Yamaha YXR70FX Owner'S Manual Download | Manualshive

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8-58

EVU01010

Troubleshooting

Although Yamaha vehicles receive an inspec-
tion before shipment from the factory, trouble
may occur during operation. Any problem in
the fuel, compression, or ignition systems 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, but
they are often inferior. Consequently, they
have a shorter service life and can lead to ex-
pensive repair bills.

WARNING

When checking the fuel system, do not
smoke 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.

EE.book Page 58 Thursday, September 6, 2007 4:28 PM

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Summary of Contents for YXR70FX

Page 1: ...5B4 F8199 10 LIT 11626 21 58 READ THIS MANUAL CAREFULLY It contains important safety information YXR70FX OWNER S MANUAL DIC2342 ...

Page 2: ...EBU00776 ...

Page 3: ...f 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 operatin...

Page 4: ...fety 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 pro...

Page 5: ... 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 state off highway noise level and spark arrester laws and regulations YXR70FX OWNER S MANUAL 2007 by Yamaha Motor Corporation U S A 1st edition August 2007 All rights reserved Any reprinting or unauthorized use without the...

Page 6: ... Fuel tank cap 4 15 Doors 4 16 Seats 4 16 Seat belts 4 17 1 2 3 4 Glove compartment 4 18 Cup holders 4 18 Cargo bed 4 19 Front and rear shock absorber adjustment 4 21 Trailer hitch bracket and receiver 4 23 Auxiliary DC jack 4 23 FOR YOUR SAFETY PRE OPERATION CHECKS 5 1 Front and rear brakes 5 3 Fuel 5 4 Engine oil 5 6 Coolant 5 7 Final gear oil 5 7 Differential gear oil 5 7 Accelerator pedal 5 8 ...

Page 7: ...ucture 7 6 Seat belts 7 6 Doors 7 9 Passenger handholds 7 9 Seat and hip restraints 7 10 Floorboard 7 11 Steering wheel 7 11 LEARNING TO OPERATE YOUR VEHICLE 7 12 Personal protective equipment 7 12 Practice for new Rhino users 7 13 Getting ready to ride 7 14 Turning 7 15 Accelerating 7 16 Braking 7 16 Engine braking 7 16 Leaving the vehicle 7 17 Parking on a flat area 7 17 Parking on a slope 7 17 ...

Page 8: ...ive select lever box check hose 8 31 V belt cooling duct check hose 8 32 V belt case drain plug 8 32 Cleaning the spark arrester 8 33 Valve clearance 8 34 Brakes 8 34 Checking the front and rear brake pads 8 34 Checking the parking brake pads 8 35 Checking the brake fluid level 8 36 Brake fluid replacement 8 37 Checking the brake pedal 8 37 Parking brake lever free play adjustment 8 38 Brake light...

Page 9: ...t 8 56 Troubleshooting 8 58 Troubleshooting charts 8 59 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 NOISE REGULATION 11 4 MAINTENANCE RECORD 11 5 YAMAHA MOTOR CORPORATION U S A SIDE SIDE VEHICLE LIMITED WARRANTY 11 6 YAMAHA EXTENDED SERVICE Y E S 11 7 9 10 11 EE book Page 4 Thursday September 6 2007 4 28 PM ...

Page 10: ...1 1 EVU00060 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 3 2 3 4 9 0 5 8 7 6 5 EE book Page 1 Thursday September 6 2007 4 28 PM ...

Page 11: ...race 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 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 v...

Page 12: ... 91kgf cm2 13psi Never set or allow tire pressure to be below the minimum Tire may dislodge from rim Gross Vehicle Weight Rating 907 kg 2000 lb maximum including vehicle weight of operator passenger accessories cargo and if applicable trailer tongue weight YAMAHA 5B4 F1696 00 WARNING Keep hands body and other people away from pinch points when lowering bed Do not hold the cage frame while closing ...

Page 13: ...1 4 6 7 YAMAHA 5UG F151J 00 MAX 7 3 INCH 185MM EE book Page 4 Thursday September 6 2007 4 28 PM ...

Page 14: ...hecklist ü Head Helmet and eye protection ü Body Seatbelt and protective clothing ü Hands Inside vehicle and holding the handholds or steering wheel ü Feet On floorboard ready to brace and door closed EE book Page 5 Thursday September 6 2007 4 28 PM ...

