Owners Manual
Page 5
... -road use only. Such use without the written permission of Yamaha Motor Corporation, U.S.A. EVU00040 AFFIX DEALER LABEL HERE YXR66FAV OWNER'S MANUAL ©2005 by law. Any reprinting or unauthorized use is prohibited by Yamaha Motor Corporation, U.S.A. 1st edition, June 2005 All rights reserved. is designed and manufactured for off -highway noise level and spark arrester laws and regulations. IMPORTANT NOTICE G G G This vehicle...
... -road use only. Such use without the written permission of Yamaha Motor Corporation, U.S.A. EVU00040 AFFIX DEALER LABEL HERE YXR66FAV OWNER'S MANUAL ©2005 by law. Any reprinting or unauthorized use is prohibited by Yamaha Motor Corporation, U.S.A. 1st edition, June 2005 All rights reserved. is designed and manufactured for off -highway noise level and spark arrester laws and regulations. IMPORTANT NOTICE G G G This vehicle...
Owners Manual
Page 6
... models)...4-6 Multi-function meter unit (special edition models)...4-9 Switches ...4-11 Accelerator pedal ...4-15 2 3 Brake pedal...4-16 Parking brake lever...4-17 Drive select lever ...4-18 Fuel tank cap ...4-18 Fuel level check window ...4-19 Starter (choke) ...4-19 Seats ...4-20 Seat belts ...4-21 Glove compartment ...4-23 Cargo bed ...4-23 Front and rear shock absorber adjustment ...4-26 Trailer hitch bracket ...4-28 Auxiliary DC jack...4-29 5 PRE-OPERATION CHECKS ...5-1 Front and rear brakes ...5-2 Fuel ...5-4 Engine oil ...5-5 Coolant...5-6 Final gear oil ...5-7 Differential gear oil...
... models)...4-6 Multi-function meter unit (special edition models)...4-9 Switches ...4-11 Accelerator pedal ...4-15 2 3 Brake pedal...4-16 Parking brake lever...4-17 Drive select lever ...4-18 Fuel tank cap ...4-18 Fuel level check window ...4-19 Starter (choke) ...4-19 Seats ...4-20 Seat belts ...4-21 Glove compartment ...4-23 Cargo bed ...4-23 Front and rear shock absorber adjustment ...4-26 Trailer hitch bracket ...4-28 Auxiliary DC jack...4-29 5 PRE-OPERATION CHECKS ...5-1 Front and rear brakes ...5-2 Fuel ...5-4 Engine oil ...5-5 Coolant...5-6 Final gear oil ...5-7 Differential gear oil...
Owners Manual
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...10 DRIVING YOUR VEHICLE...7-1 Getting to know your vehicle...7-1 Learning to operate your vehicle...7-5 Turning your vehicle ...7-6 Braking...7-7 Going uphill...7-7 Going downhill ...7-9 Crossing through shallow water ...7-11 Riding over rough terrain...7-13 Riding in brush or wooded areas...7-14 Encountering obstacles on the trail ...7-15 8 PERIODIC MAINTENANCE AND ADJUSTMENT ...8-1 Owner's manual and tool kit...8-1 Periodic maintenance/ lubrication ...8-4 Hood ...8-6 Console...8-8 Engine oil and oil filter cartridge ...8-9 Final gear oil ...8-13 Differential gear oil...8-15 Coolant ...8-17...
...10 DRIVING YOUR VEHICLE...7-1 Getting to know your vehicle...7-1 Learning to operate your vehicle...7-5 Turning your vehicle ...7-6 Braking...7-7 Going uphill...7-7 Going downhill ...7-9 Crossing through shallow water ...7-11 Riding over rough terrain...7-13 Riding in brush or wooded areas...7-14 Encountering obstacles on the trail ...7-15 8 PERIODIC MAINTENANCE AND ADJUSTMENT ...8-1 Owner's manual and tool kit...8-1 Periodic maintenance/ lubrication ...8-4 Hood ...8-6 Console...8-8 Engine oil and oil filter cartridge ...8-9 Final gear oil ...8-13 Differential gear oil...8-15 Coolant ...8-17...
