Yamaha Rhino 700 Fi Owner'S Manual Download | Manualshive

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8-2

EVU00660

Owner’s manual and tool kit

You are recommended to put this owner’s
manual in the vinyl bag and always carry it un-
derneath the driver seat as shown. Put the
owner’s tool kit and tire pressure gauge in the
space beside the battery.

1. Owner’s manual

1. Owner’s tool kit

2. Tire pressure gauge

The service information included in this man-
ual is intended to provide you, the owner, with
the necessary information for completing your
own preventive maintenance and minor re-
pairs.
The tools provided in the owner’s tool kit are
sufficient for this purpose, except that a torque
wrench is also necessary to properly tighten
nuts and bolts.

2

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1RB71_EE.book Page 2 Friday, April 20, 2012 8:38 AM

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Summary of Contents for Rhino 700 Fi

Page 1: ...1RB F8199 71 YX70SD YX70SHD YX70SSD OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information DIC183 ...

Page 2: ...Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if it is sold 1RB71_EE book Page 1 Friday April 20 2012 8 38 AM ...

Page 3: ...ding 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 op...

Page 4: ...ety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death WARNING A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury NOTICE A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property TIP A TIP prov...

Page 5: ...egulations 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 provinces off highway noise level and spark ar rester laws and regulations YX70SD YX70SHD YX70SSD OWNER S MANUAL 2012 by Yamaha Motor Co Ltd 1st edition March 2012 All rights reserved Any reprinting or u...

Page 6: ...17 Seats 4 17 Seat belts 4 18 1 2 3 4 Glove compartment 4 19 Cup holders 4 19 Cargo bed 4 20 Adjusting the front and rear shock absorber assemblies YX70SD YX70SHD 4 23 Adjusting the front shock absorber assemblies YX70SSD 4 24 Adjusting the rear shock absorber assemblies YX70SSD 4 30 Trailer hitch bracket and receiver 4 35 Auxiliary DC jack 4 36 FOR YOUR SAFETY PRE OPERATION CHECKS 5 1 Front and r...

Page 7: ...3 Passenger requirements 7 4 Occupant protection system 7 4 Protective structure 7 6 Seat belts 7 6 Doors 7 9 Passenger handholds 7 10 Seat and hip restraints 7 11 Floorboard 7 11 Steering wheel 7 12 LEARNING TO OPERATE YOUR VEHICLE 7 13 Personal protective equipment 7 13 Practice for new Rhino users 7 14 Getting ready to ride 7 15 Turning 7 15 Accelerating 7 16 Braking 7 17 Engine braking 7 17 Le...

Page 8: ...lant 8 22 Axle boots 8 23 Spark plug inspection 8 24 Cleaning the air filter element 8 27 Drive select lever box check hose 8 32 V belt cooling duct check hose 8 32 V belt case drain plug 8 33 Cleaning the spark arrester 8 33 Valve clearance 8 34 Brakes 8 35 Checking the front and rear brake pads 8 35 Checking the parking brake pads 8 36 Checking the brake fluid level 8 36 Brake fluid replacement ...

Page 9: ...ent 8 53 Replacing a headlight bulb 8 55 Headlight beam adjustment 8 58 Tail brake light bulb replacement 8 58 Troubleshooting 8 60 Troubleshooting charts 8 62 CLEANING AND STORAGE 9 1 A Cleaning 9 1 B Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification number records 11 1 YAMAHA SIDE BY SIDE OFF ROAD VEHICLE WARRANTY POLICY 11 4 9 10 11 1RB71_EE book Page 4 Friday April 20 20...

Page 10: ...1 1 EVU00060 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 2 3 5 4 6 7 8 90AB F BA0 C G M P N O H D E 43 2 J K R Q L I 1RB71_EE book Page 1 Friday April 20 2012 8 38 AM ...

Page 11: ... information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a re placement label is available from your Yamaha dealer 1 2YX70SSD 3 C M V S S CANADA N S V A C T RANSPOR T 506 1RB71_EE book Page 2 Friday April 20 2012 8 38 AM ...

Page 12: ...xx 1RB F4161 00 Any part of your body arms legs or head outside of the vehicle can be crushed by the cage frame If you think or feel that the vehicle may tip or roll brace your feet on the floorboards and keep your hands on the steering wheel Do not try to stop a vehicle tipover using your arm or leg 5B4 K7761 00 WARNING 1RB71_EE book Page 3 Friday April 20 2012 8 38 AM ...

Page 13: ...Unis et ISO 3471 por les structures de protection au retoumement ROPS m 700 kg pour ISO 3471 YAMAHA MOTOR CANADA LTD 480 Gordon Baker Road Toronto Ontario M2H 3B4 Canada 1RB F4162 00 The original equipment overhead structure on this vehicle meets US OSHA and ISO 3471 requirements for rollover protection structures m 700Kg for ISO3471 1RB71_EE book Page 4 Friday April 20 2012 8 38 AM ...

Page 14: ... be crushed by the cage frame If you think or feel that the vehicle may tip or roll brace your feet on the floorboards and keep your hands on the handholds Do not try to stop a vehicle tipover using your arm or leg 5B4 K7762 00 WARNING 1RB71_EE book Page 5 Friday April 20 2012 8 38 AM ...

Page 15: ...éhicule hors route est conforme à la norme ANSI ROHVA 1 2010 de l ANSI intitulée American National Standard for Recreational Off Highway Vehicles Date de fabrication xx xx 1RB F4161 10 1RB71_EE book Page 6 Friday April 20 2012 8 38 AM ...

Page 16: ...1 7 G H 1RB71_EE book Page 7 Friday April 20 2012 8 38 AM ...

Page 17: ...1 8 I J YAMAHA 5UG F151J 00 MAX 7 3 INCH 185MM 1RB71_EE book Page 8 Friday April 20 2012 8 38 AM ...

Page 18: ...1 9 K L 1RB71_EE book Page 9 Friday April 20 2012 8 38 AM ...

Page 19: ...1 10 M N O 1RB71_EE book Page 10 Friday April 20 2012 8 38 AM ...

Page 20: ...1 11 P Q R 1RB71_EE book Page 11 Friday April 20 2012 8 38 AM ...

Page 21: ...o chapters and the labels on the vehicle to instruct new operators and passengers Do not allow anyone else to operate your vehicle or ride as a passenger if you are unsure that he she is willing and able to follow these instructions Get to know your vehicle This off road vehicle will handle and maneuver differently from cars ATVs go carts golf cars and grounds keeping vehicles Follow these instruc...

Page 22: ...ust be able to put both feet flat on the floorboard while seated upright with their backs against the backrests Passenger must be able to reach and hold the handholds within the cage frame Both driver and passenger should wear an approved motorcycle helmet that fits properly Both driver and passenger should also wear eye protection goggles or a face shield gloves over the ankle boots long sleeved ...

Page 23: ...jects can affect handling stability and cause the risk of overturns or other accidents Read Chapter 6 before loading towing or pulling objects Do not overload the vehicle or trailer Refer to label in cargo bed for cargo bed load limit Re fer to label next to hitch for tongue weight and trailer load limits Keep weight in the cargo bed centered side to side and as low and as far forward as pos sible...

Page 24: ...truck by objects your vehicle is passing or crushed by the vehicle cage frame in a rollover accident Watch for branches brush or other hazards that could enter the vehicle Abrupt maneuvers or aggressive driving even on flat open areas can cause loss of control including rollovers The Rhino has higher ground clearance and other features to handle rug ged terrain and as a result can overturn in situ...

Page 25: ... in a turn When making tight turns from a stop or at slow speeds avoid sudden or hard accelera tion Drive straight up and down inclines not across them If crossing a hill is unavoidable drive slowly and turn downhill immediately if you feel the vehicle may tip Avoid paved surfaces Turn gradually and go slowly if you must drive on pavement This ve hicle is designed for off road use only 1RB71_EE bo...

