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Yamaha 2004 Rhino 660 YXR660FAS, Owner'S Manual, Page: 8 / 154

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Yamaha 2004 Rhino 660 YXR660FAS Owner'S Manual Download Page 8

V-belt cooling duct check hose ..... 8-26
V-belt case drain plug.................... 8-26
Spark arrester cleaning ................. 8-27
Carburetor adjustment................... 8-29
Idle speed adjustment ................... 8-29
Valve clearance adjustment .......... 8-30
Front brake pad check .................. 8-30
Rear brake pad check ................... 8-31
Checking the brake fluid level ....... 8-32
Brake fluid replacement................. 8-33
Checking the brake pedal ............. 8-33
Parking brake cable free play 

adjustment................................... 8-34

Brake light switch adjustment........ 8-36
Cable inspection and lubrication ... 8-37
Brake pedal and accelerator 

pedal lubrication .......................... 8-37

Rear knuckle upper and lower 

pivot lubrication............................ 8-38

Steering shaft lubrication............... 8-38
Wheel removal .............................. 8-39
Wheel installation .......................... 8-39
Battery ........................................... 8-41

Battery maintenance......................8-42
Fuse replacement ..........................8-43
Replacing a headlight bulb ............8-45
Headlight beam adjustment...........8-46
Tail/brake light bulb 

replacement .................................8-47

Troubleshooting .............................8-48
Troubleshooting charts ..................8-50

CLEANING AND STORAGE ............9-1

A. Cleaning ......................................9-1
B. Storage ........................................9-3

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

NOISE REGULATION.....................11-1

MAINTENANCE RECORD .............12-1

YAMAHA MOTOR CORPORATION, 
U.S.A. SIDE 

×

 SIDE VEHICLE 

LIMITED WARRANTY ....................13-1

9

10

11

12

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U5UG10.book  Page 3  Friday, August 1, 2003  7:40 PM

Summary of Contents for 2004 Rhino 660 YXR660FAS

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Page 3: ...f 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 operat...

Page 4: ...ymbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the vehicle operator a bystander or a person inspecting or repairing the vehicle CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle NOTE A NOTE provides key information to make procedures easier or clearer...

Page 5: ...oosing 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 EBU13340 YXR660FAS OWNER S MANUAL 2003 by Yamaha Motor Corporation U S A 1st edition August 2003 All rights reserved Any reprinting or unauthorized use without th...

Page 6: ... 1 Main switch 4 1 Indicator and warning lights 4 2 Coolant temperature warning 1 2 3 4 Drive select lever 4 14 Fuel tank cap 4 14 Fuel level check window 4 15 Starter choke 4 15 Seats 4 16 Seat belts 4 17 Cargo bed 4 19 Front and rear shock absorber adjustment 4 22 Trailer hitch bracket 4 24 Auxiliary DC jack 4 24 PRE OPERATION CHECKS 5 1 Front and rear brakes 5 2 Fuel 5 4 Engine oil 5 5 Coolant ...

Page 7: ... Parking on a slope 6 9 Accessories and loading 6 11 Going uphill 7 7 Going downhill 7 9 Crossing through shallow water 7 11 Riding over rough terrain 7 13 Riding in brush or wooded areas 7 14 Encountering obstacles on the trail 7 15 PERIODIC MAINTENANCE AND ADJUSTMENT 8 1 Owner s manual and tool kit 8 1 Periodic maintenance lubrication 8 4 Hood 8 6 Console 8 8 Engine oil and oil filter cartridge ...

Page 8: ...e play adjustment 8 34 Brake light switch adjustment 8 36 Cable inspection and lubrication 8 37 Brake pedal and accelerator pedal lubrication 8 37 Rear knuckle upper and lower Battery maintenance 8 42 Fuse replacement 8 43 Replacing a headlight bulb 8 45 Headlight beam adjustment 8 46 Tail brake light bulb replacement 8 47 Troubleshooting 8 48 Troubleshooting charts 8 50 CLEANING AND STORAGE 9 1 A...

Page 9: ...YAMAHA EXTENDED SERVICE Y E S 14 1 14 U5UG10 book Page 4 Friday August 1 2003 7 40 PM ...

Page 10: ...EBU04640 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS U5UG10 book Page 1 Friday August 1 2003 7 40 PM ...

Page 11: ...n all foreseeable accidents including rollover 2 WARNING IMPROPERTIREPRESSUREOROVERLOADINGCANCAUSE LOSSOFCONTROL LOSSOFCONTROLCANRESULTINSEVEREINJURYOR DEATH OPERATING TIRE PRESSURE Set with tires cold RECOMMENDED FRONT 70kPa 70kgf cm 10psi REAR 98kPa 98kgf cm 14psi MINIMUM FRONT 63kPa 63kgf cm 9psi REAR 91kPa 91kgf cm 13psi Never set tire pressure below minimum Tire may dislodge from rim Gross Ve...

