Yamaha RHINO 450 Owner'S Manual Download

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EBU00776

Summary of Contents for RHINO 450

Page 1: ...2P5 F8199 12 LIT 11626 21 21 READ THIS MANUAL CAREFULLY It contains important safety information YXR45FX OWNER S MANUAL DIC2342 ...

Page 2: ...EBU00776 ...

Page 3: ... of the features and operation of this vehicle It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your vehicle please consult a Yamaha dealer WARNING Please read this manual carefully before operating this vehicle Do not attempt to operate this vehicle until you have attained adequate knowledge of its controls and operat...

Page 4: ...o alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death WARNING A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury NOTICE A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property TIP A TIP provides key information to make ...

Page 5: ... for on road use Check the laws and regulations in force before choosing where to operate this vehicle It is illegal to operate this vehicle on public lands where vehicles its size are prohibited This vehicle complies with almost all state off highway noise level and spark arrester laws and regulations YXR45FX OWNER S MANUAL 2007 by Yamaha Motor Corporation U S A 1st edition July 2007 All rights r...

Page 6: ...4 5 Multi function meter unit Special Edition models 4 7 Switches 4 10 1 2 3 4 Fuel level check window 4 15 Starter choke 4 15 Doors 4 16 Seats 4 16 Seat belts 4 17 Glove compartment 4 18 Cargo bed 4 18 Front and rear shock absorber adjustment 4 20 Trailer hitch bracket and receiver 4 22 Auxiliary DC jack 4 22 FOR YOUR SAFETY PRE OPERATION CHECKS 5 1 Front and rear brakes 5 3 Fuel 5 4 Engine oil 5...

Page 7: ... differential gear lock switch 6 8 Parking 6 10 Passenger requirements 7 3 Occupant protection system 7 4 Protective structure 7 5 Seat belts 7 6 Doors 7 8 Passenger handholds 7 9 Seat and hip restraints 7 10 Floorboard 7 10 Steering wheel 7 11 LEARNING TO OPERATE YOUR VEHICLE 7 12 Personal protective equipment 7 12 Practice for new Rhino users 7 13 Getting ready to ride 7 14 Turning 7 14 Accelera...

Page 8: ...l system 8 4 General maintenance and Differential gear oil 8 17 Coolant 8 19 Axle boots 8 20 Spark plug inspection 8 21 Cleaning the air filter elements 8 24 Drive select lever box check hose 8 29 V belt cooling duct check hoses 8 29 V belt case drain plug 8 30 Cleaning the spark arrester 8 31 Carburetor adjustment 8 32 Idle speed adjustment 8 33 Valve clearance 8 33 Brakes 8 34 Front brake pad ch...

Page 9: ... Fuse replacement 8 49 Replacing a headlight bulb 8 51 Headlight beam adjustment 8 53 Tail brake light bulb replacement 8 54 Troubleshooting 8 56 Troubleshooting charts 8 57 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification number records 11 1 NOISE REGULATION 11 4 MAINTENANCE RECORD 11 5 YAMAHA MOTOR CORPORATION U S A SIDE SIDE VEHICLE LIMITED WARRANTY 11 6 YAMAHA EXTENDED SERVICE Y E ...

Page 10: ...EVU00060 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS 5 8 7 6 5 1 3 2 3 4 EE book Page 1 Friday August 3 2007 11 59 AM ...

Page 11: ...e crushed by the cage frame If you think or feel that the vehicle may tip or roll brace your feet on the floorboards and keep your hands on the WARNING Any part of your body arms legs or head outside of the vehicle can be crushed by the cage frame If you think or feel that the vehicle may tip or roll brace your feet on the floorboards and keep your hands on the WARNING YAMAHA 5B4 K8483 00 Do not r...

Page 12: ...REAR 91kPa 91kgf cm2 13psi Never set or allow tire pressure to be below the minimum Tire may dislodge from rim Gross Vehicle Weight Rating 907 kg 2000 lb maximum including vehicle weight of operator passenger accessories cargo and if applicable trailer tongue weight WARNING Keep hands body and other people away from pinch points when lowering bed Do not hold the cage frame while closing bed YAMAHA...

Page 13: ...ose load could change handling unexpectedly or be thrown forward and strike occupants Keep weight in the cargo bed centered side to side and as low and as far forward as possible Top heavy loads increase the risk of overturn Do not tow or pull objects from any point other than the trailer hitch bracket or winch if installed When loaded with cargo or towing a trailer Reduce speed and allow more roo...

Page 14: ...l before loading towing or Improperly loading a trailer or pulling an object can affect handling stability and risk of overturn or other accidents WARNING YAMAHA 5B4 F1558 00 Head to Toe Safety Checklist ü Head Helmet and eye protection ü Body Seatbelt and protective clothing ü Hands Inside vehicle and holding the handholds or steering wheel ü Feet On floorboard ready to brace and door closed EE b...

Page 15: ...Rhino may tip or roll Brace yourself by pressing your feet firmly on the floorboards and keep a firm grip on the steering wheel or handholds Do not put your hands or feet outside of the vehicle for any reason Be Qualified and Responsible This vehicle is intended for use only by an operator 16 or older with a valid motor vehicle license Read the Owner s Manual To reduce risk of accidents and injury...

Page 16: ...he labels on the vehicle to instruct new operators and passengers Do not allow anyone else to operate your vehicle or ride as a passenger if you are unsure that he she is willing and able to follow these instructions Get to know your vehicle This off road vehicle will handle and maneuver differently from cars ATVs go carts golf cars and grounds keeping vehicles Follow these instructions to reduce ...

Page 17: ...seat belts properly Both driver and passenger must be able to put both feet flat on the floorboard while seated upright with their backs against the seat backs Passenger must be able to reach and hold the handholds within the cage frame Both driver and passenger should wear an approved motorcycle helmet that fits properly Both driver and passenger should also wear eye protection goggles or a face ...

Page 18: ...ing objects can affect handling stability and risk of overturn or other accidents Read Chapter 6 before loading towing or pulling objects Do not overload the vehicle or trailer Refer to label in cargo bed for cargo bed load limit Re fer to label next to hitch for tongue weight and trailer load limits Keep weight in the cargo bed centered side to side and as low and as far forward as pos sible Secu...

Page 19: ...ruck by objects your vehicle is passing or crushed by the vehicle cage frame in a rollover accident Watch for branches brush or other hazards that could enter the vehicle Abrupt maneuvers or aggressive driving even on flat open areas can cause loss of control including rollovers The Rhino has higher ground clearance and other features to handle rug ged terrain and as a result can overturn in situa...