Page 26: ...r than 33 cm 13 in If you must cross shallow slow moving water choose your path carefully to avoid sharp drop offs large rocks or slippery surfaces Operating this vehicle through deep or fast flowing water can lead to loss of control or overturn To reduce your risk of drowning or other injuries use care when crossing through water When loaded with cargo or towing a trailer Reduce speed operate in ...

Page 27: ...evels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas If you experience any symp toms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDI CAL TREATMENT Do not run engine indoors Even if you try to ventilate engine exhaust with fans or open win dows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine i...

Page 28: ...old by Yamaha or modifications not specifically recommended by Yamaha even if sold and installed by a Yamaha dealer Aftermarket parts accessories and modifications While you may find aftermarket products similar in design and quality to genuine Yamaha Acces sories recognize that some aftermarket accessories or modifications are not suitable because of potential safety hazards to you or others Inst...

Page 29: ...e performance capabili ties and to provide the best combination of handling braking and comfort Other tires rims sizes and combinations may not be appropriate Refer to pages 8 44 8 46 for tire specifications and more information on replacing your tires 1RB71_EE book Page 9 Friday April 20 2012 8 38 AM ...

Page 30: ...ights 10 Rear shock absorber assembly 11 Cargo bed release levers 12 Spark plug 13 Door 14 Spark arrester 15 Passenger seat belt 16 Passenger seat 17 Passenger handholds 18 Engine oil dipstick 19 Battery 20 Fuses 21 Coolant reservoir 22 Radiator cap 23 Oil filter cartridge 24 Fuel tank cap 1 2 3 5 4 C B 6 8 A 0 7 9 L K I H F G C N M A D E J 1RB71_EE book Page 1 Friday April 20 2012 8 38 AM ...

Page 31: ...witches 29 Multi function meter unit 30 Helmet Seat belt indicator light 31 Auxiliary DC jack 32 Drive select lever 33 Parking brake lever 34 Accelerator pedal 35 Brake pedal The vehicle you have purchased may differ slightly from those shown in the figures of this manual T Q R O P S U V X Y G W 1RB71_EE book Page 2 Friday April 20 2012 8 38 AM ...

Page 32: ...r TIP TIP The helmet seat belt indicator light comes on and stays on while the key is turned to ON OFF All electrical circuits are switched off The key can be removed in this posi tion START The electric starter is engaged by turning and holding the key in this po sition Release the key when the en gine starts OFF O N S T A R T 1 OFF ON START 1RB71_EE book Page 1 Friday April 20 2012 8 38 AM ...

Page 33: ...ing brake indicator light P 7 On Command four wheel drive differential gear lock indicator 8 Coolant temperature warning light 9 Engine trouble warning light EVU01140 Low range indicator light L This indicator light comes on when the drive select lever is in the L position EVU01150 High range indicator light H This indicator light comes on when the drive select lever is in the H position 1 2 3 4 5...

Page 34: ... is applied EBU29621 On Command four wheel drive indicator On Command differential gear lock indicator and indicator light DIFF LOCK The On Command four wheel drive indicator comes on when the On Command four wheel drive switch is set to the 4WD posi tion The On Command differential gear lock indi cator and the On Command differential gear lock indicator light DIFF LOCK come on when the On Command...

Page 35: ...ing to allow time for the differential to lock or unlock 5B410002 Coolant temperature warning light If the coolant temperature reaches a specific level this light comes on to warn that the cool ant temperature is too hot If the light comes on during operation stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes See page 8 62 The electrical circuit o...

Page 36: ... flashes if a problem is detected in the electrical circuit monitoring the engine When this occurs have a Yamaha dealer check the self diagno sis system See pages 4 11 4 12 for an ex planation of the self diagnosis device The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on initially when the key is turned to ON or if the warning...

Page 37: ...y latched If the indicator light does not come on when the key is turned to ON have a Yamaha dealer check the electrical circuit 5B410004 Multi function meter unit 1 Speedometer 2 Fuel meter 3 H button 4 M button 5 Clock Hour meter Voltage display 6 Odometer Tripmeter A Tripmeter B 7 TRIP ODO button 8 Clock Hour button The multi function meter unit is equipped with the following a speedometer an o...

Page 38: ...splay which shows the battery voltage a fuel meter a self diagnosis device Odometer and tripmeter modes 1 Odometer Tripmeter A Tripmeter B 2 TRIP ODO button Pushing the TRIP ODO button switches the display between the odometer mode ODO and the tripmeter modes TRIP A and TRIP B in the following order ODO TRIP A TRIP B ODO 1 2 1RB71_EE book Page 7 Friday April 20 2012 8 38 AM ...

Page 39: ...ops TIP To switch the display between km h and mph turn the key to OFF then push and hold the TRIP ODO button while turning the key to ON Clock hour meter and voltage display modes 1 Clock Hour button 2 H button 3 M button 4 Clock Hour meter Voltage display Pushing the button switches the dis play between the clock mode CLOCK the hour meter mode HOUR and the voltage display mode in the following o...

Page 40: ... button and then re lease it to start the clock Voltage display mode This display shows the battery voltage appears for 1 second when the volt age display mode is first selected and then appears and the battery voltage is dis played If the battery voltage is less than 10 volts LO is displayed and if the voltage is above 16 volts HI is displayed 1RB71_EE book Page 9 Friday April 20 2012 8 38 AM ...

Page 41: ...hicle Fuel meter 1 Fuel level warning indicator 2 Fuel meter 3 E segment The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear from F full towards E empty as the fuel level decreases When the E segment disappears and the fuel level warning indicator flashes refuel as soon as possible 1 2 3 1RB71_EE book Page 10 Friday April 20 2012 8 38 AM ...

Page 42: ...vice 1 Engine trouble warning light 2 Error code display This model is equipped with a self diagnosis device for various electrical circuits If a problem is detected in any of those cir cuits the engine trouble warning light comes on or flashes and the multi function display indicates an error code If the multi function display indicates an error code note the code number and then have a Yamaha de...

Page 43: ...der to avoid en gine damage EVU00240 Light switch OFF 1 Light switch OFF Set the switch to to turn on the low beam and the taillights Set the switch to to turn on the high beam and the taillights Set the switch to OFF to turn off the head lights and taillights L H L H L H 1RB71_EE book Page 12 Friday April 20 2012 8 38 AM ...

Page 44: ...mmand four wheel drive and differ ential gear lock switches 1 On Command four wheel drive switch 2WD 4WD 2 On Command differential gear lock switch 4WD LOCK This vehicle is equipped with an On Com mand four wheel drive switch 2WD 4WD and a differential gear lock switch 4WD LOCK Select the appropriate drive accord ing to terrain and conditions 2WD two wheel drive Power is supplied to the rear wheel...

Page 45: ...l gear locked Unlike the 4WD mode all wheels turn at the same speed regardless of traction EVU00260 Accelerator pedal Press the accelerator pedal down to increase engine speed Spring tension returns the ped al to the rest position when released Always check that the accelerator pedal returns nor mally before starting the engine 1 Accelerator pedal 1RB71_EE book Page 14 Friday April 20 2012 8 38 AM...

Page 46: ...the parking brake lever will help keep 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 tension helps return the lever to the re leased position 1 Parking brake lever 2 Release button 1 2 1RB71_EE book Page 15 Friday April 20 2012 8 38...

Page 47: ... reverse po sitions Refer to pages 6 4 6 5 for the drive select lever operation 1 Drive select lever EVU00300 Fuel tank cap 1 Fuel tank cap To open Remove the fuel tank cap by turning it coun terclockwise To close Install the fuel tank cap by turning it clockwise 1 1RB71_EE book Page 16 Friday April 20 2012 8 38 AM ...