Page 12: ...Never carry passengers in cargo bed Cargo can affect handling and stability Read Owner s Manual before loading or towing When loading with cargo or towing a trailer Reduce speed and allow more room to stop Avoid hills and rough terrain Be sure cargo is secured a loose load could change handling unexpectedly Keep weight in the cargo bed centered and as low and far forward as possible U5UG10 book Pa...

Page 13: ...kg 110 lbs tongue weight on the towing bracket Do not tow more than 550kg 1212 lbs rolling weight trailer plus cargo Operate in low range gears only allow for increased braking distance and use extreme caution when operating on inclines Read carefully the loading information and trailer hitch sections in the owner s manual WARNING U5UG10 book Page 4 Friday August 1 2003 7 40 PM ...

Page 14: ...d motor vehicle license Adults must supervise use by minors Check state laws for minimum age requirements Gross Vehicle Weight Rating 2000 lb 907 kg maximum including operator passenger accessories cargo and ALWAYS wear a seat belt when riding in the vehicle keep your hands and feet inside the vehicle at all times watch for branches brush or other hazards that could enter the vehicle drive straigh...

Page 15: ...e wearing seat belts Never give a ride to a passenger who is too small to reach and hold the handgrip on the enclo sure Always avoid operating the vehicle on any paved surfaces including sidewalks driveways parking lots and streets Never operate this vehicle on any public street road or highway even a dirt or gravel one Never operate this vehicle without wearing an approved motorcycle helmet that ...

Page 16: ...umbs and fingers around the steering wheel This is particularly important when driving in rough terrain The front wheels will move right and left as they respond to the terrain and this movement will be felt in the steering wheel A sudden jolt could wrench the steering wheel around and your thumbs or fingers could be injured if they are in the way of the steering wheel spokes Always go slowly and ...

Page 17: ...k for obstacles before operating in a new area Never operate the vehicle in fast flowing water or water deeper than the floorboards on this model Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in rever...

Page 18: ...other sources of ignition such as the pi lot lights of water heaters and clothes dryers When transporting the vehicle in anoth er vehicle be sure it is kept in an upright position Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get...

Page 19: ...a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your vehicle in an area with adequate ventilation U5UG10 book Page 5 Friday August 1 2003 7 40 PM ...

Page 20: ...ssembly adjusting ring 3 Brake fluid reservoir 4 Air filter element 5 V belt case 6 Driver seat 7 Driver seat belt 13 Spark arrester 14 Passenger seat belt 15 Passenger seat 16 Oil filter cartridge 17 Engine oil dipstick 18 Battery 19 Fuses U5UG10 book Page 1 Friday August 1 2003 7 40 PM ...

Page 21: ...26 Starter choke 27 Main switch 28 On Command four wheel drive and differential gear lock switches 29 Indicator and warning lights 30 Auxiliary DC jack 31 Drive select lever 32 Parking brake lever 33 Accelerator pedal U5UG10 book Page 2 Friday August 1 2003 7 40 PM ...

Page 22: ...maha 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 EBU00350 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 U5UG10 book Page 3 Friday August 1 200...

Page 23: ...hicle identification number is used to identify your vehicle _ EBU07870 Model label The model label is affixed to the location in the illustration Record the information on this la bel in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label U5UG10 book Page 4 Friday August 1 2003 7 40 PM ...

Page 24: ... are supplied with power and the headlights and taillights come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position START The electric starter is engaged by turning and holding the key in this position Release the key when the engine starts U5UG10 book Page 1 Friday August 1 2003 7 40 PM ...

Page 25: ...position with the engine running or damage to the electric starter can re sult See starting instructions prior to start ing the engine See pages 6 1 6 3 for details _ EBU08020 Indicator and warning lights 1 Parking brake indicator light P 2 Reverse indicator light R 3 Neutral indicator light N 4 Four wheel drive indicator light 5 Differential gear lock indicator light 6 Coolant temperature warning...

Page 26: ...n the drive select lever is in the N position EBU08600 Coolant temperature warning light When the coolant temperature reaches a specified level this light comes on to warn that the coolant temperature is too hot If the CAUTION _ The engine may overheat if the vehicle is overloaded If this happens reduce the load to specification After restarting make sure that the light is out Continuous use while...

Page 27: ...ight comes on Coolant temperature warning light does not come on Coolant temperature and electrical circuit are OK Go ahead with riding Turn the main switch to START with the transmission in the neutral position Ask a Yamaha dealer to inspect the electrical circuit Coolant temperature warning light comes on momentarily U5UG10 book Page 4 Friday August 1 2003 7 40 PM ...

Page 28: ...r light comes on when the park ing brake is applied EBU11300 Differential gear lock indicator light This indicator light comes on when the differ ential gear lock switch is set to the LOCK 4WD position EBU00530 Switches 1 Light switch OFF EBU12040 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 swit...

Page 29: ...he engine turned off for an extend 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 _ U5UG10 book Page 6 Friday August 1 2003 7 40 PM ...