Owners Manual
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...37 Cable inspection and lubrication ...8-38 Brake pedal and accelerator pedal lubrication ...8-39 Rear knuckle upper and lower pivot lubrication...8-39 Steering shaft lubrication...8-40 Wheel removal...8-40 Wheel installation...8-41 Battery...8-42 Battery maintenance...8-43 Fuse replacement ...8-44 Replacing a headlight bulb ...8-46 Headlight beam adjustment...8-49 Tail/brake light bulb replacement ...8-50 Troubleshooting ...8-52 Troubleshooting charts ...8-53 9 CLEANING AND STORAGE ...9-1 A. Storage ...9-3 SPECIFICATIONS ...10-1 NOISE REGULATION...11-1 MAINTENANCE RECORD ...12-1 10 11 12...
...37 Cable inspection and lubrication ...8-38 Brake pedal and accelerator pedal lubrication ...8-39 Rear knuckle upper and lower pivot lubrication...8-39 Steering shaft lubrication...8-40 Wheel removal...8-40 Wheel installation...8-41 Battery...8-42 Battery maintenance...8-43 Fuse replacement ...8-44 Replacing a headlight bulb ...8-46 Headlight beam adjustment...8-49 Tail/brake light bulb replacement ...8-50 Troubleshooting ...8-52 Troubleshooting charts ...8-53 9 CLEANING AND STORAGE ...9-1 A. Storage ...9-3 SPECIFICATIONS ...10-1 NOISE REGULATION...11-1 MAINTENANCE RECORD ...12-1 10 11 12...
Owners Manual
Page 14
... extra time and distance for branches, brush, or other vehicle. Passenger must be able to overturn. ALWAYS wear a seat belt when riding in 4WD-LOCK ("DIFF.LOCK") takes more effort. NEVER USE WITH DRUGS OR ALCOHOL NEVER USE ON PUBLIC ROADS OR PAVEMENT LOCATE AND READ THE OWNER'S MANUAL. Check state laws for operators 16 and older with a valid motor vehicle license. drive straight...
... extra time and distance for branches, brush, or other vehicle. Passenger must be able to overturn. ALWAYS wear a seat belt when riding in 4WD-LOCK ("DIFF.LOCK") takes more effort. NEVER USE WITH DRUGS OR ALCOHOL NEVER USE ON PUBLIC ROADS OR PAVEMENT LOCATE AND READ THE OWNER'S MANUAL. Check state laws for operators 16 and older with a valid motor vehicle license. drive straight...
Owners Manual
Page 15
...the driver and passenger are wearing seat belts. G Never give a ride to a passenger who is too small to carry the driver and one . Always go at speeds too fast for the terrain, visibility, operating conditions, and your skills or the conditions....road, or highway, even a dirt or gravel one passenger. EVU00070 SAFETY INFORMATION This off-highway utility vehicle handles differently from other stunts. 2-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 G Never operate this vehicle on any paved surfaces, including sidewalks, driveways, parking lots, and streets. G Always avoid operating the vehicle...
...the driver and passenger are wearing seat belts. G Never give a ride to a passenger who is too small to carry the driver and one . Always go at speeds too fast for the terrain, visibility, operating conditions, and your skills or the conditions....road, or highway, even a dirt or gravel one passenger. EVU00070 SAFETY INFORMATION This off-highway utility vehicle handles differently from other stunts. 2-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 G Never operate this vehicle on any paved surfaces, including sidewalks, driveways, parking lots, and streets. G Always avoid operating the vehicle...
