Yamaha YSR45FX Owner'S Manual Download

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Summary of Contents for YSR45FX

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Page 2: ...The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 ...

Page 3: ...derstanding 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 IIF ViVl _1 t_II _ e Please read this manual carefully before operating this vehicle Do not attempt to operate this vehicle until you have attained adequate knowledge of...

Page 4: ...rsonal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death _lr VAVl 1 l_ ll_ t ll A WARNING indicates a hazardous situation which if not avoided I could result in death or serious injury I NOTICE A NOTICE indicates special precautions that must be taken to I avoid damage to the vehicle or other property I TIP A TIP provides key information to make proc...

Page 5: ... 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 reserved Any reprinting or unauthori...

Page 6: ...elerator pedal 4 12 Brake pedal 4 12 Parking brake lever 4 13 Drive select lever 4 14 Fuel tank cap 4 14 m 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 brak...

Page 7: ...IC GUIDE FOR SAFE USE 7 1 KNOW YOUR VEHICLE 7 1 Driver requirements 7 2 Passenger requirements 7 3 Occupant protection system 7 4 Protective structu re 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...

Page 8: ...ter cartridge 8 10 Final gear oil 8 15 Differential gear oil 8 17 Coolant 8 19 Axle boots 8 20 Spark plug inspection 8 21 Cleaning the air filter elements 8 24 Drive select lever box check hose 8 29 V belt cooling duct check hoses 8 29 V belt case drain plug 3 30 Cleaning the spark arrester 3 31 Carburetor adjustment 3 32 Idle speed adjustment 3 33 Valve clearance 3 33 Brakes 3 34 Front brake pad ...

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 CLEANING AND STORAGE 9 1 A Cleaning 9 1 B Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification number records 11 1 NOISE REGULATION 11 4 MAINTENANCE RECORD 11 5 YAMAHA MOTOR CORPORATION U S A SIDE x SIDE VEH...

Page 10: ...LOCATION OF THE WARNING AND SPECIFICATION LABELS J J 1 1 ...

Page 11: ...r roll brace your feet on the floorboards and keep your hands on the handholds Do not try to stop a vehicle tipover using your arm or leg Any part of your body arms legs or head outside of the vehicle can be crushed by the cage frame If you think or feel that the vehicle may tip or roll brace your feet on the floorboards and keep your hands on the steering wheel Do not try to stop a vehicle tipove...

Page 12: ...kPa 63kgf cm2 9psi REAR 91kPa 91kgf cm2 13psi Neversetorallowtire pressure to bebelowthe minimum Tire maydislodgefromrim GrossVehicleWeightRating 907kg 2000Ib maximumincluding vehicle weightof operator passenger accessories cargo and if applicable trailertongueweight YAMAHA 5B4 F1696 00 Keep hands body and other people away from pinch points when lowering bed Do not hold the cage frame while closi...

Page 13: ...thrown forward and strikeoccupants Keepweight inthe cargo bedcenteredside to side andas lowand as far forward as possible Top heavyloads increasethe risk of overturn Do nottow or pullobjects fromany pointother than the trailerhitch bracketor winch if installed Whenloadedwith cargoor towinga trailer Reducespeed and allowmore roomto stop Turn graduallyandgo slowly Avoidhills and rough terrain ReadOw...

Page 14: ...the towing bracket Do not tow more than 550 kg 1212 Ib rolling weight trailer plus cargo Tow or pull only from hitch bracket Read Owner s Manual before loading towing or pulling objects YAMAHA 5B4 F151 K 00 1 5 Head Body Hands Feet YAMAHA Helmet and eye protection Seatbelt and protective clothing Inside vehicle and holding the handholds or steering wheel On floorboard ready to brace and door close...

Page 15: ...hill is unavoidable drive slowly only by an operator 16 or older _ 1 _ _NYi and turn downhill immediately if you feel the with a valid motor vehicle license _ vehicle maytip Passenger and driver must be able to Avoid paved surfaces Turn gradually and go place both feet flat on the floorboard while slowly if you must drive on pavement This vehicle seated upright with their backs against the is desi...

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

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

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

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

Page 20: ...o far or too fast can result in a rollover Avoid sideways sliding skidding or fishtailing and never do donuts Slow down before entering a turn and avoid hard braking in a turn When making tight turns from a stop or at slow speeds avoid sudden or hard accelera tion 2 5 ...

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

Page 22: ...more room to stop Avoid hills and rough terrain Use extreme caution when towing or carrying a load on in clines Load trailer properly and use extra care when towing or pulling Do not tow or pull objects from any part of the vehicle other than the trailer hitch bracket or winch if installed 2 7 ...

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

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

Page 25: ... designed to match the performance capabili ties and to provide the best combination of handling braking and comfort Other tires rims sizes and combinations may not be appropriate Refer to pages 8 42 8 44 for tire specifications and more information on replacing your tires 2 10 ...