Page 20: ...n result in a rollover Avoid sideways sliding skidding or fishtailing and never do donuts Slow down before entering a turn and avoid hard braking in a turn When making tight turns from a stop or at slow speeds avoid sudden or hard accelera tion EE book Page 5 Friday August 3 2007 11 59 AM ...

Page 21: ...ering wheel or handholds Do not put your hands or feet outside of the vehicle for any reason Your arm or leg could be crushed Do not try to stop a vehicle tipover using your arm or leg Do not operate this vehicle on any public street road or highway even if dirt or gravel Do not operate the vehicle in fast flowing water or water deeper than 33 cm 13 in If you must cross shallow slow moving water c...

Page 22: ...id hills and rough terrain Use extreme caution when towing or carrying a load on in clines Load trailer properly and use extra care when towing or pulling Do not tow or pull objects from any part of the vehicle other than the trailer hitch bracket or winch if installed EE book Page 7 Friday August 3 2007 11 59 AM ...

Page 23: ...evels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas If you experience any symp toms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDI CAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open win dows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine i...

Page 24: ...sold by Yamaha or modifications not specifically recommended by Yamaha even if sold and installed by a Yamaha dealer Aftermarket parts accessories and modifications While you may find aftermarket products similar in design and quality to genuine Yamaha Acces sories recognize that some aftermarket accessories or modifications are not suitable because of potential safety hazards to you or others Ins...

Page 25: ...e performance capabili ties and to provide the best combination of handling braking and comfort Other tires rims sizes and combinations may not be appropriate Refer to pages 8 42 8 44 for tire specifications and more information on replacing your tires EE book Page 10 Friday August 3 2007 11 59 AM ...

Page 26: ...ervoir 4 Air filter elements engine and air intake duct 5 V belt case 6 Driver seat 7 Driver seat belt C 14 Spark arrester 15 Passenger seat belt 16 Passenger seat 17 Oil filter cartridge 18 Passenger handhold 19 Engine oil filler cap 20 Battery I H E J K L M N C O D F G EE book Page 1 Friday August 3 2007 11 59 AM ...

Page 27: ...ntial gear lock switches 31 Indicator and warning lights 32 Multi function meter unit Special Edition models 33 Auxiliary DC jack 34 Drive select lever 35 Parking brake lever The vehicle you have purchased may differ slightly from those shown in the figures of this manual Z Y H P Q R S T UV W X EE book Page 2 Friday August 3 2007 11 59 AM ...

Page 28: ...lied with power and the headlights and tail lights come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this posi tion START The electric starter is engaged by turning and holding the key in this po sition Release the key when the en gine starts OFF O N S T A R T OFF ON START EE book Page 1 Friday August 3 2007 11 59 AM ...

Page 29: ...t comes on when the park ing brake is applied EVU00161 Reverse indicator light R This indicator light comes on when the drive select lever is in the R reverse position Furthermore this indicator light flashes when the engine is being raced for 10 seconds or more If the indicator light flashes under any other circumstances have a Yamaha dealer check the speed sensor circuit EVU00170 Neutral indicat...

Page 30: ...CK position EVU00181 Coolant temperature warning light If the coolant temperature reaches a specified level this light comes on to warn that the cool ant temperature is too hot If the light comes on during operation stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes See page 8 58 NOTICE The engine may overheat if the vehicle is overloaded If this ...

Page 31: ...t 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 EE book Page 4 Friday August 3 2007 11 59 AM ...

Page 32: ...erential gear lock indica tor light DIFF LOCK This indicator light and the On Command dif ferential gear lock indicator in the display come on when the On Command differential gear lock switch is set to the LOCK position When the switch is set to LOCK the On Command differential gear lock indicator light will flash until the differential gear is locked EVU01140 Low range indicator light L This ind...

Page 33: ...er check the speed sensor circuit EVU00210 EVU01161 On Command four wheel drive differential gear lock indicator The On Command four wheel drive indicator comes on when the On Command four wheel drive switch is set to the 4WD posi tion The On Command differential gear lock indi cator in the On Command four wheel drive indicator also comes on when the On Command differential gear lock switch is set...

Page 34: ...CE The engine may overheat if the vehicle is overloaded If this happens reduce the load to specification After restarting make sure that the light is out Continuous use while the light is on may cause damage to the engine EVU01630 Multi function meter unit Special Edition models 1 Speedometer 2 Fuel meter 3 H button 4 M button 5 Clock Hour meter 6 Odometer Tripmeter A Tripmeter B 7 TRIP ODO button...

Page 35: ...meter modes A and B in the fol lowing order ODO TRIP A TRIP B ODO To reset a tripmeter select it by pushing the TRIP ODO button and then hold the TRIP ODO button for at least three seconds The tripmeters can be used to estimate the dis tance that can be traveled with a full tank of fu el This information will enable you to plan future fuel stops Holding in the TRIP ODO button and then turning the ...

Page 36: ...ing the H button 4 Set the minutes by pushing the M but ton 5 Push the button and then re lease it to start the clock Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear from F full towards E empty as the fuel level decreases When the E segment disappears and the fuel level warning indicator flashes refuel as soon as possible 1 F...

Page 37: ...to to turn on the high beam and the taillights NOTICE Do not use the headlights with the engine turned off for an extended period of time The battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it L H L H L H EE book Page 10 Friday August 3 2007 11 59 AM ...

Page 38: ...D and a differential gear lock switch 4WD LOCK Select the appropriate drive accord ing to terrain and conditions Four wheel drive 4WD Power is sup plied to the rear and front wheels Four wheel drive with the differential gear locked 4WD LOCK Power is supplied to the rear and front wheels with the differ ential gear locked Unlike the 4WD mode all wheels turn at the same speed regard less of tractio...

Page 39: ...essure returns the pedal to the rest position when released Al ways check that the accelerator pedal returns normally before starting the engine 1 Accelerator pedal EVU00270 Brake pedal Press the brake pedal to slow or stop the ve hicle 1 Brake pedal EE book Page 12 Friday August 3 2007 11 59 AM ...

Page 40: ... moving while parked To set the parking brake pull the lever up completely To release the parking brake pull up on the lever press the release button and then push the lever all the way down Spring pressure helps return the lever to the released position 1 Parking brake lever 2 Release button EE book Page 13 Friday August 3 2007 11 59 AM ...

Page 41: ...i cle into the low high neutral and reverse po sitions Refer to pages 6 6 6 7 for the drive select lever operation 1 Drive select lever EVU00300 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap EE book Page 14 Friday August 3 2007 11 59 AM ...

Page 42: ...uel level check window EVU00320 Starter choke Starting a cold engine requires a richer air fuel mixture A separate starter circuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke Refer to Starting a cold engine for proper op eration See pages 6 2 6 5 EE book Page 15 Friday August 3 2007 11 59 AM ...