Page 30: ...4WD and a differential gear lock switch LOCK 4WD Select the appropriate drive according Four wheel drive 4WD Power is supplied to the rear and front wheels Four wheel drive with the differential gear locked 4WD LOCK Power is supplied to the rear and front wheels when the differen tial gear is locked DIFF LOCK Unlike the 4WD mode all wheels turn at the same speed regardless of traction U5UG10 book ...

Page 31: ...ging from 2WD to 4WD or from 4WD to 4WD LOCK DIFF LOCK or vice versa while the vehicle is moving WHAT CAN HAPPEN The vehicle handles differently in 2WD than in 4WD and in 4WD LOCK in some circumstances Changing from 2WD to 4WD or from 4WD to 4WD LOCK or vice versa while moving may cause the vehicle to unexpectedly handle differ ently This could distract the operator and increase the risk of losing...

Page 32: ...HAZARD Riding too fast while the vehicle is in 4WD LOCK WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it takes more effort to turn the vehicle The amount of effort is more the faster you go You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are trav eling HOW TO AVOID THE HAZARD Always ride at a slow speed when ...

Page 33: ...indicator light is flashing turn ing the steering wheel back and forth will help the differential gear lock to engage Riding before the differential gear lock is properly engaged e g when the indica tor light is flashing will cause the engine speed to be limited until engagement is complete _ U5UG10 book Page 10 Friday August 1 2003 7 40 PM ...

Page 34: ...smoothly Make sure the accelerator pedal fully returns to the idle position as soon as it is released WARNING POTENTIAL HAZARD Malfunction of the accelerator pedal WHAT CAN HAPPEN The accelerator pedal could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the accelerator pedal before you st...

Page 35: ...EBU90015 Brake pedal Press the brake pedal to slow or stop the ve hicle 1 Brake pedal U5UG10 book Page 12 Friday August 1 2003 7 40 PM ...

Page 36: ...se 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 Be sure to fully release the parking brake be fore starting out Failure to do so may result in poor performance and premature wearing of the rear brake and V belt 1 Parking brake lever 2 Release button U5UG10 book Page 13 Friday...

Page 37: ...ral and reverse positions Refer to pages 6 5 6 7 for the drive select lever operation 1 Drive select lever NOTE The drive select lever cannot be shifted into or EBU00920 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap U5UG10 book Page 14 Friday August 1 2003 7 40 PM ...

Page 38: ...1 Fuel level check window EBU00950 Starter choke Starting a cold engine requires a richer air fuel mixture A separate starter circuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op eration See pages 6 1 6 3 U5UG10 book Page 15 Friday August 1 2003 7 40 PM ...

Page 39: ... 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 WARNING POTENTIAL HAZARD A loose seat WHAT CAN HAPPEN The operator or passenger could lose control or fall if the seat is loose during operation HOW TO AVOID THE HAZARD Make sure the seat is securely latched U5UG10 book Page 16 Friday August 1 2003 7 40 PM ...

Page 40: ... 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 2 Push the latch plate into the buckle until it clicks Pull up on the latch plate to make sure it is secure U5UG10 book Page 17 Friday August 1 2003 7...

Page 41: ...ll the belt out all the way and then let it retract 5 To release the buckle firmly press the re lease button WARNING POTENTIAL HAZARD Not wearing the seat belt Wearing the seat belt improperly WHAT CAN HAPPEN There is increased risk of being killed or seriously injured in an accident HOW TO AVOID THE HAZARD Always wear your seat belt when riding in the vehicle Be sure the seat belt is close fittin...

Page 42: ...te 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 U5UG10 book Page 19 Friday August 1 2003 7 40 PM ...

Page 43: ...on and be sure the latch is properly en WARNING POTENTIAL HAZARD Pinch point WHAT CAN HAPPEN You or someone else could be pinched between the cargo bed and the frame when the bed is being lowered HOW TO AVOID THE HAZARD Before closing the bed be sure others are standing away from the vehicle Keep hands and fingers away from the pinch points between the bed and the frame U5UG10 book Page 20 Friday ...

Page 44: ...cargo bed Cargo should be properly distributed Reduce speed when carrying cargo Al low greater distance for braking WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN The passenger could fall be thrown out or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger This cargo bed is designed to carry cargo only U5UG10 book Page 21 Friday Aug...

Page 45: ... increased wear or damage to the vehicle 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 NOTE _ A special wrench can be obtained at a Yamaha dealer to make this adjustment _ Standard position B A Minimum soft E Maxim...

Page 46: ...tment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same set ting U5UG10 book Page 23 Friday August 1 2003 7 40 PM ...

Page 47: ...ler See page 6 12 for precau tion information 1 Trailer hitch bracket EBU10020 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 U5UG10 book Page 24 Friday August 1 2003 7 40 PM ...

Page 48: ...e fuse to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may be come 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 U5UG10 book Page 25 Friday August ...

Page 49: ...k fuel level Fill with fuel if necessary 5 4 5 5 Engine oil Check oil level Fill with oil if necessary 5 5 8 9 8 12 Coolant reservoir Check coolant level Fill with coolant if necessary 5 6 8 17 8 18 Final gear oil Differential gear oil Check for leakage 5 7 8 13 8 16 Accelerator Check for proper accelerator pedal operation 5 7 Seat belts Check for proper operation and belt wear 5 7 Steering Check ...

