is available from a Yamaha dealer. 1. O-ring 1. Oil filter cartridge 2. Oil filter wrench 7.
EE.book Page 13 Friday, August 3, 2007 11:59 AM 9. Add the specified amount of recommended engine oil, and then reinstall the engine oil filler cap and tighten it. NOTICE: Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down. 1. Oil filter cartridge 2. Torque wrench 8. Reinstall the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) Recommended engine oil: See page 10-2.
EE.book Page 14 Friday, August 3, 2007 11:59 AM NOTICE ● ● In order to prevent clutch slippage (since the engine 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 quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. Make sure that no foreign material enters the crankcase. 1 10.
EE.book Page 15 Friday, August 3, 2007 11:59 AM EVU00710 Final gear oil Checking the final gear oil level 1. Park the vehicle on a level surface. 2. Remove the oil filler bolt, and then check the oil level in the final gear case. The oil level should be at the brim of the filler hole. ear oil 3. 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.
EE.book Page 16 Friday, August 3, 2007 11:59 AM Changing the final gear oil 1. Park the vehicle on a level surface. 2. Place a container under the final gear case to collect the used oil. 3. Remove the oil filler bolt and the drain bolt to drain the oil. 5. Add the recommended final gear oil up to the brim of the filler hole. NOTICE: Be sure no foreign material enters the final gear case. Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.25 L (0.22 Imp qt, 0.26 US qt) 6.
EE.book Page 17 Friday, August 3, 2007 11:59 AM EVU00721 Differential gear oil Checking the differential gear oil level 1. Park the vehicle on a level surface. 2. Remove the differential gear oil filler bolt and check the oil level. It should be up to the brim of the filler hole. If the level is low, add sufficient oil of the recommended type to raise it to the specified level. NOTICE: Be sure no foreign material enters the differential gear case. 3.
EE.book Page 18 Friday, August 3, 2007 6:35 PM Recommended oil: SAE 80 API GL-5 Hypoid gear oil Oil quantity: 0.32 L (0.28 Imp qt, 0.34 US qt) 6. Reinstall the differential gear oil filler bolt, and then tighten it to the specified torque. 1. Differential gear oil drain bolt 4. Reinstall the differential gear oil drain bolt, and tighten it to the specified torque. Tightening torque: Differential gear oil drain bolt: 9.8 Nm (0.98 m·kgf, 7.1 ft·lbf) 5.
EE.book Page 19 Friday, August 3, 2007 11:59 AM EVU00732 Coolant The coolant level should be checked before each ride. Checking the coolant level 1. Park the vehicle on a level surface. 2. Open the hood. (See pages 8-7–8-8 for hood opening and closing procedures.) 3. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level varies with engine temperature. The coolant should be between the minimum and maximum level marks. 1. Coolant reservoir cap 2.
EE.book Page 20 Friday, August 3, 2007 11:59 AM EVU00740 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 dealer 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.
EE.book Page 21 Friday, August 3, 2007 11:59 AM EVU00750 Spark plug inspection Removal 1. Remove the console. (See page 8-9 for console removal and installation procedures.) 2. Remove the spark plug cap. 1. Rear axle boot (× 2 each side) 1.
EE.book Page 22 Friday, August 3, 2007 11:59 AM 1. Spark plug wrench Inspection The spark plug is an important engine component 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-tolight tan for a vehicle that is being ridden normally. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.
EE.book Page 23 Friday, August 3, 2007 11:59 AM Installation 1. Measure the electrode gap with a wire thickness gauge and, if necessary, adjust the gap to specification. Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) 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.
EE.book Page 24 Friday, August 3, 2007 11:59 AM EVU00763 Cleaning the air filter elements 2. Remove the air filter element from the air intake duct grill by pulling it out as shown. Cleaning the intake duct air filter element 1. Remove the air intake duct grill by removing the quick fastener screws. 1. Air filter element 1. Quick fastener screw (× 4) 2. Air intake duct grill 2. Air intake duct grill 3. Remove any large particles from the air filter element by hand. 4.
EE.book Page 25 Friday, August 3, 2007 11:59 AM 5. Reinstall the air filter element into the air intake duct grill. 6. Reinstall the air intake duct grill by installing the quick fastener screws. Cleaning the engine air filter element There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. 1. Air filter case check hose 1. Remove the seats.
EE.book Page 26 Friday, August 3, 2007 11:59 AM 3. Remove the air filter case cover by unhooking the holders. 4. Remove the air filter element. 1. Air filter element 1. Air filter case cover holder (× 5) 2.