Page 43: ...rely latched Be sure the door is SECURELY LATCHED AFTER CLOSING IT 1 Latch 2 Door EVU00330 Seats To remove a seat pull its seat lock lever up ward lift the front of the seat and then slide the seat forward and up 1 Driver seat 2 Passenger seat 3 Seat lock lever 2 1 2 EE book Page 16 Friday August 3 2007 11 59 AM ...

Page 44: ... WARNING A loose seat could cause the operator to lose control or cause the operator or pas senger to fall EVU00340 Seat belts This vehicle is equipped with three point seat belts for both the operator and the passenger Always wear the seat belts properly while riding in the vehicle See pages 7 6 7 8 for more information EE book Page 17 Friday August 3 2007 11 59 AM ...

Page 45: ...d ucts directly in the glove compartment If they must be stored wrap them in appro priate cushioning material a Unlock b Open EVU00351 Cargo bed 1 Cargo bed 2 Tailgate 3 Cargo hook 4 For additional loading information see pages 6 11 6 13 Maximum load limit 181 kg 400 lb EE book Page 18 Friday August 3 2007 11 59 AM ...

Page 46: ...ate To close Place the tailgate in the original position and Lifting and lowering the cargo bed 1 Cargo bed release lever To lift Push down the cargo bed release lever on the left or right side of the vehicle and then slowly lift up the cargo bed until it stops EE book Page 19 Friday August 3 2007 11 59 AM ...

Page 47: ...rber adjustment The spring preload can be adjusted to suit the operating conditions You can reduce preload for a softer ride or increase preload if frequent bottoming occurs or when carrying loads WARNING Always adjust the shock absorbers on the left and right sides to the same setting Un even adjustment can cause poor handling and loss of stability which could lead to an accident NOTICE Frequent ...

Page 48: ...o decrease the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring 2 Position indicator A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Special wrench Standard position B A Minimum soft E Maximum hard EE book Page 21 Friday August 3 2007 11 59 AM ...

Page 49: ... pages 6 11 6 13 for precaution information 1 Trailer hitch bracket 2 Receiver EVU00380 Auxiliary DC jack The auxiliary DC jack is located at the right side of the front panel The auxiliary DC jack can be used for suitable work lights radios etc The auxiliary DC jack should only be used when the engine is running 1 Auxiliary DC jack cap 1 Set the light switch to OFF 2 1 EE book Page 22 Friday Augu...

Page 50: ...circuit and cause the fuse to blow If accessories are used without the en gine running the battery will lose its charge and engine starting may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A EE book Page 23 Friday August 3 2007 11 59 AM ...

Page 51: ...accident or equipment damage Do not operate the vehicle if you find any problem If a problem cannot be corrected by the procedures provided in this manual have the vehicle inspect ed by a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Brakes Check operation free play fluid level and fluid leakage Fill with DOT 4 brake fluid if necessary 5 3 8 34 8 37 8 39 Park...

Page 52: ...eration and belt wear 5 8 Steering Check for proper operation 5 8 Fittings and fasteners Check all fittings and fasteners 5 8 Lights and switches Check for proper operation 5 8 8 51 8 55 Wheels and tires Check tire pressure and for wear and damage 5 9 5 11 8 42 8 44 Axle boots Check for damage 8 20 8 21 ITEM ROUTINE PAGE EE book Page 2 Friday August 3 2007 11 59 AM ...

Page 53: ... neces sary See pages 8 35 8 36 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir Ap ply the brakes firmly for one minute If there is any leakage have the vehicle inspected by a Yamaha dealer Brake operation Check the operation of the brakes at the start of every ride Test the brakes at slow speed after starting out to make sure they...

Page 54: ... flames or oth er sources of ignition such as the pilot lights of water heaters and clothes dry ers 2 Do not overfill the fuel tank Because fuel 4 Be sure the fuel tank cap is closed se curely WARNING Gasoline is poisonous and can cause inju ry or death Handle gasoline with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasolin...

Page 55: ...amaha because it may cause fuel system damage or vehicle performance problems Portable gas containers If you carry a portable gas can in the bed of the Rhino be sure to secure it with the cap tightened before driving the vehicle Always place a portable gas container on the ground before filling it Before removing the container cap touch the container with the gas dispenser nozzle Keep gas dispense...

Page 56: ... not mix any chemical addi tives with oil Do not use oils with a die sel specification of CD or oils of a higher quality than specified In addi tion do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase 1 CD specification 2 ENERGY CONSERVING II Recommended engine oil type and quantity See page 10 2 1 2 EE book Page 6 Friday August 3 2007 11...

Page 57: ...8 19 8 20 for details NOTICE Hard water or salt water is harmful to the engine You may use soft water if you can not get distilled water EVU00430 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 15 8 16 for details If desired an SAE 80W90 hypoid gear oil may be used for all conditions TIP TIP GL 4 is a quality and additive rating GL 5 or GL 6 r...

Page 58: ... off any dirt or mud that could af fect operation Have a Yamaha dealer repair as necessary for proper operation A crash can damage the restraint systems in your vehicle A damaged restraint system may not properly protect the person using it resulting in serious injury or death in a crash To help make sure your restraint systems are working properly after a crash have them in spected and any necess...

Page 59: ...and you could be unable to control the vehicle EVU00500 Tires Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage EVU00510 Tire pressure Use the tire pressure gauge to check and ad just tire pressures when the tires are cold Tire pressures must be equal on both sides WARNING Operation of this vehicle with improper tire pressure may caus...

Page 60: ...e the second reading Dust or dirt in the gauge could cause the first reading to be incorrect 1 Tire pressure gauge Recommended pressure Minimum Maximum Front 70 kPa 0 70 kgf cm2 10 psi 63 kPa 0 63 kgf cm2 9 psi 77 kPa 0 77 kgf cm2 11 psi Rear 98 kPa 0 98 kgf cm2 14 psi 91 kPa 0 91 kgf cm2 13 psi 105 kPa 1 05 kgf cm2 15 psi EE book Page 10 Friday August 3 2007 11 59 AM ...

Page 61: ...EVU00520 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit EE book Page 11 Friday August 3 2007 11 59 AM ...

Page 62: ...hicle than the period between zero and 20 hours For this reason we ask that you read the fol lowing material carefully Because the engine is brand new you must not put an excessive load on it for the first several hours of opera tion During the first 20 hours the various parts in the engine wear and polish them selves to achieve the correct operating clear ances During this period prolonged full t...

Page 63: ... speed of the vehicle from time to time Do not operate it at one set throttle position 10 20 hours Avoid prolonged operation above three quar ter throttle EVU00540 Starting a cold engine 1 Apply the brake pedal 2 Shift the drive select lever into the neutral position When the drive select lever is in the neutral position the neutral indicator light should come on If the neutral in dicator light do...