Page 50: ... Check the brake fluid level Add fluid if necessary See pages 8 32 8 33 WARNING POTENTIAL HAZARD Failure to inspect the vehicle before op erating Failure to properly maintain the vehicle WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition Always ...

Page 51: ...t provide proper braking per formance inspect the brake system See pages 8 30 8 34 WARNING POTENTIAL HAZARD Driving with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not operate the vehicle if you find any problem with the brakes If a problem cannot be correct...

Page 52: ... If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Gasohol There are two types of gasohol gasohol con taining ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 Gaso hol containing methanol is not recommended by Yamaha...

Page 53: ...gher Make sure that no foreign material en ters the crankcase _ WARNING POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especi...

Page 54: ...lled water Change the coolant every two years See pages 8 17 8 18 for details CAUTION _ Hard water or salt water is harmful to the engine You may use soft water if you can not get distilled water _ WARNING POTENTIAL HAZARD Removing the radiator cap when the en gine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD...

Page 55: ...hat the accelerator pedal oper ates correctly It must operate smoothly and fully spring back to the idle position when re leased Have a Yamaha dealer repair as nec essary for proper operation EBU90027 Seat belts Make sure that both seat belts are not frayed or damaged The seat belt must move smoothly when pulled out and retract on its own when re leased The latch plate should click securely into t...

Page 56: ...adlights and tail brake lights to make sure they are in working condition Re pair as necessary for proper operation EBU01570 Tires WARNING POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this vehicle or operation of this vehicle with improper or uneven tire pressure may cause loss of control increasing yo...

Page 57: ...ed could cause the tire to dislodge from the rim under severe riding conditions The following are minimums Front 63 kPa 0 63 kgf cm2 9 psi Rear 91 kPa 0 91 kgf cm2 13 psi 4 Use no more than the following pressures when seating the tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast...

Page 58: ...irt in the gauge could cause the first reading to be incorrect _ Set pressure with tires cold Set tire pressures to the following specifica tions ACE 02E 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 91 kPa 0 91 kgf cm2 105 kPa 1 05 kgf cm2 U5UG10 book Page 10 Friday August 1...

Page 59: ...EBU01600 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit U5UG10 book Page 11 Friday August 1 2003 7 40 PM ...

Page 60: ...ry HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask your Yamaha dealer WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the vehi cle which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables wo...

Page 61: ...ed to shift into neutral before starting the engine _ 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 warm Position 3 Cold engine start ambient temperature above 25 C 80 F and warm engine start position a Starter choke 1 Fully open 2 Half open 3 Closed 4 Wit...

Page 62: ...engine 6 Continue warming up the engine until it idles smoothly and return the starter choke to position 3 before riding EBU01800 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 EBU90028 Jump starting Jump starting the vehicle should be avoided The battery should be removed and charg...

Page 63: ...ative lead of the jumper cable to the negative terminal of the battery in the vehicle Be especially careful not to touch the positive leads of the jumper cable to the negative leads reverse the polarity of the jumper cables when connecting to the bat teries battery explosion and or se rious damage to the electrical system may occur _ 6 Start the engine Refer to Starting a cold engine on pages 6 1 ...

Page 64: ...rive select lever operation and reverse driving CAUTION _ Before shifting you must stop the vehicle and take your foot off the accelerator ped al Otherwise the transmission may be damaged _ 2 Apply the brakes then shift by moving the drive select lever along the shift guide NOTE _ Make sure that the drive select lever is com pletely shifted into position _ 1 Drive select lever 3 Release the brakes...

Page 65: ... Shift from neutral to reverse or vice versa by moving the drive select lever along the shift guide 1 Drive select lever NOTE _ When in reverse the reverse indicator light should be on If the light does not come on ask a Yamaha dealer to inspect the reverse indicator light electrical cir cuit Due to the synchronizing mechanism in the engine the light may not come on un U5UG10 book Page 6 Friday Au...

Page 66: ...n the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle oper ation or any condition which 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 WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an ...

Page 67: ...ours Avoid continuous operation above half throt tle Allow a cooling off period of five to ten min utes 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 3 4 throttle Rev the vehicle freely but do not use full throt tle at any time After break in Avoid prolonged full throttle oper...

Page 68: ...l or other incline WHAT CAN HAPPEN The vehicle could roll out of control in creasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the vehicle at all on hills that are so steep you could not walk up them easily U5UG10 book P...

Page 69: ...by applying the brakes 2 Stop the engine 3 With the brakes applied set the parking brake NOTE Like many other vehicles the parking brake acts on the rear wheels For the parking brake U5UG10 book Page 10 Friday August 1 2003 7 40 PM ...

Page 70: ...he quality or suitability of them Choose a genuine Yamaha accessory or one that is equiva lent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are operating could affect your ability to control the vehi cle Do not mount an accessory where it could interfere with your ability to control the vehi cle Examples inclu...