Owners Manual
Page 20
... ring 3. Air filter element (engine and air intake duct) 5. Spark plug 9. Rear shock absorber assembly adjusting ring 12. Cargo bed release levers 13. Passenger seat belt 15. Fuses 20. EVU00080 1- Headlights 2. Brake fluid reservoir 4. Tail/brake lights 11. Battery 19. Coolant reservoir 21. Radiator cap 22. Passenger seat 16. Driver seat 7. Oil filter cartridge 17. Fuel tank cap 3-1 Driver seat belt 8. Cargo bed 10. Spark arrester 14. V-belt case 6. Fuel level check window 23. DESCRIPTION AND VEHICLE IDENTIFICATION 1. Engine oil dipstick 18...
... ring 3. Air filter element (engine and air intake duct) 5. Spark plug 9. Rear shock absorber assembly adjusting ring 12. Cargo bed release levers 13. Passenger seat belt 15. Fuses 20. EVU00080 1- Headlights 2. Brake fluid reservoir 4. Tail/brake lights 11. Battery 19. Coolant reservoir 21. Radiator cap 22. Passenger seat 16. Driver seat 7. Oil filter cartridge 17. Fuel tank cap 3-1 Driver seat belt 8. Cargo bed 10. Spark arrester 14. V-belt case 6. Fuel level check window 23. DESCRIPTION AND VEHICLE IDENTIFICATION 1. Engine oil dipstick 18...
Owners Manual
Page 30
... warning light " " When the coolant temperature reaches a specified level, this light comes on when the "2WD"/ "4WD" switch is in the "R" reverse position. EVU00160 Reverse indicator light "R" This indicator light comes on when the parking brake is set to cool down for about 10 minutes. 4-7 DIFF. The differential gear lock indicator "DIFF.LOCK" in the differential gear case, the four-wheel drive indicator may not come on until the vehicle starts...
... warning light " " When the coolant temperature reaches a specified level, this light comes on when the "2WD"/ "4WD" switch is in the "R" reverse position. EVU00160 Reverse indicator light "R" This indicator light comes on when the parking brake is set to cool down for about 10 minutes. 4-7 DIFF. The differential gear lock indicator "DIFF.LOCK" in the differential gear case, the four-wheel drive indicator may not come on until the vehicle starts...
Owners Manual
Page 56
... if any brake fluid is any problem with improperly operating brakes. If the brakes do not provide proper braking performance, inspect the brake system. (See pages 8-32-8-35.) WARNING POTENTIAL HAZARD Driving with the brakes. Do not operate the vehicle if you find any leakage, have the vehicle inspected by a Yamaha dealer. HOW TO AVOID THE HAZARD Always check the brakes at slow speed after starting out...
... if any brake fluid is any problem with improperly operating brakes. If the brakes do not provide proper braking performance, inspect the brake system. (See pages 8-32-8-35.) WARNING POTENTIAL HAZARD Driving with the brakes. Do not operate the vehicle if you find any leakage, have the vehicle inspected by a Yamaha dealer. HOW TO AVOID THE HAZARD Always check the brakes at slow speed after starting out...
Owners Manual
Page 61
... level ground. EVU00490 Switches Check the operation of chassis fittings and fasteners before a ride. Have a Yamaha dealer repair as necessary for proper operation. EVU00470 Tires WARNING POTENTIAL HAZARD Operating this vehicle with improper tires, or with improper or uneven tire pressure, may cause loss of control, increasing your risk of this vehicle with improper or uneven tire pressure. Turn the steering wheel right and left. EVU01230 EVU00500 Steering Park...
... level ground. EVU00490 Switches Check the operation of chassis fittings and fasteners before a ride. Have a Yamaha dealer repair as necessary for proper operation. EVU00470 Tires WARNING POTENTIAL HAZARD Operating this vehicle with improper tires, or with improper or uneven tire pressure, may cause loss of control, increasing your risk of this vehicle with improper or uneven tire pressure. Turn the steering wheel right and left. EVU01230 EVU00500 Steering Park...
Owners Manual
Page 66
... starter (choke) in any gear if the brake is applied. Half open 3. G The engine can be started in reference to the figure: Position 1 : Cold engine startambient temperature below 5 °C (40 °F). NOTE: G When the drive select lever is recommended to shift into neutral before starting the engine. _ _ Position 3 : Cold engine startambient temperature above 25 °C (80 °F) and warm engine start the engine by turning the key...