EE.book Page 27 Friday, August 3, 2007 11:59 AM 5. Remove the sponge material from its frame. 1. Air filter frame 3. Element retaining plate 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 filter element can cause a fire or explosion, 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 28 Friday, August 3, 2007 11:59 AM 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 thoroughly. Inspect the sponge material and replace it if damaged. 11.
EE.book Page 29 Friday, August 3, 2007 11:59 AM 2P512001 EVU00770 Drive select lever box check hose The drive select lever box check hose is located under the console. (See page 8-9 for console removal and installation procedures.) If dust or water collects in the drive select lever box check hose, remove the hose and clean it. V-belt cooling duct check hoses The V-belt cooling duct check hoses are located under the console and cargo bed. (See page 8-9 for console removal and installation procedures.
EE.book Page 30 Friday, August 3, 2007 11:59 AM EVU00780 1 1. V-belt cooling duct check hose 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 water to enter the V-belt case, remove the drain plug to drain any water from the case.
EE.book Page 31 Friday, August 3, 2007 11:59 AM EVU00792 Cleaning the spark arrester WARNING Hot exhaust system may cause burns. To avoid burns or fires, make sure that the engine is stopped and the exhaust system is cool before cleaning spark arrester. Do not start the engine while cleaning the exhaust system. 2. Remove the tailpipe by pulling it out of the muffler. 3.
EE.book Page 32 Friday, August 3, 2007 11:59 AM EVU00800 Tightening torque: Tailpipe bolt: 9.5 Nm (0.95 m·kgf, 6.9 ft·lbf) Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idling speed adjustment may be performed by the owner as a part of the usual maintenance routine.
EE.book Page 33 Friday, August 3, 2007 11:59 AM EVU00810 Idle speed adjustment A diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it responds quickly to the throttle with the choke off. 2. Remove the seats. (See pages 4-16– 4-17 for seat removal and installation procedures.) 3. Remove the console.
EE.book Page 34 Friday, August 3, 2007 11:59 AM Brakes Replacement of brake components requires professional knowledge. Brake service should be performed by a Yamaha dealer. The wheels need to be removed to check the brake pads. (See pages 8-42–8-44 for wheel removal and installation procedures.) WARNING 1 Operating with improperly serviced or adjusted brakes could lead to a loss in braking ability and an accident.
EE.book Page 35 Friday, August 3, 2007 11:59 AM EVU00840 EVU00850 Rear brake pad check Each brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble 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 indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set. Checking the brake fluid level 1.
EE.book Page 36 Friday, August 3, 2007 11:59 AM 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 deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4 ● ● Refill with the same type of brake fluid.
EE.book Page 37 Friday, August 3, 2007 11:59 AM EVU01220 EVU00870 Checking the brake pedal Have a Yamaha dealer check the brakes at the intervals specified in the periodic maintenance 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.
EE.book Page 38 Friday, August 3, 2007 11:59 AM a. Parking brake lever free play 5. The parking brake lever must be released when checking and adjusting the parking brake lever free play. 6. Loosen the locknut. 1. Locknut 2. Adjusting nut 7. Turn the adjusting nut in direction a to increase the free play or in direction b to decrease the free play. 8. Tighten the locknut. 9. Reinstall the console. 10. Reinstall the seats.
EE.book Page 39 Friday, August 3, 2007 11:59 AM 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.
EE.book Page 40 Friday, August 3, 2007 11:59 AM EVU00890 EVU00900 Cable inspection and lubrication Brake pedal and accelerator pedal lubrication Lubricate the pivoting parts. WARNING Damaged cables could restrict operation, which may cause an accident or injury. Inspect control cables frequently and replace 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.
EE.book Page 41 Friday, August 3, 2007 11:59 AM EVU00910 EVU00920 Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun. Steering shaft lubrication Lubricate the pivot points.
EE.book Page 42 Friday, August 3, 2007 11:59 AM 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. 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 designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort.
EE.book Page 43 Friday, August 3, 2007 11:59 AM EVU00940 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 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.
EE.book Page 44 Friday, August 3, 2007 11:59 AM Wheel nut torque: Front: 55 Nm (5.5 m·kgf, 40 ft·lbf) Rear: 55 Nm (5.5 m·kgf, 40 ft·lbf) 1.
EE.book Page 45 Friday, August 3, 2007 11:59 AM 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 battery. If the battery seems to have discharged, consult a Yamaha dealer. NOTICE Do not try to remove the sealing caps of the battery cells. You may damage the battery. WARNING Avoid battery contact with skin, eyes, or clothing. Shield eyes when working near batteries. Keep out of reach of children.