Page 48: ...atched Be sure the door is SE CURELY LATCHED AFTER CLOSING IT 1 Latch 2 Door EVU00330 Seats To remove a seat pull its seat lock lever up ward lift the front of the seat and then slide the seat forward and up 1 Driver seat 2 Passenger seat 3 Seat lock lever 2 1 2 1 3 1RB71_EE book Page 17 Friday April 20 2012 8 38 AM ...

Page 49: ... A loose seat could cause the operator to lose control or cause the operator or pas senger to fall EVU00340 Seat belts This vehicle is equipped with three point seat belts for both the operator and the passenger Always wear the seat belts properly while riding in the vehicle See pages 7 6 7 9 for more information 1 Seat belt 2 1 1RB71_EE book Page 18 Friday April 20 2012 8 38 AM ...

Page 50: ...bottles may not fit into the cup holders depending on their size and shape WARNING Never ride with any open or glass con tainers in the cup holders otherwise the contents may spill and the glass containers may be thrown about and break and possibly injure people in the vehicle during sudden braking or an accident Do not place any other items than sealable plastic containers in the cup holders othe...

Page 51: ...e specified maximum load limits Heavier cargo could cause loss of control because of improper weight balance 1 Cargo bed 2 Tailgate 3 Cargo hook 4 For additional loading information see pages 6 9 6 11 2 1 Maximum load limit 181 kg 400 lb 1RB71_EE book Page 20 Friday April 20 2012 8 38 AM ...

Page 52: ...and then lower the tail gate To close Lift the tailgate to the original position and then hook the latches NOTICE The tailgate is not designed to hold heavy loads when open The tailgate could col lapse if you put heavy cargo or sit on it 1RB71_EE book Page 21 Friday April 20 2012 8 38 AM ...

Page 53: ...y lift up the cargo bed until it stops To lower With hands and fingers clear of pinch points lower the cargo bed slowly to its original posi tion and be sure it is locked into place WARNING Keep hands body and other people away from pinch points when low ering bed Do not hold onto the cage frame while closing the bed 1RB71_EE book Page 22 Friday April 20 2012 8 38 AM ...

Page 54: ...oads NOTICE Frequent or severe bottoming can cause increased wear or damage to the vehicle The rear wheels need to be removed to adjust the rear shock absorber assemblies See pages 8 44 8 46 for wheel removal and in stallation procedures Adjust the spring preload as follows To increase the spring preload turn the spring preload adjusting ring in direction a To decrease the spring preload turn the ...

Page 55: ...nformation be fore handling the shock absorber assem blies Do not tamper with or attempt to open the cylinder assemblies Do not subject the shock absorber as semblies to an open flame or other high heat source This may cause the unit to explode due to excessive gas pressure Do not deform or damage the cylin ders in any way Cylinder damage will result in poor damping performance Standard position B...

Page 56: ...ed to suit the operating conditions NOTICE Never turn an adjusting mechanism be yond the minimum and maximum settings Spring preload 1 Loosen the locknut 2 Turn the spring preload adjusting nut in direction a to increase the spring pre load and thereby harden the suspension and in direction b to decrease the spring preload and thereby soften the suspen sion 1 Locknut 2 Spring preload adjusting nut...

Page 57: ...With each complete turn of the adjusting nut distance A is changed by 1 5 mm 0 06 in 1 Distance A 3 Tighten the locknut to the specified torque NOTICE Always tighten the locknut against the ad justing nut and then tighten it to the spec ified torque Spring preload setting Minimum soft Distance A 62 mm 2 44 in Standard Distance A 67 mm 2 64 in Maximum hard Distance A 77 mm 3 03 in Tightening torque...

Page 58: ...amping force adjusting screw 2 Position indicator mark 3 Match mark TIP Make sure that the position indicator mark is aligned with the match mark when the shock absorber assembly is set to the standard set ting 1 2 3 b a Rebound damping setting Minimum soft 12 click s in direction b Standard 10 click s in direction b Maximum hard 9 click s in direction b With the adjusting screw fully turned in di...

Page 59: ...pression damping force adjusting screw 2 Position indicator mark 3 Match mark TIP Make sure that the position indicator mark is aligned with the match mark when the shock absorber assembly is set to the standard set ting 1 3 2 Compression damping setting Minimum soft 12 click s in direction b Standard 10 click s in direction b Maximum hard 9 click s in direction b With the adjusting screw fully tu...

Page 60: ...justing mech anism and to modify the specifications as nec essary WARNING Suspension components become hot during operation Never touch the compression damping force adjusting screw the rebound damping force ad justing screw or the oil reservoir with your bare hand or skin until suspen sion components have cooled Always adjust the shock absorber as semblies on the left and right side to the same s...

Page 61: ...s may cause the unit to explode due to excessive gas pressure Do not deform or damage the cylin ders in any way Cylinder damage will result in poor damping performance Do not dispose of a damaged or worn out shock absorber assembly your self Take the shock absorber assem bly to a Yamaha dealer for any service The spring preload rebound damping and compression damping forces of the rear shock absor...

Page 62: ...reload adjusting nut 3 Special wrench TIP A special wrench can be obtained at a Yamaha dealer to make this adjustment The spring preload setting is determined by measuring distance A shown in the il lustration The shorter distance A is the lower the spring preload the longer dis tance A is the higher the spring preload With each complete turn of the adjusting nut distance A is changed by 1 5 mm 0 ...

Page 63: ... damping force and thereby harden the damp ing and in direction b to decrease the re bound damping force and thereby soften the damping 1 Rebound damping force adjusting screw 2 Position indicator mark 3 Match mark Spring preload setting Minimum soft Distance A 63 5 mm 2 50 in Standard Distance A 63 5 mm 2 50 in Maximum hard Distance A 78 5 mm 3 09 in Tightening torque Locknut 42 Nm 4 2 m kgf 30 f...

Page 64: ...on damping force and thereby harden the damping and in direction b to decrease the compression damping force and thereby soften the damping 1 Compression damping force adjusting screw 2 Position indicator mark 3 Match mark Rebound damping setting Minimum soft 20 click s in direction b Standard 12 click s in direction b Maximum hard 3 click s in direction b With the adjusting screw fully turned in ...

Page 65: ...in production the actual number of clicks always represents the entire adjust ing range To obtain a precise adjustment it would be advisable to check the number of clicks of each damping force adjusting mech anism and to modify the specifications as nec essary Compression damping setting Minimum soft 12 click s in direction b Standard 7 click s in direction b Maximum hard 2 click s in direction b ...

Page 66: ...ies on the left and right side to the same setting Uneven adjustment can cause poor handling and loss of stability which could lead to an acci dent EVU00370 Trailer hitch bracket and receiver This vehicle is equipped with a trailer hitch bracket and a 5 cm 2 in receiver for a stan dard trailer hitch Trailer towing equipment can be obtained at a Yamaha dealer See pages 6 9 6 11 for precaution infor...

Page 67: ... are turned off 1 Auxiliary DC jack cap 1 Set the light switch to OFF 2 Turn the accessory off 3 Start the engine See pages 6 2 6 3 EVU00380 4 Open the auxiliary DC jack cap and then insert the accessory power plug into the jack 1 Auxiliary DC jack 5 Turn the accessory on 6 When the auxiliary DC jack is not being used cover it with the cap Maximum rated capacity for the auxiliary DC jack DC 12 V 1...

Page 68: ... overload the cir cuit and cause the fuse to blow If accessories are used without the engine running the battery may dis charge Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged 1RB71_EE book Page 37 Friday April 20 2012 8 38 AM ...