Page 71: ...ith 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 Load cargo in the cargo bed as close to the center of the vehicle as possible Tie down cargo securely in the trailer Make sure cargo in the trailer cannot move around A shifting load can c...

Page 72: ...sharp turns unless at very slow speeds Avoid hills and rough terrain Choose ter rain carefully Added weight affects the sta bility and handling of the vehicle WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity f...

Page 73: ...2 5 Please also read all caution and warning labels on your vehicle This vehicle is designed for the operator and one passenger The driver and passenger must always wear a seat belt Never carry passengers in the cargo bed WARNING POTENTIAL HAZARD Not wearing the seat belt Wearing the seat belt improperly WHAT CAN HAPPEN There is increased risk of being killed or seriously injured in an accident HO...

Page 74: ...ar rying a passenger and cargo can affect vehi cle handling WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN The passenger could fall or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed The cargo bed is designed to carry cargo only U5UG10 book Page 2 Friday August 1 2003 7 40 PM ...

Page 75: ...verloading this vehicle or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the ins...

Page 76: ...re head injury or death in the event of an ac cident Operating without eye protection can re sult in an accident and increases your chances of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants U5UG10 book Page...

Page 77: ...ore difficult ma neuvers Perform the Pre Operation Checks on pages 5 1 5 11 Set the parking brake shift to neu tral and follow the instructions on page 6 1 to start the engine Once it has warmed up and you have turned the choke off you are ready to begin driving your vehicle With the engine idling shift the drive select lever into low or high Then release the parking brake Press the accelerator pe...

Page 78: ...ou attempt sharp high speed turns You should also be careful making sharp turns on rough terrain Do not attempt to turn around or make abrupt maneuvers on Position your hands on the steering wheel so that your thumbs and fingers do not wrap around the wheel This is particularly impor tant when driving in rough terrain The front wheels will move right and left as they re spond to the terrain and th...

Page 79: ... basic maneuvers on flat ground Use proper driving techniques to avoid over turns on hills and slopes Drive straight up hills and avoid crossing the side of a hill which increases your chance of rollover Practice first on gentle slopes before attempt ing steeper hills Always check the terrain carefully before attempting any hill Use com Choose carefully which hills you attempt to climb Avoid hills...

Page 80: ... is on the other side there could be another person an ob stacle or a sharp drop off WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level sur faces or small hills HOW TO AVOID THE HAZARD Never operate your vehicle on hills too steep for it or your abilities Never oper ate vehicles on hills steeper ...

Page 81: ...o slow your descent Release the brake and begin to coast down the hill Use engine braking as much as possi ble gently applying the brakes when neces sary GOING DOWNHILL Check the terrain carefully before going down a hill When possible choose a path that lets you drive your vehicle straight downhill Avoid sharp angles that could allow the vehicle to pitch or roll over Carefully choose your path an...

Page 82: ...an obsta cle do so slowly and carefully If the vehicle starts to tip gradually steer in the downhill di rection if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you want to go WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the vehicle to overturn HOW TO AVOID THE HAZARD Always chec...

Page 83: ...ssary apply the brakes several times to let friction dry out the linings WARNING POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water WHAT CAN HAPPEN Loss of control which could result in an accident including overturn which could increase the risk of drowning HOW TO AVOID THE HAZARD Never operate this vehicle in fast flow ing water or in water deeper than 33 cm 13 in Remembe...

Page 84: ...t 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 _ 1 Air filter case check hose U5UG10 book Page 12 Friday August 1 2003 7 40 PM ...

Page 85: ...void jumping the vehi cle as injury loss of control and damage to the vehicle could occur WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the vehicle over turning or going out of control HOW TO AVOID THE HAZARD U5UG10 book Page 13 Friday Au...

Page 86: ...or obstacles such as branches that the vehicle might hit causing an accident or for brush that might enter the vehicle as you pass and strike the driver or passenger Nev er hold onto the enclosure so your hand is outside the vehicle Hold only onto the hand grip inside the enclosure U5UG10 book Page 14 Friday August 1 2003 7 40 PM ...

Page 87: ...maintain your momentum but still give yourself plenty of time to react to changes 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 WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or ...

Page 88: ...nd tool kit You are recommended to put this owner s manual in the vinyl bag and always carry it on the bottom of the driver seat as shown Put the owner s tool kit and tire pressure gauge in the space beside the battery WARNING POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause ...

Page 89: ...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 NOTE _ 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 _ U5UG10 book Page 2 Frid...

Page 90: ...g which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this vehicle through im proper installation or use of accesso ries All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this vehicle and should be in stalled and used according to instruc U5UG10 book Page 3 Friday August 1 2003 7 40 PM ...

Page 91: ... 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Valves Check valve clearance Adjust if necessary Cooling system Check coolant leakage Repair if necessary Replace coolant every 24 months Spark plug Check condition Adjust gap and clean Replace if necessary Air filter element Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor Check and adjust idle speed star...

Page 92: ... 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 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 opera...