Page 15: ...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 hands or feet outside of the vehicle for any reason Be Qualified and Responsible This vehicle is intended for use only by an operator 16 or older with a valid motor vehicle license Read the Owner s Manual To reduce risk of accidents and injury...

Page 16: ...he 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 instructions to reduce ...

Page 17: ...r and passenger must be able to put both feet flat on the floorboard while seated upright with their backs against the seat backs 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 b...

Page 18: ...ing objects can affect handling stability and risk of overturn 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 Secu...

Page 19: ...ruck 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 situa...

Page 20: ...n result in a rollover Avoid sideways sliding skidding or fishtailing and never do donuts Slow down before entering a turn and avoid hard braking in a turn When making tight turns from a stop or at slow speeds avoid sudden or hard accelera tion EE book Page 5 Thursday September 6 2007 4 28 PM ...

Page 21: ...ering wheel or handholds Do not put your hands or feet outside of the vehicle for any reason Your arm or leg could be crushed Do not try to stop a vehicle tipover using your arm or leg Do not operate this vehicle on any public street road or highway even if dirt or gravel Do not operate the vehicle in fast flowing water or water deeper than 33 cm 13 in If you must cross shallow slow moving water c...

Page 22: ...id hills and rough terrain Use extreme caution when towing or carrying a load on in clines Load trailer properly and use extra care when towing or pulling Do not tow or pull objects from any part of the vehicle other than the trailer hitch bracket or winch if installed EE book Page 7 Thursday September 6 2007 4 28 PM ...

Page 23: ...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 24: ...sold 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 Ins...

Page 25: ...he 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 43 8 46 for tire specifications and more information on replacing your tires EE book Page 10 Thursday September 6 2007 4 28 PM ...

Page 26: ... brake lights 10 Rear shock absorber assembly 11 Cargo bed release levers 12 Spark plug 13 Door C BA 0 8 9 14 Spark arrester 15 Passenger seat belt 16 Passenger seat 17 Passenger handhold 18 Engine oil dipstick 19 Battery 20 Fuses 21 Coolant reservoir 22 Radiator cap 23 Oil filter cartridge 24 Fuel tank cap H G F E I J K L A C M N D EE book Page 1 Thursday September 6 2007 4 28 PM ...

Page 27: ...erential gear lock switches 29 Multi function meter unit 30 Auxiliary DC jack 31 Drive select lever 32 Parking brake lever 33 Accelerator pedal 34 Brake pedal The vehicle you have purchased may differ slightly from those shown in the figures of this manual Q R O P S T W X G U V EE book Page 2 Thursday September 6 2007 4 28 PM ...

Page 28: ...ied with power and the headlights and tail lights come on when the light switch is 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 EE book Page 1 Thursday September 6 2007 4 28 PM ...

Page 29: ...ear lock indica tor light DIFF LOCK This indicator light and the On Command dif ferential gear lock indicator in the display come on when the On Command differential gear lock switch is set to the LOCK position When the switch is set to LOCK the On Command differential gear lock indicator light will flash until the differential gear is locked EVU01140 Low range indicator light L This indicator lig...

Page 30: ... 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 in the On Command four wheel drive indicator also comes on when the On Command differential gear lock switch is set to the LOCK position Due to the synchronizing mechanism in the differential gear case the four wheel drive indicator may not come u...

Page 31: ...e may overheat if the vehicle is overloaded If this happens reduce the load to specification After restarting make sure that the light is out Continuous use while the light is on may cause damage to the engine 5B410003 Engine trouble warning light This warning light comes on or flashes when an electrical circuit monitoring the engine is defective When this occurs have a Yamaha dealer check the sel...

Page 32: ...uipped with the following a speedometer which shows the riding speed an odometer which shows the total dis tance traveled two tripmeters which show the distance traveled since they were last set to zero a clock an hour meter which shows the total time the key has been turned to ON a voltage display which shows the battery voltage a fuel meter a self diagnosis device 1 2 3 4 5 6 7 8 EE book Page 5 ...

Page 33: ...DO To reset a tripmeter select it by pushing the TRIP ODO button and then hold the TRIP ODO button for at least three seconds The tripmeters can be used to estimate the dis tance that can be traveled with a full tank of fu el This information will enable you to plan future fuel stops To switch the display between mph and km h push and hold the TRIP ODO button while turning the key to ON 1 2 EE boo...