Page 26: ...iver seat belt 8 Cargo bed 9 Tail brake lights 10 Rear shock absorber assembly spring preload adjusting ring 11 Cargo bed release levers 12 Spark plug 13 Door 14 Spark arrester 15 Passenger seat belt 16 Passenger seat 17 Oil filter cartridge 18 Passenger handhold 19 Engine oil filler cap 20 Battery 21 Fuses 22 Coolant reservoir 23 Radiator cap 24 Fuel level check window 25 Fuel tank cap 3 1 ...

Page 27: ...ial 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 36 Accelerator pedal 37 Brake pedal The vehicle you have purchased may differ slightly from those shown in the figures of this manual m 3 2 ...

Page 28: ... electrical circuits are supplied with power and the headlights and tail lights come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this posi tion START The electric starter is engaged by turning and holding the key in this po sition Release the key when the en gine starts 4 1 ...

Page 29: ... P This indicator light comes on when the park ing brake is applied 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 Neutral ind...

Page 30: ...ar lock switch is set to the LOCK position 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 vehicl...

Page 31: ...switch to START with the transmission in the neutral position Coolant temperatu re warning light comes on momentarily Coolant temperature and electrical circuit are OK Go ahead with riding Coolant temperature warning light does not come on I I Coolant temperature J warning light comes on Ask a Yamaha dealer to inspect the electrical circuit 4 4 ...

Page 32: ...sh until the differential gear is locked 1 On Command differential gear lock indicator light DIFF LOCK 2 Low range indicator light L 3 High range indicator light H 4 Neutral indicator light N 5 Reverse indicator light R 6 Parking brake indicator light P 7 On Command four wheel drive differential gear lock indicator _ t _ 8 Coolant temperature warning light _ _E Low range indicator light L This ind...

Page 33: ...s indicator light comes on when the park ing brake is applied On Command four wheel d rive 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...

Page 34: ... Edition models NOTICE The engine may overheat if the vehicle is overloaded If this happens reduce the load to specification After restarting make sure that the light is out Continuous use while the light is on may cause damage to the engine 1 Speedometer 2 Fuel meter 3 H button 4 M button 5 Clock Hour meter 6 Odometer Tripmeter A Tripmeter B 7 TRIPiODO button 8 Clock Hour button __ _ The multi fu...

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

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

Page 37: ... may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it 1 Light switch OFF G_ _ Set the switch to _ to turn on the low beam and the taillights Set the switch to to turn on the high beam and the taillights Set the switch to OFF to turn off all the lights 4 10 ...

Page 38: ...erential gear lock switch 4WD LOCK Select the appropriate drive accord ing to terrain and conditions Two wheel drive 2WD Power is sup plied to the rear wheels only Four wheel drive 4WD Power is sup plied to the rear and front wheels Four wheel drive with the differential gear locked 4WD LOCK Power is supplied to the rear and front wheels with the differ ential gear locked Unlike the 4WD mode all w...

Page 39: ...peed Spring pressure returns the pedal to the rest position when released Al ways check that the accelerator pedal returns normally before starting the engine O 0 0 0 o o Brake pedal Press the brake pedal to slow or stop the ve hicle 1 Brake pedal 1 Accelerator pedal 4 12 ...

Page 40: ... vehicle from moving while parked To set the parking brake pull the lever up completely To release the parking brake pull up on the lever press the release button and then push the lever all the way down Spring pressure helps return the lever to the released position Ii f 1 Parking brake lever 2 Release button 4 13 ...

Page 41: ...sed to shift the vehi cle into the low high neutral and reverse po sitions Refer to pages 6 6 6 7 for the drive select lever operation Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap 1 Drive select lever 4 14 ...

Page 42: ... level check window Starter choke I_1 Starting a cold engine requires a richer air fuel mixture A separate starter circuit supplies this mixture Move in direction _ to turn on the starter choke Move in direction to turn off the starter choke Refer to Starting a cold engine for proper op eration See pages 6 2 6 5 A Starter choke 1_1 1 Fully open 2 Half open 3 Closed 4 15 ...

Page 43: ...oor inward until it is securely latched Be sure the door is SECURELY LATCHED AFTER CLOSING IT Seats To remove a seat pull its seat lock lever up ward lift the front of the seat and then slide the seat forward and up 1 Latch 2 Door 1 Driver seat 2 Passenger seat 3 Seat lock lever 2 4 16 ...

Page 44: ...eats are securely latched WARNING A loose seat could cause the operator to lose control or cause the operator or pas senger to fall Seat belts This vehicle is equipped with three point seat belts for both the operator and the passenger Always wear the seat belts properly while riding in the vehicle See pages 7 6 7 8 for more information 4 17 ...

Page 45: ...or sharply edged prod ucts directly in the glove compartment If they must be stored wrap them in appro priate cushioning material Cargo bed 1 Cargo bed 2 Tailgate 3 Cargo hook 4 Maximum load limit 181 kg 400 Ib For additional loading information see pages 6 11 6 13 a Unlock b Open 4 18 ...