... starter (choke) in any gear if the brake is applied. Half open 3. G The engine can be started in reference to the figure: Position 1 : Cold engine startambient temperature below 5 °C (40 °F). NOTE: G When the drive select lever is recommended to shift into neutral before starting the engine. _ _ Position 3 : Cold engine startambient temperature above 25 °C (80 °F) and warm engine start the engine by turning the key...
Owners Manual
Page 70
... light should be on. Check behind for people or obstacles, then release the brake pedal. 6-6 Shifting: Neutral to inspect the reverse indicator light electrical circuit. G Due to reverse or vice versa by moving . _ _ 4. Stop the vehicle. Drive select lever NOTE: G When in the engine, the light may not come on until the vehicle starts moving the drive select lever along the shift guide...
... light should be on. Check behind for people or obstacles, then release the brake pedal. 6-6 Shifting: Neutral to inspect the reverse indicator light electrical circuit. G Due to reverse or vice versa by moving . _ _ 4. Stop the vehicle. Drive select lever NOTE: G When in the engine, the light may not come on until the vehicle starts moving the drive select lever along the shift guide...
Owners Manual
Page 82
... vehicles. Also practice driving in a large, flat area that speed before attempting more difficult maneuvers. Drive first at slow speed and become familiar with the differential locked (DIFF. Perform the Pre-Operation Checks on page 6-1 to start to lose traction, reducing control and increasing the possibility of the accelerator pedal, brakes, steering, and drive select lever. Improper use of the brakes can cause the tires...
... vehicles. Also practice driving in a large, flat area that speed before attempting more difficult maneuvers. Drive first at slow speed and become familiar with the differential locked (DIFF. Perform the Pre-Operation Checks on page 6-1 to start to lose traction, reducing control and increasing the possibility of the accelerator pedal, brakes, steering, and drive select lever. Improper use of the brakes can cause the tires...
Owners Manual
Page 96
... 4,800 (1,500) (3,000) 150 300 Valves* Cooling system Spark plug Air filter elements (engine and air intake duct) Carburetor* Crankcase breather system* Exhaust system* Spark arrester Fuel line* Engine oil Engine oil filter cartridge Final gear oil Differential gear oil Check valve clearance. Adjust gap and clean. Replace if necessary. Replace if necessary. Tighten if necessary. Replace. Check oil level/oil leakage. Every 20-40 hours (More often in mind that if the vehicle isn't used for leakage. G Items...
... 4,800 (1,500) (3,000) 150 300 Valves* Cooling system Spark plug Air filter elements (engine and air intake duct) Carburetor* Crankcase breather system* Exhaust system* Spark arrester Fuel line* Engine oil Engine oil filter cartridge Final gear oil Differential gear oil Check valve clearance. Adjust gap and clean. Replace if necessary. Replace if necessary. Tighten if necessary. Replace. Check oil level/oil leakage. Every 20-40 hours (More often in mind that if the vehicle isn't used for leakage. G Items...
Owners Manual
Page 130
Lubricate the inner cables and the cable ends. Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil 8-38 1. Close the hood. Cables can result when the outer covering of controls could be restricted, which could cause an accident or injury. Brake light switch 2. Operation of control cables becomes damaged. Replace damaged cables. HOW TO AVOID THE HAZARD Inspect cables frequently...
Lubricate the inner cables and the cable ends. Recommended lubricant: Yamaha chain and cable lube or SAE 10W30 motor oil 8-38 1. Close the hood. Cables can result when the outer covering of controls could be restricted, which could cause an accident or injury. Brake light switch 2. Operation of control cables becomes damaged. Replace damaged cables. HOW TO AVOID THE HAZARD Inspect cables frequently...