Page 64: ... ambient temperature at 0 C 30 F 30 C 90 F and warming up position Position 3 Cold engine start ambient temperature above 25 C 80 F and warm engine start position a Starter choke 1 Fully open 2 Half open 3 Closed 4 With your foot off the accelerator pedal start the engine by turning the key to START EE book Page 3 Friday August 3 2007 11 59 AM ...

Page 65: ...may result WARNING The speed of a cold engine may increase enough as it warms up to cause the vehi cle to move on its own while the choke is being used Do not get out of the vehicle while the engine is running and the drive select lever is in any gear Unwanted vehicle movement can cause serious injury or death and it may be dan gerous to try to stop the vehicle The park ing brake may not keep the ...

Page 66: ...warm engine To start a warm engine refer to the Starting a cold engine section The starter choke should not be used Press the accelerator pedal slightly EVU00561 Warming up To get maximum engine life always warm up the engine before starting off To see whether or not the engine is warm check for smooth throttle response with the vehicle in neutral and the starter choke turned off Never accelerate ...

Page 67: ...cur Shifting neutral to high and high to low 1 Stop the vehicle Take your foot off the accelerator pedal 2 Apply the brake pedal then shift by mov ing the drive select lever along the shift guide Make sure that the drive select le ver is completely shifted into position 1 Drive select lever 3 Release the brake pedal and press the accelerator pedal gradually EE book Page 6 Friday August 3 2007 11 5...

Page 68: ...Apply the brake pedal 3 Shift from neutral to reverse or vice versa by moving the drive select lever along the shift guide When in reverse the reverse indicator light should be on Due to the synchro nizing mechanism in the engine the light may not come on until the vehicle 1 Drive select lever 4 Check behind the vehicle for people or obstacles and then release the brake pedal 5 Press the accelerat...

Page 69: ...fore changing between 2WD and 4WD or 4WD and 4WD LOCK DIFF LOCK 2WD 4WD To change from 2WD to 4WD stop the vehi cle and then set the switch to 4WD When the vehicle is in 4WD the four wheel drive in dicator light or for Special Edition models the four wheel drive indicator will come on in the multi function display To change from 4WD to 2WD stop the vehicle be sure the differential gear lock lever ...

Page 70: ... locked the differential gear lock indicator light or for special edition modes the differential gear lock indicator light DIFF LOCK will come on along with the differential gear lock indicator in the multi function display To release the differen tial gear lock stop the vehicle and set the switch to 4WD If the differential gear lock is not engaging properly turn the steering wheel back and forth ...

Page 71: ... lock to engage Driving before the differential gear lock is properly engaged e g when the indicator and indicator light are flashing will cause the engine speed to be limited until en gagement is complete EVU01210 Parking When parking stop the engine and shift the drive select lever into the neutral position Ap ply the parking brake to help prevent the vehi cle from rolling See page 7 17 for more...

Page 72: ... accident Do not exceed the Maximum Loading Limits for the vehicle see box or vehi cle labeling Keep weight in the cargo bed centered side to side and as low and as far for ward as possible Top heavy loads in Do not exceed the maximum tongue weight Make sure the load does not interfere with your control or ability to see where you are going Tie down cargo in the trailer securely Make sure cargo in...

Page 73: ...load in the trailer if necessary to reduce the weight on hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum vehicle load limit MAXIMUM LOADING LIMIT Vehicle loading limit total weight of cargo operator passenger and accessories and tongue weight 398 kg 877 lb Cargo bed 181 kg 400 lb Trailer hitch Pulling load total weight of trailer and cargo 550 kg 1 212...

Page 74: ...kes longer to stop Avoid hills and rough terrain Choose Pulling something other than a trailer Yamaha recommends that loads be transport ed in the bed or in a trailer If you need to move an object a short distance use a winch and follow the winch manufacturer s instruc tions If you choose to use something other than a winch use extreme caution follow the manu facturer s instructions for that produ...

Page 75: ...ARNING Follow these instructions to reduce your risk of an accident and to reduce the risk of serious injury or death in the event of an accident KNOW YOUR VEHICLE This off road vehicle will handle and maneu ver differently from cars ATVs go carts golf cars and grounds keeping vehicles The Rhino has higher ground clearance and other features to handle rugged terrain and as a result can overturn in...

Page 76: ...struc ture and seat belts to help protect occupants but the best way to avoid injuries is to avoid accidents There is a risk of injury or death in any accident even with these safety features Driver requirements This vehicle is intended for use only by an operator 16 or older with a valid motor vehi cle license The driver must be able to place both feet flat on the floorboard while seated upright ...

Page 77: ...quirements This vehicle is designed for the operator and one passenger Carrying passengers improp erly can lead to serious injury or death As the operator you are responsible for your pas senger Your passenger must be able to place both feet on the floorboard while seated upright with his her back against the seat back Allow only one passenger in the vehicle and only in the passenger seat Do not c...

Page 78: ...Occupant protection system 1 Passenger handhold 2 Seat belt 3 Door 1 Passenger handhold 1 2 2 3 1 1 EE book Page 4 Friday August 3 2007 11 59 AM ...

Page 79: ...they can cause injury Protective structure The vehicle cage frame provides a protective structure that helps limit intrusions by branch es or other objects and may reduce your risk of injury in accidents The protective structure will not protect occupants in all rollovers or ac cidents Body parts outside of vehicle can be struck by passing objects or crushed during vehicle roll over Do not put you...

Page 80: ...ve structure or oth er objects in an accident or during operation You may also fall completely out or be partial ly ejected from the vehicle which may lead to being crushed between the ground and the vehicle Wearing the seat belt helps you re main in the vehicle the doors and handholds are not a substitute for using a seat belt A crash can damage the restraint systems in your vehicle A damaged res...

Page 81: ...vehicle your clothing or any equipment you are carrying 2 If the latch plate is not positioned in the correct location along the seat belt squeeze the latch plate ends together along its long edges in order to more eas ily adjust its location up or down along the length of the belt 3 Push the latch plate into the buckle until it clicks Pull up on the latch plate to make sure it is secure EE book P...

Page 82: ...y press the re lease button Doors The doors are designed to reduce the likeli hood that you will stick your leg out to stop the vehicle from tipping over or for any other rea son in a rollover The doors may also reduce intrusion of objects into the occupant area Make sure the doors are securely latched be fore operation Do not place your arm or hand on the door during operation Your hand or arm ma...

Page 83: ...hat the passenger puts a hand outside the vehicle if the vehicle begins to tip There are two handholds on the protective structure and two handholds on the passen ger s left side for the right and left hands The driver should make sure the passenger is holding onto the handholds with both hands before operating the vehicle EE book Page 9 Friday August 3 2007 11 59 AM ...

