Rhino 660

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EE.book Page 1 Tuesday, July 27, 2004 5:17 PM
EVU00010
INTRODUCTION
1-
Congratulations on your purchase of the Yamaha YXR660FA. It represents the result of many
years of Yamaha experience in the production of fine sporting, touring, and pace-setting racing
vehicles. With the purchase of this Yamaha, you can now appreciate the high degree of crafts-
manship and reliability that have made Yamaha a leader in these fields.
This manual will provide you with a good basic understanding of the features and operation of this
vehicle. It also includes basic maintenance and inspection procedures. If you have any questions
regarding the operation or maintenance of your vehicle, please consult a Yamaha dealer.
_
WARNING
Please read this manual carefully before operating this vehicle. Do not attempt to operate
this vehicle until you have attained adequate knowledge of its controls and operating fea-
tures. Regular inspections and careful maintenance, along with good operating tech-
niques, will help ensure that you safely enjoy the capabilities and reliability of this vehicle.
_

EVU00020
IMPORTANT MANUAL INFORMATION

1-
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN

SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe

WARNING
injury or death to the vehicle operator, a bystander or a person
inspecting or repairing the vehicle.
CAUTION: A CAUTION indicates special precautions that must be taken to

avoid damage to the vehicle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

EVU00030
IMPORTANT NOTICE
2-
● This vehicle is designed and manufactured for off-road use only. It is illegal to operate
this vehicle on any public street, road, or highway. Such use is prohibited by law.
● 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.
EVU00040
YXR660FAT
OWNER’S MANUAL
©2004 by Yamaha Motor Corporation,
AFFIX DEALER
U.S.A.
1st edition, July 2004
LABEL HERE
All rights reserved. Any reprinting or
unauthorized use without the written
permission of
EVU00050
CONTENTS Fuel level check window ................4-14

Starter (choke) ...............................4-14
1 LOCATION OF THE WARNING Seats ..............................................4-15
AND SPECIFICATION LABELS....... 1-1 Seat belts .......................................4-16
Glove compartment .......................4-18
2 SAFETY INFORMATION.................. 2-1 Cargo bed ......................................4-18
Front and rear shock absorber
3 DESCRIPTION AND VEHICLE adjustment ...................................4-21
IDENTIFICATION ............................. 3-1 Trailer hitch bracket .......................4-23
Identification number records.......... 3-3 Auxiliary DC jack............................4-24
Key identification number................ 3-3
Vehicle identification number .......... 3-4 5 PRE-OPERATION CHECKS ............5-1
Model label ...................................... 3-4 Front and rear brakes ......................5-2
Fuel ..................................................5-4
4 CONTROL FUNCTIONS .................. 4-1 Engine oil .........................................5-5
Main switch...................................... 4-1 Coolant.............................................5-6
Indicator and warning lights ............ 4-3 Final gear oil ....................................5-7
Switches .......................................... 4-6 Differential gear oil ...........................5-7
Switches.......................................... 5-8 Going downhill ................................. 7-9

Tires ................................................ 5-8 Crossing through shallow water .... 7-11
How to measure tire pressure....... 5-10 Riding over rough terrain............... 7-13
Tire wear limit................................ 5-11 Riding in brush or wooded
areas............................................ 7-14
6 OPERATION..................................... 6-1 Encountering obstacles on the
Starting a cold engine ..................... 6-1 trail ............................................... 7-15
Starting a warm engine................... 6-3
Jump-starting .................................. 6-3 8 PERIODIC MAINTENANCE AND
Warming up..................................... 6-5 ADJUSTMENT .................................. 8-1
Drive select lever operation and Owner’s manual and tool kit............ 8-1
reverse driving............................... 6-5 Periodic maintenance/
Engine break-in............................... 6-7 lubrication ...................................... 8-4
Parking ............................................ 6-9 Hood ................................................ 8-6
Parking on a slope .......................... 6-9 Console............................................ 8-8
Accessories and loading............... 6-11 Engine oil and oil filter cartridge ...... 8-9
Final gear oil .................................. 8-13
7 DRIVING YOUR VEHICLE............... 7-1 Differential gear oil......................... 8-15
Cleaning the air filter elements...... 8-22 Battery............................................8-42

V-belt cooling duct check hose ..... 8-27 Battery maintenance......................8-43
V-belt case drain plug.................... 8-28 Fuse replacement ..........................8-44
Spark arrester cleaning ................. 8-29 Replacing a headlight bulb ............8-46
Carburetor adjustment................... 8-30 Headlight beam adjustment...........8-47
Idle speed adjustment ................... 8-31 Tail/brake light bulb
Valve clearance adjustment .......... 8-31 replacement .................................8-48
Front brake pad check .................. 8-32 Troubleshooting .............................8-50
Rear brake pad check ................... 8-33 Troubleshooting charts ..................8-51
Checking the brake fluid level ....... 8-33
Brake fluid replacement................. 8-34 9 CLEANING AND STORAGE ............9-1
Checking the brake pedal ............. 8-35 A. Cleaning ......................................9-1
Parking brake lever free play B. Storage ........................................9-3
adjustment................................... 8-36
Brake light switch adjustment........ 8-37 10 SPECIFICATIONS .........................10-1
Cable inspection and lubrication ... 8-38
Brake pedal and accelerator 11 NOISE REGULATION.....................11-1
pedal lubrication .......................... 8-39
13 YAMAHA MOTOR CORPORATION,

U.S.A. SIDE × SIDE VEHICLE
LIMITED WARRANTY ................... 13-1
14 YAMAHA EXTENDED SERVICE

(Y.E.S.) .......................................... 14-1

EVU00060
LOCATION OF THE WARNING AND

1-
SPECIFICATION LABELS

Read and understand all of the labels on your 2

vehicle. They contain important information 1
for safe and proper operation of your vehicle. WARNING 2
IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE
Never remove any labels from your vehicle. If 3
LOSS OF CONTROL.
a label becomes difficult to read or comes off, LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR 4
a replacement label is available from your DEATH. 5
Yamaha dealer. OPERATING TIRE PRESSURE: Set with tires cold.
RECOMMENDED: FRONT: 70kPa, {.70kgf/cm}, 10psi 6
1 REAR: 98kPa, {.98kgf/cm}, 14psi 7
MINIMUM: FRONT: 63kPa, {.63kgf/cm}, 9psi
WARNING REAR: 91kPa, {.91kgf/cm}, 13psi
Never set tire pressure below minimum. Tire may
8
9
The enclosure cannot protect occupants
in all foreseeable accidents, including dislodge from rim.
10
rollover. Gross Vehicle Weight Rating: 907 kg (2000lb)
YAMAHA 5UG-K8483-00 maximum including weight of operator, 11
passenger, accessories, cargo, and
12
(if applicable) trailer tongue weight.
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3 4
WARNING WARNING
Keep hands, body, other Severe INJURY or DEATH can result
persons away when closing bed.
Do not operate the vehicle
if you ignore the following:
YAMAHA
with bed up.
5UG-K7764-00
Maximum Load in Cargo Bed:181kg. (400lb).
Never carry passengers in cargo bed.
Cargo can affect handling and stability.
Read Owner’s Manual before loading or
towing.
When loading with cargo or towing a
trailer: Reduce speed and allow more
room to stop. Avoid hills and rough
terrain.
Be sure cargo is secured - a loose load
could change handling unexpectedly.
Keep weight in the cargo bed centered,
and as low and far forward as possible.
5 6
WARNING
Improperly loading a trailer
and failure to use extra care
when pulling trailer can cause
an accident or injury. Never
MAX 7.3 INCH load more than 50kg (110 lbs)
(185MM) tongue weight on the towing
YAMAHA 5UG-F151J-00 bracket. Do not tow more than
550kg (1212 lbs) rolling weight
(trailer plus cargo). Operate
in low-range gears only, allow
for increased braking distance,
and use extreme caution when
operating on inclines. Read
carefully the loading information
and trailer hitch sections in the
owner’s manual.
WARNING
Turning the off road vehicle in 4WD-LOCK
(“DIFF.LOCK”) takes more effort.
Operate at a slow speed and allow
extra time and distance for maneuvers
to avoid loss of control.
5UG-F1558-00
8
WARNING
Improper use can result in Severe INJURY or DEATH.
This off-highway utility vehicle will handle and ALWAYS
maneuver differently from an ordinary passenger car
or other vehicle. wear a seat belt when riding in the vehicle.
keep your hands and feet inside the vehicle at all ALWAYS USE AN
Vehicle capacity: 1 operator and 1 passenger. Passenger times-watch for branches, brush, or other hazards APPROVED HELMET
AND PROTECTIVE GEAR
must be able to reach and hold the handgrip inside that could enter the vehicle.
enclosure. drive straight up and down inclines-driving across
the side of an incline increase the risk of overturn.
This vehicle is recommended only for operators 16 and
older with a valid motor vehicle license. Adults must NEVER
supervise use by minors. Check state laws for minimum
age requirements. operate through water deeper than 13” (33cm) or fast NEVER USE ON PUBLIC
flowing water-if you must cross shallow, slow moving ROADS OR PAVEMENT
Gross Vehicle Weight Rating: 2000 lb (907 kg) maximum water, choose your path carefully to avoid sharp
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including operator, passenger, accessories, cargo and
engine drop-offs, large rocks, or slippery surfaces that
EVU00070
SAFETY INFORMATION 1
2
This off-highway utility vehicle handles differently from other vehicles including cars and ATVs.
SEVERE INJURY OR DEATH can result if you do not follow these instructions: 3
● Read this manual and all labels carefully and follow the operating procedures described. 4
● This vehicle is designed to carry the driver and one passenger. Never carry passengers in the
5
cargo bed.
● Always be sure the driver and passenger are wearing seat belts.
6
● Never give a ride to a passenger who is too small to reach and hold the handgrip on the enclo- 7
sure.
8
● Always avoid operating the vehicle on any paved surfaces, including sidewalks, driveways,
parking lots, and streets. 9
● Never operate this vehicle on any public street, road, or highway, even a dirt or gravel one. 10
● Never operate this vehicle without wearing an approved motorcycle helmet that fits properly.
11
You should also wear eye protection (goggles or a face shield), gloves, over-the-ankle boots,
long-sleeved shirt or jacket, and long pants. 12
● Never consume alcohol or drugs before or while operating this vehicle.
● Always inspect your vehicle each time you use it to be sure it is in safe operating condition. Al-
ways follow the inspection and maintenance procedures and schedules described in this man-
ual.
● Always keep both hands, arms, feet, and legs inside the vehicle at all times during operation.
Keep your feet on the floorboard. Never hold onto the enclosure except when using the hand-
grip inside the enclosure. Otherwise, your hand could be injured if it is caught between the en-
closure and an obstacle outside the vehicle.
● Always keep both hands on the steering wheel when driving.
● Never wrap your thumbs and fingers around the steering wheel. This is particularly important
when driving in rough terrain. The front wheels will move right and left as they respond to the
terrain, and this movement will be felt in the steering wheel. A sudden jolt could wrench the
steering wheel around, and your thumbs or fingers could be injured if they are in the way of the
steering wheel spokes.
● Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when driving the vehicle.
● Never operate on excessively rough, slippery, or loose terrain until you have learned and prac-
ticed the skills necessary to control the vehicle on such terrain. Always be especially cautious
on these kinds of terrain.
● Never operate on hills that are slippery or ones where you will not be able to see far enough
ahead of you. Never go over the top of a hill at speed if you cannot see what is on the other
side.
● Always follow proper procedures for going uphill. If you lose momentum and cannot continue
up a hill, back down the hill with the engine in reverse gear. Use engine braking to help you go
slowly. If necessary, use the brakes gradually to help you go slowly.
● Always check terrain carefully before going down hills. Go as slowly as possible. Never go
down a hill at high speed.
● Always check for obstacles before operating in a new area.
● Never operate the vehicle in fast flowing water or water deeper than the floorboards on this
model. Remember that wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several times to let friction dry out the linings.
● Always be sure there are no obstacles or people behind you when you operate in reverse.
When it is safe to proceed in reverse, go slowly. Do not brake abruptly when carrying loads in
the cargo bed.
● Always use the size and type of tires specified in this manual.
● Always maintain proper tire pressure as described in this manual.
● Never exceed the stated load capacity. Cargo should be as far forward in the bed as possible,
WARNING When transporting the vehicle in anoth-

POTENTIAL HAZARD er vehicle, be sure it is kept in an upright
Improper handling of gasoline. position. Otherwise, fuel may leak out of
WHAT CAN HAPPEN the carburetor or fuel tank.
Gasoline can catch fire and you could WHAT CAN HAPPEN
be burned. Gasoline is poisonous and can cause
HOW TO AVOID THE HAZARD injuries.
Always turn off the engine when refuel- HOW TO AVOID THE HAZARD
ing. Do not refuel right after the engine If you should swallow some gasoline or
has been running and is still very hot. inhale a lot of gasoline vapor, or get
Do not spill gasoline on the engine or some gasoline in your eyes, see your
exhaust pipe/muffler when refueling. doctor immediately. If gasoline spills on
Never refuel while smoking, or while in your skin, wash with soap and water. If
the vicinity of sparks, open flames, or gasoline spills on your clothing, change
other sources of ignition such as the pi- your clothes.
lot lights of water heaters and clothes
dryers.
WARNING
POTENTIAL HAZARD
Starting or running the engine in a
closed area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death
within a short time.
HOW TO AVOID THE HAZARD
Always operate your vehicle in an area
with adequate ventilation.