Page 69: ...m If a problem cannot be corrected by the procedures provided in this manual have the vehicle inspect ed by a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Brakes Check operation free play fluid level and fluid leakage Fill with DOT 4 brake fluid if necessary 5 3 8 35 8 38 8 40 Parking brake Check for proper operation condition and free play 8 38 8 39 Fuel Ch...

Page 70: ...t wear 5 7 5 8 Steering Check for proper operation 5 8 Fittings and fasteners Check all fittings and fasteners 5 8 Instruments lights and switches Check operation and correct if necessary 5 8 8 55 8 60 Wheels and tires Check tire pressure and for wear and damage 5 9 5 10 8 44 8 46 Axle boots Check for damage 8 23 8 24 ITEM ROUTINE PAGE 1RB71_EE book Page 2 Friday April 20 2012 8 38 AM ...

Page 71: ... if neces sary See pages 8 36 8 37 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir Ap ply the brakes firmly for one minute If there is any leakage 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 t...

Page 72: ... tank 3 Wipe up any spilled fuel immediately 4 Be sure the fuel tank cap is closed se curely WARNING Gasoline is poisonous and can cause inju ry 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 immediately If gasoline spills on your skin wash with soap and water ...

Page 73: ...he cap tightened before driving the vehicle Always place a portable fuel container on the ground before filling it Before removing the container cap touch the container with the fuel dispenser nozzle Keep fuel dispenser nozzle in contact with container inlet when fill ing WARNING Never refill a fuel container in the bed of any vehicle Fire may result from a build up of static electricity The disch...

Page 74: ...n the engine is cold the coolant level will vary with engine temperature The coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir If the coolant level is at or below the minimum level mark add addi tional coolant to bring the level up to maxi mum level mark If coolant is not available add distilled water Change the coolant every two years See ...

Page 75: ...ust operate smoothly and spring back to the idle position fully when re leased Have a Yamaha dealer repair as nec essary for proper operation EVU00460 Seat belts Make sure that the seat belts are not frayed torn stretched or damaged The seat belts must move smoothly when pulled out and re tract on its own when released The seat belts must also lock up when quickly pulled out The latch plate should...

Page 76: ...rough feeling Have a Yamaha dealer repair as necessary for proper operation EVU00470 Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the vehicle to a Yamaha dealer or refer to the Service Manual for correct tightening torque Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary...

Page 77: ...trol or roll over Tire pressure below the minimum specified could also cause the tire to dis lodge from the rim under severe riding conditions Set tire pressures to the following specifica tions ACE 02E 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 incorr...

Page 78: ...5 10 1 Tire pressure gauge 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 1RB71_EE book Page 10 Friday April 20 2012 8 38 AM ...

Page 79: ...period between 0 and 20 hours For this reason we ask that you read the fol lowing material carefully Because the engine is brand new you must not put an excessive load on it for the first several hours of opera tion During the first 20 hours the various parts in the engine wear and polish them selves to achieve the correct operating clear ances During this period prolonged full throttle oper ation...

Page 80: ...20 hours Avoid prolonged operation above three quar ter throttle After break in The vehicle may now be operated normally 5B410007 Starting the engine 1 Turn the key to ON NOTICE The coolant temperature warning light and engine trouble warning light should come on then go off If a warning light does not go off see pag es 4 4 4 5 for the corresponding warning light circuit check 2 Apply the brake pe...

Page 81: ...conds before the next attempt Each attempt should be as short as possible to preserve battery energy NOTICE Do not crank the engine more than 5 seconds on each attempt or starter damage could occur Wait at least 5 seconds between each operation of the electric starter to let it cool Do not turn the key to the START position with the engine running otherwise damage to the electric starter may resul...

Page 82: ...Stop the vehicle and take your foot off the accelerator pedal 2 Apply the brake pedal then shift by mov ing the drive select lever along the shift guide Make sure that the drive select le ver is completely shifted into position 1 Drive select lever 2 L Low range 3 H High range 4 N Neutral 5 R Reverse 3 Release the parking brake 4 Release the brake pedal and press the accelerator pedal gradually 2 ...

Page 83: ...g the shift guide When in reverse the reverse indicator light should be on Due to the synchro nizing mechanism in the engine the light may not come on until the vehicle starts moving If the light does not come on ask a Yamaha dealer to inspect the reverse indicator light electrical circuit 1 Drive select lever 2 L Low range 3 H High range 4 N Neutral 5 R Reverse 4 Release the parking brake 5 Check...

Page 84: ... Al ways stop the vehicle before changing be tween 2WD and 4WD or 4WD and LOCK 2WD 4WD To change from 2WD to 4WD stop the ve hicle and then set the switch to 4WD When the vehicle is in four wheel drive the four wheel drive indicator will come on in the multi function display To change from 4WD to 2WD stop the vehicle and then set the switch to 2WD 1 On Command four wheel drive switch 2WD 4WD 1RB71...

Page 85: ...ifferential gear lock indicator light DIFF LOCK will come on along with the differential gear lock indicator in the multi function display To unlock the differential gear stop the vehicle and set the switch to 4WD When the switch is set to LOCK or 4WD the differential gear lock indicator and indi cator light will flash until the differential gear is completely locked or unlocked When the indicator...

Page 86: ...limited until the differential gear is completely engaged or disengaged EVU01210 Parking When parking stop the engine and shift the drive select lever into the neutral position Ap ply the parking brake to help prevent the vehi cle from rolling See pages 7 18 7 19 for more information on parking and parking on a slope 1RB71_EE book Page 8 Friday April 20 2012 8 38 AM ...

Page 87: ... side and as low and as far for ward as possible Top heavy loads in crease the risk of overturn Be sure cargo is secured a loose load could change handling unexpectedly or strike occupants Do not exceed the maximum tongue weight Make sure the load does not interfere with your control or ability to see where you are going Tie down cargo in the trailer securely Make sure cargo in the trailer cannot ...

Page 88: ... loads or when towing a trailer WARNING Carrying loads or towing a trailer can in crease the risk of loss of control an over turn or other accident To reduce the risk of an accident Reduce speed operate in low gear only and allow more room to stop A heavier vehicle takes longer to stop Avoid hills and rough terrain Choose terrain carefully Use extreme caution when towing or carrying a load on in c...

Page 89: ...structions for that product and only attach to the hitch or hitch bracket of the Rhino WARNING Improperly pulling can cause serious injury or death Never ex ceed the Pulling Load limit of the Rhino Avoid pulling on inclines Pulling objects on the ground can be more hazardous than pulling a trailer It may be dif ficult to predict how the load will affect vehicle operation That effect could also cha...

Page 90: ...ow these instructions to reduce your risk of an accident and to reduce the risk of serious injury or death in the event of an accident KNOW YOUR VEHICLE This off road vehicle will handle and maneu ver differently from cars ATVs go carts golf cars and grounds keeping vehicles The Rhino has higher ground clearance and other features to handle rugged terrain and as a result can overturn in situations...

Page 91: ... inju ries or death to drivers or passengers As the owner operator it is your responsibility to protect yourself and your passenger from accidents including rollovers The Rhino has many features including a protective struc ture and seat belts to help protect occupants but the best way to avoid injuries is to avoid accidents There is a risk of injury or death in any accident even with these safety...

Page 92: ...he vehicle is not in use to prevent unauthorized use of the machine Parents Many provinces have implemented new mo tor vehicle licensing requirements for young drivers These requirements are in response to the disproportionately high rate of crashes involving youthful drivers As with automo biles to promote safe driving behaviors you should supervise younger drivers and consid er setting rules and...

Page 93: ...o not carry any other passengers Do not carry passengers in the cargo bed Do not allow someone to ride as a passen ger who has been using drugs or alcohol Do not allow children who need child safety seats or booster seats in the Rhino The seat belt is not designed to restrain auto motive child safety seats Occupant protection system WARNING Do not make changes to the occupant pro tection system If...