Page 34: ...e hour meter mode HOUR and the voltage display mode btry in the following order CLOCK HOUR btry CLOCK To set the clock 1 Set the display to the clock 2 Push the button until the clock starts flashing 3 Set the hours by pushing the H button 4 Set the minutes by pushing the M but ton 5 Push the button and then re lease it to start the clock 4 1 2 3 EE book Page 7 Thursday September 6 2007 4 28 PM ...

Page 35: ...f the battery voltage is less than 10 volts LO is displayed and if the voltage is above 16 volts HI is displayed NOTICE If the voltage display indicates LO or HI there may be trouble with the battery charging circuit or the battery may be faulty If LO or HI appears in the dis play have a Yamaha dealer check or repair the vehicle EE book Page 8 Thursday September 6 2007 4 28 PM ...

Page 36: ...el level decreases When the E segment disappears and the fuel level warning indicator flashes refuel as soon as possible TIP This fuel meter is equipped with a self diagno sis system If the electrical circuit is defective all the display segments and fuel level warn ing indicator will start flashing If this occurs have a Yamaha dealer check the electrical circuit 1 2 3 EE book Page 9 Thursday Sept...

Page 37: ...ome on or flash and then the multi function display will indicate a two digit error code If the multi function display indicates such an error code note the code number and then have a Yamaha dealer check the vehicle NOTICE If the multi function display indicates an error code the vehicle should be checked as soon as possible in order to avoid en gine damage 1 EE book Page 10 Thursday September 6 ...

Page 38: ...eam and the taillights Set the switch to OFF to turn off all the lights NOTICE Do not use the headlights with the engine turned off for an extended period of time The battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it L H L H L H EE book Page 11 Thursday September 6 2007 4 28 PM ...

Page 39: ...switch 4WD LOCK Select the appropriate drive accord ing to terrain and conditions Two wheel drive 2WD Power is sup plied to the rear wheels only Four wheel drive 4WD Power is sup plied to the rear and front wheels Four wheel drive with the differential gear locked 4WD LOCK Power is supplied to the rear and front wheels with the differ ential gear locked Unlike the 4WD mode all wheels turn at the s...

Page 40: ...essure returns the pedal to the rest position when released Al ways check that the accelerator pedal returns normally before starting the engine 1 Accelerator pedal EVU00270 Brake pedal Press the brake pedal to slow or stop the ve hicle 1 Brake pedal EE book Page 13 Thursday September 6 2007 4 28 PM ...

Page 41: ...oving 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 pressure helps return the lever to the released position 1 Parking brake lever 2 Release button 1 2 EE book Page 14 Thursday September 6 2007 4 28 PM ...

Page 42: ... cle into the low high neutral and reverse po sitions Refer to pages 6 4 6 5 for the drive select lever operation 1 Drive select lever EVU00300 Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap 1 EE book Page 15 Thursday September 6 2007 4 28 PM ...

Page 43: ...urely latched Be sure the door is SECURELY 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 EE book Page 16 Thursday September 6 2007 4 28 PM ...

Page 44: ... WARNING 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 8 for more information EE book Page 17 Thursday September 6 2007 4 28 PM ...

Page 45: ...re placing it in a cup holder Some plastic bottles may not fit into the cup holders depending on their size and shape WARNING While the vehicle is moving do not place any open or glass containers in the cup holders otherwise the con tents may spill and the glass contain ers may break Do not place any items other than cups or plastic bottles in the cup holders otherwise they may be thrown about and...

Page 46: ...holder 1 2 Cup holder 2 EVU00351 Cargo bed 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 EE book Page 19 Thursday September 6 2007 4 28 PM ...

Page 47: ...se Place the tailgate in the original position and then hook the latches Lifting and lowering the cargo bed 1 Cargo bed release lever To lift Push down the cargo bed release lever on the left or right side of the vehicle and then slowly lift up the cargo bed until it stops EE book Page 20 Thursday September 6 2007 4 28 PM ...

Page 48: ...conditions You can reduce preload for a softer ride or increase preload if frequent bottoming occurs or when carrying loads WARNING Always adjust the shock absorbers on the left and right sides to the same setting Un even adjustment can cause poor handling and loss of stability which could lead to an accident NOTICE Frequent or severe bottoming can cause increased wear or damage to the vehicle The...