EVU00080
DESCRIPTION AND VEHICLE IDENTIFICATION

1-
1. Headlights 13. Spark arrester

2. Front shock absorber assembly adjusting ring 14. Passenger seat belt
3. Brake fluid reservoir 15. Passenger seat
4. Air filter element (Engine and air intake duct) 16. Oil filter cartridge
5. V-belt case 17. Engine oil dipstick
6. Driver seat 18. Battery
7. Driver seat belt 19. Fuses
3
4
9
24. Light switch
25. Steering wheel
26. Starter (choke)
10
27. Main switch
28. On-Command four-wheel drive and differential gear lock switches 11
29. Indicator and warning lights
30. Auxiliary DC jack 12
31. Drive select lever
32. Parking brake lever
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Accelerator pedal manuals search engine 13
EVU00090 EVU00100
Identification number records Key identification number

Record the key identification number, vehicle The key identification number is stamped on
identification number and model label infor- the key as shown in the following illustration.
mation in the spaces provided for assistance This number can be used for ordering a new
when ordering spare parts from a Yamaha key.
dealer or for reference in case the vehicle is
stolen.
1. KEY IDENTIFICATION NUMBER:

ACA-02E
2. VEHICLE IDENTIFICATION NUMBER:

ACA-02E
1. Key identification number
3. MODEL LABEL INFORMATION:

EVU00110 EVU00120
Vehicle identification number Model label

The vehicle identification number is stamped The model label is affixed to the location in the
into the frame. illustration. Record the information on this la-
bel in the space provided. This information will
be needed to order spare parts from your
Yamaha dealer.
1. Vehicle identification number
NOTE:
_
The vehicle identification number is used to

identify your vehicle. 1. Model label
_

EVU00130
CONTROL FUNCTIONS
1-
Functions of the respective switch positions
are as follows:
ON:
EVU00140
All electrical circuits are supplied with power,
Main switch and the headlights and taillights come on
when the light switch is on.
OFF:
All electrical circuits are switched off. The key
can be removed in this position.
START:
The electric starter is engaged by turning and
holding the key in this position. Release the
key when the engine starts.
1. Main switch

CAUTION:
_
1
● Do not operate the electric starter
continuously for more than 5 sec- 2
onds, or starter damage could occur. 3
Wait at least 5 seconds between each
4
operation of the electric starter to let it
cool. 5
● Do not turn the key to the “START” 6
position with the engine running, or
7
damage to the electric starter can re-
sult. 8
● See starting instructions prior to start- 9
ing the engine. (See pages 6-1–6-3 for
10
details.)
11
_
12

EVU00150 EVU00210
Indicator and warning lights Parking brake indicator light “P”

This indicator light comes on when the park-
ing brake is applied.
EVU00160
Reverse indicator light “R”

This indicator light comes on when the drive
select lever is in the “R” reverse position.
NOTE:
_
If the indicator light flashes while riding, have

a Yamaha dealer check the speed sensor cir-
1. Parking brake indicator light “P”
2. Reverse indicator light “R”
cuit.
_
3. Neutral indicator light “N”

4. Four-wheel-drive indicator light “ ”
5. Differential gear lock indicator light “ DIFF.
LOCK
” EVU00170
6. Coolant temperature warning light “ ”
Neutral indicator light “N”
This indicator light comes on when the drive
select lever is in the “N” position.
EVU00200 EVU00180
Four-wheel-drive indicator light “ ” Coolant temperature warning light “ ”

This indicator light comes on when the “2WD/ When the coolant temperature reaches a
4WD” switch is in the “4WD” position. specified level, this light comes on to warn
NOTE: that the coolant temperature is too hot. If the
_
Due to the synchronizing mechanism in the light comes on during operation, stop the en-
differential gear case, the light may not come gine as soon as it is safe to do so and allow
on until the vehicle starts moving. the engine to cool down for about 10 minutes.
_
_
CAUTION:
EVU00220 ● The engine may overheat if the vehicle
Differential gear lock indicator light “ ” DIFF.
LOCK
is overloaded. If this happens, reduce

This indicator light comes on when the differ- the load to specification.
ential gear lock switch is set to the “LOCK- ● After restarting, make sure that the
4WD” position. light is out. Continuous use while the
light is on may cause damage to the
engine.
_

EVU00190
Coolant temperature warning light checking method
Turn the main switch to “ON”.
Coolant temperature warning Coolant temperature

light does not come on. warning light comes on.
Turn the main switch to “START” with

the transmission in the neutral position.
Coolant temperature Coolant temperature

warning light comes on warning light does not
momentarily. come on.
Coolant temperature and

electrical circuit are OK. Ask a Yamaha dealer to
Go ahead with riding. inspect the electrical circuit.
EVU00230
Switches
_
CAUTION:
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.
_
1. Light switch “OFF/ L / H ”

EVU00240
Light switch “OFF/ L / H ”

Set the switch to “ L ” to turn on the low beam
and the taillights.
Set the switch to “ H ” to turn on the high
beam and the taillights.
Set
Downloaded fromthe switch to “OFF”
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manuals search engineoff all the lights.
EVU00250
On-Command four-wheel drive and differ- ● Four-wheel drive (“4WD”): Power is sup-
ential gear lock switches 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 when the differ-
ential gear is locked (“DIFF.LOCK”). Unlike
the 4WD mode, all wheels turn at the same
speed regardless of traction.
1. On-Command four-wheel drive switch “2WD”/“4WD”

2. Differential gear lock switch “LOCK”/“4WD”
This vehicle is equipped with an On-Com-

mand four-wheel drive switch “2WD”/“4WD”
and a differential gear lock switch “LOCK”/
“4WD”. Select the appropriate drive according
to terrain and the conditions.
WARNING On-Command four-wheel drive switch

“2WD”/“4WD”
POTENTIAL HAZARD
Changing from 2WD to 4WD or from
4WD to 4WD-LOCK (“DIFF.LOCK”), or
vice-versa while the vehicle is moving.
WHAT CAN HAPPEN
The vehicle handles differently in 2WD
than in 4WD and in 4WD-LOCK in some
circumstances. Changing from 2WD to
4WD or from 4WD to 4WD-LOCK, or
vice-versa while moving may cause the
vehicle to unexpectedly handle differ- 1. Lever
ently. This could distract the operator 2. On-Command four-wheel drive switch “2WD”/“4WD”
and increase the risk of losing control To change from 2WD to 4WD, stop the vehi-
and an accident. cle, and then set the switch to “4WD”. When
HOW TO AVOID THE HAZARD the vehicle is in 4WD, the 4WD indicator light
Always stop the vehicle before chang- “ ” will come on. To change from 4WD to
2WD, stop the vehicle, be sure the lever is set
Differential gear lock switch “LOCK”/ WARNING

“4WD”
POTENTIAL HAZARD
Riding too fast while the vehicle is in
4WD-LOCK.
WHAT CAN HAPPEN
All wheels turn at the same speed when
the differential is locked, so it takes
more effort to turn the vehicle. The
amount of effort required is greater the
faster you go. You may lose control and
have an accident if you cannot make a
1. Differential gear lock switch “LOCK”/“4WD” sharp enough turn for the speed you are
2. Lever traveling.
To lock the differential gear in 4WD, stop the HOW TO AVOID THE HAZARD
vehicle, make sure the On-Command four- Always ride at a slow speed when the
wheel-drive switch is set to “4WD”, move the vehicle is in 4WD-LOCK, and allow extra
lever to position b, and then set the switch to time and distance for maneuvers.
“LOCK”. When the differential gear is locked,
EVU00260
NOTE:
_
Accelerator pedal
● If the differential gear lock is not engag- Press the accelerator pedal down to increase
ing properly, turn the steering wheel back engine speed. Spring pressure returns the
and forth to help it engage. pedal to the rest position when released. Al-
● Riding before the differential gear lock is ways check that the accelerator pedal returns
properly engaged will cause the engine normally before starting the engine.
speed to be limited until engagement is
complete.
_
1. Accelerator pedal

EVU00270
Before starting the engine, check the acceler- Brake pedal

ator pedal to be sure it is operating smoothly. Press the brake pedal to slow or stop the ve-
Make sure the accelerator pedal fully returns hicle.
to the idle position as soon as it is released.
WARNING
POTENTIAL HAZARD
Malfunction of the accelerator pedal.
WHAT CAN HAPPEN
The accelerator pedal could be hard to
operate, making it difficult to speed up
or slow down when you need to. This
could cause an accident.
HOW TO AVOID THE HAZARD 1. Brake pedal
Check the operation of the accelerator
pedal before you start the engine. If it
does not work smoothly, check for the
cause. Correct the problem before oper-
EVU00280
Parking brake lever

The parking brake lever is located at the right
side of the driver’s seat. It will help hold the
vehicle from moving while parked.
To set the parking brake, pull the lever up
completely.
To release the parking brake, pull up on the
lever, press the release button, and then push
the lever all the way down. Spring pressure
helps return the lever to the released position. 1. Parking brake lever 2. Release button
Be sure to fully release the parking brake be-
fore starting out. Failure to do so may result in
poor performance and premature wearing of
the rear brake and V-belt.

EVU00290 EVU00300
Drive select lever Fuel tank cap

The drive select lever is used to shift your ve- Remove the fuel tank cap by turning it coun-
hicle into the low, high, neutral and reverse terclockwise.
positions. (Refer to pages 6-5–6-7 for the
drive select lever operation.)
1. Fuel tank cap

EVU00310 EVU00320
Fuel level check window Starter (choke) “ ”

The amount of fuel in the fuel tank can be Starting a cold engine requires a richer air-fuel
checked through the fuel level check window. mixture. A separate starter circuit supplies this
If the fuel level is low, refuel as soon as possi- mixture.
ble. Move in direction a to turn on the starter
(choke).
Move in direction b to turn off the starter
(choke).
Refer to “Starting a cold engine” for proper op-
eration. (See pages 6-1–6-3.)
1. Fuel level check window

EVU00330
Seats To install a seat, insert the projections on the

To remove a seat, pull its seat lock lever up- rear of the seat into the seat holders and push
ward, lift the front of the seat, and then slide down on the seat at the front.
the seat forward and up. WARNING
POTENTIAL HAZARD
A loose seat.
WHAT CAN HAPPEN
The operator could lose control or the
operator or passenger could fall if the
seat is loose during operation.
Make sure the seat is securely latched.
1. Driver seat 2. Passenger seat

3. Seat lock lever (× 2)

EVU00340
Seat belts To wear the seat belt properly, do the follow-

This vehicle is equipped with three-point seat ing:
belts for both the operator and passenger. Al- 1. Hold the latch plate as you pull the belt
ways wear the seat belt while riding in the ve- across your lap and chest. Make sure the
hicle. belt is not twisted and is not caught on
any portion of the vehicle, your clothing,
or any equipment you are carrying.
2. Push the latch plate into the buckle until it
clicks. Pull up on the latch plate to make
sure it is secure.
1. Seat belt (× 2) 2. Latch plate (× 2)

3. Buckle (× 2)

3. Put the lap portion of the belt low on your WARNING

hips. Push down on the buckle end of the
belt as you pull up on the shoulder part so POTENTIAL HAZARD
the belt is snug across your hips. Not wearing the seat belt.
4. Position the shoulder belt over your Wearing the seat belt improperly.
shoulder and across your chest. The WHAT CAN HAPPEN
shoulder belt should fit against your There is increased risk of being killed or
chest. If it is loose, pull the belt out all the seriously injured in an accident.
way and then let it retract. HOW TO AVOID THE HAZARD
5. To release the buckle, firmly press the re- Always wear your seat belt when riding
lease button. in the vehicle.
Be sure the seat belt is close-fitting
across your hips and chest and is
latched securely.

EVU01191 EVU00350
Glove compartment Cargo bed
_
CAUTION:
To protect from damage, do not put metal
products, like tools or sharply edged prod-
ucts directly in the glove compartment. If
they must be stored, wrap them in appro-
priate cushion material.
_
1. Cargo bed 2. Tailgate

3. Cargo hook (× 4)

Opening and closing the tailgate Lifting and lowering the cargo bed
1. Tailgate 2. Latch (× 2) 1. Cargo bed release lever
To open To lift
Unhook the latches, and then lower the tail- Push the cargo bed release lever down, and
gate. then slowly lift up the cargo bed until it stops.
To close To lower
Place the tailgate in the original position, and Lower the cargo bed slowly to its original posi-
then hook the latches. tion and be sure the it is locked into place.
WARNING WARNING
POTENTIAL HAZARD POTENTIAL HAZARD
Pinch points. Overloading the cargo bed
WHAT CAN HAPPEN WHAT CAN HAPPEN
You or someone else could be pinched Could cause changes in vehicle han-
between the cargo bed and the frame dling which could lead to an accident.
when the bed is being lowered. HOW TO AVOID THE HAZARD
HOW TO AVOID THE HAZARD Never exceed the stated maximum load
Before closing the bed, be sure others limit for this cargo bed.
are standing away from the vehicle. Cargo should be properly distributed
Keep hands and fingers away from the and securely attached.
pinch points between the bed and the Reduce speed when carrying cargo. Al-
frame. low greater distance for braking.