Page 46: ...l gate To close Place the tailgate in the original position and then hook the latches Lifting and lowering the cargo bed k_ _ _3 b v_J j 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 4 19 ...

Page 47: ...shock absorber adjustment The spring preload can be adjusted to suit the operating conditions You can reduce preload for a softer ride or increase preload if frequent bottoming occurs or when carrying loads IIV w _I t _II _ ell 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 ac...

Page 48: ...ng in direction _ To decrease the spring preload turn the ad justing ring in direction A 8 C D 1 Spring preload adjusting ring 2 Position indicator A special wrench can be obtained at Yamaha dealer to make this adjustment Standard position B A Minimum soft E Maximum hard Special wrench 4 21 ...

Page 49: ...ion 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 Trailer hitch bracket 2 Receiver 1 Auxiliary DC jack cap 1 Set the light switch to OFF 2 Start the engine See pages 6 2 6 5 3 Open the auxiliary DC jack cap and then i...

Page 50: ... accessories requiring more than the maximum capacity stated above This may overload the circuit and cause the fuse to blow If accessories are used without the en gine running the battery will lose its charge and engine starting may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged 4 23 ...

Page 51: ...m If a problem cannot be corrected by the procedures provided in this manual have the vehicle inspect ed by a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Brakes Check operation free play fluid level and fluid leakage Fill with DOT 4 brake fluid if necessary 5 3 8 34 8 37 8 39 Parking brake Check for proper operation condition and free play 8 37 8 38 Check f...

Page 52: ...tion 5 8 Seat belts Check for proper operation and belt wear 5 8 Steering Check for proper operation 5 8 Fittings and fasteners Check all fittings and fasteners 5 8 Lights and switches Check for proper operation 5 8 8 51 8 55 Wheels and tires Check tire pressure and for wear and damage 5 9 5 11 8 42 8 44 Axle boots Check for damage 8 20 8 21 5 2 ...

Page 53: ...vel Add fluid if neces sary See pages 8 35 8 36 Recommended brake fluid DOT 4 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 s...

Page 54: ...lights of water heaters and clothes dry ers 2 Do not overfill the fuel tank Because fuel expands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 3 Wipe up any spilled fuel immediately 5 4 4 Be sure the fuel tank cap is closed se curely IIV _l VAVl_ t _ I I_ e I Gasoline is poisonous and can cause inju ry or death Handle gasoline with care Never siphon ...

Page 55: ...amaha because it may cause fuel system damage or vehicle performance problems Recommended fuel Unleaded gasoline only Fuel tank capacity 30 0 L 6 60 Imp gal 7 93 US gal 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 rem...

Page 56: ...es the clutch do not mix any chemical addi tives with oil Do not use oils with a die sel specification of CD or oils of a higher quality than specified In addi tion do not use oils labeled ENERGY CONSERVING I1 or higher Make sure that no foreign material en ters the crankcase SAE 1 CD specification 2 ENERGY CONSERVING I1 Recommended engine oil type and quantity See page 10 2 5 6 ...

Page 57: ...or salt water is harmful to the engine You may use soft water if you can not get distilled water Coolant reservoir capacity up to the maximum level mark 0 35 L 0 31 Imp qt 0 37 US qt 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 Recommended oil SAE 80 API GL 4 Hypoid gear oil If desired an SAE 80W90 hypoid gear oil may be...

Page 58: ...eration Have a Yamaha dealer repair as necessary for proper operation A crash can damage the restraint systems in your vehicle A damaged restraint system may not properly protect the person using it resulting in serious injury or death in a crash To help make sure your restraint systems are working properly after a crash have them in spected and any necessary replacements made as soon as possible ...

Page 59: ...eeze in cold weather and you could be unable to control the vehicle Tires Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage 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 c...

Page 60: ...77 kgficm 2 10 psi 9 psi 11 psi 98 kPa 91 kPa 105 kPa Rear 0 98 kgficm 2 0 91 kgficm 2 1 05 kgficm 2 14 psi 13 psi 15 psi The tire pressure gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect 1 Tire pressure gauge 5 10 ...

Page 61: ...Tire wear limit When the tire groove decreases to 0 12 in due to wear replace the tire 3mm i a Tire wear limit 5 11 ...

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

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

Page 64: ...mbient temperature at 0 C 30 F 30 C 90 F and warming up position Cold engine start ambient temperature above 25 C 80 F and warm engine start position AMBIENT TEMP STARTER CHOKE POSITION 0 10 20 30 C i i i l I I I 7oo a Starter choke 1 Fullyopen 2 Half open 3 Closed 4 With your foot off the accelerator pedal start the engine by turning the key to START 6 3 ...

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

Page 66: ...d V belt 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 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 ...