Page 49: ...o decrease the spring preload turn the ad justing ring in direction b 1 Spring preload adjusting ring 2 Position indicator A special wrench can be obtained at a Yamaha dealer to make this adjustment 1 Special wrench Standard position B A Minimum soft E Maximum hard EE book Page 22 Thursday September 6 2007 4 28 PM ...

Page 50: ...cket 2 Receiver EVU00380 Auxiliary DC jack The auxiliary DC jack is located at the right side of the front panel The auxiliary DC jack can be used for suitable work lights radios etc The auxiliary DC jack should only be used when the engine is running 1 Auxiliary DC jack cap 1 Set the light switch to OFF 2 Start the engine See pages 6 2 6 3 3 Open the auxiliary DC jack cap and then insert the acce...

Page 51: ... circuit and cause the fuse to blow If accessories are used without the en gine running the battery will lose its charge and engine starting may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A EE book Page 24 Thursday September 6 2007 4 28 P...

Page 52: ...e 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 34 8 37 8 39 8 40 Parking brake Check for proper operation condition and free play 8 38 8 39 Fuel Check fuel level Fil...

Page 53: ...Check for proper operation and belt wear 5 8 Steering Check for proper operation 5 8 Fittings and fasteners Check all fittings and fasteners 5 8 Lights and switches Check for proper operation 5 9 8 53 8 57 Wheels and tires Check tire pressure and for wear and damage 5 9 5 11 8 43 8 46 Axle boots Check for damage 8 23 ITEM ROUTINE PAGE EE book Page 2 Thursday September 6 2007 4 28 PM ...

Page 54: ... 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 they...

Page 55: ...e fuel 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 ...

Page 56: ...he cap tightened before driving the vehicle Always place a portable gas container on the ground before filling it Before removing the container cap touch the container with the gas dispenser nozzle Keep gas 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 discharg...

Page 57: ... not mix any chemical addi tives with oil Do not use oils with a die sel specification of CD or oils of a higher quality than specified In addi tion do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material en ters the crankcase 1 CD specification 2 ENERGY CONSERVING II Recommended engine oil type and quantity See page 10 2 1 2 EE book Page 6 Thursday September 6 20...

Page 58: ... the engine You may use soft water if you can not get distilled water EVU00430 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 16 8 18 for details If desired an SAE 80W90 hypoid gear oil may be used for all conditions TIP TIP GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils may also be used EVU00440 Differential gear o...

Page 59: ... dealer repair as necessary for proper operation A crash can damage the restraint systems 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 EVU01230 Steering Par...

Page 60: ...and you could be unable to control the vehicle EVU00500 Tires Check tire pressure regularly to make sure it is at the recommended specifications Also check for wear and damage EVU00510 Tire pressure Use the tire pressure gauge to check and ad just tire pressures when the tires are cold Tire pressures must be equal on both sides WARNING Operation of this vehicle with improper tire pressure may caus...

Page 61: ...e the second reading Dust or dirt in the gauge could cause the first reading to be incorrect 1 Tire pressure gauge Recommended pressure Minimum Maximum Front 70 kPa 0 70 kgf cm2 10 psi 63 kPa 0 63 kgf cm2 9 psi 77 kPa 0 77 kgf cm2 11 psi Rear 98 kPa 0 98 kgf cm2 14 psi 91 kPa 0 91 kgf cm2 13 psi 105 kPa 1 05 kgf cm2 15 psi EE book Page 10 Thursday September 6 2007 4 28 PM ...

Page 62: ...5 11 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 EE book Page 11 Thursday September 6 2007 4 28 PM ...

Page 63: ...eriod between zero 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 ati...

Page 64: ... 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 main switch 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 page 4 4 for the corresponding warning light circuit check 2 Apply the brake...

Page 65: ...seconds 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 or damage to the electric starter may result TIP...

Page 66: ...cur Shifting neutral to high and high to low 1 Stop the vehicle 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 3 Release the brake pedal and press the accelerator pedal gradually EE book Page 4 Thursday September 6 2007...

Page 67: ... versa by moving the drive select lever along 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 4 Check behind the vehicle for people or obs...