EVU00360
WARNING Front and rear shock absorber adjustment

The spring preload can be adjusted to suit the
POTENTIAL HAZARD operating conditions.
Carrying a passenger in the cargo bed You can reduce preload for a softer ride, or in-
WHAT CAN HAPPEN crease preload if frequent bottoming occurs.
The passenger could fall, be thrown out,
or be struck by objects in the cargo bed. CAUTION:
HOW TO AVOID THE HAZARD Frequent or severe bottoming can cause
Never carry a passenger in the cargo increased wear or damage to the vehicle.
bed. This cargo bed is designed to carry
cargo only. Adjust the spring preload as follows.
To increase the spring preload, turn the ad-
justing ring in direction a.
To decrease the spring preload, turn the ad-
justing ring in direction b.

1. Spring preload adjusting ring 1. Special wrench

2. Position indicator
NOTE:
_
A special wrench can be obtained at a

Yamaha dealer to make this adjustment.
_
Standard position: B
A- Minimum (soft)
Downloaded from E- Maximum (hard)
www.Manualslib.com manuals search engine
EVU00370
WARNING Trailer hitch bracket

This vehicle is equipped with a 5 cm (2 in) re-
POTENTIAL HAZARD ceiver bracket for a standard trailer hitch.
Improper shock absorber adjustment. Trailer towing equipment can be obtained at a
WHAT CAN HAPPEN Yamaha dealer. (See pages 6-12–6-13 for
Uneven adjustment can cause poor precaution information.)
handling and loss of stability, which
could lead to an accident.
Always adjust the shock absorbers on
the left and right side to the same set-
ting.
1. Trailer hitch bracket

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
Maximum rated capacity for the auxiliary

DC jack:
DC 12 V, 120 W (10 A)
1. Auxiliary DC jack cap

4. When the auxiliary DC jack is not being

used, cover it with the cap.
_
CAUTION:
● Do not use accessories requiring
more than the above maximum capac-
ity. This may overload the circuit and
cause the fuse to blow.
● If accessories are used without the
engine running or with the headlights
turned on, the battery will lose its
charge and engine starting may be-
come difficult.
● Do not use an automotive cigarette
lighter or other accessories with a
plug that gets hot because the jack
can be damaged.
_

EVU01200
1- PRE-OPERATION CHECKS
1
Before using this vehicle, check the following points:
2
ITEM ROUTINE PAGE
3
• Check operation, free play, fluid level and fluid leakage.
Brakes 5-2–5-3, 8-32–8-35 4
• Fill with DOT 4 brake fluid if necessary.
Parking brake • Check for proper operation, condition and free play. 8-36–8-37 5
• Check fuel level.
Fuel 5-4–5-5 6
• Fill with fuel if necessary.
• Check oil level. 7
Engine oil 5-5, 8-9–8-12
• Fill with oil if necessary.
• Check coolant level. 8
Coolant reservoir 5-6, 8-17–8-18
• Fill with coolant if necessary.
9
Final gear oil/
• Check for leakage. 5-7, 8-13–8-16
Differential gear oil 10
Accelerator pedal • Check for proper accelerator pedal operation. 5-7
11
Seat belts • Check for proper operation and belt wear. 5-7
Steering • Check for proper operation. 5-8 12
Fittings and fasteners • Check all fittings and fasteners. 5-8
EVU00390
WARNING Front and rear brakes

Brake pedal
POTENTIAL HAZARD Check for correct brake pedal free play. If the
Failure to inspect the vehicle before op- brake pedal free play is incorrect, have a
erating. Failure to properly maintain the Yamaha dealer adjust it. (See page 8-35.)
vehicle. Check the operation of the brake pedal. It
WHAT CAN HAPPEN should move smoothly and there should be a
Increases the possibility of an accident firm feeling when the brakes are applied. If
or equipment damage. not, have the vehicle inspected by a Yamaha
HOW TO AVOID THE HAZARD dealer.
Always inspect your vehicle each time
you use it to make sure the vehicle is in Brake fluid level
safe operating condition. Always follow Check the brake fluid level.
the inspection and maintenance proce- Add fluid if necessary. (See pages 8-33–
dures and schedules described in the 8-34.)
Owner’s Manual.
Recommended brake fluid: DOT 4

Brake fluid leakage WARNING

Check to see if any brake fluid is leaking out of
the pipe joints or the brake fluid reservoir. Ap- POTENTIAL HAZARD
ply the brakes firmly for one minute. If there is Driving with improperly operating
any leakage, have the vehicle inspected by a brakes.
Yamaha dealer. WHAT CAN HAPPEN
You could lose braking ability, which
Brake operation could lead to an accident.
Test the brakes at slow speed after starting HOW TO AVOID THE HAZARD
out to make sure they are working properly. If Always check the brakes at the start of
the brakes do not provide proper braking per- every ride. Do not operate the vehicle if
formance, inspect the brake system. (See you find any problem with the brakes. If
pages 8-32–8-35.) a problem cannot be corrected by the
adjustment procedures provided in this
manual, have the vehicle inspected by a
Yamaha dealer.

EVU00400
Fuel Your Yamaha engine has been designed to

Make sure there is sufficient gasoline in the use regular unleaded gasoline with a pump
tank. octane number ([R+M]/2) of 86 or higher, or
research octane number of 91 or higher. If
Recommended fuel: knocking or pinging occurs, use a different
UNLEADED GASOLINE ONLY brand of gasoline or premium unleaded fuel.
Fuel tank capacity: Unleaded fuel will give you longer spark plug
30.0 L (6.60 Imp gal, 7.93 US gal) life and reduced maintenance cost.
_
CAUTION: Gasohol
Use only unleaded gasoline. The use of There are two types of gasohol; gasohol con-
leaded gasoline will cause severe damage taining ethanol and that containing methanol.
to internal engine parts, such as the valves Gasohol containing ethanol can be used if
and piston rings, as well as to the exhaust ethanol content does not exceed 10%. Gaso-
system. hol containing methanol is not recommended
_
by Yamaha because it may cause fuel system

damage or vehicle performance problems.
EVU00410
WARNING Engine oil

Make sure the engine oil is at the specified
POTENTIAL HAZARD level. Add oil as necessary. (See pages 8-9–
Improper care when refueling. 8-12.)
WHAT CAN HAPPEN
Fuel can spill, which can cause a fire _
CAUTION:
and severe injury. ● In order to prevent clutch slippage
Fuel expands when it heats up. If the (since the engine oil also lubricates
fuel tank is overfilled, fuel could spill out the clutch), do not mix any chemical
due to heat from the engine or the sun. additives. Do not use oils with a diesel
HOW TO AVOID THE HAZARD specification of “CD” or oils of a high-
Do not overfill the fuel tank. Be careful er quality than specified. In addition,
not to spill fuel, especially on the engine do not use oils labeled “ENERGY
or exhaust pipe. Wipe up any spilled fuel CONSERVING II” or higher.
immediately. Be sure the fuel tank cap is ● Make sure that no foreign material en-
closed securely. ters the crankcase.
_

Recommended engine oil type and
EVU00420
Coolant WARNING
Check the coolant level in the coolant reser-
voir when the engine is cold. (The coolant lev- POTENTIAL HAZARD
el will vary with engine temperature.) The Removing the radiator cap when the en-
coolant level is satisfactory if it is between the gine and radiator are still hot.
minimum and maximum level marks on the WHAT CAN HAPPEN
coolant reservoir. If the coolant level is at or You could be burned by hot fluid and
below the minimum level mark, add additional steam blown out under pressure.
coolant to bring the level up to maximum level HOW TO AVOID THE HAZARD
mark. If coolant is not available, add distilled Wait for the engine to cool before re-
water. Change the coolant every two years. moving the radiator cap. Always use a
(See pages 8-17–8-18 for details.) thick rag over the cap. Allow any re-
maining pressure to escape before
_
CAUTION: completely removing the cap.
Hard water or salt water is harmful to the
engine. You may use soft water if you can-
not get distilled water.
_

EVU00430 EVU00450
Final gear oil Accelerator pedal

Make sure the final gear oil is at the specified Check to see that the accelerator pedal oper-
level. Add oil as necessary. (See pages 8-13– ates correctly. It must operate smoothly and
8-14 for details.) fully spring back to the idle position when re-
leased. Have a Yamaha dealer repair as nec-
Recommended oil: essary for proper operation.
SAE 80 API GL-4 Hypoid gear oil
EVU00460
If desired, an SAE 80W90 hypoid gear oil may
Seat belts
be used for all conditions.
Make sure that both seat belts are not frayed
NOTE:
_
or damaged.
GL-4 is a quality and additive rating, GL-5 or
The seat belt must move smoothly when
GL-6 rated hypoid gear oils may also be used. pulled out and retract on its own when re-
_
leased. The latch plate should click securely

EVU00440 into the buckle and release when the release
Differential gear oil button is pushed firmly. Wash off any dirt or
Make sure the differential gear oil is at the mud which could affect operation. Have a
specified level. Add oil as necessary. (See Yamaha dealer repair as necessary for proper
EVU01230 EVU00500
Steering Tires
Park on level ground. Turn the steering wheel WARNING
right and left. Check for excessive free play,
abnormal noises, or a rough feeling. Have a POTENTIAL HAZARD
Yamaha dealer repair as necessary for proper Operating this vehicle with improper
operation. tires, or with improper or uneven tire
pressure.
EVU00470
WHAT CAN HAPPEN
Fittings and fasteners Use of improper tires on this vehicle, or
Always check the tightness of chassis fittings operation of this vehicle with improper
and fasteners before a ride. Take the vehicle
or uneven tire pressure, may cause loss
to a Yamaha dealer or refer to the Service
of control, increasing your risk of acci-
Manual for correct tightening torque.
dent.
EVU00480 HOW TO AVOID THE HAZARD
Lights 1. The tires listed below have been ap-
Check the headlights and tail/brake lights to proved by Yamaha Motor Manufac-
make sure they are in working condition. Re- turing corporation of America for
pair as necessary for proper operation. this model. Other tire combinations
2. The tires should be set to the rec- 4. Use no more than the following
ommended pressure: pressures when seating the tire
● Recommended tire pressure beads.
Front 70 kPa (0.70 kgf/cm2, 10 psi) Front 250 kPa (2.5 kgf/cm2, 36 psi)
Rear 98 kPa (0.98 kgf/cm2, 14 psi) Rear 250 kPa (2.5 kgf/cm2, 36 psi)
Check and adjust tire pressures when Higher pressures may cause the
the tires are cold. tire to burst. Inflate the tires very
Tire pressures must be equal on both slowly and carefully. Fast inflation
sides. could cause the tire to burst.
3. Tire pressure below the minimum
specified could cause the tire to
dislodge from the rim under severe
riding conditions. The following are
minimums:
Front 63 kPa (0.63 kgf/cm2, 9 psi)
Rear 91 kPa (0.91 kgf/cm2, 13 psi)

EVU00510
How to measure tire pressure

Use the tire pressure gauge.
NOTE:
_
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.
_
Set pressure with tires cold.

1. Tire pressure gauge
Set tire pressures to the following specifica-
tions:
ACE-02E
Recommended
Minimum Maximum
pressure
70 kPa 63 kPa 77 kPa
Front (0.70 kgf/cm2, (0.63 kgf/cm2, (0.77 kgf/cm2,
10 psi) 9 psi) 11 psi)
98 kPa 91 kPa 105 kPa
2 2
DownloadedRear
from www.Manualslib.com , (0.91
(0.98 kgf/cm manuals kgf/cm
search engine, (1.05 kgf/cm2,
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

EVU00530 EVU00540
OPERATION
1-
Starting a cold engine
WARNING
WARNING
POTENTIAL HAZARD
POTENTIAL HAZARD
Freezing control cables in cold weather.
Operating vehicle without being familiar
WHAT CAN HAPPEN
with all controls.
You could be unable to control the vehi-
WHAT CAN HAPPEN
cle, which could lead to an accident or
Loss of control, which could cause an
collision.
accident or injury.
When riding in cold weather, always
Read the Owner’s Manual carefully. If
make sure all control cables work
there is a control or function you do not
smoothly before you begin riding.
understand, ask your Yamaha dealer.
1. Apply the brake.
2. Shift the drive select lever into the neutral
position.