Page 67: ...y occur Shifting neutral to high and high to low 1 Stop the vehicle Take your foot off the accelerator pedal 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 L Low H High I N Neutral R Reverse 1 Drive select lever 3 Release the brake pedal and press the accelerator pedal gradually 6 6...

Page 68: ... or vice versa by moving the drive select lever along the shift guide When in reverse the reverse indicator light should be on Due to the synchro nizing mechanism in the engine the light may not come on until the vehicle starts moving If the light does not come on ask a Yamaha dealer to inspect the reverse indicator light electrical circuit 6 7 L Low H High _ N Neutral r R Reverse 1 Drive select l...

Page 69: ...D 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 is set to position _...

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

Page 71: ...elp the differential gear lock to engage Driving before the differential gear lock is properly engaged e g when the indicator and indicator light are flashing will cause the engine speed to be limited until en gagement is complete 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 pa...

Page 72: ... Loading Limits for the vehicle see box or vehi cle labeling Keep weight in the cargo bed centered side to side and as low and as far for ward as possible Top heavy loads in crease the risk of overturn Be sure cargo is secured a loose load could change handling unexpectedly or strike occupants Do not exceed the maximum tongue weight Make sure the load does not interfere with your control or abilit...

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

Page 74: ...carrying a load on in clines Turn gradually and go slowly Pulling something other than a trailer Yamaha recommends that loads be transport ed in the bed or in a trailer If you need to move an object a short distance use a winch and follow the winch manufacturer s instruc tions If you choose to use something other than a winch use extreme caution follow the manu facturer s instructions for that pro...

Page 75: ... VAVl_ t _ II _ e W 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 ca...

Page 76: ...t is your responsibility to protect yourself and your passenger from accidents including rollovers The Rhino has many features including a protective struc ture and seat belts to help protect occupants but the best way to avoid injuries is to avoid accidents There is a risk of injury or death in any accident even with these safety features The driver must be able to place both feet flat on the flo...

Page 77: ...be used Passenger requirements This vehicle is designed for the operator and one passenger Carrying passengers improp erly can lead to serious injury or death As the operator you are responsible for your pas senger Your passenger must be able to place both feet on the floorboard while seated upright with his her back against the seat back Allow only one passenger in the vehicle and only in the pas...

Page 78: ...Occupant protection system 1 Passenger handhold 2 Seat belt 3 Door 1 Passenger handhold 1 Door 7 4 ...

Page 79: ...rame provides a protective structure that helps limit intrusions by branch es or other objects and may reduce your risk of injury in accidents The protective structure will not protect occupants in all rollovers or ac cidents Body parts outside of vehicle can be struck by passing objects or crushed during vehicle roll over Do not put your hands or feet outside of the vehicle for any reason Do not ...

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

Page 81: ...n of the 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 ...

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

Page 83: ...duce the likelihood that the passenger puts a hand outside the vehicle if the vehicle begins to tip There are two handholds on the protective structure and two handholds on the passen ger s left side for the right and left hands The driver should make sure the passenger is holding onto the handholds with both hands before operating the vehicle 7 9 ...

Page 84: ... when the vehicle is moving Your hand or arm may be struck by objects or crushed against outside objects or the ground during a rollover Floorboard The floorboard allows you to brace your feet which helps you keep your body in the vehicle in the event of an accident or rollover Keep your feet on the floorboard during operation 7 10 ...

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

Page 86: ...op erly Eye protection goggles helmet face shield or protective eyewear Over the ankle boots gloves long sleeved shirt or jacket and long pants An approved helmet and other personal pro tective equipment can help in a variety of ways including Reduce the severity of injuries if any part of you is outside the vehicle cage frame pro tective structure during a rollover Help protect you if outside obj...

Page 87: ...ra tion and turning Practice smooth throttle ap plication Practice slowing down before turning Practice maintaining a steady throttle through the turn Avoid higher speeds until you are thoroughly familiar with the operation of your vehicle Remember driving aggres sively or making abrupt maneuvers even on flat open areas can cause side rollovers 7 13 Become familiar with the way the vehicle feels i...

Page 88: ...wnbeforeenteringturns Whenmakingtightturnsfromastandstillorat slowspeeds avoidsuddenor hardaccelera tion Drivingaggressivelyor makingabrupt maneuverseven on flat open areas can causeside rollovers Avoidsidewayssliding skidding orfishtailing andneverdodonuts If youfeelthe Rhinobeginto slidesidewaysor fishtailduringaturn steerintothedirectionof theslide if possible and graduallylet offthe accelerato...

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

Page 90: ...off road With this feature the engine helps slow the vehicle down after you take your foot off the accelerator Engine braking is more no ticeable in 4WD Application of vehicle brakes provides additional stopping power 7 16 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 eng...

Page 91: ...oosteepthevehi clemayrolloutof control Neverparkonhills that are so steepyou cannotwalk up them easily If you mustpark on an inclinefollow theseinstructions 1 Bringthevehicleto astopbyapplying the brakes 2 Putthevehiclein4WDDiff Lock 3 Turntheengineoff 4 With the brake pedal applied set the parkingbrake 5 Block the front and rear wheels with rocksorotherobjects Loading The totalweightof operator p...