Page 68: ...changing between 2WD and 4WD or 4WD and 4WD LOCK DIFF LOCK 1 Differential gear lock lever 2 On Command four wheel drive switch 2WD 4WD 2WD 4WD To change from 2WD to 4WD stop the vehi cle and then set the switch to 4WD When the vehicle is in 4WD the four wheel drive in dicator will come on in the multi function display To change from 4WD to 2WD stop the vehicle be sure the differential gear lock le...

Page 69: ...locked the differential gear lock indicator light DIFF LOCK will come on along with the differential gear lock indica tor in the multi function display To re lease the differential gear lock stop the vehicle and set the switch to 4WD When the switch is set to LOCK the dif ferential gear lock indicator and indicator light will flash until the differential gear is locked When the indicator and indic...

Page 70: ...speed to be limited until en gagement is complete 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 17 7 18 for more information on parking and parking on a slope EE book Page 8 Thursday September 6 2007 4 28 PM ...

Page 71: ...ehicle see box or vehi cle labeling Keep weight in the cargo bed centered side to 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 go...

Page 72: ... load in the trailer if necessary to reduce the weight on hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum vehicle load limit MAXIMUM LOADING LIMIT Vehicle loading limit total weight of cargo operator passenger and accessories and tongue weight 367 kg 809 lb Cargo bed 181 kg 400 lb Trailer hitch Pulling load total weight of trailer and cargo 550 kg 1 21...

Page 73: ... Turn gradually and go slowly Pulling something other than a trailer Yamaha recommends that loads be transport ed in the bed or in a trailer If you need to move an object a short distance use a winch and follow the winch manufacturer s instruc tions If you choose to use something other than a winch use extreme caution follow the manu facturer s instructions for that product and only attach to the ...

Page 74: ...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 75: ...s 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 safet...

Page 76: ...n the vehicle is not in use to prevent unauthorized use of the machine Parents Many states have implemented new motor vehicle licensing requirements for young driv ers These requirements are in response to the disproportionately high rate of crashes in volving youthful drivers As with automobiles to promote safe driving behaviors you should supervise younger drivers and consider set ting rules and...

Page 77: ...both feet on the floorboard while seated upright with his her back against the seat back Allow only one passenger in the vehicle and only in the passenger seat Do not car ry any other passengers Do not carry pas sengers in the cargo bed Do not allow someone to ride as a passen ger who has been using drugs or alcohol Occupant protection system 1 Passenger handhold 2 Seat belt 3 Door 1 Door 1 2 2 3 ...

Page 78: ... injury or death You are re sponsible for any such changes to the ve hicle The Rhino comes with a variety of features 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 1 EE book Page 5 Thursday September 6...

Page 79: ... the 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 driv...

Page 80: ...nt systems 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...

Page 81: ... Pull up on the latch plate to make sure it is secure 1 Buckle 2 Latch plate 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 5 Position the shoulder belt over your shoulder and across your chest The shoulder belt should fit against your chest If it is loose pull the belt out all the way and then let it retract 6 To release the bu...

Page 82: ...shed against outside objects or the ground during a roll over Passenger handholds Handholds are provided to grip during opera tion to maintain proper position and balance Holding onto the handholds helps to reduce the likelihood that 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 l...

Page 83: ... designed to help keep you in the vehicle Do not hold onto hip restraint bar when the vehicle is moving Your hand or arm may be struck by objects or crushed against outside objects or the ground during a rollover EE book Page 10 Thursday September 6 2007 4 28 PM ...

Page 84: ...your palms on the out side of the steering wheel Similar to other off road vehicles if the Rhino hits a deep rut or large 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 t...

Page 85: ...protective equipment 1 Approved motorcycle helmet 2 Eye protection 3 Long sleeved shirt or jacket 4 Gloves 5 Long pants 6 Over the ankle boots CORRECT GRIP EXAMPLE INCORRECT GRIP EXAMPLE 1 2 3 4 5 6 EE book Page 12 Thursday September 6 2007 4 28 PM ...

Page 86: ...he vehicle to reduce the risk of a serious ac cident or injury Eye protection such as a face shield or goggles may reduce the risk of for eign material getting in your eyes and help prevent loss of vision Practice for new Rhino users You should become familiar with the perfor mance characteristics of the vehicle in a large flat area that is free of obstacles and other ve hicles Practice controllin...