NOTE:
_
Position 3 : Cold engine start-
● When the drive select lever is in the neu- ambient temperature above 1
tral position, the neutral indicator light 25 °C (80 °F) and warm engine
2
should come on. If the neutral indicator start position.
light does not come on, ask a Yamaha 3
dealer to inspect the electric circuit. 4
● The engine can be started in any gear if
5
the brake is applied. However, it is rec-
ommended to shift into neutral before 6
starting the engine. 7
_
3. Use the starter (choke) in reference to 8

the figure: 9
Position 1 : Cold engine start-
10
ambient temperature below 5 °C
(40 °F). a. Starter (choke) 1. Fully open 11
Position 2 : Cold engine start- 2. Half open 3. Closed
12
ambient temperature at 0 °C 4. With your foot off the accelerator pedal,
(30 °F)–30
Downloaded from www.Manualslib.com °Cengine
manuals search (90 °F) and warm- start the engine by turning the key to 13
EVU00550
NOTE:
_
Starting a warm engine
If the engine fails to start, release the key, and To start a warm engine, refer to the “Starting a
then try starting again. Wait a few seconds cold engine” section. The starter (choke)
before the next attempt. Each cranking should should not be used. Press the accelerator
be as short as possible to preserve battery pedal slightly.
energy. Do not crank the engine more than
5 seconds on each attempt. EVU00560
Jump-starting
_
5. If the engine is started with the starter Jump-starting the vehicle should be avoided.
(choke) in position 1, the starter (choke) The battery should be removed and charged
should be returned to position 2 to warm instead. (See pages 8-42–8-43 for battery re-
up the engine. If the engine is started with moval and installation procedures.) However,
the starter (choke) in position 2, keep if the vehicle must be jump-started, proceed
the starter (choke) in this position to as follows.
warm up the engine. 1. Turn the key to “OFF”.
6. Continue warming up the engine until it 2. Open the hood. (See pages 8-6–8-7 for
idles smoothly and return the starter hood opening and closing procedures.)
(choke) to position 3 before riding. 3. Remove the battery compartment cover.
4. Using a charged 12 V battery, connect

WARNING
the positive lead of the jumper cable to
Do not connect the negative lead of the
the positive terminal of the battery in the
jumper cable to the negative terminal of
vehicle and the other end of the positive
the battery in the vehicle.
lead to the positive terminal of the
● Be especially careful not to:
charged battery.
• touch the positive lead of the jump-
er cable to the negative lead.
• reverse the polarity of the jumper
cables when connecting to the bat-
teries - battery explosion and/or se-
rious damage to the electrical
system may occur.
_
6. Start the engine. (Refer to “Starting a

cold engine” on pages 6-1–6-3.)
7. After the engine starts, disconnect the
1. Jumper cable positive lead
2. Jumper cable negative lead negative lead of the jumper cable from
the vehicle and charged battery, and
5. Connect the negative lead of the jumper
EVU00570
Warming up 2. Apply the brakes, then shift by moving

To get maximum engine life, always warm up the drive select lever along the shift
the engine before starting off. Never acceler- guide.
ate hard with a cold engine! To see whether or NOTE:
_
not the engine is warm, check if it responds to Make sure that the drive select lever is com-
the throttle normally with the starter (choke) pletely shifted into position.
turned off. _
EVU00580
Drive select lever operation and reverse

driving
_
CAUTION:
Before shifting, you must stop the vehicle
and take your foot off the accelerator ped-
al. Otherwise, the transmission may be
damaged.
_
Shifting: Neutral to High and High to Low
3. Release the brakes and press the accel-
Shifting: Neutral to Reverse

1. Stop the vehicle. Keep your foot off the
accelerator pedal.
2. Apply the brake pedal.
3. Shift from neutral to reverse or vice versa
by moving the drive select lever along the
shift guide.
NOTE:
_
● When in reverse, the reverse indicator

light should be on. If the light does not
come on, ask a Yamaha dealer to inspect
the reverse indicator light electrical cir-
cuit.
● Due to the synchronizing mechanism in
Downloaded from www.Manualslib.com manuals search engine the engine, the light may not come on un-
EVU00590
5. Press the accelerator pedal gradually Engine break-in

and continue to watch to the rear while There is never a more important period in the
backing. life of your vehicle than the period between
WARNING zero and 20 hours.
For this reason, we ask that you carefully read
POTENTIAL HAZARD the following material. Because the engine is
Improperly operating in reverse. brand new, you must not put an excessive
WHAT CAN HAPPEN load on it for the first several hours of running.
You could hit an obstacle or person be- During the first 20 hours, the various parts in
hind you, resulting in serious injury. the engine wear and polish themselves to the
HOW TO AVOID THE HAZARD correct operating clearances.
When you shift into reverse, make sure During this period, prolonged full throttle oper-
there are no obstacles or people behind ation or any condition which might result in ex-
you. When it is safe to proceed, go slow- cessive engine heating must be avoided.
ly. However, momentary (2–3 seconds maxi-
mum) full throttle operation under load does
not harm the engine.
Each full throttle acceleration sequence 10–20 hours:

should be followed with a substantial rest pe- Avoid prolonged operation above 3/4 throttle.
riod for the engine by cruising at lower r/min Rev the vehicle freely but do not use full throt-
so the engine can rid itself of the temporary tle at any time.
build up of heat. If any abnormality is noticed
during this period, consult a Yamaha dealer. After break-in:
The vehicle can now be operated normally.
0–10 hours:
Avoid continuous operation above half throt-
tle. Allow a cooling off period of five to ten min-
utes after every hour of operation. Vary the
speed of the vehicle from time to time. Do not
operate it at one set throttle position.

EVU01210 EVU00600
Parking Parking on a slope

When parking, stop the engine and shift the WARNING
drive select lever into the neutral position. Ap-
ply the parking brake to help prevent the vehi- POTENTIAL HAZARD
cle from rolling. Parking on a hill or other incline.
WHAT CAN HAPPEN
The vehicle could roll out of control, in-
creasing the chance of an accident.
Avoid parking on hills or other inclines.
If you must park on an incline, apply the
parking brake, and block the front and
rear wheels with rocks or other objects.
Do not park the vehicle at all on hills that
are so steep you could not walk up them
easily.

1. Bring the vehicle to a stop by applying the

brakes.
2. Stop the engine.
3. With the brakes applied, set the parking
brake.
NOTE:
Like many other vehicles, the parking brake
acts on the rear wheels. For the parking brake
EVU00610
Accessories and loading ● Accessories should be rigidly and securely

mounted. An accessory which can shift po-
EVU00620 sition or come off while you are operating
Accessories could affect your ability to control the vehi-
Accessories can affect the handling and con- cle.
trol of your vehicle. Keep the following in mind ● Do not mount an accessory where it could
when considering an accessory or operating a interfere with your ability to control the vehi-
vehicle which has accessories. cle. Examples include (but are not limited
● Choose only accessories designed for your to) an object that limits your ability to turn
vehicle. Your Yamaha dealer has a variety the steering wheel or one that limits your
of genuine Yamaha accessories. Other ac- view.
cessories may also be available on the ● Use extra caution when driving a vehicle
market. However, it is not possible for with accessories. The vehicle may handle
Yamaha to test all non-Yamaha accesso- differently than it does without accessories.
ries, nor have any control over the quality or
suitability of them. Choose a genuine
Yamaha accessory, or one that is equiva-
lent in design and quality.
EVU00630
Loading ● Choose a trailer hitch drawbar designed for

Cargo or a trailer can change the stability and use with a 5 cm (2 in) receiver. (See page
handling of a vehicle. 4-23 for more information.)
You must use common sense and good judg- ● Do not exceed the maximum tongue
ment when carrying cargo or towing a trailer. weight. You can measure tongue weight
Keep the following points in mind: with a bathroom scale. Put the tongue of
● Never exceed the weight limits shown. An the loaded trailer on the scale with the
overloaded vehicle can be unstable. tongue at hitch height. Adjust the load in the
trailer, if necessary, to reduce the weight on
MAXIMUM LOADING LIMIT hitch. If you are carrying cargo and towing a
● Vehicle loading limit (total weight of
trailer, include the tongue weight in the
cargo, operator, passenger and maximum vehicle load limit.
accessories, and tongue weight): ● Load cargo in the cargo bed as close to the
398 kg (878 lb) center of the vehicle as possible and tie it
● Cargo bed: 181 kg (400 lb)
down using the cargo hooks equipped on
● Trailer hitch:
the cargo bed.
Pulling load (total weight of trailer ● Tie down cargo securely in the trailer. Make
and cargo): 550 kgf (1,212 lbf) sure cargo in the trailer cannot move
Tongue weight (vertical weight on
● Make sure the load does not interfere with WARNING

controls or your ability to see where you are
going. POTENTIAL HAZARD
● Drive more slowly than you would without a Overloading this vehicle or carrying or
load. The more weight you carry, the slow- towing cargo improperly.
er you should go. Although conditions vary, WHAT CAN HAPPEN
it is good practice not to exceed low range Could cause changes in vehicle han-
whenever you are carrying heavier loads or dling which could lead to an accident.
when towing a trailer. HOW TO AVOID THE HAZARD
● Allow more braking distance. A heavier ve- Never exceed the stated load capacity
hicle takes longer to stop. for this vehicle.
● Avoid making sharp turns unless at very Cargo should be properly distributed
slow speeds. and securely attached.
● Avoid hills and rough terrain. Choose ter- Reduce speed when carrying cargo or
rain carefully. Added weight affects the sta- pulling a trailer. Allow greater distance
bility and handling of the vehicle. for braking.

EVU00640
DRIVING YOUR VEHICLE

1-
WARNING
1
GETTING TO KNOW YOUR VEHICLE POTENTIAL HAZARD
This off-highway utility vehicle will handle and Not wearing the seat belt. 2
maneuver differently from an ordinary pas- Wearing the seat belt improperly. 3
senger car or other vehicle. WHAT CAN HAPPEN 4
Before you begin to use your vehicle, be sure There is increased risk of being killed or
you have read this Owner’s Manual complete- seriously injured in an accident. 5
ly and understand the operation of the con- HOW TO AVOID THE HAZARD 6
trols. Pay particular attention to the safety Always wear your seat belt when riding 7
information on pages 2-1–2-5. Please also in the vehicle.
read all caution and warning labels on your Be sure the seat belt is close-fitting 8
vehicle. across your hips and chest and is 9
This vehicle is designed for the operator and latched securely.
10
one passenger. The driver and passenger
must always wear a seat belt. Never carry 11
passengers in the cargo bed. 12

WARNING The total weight of operator, passenger, ac-

cessories, cargo, trailer tongue weight, and
POTENTIAL HAZARD the vehicle itself must not exceed 907 kg
Carrying a passenger in the cargo bed. (2,000 lb). (See “Loading” on page 6-12.) Car-
WHAT CAN HAPPEN rying a passenger and cargo can affect vehi-
The passenger could fall or be struck by cle handling.
objects in the cargo bed.
Never carry a passenger in the cargo
bed. The cargo bed is designed to carry
cargo only.

WARNING The driver and passenger must always wear a

seat belt and an approved motorcycle helmet.
POTENTIAL HAZARD Also wear eye protection and protective cloth-
Overloading this vehicle or carrying or ing, including over-the-ankle boots, gloves, a
towing cargo improperly. long-sleeved shirt or jacket, and long pants.
WHAT CAN HAPPEN Keep hands and feet inside the vehicle at all
Could cause changes in vehicle han- times.
dling which could lead to an accident.
Never exceed the stated load capacity
for this vehicle.
Cargo should be properly distributed
and securely attached.
Reduce speed when carrying cargo or
pulling a trailer. Allow greater distance
for braking.
Always follow the instructions in your
Owner’s Manual for carrying cargo or
WARNING HOW TO AVOID THE HAZARD

POTENTIAL HAZARD Always wear an approved motorcycle
Operating this vehicle without wearing helmet that fits properly. You should
an approved motorcycle helmet, eye also wear:
protection, and protective clothing. eye protection
WHAT CAN HAPPEN (goggles or face shield)
Operating without gloves
an approved motor- boots
cycle helmet in- long-sleeved shirt or jacket
creases your long pants
chances of a severe
head injury or death
in the event of an ac-
cident.
Operating without eye protection can re-
sult in an accident and increases your
chances of a severe injury in the event
of an accident.
LEARNING TO OPERATE YOUR VEHICLE Perform the Pre-Operation Checks on pages

You should become familiar with the perfor- 5-1–5-11. Set the parking brake, shift to neu-
mance characteristics of the vehicle in a large, tral, and follow the instructions on page 6-1 to
flat area that is free of obstacles and other ve- start the engine. Once it has warmed up and
hicles. Practice control of the accelerator ped- you have turned the choke off, you are ready
al, brakes, steering, and drive select lever. to begin driving your vehicle. With the engine
Drive first at slow speed and become comfort- idling, shift the drive select lever into low or
able at that speed before gradually increasing high. Then release the parking brake. Press
your speed. Become familiar with the way the the accelerator pedal slowly and smoothly.
vehicle feels in low and high ranges, first in The centrifugal clutch will engage and you will
two-wheel drive (2WD) and then in four-wheel start to accelerate. Avoid higher speeds until
drive (4WD) and four-wheel drive with the dif- you are thoroughly familiar with the operation
ferential locked (DIFF. LOCK). Also practice of your vehicle.
driving in reverse. Take the time to learn basic When slowing down or stopping, take your
operation before attempting more difficult ma- foot off the accelerator pedal and smoothly
neuvers. press the brake pedal. Improper use of the
brakes can cause the tires to lose traction, re-
ducing control and increasing the possibility of
Position your hands on the steering wheel so

CAUTION:
_
that your thumbs and fingers do not wrap
Do not shift from low to high or vice versa around the wheel. This is particularly impor-
without coming to a complete stop and tant when driving in rough terrain. The front
waiting for the engine to return to normal wheels will move right and left as they re-
idle speed. Damage to the engine or drive spond to the terrain, and this movement will
train may occur. be felt in the steering wheel. A sudden jolt
_
could wrench the steering wheel around, and

TURNING YOUR VEHICLE your thumbs or fingers could be injured if they
The vehicle is easier to steer in two-wheel are in the way of the steering wheel spokes.
drive (2WD) than four-wheel drive (4WD).
Steering takes the most effort in 4WD with the
differential locked (DIFF. LOCK).
It is possible for the vehicle to roll over or go
out of control if you attempt sharp, high-speed
turns. You should also be careful making
sharp turns on rough terrain. Do not attempt
to from
Downloaded turn around or make
www.Manualslib.com abrupt
manuals search enginemaneuvers on
BRAKING
Braking ability is affected by the type of ter-
rain. In most cases, gradually application of
the brakes is more effective than abrupt brak-
ing, particularly on loose surfaces like gravel.
Always allow for greater braking distance on
rough, loose, or slippery surfaces.
GOING UPHILL
Do not attempt to climb hills until you have
mastered basic maneuvers on flat ground.
Use proper driving techniques to avoid over-
turns on hills and slopes. Drive straight up
Choose carefully which hills you attempt to
hills, and avoid crossing the side of a hill,
climb. Avoid hills with slippery surfaces or
which increases your chance of rollover.
ones where you will not be able to see far
Practice first on gentle slopes before attempt-
enough ahead of you.
ing steeper hills. Always check the terrain
carefully before attempting any hill. Use com-
WARNING Before climbing the hill, first be sure you are

operating in low range 4WD or, if necessary,
POTENTIAL HAZARD with 4WD Diff. Lock. To climb a hill, you need
Operating on excessively steep hills. traction, momentum, and steady throttle.
WHAT CAN HAPPEN Travel fast enough to keep your momentum
The vehicle can overturn more easily on going, but not so fast that you cannot react to
extremely steep hills than on level sur- changes in the terrain as you climb. Slow
faces or small hills. down when you reach the crest of the hill if
HOW TO AVOID THE HAZARD you cannot clearly see what is on the other
Never operate your vehicle on hills too side – there could be another person, an ob-
steep for it or your abilities. Never oper- stacle, or a sharp drop off.
ate vehicles on hills steeper than 15°.
Do not drive across the face of a hill. Go
straight up the hill.
Practice on smaller hills before attempt-
ing large hills.