Page 94: ...tures to help reduce the risk of driver and passenger injury These features work together and when properly used these features will help protect the occupants in the event of an acci dent If these features are not used properly they can cause injury 3 2 1 1 1RB71_EE book Page 5 Friday April 20 2012 8 38 AM ...

Page 95: ...he vehicle may tip or roll do not put your hands or feet outside the vehicle for any reason You will not be able to stop the vehicle from tipping over using your body Any part of your body arms legs or head outside of the vehicle can be crushed by the vehicle cage frame Seat belts Seat belts should be worn by both driver and passenger Driver must be sure that the pas senger is belted before drivin...

Page 96: ...ystems in your vehicle A damaged restraint system may not properly protect the person using it resulting in serious injury or death in a crash To help make sure your restraint systems are working properly after a crash have them in spected and any necessary replacements made as soon as possible 1 Seat belt 2 2 Latch plate 2 3 Buckle 2 To wear the seat belt properly do the follow ing 1 Hold the lat...

Page 97: ...h plate to make sure it is secure 1 Buckle 2 Latch plate 3 Release button 4 Put the lap portion of the belt low on your hips Pull up on the shoulder part so the belt is snug across your hips Be sure the seat belt is not caught on the hip restraint or other object 5 Position the shoulder belt over your shoulder and across your chest The shoulder belt should fit against your chest If it is loose pul...

Page 98: ...lease button Doors The doors are designed to reduce the likeli hood that you will stick your leg out to stop the vehicle from tipping over or for any other rea son in a rollover The doors may also reduce intrusion of objects into the occupant area Make sure the doors are securely latched be fore operation Do not place your arm or hand on the door during operation Your hand or arm may be struck by ...

Page 99: ...hat the passenger puts a hand outside the vehicle if the vehicle begins to tip There are two handholds on the protective structure and two handholds on the passen ger s left side for the right and left hands The driver should make sure the passenger is holding onto the handholds with both hands before operating the vehicle 1RB71_EE book Page 10 Friday April 20 2012 8 38 AM ...

Page 100: ...ving Your hand or arm may be struck by objects or crushed against outside objects or the ground during a rollover Floorboard The floorboard allows you to brace your feet which helps you keep your body in the vehicle in the event of an accident or rollover Keep your feet on the floorboard during operation 1RB71_EE book Page 11 Friday April 20 2012 8 38 AM ...

Page 101: ...ge obstacle the steering wheel could brief ly jerk in one direction or back and forth as the tires and vehicle respond to the obstacle This quick motion could injure your thumbs or wrist if your thumbs or hand s are inside the steer ing wheel Grip the steering wheel so that your thumbs will not be hit by the spokes As an example see the illustration CORRECT GRIP EXAMPLE INCORRECT GRIP EXAMPLE 1RB7...

Page 102: ...les helmet face shield or protective eyewear Over the ankle boots gloves long sleeved shirt or jacket and long pants An approved helmet and other personal pro tective equipment can help in a variety of ways including Reduce the severity of injuries if any part of you is outside the vehicle cage frame pro tective structure during a rollover Help protect you if outside objects intrude inside the veh...

Page 103: ...actice smooth throttle ap plication Practice slowing 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 aggres sively or making abrupt maneuvers even on flat open areas can cause side rollovers Become familiar with the way the vehicle feels in low and high ranges first...

Page 104: ...void sudden or hard accelera tion Driving aggressively or making abrupt maneuvers even on flat open areas can cause side rollovers Avoid sideways sliding skidding or fishtailing and never do donuts If you feel the Rhino begin to slide sideways or fishtail during a turn steer into the direction of the slide if possible and gradually let off the accelerator pedal to regain directional control and av...

Page 105: ...foot on the brake shift the drive select lever into low or high NOTICE Do not shift from low to high or vice versa without coming to a complete stop and waiting for the engine to return to normal idle speed damage to the engine or drive train may occur Then release the parking brake Press the accel erator pedal slowly and smoothly The centrif ugal clutch will engage and the vehicle will begin to a...

Page 106: ...e brakes is more effective than abrupt braking particu larly on loose surfaces such as gravel Al ways allow for greater braking distance on rough loose or slippery surfaces 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 after you take your foot off the accelerator Engine braking is more...

Page 107: ...king on a flat area stop the engine and shift the drive select lever into the neutral position Apply the parking brake to help pre vent the vehicle from rolling 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 LOCK before stopping the engine If you park on a hill that is too steep the vehi cle may roll ou...

Page 108: ...y handle differently in certain types of terrains or on certain surfaces You may come upon hidden rocks bumps or holes without enough time to react To avoid loss of control or rollover always be alert to changing surfaces or terrain when operating the vehicle The Rhino has higher ground clearance and other features to handle rugged terrain and as a result can overturn in situations where some vehi...

Page 109: ...d rearward forward or sideways rollovers on hills and slopes Drive straight up and down inclines not across them If crossing a hill is unavoidable drive slowly Turn downhill immediately if you feel the vehicle may tip If you think or feel the Rhino may tip or roll Brace yourself by pressing your feet firmly on the floorboards and keep a firm grip on the steering wheel or handholds Do not put your ...

Page 110: ...t not so fast that you cannot react to changes in the terrain as you climb Slow down when you reach the crest of the hill if you cannot see clearly what is on the other side there could be another person an ob stacle or a sharp drop off If you start to lose traction or momentum when climbing and decide you will be unable to continue use the brakes to stop Do not at tempt to turn the vehicle around...

Page 111: ...u begin to go too fast apply the brakes gently Avoid hard applica tion of the brakes which could cause the vehi cle to slide If you are sliding or skidding try to steer in the direction the vehicle is sliding to regain con trol For example if you feel the back of the vehicle start to slide to your right steer to the right If you must turn on the hill to avoid an obsta cle do so slowly and carefull...

Page 112: ...your path carefully to avoid sharp drop offs large rocks or slippery surfaces that could cause the vehicle to overturn Nev er operate through water deeper than 33 cm 13 in or fast flowing water Choose a path where both your entrance into and exit point from the water is a gradual incline Determine the water depth and currents before crossing Operating this vehicle through deep or fast flowing wate...

Page 113: ...ing on slippery terrain including wet muddy or icy conditions as well as loose gravel be aware that you could begin skid ding or sliding To avoid loss of control slow down and put the Rhino in four wheel drive before driving on a slippery surface and plan your path to avoid making abrupt maneuvers If you feel the Rhino begin to slide sideways or fishtail during a turn steer into the direction of t...

Page 114: ...fter operating in areas where combustible materials may have collected Do not idle or park the vehicle in long dry grass or other dry ground cover Encountering obstacles If you cannot go around an obstacle such as a fallen tree or a ditch stop the vehicle where it is safe to do so Set the parking brake and get out to inspect the area thoroughly Look from both your approach side and exit side If yo...

Page 115: ...during service or while using the ve hicle If you are not familiar with vehicle service have a Yamaha dealer perform service WARNING Turn off the engine when performing main tenance unless otherwise specified A running engine has moving parts that can catch on body parts or cloth ing and electrical parts that can cause shocks or fires Running the engine while servicing can lead to eye injury burns...

Page 116: ...wner s manual 1 Owner s tool kit 2 Tire pressure gauge The service information included in this man ual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor re pairs The tools provided in the owner s tool kit are sufficient for this purpose except that a torque wrench is also necessary to properly tighten nuts and bolts 2 1 1R...

Page 117: ...t have a torque wrench available during a service operation requiring one take your vehicle to a Yamaha dealer to check the torque settings and adjust them as necessary 1RB71_EE book Page 3 Friday April 20 2012 8 38 AM ...