Page 92: ... react To avoid loss of control or rollover always be alert to changing surfaces or terrain when operating the vehicle The Rhino has higher ground clearance and other features to handle rugged terrain and as a result can overturn in situations where some vehicles may not Abrupt maneuvers or aggressive driving can cause loss of control including rollovers even on flat open areas These rollovers can...

Page 93: ...our 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 7 19 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 t...

Page 94: ...ethebrakeandbe ginto coastdownthe hill Useenginebraking as much as possible gently applying the brakeswhennecessary Downhill Check the terrain carefully before going downhill Whenpossible choosea paththat lets you drive yourvehiclestraightdownhill Chooseyour pathcarefullyand drive slowly enoughto be ableto reactto obstaclesthat youencounter For moretractionand control before going downsteeperand o...

Page 95: ...here are no obstacles in your path As you regain proper balance gradually steer again in the direction you want to go Rough terrain Operation over rough terrain should be done with caution Look for and avoid obstacles that could cause damage to the vehicle or could lead to a rollover or accident Do not drive in a way that will get the Rhino airborne as injury loss of control and damage to the vehi...

Page 96: ...your vehicle in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case the V belt cooling duct check hoses the drive select lever box check hose and the V belt case drain plug Wash the vehi cle in fresh water if it has been operated in salt water or muddy conditions Operating this vehicle through deep or fast flowing water can lead to loss of contr...

Page 97: ...ith brush or trees watch carefully on both sides and above the vehicle for obstacles such as branches that the vehicle might hit causing an accident Watch for brush that might enter the vehicle as you pass and strike you or the passenger Never hold onto the cage frame The passen ger should always hold onto the handholds with both hands The muffler and other engine parts become extremely hot during...

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

Page 99: ...le or performing maintenance activities incor rectly may increase your risk of injury or death during service or while using the ve hicle If you are not familiar with vehicle service have a Yamaha dealer perform service 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 ca...

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

Page 101: ...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 8 3 ...

Page 102: ... tools data and technical skills ITEM INITIAL month 1 3 km 320 1 200 mi 200 750 hours 20 75 Whichever 6 ROUTINE comes first 2 400 E_ 1 SO0 150 Check fuel hose for cracks or damage 0 Replace if necessary Check valve clearance Adjust if necessary O Check condition Adjust gap and clean O Replace if necessary Check idle speed starter operation O Adjust if necessary Check breather hose for cracks or da...

Page 103: ...imit Check operation brake pad wear fluid leakage see page 8 6 Correct if necessary Replace pads if worn to the limit Check operation and free play Check operation Check for wear cracks or damage Check balance damage runout Repair if necessary Check bearing assemblies for looseness damage Replace if damaged Check operation and for leakage Correct if necessary Check operation and for looseness Repl...

Page 104: ...rrect if necessary 0 0 0 0 0 Recommended brake fluid DOT 4 Brake fluid replacement INITIAL EVERY Whichever month 1 3 6 6 12 comes first km 320 1 200 2 400 2 400 4 800 _ mi 200 750 1 500 1 500 3 000 hours 20 75 150 150 300 O O O o Replace the brake fluid when disassembling the master cylinder or caliper Check the brake fluid level regularly and add fluid as required Replace the oil seals on the inn...

Page 105: ...Hood To open Unhook the hood latches and then slowly tilt the hood up until it stops 1 Latch 2 1 Hood 8 7 ...

Page 106: ...he hood into slots _ on the back of the instrument panel Secure slotsQ on the side of the hood around projections Q on the frame 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 1 Projection x 2 2 Slot x 2 3 Slot 2 4 Projection 2 8 8 ...

Page 107: ...r boot will come loose 1 Console To install 1 Place the console in its original position 2 Install the parking brake lever boot 3 Install the seats NOTICE When installing the console be sure not to pinch the cables or wires Make sure that the groove at the bottom of the parking brake lever boot and the drive select lever boot fits securely around the edge of the hole in the con sole 8 9 ...

Page 108: ...the vehicle on a level surface 2 Remove the console See page 8 9 for console removal and installation proce dures 3 Check the engine oil level on a cold en gine If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil settles for an accurate reading 4 Remove the engine oil filler cap and wipe off the dipstic...

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

Page 110: ...er 1 Oil filter cartridge 2 Oil filter wrench Apply a light coat of clean engine oil to the O ring of the new oil filter cartridge Make sure the O ring is seated properly 1 O ring 7 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf 8 12 ...

Page 111: ...ecified amount of recommend ed engine oil and then reinstall the en gine oil filler cap and tighten it NOTICE Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down 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 8 1...

Page 112: ...se oils labeled ENERGY CONSERVING I1 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 co...