EE.book Page 46 Friday, August 3, 2007 11:59 AM 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 recharge the battery before reinstallation. NOTICE _ A special battery charger (constant voltage/ampere or constant voltage) is required for recharging a sealed-type battery. Using a conventional battery charger may shorten the battery life. _ 2.
EE.book Page 47 Friday, August 3, 2007 11:59 AM 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 terminal 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 Friday, August 3, 2007 11:59 AM 1. Jumper cable positive lead 2. Jumper cable negative lead 5. Connect the negative lead of the jumper cable to the negative terminal of the charged battery and the other end of the negative lead to an unpainted metal surface of the vehicle to be started. 6. Start the engine. (Refer to “Starting a cold engine” on pages 6-2–6-5.) 7.
EE.book Page 49 Friday, August 3, 2007 11:59 AM EVU00970 Fuse replacement The main fuse and the fuse box are located under the hood. (See pages 8-7–8-8 for hood opening and closing procedures.) If a fuse is blown, turn off the main switch and install a new fuse of the specified amperage. If a fuse is blown, replace it as follows. 1. Remove the battery compartment cover by lifting it up and pulling it out. Turn the key to “OFF” and turn off the electrical circuit in question.
EE.book Page 50 Friday, August 3, 2007 11:59 AM 1. 3. 5. 7. 8. Main fuse 2. Spare main fuse Headlight fuse 4. Ignition fuse Auxiliary DC jack fuse 6. Four-wheel-drive motor fuse Signaling system fuse Backup fuse (for odometer and clock on Special Edition models) 9. Carburetor warmer fuse 10. Spare fuse (× 3) Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Auxiliary DC jack fuse: Signaling system fuse: Carburetor warmer fuse: Four-wheel-drive motor fuse: Backup fuse: 30.0 A 15.0 A 10.0 A 10.
EE.book Page 51 Friday, August 3, 2007 11:59 AM EVU01670 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 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. 3. Remove the headlight bulb holder cover by pulling it off. 1. Headlight bulb holder cover 1.
EE.book Page 52 Friday, August 3, 2007 11:59 AM 4. Remove the headlight bulb holder by pushing it in and turning it counterclockwise. 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. Headlight bulb holder 1. Do not touch the glass part of the bulb.
EE.book Page 53 Friday, August 3, 2007 11:59 AM EVU00990 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. Headlight beam adjustment NOTICE It is advisable to have a Yamaha dealer make this adjustment.
EE.book Page 54 Friday, August 3, 2007 11:59 AM 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 replacing the right tail/brake light bulb). 1. Panel B 1.
EE.book Page 55 Friday, August 3, 2007 11:59 AM 2. Lift the cargo bed up. (See pages 4-19– 4-20 for cargo bed lifting and lowering procedures.) 3. Remove the panel. 4. Remove the bulb holder (together with the bulb) by turning it counterclockwise. 7. Reinstall the bulb holder (together with the bulb) by turning it clockwise. 8. Install the panel. 9. Lower the cargo bed. 10. Reinstall the quick fastener screws and bolts, and then tighten the bolts to the specified torque. Tightening torque: Panel bolt: 6.
EE.book Page 56 Friday, August 3, 2007 11:59 AM EVU01010 Troubleshooting Although Yamaha vehicles receive an inspection 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 dealer.
EE.book Page 57 Friday, August 3, 2007 11:59 AM EVU01020 Troubleshooting charts Starting problems or poor engine performance 1. Fuel There is fuel. Remove the fuel hose from the fuel pump. No fuel. Supply fuel. Check the fuel flow. No fuel. Fuel pump is clogged. Check if there is fuel in the fuel tank. 2. Compression Use the electric starter to see if there is compression. 3. Ignition There is compression. Compression normal. No compression. Ask a Yamaha dealer to inspect.
EE.book Page 58 Friday, August 3, 2007 11:59 AM 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. Leakage. Ask a Yamaha dealer to inspect and repair the cooling system. No leakage. Add coolant. (See the text below.
EE.book Page 1 Friday, August 3, 2007 11:59 AM EVU01030 CLEANING AND STORAGE 1- 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.
EE.book Page 2 Friday, August 3, 2007 11:59 AM EVU01041 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.
EE.book Page 3 Friday, August 3, 2007 11:59 AM 3. Remove the spark plug, pour about one tablespoon of SAE 10W-40 or 20W-50 motor oil in the spark plug hole and reinstall the spark plug. Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil. 4. Lubricate all control cables. 5. Block up the frame to raise all wheels off the ground. 6. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering. 7.