If you start to lose traction or momentum GOING DOWNHILL

when climbing, and you decide you will be un- Check the terrain carefully before going down
able to continue, use the brakes to come to a a hill. When possible, choose a path that lets
stop. Do not attempt to turn the vehicle you drive your vehicle straight downhill. Avoid
around. With your foot on the brake, look be- sharp angles that could allow the vehicle to
hind you and plan your descent. Shift the pitch or roll over. Carefully choose your path
drive select lever in reverse so you can use and drive no faster than you will be able to re-
the engine brake if necessary to slow your de- act to obstacles that may appear.
scent. Release the brake and begin to coast
down the hill. Use engine braking as much as
possible, gently applying the brakes when
necessary.

WARNING Before starting down hill, make sure the vehi-

cle is in low-range 4WD. On most slopes, this
POTENTIAL HAZARD will let you use engine braking to help you go
Going down a hill improperly. downhill slowly. Go as slowly as possible. If
WHAT CAN HAPPEN you are starting to go too fast, apply the
Could cause loss of control or cause the brakes gently. Avoid sudden application of the
vehicle to overturn. brakes, which could cause the vehicle to start
HOW TO AVOID THE HAZARD sliding.
Always check the terrain carefully be- If you are sliding or skidding, try to steer in the
fore you start down any hill. Never go direction the vehicle is sliding to help you re-
down a hill at high speed. Avoid going gain control.
down a hill at an angle that would cause If you must turn on the hill to avoid an obsta-
the vehicle to lean sharply to one side. cle, do so slowly and carefully. If the vehicle
Go straight down the hill where possi- starts to tip, gradually steer in the downhill di-
ble. rection if there are no obstacles in your path.
As you regain proper balance, gradually steer
again in the direction you want to go.
CROSSING THROUGH SHALLOW WATER WARNING

If you must cross shallow, slow moving water
up to the depth of the vehicle’s floorboards, POTENTIAL HAZARD
choose your path carefully to avoid sharp Operating this vehicle through deep or
drop-offs, large rocks, or slippery surfaces fast-flowing water.
that could cause the vehicle to overturn. Nev- WHAT CAN HAPPEN
er operate through water deeper than 33 cm Loss of control, which could result in an
(13 in) or fast flowing water. accident including overturn, which
Wet brakes may have reduced effectiveness. could increase the risk of drowning.
After leaving the water, test your brakes. If HOW TO AVOID THE HAZARD
necessary, apply the brakes several times to Never operate this vehicle in fast flow-
let friction dry out the linings. ing water or in water deeper than 33 cm
(13 in).
Remember that wet brakes may have re-
duced stopping ability. Test your brakes
after leaving water. If necessary, apply
them several times to let friction dry out
the linings.
_
CAUTION:
After riding your vehicle in water, be sure
to drain the trapped water by removing the
check hose at the bottom of the air filter
case, the V-belt cooling duct check hose,
the drive select lever box check hose and
the V-belt case drain plug. Wash the vehi-
cle in fresh water if it has been operated in
salt water or muddy conditions.
_
1. Air filter case check hose

RIDING OVER ROUGH TERRAIN

Operating over rough terrain should be done
with caution. Look for obstacles that could
cause damage to the vehicle or could lead to
a rollover or accident. Avoid jumping the vehi-
cle as injury, loss of control, and damage to
the vehicle could occur.
WARNING
POTENTIAL HAZARD
1. Drive select lever box check hose
Failure to use extra care when operating
this vehicle on unfamiliar terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks,
bumps, or holes, without enough time to
react. Could result in the vehicle over-
turning or going out of control.
RIDING IN 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, or
for brush that might enter the vehicle as you
pass and strike the driver or passenger. Nev-
er hold onto the enclosure so your hand is
outside the vehicle. Hold only onto the hand-
grip inside the enclosure.

ENCOUNTERING OBSTACLES ON THE WARNING

TRAIL
If you cannot go around an obstacle such as a POTENTIAL HAZARD
fallen tree trunk or a ditch, stop the vehicle Improperly operating over obstacles
where it is safe to do so. Set the parking brake WHAT CAN HAPPEN
and get out to inspect the area thoroughly. Could cause loss of control or a colli-
Look from both your approach side and the sion. Could cause the vehicle to over-
exit side. If you believe you can continue safe- turn.
ly, decide the path that will allow you to get HOW TO AVOID THE HAZARD
over the obstacle at as close to a right angle Before operating in a new area, check
as possible to minimize vehicle tipping. Go for obstacles.
only fast enough to maintain your momentum Use extreme caution when operating
but still give yourself plenty of time to react to over large obstacles, such as large
changes in conditions. If there is any question rocks or fallen trees.
about your ability to maneuver safely over the
obstacle, you should turn around, if the
ground is flat and you have the room, or back
up until you find a less difficult path.
EVU00650
PERIODIC MAINTENANCE AND

1-
Have a Yamaha dealer perform service if
ADJUSTMENT you are not familiar with vehicle service.
Periodic inspection, adjustment and lubrica-
tion will keep your vehicle in the safest and EVU00660
most efficient condition possible. Safety is an Owner’s manual and tool kit
obligation of the vehicle owner. The most im- You are recommended to put this owner’s
portant points of vehicle inspection, adjust- manual in the vinyl bag and always carry it on
ment and lubrication are explained on the the bottom of the driver seat as shown. Put
following pages. the owner’s tool kit and tire pressure gauge in
WARNING the space beside the battery.
POTENTIAL HAZARD
Servicing an engine while it is running.
WHAT CAN HAPPEN
Moving parts can catch clothing or parts
of the body, causing injury.
Electrical components can cause
Downloadedshocks or can start
from www.Manualslib.com manualsfires.
search engine
The service information included in this man-

ual is intended to provide you, the owner, with 1
the necessary information for completing your
2
own preventive maintenance and minor re-
pairs. The tools provided in the Owner’s tool 3
kit are sufficient for this purpose, except that a 4
torque wrench is also necessary to properly
5
tighten nuts and bolts.
6
NOTE:
_
1. Owner’s tool kit 2. Tire pressure gauge If you do not have a torque wrench available 7
during a service operation requiring one, take 8
your vehicle to a Yamaha dealer to check the
9
torque settings and adjust them as necessary.
_
10
11
12

WARNING
POTENTIAL HAZARD
Operating this vehicle with improper
modifications.
WHAT CAN HAPPEN
Improper installation of accessories or
modification of this vehicle may cause
changes in handling which in some situ-
ations could lead to an accident.
Never modify this vehicle through im-
proper installation or use of accesso-
ries. All parts and accessories added to
this vehicle should be genuine Yamaha
or equivalent components designed for
use on this vehicle and should be in-
stalled and used according to instruc-
EVU00670
PERIODIC MAINTENANCE/LUBRICATION
NOTE:
● For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals.
● For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in
mind that if the vehicle isn’t used for a long period of time, the month maintenance intervals should be followed.
INITIAL EVERY
Whichever month 1 3 6 6 12
ITEM ROUTINE 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
• Check valve clearance.
Valves*
• Adjust if necessary.
• Check coolant leakage.
Cooling system • Repair if necessary.
• Replace coolant every 24 months.
• Check condition.
Spark plug • Adjust gap and clean.
• Replace if necessary.
Air filter elements • Clean. Every 20–40 hours
(Engine and air intake duct) • Replace if necessary. (More often in wet or dusty areas.)
• Check idle speed/starter operation.
Carburetor*
• Adjust if necessary.
• Check breather hose for cracks or damage.
Crankcase breather system*
• Replace if necessary.
• Check for leakage.
Exhaust system* • Tighten if necessary.
• Replace gasket(s) if necessary.
DownloadedSparks arrester
from www.Manualslib.com • Clean.
manuals search engine
INITIAL EVERY
Whichever month 1 3 6 6 12
ITEM ROUTINE 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
• Check operation/brake pad wear/fluid leakage/see NOTE page 8-5.
Rear brake*
• Correct if necessary. Replace pads if worn to the limit.
Accelerator pedal* • Check operation and free play.
• Check operation.
V-belt*
• Check for wear, cracks, or damage.
• Check balance/damage/runout.
Wheels*
• Repair if necessary.
• Check bearing assemblies for looseness/damage.
Wheel bearings*
• Replace if damaged.
Front and rear • Check operation and for leakage.
suspension* • Correct if necessary.
• Check operation and for looseness/Replace if damaged.
Steering system*
• Check toe-in/Adjust if necessary.
Rear upper and lower knuckle
• Lubricate with lithium-soap-based grease.
pivots*
Drive shaft universal joint* • Lubricate with lithium-soap-based grease.
• Check for cracks or damage.
Engine mount*
• Check bolt tightness.
• Check operation.
Front and rear axle boots*
• Replace if damaged.
Stabilizer bushings* • Check for cracks or damage.
• Check all chassis fittings and fasteners.
Fittings and fasteners*
• Correct if necessary.
* Since these items require special tools, data and technical skills have a Yamaha dealer perform the service.
NOTE:
● Recommended brake fluid: DOT 4
Downloaded●
fromBrake
www.Manualslib.com manuals search engine
fluid replacement:
EVU00680
Hood
To open
Unhook the hood latches, and then slowly tilt
the hood up until it stops.
1. Hood
1. Latch (× 2)

To close
CAUTION:
Lower the hood slowly to its original position, _
and then hook the hood latches. ● Make sure that all cables and wires
Secure projections 1 on the underside of the are in place when closing the hood.
hood into slots 2 on the back of the instru- ● Do not drive the vehicle with the hood
ment panel. Secure slots 3 on the side of the open, unlatched, or removed.
_
hood around projections 4 on the frame.
1. Projection (× 2) 2. Slot (× 2)
3. from
Downloaded Slotwww.Manualslib.com
(× 2) manuals4.search
Projection
engine (× 2)
EVU00690
Console To install
To remove 1. Place the console in its original position.
1. Remove the seats. (See page 4-15 for 2. Install the parking brake lever boot.
seat removal and installation proce- 3. Install the drive select lever boot correct-
dures.) ly.
2. Remove the parking brake lever boot. 4. Install the seats.
3. Pull the console upward.
_
CAUTION:
● When installing the console, be sure
not to pinch the cables or wires.
● Make sure that the groove at the bot-
tom of the parking brake lever boot
and the drive select lever boot fits se-
curely around the edge of the hole in
the console.
_
1. Console
EVU00700
Engine oil and oil filter cartridge NOTE:

_
The engine oil level should be checked before The engine oil should be between the mini-
each operation. In addition, the oil must be mum and maximum level marks.
_
changed and the oil filter cartridge replaced at

the intervals specified in the periodic mainte-
nance and lubrication chart.
To check the engine oil level

1. Place the vehicle on a level surface.
2. Remove the console. (See page 8-8 for
console removal and installation proce-
dures.)
3. Start the engine, warm it up for several
minutes, and then turn it off. 1. Maximum level mark 2. Minimum level mark
4. Wait a few minutes until the oil settles. 3. Dipstick 4. Engine oil filler cap
5. Remove the engine oil filler cap and wipe 7. If the engine oil is at or below the mini-
off the dipstick with a clean rag. mum level mark, add sufficient oil of the
6. Insert the dipstick in the oil filler hole
recommended type to raise it to the cor-
To change the engine oil (with or without NOTE:

_
oil filter cartridge replacement) Skip steps 5–7 if the oil filter cartridge is not
1. Remove the console. (See page 8-8 for being replaced.
_

5. Remove the oil filter cartridge with an oil
dures.)
filter wrench.
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. Oil filter cartridge 2. Oil filter wrench
NOTE:
_
Downloaded from www.Manualslib.com manuals search engine An oil filter wrench is available at a nearby
6. Apply a light coat of engine oil to the

O-ring of the new oil filter cartridge.
NOTE:
_
Make sure the O-ring is seated properly.