Page 118: ...med by a Yamaha dealer as they require spe cial tools data and technical skills ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1200 750 2400 1500 2400 1500 4800 3000 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 plug Check condition Adjust gap and clean Replace if n...

Page 119: ...cessary Replace pads if worn to the limit Rear brake Check operation brake pad wear fluid leakage see page 8 6 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 bala...

Page 120: ...luid Replace the brake hoses every four years and if cracked or damaged Drive shaft universal joint Lubricate with lithium soap based grease Engine mount Check for cracks or damage Check bolt tightness Front and rear axle boots Check operation Replace if damaged Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary ITEM ROUTINE Whichever comes first INITIAL EVERY mon...

Page 121: ...8 7 EVU00680 Hood To open Unhook the hood latches and then slowly tilt the hood up until it stops 1 Hood latch 2 1 Hood 1RB71_EE book Page 7 Friday April 20 2012 8 38 AM ...

Page 122: ... on the back of the instrument panel Secure slots 3 on the side of the hood around projections 4 on the frame 1 Projection 2 2 Slot 2 3 Slot 2 4 Projection 2 NOTICE Make sure that all cables and wires are in place when closing the hood Do not drive the vehicle with the hood open unlatched or removed 1RB71_EE book Page 8 Friday April 20 2012 8 38 AM ...

Page 123: ...w gear L po sition 1 Console To install 1 Place the console in its original position 2 Install the parking brake lever boot 3 Install the seats NOTICE Be sure to position the seat belt buck les to the outside of the console 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 fi...

Page 124: ... on a level surface 2 Remove the console See page 8 9 for console removal and installation proce dures 3 Check the engine oil level on a cold en gine TIP If the engine was started before checking the oil level be sure to warm up the engine suffi ciently and then wait at least 10 minutes until the oil settles for an accurate reading 4 Remove the engine oil dipstick and then wipe it off with a clean...

Page 125: ...the mini mum and maximum level marks 1 Maximum level mark 2 Minimum level mark 6 If the engine oil is at or below the mini mum level mark add sufficient oil of the recommended type to raise it to the cor rect level 7 Insert the dipstick completely into the oil filler hole 8 Install the console 1 2 1RB71_EE book Page 11 Friday April 20 2012 8 38 AM ...

Page 126: ...nutes and then turn it off 4 Place an oil pan under the engine to col lect the used oil and then remove the dipstick 5 Remove the engine oil drain bolt and its gasket to drain the oil from the crank case 1 Engine oil drain bolt 2 Gasket TIP Skip steps 6 10 if the oil filter cartridge is not being replaced 6 Lift the cargo bed up See page 4 22 for cargo bed lifting and lowering proce dures 2 1 1RB7...

Page 127: ...m a Yamaha dealer 1 Oil filter cartridge 2 Oil filter wrench 8 Apply a light coat of clean engine oil to the O ring of the new oil filter cartridge TIP Make sure that the O ring is properly seated 1 O ring 9 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 2 Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft...

Page 128: ...stick completely into the oil filler hole TIP Be sure to wipe off spilled oil on any parts af ter the engine and exhaust system have cooled down Tightening torque Engine oil drain bolt 30 Nm 3 0 m kgf 22 ft lbf 1 2 Recommended engine oil See pages 10 1 10 2 Oil quantity Without oil filter cartridge replacement 2 00 L 2 11 US qt 1 76 Imp qt With oil filter cartridge replacement 2 10 L 2 22 US qt 1 ...

Page 129: ... checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 14 Turn the engine off wait at least 10 min utes and then check the oil level and cor rect it if necessary 15 Install the console 5B410013 Final gear oil Checking the final gear oil level 1 Park the vehicle on a level surface 2 Remove the final gear oil filler bolt and its O ring and then check t...

Page 130: ...l the oil filler bolt and its new O ring and then tighten the bolt to the specified torque Changing the final gear oil 1 Park the vehicle on a level surface 2 Remove the final gear case guard by re moving the bolts and the collars 1 Final gear case guard 2 Bolt and collar 7 Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 2 1 2 1RB71_EE book Page 16 Friday April 20 2012 8 38 ...

Page 131: ... gear oil up to the brim of the filler hole NOTICE Be sure no foreign material enters the final gear case 7 Install the oil filler bolt and its new O ring and then tighten the bolt to the specified torque 8 Check for oil leakage If oil leakage is found check for the cause Tightening torque Final gear oil drain bolt 20 Nm 2 0 m kgf 14 ft lbf 2 1 Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil q...

Page 132: ... surface 2 Remove the differential gear oil filler bolt and its gasket and then check the oil lev el It should be up to the brim of the filler hole 3 If the level is low add sufficient oil of the recommended type to raise it to the spec ified level NOTICE Be sure no foreign material enters the differential gear case Tightening torque Final gear case guard bolt 7 Nm 0 7 m kgf 5 1 ft lbf 1RB71_EE bo...

Page 133: ...k the gasket for damage and re place it if necessary 5 Install the differential gear oil filler bolt and its gasket and then tighten the bolt to the specified torque 1 2 3 4 Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf 1RB71_EE book Page 19 Friday April 20 2012 8 38 AM ...

Page 134: ...3 Place an oil pan under the differential gear case to collect the used oil 4 Remove the differential gear oil filler bolt the differential gear oil drain bolt and their gasket to drain the oil 1 Differential gear oil drain bolt 2 Gasket 5 Install the differential gear oil drain bolt and its new gasket and tighten the bolt to the specified torque 1 2 2 2 1 2 1RB71_EE book Page 20 Friday April 20 2...

Page 135: ...l leakage is found check for the cause 10 Install the differential gear case guard by installing the bolts and the collars and then tightening the bolts to the specified torque Tightening torque Differential gear oil drain bolt 9 8 Nm 0 98 m kgf 7 1 ft lbf Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 18 L 0 19 US qt 0 16 Imp qt Tightening torque Differential gear oil filler bolt ...

Page 136: ...engine tempera ture TIP The coolant should be between the minimum and maximum level marks 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark 3 If the coolant is at or below the minimum level mark remove the coolant reservoir cap add coolant to the maximum level mark install the reservoir cap Coolant reservoir capacity up to the maximum level mark 0 32 L 0 34 US qt 0 28 Imp qt 1 2 3 ...

Page 137: ... coolant as soon as possible The radiator fan is automatically switched on or off according to the coolant temperature in the radiator NOTICE Mix antifreeze with distilled water only However if distilled water is not available soft water may be used for refilling If your vehicle overheats see page 8 63 for instructions EVU00740 Axle boots Check the axle boots for holes or tears If any damage is fo...

Page 138: ...moval 1 Remove the console See page 8 9 for console removal and installation proce dures 2 Remove the spark plug cap 1 Spark plug cap 3 Use the spark plug wrench in the tool kit to remove the spark plug as shown 1 1 1 1RB71_EE book Page 24 Friday April 20 2012 8 38 AM ...

Page 139: ...trode is a medium to light tan for a vehicle that is being ridden nor mally 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 with the specified plug 1 Specified spark plug CPR7EA 9 NGK 1RB...

Page 140: ...ark plug and tighten it to the specified torque If a torque wrench is not available when you are installing the spark plug a good estimate of the correct torque is one quarter to one half turn past finger tight Have the spark plug tightened to the specified torque as soon as possible 3 Install the spark plug cap 4 Install the console Spark plug gap 0 8 0 9 mm 0 031 0 035 in Tightening torque Spark...

Page 141: ... air filter case and at the bottom of the air duct un der the case If dust or water collects in a check hose empty the hose and clean the air filter element and air filter case 1 Air filter case check hose 1 Air filter case check hose 1 1 1RB71_EE book Page 27 Friday April 20 2012 8 38 AM ...

