2009 YAMAHA RHINO 700 maintenance

EVU00010
1-INTRODUCTION
Congratulations on your purchase of the Yamaha
YXR70FSP2Y. It represents the result of many
years of Yamaha experience in the production of
fine sporting, touring, and pace-setting racing vehi-
cles. With the purchase of this Yamaha, you can
now appreciate the high degree of craftsmanship
and reliability that have made Yamaha a leader in
these fields.
This manual will provide you with a good basic un-
derstanding of the features and operation of this
vehicle. It also includes basic maintenance and in-
spection procedures. If you have any questions re-
garding the operation or maintenance of your
vehicle, please consult a Yamaha dealer.
WARNING
Please read this manual carefully before oper-
ating 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 mainte-
nance, along with good operating techniques,
will help ensure that you safely enjoy the capa-
bilities and reliability of this vehicle.
EE.book Page 4 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
EE.book Page 3 Tuesday, June 17, 2008 9:00 AM

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
EE.book Page 1 Tuesday, June 17, 2008 9:00 AM

5-13
WARNING
Gasoline is poisonous and can cause injury or
death. Handle gasoline with care. Never siphon
gasoline by mouth. If you should swallow some
gasoline or inhale a lot of gasoline vapor, or get
some gasoline in your eyes, see your doctor im-
mediately. If gasoline spills on your skin, wash with
soap and water. If gasoline spills on your clothing,
change your clothes.Your Yamaha engine has been designed to use
regular unleaded gasoline with a research octane
number of 91 or higher. If knocking or pinging oc-
curs, use a different brand of gasoline or premium
unleaded fuel. Unleaded fuel will give you longer
spark plug life and reduced maintenance cost.
EE.book Page 13 Tuesday, June 17, 2008 9:00 AM

8-1
EVU00650
1 -PERIODIC MAINTENANCE AND
ADJUSTMENTPeriodic inspection, adjustment, and lubrication
will keep your vehicle in the safest and most effi-
cient condition possible.
Safety is an obligation of the vehicle owner/opera-
tor. The most important points of vehicle inspec-
tion, adjustment, and lubrication are explained on
the following pages.
WARNING
Failure to properly maintain the vehicle or per-
forming maintenance activities incorrectly
may increase your risk of injury or death dur-
ing service or while using the vehicle. If you
are not familiar with vehicle service, have a
Yamaha dealer perform service.
EE.book Page 1 Tuesday, June 17, 2008 9:00 AM

8-5 1. Owner’s manual
1. Manuel du propriétaire
1. Manual de instrucciones
1. Owner’s tool kit 2. Tire pressure gauge
1. Trousse de réparation 2. Manomètre pour pneus
1. Juego de herramientas 2. Manómetro para neumáticos
21
EVU00660
Owner’s manual and tool kit
You are recommended to put this owner’s manual
in the vinyl bag and always carry it underneath the
driver seat as shown. Put the owner’s tool kit and
tire pressure gauge in the space beside the bat-
tery.
The service information included in this manual is
intended to provide you, the owner, with the nec-
essary information for completing your own pre-
ventive maintenance and minor repairs.
The tools provided in the owner’s tool kit are suffi-
cient for this purpose, except that a torque wrench
is also necessary to properly tighten nuts and
bolts.
If you do not have a torque wrench available dur-
ing a service operation requiring one, take your ve-
hicle to a Yamaha dealer to check the torque
settings and adjust them as necessary.
EE.book Page 5 Tuesday, June 17, 2008 9:00 AM

8-7
EVU01640
Periodic maintenance chart for the emission control system

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 in-
tervals. However, keep in mind that if the vehicle isn’t used for a long period of time, the month mainte-
nance intervals should be followed.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
Fuel line*Check fuel hose for cracks or damage.
Replace if necessary.
Valves*Check valve clearance.
Adjust if necessary.Spark plugCheck condition.
Adjust gap and clean.
Replace if necessary.Crankcase breather
system*Check breather hose for cracks or damage.
Replace if necessary.Exhaust system*Check for leakage.
Tighten if necessary.
Replace gasket(s) if necessary.Spark arresterClean.EE.book Page 7 Tuesday, June 17, 2008 9:00 AM

8-8
EVU01650
General maintenance and lubrication chart
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
Cooling systemCheck coolant leakage.
Repair if necessary.
Replace coolant every 24 months.
Air filter elementClean.
Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Engine oilReplace (warm engine before draining).Engine oil filter cartridgeReplace.Final gear oil
Check oil level/oil leakage.
Replace.Differential gear oil
Front brake*Check operation/brake pad wear/fluid leakage/see page 8-9.
Correct if necessary. Replace pads if worn to the limit.Rear brake*Check operation/brake pad wear/fluid leakage/see page 8-9.
Correct if necessary. Replace pads if worn to the limit.Parking brake*Check operation and free play/brake pad wear.
Correct if necessary. Replace pads if worn to the limit.Accelerator pedal*Check operation and free play.V-belt*Check operation.
Check for wear, cracks, or damage.Wheels*Check balance/damage/runout.
Repair if necessary.Wheel bearings*Check bearing assemblies for looseness/damage.
Replace if damaged.Front and rear
suspension*Check operation and for leakage.
Correct if necessary.Steering system*Check operation and for looseness/Replace if damaged.
Check toe-in/Adjust if necessary.Rear upper and lower
knuckle pivots*Lubricate with lithium-soap-based grease.
EE.book Page 8 Tuesday, June 17, 2008 9:00 AM