Page 84: ...moving Your hand or arm may be struck by objects or crushed against outside objects or the ground during a rollover Floorboard The floorboard allows you to brace your feet which helps you keep your body in the vehicle in the event of an accident or rollover Keep your feet on the floorboard during operation EE book Page 10 Friday August 3 2007 11 59 AM ...

Page 85: ...ge obstacle the steering wheel could brief ly jerk in one direction or back and forth as the tires and vehicle respond to the obstacle This quick motion could injure your thumbs or wrist if your thumbs or hand s are inside the steer ing wheel Grip the steering wheel so that your thumbs will not be hit by the spokes As an example see the illustration CORRECT GRIP EXAMPLE INCORRECT GRIP EXAMPLE EE b...

Page 86: ...otective eyewear Over the ankle boots gloves long sleeved shirt or jacket and long pants An approved helmet and other personal pro tective equipment can help in a variety of ways including Reduce the severity of injuries if any part of you is outside the vehicle cage frame pro tective structure during a rollover Help protect you if outside objects intrude inside the vehicle during operation 1 2 3 ...

Page 87: ...controlling the accelerator pedal brakes steering and drive select lever Drive at slow speeds with gradual accelera tion and turning Practice smooth throttle ap plication Practice slowing down before turning Practice maintaining a steady throttle through the turn Avoid higher speeds until Become familiar with the way the vehicle feels in low and high ranges first in two wheel drive 2WD and then in...

Page 88: ...ight turns from a standstill or at slow speeds avoid sudden or hard accelera tion Driving aggressively or making abrupt maneuvers even on flat open areas can cause side rollovers Avoid sideways sliding skidding or fishtailing and never do donuts If you feel the Rhino begin to slide sideways or fishtail during a turn steer into the direction of the slide if possible and gradually let off the accele...

Page 89: ...foot on the brake shift the drive select lever into low or high NOTICE Do not shift from low to high or vice versa without coming to a complete stop and waiting for the engine to return to normal idle speed damage to the engine or drive train may occur Then release the parking brake Press the accel erator pedal slowly and smoothly The centrif ugal clutch will engage and the vehicle will begin to a...

Page 90: ...braking Engine compression braking is designed to assist you when operating your Rhino off Leaving the vehicle Do not get out of the vehicle while the engine is running and the drive select lever is in any gear There is a risk of injury because The speed of a cold engine may increase enough as it warms up to cause the vehicle to move on its own while the choke is being used Children or others may ...

Page 91: ... that is too steep the vehi cle may roll out of control Never park on hills that are so steep you cannot walk up them easily If you must park on an incline follow these instructions 1 Bring the vehicle to a stop by applying the 4 With the brake pedal applied set the parking brake 5 Block the front and rear wheels with rocks or other objects Loading The total weight of operator passenger ac cessori...

Page 92: ... or holes without enough time to react To avoid loss of control or rollover always be alert to changing surfaces or terrain when operating the vehicle The Rhino has higher ground clearance and other features to handle rugged terrain and as a result can overturn in situations where some vehicles may not Abrupt maneuvers or aggressive driving can cause loss of control including rollovers even on fla...

Page 93: ... Rhino may tip or roll Brace yourself by pressing your feet firmly Uphill Do not attempt to climb hills until you have mastered basic maneuvers on flat ground Drive straight up hills and avoid crossing the side of a hill which increases your risk of roll over Practice first on gentle slopes before at tempting steeper hills Always check the terrain carefully before attempting any hill To climb a hi...

Page 94: ...to coast down the hill Use engine braking as much as possible gently applying the brakes when necessary Downhill Check the terrain carefully before going downhill When possible choose a path that lets you drive your vehicle straight downhill Choose your path carefully and drive slowly enough to be able to react to obstacles that you encounter For more traction and control before going down steeper...

Page 95: ... in your path As you regain proper balance gradually steer again in the direction you want to go Rough terrain Operation over rough terrain should be done with caution Look for and avoid obstacles that could cause damage to the vehicle or could lead to a rollover or accident Do not drive in a way that will get the Rhino airborne as injury loss of control and damage to the vehicle could occur Pavem...

Page 96: ...ater depth and currents before crossing Operating this vehicle through deep or fast flowing water can lead to loss of control or overturn To reduce your risk of drowning or other injuries use care when crossing through water NOTICE After driving your vehicle in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case the V belt cooling duct check hos...

Page 97: ...eer to the right Brush or wooded areas When operating in areas with brush or trees watch carefully on both sides and above the vehicle for obstacles such as branches that the vehicle might hit causing an accident Watch for brush that might enter the vehicle as you pass and strike you or the passenger Never hold onto the cage frame The passen ger should always hold onto the handholds with both hand...

Page 98: ...ly choose the path that will allow you to get over the ob stacle and at as close to a right angle as pos sible to minimize vehicle tipping Go only fast enough to maintain your momentum but still give yourself plenty of time to react to chang es in conditions If there is any question about your ability to maneuver safely over the obstacle you should turn around if the ground is flat and you have th...

Page 99: ...enance activities incor rectly may increase your risk of injury or death during service or while using the ve hicle If you are not familiar with vehicle service have a Yamaha dealer perform service WARNING Turn off the engine when performing main tenance unless otherwise specified A running engine has moving parts that can catch on body parts or cloth ing and electrical parts that can cause shocks...

Page 100: ...attery 1 Owner s manual 1 Owner s tool kit 2 Tire pressure gauge The service information included in this man ual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor re pairs The tools provided in the owner s tool kit are sufficient for this purpose except that a torque wrench is also necessary to properly tighten EE book Pag...

Page 101: ...t have a torque wrench available during a service operation requiring one take your vehicle to a Yamaha dealer to check the torque settings and adjust them as necessary EE book Page 3 Friday August 3 2007 11 59 AM ...

Page 102: ...should be performed by a Yamaha dealer as they require spe cial tools data and technical skills ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Fuel line Check fuel hose for cracks or damage Replace if necessary Valves Check valve clearance Adjust if necessary Spark plug Check condition Adjust gap...

Page 103: ...Replace Final gear oil Check oil level oil leakage Replace Differential gear oil Front brake Check operation brake pad wear fluid leakage see page 8 6 Correct if necessary Replace pads if worn to the limit Rear brake Check operation brake pad wear fluid leakage see page 8 6 Correct if necessary Replace pads if worn to the limit Accelerator pedal Check operation and free play V belt Check operation...

Page 104: ...acked or damaged Drive shaft universal joint Lubricate with lithium soap based grease Engine mount Check for cracks or damage Check bolt tightness Front and rear axle boots Check operation Replace if damaged Stabilizer bushings Check for cracks or damage Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6...