Page 93: ...EBU90011 Hood To open Unhook the hood latches and then slowly tilt the hood up until it stops 1 Latch 2 1 Hood U5UG10 book Page 6 Friday August 1 2003 7 40 PM ...

Page 94: ...n the back of the instru ment 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 CAUTION _ 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 _ U5UG10 book Page 7 Friday August 1 2003 7 40 PM ...

Page 95: ...onsole in its original position 2 Install the parking brake lever boot 3 Install the drive select lever boot correct ly 4 Install the seats CAUTION _ When installing the console be sure not to pinch the cables or wires Make sure that the groove at the bot tom of the parking brake lever rubber boot fits securely around the edge of the hole in the console _ U5UG10 book Page 8 Friday August 1 2003 7 ...

Page 96: ...stallation proce dures 3 Start the engine warm it up for several minutes and then turn it off 4 Wait a few minutes until the oil settles 5 Remove the engine oil filler cap and wipe off the dipstick with a clean rag 6 Insert the dipstick in the oil filler hole NOTE _ The engine oil should be between the mini mum and maximum level marks _ 1 Maximum level mark 2 Minimum level mark 3 Dipstick 4 Engine...

Page 97: ...il pan under the engine to col lect the used oil and then remove the en gine oil filler cap 4 Remove the engine oil drain bolt to drain the oil from the crankcase NOTE _ Skip steps 5 7 if the oil filter cartridge is not being replaced _ 5 Remove the oil filter cartridge with an oil filter wrench 1 Oil filter cartridge 2 Oil filter wrench NOTE _ An oil filter wrench is available at a nearby U5UG10 ...

Page 98: ...rtridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 Oil filter cartridge 2 Torque wrench 8 Install the engine oil drain bolt and then tighten it to the specified torque 9 Add the specified amount of recommend Tightening torque Engine oil drain bolt 30 Nm 3 0 m kgf 22 ft lbf U5UG10 book Page 11 Friday August 1 2003 7 40 PM ...

Page 99: ...ial en 10 Start the engine and warm it up for seve ral minutes While warming up check for oil leakage If oil leakage is found turn the engine off immediately and check for the cause 11 Turn the engine off and then check the oil level and correct it if necessary 12 Install the console Recommended engine oil See page 10 2 Oil quantity Without oil filter cartridge replacement 2 10 L 1 85 Imp qt 2 22 ...

Page 100: ...ar oil filler bolt 2 Final gear oil 3 Proper oil level NOTE _ The oil level should be at the brim of the filler 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 CAUTION _ Be sure no foreign material enters the final gear case _ 4 Install the oil filler bolt U5UG10 book Page 13 Friday August 1 2003 7 40 PM ...

Page 101: ...en tighten it to 5 Add the recommended final gear oil up to the brim of the filler hole CAUTION _ Be sure no foreign material enters the final gear case _ 6 Install the oil filler bolt 7 Check for oil leakage If oil leakage is found check for the cause Tightening torque Final gear oil drain bolt 20 Nm 2 0 m kgf 14 ft lbf Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 25 L 0 22 Imp ...

Page 102: ...raise it to the specified level 1 Differential gear oil filler bolt CAUTION _ Be sure no foreign material enters the dif ferential gear case _ 3 Install the differential gear oil filler bolt Differential gear oil replacement 1 Place the vehicle on a level surface 2 Place a container under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and differen...

Page 103: ... foreign material enters the dif ferential gear case _ 6 Install the differential gear oil filler bolt 7 Check for oil leakage If oil leakage is found check for the cause Tightening torque Differential gear oil drain bolt 9 8 Nm 0 98 m kgf 7 1 ft lbf Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 32 L 0 28 Imp qt 0 34 US qt U5UG10 book Page 16 Friday August 1 2003 7 40 PM ...

Page 104: ... when the engine is cold as the coolant level varies with engine tempera ture NOTE _ The coolant should be between the minimum and maximum level marks _ 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark 4 If the coolant is at or below the minimum level mark remove the reservoir cap add coolant to the maximum level mark install the reservoir cap and then close the hood Coolant reser...

Page 105: ...n the periodic maintenance and lubrication chart NOTE _ 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 con tent of the coolant as soon as possible The radiator fan operation is completely automatic It is switched on or off accord ing to the coolant temperature in the radi U5UG10 book Page 18...

Page 106: ...ots 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 U5UG10 book Page 19 Friday August 1 2003 7 40 PM ...

Page 107: ...ift the cargo bed up See pages 4 20 4 21 for cargo bed lifting and lowering procedures 2 Remove the spark plug cap 1 Spark plug cap 3 Use the spark plug wrench in the tool kit 1 Spark plug wrench U5UG10 book Page 20 Friday August 1 2003 7 40 PM ...

Page 108: ... yourself Instead take the vehicle to a Yamaha dealer 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 Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary...

Page 109: ...d torque as soon as possible _ 4 Install the spark plug cap 5 Lower the cargo bed EBU12110 Air filter element cleaning NOTE _ There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case _ 1 Air filter case check hose 1 Remove the seats See page 4 16 for Tightening torque Spark plug 17 5 Nm 1 7...

