actual bulletin from Yamaha. What to expect when visiting dealership. Would not let me post actual file. Text only
SIDE BY SIDE
©2009 YAMAHA MOTOR CORPORATION, U.S.A.
2004~2009 YXR450/660/700 (RHINO 450/660/700)
Free Repair Program
In cooperation with the Consumer Product Safety
Commission (CPSC), Yamaha Motor Corporation,
U.S.A. is providing certain free repairs for all
2006~2009 Rhino 450, all 2004~2007 Rhino 660,
and all 2008~2009 Rhino 700 Side x Side (SxS)
Free Repair Program:
The following two repairs are being offered free of
charge by Yamaha in cooperation with the CPSC
to “help reduce the chance of rollover and improve
1. Installation of a 2" spacer on each of the rear
2. Removal of the rear anti-sway bar.
Follow the procedures outlined in this bulletin to
install these rear wheel spacers and remove the
stock rear anti-sway bar.
Yamaha also strongly recommends the installation of the free doors, extra passenger handholds, and updated
center-console warning label on any units which do not have them. If a customer brings in his or her Rhino for
this free repair, and the vehicle does not have these features, please encourage him or her to have these free
components installed at the same time as this free repair. Refer to Technical Bulletin SXS2007-006 for details.
This modification is designed primarily for Rhino vehicles that are in stock condition or units with Yamahaapproved
accessories. Rhino vehicles with other accessories or other modifications that have no effect on the
vehicle’s handling, stability, or operational characteristics are also eligible for this modification. Any accessories
or modifications which affect the vehicle’s handling, stability, or operational characteristics must be removed
and the vehicle returned to stock condition before this modification can be done.
Examples of modifications which do not affect the vehicle’s handling, stability, or operational characteristics include
(but are not limited to):
• Yamaha-brand or other accessories and features such as side panel doors, additional passenger handholds,
windshields, sun tops, overfenders, seat belts, or similar changes to the interior of the cabin or exterior of the
Examples of modifications which can affect handling, stability, or operational characteristics include (but are not
• Aftermarket suspension components which could affect handling (such as longer A-arms and longer travel
• Aftermarket wheels or tires that change operational characteristics (such as larger diameter wheels or tires,
paddle tires or aggressive mud tires, etc.)
PAGE 1 of 6
• Engine or ignition system modifications that allow the vehicle to go faster than designed
• Rear seat kits that make it possible for passengers to ride in the cargo bed. Passengers should never ride
in the cargo area. Installing seating in this area is dangerous for occupants and affects the handling and
stability of the vehicle.
Urge customers to remove any such non-Yamaha aftermarket modifications. Such modifications may put the
operator and others at risk of serious injury or death. The Rhino owner is responsible for any such changes to
Yamaha urges Rhino owners to participate in this voluntary repair program, so please contact your
Regional Technical Advisor if you have any questions about the eligibility requirements or steps that
should be taken to be able to provide the repairs.
Units: All customer-owned units are eligible for this free repair offer as long as the unit is not modified
in a way that changes handling, stability, or operation of the vehicle (see Eligibility Information on
page 1). While Yamaha encourages all customers to take advantage of this offer, you must have
the customer’s permission to perform this free repair.
Required: Yes. Order a Rear Wheel Spacer Kit for each affected unit (see Parts Information section). Give
customer-owned units priority for repair.
Incentive: Refer to the Sales Bulletin #0972 for details.
Customers: Yes. Yamaha will send letters to customers whose Rhinos were registered for warranty as of
5/19/09. You must immediately contact any customer whose Rhino has been sold but is still unregistered
on that date. A copy of the customer letter is attached. This letter includes a form the
customer should bring in to your dealership to take advantage of the Helmet Incentive offer (the
form is not required to receive the Free Repair). Blank forms are available on YDS (see Sales Bulletin
Warranty: Submit a Service-Per-Bulletin (90 Code) Warranty Request for parts and labor (see Warranty
Units: If units have disqualifying modifications, please contact your RTA for further instructions.
All 2006~2009 YXR45 All 2004~2007 YXR66 All 2008~2009 YXR70
NOTE: Units invoiced after May 1, 2009, will already have the modification performed.
PAGE 2 of 6
Review the Eligibility Information on page 1 before
beginning these procedures. Units which have disqualifying
modifications (see Eligibility Information
on page 1) should not have the service procedures
described in this bulletin performed.
1. Park the vehicle on a level surface. Set the parking
2. Lift the rear of the unit using a suitable jack so
both rear wheels are off the ground.
3. Remove all 8 rear wheel lug nuts and the rear
4. Using a brass hammer, carefully drive the rear
wheel lug-nut studs out of the rear wheel hub.
NOTE: The lug-nut studs will not be re-used.
5. Remove the anti-sway bar and all of the hardware
shown. Put all mounting hardware in a bag
and tape it to the anti-sway bar.
6. Attach the aluminum wheel spacer to the wheel
hub using the supplied 12 x 43mm bolts with
washers and lock nuts. Place a washer on each
bolt, then pass the bolts through the recessed
holes in the wheel spacer, and finally through
the holes in the wheel hub previously used for
the lug-nut studs. Place the nuts on the inside of
the wheel hub. Torque the bolts to 100 Nm (10.0
m-kg, 73 ft-lb).
DRIVE LUG NUT
STUDS OUT WITH
100 Nm (10.0 m-kg, 73 ft-lb)
55 Nm (5.5 m-kg, 40 ft-lb)
PAGE 3 of 6
7. Place the steel protector plate over the studs on
the aluminum spacer, and then install the wheel
using the original rear wheel lug-nuts removed
in step 3. Torque the lug-nuts to specification:
55 Nm (5.5 m-kg, 40 ft-lb).
Aluminum or aftermarket wheels can be damaged
if the wrong lug nuts are used. Be sure to
reuse the lug-nuts previously removed. Do not
substitute other lug-nuts.
8. Tag and hold all replaced parts for 90 days from
the date you submit your Warranty Request.
Wheel Spacer Kit
12 x 43mm Bolt (90105-12062-00)
12mm Lock Nut (90185-12007-00)
12mm Flat Washer (90201-14020-00)
* Included in kit.
This modification is authorized for all Rhino vehicles regardless of warranty status as long as the unit is not
modified in a way that changes handling, stability, or operation of the vehicle (see Eligibility Information on
To receive credit for parts and labor for the repair after completion, select 090US from the Problem Code pull
down menu in the Yamaha Dealer System (YDS). If submitting a paper warranty claim, use Problem Code
90US. The labor allowance for this modification is 0.5 hour.
If the customer brought in the Rhino Free Repair & Helmet Offer form, complete it and submit it to Yamaha as
instructed on the