Page 113: ...ler hole 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 1 Final gear oil filler bolt 2 Final gear oil 3 Correct...

Page 114: ...ening torque Final gear oil drain bolt 20 Nm 2 0 m kgf 14 ft lbf 8 16 Add the recommended final gear oil up to the brim of the filler hole NOTICE Be sure no foreign material enters the fi nal gear case Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 25 L 0 22 Imp qt 0 26 US qt 6 Reinstall the oil filler bolt and then tight en it to the specified torque Tightening torque Final gear o...

Page 115: ...erial enters the differential gear case l 3 Reinstall the differential gear oil filler bolt and then tighten it to the specified torque Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 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 f...

Page 116: ...e with the rec ommended oil NOTICE Be sure no for eign material enters the differential gear case Recommended oil SAE 80 API GL 5 Hypoid gear oil Oil quantity 0 32 L 0 28 Imp qt 0 34 US qt 6 Reinstall the differential gear oil filler bolt and then tighten it to the specified torque Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 7 Check for oil leakage If oil leakage ...

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

Page 118: ...freeze content of the coolant as soon as possible The radiator fan is automatically switched on or off according to the coolant temperature in the radiator 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 instructions Axle boots Check the protective boots for holes or tears I...

Page 119: ...emove the console See page 8 9 for console removal and installation proce dures 2 Remove the spark plug cap 1 Rear axle boot x 2 each side 1 Spark plug cap 3 Use the spark plug wrench in the tool kit to remove the spark plug as shown 8 21 ...

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

Page 121: ...hen 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 Tightening torque Spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbf 4 Install the spark plug cap 5 Reinstall the console a Spark plug gap 2 Clean the surface of the spark plug gas ket and its mating surface a...

Page 122: ...tener screws 2 Remove the air filter element from the air intake duct grill by pulling it out as shown 1 Quick fastener screw 4 2 Air intake duct grill 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 8 24 ...

Page 123: ...r element There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case 1 Air filter case check hose 1 Remove the seats See pages 4 16 4 17 for seat removal and installation procedures 2 Remove the console See page 8 9 for console removal and installation proce dures 8 25 ...

Page 124: ...3 Remove the air filter case cover by un hooking the holders 1 Air filter case cover holder 5 2 Air filter case cover 4 Remove the air filter element 1 Air filter element 8 26 ...

Page 125: ... material gently but thoroughly in parts cleaning solvent WARNING Using gasoline or other flammable solvents to clean the air fil ter element can cause a fire or explo sion which could lead to serious injury 7 Squeeze the excess solvent out of the sponge material NOTICE Do not twist the sponge material when squeezing it 8 27 ...

Page 126: ...to the air filter case 15 Install the console 16 Install the seats The air filter element should be cleaned every 20 40 hours It should be cleaned and lubri cated more often if the vehicle is operated in extremely dusty areas Each time air filter ele ment maintenance is performed check the air inlet to the air filter case for obstructions Check the air filter element rubber joint to the carburetor...

Page 127: ...ive select lever box check hose remove the hose and clean it V belt cooling duct check hoses The V belt cooling duct check hoses are 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 Drive select lever box check hose 1 V belt cooling duct check hose 8 2...

Page 128: ...removal and installation procedures After riding in water deep enough to allow wa ter to enter the V belt case remove the drain plug to drain any water from the case If water drains from the V belt case after re moving the drain plug have a Yamaha dealer inspect the vehicle as the water may affect other engine parts 1 V belt case drain plug 8 30 ...

Page 129: ...aust system 1 Remove the bolts 1 Bolt x3 3 Remove the tailpipe by pulling it out of the muffler Tap the tailpipe lightly and then use a wire brush to remove any carbon depos its from the spark arrester portion of the tailpipe and inside of the tailpipe housing 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install the tailpipe by installing the bolts ...

Page 130: ...e left to a Yamaha dealer who has the professional knowledge and ex perience to do so However the idling speed adjustment may be performed by the owner as a part of the usual maintenance routine NOTICE The carburetor was set at the Yamaha fac tory after many tests If the settings are disturbed by someone without sufficient technical knowledge poor engine perfor mance and damage may result 8 32 ...

Page 131: ...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 screw Turn the screw in direction _ to increase the engine speed and in direc tion to decrease the engine speed 8 33 Specified idle speed 1 450 1 550 r min 1 Throttle stop screw 5 Reinstall the console 6 Reinstall the seats Valve clearance The ...

Page 132: ... the brake pads See pages 8 42 8 44 for wheel removal and installation procedures 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 ...

Page 133: ...dealer replace the brake pads as a set 1 Brake pad wear indicator groove 8 35 Checking the brake fluid level 1 Minimum level mark Insufficient brake fluid may allow air to enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indi cate worn brake pads a...