_
1. Oil filter cartridge 2. Torque wrench
8. Install the engine oil drain bolt, and then

tighten it to the specified torque.
Tightening torque:
1. O-ring Engine oil drain bolt:
30 Nm (3.0 m·kgf, 22 ft·lbf)
7. Install the new oil filter cartridge with an
oil filter wrench, and then tighten it to the 9. Add the specified amount of recommend-
specified torque with a torque wrench.
10. Start the engine and warm it up for seve-

Recommended engine oil:
ral minutes. While warming up, check for
See page 10-2.
oil leakage. If oil leakage is found, turn
Oil quantity:
the engine off immediately and check for
Without oil filter cartridge replacement:
the cause.
1.90 L (1.67 Imp qt, 2.01 US qt)
11. Turn the engine off, and then check the
With oil filter cartridge replacement:
oil level and correct it if necessary.
2.00 L (1.76 Imp qt, 2.11 US qt)
12. Install the console.
_
CAUTION:
● In order to prevent clutch slippage
(since the engine oil also lubricates
the clutch), do not mix any chemical
additives. Do not use oils with a diesel
specification of “CD” or oils of a high-
er quality than specified. In addition,
do not use oils labeled “ENERGY
CONSERVING II” or higher.
● Make sure that no foreign material en-
EVU00710
Final gear oil 3. If the oil is below the brim of the filler hole,
Checking the final gear oil level add sufficient oil of the recommended
1. Place the vehicle on a level surface. type to raise it to the correct level.
2. Remove the oil filler bolt, and then check
the oil level in the final gear case. _
CAUTION:
Be sure no foreign material enters the final
gear case.
_
4. Install the oil filler bolt, and then tighten it

to the specified torque.
Tightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf, 16 ft·lbf)
1. Final gear oil filler bolt 2. Final gear oil

3. Proper oil level
NOTE:
_
The oil level should be at the brim of the filler

Changing the final gear oil 5. Add the recommended final gear oil up to
1. Place the vehicle on a level surface. the brim of the filler hole.
2. Place a container under the final gear
case to collect the used oil. Recommended oil:
3. Remove the oil filler bolt and the drain SAE 80 API GL-4 Hypoid gear oil
bolt to drain the oil. Oil quantity:
0.25 L (0.22 Imp qt, 0.26 US qt)
_
CAUTION:
Be sure no foreign material enters the final
gear case.
_
6. Install the oil filler bolt, and then tighten it

to the specified torque.
Tightening torque:
Final gear oil filler bolt:
1. Final gear oil drain bolt
23 Nm (2.3 m·kgf, 16 ft·lbf)
4. Install the drain bolt, and then tighten it to
EVU00720
Differential gear oil

CAUTION:
Checking the differential gear oil _
1. Place the vehicle on a level surface. Be sure no foreign material enters the dif-
2. Remove the differential gear oil filler bolt ferential gear case.
_
and check the oil level. It should be up to 3. Install the differential gear oil filler bolt,
the brim of the filler hole. If the level is and then tighten it to the specified torque.
low, add sufficient oil of the recommend-
ed type to raise it to the specified level. Tightening torque:
Differential gear oil filler bolt:
23 Nm (2.3 m·kgf, 16 ft·lbf)
Changing the differential gear oil

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 drain
1. Differential gear oil filler bolt the oil.
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
Oil quantity:
0.32 L (0.28 Imp qt, 0.34 US qt)
_
CAUTION:
Be sure no foreign material enters the dif-
ferential gear case.
_
1. Differential gear oil drain bolt 6. Install the differential gear oil filler bolt,
4. Install the differential gear oil drain bolt, and then tighten it to the specified torque.
and tighten it to the specified torque.
Tightening torque:
Tightening torque: Differential gear oil filler bolt:
Differential gear oil drain bolt: 23 Nm (2.3 m·kgf, 16 ft·lbf)
9.8 Nm (0.98 m·kgf, 7.1 ft·lbf)
7. Check for oil leakage. If oil leakage is
5. Fill the differential gear case with the rec- found, check for the cause.
EVU00730
Coolant
The coolant level should be checked before
each ride.
Checking the coolant level
2. Open the hood. (See pages 8-6–8-7 for
hood opening and closing procedures.)
3. Check the coolant level in the coolant
reservoir when the engine is cold as the
coolant level varies with engine tempera- 1. Coolant reservoir cap
ture. 2. Maximum level mark 3. Minimum level mark
NOTE:
_
4. If the coolant is at or below the minimum
The coolant should be between the minimum level mark, remove the reservoir cap,
and maximum level marks. add coolant to the maximum level mark,
_
install the reservoir cap, and then close

the hood.
Coolant reservoir capacity

_
CAUTION:
Mix anti freeze with distilled water only.
However, if distilled water is not available,
soft water may be used for refilling.
_
Changing the coolant

The coolant must be changed by a Yamaha
dealer at the intervals specified in the periodic
maintenance and lubrication chart.
_
NOTE:
● Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, have a
Yamaha dealer check the antifreeze con-
tent of the coolant as soon as possible.
● The radiator fan operation is completely
automatic. It is switched on or off accord-
ing to the coolant
Downloaded from www.Manualslib.com manualstemperature
search engine in the radi-
EVU00740
Axle boots
Check the protective boots for holes or tears.
If any damage is found, have them replaced
by a Yamaha dealer.
1. Rear axle boot (× 2 each side)
1. Front axle boot (× 2 each side)

EVU00750
Spark plug inspection

Removal
1. Lift the cargo bed up. (See pages 4-18–
4-21 for cargo bed lifting and lowering
procedures.)
2. Remove the spark plug cap.
1. Spark plug wrench
1. Spark plug cap
3. Use the spark plug wrench in the tool kit

Inspection Installation
The spark plug is an important engine compo- 1. Measure the electrode gap with a wire
nent and is easy to inspect. The condition of thickness gauge and, if necessary, adjust
the spark plug can indicate the condition of the gap to specification.
the engine.
The ideal color of the porcelain insulator Spark plug gap:
around the center electrode is a medium-to- 0.8–0.9 mm (0.031–0.035 in)
light tan for a vehicle that is being ridden nor-
mally.
Do not attempt to diagnose such problems
yourself.
Instead, take the vehicle to a Yamaha dealer.
You should periodically remove and inspect
the spark plug because heat and deposits will
cause the spark plug to slowly break down
and erode. If electrode erosion becomes ex-
cessive, or if carbon and other deposits are
excessive, you should replace the spark plug
a. Spark plug gap
EVU00761
3. Install the spark plug and tighten it to the Cleaning the air filter elements
specified torque. Cleaning the intake duct air filter element
1. Remove the air intake duct grill by remov-
Tightening torque: ing the quick fastener screws.
Spark plug:
17.5 Nm (1.75 m·kgf, 12.7 ft·lbf)
NOTE:
_
If a torque wrench is not available when you

are installing the spark plug, a good estimate
of the correct torque is 1/4 to 1/2 turn past fin-
ger tight. Have the spark plug tightened to the
specified torque as soon as possible.
_
4. Install the spark plug cap.

5. Lower the cargo bed. 1. Quick fastener screw (× 4)
2. Air intake duct grill
2. Remove the air filter element from the air

intake duct grill by pulling it out.
1. Air filter element 2. Air intake duct grill 1. Air filter element
3. Remove any large particles from the air 5. Install the air filter element into the air in-
filter element by hand. take duct grill.
4. Tap the air filter element to remove most 6. Install the air intake duct grill by installing
of the dust and dirt, and then blow the re- the quick fastener screws.
maining dirt out with compressed air.

Cleaning the engine air filter element 3. Remove the air filter case cover by un-
hooking the holders.
NOTE:
_
There is a check hose at the bottom of the air

filter case. If dust or water collects in this
hose, empty the hose and clean the air filter
element and air filter case.
_
1. Holder (× 4) 2. Air filter case cover
4. Remove the air filter element.

5. Remove the air filter element from its
frame.
1. Air filter case check hose
1. Remove the seats. (See page 4-15 for

6. Wash the air filter element gently but

thoroughly in solvent.
WARNING
POTENTIAL HAZARD
Using low flash point solvents or gaso-
line to clean the air filter element.
WHAT CAN HAPPEN
Low flash point solvents or gasoline can
catch fire or explode.
1. Air filter element
Use parts cleaning solvent to clean the
air filter element.
7. Squeeze the excess solvent out of the air
filter element and let it dry.
_
CAUTION:
Do not twist the air filter element when
9. Thoroughly apply Yamaha foam air filter 13. Install the console.
oil or other quality liquid foam air filter oil 14. Install the seats.
(not spray type) to the air filter element. NOTE:
_
NOTE:
_
The air filter element should be cleaned every
The air filter element should be wet but not 20–40 hours. It should be cleaned and lubri-
dripping. cated more often if the vehicle is operated in
_
extremely dusty areas. Each time air filter ele-

10. Pull the air filter element over its frame.
ment maintenance is performed, check the air
11. Install the air filter element. inlet to the air filter case for obstructions.
12. Install the air filter case cover and be sure
Check the air filter element rubber joint to the
the crankcase breather hose is connect-
carburetor and manifold fittings for an airtight
ed. seal. Tighten all fittings securely to avoid the
possibility of unfiltered air entering the engine.
_

EVU00770
V-belt cooling duct check hose

CAUTION:
_
The V-belt cooling duct check hose is located
Never operate the engine with the air filter under the driver seat. (See page 4-15 for seat
element removed. This will allow unfiltered removal and installation procedures.)
air to enter, causing rapid engine wear and If dust or water collects in the V-belt cooling
possible engine damage. Additionally, op- duct check hose, remove the hose and clean
eration without the air filter element will af- it.
fect carburetor jetting with subsequent
poor performance and possible engine
overheating.
1. V-belt cooling duct check hose

EVU00780
V-belt case drain plug

The V-belt case drain plug is located under
the driver seat. (See page 4-15 for seat re-
moval and installation procedures.)
After riding in water deep enough to allow wa-
ter to enter the V-belt case, remove the drain
plug to drain any water from the case.
NOTE:
_
If water drains from the V-belt case after re-

moving the drain plug, have a Yamaha dealer 1. V-belt case drain plug
inspect the vehicle as the water may affect
other engine parts.
_

EVU00790
Spark arrester cleaning

Be sure the exhaust pipe and muffler are cool
before cleaning the spark arrester.
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. 1. Bolt (× 3)
4. Insert the tailpipe into the muffler and
align the bolt holes.
5. Install the tailpipe by installing the bolts,
and then tighten the bolts to the specified
torque.
Tightening torque:
Tailpipe bolt:
9.5 N·m (0.95 m·kgf, 6.9 ft·lbf)
EVU00800
WARNING Carburetor adjustment

The carburetor is a vital part of the engine and
POTENTIAL HAZARD requires very sophisticated adjustment. Most
Improper cleaning of the spark arrester. adjusting should be left to a Yamaha dealer
Hot exhaust system who has the professional knowledge and ex-
WHAT CAN HAPPEN perience to do so. However, the idling speed
Could injure the eyes. may be performed by the owner as a part of
Could cause burns. the usual maintenance routine.
Could cause carbon monoxide poison-
ing, possibly leading to death. _
CAUTION:
Could start a fire. The carburetor was set at the Yamaha fac-
HOW TO AVOID THE HAZARD tory after many tests. If the settings are
When cleaning the spark arrester: disturbed by someone without sufficient
Always let the exhaust system cool pri- technical knowledge, poor engine perfor-
or to touching exhaust components. mance and damage may result.
Do not start the engine when cleaning _
the exhaust system.

EVU00810
Idle speed adjustment

NOTE:
_
A diagnostic tachometer must be used for this

procedure.
_
1. Start the engine and warm it up for a few

minutes at approximately 1,000 to
2,000 r/min. Occasionally rev the engine
to 4,000 to 5,000 r/min. The engine is
warm when it quickly responds to the
throttle. 1. Throttle stop screw
seat removal and installation procedures.)
3. Remove the console. (See page 8-8 for 6. Install the seats.
dures.) EVU00820
4. Connect the tachometer to the spark plug Valve clearance adjustment

lead, and then set the idle to the specified The correct valve clearance changes with
idling speed by adjusting the throttle stop use, resulting in improper fuel/air supply or
Downloaded fromscrew. Turn the
www.Manualslib.com screw
manuals in direction a to
search engine engine noise. To prevent this, the valve clear-
EVU00830
Front brake pad check NOTE:

_
Each brake pad is provided with wear indica- The wheels need to be removed to check the
tor grooves, which allow you to check the brake pads. (See pages 8-40–8-41 for wheel
brake pad wear without having to disassem- removal and installation procedures.)
_
ble the brake. To check the brake pad wear,

check the wear indicator grooves. If a brake
pad has worn to the point that the wear indica-
tor grooves have almost disappeared, have a
Yamaha dealer replace the brake pads as a
set.