Owners Manual
Page 136
... fuse 2. Ignition fuse Auxiliary DC jack fuse 6. Spare main fuse Headlight fuse 4. Spare fuse (× 3) CAUTION: _ To prevent accidental short-circuiting, turn off the electrical circuit in question. 8-44 1. 3. 5. 7. 8. 9. Four-wheel-drive fuse Signaling system fuse Backup fuse (for hood opening and closing procedures.) If a fuse is blown, replace it out. Remove the battery compartment cover by lifting it up and pulling it as follows. 1. Battery compartment cover 2. Turn the key to "OFF" and turn off the main switch...
... fuse 2. Ignition fuse Auxiliary DC jack fuse 6. Spare main fuse Headlight fuse 4. Spare fuse (× 3) CAUTION: _ To prevent accidental short-circuiting, turn off the electrical circuit in question. 8-44 1. 3. 5. 7. 8. 9. Four-wheel-drive fuse Signaling system fuse Backup fuse (for hood opening and closing procedures.) If a fuse is blown, replace it out. Remove the battery compartment cover by lifting it up and pulling it as follows. 1. Battery compartment cover 2. Turn the key to "OFF" and turn off the main switch...
Owners Manual
Page 137
Close the hood. 8-45 Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Auxiliary DC jack fuse: Signaling system fuse: Carburetor warmer fuse: Four-wheel-drive fuse: Backup fuse: WARNING 30.0 A 15.0 A 10.0 A 10.0 A 10.0 A 10.0 A 3.0 A 10.0 A POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system, which could lead to check if the device operates. 5. Never use a fuse of the proper fuse. 4. HOW TO...
Close the hood. 8-45 Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Auxiliary DC jack fuse: Signaling system fuse: Carburetor warmer fuse: Four-wheel-drive fuse: Backup fuse: WARNING 30.0 A 15.0 A 10.0 A 10.0 A 10.0 A 10.0 A 3.0 A 10.0 A POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system, which could lead to check if the device operates. 5. Never use a fuse of the proper fuse. 4. HOW TO...
Owners Manual
Page 147
... wheel bearings, brakes, transmission seals and electrical devices. A plastic bag and strong rubber band may cause water seepage and deterioration of the dirt has been hosed off with warm water and mild, detergent-type soap. CLEANING Frequent, thorough cleaning of your vehicle will not only enhance its appearance but will improve its general performance and extend the useful life of the exhaust...
... wheel bearings, brakes, transmission seals and electrical devices. A plastic bag and strong rubber band may cause water seepage and deterioration of the dirt has been hosed off with warm water and mild, detergent-type soap. CLEANING Frequent, thorough cleaning of your vehicle will not only enhance its appearance but will improve its general performance and extend the useful life of the exhaust...
Owners Manual
Page 157
Model Specified fuses: Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four-wheel-drive fuse Carburetor warmer fuse Signaling system fuse Backup fuse 30.0 A 15.0 A 10.0 A 10.0 A 3.0 A 10.0 A 10.0 A 10.0 A YXR66FAV 10-7
Model Specified fuses: Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four-wheel-drive fuse Carburetor warmer fuse Signaling system fuse Backup fuse 30.0 A 15.0 A 10.0 A 10.0 A 3.0 A 10.0 A 10.0 A 10.0 A YXR66FAV 10-7
Owners Manual
Page 160
... as spark plugs, oil, oil filter, air filter, and brake shoes. Parts used for this warranty. b. WARRANTY TRANSFER: To transfer the warranty from defects in warranty repairs will be warranted for this warranty shall include any and all U. emissions standards applicable at the time of purchase, with all apparent defects within the period listed immediately below. AND EXCLUDED FROM THIS WARRANTY. All parts replaced under this warranty shall...
... as spark plugs, oil, oil filter, air filter, and brake shoes. Parts used for this warranty. b. WARRANTY TRANSFER: To transfer the warranty from defects in warranty repairs will be warranted for this warranty shall include any and all U. emissions standards applicable at the time of purchase, with all apparent defects within the period listed immediately below. AND EXCLUDED FROM THIS WARRANTY. All parts replaced under this warranty shall...