Page 110: ...er case cover by un hooking the holders 1 Holder 4 2 Air filter case cover 4 Remove the air filter element 5 Remove the air filter element from its frame 1 Air filter element U5UG10 book Page 23 Friday August 1 2003 7 40 PM ...

Page 111: ...lter element should be wet but not dripping _ 10 Pull the air filter element over its frame 11 Install the air filter element 12 Install the air filter case cover and be sure to connect the hose WARNING POTENTIAL HAZARD Using low flash point solvents or gaso line to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD U...

Page 112: ...er element rubber joint to the carburetor and manifold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine _ CAUTION _ 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 w...

Page 113: ...e EBU90030 V belt case drain plug The V belt case drain plug is located under the driver seat See page 4 16 for seat re moval 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 NOTE _ If water drains from the V belt case after re moving the drain plug have a Yamaha dealer inspect the vehicle ...

Page 114: ...ove the bolts 2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon depos its from the spark arrester portion of the tailpipe 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install and tighten the bolts U5UG10 book Page 27 Friday August 1 2003 7 40 PM ...

Page 115: ...uld cause burns Could cause carbon monoxide poison ing possibly leading to death Could start a fire HOW TO AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool pri or to touching exhaust components Do not start the engine when cleaning the exhaust system U5UG10 book Page 28 Friday August 1 2003 7 40 PM ...

Page 116: ...e and damage may result _ EBU12580 Idle speed adjustment NOTE _ 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 quickly responds to the throttle 2 Remove the seats See page 4 16 for seat removal and installation procedure...

Page 117: ...r EBU13090 Front brake pad check Each brake pad is provided with wear indica tor grooves which allow you to check the brake pad wear without having to disassem ble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indica tor grooves have almost disappeared have a Yamaha dealer replace the brake pads as a set U5UG10 book Page 3...

Page 118: ...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 U5UG10 book Page 31 Friday August 1 2003 7 40 PM ...

Page 119: ...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 bra...

Page 120: ...ic maintenance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every four years 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 brake...

Page 121: ...y The free play should measure 2 3 mm 0 08 0 12 in as shown If necessary adjust the free play as follows WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the brake pedal position is correct Make sure the ...

Page 122: ...g the parking brake cable free play _ 5 Loosen the locknut 1 Locknut 2 Adjusting nut 6 Turn the adjusting nut in direction a to increase the free play or in direction b to decrease the free play 7 Tighten the locknut 8 Install the console 9 Install the seats U5UG10 book Page 35 Friday August 1 2003 7 40 PM ...

Page 123: ...switch as follows 1 Open the hood See pages 8 6 8 7 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 1 Brake light switch 2 Adjusting nut 3 Close the hood U5UG10 book Page 36 Friday ...

Page 124: ...NING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables Recommended lubricant Lithium soap based grease all purpose grea...

Page 125: ...uckle upper and lower pivots with a grease gun EBU12810 Steering shaft lubrication Lubricate the pivot points Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease all purpose grease U5UG10 book Page 38 Friday August 1 2003 7 40 PM ...

Page 126: ...el 4 Remove the wheel 1 Nut 4 EBU11210 Wheel installation 1 Install the wheel and the nuts NOTE _ Tapered nuts are used for both the front and rear wheels Install the nut with its ta pered side towards the wheel The arrow mark on the tire must point toward the rotating direction of the wheel _ U5UG10 book Page 39 Friday August 1 2003 7 40 PM ...

Page 127: ...the vehicle so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf U5UG10 book Page 40 Friday August 1 2003 7 40 PM ...

Page 128: ...AT CAN HAPPEN You could be poisoned You could be HOW TO AVOID THE HAZARD Avoid contact with skin eyes or cloth ing Always shield eyes when working near batteries Keep out of reach of chil dren Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magne sia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minute...

Page 129: ...n CAUTION _ A special battery charger constant volt age ampere or constant voltage is re quired for recharging a sealed type battery Using a conventional battery charger may shorten the battery life _ 2 Always make sure the connections are correct when putting the battery back in the vehicle 1 Negative battery lead 2 Positive battery lead U5UG10 book Page 42 Friday August 1 2003 7 40 PM ...

Page 130: ...fied amperage If a fuse is blown replace it as follows 1 Remove the battery case cover by lifting it up and pulling it out CAUTION _ 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 1 Main fuse 2 Spare main fuse 3 Headlight fuse 4 Ignition fuse U5UG10 book Page 43 Friday...

Page 131: ...fuse 15 A Ignition fuse 10 A Auxiliary DC jack fuse 10 A Signaling system fuse 10 A Carburetor heater fuse 10 A Four wheel drive fuse 3 A Terminal fuse 10 A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified am perage Never use any material i...

Page 132: ...See pages 8 6 8 7 for hood opening and closing procedures 2 Remove the bulb holder cover at the rear of the headlight by pulling it off 1 Headlight bulb holder cover 1 Headlight bulb holder 4 Remove the defective bulb by unhooking the headlight bulb holder tabs U5UG10 book Page 45 Friday August 1 2003 7 40 PM ...