EVU00840 EVU00850
Rear brake pad check Checking the brake fluid level

Each brake pad is provided with wear indica-
tor grooves, which allow you to check the
brake pad wear without having to disassem-
ble the brake. To check the brake pad wear,
check the wear indicator grooves. If a brake
pad has worn to the point that the wear indica-
tor grooves have almost disappeared, have a
Yamaha dealer replace the brake pads as a
set.
1. Minimum level mark
Insufficient brake fluid may let air 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-
The brake fluid reservoir is located under the ● Brake fluid may deteriorate painted surfac-
hood. (See pages 8-6–8-7 for hood opening es or plastic parts. Always clean up spilled
and closing procedures.) fluid immediately.
Observe these precautions: ● Have a Yamaha dealer inspect the brake
● When checking the fluid level, make sure system if the brake fluid level goes down.
the top of the brake fluid reservoir is level.
● Use only the recommended quality brake EVU00860
fluid. Otherwise, the rubber seals may de- Brake fluid replacement
teriorate, causing leakage and poor braking Complete fluid replacement should be done
performance. only by trained Yamaha service personnel.
Have a Yamaha dealer replace the following
Recommended brake fluid: DOT 4 components during periodic maintenance or
when they are damaged or leaking.
● Refill with the same type of brake fluid. Mix-
● Replace the oil seals every two years.
ing fluids may result in a harmful chemical
● Replace the brake hoses every four years.
reaction and lead to poor braking perfor-
mance.
● Be careful that water does not enter the
brake
Downloaded from fluid reservoir
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manuals search engine refilling. Water
EVU01220
Checking the brake pedal WARNING

Have a Yamaha dealer check the brakes at
the intervals specified in the periodic mainte- POTENTIAL HAZARD
nance and lubrication chart. There should be Operating with improperly serviced or
no free play in the brake pedal. The brakes adjusted brakes.
should operate smoothly and there should be WHAT CAN HAPPEN
no brake drag. If the brakes feel soft or You could lose braking ability, which
spongy, this could indicate air in the brake could lead to an accident.
system. Have a Yamaha dealer check the HOW TO AVOID THE HAZARD
brake system if necessary. After servicing:
● Make sure the brakes operate
smoothly and that the brake pedal
position is correct.
● Make sure the brakes do not drag.
● All air must be bled from the brake
system.
Replacement of brake components re-
quires professional knowledge. These
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”.
seat removal and installation proce-
dures.)
3. Remove the console. (See page 8-8 for
console removal and installation proce- a. Parking brake lever free play
dures.)
NOTE:
4. Check the parking brake lever free play. _
The parking brake lever must be released

The maximum free play is equal to one
when checking and adjusting the parking
click of the parking brake lever. If neces-
brake lever free play.
sary, adjust the free play as follows. _
5. Loosen the locknut.

EVU00880
Brake light switch adjustment

The brake light switch, which is activated by
the brake pedal, is properly adjusted when the
brake light comes on just before braking takes
effect. If necessary, adjust the brake light
switch as follows.
1. Open the hood. (See pages 8-6–8-7 for
2. Turn the adjusting nut while holding the
1. Locknut 2. Adjusting nut
brake light switch in place. To make the
brake light come on earlier, turn the ad-
6. Turn the adjusting nut in direction a to
justing nut in direction a. To make the
increase the free play or in direction b to
brake light come on later, turn the adjust-
decrease the free play.
ing nut in direction b.
7. Tighten the locknut.
9. Install the seats.

EVU00890
Cable inspection and lubrication

WARNING
POTENTIAL HAZARD
Damaged control cables.
WHAT CAN HAPPEN
Corrosion can result when the outer
covering of control cables becomes
damaged. Cables can also become
frayed or kinked. Operation of controls
1. Brake light switch 2. Adjusting nut
could be restricted, which could cause
3. Close the hood. an accident or injury.
Inspect cables frequently. Replace dam-
aged cables.
Lubricate the inner cables and the cable ends.
If the cables do not operate smoothly, ask a
Downloaded from www.Manualslib.com manuals search engine Yamaha dealer to replace them.
EVU00900 EVU00910
Brake pedal and accelerator pedal Rear knuckle upper and lower pivot
lubrication lubrication
Lubricate the pivoting parts. Lubricate the knuckle upper and lower pivots
with a grease gun.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
EVU00920 EVU00930
Steering shaft lubrication Wheel removal

Lubricate the pivot points. 1. Loosen the wheel nuts.
2. Elevate the vehicle and place a suitable
Recommended lubricant: stand under the frame.
Lithium-soap-based grease 3. Remove the nuts from the wheel.
(all purpose grease) 4. Remove the wheel.
1. Nut (× 4)

EVU00940
Wheel installation
1. Install the wheel and the nuts.
NOTE:
_
● The arrow mark on the tire must point

toward the rotating direction of the wheel.
● Tapered nuts are used for both the front
and rear wheels. Install the nut with its ta-
pered side towards the wheel.
_
1. Tapered nut
2. Lower the vehicle so that the wheel is on

the ground.
3. Tighten the wheel nuts to the specified
torque.
Wheel nut torque:

Front: 55 Nm (5.5 m·kgf, 40 ft·lbf)
Downloaded from www.Manualslib.com manuals search engine Rear: 55 Nm (5.5 m·kgf, 40 ft·lbf)
EVU00950
Battery
This vehicle is equipped with a sealed-type
Avoid contact with skin, eyes or cloth-
battery. Therefore it is not necessary to check
ing. Always shield eyes when working
the electrolyte or add distilled water in the bat-
near batteries. Keep out of reach of chil-
tery. If the battery seems to have discharged,
dren.
consult a Yamaha dealer.
Antidote:
CAUTION: EXTERNAL: Flush with water.
_
Do not try to remove the sealing caps of INTERNAL: Drink large quantities of wa-
the battery cells. You may damage the bat- ter or milk. Follow with milk of magne-
tery. sia, beaten egg or vegetable oil. Get
_
prompt medical attention.
WARNING EYES: Flush with water for 15 minutes
and get prompt medical attention. Keep
POTENTIAL HAZARD
batteries away from sparks, flames, cig-
Failure to handle batteries or battery
arettes or other sources of ignition. Ven-
electrolyte carefully.
tilate when charging or using in a closed
WHAT CAN HAPPEN
space.
You could be poisoned. You could be
EVU00960
Battery maintenance
1. When the vehicle is not used for a month
or longer, remove the battery and store it
in a cool, dark place. Completely re-
charge the battery before reinstallation.
_
CAUTION:
A special battery charger (constant volt-
age/ampere or constant voltage) is re-
quired for recharging a sealed-type
1. Negative battery lead 2. Positive battery lead
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.

EVU00970
Fuse replacement
CAUTION:
The main fuse and the fuse box are located _
under the hood. (See pages 8-6–8-7 for hood To prevent accidental short-circuiting,
opening and closing procedures.) turn off the main switch when checking or
If a fuse is blown, turn off the main switch and replacing a fuse.
_
install a new fuse of the specified amperage. 3. Remove the blown fuse, and then install
If a fuse is blown, replace it as follows. a new fuse of the specified amperage.
1. Remove the battery compartment cover
by lifting it up and pulling it out.
1. Main fuse 2. Spare main fuse

3. Headlight fuse 4. Ignition fuse
Specified fuses: WARNING

Main fuse: 30.0 A POTENTIAL HAZARD
Headlight fuse: 15.0 A Using an improper fuse
Ignition fuse: 10.0 A WHAT CAN HAPPEN
Auxiliary DC jack fuse: 10.0 A An improper fuse can cause damage to
Signaling system fuse: 10.0 A the electrical system, which could lead
Carburetor heater fuse: 10.0 A to a fire.
Four-wheel-drive fuse: 3.0 A HOW TO AVOID THE HAZARD
Backup fuse: 10.0 A Always use a fuse of the specified rat-
4. Turn the key to “ON” and turn on the ing. Never use a material in place of the
electrical circuit in question to check if the proper fuse.
device operates.
5. If the fuse immediately blows again, have
a Yamaha dealer check the electrical
system.
6. Install the battery compartment cover.
7. Close the hood.
EVU00980
Replacing a headlight bulb

If a headlight bulb burns out, replace it as fol-
lows.
1. Lift the hood up. (See pages 8-6–8-7 for
2. Remove the bulb holder cover at the rear
of the headlight by pulling it off.
1. Headlight bulb holder
4. Remove the defective bulb by unhooking

the headlight bulb holder tabs.
1. Headlight bulb holder cover

EVU00990
WARNING Headlight beam adjustment
POTENTIAL HAZARD _
CAUTION:
A headlight bulb is hot when it is on and It is advisable to have a Yamaha dealer
immediately after it is turned off. make this adjustment.
WHAT CAN HAPPEN _
You can be burned, or a fire could start To raise the beam, turn the adjusting screw in
if the bulb touches something flamma- direction a.
ble. To lower the beam, turn the adjusting screw in
HOW TO AVOID THE HAZARD direction b.
Wait for the bulb to cool before touching
or removing it.
5. Insert a new headlight bulb into the bulb
holder, and then hook the headlight bulb
holder tabs.
6. Install the headlight bulb holder by turn-
ing it clockwise.
7.fromInstall
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engine
EVU01000
Tail/brake light bulb replacement

If a tail/brake light bulb burns out, replace it as
follows:
1. Remove panel A (if replacing the left tail/
brake bulb) or panel B (if replacing the
right tail/brake bulb) by removing the
quick fasteners and bolts.
1. Panel B
1. Panel A
2. Remove the bulb holder (together with

Tightening torque:
the bulb) by turning it counterclockwise.
Panel bolt:
6.5 N·m (0.65 m·kgf, 4.7 ft·lbf)
1. Tail/brake light bulb holder
3. Push the defective bulb in and turn it

counterclockwise to remove it from the
bulb holder.
4. Push a new bulb in and turn it clockwise
to install in the bulb holder.
EVU01010
Troubleshooting WARNING
Although Yamaha vehicles receive a rigid in-
spection before shipment from the factory, POTENTIAL HAZARD
trouble may occur during operation. Any prob- Checking the fuel system while smok-
lem in the fuel, compression, or ignition sys- ing or near an open flame.
tems can cause poor starting and loss of WHAT CAN HAPPEN
power. The troubleshooting chart describes a Fuel can ignite or explode, causing se-
quick, easy procedure for making checks. If vere injury or property damage.
your vehicle requires any repair, take it to a HOW TO AVOID THE HAZARD
Yamaha dealer. Do not smoke when checking the fuel
The skilled technicians at a Yamaha dealer- system. Make sure there are no open
ship have the tools, experience, and know- flames or sparks in the area, including
how to properly service your vehicle. Use only pilot lights from water heaters or furnac-
genuine Yamaha parts on your vehicle. Imita- es.
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.
EVU01020
Troubleshooting charts
Starting problems or poor engine performance
1. Fuel Remove the fuel hose Check the Fuel pump is

There is fuel. No fuel.
from the fuel pump. fuel flow. clogged.
Check if there is fuel
in the fuel tank.
Supply fuel. Ask a Yamaha dealer to
No fuel. Restart the engine.
inspect.
2. Compression
There is compression. Compression normal.
Use the electric
starter to see if
there is compression. Ask a Yamaha dealer to
No compression.
inspect.
3. Ignition Wet Wipe clean with dry cloth.

Ignition system is
Remove the Spark is good.
normal.
spark plug and
check the electrodes. Use the
Attach spark plug cap and
Dry electric starter. Spark is weak.
ground to chassis.
No spark. Adjust the spark plug gap

4. Battery Engine turns over or replace the spark plug.
quickly. Battery is good.
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manuals search engine
Engine overheating
WARNING HOW TO AVOID THE HAZARD
POTENTIAL HAZARD Wait for the engine to cool before re-
Removing the radiator cap when the en- moving the radiator cap. Always use a
gine and radiator are still hot. thick rag over the cap. Allow any re-
WHAT CAN HAPPEN maining pressure to escape before
You could be burned by hot fluid and completely removing the cap.
steam blown out under pressure.
Ask a Yamaha dealer to inspect

Leakage.
and repair the cooling system.
Level is low, check the
cooling system for leakage.
No
Add coolant. (See NOTE.)
Wait until the Check the coolant level in the leakage.
engine has cooled. coolant reserver and/or radiator.
Restart the engine. If the engine overheats again, ask a

Level is OK.
Yamaha dealer to inspect and/or repair the cooling system.

EVU01030
CLEANING AND STORAGE

1-
CAUTION:
_
A. CLEANING Excessive water pressure may cause wa-

Frequent, thorough cleaning of your vehicle ter seepage and deterioration of wheel
will not only enhance its appearance but will bearings, brakes, transmission seals and
improve its general performance and extend electrical devices. Many expensive repair
the useful life of many components. bills have resulted from improper high
1. Before cleaning the vehicle: pressure detergent applications such as
a. Block off the end of the exhaust pipe to those available in coin-operated car wash-
prevent water entry. A plastic bag and ers.
_
strong rubber band may be used.