Page 105: ...EVU00680 Hood To open Unhook the hood latches and then slowly tilt the hood up until it stops 1 Latch 2 1 Hood EE book Page 7 Friday August 3 2007 11 59 AM ...

Page 106: ...2 on the back of the instrument panel Secure slots 3 on the side of the hood around projections 4 on the frame 1 Projection 2 2 Slot 2 3 Slot 2 4 Projection 2 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 8 Friday August 3 2007 11 59 AM ...

Page 107: ... 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 Make sure that the groove at the bottom of the parking brake lever boot and the drive select lever boot fits securely around the edge of the hole in the con sole EE book Page 9 Friday August 3 2007...

Page 108: ...ine If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil settles for an accurate reading 4 Remove the engine oil filler cap and wipe 5 Insert the dipstick in the oil filler hole without screwing it in and then remove it again to check the oil level The engine oil should be between the minimum and maximum...

Page 109: ...ent 1 Remove the console See page 8 9 for console removal and installation proce dures 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the engine to col lect the used oil and then remove the en gine oil filler cap 4 Remove the engine oil drain bolt to drain the oil from the crankcase EE book Page 11 Friday August 3 2007 11 59 AM ...

Page 110: ...aler 1 Oil filter cartridge 2 Oil filter wrench 6 Apply a light coat of clean engine oil to the O ring of the new oil filter cartridge Make sure the O ring is seated properly 1 O ring 7 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench Tightening torque EE book Page 12 Friday August 3 2007 11 59 AM ...

Page 111: ... and tighten it NOTICE Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down Tightening torque Engine oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf Recommended engine oil See page 10 2 Oil quantity Without oil filter cartridge replacement 2 50 L 2 20 Imp qt 2 64 US qt With oil filter cartridge replacement 2 60 L 2 29 Imp qt 2 75 US qt EE book Page 13 Friday A...

Page 112: ...e oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase 10 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 11 Turn the engine off wait at least ten min utes and then check the oil level and cor rect it if necessary 12 Reinstall the con...

Page 113: ...le 1 Final gear oil filler bolt 2 Final gear 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 Reinstall the oil filler bolt and then tight en it to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf EE book Page 15...

Page 114: ...d the recommended final gear oil up to the brim of the filler hole NOTICE Be sure no foreign material enters the fi nal gear case 6 Reinstall the oil filler bolt and then tight en it to the specified torque 7 Check for oil leakage If oil leakage is found check for the cause Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 25 L 0 22 Imp qt 0 26 US qt Tightening torque Final gear oil f...

Page 115: ...CE Be sure no foreign material enters the differential gear case 3 Reinstall the differential gear oil filler bolt and then tighten it to the specified torque Changing the differential gear oil 1 Park the vehicle on a level surface 2 Place a container under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and differential gear oil drain bolt to drai...

Page 116: ...er bolt and then tighten it to the specified torque 7 Check for oil leakage If oil leakage is found check for the cause Tightening torque Differential gear oil drain bolt 9 8 Nm 0 98 m kgf 7 1 ft lbf Recommended oil SAE 80 API GL 5 Hypoid gear oil Oil quantity 0 32 L 0 28 Imp qt 0 34 US qt Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf EE book Page 18 Friday August 3...

Page 117: ...voir when the engine is cold as the coolant level varies with engine tempera ture The coolant should be between the minimum and maximum level marks 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark 4 If the coolant is at or below the minimum level mark remove the reservoir cap add coolant to the maximum level mark reinstall the reservoir cap and then close the hood Coolant reservoi...

Page 118: ...the coolant as soon as possible The radiator fan is automatically switched on or off according to the coolant temperature in the radiator NOTICE Mix antifreeze with distilled water only However if distilled water is not available soft water may be used for refilling If your vehicle overheats see page 8 58 for EVU00740 Axle boots Check the protective boots for holes or tears If any damage is found ...

Page 119: ...ach side EVU00750 Spark plug inspection Removal 1 Remove the console See page 8 9 for console removal and installation proce dures 2 Remove the spark plug cap 1 Spark plug cap EE book Page 21 Friday August 3 2007 11 59 AM ...

Page 120: ...lectrode is a medium to light tan for a vehicle that is being ridden nor mally You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes ex cessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug Specified spark plug DR8EA NGK EE bo...

Page 121: ... is not available when you are installing the spark plug a good estimate of the correct torque is one quarter to one half turn past finger tight Have the spark plug tightened to the specified torque as soon as possible 4 Install the spark plug cap 5 Reinstall the console Spark plug gap 0 6 0 7 mm 0 024 0 028 in Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf EE book Page 23 Friday Augu...

Page 122: ...uick fastener screw 4 2 Air intake duct grill 2 Remove the air filter element from the air intake duct grill by pulling it out as shown 1 Air filter element 2 Air intake duct grill 3 Remove any large particles from the air filter element by hand 4 Tap the air filter element to remove as much dust and dirt as possible EE book Page 24 Friday August 3 2007 11 59 AM ...

Page 123: ...aning the engine air filter element There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case 1 Air filter case check hose 1 Remove the seats See pages 4 16 4 17 for seat removal and installation EE book Page 25 Friday August 3 2007 11 59 AM ...

Page 124: ...e the air filter case cover by un hooking the holders 1 Air filter case cover holder 5 2 Air filter case cover 4 Remove the air filter element 1 Air filter element EE book Page 26 Friday August 3 2007 11 59 AM ...

Page 125: ...thoroughly in parts cleaning solvent WARNING Using gasoline or other flammable solvents to clean the air fil ter element can cause a fire or explo sion which could lead to serious injury 7 Squeeze the excess solvent out of the sponge material NOTICE Do not twist the sponge material when squeezing it EE book Page 27 Friday August 3 2007 11 59 AM ...

Page 126: ...lders onto the air filter case The air filter element should be cleaned every 20 40 hours It should be cleaned and lubri cated more often if the vehicle is operated in extremely dusty areas Each time air filter ele ment maintenance is performed check the air inlet to the air filter case for obstructions Check the air filter element rubber joint to the carburetor and manifold fittings for an airtig...

Page 127: ...check hose remove the hose and clean it 1 Drive select lever box check hose EVU00770 V belt cooling duct check hoses The V belt cooling duct check hoses are lo cated under the console and cargo bed See page 8 9 for console removal and installation procedures If dust or water collects in the V belt cooling duct check hose remove the hose and clean it 1 V belt cooling duct check hose EE book Page 29...