Page 142: ...e air intake duct shroud by re moving the quick fastener screws 1 Quick fastener screw 2 2 Air intake duct shroud 3 Remove the air filter case cover by un hooking the holders 1 Air filter case cover holder 5 2 Air filter case cover 1 2 1 1 2 1RB71_EE book Page 28 Friday April 20 2012 8 38 AM ...

Page 143: ...29 4 Remove the air filter element 1 Air filter element 5 Remove the sponge material from the air filter frame 1 Air filter frame 2 Sponge material 1 2 1 1RB71_EE book Page 29 Friday April 20 2012 8 38 AM ...

Page 144: ...r to remove remaining solvent then rinse thoroughly with plain warm water 9 Squeeze excess water out of the sponge material NOTICE Do not twist the sponge material when squeezing it 10 Allow the sponge material to dry thor oughly Inspect the sponge material and replace it if damaged 11 Thoroughly apply Yamaha foam air filter oil or other quality liquid foam air filter oil not spray type to the spo...

Page 145: ... filter ele ment maintenance is performed check the air inlet to the air filter case for obstructions Check the air filter element rubber joint to the throttle body and manifold fittings for an air tight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the en gine NOTICE Never operate the engine with the air filter element removed This will allow unfiltered ai...

Page 146: ...llects in the drive select lever box check hose remove the hose and clean it 1 Drive select lever box check hose 5B410017 V belt cooling duct check hose The V belt cooling duct check hose is located under the cargo bed If dust or water collects in the V belt cooling duct check hose remove the hose and clean it 1 V belt cooling duct check hose 1 1 1RB71_EE book Page 32 Friday April 20 2012 8 38 AM ...

Page 147: ...V belt case after re moving the drain plug have a Yamaha dealer inspect the vehicle as the water may affect other engine parts 1 V belt case drain plug 5B410018 Cleaning the spark arrester WARNING Hot exhaust system may cause burns To avoid burns or fires make sure that the en gine is stopped and the exhaust system is cool before cleaning the spark arrester Do not start the engine while cleaning t...

Page 148: ...t and then insert the tailpipe into the muffler and align the bolt holes 5 Install the bolts and tighten them to the specified torque Valve clearance The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clear ance must be adjusted regularly This adjust ment however should be left to a professional Yamaha service technician 3 1...

Page 149: ...ith 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 The wheels need to be removed to check the brake pads See pages 8 44 8 46 for w...

Page 150: ... Yamaha dealer replace the brake pads as a set 1 Brake pad wear indicator groove EVU00850 Checking the brake fluid level The brake fluid reservoir is located under the hood See pages 8 7 8 8 for hood opening and closing procedures Before riding check that the brake fluid is above the minimum level mark Check the brake fluid level with the top of the reservoir level Replenish the brake fluid if nec...

Page 151: ...may result in vapor lock NOTICE Brake fluid may damage painted surfaces or plastic parts Always clean up spilled fluid immediately As the brake pads wear it is normal for the brake fluid level to gradually go down A low brake fluid level may indicate worn brake pads and or brake system leakage therefore be sure to check the brake pads for wear and the brake system for leakage If the brake fluid le...

Page 152: ...sary 1 Brake pedal a No brake pedal free play 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 2 Remove the seats See pages 4 17 4 18 for seat removal and installation procedures 3 Remove the console See page 8 9 for console removal and installation proce dures 4 Check th...

Page 153: ...locknut 1 Rubber cover 2 Locknut 3 Adjusting nut 8 Turn the adjusting nut in direction a to increase the free play or in direction b to decrease the free play 9 Tighten the locknut and then slide the rubber cover to its original position 10 Install the console 11 Install the seats a a b 2 1 3 1RB71_EE book Page 39 Friday April 20 2012 8 38 AM ...

Page 154: ...itch as follows 1 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the ad justing nut in direction a To make the brake light come on later turn the adjust ing nut in direction b 1 Brake light switch 2 Adjusting nut 3 Close the hood 1 a b 2 1RB71_EE book Page 40...

Page 155: ...the outer covering of control cables becomes damaged Cables can also become frayed or kinked Lubricate the cable ends If the cables do not operate smoothly ask a Yamaha dealer to re place them EVU00900 Brake pedal and accelerator pedal lubrication Lubricate the pivoting parts Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease 1RB71_EE book Page 41 Frida...

Page 156: ...t and right 1 Remove the lower arm protector by re moving the bolts 1 Bolt 3 2 Lower arm protector 2 Lubricate the knuckle upper and lower pivots with a grease gun 1 2 Recommended lubricant Lithium soap based grease 1RB71_EE book Page 42 Friday April 20 2012 8 38 AM ...

Page 157: ...tightening them to the specified torque EVU00920 Steering shaft lubrication Lubricate the pivot points Tightening torque Lower arm protector bolt 7 Nm 0 7 m kgf 5 1 ft lbf Recommended lubricant Lithium soap based grease 1RB71_EE book Page 43 Friday April 20 2012 8 38 AM ...

Page 158: ...ur Rhino were de signed to match the performance capabilities and to provide the best combination of han dling braking and comfort It is best to re place all four tires at the same time If that is not possible you must replace the tires in pairs front or rear with tires of the same size and type as the originals Never replace just one tire WARNING Installing improper tires on your Rhino can affect...

Page 159: ... front and rear wheels Install the nuts with their tapered side towards the wheel 2 Lower the vehicle so that the wheel is on the ground 3 Tighten the wheel nuts in crisscross pat tern to the specified torque WARNING Do not reverse the rims on the Rhino to widen the track width Installing wheels improperly increases the risk of wheel fail ure and accidents Manufacturer Size Type Front MAXXIS 25 8 ...

Page 160: ...8 46 1 Arrow mark 1 Tapered nut 1 Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf 1RB71_EE book Page 46 Friday April 20 2012 8 38 AM ...

Page 161: ...ries Keep out of reach of children You could be poisoned or severely burned by the sulfuric acid in battery electrolyte In case of accidental contact with battery electrolyte EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes and get prompt medical atte...

Page 162: ... screws 4 Remove the battery compartment cover by lifting it up and pulling it out 1 Quick fastener screw 2 2 Battery compartment cover 5 Unhook the battery band 6 Disconnect the negative battery lead first then the positive battery lead by remov ing their bolt NOTICE When removing the battery the main switch must be off and the negative lead must be dis connected before the positive lead 1 2 1RB7...

Page 163: ...ptional electrical accessories NOTICE To charge a VRLA Valve Regulated Lead Acid battery a special constant voltage battery charger is required Using a con ventional battery charger will damage the battery To store the battery If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for more than ...

Page 164: ...attery lead first then the negative battery lead by install ing their bolt NOTICE When installing the battery the main switch must be off and the positive lead must be con nected before the negative lead 1 Positive battery lead red 2 Negative battery lead black 3 Hook the battery band 4 Install the battery compartment cover by installing the quick fastener screws 5 Close the hood 1 2 1RB71_EE book...

Page 165: ...teries However if the vehicle must be jump started proceed as follows 1 Turn the key to OFF 2 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 3 Remove the battery compartment cover See pages 8 48 8 50 for battery com partment cover removal and installation procedures 4 Remove the console See page 8 9 for console removal and installation proce dures 5 Using a charged 12 volt...

Page 166: ...the crankcase to be started 1 Jumper cable negative lead 7 Start the engine Refer to Starting the engine on pages 6 2 6 3 8 After the engine starts disconnect the negative lead of the jumper cable from the crankcase and charged battery and then disconnect the positive lead of the jumper cable from the charged battery and the battery in the vehicle 1 1 1RB71_EE book Page 52 Friday April 20 2012 8 3...