4. Once the majority of the dirt has been
b. Make sure the spark plug and all filler
hosed off, wash all surfaces with warm
caps are properly installed.
water and mild, detergent-type soap. An
2. If the engine case is excessively greasy,
old toothbrush or bottle brush is handy for
apply degreaser with a paint brush. Do
hard-to-get-at places.
not apply degreaser to the wheel axles.
5. Rinse the vehicle off immediately with
3. Rinse the dirt and degreaser off with a
clean water and dry all surfaces with a
garden hose. Use only enough pressure
Downloaded from www.Manualslib.com manuals search engine chamois, clean towel or soft absorbent
to do the job.
6. Clean the seats with a vinyl upholstery WARNING

cleaner to keep the cover pliable and 1
glossy. POTENTIAL HAZARD
Operation with wet brakes after wash- 2
7. Automotive type wax may be applied to
all painted and chrome plated surfaces. ing. 3
Avoid combination cleaner-waxes. Many WHAT CAN HAPPEN 4
contain abrasives which may scratch the Wet brakes may have reduced stopping
ability, increasing the chance of an acci- 5
paint or protective finish. When finished,
start the engine and let it idle for several dent. 6
minutes. HOW TO AVOID THE HAZARD 7
Test the brakes after washing. Apply the
brakes several times at slow speeds to 8
let friction dry out the linings. 9
10
11
12

EVU01040
B. STORAGE NOTE:
_
Long term storage (60 days or more) of your Use of fuel stabilizer and conditioner elimi-
vehicle will require some preventive proce- nates the need to drain the fuel system. Con-
dures to guard against deterioration. After sult a Yamaha dealer if the fuel system needs
thoroughly cleaning the vehicle, prepare for to be drained instead.
_
storage as follows:
3. Remove the spark plug, pour about one
1. Fill the fuel tank with fresh fuel and add
tablespoon of SAE 10W30 or 20W40
the specified amount of Yamaha Fuel
motor oil in the spark plug hole and rein-
Stabilizer and Conditioner or equivalent
stall the spark plug. Ground the spark
product. Operate the vehicle for at least 5
plug wire and turn the engine over seve-
minutes to distribute treated fuel through
ral times to coat the cylinder wall with oil.
the fuel system.
4. Lubricate all control cables.
2. Drain the fuel from the carburetor float
5. Block up the frame to raise all wheels off
chamber into a clean container by loos-
the ground.
ening the drain bolt; this will help prevent
6. Tie a plastic bag over the exhaust pipe
fuel deposits from building up. Pour the
outlet to prevent moisture from entering.
drained fuel into the fuel tank.
7. If storing in a humid or salt-air atmo-
Specified amount: sphere, coat all exposed metal surfaces
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)).
NOTE:
_
Make any necessary repairs before storing

the vehicle.
_

EVU01050
SPECIFICATIONS
1-
Model YXR660FA
Dimensions:
Overall length 2,885 mm (113.6 in)
Overall width 1,385 mm (54.5 in)
Overall height 1,853 mm (73.0 in)
Seat height 818 mm (32.2 in)
Wheelbase 1,910 mm (75.2 in)
Ground clearance 273 mm (10.75 in)
Minimum turning radius 3,900 mm (153.5 in)
Basic weight:
With oil and full fuel tank 509.0 kg (1,122 lb)
Engine:
Engine type Liquid-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 660.0 cm3
Bore × stroke 100.0 × 84.0 mm (3.94 × 3.31 in)
Compression ratio 9.10 :1
Model YXR660FA
Engine oil: 1
0° 10° 30° 50° 70° 90° 110° 130°F
Type
2
YAMALUBE 4 (20W40) or SAE 20W40
3
YAMALUBE 4 (10W30) or SAE 10W30
4
SAE 5W30
5
-20° -10° 0° 10° 20° 30° 40° 50°C
Recommended engine oil classification API Service SE, SF, SG type or higher 6
7
CAUTION:
In order to prevent clutch slippage (since the en- 8
gine oil also lubricates the clutch), do not mix any
9
chemical additives. Do not use oils with a diesel
specification of “CD” or oils of a higher quality 10
than specified. In addition, do not use oils labeled
“ENERGY CONSERVING II” or higher. 11
12
Quantity:
Without oil filter
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search engine 1.90 L (1.67 Imp qt, 2.01 US qt) 13
Model YXR660FA
Final gear case oil:
Type SAE80 API GL-4 Hypoid gear oil
Quantity: 0.25 L (0.22 Imp qt, 0.26 US qt)
Differential gear case oil:
Type SAE80 API GL-4 Hypoid gear oil
Quantity: 0.32 L (0.28 Imp qt, 0.34 US qt)
Radiator capacity (including all routes): 2.50 L (2.20 Imp qt, 2.64 US qt)
Air filter: Wet element
Fuel:
Type UNLEADED GASOLINE ONLY
Fuel tank capacity 30.0 L (6.60 lmp gal, 7.93 US gal)
Carburetor:
Type/quantity BSR42/1
Manufacturer MIKUNI
Spark plug:
Type/manufacturer DPR8EA-9/NGK
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Clutch
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Model YXR660FA
Transmission:
Primary reduction system V-belt
Secondary reduction system Shaft drive
Secondary reduction ratio 41/21 × 24/18 × 33/9 (9.544)
Transmission type V-belt automatic
Operation Right hand operation
Reverse gear 25/17 (1.471)
Sub transmission ratio low 35/17 (2.058)
high 28/19 (1.473)
Chassis:
Frame type Steel tube frame
Caster angle 5.0°
Trail 26.0 mm (1.02 in)
Tire:
Type Tubeless
Size front 25 × 8-12NHS
rear 25 × 10-12NHS
Model YXR660FA
Brakes:
System Front and rear unified
Type front Dual disc brake
rear Single disc brake
Operation Foot operation
Suspension:
Front suspension Double wishbone
Rear suspension Double wishbone
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/oil damper
Wheel travel:
Front wheel travel 185.0 mm (7.28 in)
Rear wheel travel 185.0 mm (7.28 in)
Electrical:
Ignition system DC. CDI
Generator system A.C. magneto
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Model YXR660FA
Bulb voltage, wattage × quantity:
Headlight 12 V 30 W/30.0 W × 2
Tail/brake light 12 V 5 W/21.0 W × 2
Indicator lights:
Neutral indicator light 12 V 1.7 W × 1
Reverse indicator light 12 V 1.7 W × 1
Coolant temperature warning light 12 V 1.7 W × 1
Parking brake indicator light 12 V 1.7 W × 1
Four-wheel-drive indicator light 12 V 1.7 W × 1
Differential gear lock indicator light 12 V 1.7 W × 1
Specified fuses:
Main fuse 30.0 A
Headlight fuse 15.0 A
Ignition fuse 10.0 A
Auxiliary DC jack fuse 10.0 A
Four-wheel-drive fuse 3.0 A
Carburetor heater fuse 10.0 A
Signaling system
Downloaded from www.Manualslib.com fusesearch engine
manuals 10.0 A
EVU01060
1- NOISE REGULATION
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inop-
erative by any person other than for purposes of maintenance, repair, or replacement of any de-
vice or element of design incorporated into any new vehicle for the purpose of noise control prior
to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after
such device or element of design has been removed or rendered inoperative by any person.
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED
BELOW.”
These acts include tampering with the following systems; i.e., modification, removal, etc.
Muffler
Exhaust system Exhaust pipe
Silencer
Air cleaner case
Intake system Air cleaner element
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EVU01070
1- MAINTENANCE RECORD
1
Copies of work orders and/or receipts for parts you purchase and install will be required to docu-
ment maintenance done in accordance with the warranty. The chart below is printed only as a re- 2
minder to you that the maintenance work is required. It is not acceptable proof of maintenance 3
work. 4
MAINTENANCE 5
INTERVAL DATE OF SERVICING DEALER
MILEAGE REMARKS
SERVICE NAME AND ADDRESS 6
month km (mi) hours
1 320 (200) 20 7
3 1,200 (750) 75 8
6 2,400 (1,500) 150
12 4,800 (3,000) 300 9
18 7,200 (4,500) 450 10
24 9,600 (6,000) 600
30 12,000 (7,500) 750
11
36 14,400 (9,000) 900 12
42 16,800 (10,500) 1,050
48 19,200 (12,000) 1,200
EVU01080
YAMAHA MOTOR CORPORATION, U.S.A.

SIDE × SIDE VEHICLE LIMITED WARRANTY
Yamaha Motor Corporation, U.S.A. hereby warrants GENERAL EXCLUSIONS from this warranty shall YAMAHA MOTOR CORPORATION, U.S.A. MAKES
that new Yamaha Side × Side vehicles purchased include any failures caused by: NO OTHER WARRANTY OF ANY KIND, EXPRESSED
from an authorized Yamaha Side × Side Vehicle a. Competition or racing use. OR IMPLIED. ALL IMPLIED WARRANTIES OF
dealer in the continental United States will be free b. Installation of parts or accessories that are not MERCHANTABILITY AND FITNESS FOR A
from defects in material and workmanship for the qualitatively equivalent to genuine Yamaha parts. PARTICULAR PURPOSE WHICH EXCEED THE
period of time stated herein, subject to certain stated c. Abnormal strain, neglect, or abuse. OBLIGATIONS AND TIME LIMITS STATED IN THIS
limitations. d. Lack of proper maintenance. WARRANTY ARE HEREBY DISCLAIMED BY
e. Accident or collision damage. YAMAHA MOTOR CORPORATION, U.S.A. AND
THE PERIOD OF WARRANTY for YXR OR YXP f. Modification to original parts. EXCLUDED FROM THIS WARRANTY.
Yamaha Side × Side vehicles shall be six (6) months g. Damage due to improper transportation.
from the date of purchase, with no mileage limitation. SOME STATES DO NOT ALLOW LIMITATIONS ON
SPECIFIC EXCLUSIONS from this warranty shall HOW LONG AN IMPLIED WARRANTY LASTS, SO
MODELS EXCLUDED FROM WARRANTY include include parts replaced due to normal wear or routine THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
those used for non-Yamaha-authorized renting, maintenance; such as spark plugs, oil, oil filter, air ALSO EXCLUDED FROM THIS WARRANTY ARE
leasing, or other commercial purposes. filter, and brake shoes. ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES
INCLUDING LOSS OF USE. SOME STATES DO
DURING THE PERIOD OF WARRANTY any THE CUSTOMER’S RESPONSIBILITY under this NOT ALLOW THE EXCLUSION OR LIMITATION OF
authorized Yamaha Side × Side Vehicle dealer will warranty shall be to: INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO
free of charge, repair or replace, at Yamaha’s option, 1. Operate and maintain the Side-by-Side vehicle as THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.
any part adjudged defective by Yamaha due to faulty specified in the appropriate Owner’s Manual, and THIS WARRANTY GIVES YOU SPECIFIC LEGAL
workmanship or material from the factory. Parts used 2. Give notice to an authorized Yamaha Side × Side RIGHTS, AND YOU MAY ALSO HAVE OTHER
in warranty repairs will be warranted for the balance Vehicle dealer of any and all apparent defects RIGHTS WHICH VARY FROM STATE TO STATE.
of the product’s warranty period. All parts replaced within ten (10) days after discovery, and make the
under warranty become property of Yamaha Motor machine available at that time for inspection and
Corporation, U.S.A. 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-by-Side
vehicle be inspected and registered for warranty by
an authorized Yamaha Side-by-Side Vehicle dealer. In
Downloaded from www.Manualslib.com manuals search engine order for this warranty to remain in effect, this
EVU01090
YAMAHA EXTENDED SERVICE (Y.E.S.)

1
3
4
10
11
12



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com manuals search engine

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IMPORTANT MANUAL INFORMATION

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN

Failure to follow WARNING instructions could result in severe

CAUTION: A CAUTION indicates special precautions that must be taken to

NOTE: A NOTE provides key information to make procedures easier or clearer.

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CONTENTS Fuel level check window ................4-14

Switches.......................................... 5-8 Going downhill ................................. 7-9

Cleaning the air filter elements...... 8-22 Battery............................................8-42

13 YAMAHA MOTOR CORPORATION,

14 YAMAHA EXTENDED SERVICE

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LOCATION OF THE WARNING AND

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Read and understand all of the labels on your 2

WARNING When transporting the vehicle in anoth-

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DESCRIPTION AND VEHICLE IDENTIFICATION

1. Headlights 13. Spark arrester

Identification number records Key identification number

1. KEY IDENTIFICATION NUMBER:

2. VEHICLE IDENTIFICATION NUMBER:

1. Key identification number

3. MODEL LABEL INFORMATION:

Vehicle identification number Model label

1. Vehicle identification number

The vehicle identification number is used to

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Indicator and warning lights Parking brake indicator light “P”

Reverse indicator light “R”

If the indicator light flashes while riding, have

3. Neutral indicator light “N”

Four-wheel-drive indicator light “ ” Coolant temperature warning light “ ”

is overloaded. If this happens, reduce

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Coolant temperature warning light checking method

Turn the main switch to “ON”.

Coolant temperature warning Coolant temperature

Turn the main switch to “START” with

Coolant temperature Coolant temperature

Coolant temperature and

1. Light switch “OFF/ L / H ”

Light switch “OFF/ L / H ”

1. On-Command four-wheel drive switch “2WD”/“4WD”

This vehicle is equipped with an On-Com-

WARNING On-Command four-wheel drive switch

Differential gear lock switch “LOCK”/ WARNING

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Before starting the engine, check the acceler- Brake pedal

Parking brake lever

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Drive select lever Fuel tank cap

1. Fuel tank cap

1. Drive select lever