2009 YAMAHA RHINO 700 brakes

EVU00050
1 -CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ....................... 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION ........................................ 3-1
INSTRUMENT AND CONTROL
FUNCTIONS ............................................ 4-1
Main switch........................................... 4-1
Indicator and warning lights.................. 4-3
Multi-function meter unit ..................... 4-15
Switches ............................................. 4-27
Accelerator pedal ............................... 4-31
Brake pedal ........................................ 4-33
Parking brake lever ............................ 4-33
Drive select lever ................................ 4-35
Fuel tank cap ...................................... 4-35
Doors .................................................. 4-37
Seats .................................................. 4-39
Seat belts ........................................... 4-41
Glove compartment ............................ 4-41
Cup holders ........................................ 4-43
Cargo bed........................................... 4-45
1234
Adjusting the front shock absorber
assemblies ....................................... 4-49
Adjusting the rear shock absorber
assemblies ....................................... 4-63
Trailer hitch bracket and receiver....... 4-75
Auxiliary DC jack ................................ 4-75
FOR YOUR SAFETY –
PRE-OPERATION CHECKS ................... 5-1
Front and rear brakes .......................... 5-7
Fuel .................................................... 5-11
Engine oil ........................................... 5-19
Coolant............................................... 5-21
Final gear oil ...................................... 5-23
Differential gear oil ............................. 5-23
Accelerator pedal ............................... 5-25
Seat belts ........................................... 5-25
Steering.............................................. 5-27
Fittings and fasteners......................... 5-27
Lights ................................................. 5-27
Switches............................................. 5-29
Control cables .................................... 5-29
Tires ................................................... 5-29
5
EE.book Page 1 Tuesday, June 17, 2008 9:00 AM

PERIODIC MAINTENANCE AND
ADJUSTMENT ......................................... 8-1
Owner’s manual and tool kit ................. 8-5
Periodic maintenance chart for the
emission control system ..................... 8-7
General maintenance and lubrication
chart ................................................... 8-8
Hood ................................................... 8-17
Console .............................................. 8-21
Engine oil and oil filter cartridge ......... 8-25
Final gear oil ....................................... 8-39
Differential gear oil ............................. 8-47
Coolant ............................................... 8-53
Axle boots........................................... 8-57
Spark plug inspection ......................... 8-59
Cleaning the air filter element............. 8-65
Drive select lever box check hose ...... 8-77
V-belt cooling duct check hose........... 8-77
V-belt case drain plug......................... 8-79
Cleaning the spark arrester ................ 8-81
Valve clearance .................................. 8-83
Brakes ................................................ 8-85
Checking the front and rear brake
pads ................................................. 8-87
Checking the parking brake pads ....... 8-89
Checking the brake fluid level ............ 8-91
Brake fluid replacement...................... 8-95
8
Checking the brake pedal .................. 8-95
Parking brake lever free play
adjustment ....................................... 8-97
Brake light switch adjustment .......... 8-101
Cable inspection and lubrication ...... 8-103
Brake pedal and accelerator pedal
lubrication ...................................... 8-105
Rear knuckle upper and lower pivot
lubrication ...................................... 8-107
Steering shaft lubrication ................. 8-111
Wheel removal ................................. 8-111
Tire replacement .............................. 8-113
Wheel installation ............................. 8-115
Battery.............................................. 8-119
Jump-starting ................................... 8-129
Fuse replacement ............................ 8-135
Replacing a headlight bulb............... 8-141
Headlight beam adjustment ............. 8-147
Tail/brake light bulb replacement ..... 8-149
Troubleshooting ............................... 8-155
Troubleshooting charts .................... 8-157
CLEANING AND STORAGE ................... 9-1
A. Cleaning .......................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS................................. 10-1
910
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5-1
EVU01200
1 -FOR YOUR SAFETY – PRE-OPERATION CHECKS
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always fol-
low the inspection and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equip-
ment damage. Do not operate the vehicle if you find any problem. If a problem cannot be corrected
by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEM ROUTINE PAGE
BrakesCheck operation, free play, fluid level, and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-7–5-9, 8-85–8-87,
8-91–8-95, 8-101
Parking brakeCheck for proper operation, condition, and free play. 8-89, 8-97–8-99
FuelCheck fuel level.