Page 167: ...own turn off the main switch and install a new fuse of the specified amperage If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question NOTICE To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 2 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 1RB71_EE book Page 53 Friday Apr...

Page 168: ... use any material in place of the proper fuse Using an improper fuse can cause damage to the electrical system and may lead to a fire 1 Fuel injection system spare fuse 2 Fuel injection system fuse 3 Main fuse 4 Headlight fuse HEAD 5 Signaling system fuse SIGNAL 6 Auxiliary DC jack fuse TERMINAL 7 Four wheel drive motor fuse DIFF 8 Ignition fuse IGNITION 9 Backup fuse BACK UP for clock 10 Spare fu...

Page 169: ... a headlight bulb burns out replace it as fol lows 1 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 2 Remove the cover at the rear of the headlight by pulling it off 1 Cover at the rear of the headlight Specified fuses Main fuse 40 0 A Fuel injection system fuse 10 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Signaling system fuse 10 0 A Fou...

Page 170: ...t bulb holder cover by pulling it off 1 Headlight bulb holder cover 4 Remove the headlight bulb holder by pushing it in and turning it counterclock wise 1 Headlight bulb holder 1RB71_EE book Page 56 Friday April 20 2012 8 38 AM ...

Page 171: ...versely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moist ened with alcohol or thinner 1 Do not touch the glass part of the bulb 7 Install the bulb holder by pushing it in and turning it clockwise 8 Install the bulb holder cover and the cov er at the rear of the headlight NOTICE Make sure the headlight bulb holder cover is securely fitted over the bu...

Page 172: ...e headlight beam adjusting screw in direction b 1 Headlight beam adjusting screw EVU01000 Tail brake light bulb replacement If a tail brake light bulb burns out replace it as follows 1 Remove the quick fastener screws nuts and bolts from panel A if replacing the left tail brake light bulb or panel B if re placing the right tail brake light bulb 1 Panel A 1RB71_EE book Page 58 Friday April 20 2012 ...

Page 173: ...e panel panel A or B 4 Remove the tail brake light bulb holder together with the bulb by turning it coun terclockwise 1 Tail brake light bulb holder 5 Push the burnt out bulb in and turn it counterclockwise to remove it from the bulb holder 6 Push a new bulb in and turn it clockwise to install in the bulb holder 1RB71_EE book Page 59 Friday April 20 2012 8 38 AM ...

Page 174: ...tems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your vehicle requires any repair take it to a Yamaha deal er The skilled technicians at a Yamaha dealer ship have the tools experience and know how to properly service your vehicle Use only genuine Yamaha parts on your vehicle Imita tion parts may look like Yamaha parts bu...

Page 175: ...and make sure there are no open flames or sparks in the area including pi lot lights from water heaters or furnaces Gasoline or gasoline vapors can ignite or explode causing severe injury or property damage 1RB71_EE book Page 61 Friday April 20 2012 8 38 AM ...

Page 176: ...Remove the spark plug and check the electrodes Wet Wipe clean with dry cloth Dry Attach spark plug cap and ground to chassis Use the electric starter Spark is good Ignition system is normal Spark is weak Adjust the spark plug gap or replace the spark plug No spark Ask a Yamaha dealer to inspect 4 Battery Use the electric starter Engine turns over quickly Battery is good Engine turns over slowly Ch...

Page 177: ...d coolant tap water can be used temporarily provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the coolant reservoir and or radiator Level is OK Level is low check the cooling system for leakage No leakage Leakage Ask a Yamaha dealer to inspect and repair the cooling system Add coolant See the text below Restart th...

Page 178: ... a paint brush Do not apply degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job WARNING Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings Wet brakes may have reduced stopping ability increasing the chance of an ac cident NOTICE Excessive water pressure may cause water...

Page 179: ...ives which may scratch the paint or protective finish When finished start the engine and let it idle for several minutes 5B410025 B Storage Long term storage 60 days or more of your vehicle will require some preventive proce dures to guard against deterioration Make any necessary repairs before storing the vehi cle After thoroughly cleaning the vehicle prepare for storage as follows 1 Fill the fue...

Page 180: ...re from entering 6 If storing in a humid or salt air atmo sphere coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat covers 7 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 Use of fuel stabilizer and co...

Page 181: ...angement Single cylinder Displacement 686 cm Bore stroke 102 0 84 0 mm 4 02 3 31 in Compression ratio 9 20 1 Starting system Electric starter Lubrication system Wet sump Engine oil Recommended brand YAMALUBE Type SAE 5W 30 10W 30 10W 40 15W 40 20W 40 or 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Without oil filter cartridge replacement 2 ...

Page 182: ...d fuel Regular unleaded gasoline only Fuel tank capacity 30 0 L 7 93 US gal 6 60 Imp gal Fuel injection Throttle body ID mark 5B41 00 Spark plug s Manufacturer model NGK CPR7EA 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Clutch Clutch type Wet centrifugal automatic Transmission Primary reduction system V belt Secondary reduction system Shaft drive Secondary reduction ratio 41 21 17 12 33 9 10 142 T...

Page 183: ...a 0 910 kgf cm 13 psi Front wheel Wheel type YX70SD Panel wheel YX70SHD Panel wheel YX70SSD Cast wheel Rim size 12 6 0AT Rear wheel Wheel type YX70SD Panel wheel YX70SHD Panel wheel YX70SSD Cast wheel Rim size 12 7 5AT Front brake Type Disc brake Operation Unified brake Specified brake fluid DOT 4 Rear brake Type Disc brake Operation Unified brake Specified brake fluid DOT 4 Front suspension Type ...

Page 184: ...12 V 5 0 21 0 W 2 Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light LED Engine trouble warning light LED Parking brake indicator light LED On Command four wheel drive differential gear lock indica tor LCD High range indicator light LED Low range indicator light LED Differential gear lock indicator light LED Helmet Seat belt indicator light 14 V 1 7 W Fuses M...

Page 185: ...10 5 Four wheel drive motor fuse 10 0 A Radiator fan fuse 25 0 A 1RB71_EE book Page 5 Friday April 20 2012 8 38 AM ...

Page 186: ... number and model label infor mation in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER ACA 02E 2 VEHICLE IDENTIFICATION NUMBER ACA 02E 3 MODEL LABEL INFORMATION ACA 01E 1RB71_EE book Page 1 Friday April 20 2012 8 38 AM ...

Page 187: ...ollowing illustration This number can be used for ordering a new key 1 Key identification number EVU00110 Vehicle identification number The vehicle identification number is stamped into the frame 1 Vehicle identification number The vehicle identification number is used to identify your vehicle 1RB71_EE book Page 2 Friday April 20 2012 8 38 AM ...

Page 188: ...s from your Yamaha dealer 1 Model label Vehicle Emission Control Information la bel The Vehicle Emission Control Information la bel is affixed at the location in the illustration This label shows specifications related to ex haust emissions as required by federal law state law and Environment Canada 1 Vehicle Emission Control Information label 1 1 1RB71_EE book Page 3 Friday April 20 2012 8 38 AM ...

Page 189: ...usly manufactured The warranty set forth in Section A may be transferred to any subsequent owner provided that the period of warranty has not expired and that the CUSTOMER has complied with all terms and conditions of this warranty The subsequent owner has the responsibility for ensuring that a change of registration is sent to YAMAHA at the time of such transfer of ownership This transfer MUST be...

Page 190: ...ssed or implied including any warranty of performance merchantability or fitness for a particular purpose on the part of YAMAHA and any other obligation or liability on behalf of YAMAHA and the above warranty constitutes your sole remedy and the full liability of YAMAHA In no event shall YAMAHA be liable for special incidental or consequential damages howsoever caused whether by negligence or othe...

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