Page 133: ...aha 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 WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flamma ble HOW TO AVOID THE HAZARD Wait for the bulb to cool b...

Page 134: ... light bulb burns out replace it as follows 1 Remove panel A if replacing the left tail brake bulb or panel B if replacing the right tail brake bulb by removing the quick fasteners and bolts 1 Panel A 1 Panel B U5UG10 book Page 47 Friday August 1 2003 7 40 PM ...

Page 135: ...ion Any prob lem in the fuel compression or ignition sys tems 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 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 you...

Page 136: ...PEN Fuel can ignite or explode causing se vere injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnac es U5UG10 book Page 49 Friday August 1 2003 7 40 PM ...

Page 137: ...sion 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 4 Battery Use the electric starter Engine turns over quickly Battery is good Check the f...

Page 138: ...over the cap Allow any re maining pressure to escape before completely removing the cap Wait until the engine has cooled Check the coolant level in the coolant reserver and or radiator Level is OK Level is low check the cooling system for leakage No leakage Leakage Ask a Yamaha dealer to inspect and repair the cooling system Add coolant See NOTE Restart the engine If the engine overheats again ask...

Page 139: ...to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION _ Excessive water pressure may cause wa ter seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car wash ...

Page 140: ... paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after wash ing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an acci dent HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings U5UG...

Page 141: ...ilding up Pour the drained fuel into the fuel tank NOTE _ 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 instead _ 3 Remove the spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and rein stall the spark plug Ground the spark plug wire and turn the engine o...

Page 142: ...y 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 NOTE _ Make any necessary repairs before storing the vehicle _ U5UG10 book Page 4 Friday August 1 2003 7 40 PM ...

Page 143: ...m 32 2 in Wheelbase 1 910 mm 75 2 in Ground clearance 273 mm 10 75 in Minimum turning radius 3 900 mm 153 5 in Basic weight With oil and full fuel tank 510 kg 1 124 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 660 cm3 Bore stroke 100 84 mm 3 94 3 31 in Compression ratio 9 1 1 U5UG10 book Page 1 Friday August 1 2003 7 40 PM ...

Page 144: ... Without oil filter cartridge replacement 2 10 L 1 85 Imp qt 2 22 US qt Model YXR660FA CAUTION In order to prevent clutch slippage since the en gine oil also lubricates the clutch do not mix any chemical additives 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 U5UG10 book Page 2 Friday ...

Page 145: ...capacity including all routes 2 50 L 2 20 Imp qt 2 64 US qt Air filter Wet type element Fuel Type UNLEADED GASOLINE ONLY Fuel tank capacity 30 0 L 6 60 lmp gal 7 93 US gal Carburetor Type quantity BSR42 1 Manufacturer MIKUNI Spark plug Type manufacturer DPR8EA 9 NGK Spark plug gap 0 8 0 9 mm 0 031 0 035 in Clutch type Wet centrifugal automatic Model YXR660FA U5UG10 book Page 3 Friday August 1 2003...

Page 146: ...smission type V belt automatic Operation Right hand operation Reverse gear 25 17 1 471 Sub transmission ratio low 35 17 2 058 high 28 19 1 473 Chassis Frame type Steel tube frame Caster angle 5 Trail 26 mm 1 02 in Tire Type Tubeless Size front AT25 8 12NHS rear AT25 10 12NHS Model YXR660FA U5UG10 book Page 4 Friday August 1 2003 7 40 PM ...

Page 147: ...one 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 28 in Rear wheel travel 185 mm 7 28 in Electrical Ignition system DC C D I Generator system A C magneto Battery type U1L 11 Model YXR660FA U5UG10 book Page 5 Friday August 1 2003 7 40 PM ...

Page 148: ...ing light 12 V 1 7 W 1 Parking brake indicator light 12 V 1 7 W 1 Four wheel drive indicator light 12 V 1 7 W 1 Differential gear lock indicator light 12 V 1 7 W 1 Specified fuses Main fuse 30 A Headlight fuse 15 A Ignition fuse 10 A Auxiliary DC jack fuse 10 A Four wheel drive fuse 3 A Carburetor heater fuse 10 A Signaling system fuse 10 A Model YXR660FA U5UG10 book Page 6 Friday August 1 2003 7 ...

Page 149: ...le 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 Exh...

Page 150: ...o 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 U5UG10 book Pag...

Page 151: ...t the Side by Side vehicle be inspected and registered for warranty by an authorized Yamaha Side by Side Vehicle dealer In order for this warranty to remain in effect this YAMAHA MOTOR CORPORATION U S A MAKES NOOTHERWARRANTYOFANYKIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRAN...

Page 152: ...EBU13700 YAMAHA EXTENDED SERVICE Y E S U5UG10 book Page 1 Friday August 1 2003 7 40 PM ...

Page 153: ...1 2 3 4 5 6 7 8 9 10 11 12 13 U5UG10 book Page 2 Friday August 1 2003 7 40 PM ...

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