Fill with fuel if necessary.5-11–5-17
Engine oilCheck oil level.
Fill with oil to proper level if necessary.5-19, 8-25–8-37
Coolant reservoirCheck coolant level.
Fill with coolant if necessary.5-21, 8-53–8-55
Final gear oil/
Differential gear oilCheck for leakage. 5-23, 8-39–8-51
Accelerator pedalCheck for proper accelerator pedal operation. 5-25
Seat beltsCheck for proper operation and belt wear. 5-25
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5-7
EVU00390
Front and rear brakes
Brake pedal
Check that there is no free play in the brake pedal.
If there is free play, have a Yamaha dealer check
the brake system. (See page 8-95.)
Check the operation of the brake pedal. It should
move smoothly and there should be a firm feeling
when the brakes are applied. If not, have the vehi-
cle inspected by a Yamaha dealer.
Brake fluid level
Check the brake fluid level. Add fluid if necessary.
(See pages 8-91–8-95.)
Recommended brake fluid: DOT 4
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5-9
Brake fluid leakage
Check to see if any brake fluid is leaking out of the
pipe joints or the brake fluid reservoir. Apply the
brakes firmly for one minute. If there is any leak-
age, have the vehicle inspected by a Yamaha
dealer.
Brake operation
Check the operation of the brakes at the start of
every ride. Test the brakes at slow speed after
starting out to make sure they are working proper-
ly. If the brakes do not provide proper braking per-
formance, inspect the brake system. (See pages
8-85–8-87, 8-91–8-95.)
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7-33
Wear eye protection when operating or riding the
vehicle to reduce the risk of a serious accident or
injury. Eye protection, such as a face shield or
goggles, may reduce the risk of foreign material
getting in your eyes and help prevent loss of vi-
sion.
Practice for new Rhino users
You should become familiar with the performance
characteristics of the vehicle in a large, flat area
that is free of obstacles and other vehicles. Prac-
tice controlling the accelerator pedal, brakes,
steering, and drive select lever. Drive at slow
speeds with gradual acceleration and turning.
Practice smooth throttle application. Practice slow-
ing down before turning. Practice maintaining a
steady throttle through the turn. Avoid higher
speeds until you are thoroughly familiar with the
operation of your vehicle. Remember, driving ag-
gressively or making abrupt maneuvers even on
flat, open areas can cause side rollovers.
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7-43
Braking
When slowing down or stopping, take your foot off
the accelerator pedal and press the brake pedal
smoothly. Improper use of the brakes can cause
the tires to lose traction, reducing control of the ve-
hicle and increasing the possibility of an accident.
Braking ability is affected by type of terrain. In most
cases, gradual application of the brakes is more
effective than abrupt braking, particularly on loose
surfaces, such as gravel. Always allow for greater
braking distance on rough, loose, or slippery sur-
faces.
Engine braking
Engine compression braking is designed to assist
you when operating your Rhino off-road. With this
feature, the engine helps slow the vehicle down af-
ter you take your foot off the accelerator. Engine
braking is more noticeable in 4WD. Application of
vehicle brakes provides additional stopping power.
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7-47
Parking on a slope
The parking brake acts only on the rear wheels
when in 2WD. For the parking brake to take effect
on all four wheels, shift to 4WD Diff. Lock before
stopping the engine.
If you park on a hill that is too steep the vehicle
may roll out of control. Never park on hills that are
so steep you cannot walk up them easily. If you
must park on an incline follow these instructions:
1. Bring the vehicle to a stop by applying the
brakes.
2. Put the vehicle in 4WD Diff. Lock.
3. Turn the engine off.
4. With the brake pedal applied, set the parking
brake.
5. Block the front and rear wheels with rocks or
other objects.
EE.book Page 47 Tuesday, June 17, 2008 9:00 AM