Page 134: ...oor brakingperfor mance Be carefulthat waterdoes not enter the brake fluid reservoirwhen refilling Water will significantlylower the boilingpoint of thefluidand mayresultinvaporlock Brakefluid maydeterioratepaintedsurfac es or plasticparts Alwayscleanupspilled fluidimmediately Have a Yamahadealerinspectthe brake systemif thebrakefluidlevelgoesdown Brake fluid replacement Complete fluid replacement...

Page 135: ...ler check the brake system if necessary 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 _C _ 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 br...

Page 136: ...checking and adjusting the parking brake lever free play 6 Loosen the Iocknut 1 Locknut 2 Adjusting nut 7 Turn the adjusting nut in direction to increase the free play or in direction to decrease the free play 8 Tighten the Iocknut 9 Reinstall the console 10 Reinstall the seats 8 38 ...

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

Page 138: ...Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Lubricate the cable ends If the cables do not operate smoothly ask a Yamaha dealer to re place them Recommended lubricant J Lithium soap based grease Brake pedal and accelerator pedal lubrication Lubricate the pivoting parts Recommended lubricant Lithium soap based grease I 8140 ...

Page 139: ...vot lubrication Lubricate the knuckle upper and lower pivots with a grease gun Steering shaft lubrication Lubricate the pivot points Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease 8 41 ...

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

Page 141: ...mark L_ on the tire must point toward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nut with its tapered side towards the wheel 2 Lower the vehicle so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque _V _ VlVl _ t II e Do not reverse the rims on the Rhino to widen the track width Installing wheels improperly...

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 Tapered nut 8144 ...

Page 143: ...ear batteries Keep out of reach of children You could be poisoned or severely burned by the sulfuric acid in battery electrolyte In case of accidental contact with battery electrolyte EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes and get prompt med...

Page 144: ...re reinstallation NOTICE A special battery charger constant volt age ampere or constant voltage is re quired for recharging a sealed type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the vehicle 2 1 Negative battery lead black 2 Positive battery lead red 8146 ...

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

Page 146: ...nted metal sur face of the vehicle to be started 6 Start the engine Refer to Starting a cold engine on pages 6 2 6 5 7 After the engine starts disconnect the negative lead of the jumper cable from the vehicle and charged battery and then disconnect the positive lead of the jumper cable from the charged battery and the battery in the vehicle 8 Reinstall the battery compartment cover 9 Close the hoo...

Page 147: ...y lifting 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 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 imp...

Page 148: ...fuses Main fuse 30 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Signaling system fuse 10 0 A Carburetor warmer fuse 10 0 A Four wheel drive motor fuse 3 0 A Backup fuse 10 0 A 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse blows again immediately have a Yamaha dealer check the electrical system 5 Rei...

Page 149: ...ows 1 Lift the hood up See pages 8 7 8 8 for hood opening and closing procedures 2 Remove the cover at the rear of the headlight by pulling it off 3 Remove the headlight bulb holder cover by pulling it off 1 Headlight bulb holder cover 1 Cover at the rear of the headlight 8 51 ...

Page 150: ...it counterclock wise 1 Headlight bulb holder 5 Wait for the headlight bulb to cool before touching or removing it Remove the bulb by pulling it out 6 Insert a new headlight bulb into the bulb holder by pushing it in i I 1 Do not touch the glass part of the bulb 8 52 ...

Page 151: ...lb holder cover is securely fitted over the bulb holder and seated properly 8 Close the hood 9 Adjust the headlight beam if necessary Headlight beam adjustment NOTICE It is advisable to have a Yamaha dealer make this adjustment To raise the beam turn the adjusting screw in direction _ To lower the beam turn the adjusting screw in direction 1 Headlight beam adjusting screw 8 53 ...

Page 152: ... 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 B 1 Panel A 1 Quick fastener screw 8 3 Panel A 2 Bolt x2 8154 ...

Page 153: ...efective bulb in and turn it counterclockwise to remove it from the bulb holder 6 Push a new bulb in and turn it clockwise to install in the bulb holder 8 55 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 b...

Page 154: ...skilledtechniciansat a Yamahadealer ship have the tools experience and know howto properlyserviceyourvehicle Useonly genuineYamahapartsonyourvehicle Imita tion parts may look like Yamahaparts but they are often inferior Consequently they havea shorterservicelifeandcanleadto ex pensiverepairbills When checking the fuel system do not smoke and make sure there are no open flames or sparks in the area...

Page 155: ...f there is compression There is compression Compression normal No compression ASkinspect a Yamaha dealer to nton Wet W eceanw Remove the _ spark plug and check the electrodes Dry _ Attach spark plug cap andground to chassis H Use_lestarter 4 Battery _ Engine turns over _1 vl Use quickly Battery is good the electric starter q Engine turns over ____U Checkthe connections I slowly recharge J Spark is...

Page 156: ...nd repairthe cooling system I I Level is low check the I I i _ coolingsystemforleakage H __ _l Wait until the I ICheck the coolant level in the I I _ Add coolant See the text below I engine has cooled _ coolant reservoir and or radiator q I _ _ I Restart the engine If the engine overheats again ask a I _ 1 Level Is OK _ _1 Yamaha dealer to inspect and or repair the cooling system J If it is diffic...