Page 128: ...al and installation procedures After riding in water deep enough to allow wa ter to enter the V belt case remove the drain plug to drain any water from the case If water drains from the V belt case after re moving the drain plug have a Yamaha dealer inspect the vehicle as the water may affect other engine parts 1 EE book Page 30 Friday August 3 2007 11 59 AM ...

Page 129: ...t start the engine while cleaning the exhaust system 1 Remove 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 and inside of the tailpipe housing 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muffler and EE book Page 31 Friday August 3 200...

Page 130: ...to do so However the idling speed adjustment may be performed by the owner as a part of the usual maintenance routine NOTICE The carburetor was set at the Yamaha fac tory after many tests If the settings are disturbed by someone without sufficient technical knowledge poor engine perfor mance and damage may result Tightening torque Tailpipe bolt 9 5 Nm 0 95 m kgf 6 9 ft lbf EE book Page 32 Friday A...

Page 131: ... 2 Remove the seats See pages 4 16 4 17 for seat removal and installation procedures 3 Remove the console See page 8 9 for console removal and installation proce dures 4 Connect the tachometer to the spark plug lead and then set the idle to the specified idling speed by adjusting the throttle stop 1 Throttle stop screw 5 Reinstall the console 6 Reinstall the seats Valve clearance The correct valve...

Page 132: ... 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 The wheels need to be removed to check the brake pads See pages 8 42 8 44 for wheel removal and installation pr...

Page 133: ...nt that the wear indica tor grooves have almost disappeared have a Yamaha dealer replace the brake pads as a set EVU00850 Checking the brake fluid level 1 Minimum level mark Insufficient brake fluid may allow air to enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake...

Page 134: ...king perfor mance Be careful that water does not enter the brake fluid reservoir when refilling Water Brake fluid may deteriorate painted surfac es or plastic parts Always clean up spilled fluid immediately Have a Yamaha dealer inspect the brake system if the brake fluid level goes down EVU00860 Brake fluid replacement Complete fluid replacement should be done only by trained Yamaha service person...

Page 135: ...e brake system if necessary EVU00870 Parking brake lever free play adjustment Periodically check the parking brake lever free play and adjust it if necessary 1 Shift the drive select lever into low gear L 2 Remove the seats See pages 4 16 4 17 for seat removal and installation procedures 3 Remove the console See page 8 9 for console removal and installation proce dures 4 Check the parking brake le...

Page 136: ...the parking brake lever free play 6 Loosen the locknut 1 Locknut 2 Adjusting nut 7 Turn the adjusting nut in direction a to increase the free play or in direction b to decrease the free play 8 Tighten the locknut 9 Reinstall the console 10 Reinstall the seats EE book Page 38 Friday August 3 2007 11 59 AM ...

Page 137: ...t switch as follows 1 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the ad justing nut in direction a To make the brake light come on later turn the adjust ing nut in direction b 3 Close the hood 1 Brake light switch 2 Adjusting nut EE book Page 39 Friday Au...

Page 138: ...the outer covering of control cables becomes damaged Cables can also become frayed or kinked Lubricate the cable ends If the cables do not operate smoothly ask a Yamaha dealer to re place them EVU00900 Brake pedal and accelerator pedal lubrication Lubricate the pivoting parts Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease EE book Page 40 Friday Augu...

Page 139: ...cate the knuckle upper and lower pivots with a grease gun EVU00920 Steering shaft lubrication Lubricate the pivot points Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease EE book Page 41 Friday August 3 2007 11 59 AM ...

Page 140: ...Rhino were de signed to match the performance capabilities and to provide the best combination of han dling braking and comfort It is best to re place all four tires at the same time If that is not possible you must replace the tires in pairs front or rear with tires of the same size and type as the originals Never replace just one tire WARNING Installing improper tires on your Rhino can affect ha...

Page 141: ... are used for both the front and rear wheels Install the nut with its tapered side towards the wheel 2 Lower the vehicle so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque WARNING Do not reverse the rims on the Rhino to widen the track width Installing wheels improperly increases the risk of wheel fail Manufacturer Size Type Front MAXXIS 25 8 12NHS M951Y Rear MAXXI...

Page 142: ...1 Arrow mark Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf EE book Page 44 Friday August 3 2007 11 59 AM ...

Page 143: ...h skin eyes or clothing Shield eyes when working near batteries Keep out of reach of children You could be poisoned or severely burned by the sulfuric acid in battery electrolyte In case of accidental contact with battery electrolyte EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical attention EYES ...

Page 144: ... NOTICE _ A special battery charger constant volt age ampere or constant voltage is re quired for recharging a sealed type battery Using a conventional battery charger may shorten the battery life _ 2 Always make sure the connections are correct when putting the battery back in the vehicle 1 Negative battery lead black 2 Positive battery lead red EE book Page 46 Friday August 3 2007 11 59 AM ...

Page 145: ...lead Do not reverse the polarity of the jumper cables when connecting to the batteries However if the vehicle must be jump started proceed as follows 1 Turn the key to OFF 2 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 3 Remove the battery compartment cover 4 Using a charged 12 volt battery connect the positive lead of the jumper cable to the positive terminal of the bat...

Page 146: ...f the vehicle to be started 6 Start the engine Refer to Starting a cold engine on pages 6 2 6 5 7 After the engine starts disconnect the negative lead of the jumper cable from the vehicle and charged battery and then disconnect the positive lead of the jumper cable from the charged battery and the battery in the vehicle 8 Reinstall the battery compartment cover 9 Close the hood EE book Page 48 Fri...

Page 147: ...ifting it up and pulling it out Turn the key to OFF and turn off the electri cal circuit in question NOTICE To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 2 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Always use a fuse of the specified amperage Never use any material in place of the proper fuse Using an impr...

Page 148: ...nd turn on the electrical circuit in question to check if the device operates 4 If the fuse blows again immediately have a Yamaha dealer check the electrical system 5 Reinstall the battery compartment cover Specified fuses Main fuse 30 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Signaling system fuse 10 0 A Carburetor warmer fuse 10 0 A Four wheel drive motor fuse ...

Page 149: ...ood up See pages 8 7 8 8 for hood opening and closing procedures 2 Remove the cover at the rear of the headlight by pulling it off 1 Cover at the rear of the headlight 3 Remove the headlight bulb holder cover by pulling it off 1 Headlight bulb holder cover EE book Page 51 Friday August 3 2007 11 59 AM ...

Page 150: ...e 1 Headlight bulb holder 5 Wait for the headlight bulb to cool before touching or removing it Remove the bulb by pulling it out 6 Insert a new headlight bulb into the bulb holder by pushing it in 1 Do not touch the glass part of the bulb EE book Page 52 Friday August 3 2007 11 59 AM ...