EE.book Page 1 Friday, August 3, 2007 11:59 AM EVU01050 SPECIFICATIONS 1- Model Dimensions: Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore × stroke YXR45FX 2,885 mm (113.6 in) 1,385 mm (54.5 in) 1,853 mm (73.0 in) 818 mm (32.2 in) 1,910 mm (75.2 in) 280 mm (11.0 in) 3,900 mm (154 in) 509.
EE.book Page 2 Friday, August 3, 2007 11:59 AM Model YXR45FX 1 Engine oil: Type: 0 10 30 50 70 90 110 130 ˚F YAMALUBE 4 (20W-50) or SAE 20W-50 2 3 4 YAMALUBE 4 (10W-40) or SAE 10W-40 5 YAMALUBE 4-CW (5W-30) or SAE 5W-30 -20 Recommended engine oil classification -10 0 10 20 30 40 50 ˚C 6 API service SG type or higher, JASO standard MA 7 NOTICE In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives with oil.
EE.book Page 3 Friday, August 3, 2007 11:59 AM Model Final gear case oil: Type Quantity Differential gear case oil: Type Quantity Radiator capacity (including all routes): Air filter: Engine Intake duct Fuel: Type Fuel tank capacity Carburetor: Type/quantity Manufacturer Spark plug: YXR45FX SAE 80 API GL-4 Hypoid gear oil 0.25 L (0.22 Imp qt, 0.26 US qt) SAE 80 API GL-5 Hypoid gear oil 0.32 L (0.28 Imp qt, 0.34 US qt) 2.70 L (2.38 Imp qt, 2.85 US qt) Wet element Dry element Unleaded gasoline only 30.
EE.book Page 4 Friday, August 3, 2007 11:59 AM Model Transmission: Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Reverse gear Sub transmission ratio Chassis: Frame type Caster angle Trail Tire: Type Size YXR45FX low high V-belt Shaft drive 43/20 × 24/17 × 33/9 (11.129) V-belt automatic Right hand operation 30/15 (2.000) 43/18 (2.389) 39/22 (1.773) Steel tube frame 5.0° 26.0 mm (1.
EE.book Page 5 Friday, August 3, 2007 11:59 AM Model Brakes: System Type Operation Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system YXR45FX front rear Front and rear unified Dual disc brake Single disc brake Foot operation Double wishbone Double wishbone Coil spring/oil damper Coil spring/oil damper 185 mm (7.3 in) 185 mm (7.
EE.book Page 6 Friday, August 3, 2007 11:59 AM Model Bulb voltage, wattage × quantity: Headlight Tail/brake light Indicator lights: Neutral indicator light Reverse indicator light Coolant temperature warning light Parking brake indicator light On-Command four-wheel-drive indicator light (except Special Edition models) On-Command four-wheel-drive/differential gear lock indicator (Special Edition models) On-Command differential gear lock indicator light YXR45FX 12 V 30.0 W/30.0 W × 2 12 V 5.0 W/21.
EE.book Page 7 Friday, August 3, 2007 11:59 AM Model Specified fuses: Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four-wheel-drive motor fuse Carburetor warmer fuse Signaling system fuse Backup fuse YXR45FX 30.0 A 15.0 A 10.0 A 10.0 A 3.0 A 10.0 A 10.0 A 10.
EE.book Page 1 Friday, August 3, 2007 11:59 AM CONSUMER INFORMATION 1- EVU00090 Identification number records Record the key identification number, vehicle identification number, and model label information 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 1 2 3 4 2. VEHICLE IDENTIFICATION NUMBER: 5 ACA-02E 6 7 8 3.
EE.book Page 2 Friday, August 3, 2007 11:59 AM EVU00100 EVU00110 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. Vehicle identification number The vehicle identification number is stamped into the frame. 1. Vehicle identification number 1. Key identification number The vehicle identification number is used to identify your vehicle.
EE.book Page 3 Friday, August 3, 2007 11:59 AM 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.
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EE.book Page 5 Friday, August 3, 2007 11:59 AM EVU01070 MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.
EE.book Page 6 Friday, August 3, 2007 11:59 AM 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.
EE.book Page 7 Friday, August 3, 2007 11:59 AM EVU01090 YAMAHA EXTENDED SERVICE (Y.E.S.
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YAMAHA MOTOR CO., LTD. PRINTED IN USA 2007.08-2.