Page 157: ...y degreaser with a paint brush Do not apply degreaser to the wheel axles 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 m...

Page 158: ...et it idle for several minutes B Storage Long term storage 60 days or more of your vehicle will require some preventive proce dures to guard against deterioration Make any necessary repairs before storing the vehi cle After thoroughly cleaning the vehicle prepare for storage as follows 1 Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or eq...

Page 159: ... outletto preventmoisturefromentering 7 If storing in a humid or salt air atmo sphere coatall exposedmetalsurfaces witha lightfilm of oil Donot applyoil to anyrubberpartsortheseatcovers Remove the battery and charge it Store it in a dry place and recharge it once a month Do not store the battery in an ex cessively warm or cold place less than 0 C 30 F or more than 30 C 90 F Use of fuel stabilizer ...

Page 160: ... 1 910 mm 75 2 in 280 mm 11 0 in Minimum turning radius Basic weight With oil and full fuel tank Engine Engine type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubrication system 3 900 mm 154 in 509 0 kg 1 122 Ib Liquid cooled 4 stroke SOHC Forward inclined single cylinder 421 0 cm 3 84 5 x 75 0 mm 3 33 x 2 95 in 10 00 1 Electric starter Wet sump 10 1 ...

Page 161: ...UBE 4 CW 5W 30 or SAE 5W 30 i 20 10 0 10 20 30 40 50 C API service SG type or higher JASO standard MA 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 I1 or higher 2...

Page 162: ...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 Imp gal 7 93 US gal Carburetor Type quantity BSR33 1 Manufacturer MIKUNI Spark plug Type man ufactu rer D R8EA N GK Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch type Wet centrifugal automatic 10 3...

Page 163: ...eration Reverse gear Sub transmission ratio low high YXR45FX V belt Shaft drive 43 20 24 17 33 9 11 129 V belt automatic Right hand operation 30 15 2 000 43 18 2 389 39 22 1 773 Chassis Frame type Caster angle Trail Tire Type Size Steel tube frame 5 0 26 0 mm 1 02 in front rear Tubeless 25 x 8 12NHS 25 x 10 12NHS 10 4 ...

Page 164: ...c brake Foot operation Double wishbone Double wishbone Front shock absorber Rear shock absorber Wheel travel Front wheel travel Rear wheel travel Electrical Ignition system Generator system Battery type Battery capacity Headlight type Coil spring oil damper Coil spring oil damper 185 mm 7 3 in 185 mm 7 3 in DC CDI AC magneto U1L 11 12 V 28 0 Ah Krypton bulb 10 5 ...

Page 165: ...r wheel drive differential gear lock indicator Special Edition models On Command differential gear lock indicator light High range indicator light Special Edition models Low range indicator light Special Edition models YXR45FX 12 V 30 0 W 30 O W x 2 12 V 5 0 W 21 0 W x 2 12V1 7Wx1 LED Special Edition models 12V1 7Wx1 LED Special Edition models 12V1 7Wx1 LED Special Edition models 12V1 7Wx1 LED Spe...

Page 166: ...Specified fuses Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four wheel drive motor fuse Carburetor warmer fuse Signaling system fuse Backup fuse 30 0 A 15 0A 10 0A 10 0A 3 0A 10 0A 10 0A 10 0A 10 7 ...

Page 167: ...vehicle identification number and model label infor mation in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen I I 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION I I 11 1 ...

Page 168: ... following illustration This number can be used for ordering a new key Vehicle identification number The vehicle identification number is stamped into the frame Q 1 Vehicle identification number 1 Key identification number The vehicle identification number is used to identify your vehicle 11 2 ...

Page 169: ...he model label is affixed to the frame under the driver seat Record the information on this label in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label 11 3 ...

Page 170: ...cle 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 Ex...

Page 171: ...hat the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL month km mi hours 1 320 200 20 3 1 200 750 75 6 2 400 1 500 150 12 4 800 3 000 300 18 7 200 4 500 450 24 9 600 6 000 600 30 12 000 7 500 750 36 14 400 9 000 900 42 16 800 10 500 1 050 48 19 200 12 000 1 200 54 21 600 13 500 1 350 60 24 000 15 000 1 500 DATE OF SERVICE MILEAGE SERVICING DEALER N...

Page 172: ...t that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent purchaser s it is imperative that the Side x Side vehicle be inspected and registered for warranty by an authorized Yamaha Side x Side Vehicle dealer in order for this warranty to remain in effect this inspection and registration must ta...

Page 173: ...ere s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls ...

Page 174: ...arranty expires You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 Y YAMAHA EXTENDED S SERVICE 11 8 ...

Page 175: ...PRINTED INUSA 2007 08o2 9 1 CR E ...

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Yamaha YSR45FX, Owner'S Manual

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