Page 151: ... cover is securely fitted over the bulb holder and seated properly 8 Close the hood 9 Adjust the headlight beam if necessary EVU00990 Headlight beam adjustment NOTICE It is advisable to have a Yamaha dealer make this adjustment To raise the beam turn the adjusting screw in direction a To lower the beam turn the adjusting screw in direction b EE book Page 53 Friday August 3 2007 11 59 AM ...

Page 152: ...ht bulb burns out replace it as follows 1 Remove the quick fastener screws and bolts from panel A if replacing the left tail brake light bulb or panel B if replac ing the right tail brake light bulb 1 Panel A 1 Panel B EE book Page 54 Friday August 3 2007 11 59 AM ...

Page 153: ... Tail brake light bulb holder 5 Push the defective bulb in and turn it 7 Reinstall the bulb holder together with the bulb by turning it clockwise 8 Install the panel 9 Lower the cargo bed 10 Reinstall the quick fastener screws and bolts and then tighten the bolts to the specified torque Tightening torque Panel bolt 6 5 Nm 0 65 m kgf 4 7 ft lbf EE book Page 55 Friday August 3 2007 11 59 AM ...

Page 154: ... at a Yamaha dealer ship have the tools experience and know how to properly service your vehicle Use only genuine Yamaha parts on your vehicle Imita tion parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to ex pensive repair bills WARNING When checking the fuel system do not smoke and make sure there are no open flames or sparks...

Page 155: ...ssion 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 ...

Page 156: ...d coolant tap water can be used temporarily provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the coolant reservoir and or radiator Level is OK Level is low check the cooling system for leakage No leakage Leakage Ask a Yamaha dealer to inspect and repair the cooling system Add coolant See the text below Restart th...

Page 157: ... degreaser with a paint brush Do not apply degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job WARNING Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings Wet brakes may have reduced stopping ability increasing the chance of an ac cident NOTICE Excessive water pressure ...

Page 158: ...ive finish When finished start the engine and let it idle for several EVU01041 B Storage Long term storage 60 days or more of your vehicle will require some preventive proce dures to guard against deterioration Make any necessary repairs before storing the vehi cle After thoroughly cleaning the vehicle prepare for storage as follows 1 Fill the fuel tank with fresh fuel and add the specified amount...

Page 159: ... prevent moisture from entering 7 If storing in a humid or salt air atmo sphere coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat covers 8 Remove the battery and charge it Store it in a dry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F Use of fuel st...

Page 160: ...se 1 910 mm 75 2 in Ground clearance 280 mm 11 0 in Minimum turning radius 3 900 mm 154 in Basic weight With oil and full fuel tank 509 0 kg 1 122 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 421 0 cm3 Bore stroke 84 5 75 0 mm 3 33 2 95 in Compression ratio 10 00 1 EE book Page 1 Friday August 3 2007 11 59 AM ...

Page 161: ... 0 10 20 30 40 50 C YAMALUBE 4 10W 40 or SAE 10W 40 YAMALUBE 4 CW 5W 30 or SAE 5W 30 YAMALUBE 4 20W 50 or SAE 20W 50 NOTICE In order to prevent clutch slippage since the en gine oil also lubricates the clutch do not mix any chemical additives with oil Do not use oils with a diesel specification of CD or oils of a higher qual ity than specified In addition do not use oils la beled ENERGY CONSERVING...

Page 162: ... 28 Imp qt 0 34 US qt Radiator capacity including all routes 2 70 L 2 38 Imp qt 2 85 US qt Air filter Engine Wet element Intake duct Dry element Fuel Type Unleaded gasoline only Fuel tank capacity 30 0 L 6 60 lmp gal 7 93 US gal Carburetor Type quantity BSR33 1 Manufacturer MIKUNI Spark plug Type manufacturer DR8EA NGK Model YXR45FX EE book Page 3 Friday August 3 2007 11 59 AM ...

Page 163: ...ransmission type V belt automatic Operation Right hand operation Reverse gear 30 15 2 000 Sub transmission ratio low 43 18 2 389 high 39 22 1 773 Chassis Frame type Steel tube frame Caster angle 5 0 Trail 26 0 mm 1 02 in Tire Type Tubeless Size front 25 8 12NHS rear 25 10 12NHS Model YXR45FX EE book Page 4 Friday August 3 2007 11 59 AM ...

Page 164: ...ne Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 185 mm 7 3 in Rear wheel travel 185 mm 7 3 in Electrical Ignition system DC CDI Generator system AC magneto Battery type U1L 11 Model YXR45FX EE book Page 5 Friday August 3 2007 11 59 AM ...

Page 165: ...perature warning light 12 V 1 7 W 1 LED Special Edition models Parking brake indicator light 12 V 1 7 W 1 LED Special Edition models On Command four wheel drive indicator light except Special Edition models 12 V 1 7 W 1 On Command four wheel drive differential gear lock indicator Special Edition models LCD On Command differential gear lock indicator light 12 V 1 7 W 1 LED Special Edition models Mo...

Page 166: ...light fuse 15 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Four wheel drive motor fuse 3 0 A Carburetor warmer fuse 10 0 A Signaling system fuse 10 0 A Backup fuse 10 0 A Model YXR45FX EE book Page 7 Friday August 3 2007 11 59 AM ...

Page 167: ... identification number and model label infor mation in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER ACA 02E 2 VEHICLE IDENTIFICATION NUMBER ACA 02E 3 MODEL LABEL INFORMATION ACA 01E EE book Page 1 Friday August 3 2007 11 59 AM ...

Page 168: ...tion This number can be used for ordering a new key 1 Key identification number EVU00110 Vehicle identification number The vehicle identification number is stamped into the frame 1 Vehicle identification number The vehicle identification number is used to identify your vehicle EE book Page 2 Friday August 3 2007 11 59 AM ...

Page 169: ...s affixed to the frame under the driver seat Record the information on this label in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label EE book Page 3 Friday August 3 2007 11 59 AM ...

Page 170: ...pose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Mu...

Page 171: ...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 EE book Page 5 ...

Page 172: ...IOD OF WARRANTY any authorized Yamaha Side Side Vehicle dealer will for free of charge repair or replace at Yamaha s option any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corporation U S A O...

Page 173: ...EVU01090 YAMAHA EXTENDED SERVICE Y E S EE book Page 7 Friday August 3 2007 11 59 AM ...

Page 174: ...EE book Page 8 Friday August 3 2007 11 59 AM ...

Page 175: ...B6 yoko fm Page 1 Wednesday March 8 2006 10 46 AM ...

Page 176: ...PRINTED IN USA 2007 08 2 9 1 CR E DIC2342 YAMAHA MOTOR CO LTD ...

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Yamaha RHINO 450, Owner'S Manual

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Summary of Contents for RHINO 450

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