Page 87: ...teering may take more effort in 4WD with the differential locked DIFF LOCK Also practice driving in re verse Take the time to learn basic operation of the vehicle before attempting more difficult ma neuvers Getting ready to ride Perform the Pre Operation Checks on pages 5 1 5 11 Follow the instructions starting on pages 6 2 6 3 to start the engine EE book Page 14 Thursday September 6 2007 4 28 PM ...

Page 88: ...l during a turn steer into the direction of the slide if possible and gradually let off the accelerator pedal to regain directional control and avoid rollover For example if you feel the back of the vehicle start to slide to your right steer to the right If you think or feel that the vehicle may tip or roll keep your body completely inside the pro tective structure of the vehicle Brace yourself by...

Page 89: ...ng 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 re ducing control of the vehicle 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 particu larly on loose surfa...

Page 90: ...n 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 4WD Diff Lock before stopping the engine If you park on a hill that is too steep the vehi cle may roll...

Page 91: ...ay 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 veh...

Page 92: ...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 93: ...m but not so fast that you can not 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 a...

Page 94: ... If you begin to go too fast apply the brakes gently Avoid hard application of the brakes which could cause the vehicle 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 care...

Page 95: ... 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 wat...

Page 96: ...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 4WD 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 the slide if p...

Page 97: ...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 98: ...es incor rectly may increase your risk of injury or death 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 Runni...

Page 99: ...e 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...

Page 100: ...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 EE book Page 3 Thursday September 6 2007 4 28 PM ...

Page 101: ... 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 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 plug Check condition Adjust gap and clean Replace ...

Page 102: ...f necessary 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 ...

Page 103: ...acked 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 Stabilizer bushings Check for cracks or damage Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6...

Page 104: ...8 7 EVU00680 Hood To open Unhook the hood latches and then slowly tilt the hood up until it stops 1 Latch 2 1 Hood EE book Page 7 Thursday September 6 2007 4 28 PM ...

Page 105: ...2 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 EE book Page 8 Thursday September 6 2007 4 28 PM ...

Page 106: ...low 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 buckles 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 bottom of the parking brake lever boot and the drive select lever boot fi...

Page 107: ...k the vehicle 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 If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil settles for an accurate reading 4 Remove the dipstick and then wipe it off with a clean r...

Page 108: ...e minimum 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 Reinstall the console 1 2 EE book Page 11 Thursday September 6 2007 4 28 PM ...

Page 109: ...or several minutes 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 to drain the oil from the crankcase 1 Engine oil drain bolt Skip steps 6 10 if the oil filter cartridge is not being replaced 6 Lift the cargo bed up See pages 4 20 4 21 for cargo bed lifting and lowering procedures 1 EE book Page 12 T...

Page 110: ...il leak age may occur 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 Make sure the O ring is seated properly 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 lbf ...

Page 111: ...pletely into the oil filler hole NOTICE Be sure to wipe off spilled oil on any parts after the engine and ex haust 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 page 10 2 Oil quantity Without oil filter cartridge replacement 2 00 L 1 76 Imp qt 2 11 US qt With oil filter cartridge replacement 2 10 L 1 85 Imp qt 2 22 US qt EE...

Page 112: ... CONSERVING II or higher Make sure that no foreign material en ters the crankcase 1 CD specification 2 ENERGY CONSERVING II 13 Start the engine and then let it idle for several minutes while 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 ten min utes and then check the oil level and cor rect it if necessary...

Page 113: ...ar oil filler bolt 2 Final gear oil 3 Correct oil level 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level NOTICE Be sure no foreign material enters the final gear case 4 Reinstall the oil filler bolt and then tight en it to the specified torque 1 2 1 3 Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf ...

Page 114: ...t and collar 7 3 Place a container under the final gear case to collect the used oil 4 Remove the oil filler bolt and the drain bolt to drain the oil 1 Final gear oil drain bolt 5 Reinstall the drain bolt and then tighten it to the specified torque 2 1 2 Tightening torque Final gear oil drain bolt 20 Nm 2 0 m kgf 14 ft lbf 1 EE book Page 17 Thursday September 6 2007 4 28 PM ...

Page 115: ...il leakage is found check for the cause 9 Install the final gear case guard by install ing the bolts and the collars and then tightening the bolts to the specified torque Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 25 L 0 22 Imp qt 0 26 US qt Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft lbf Tightening torque Final gear case guard bolt 7 Nm 0 7 m kgf 5 1 ft ...

Page 116: ...terial enters the differential gear case 1 Differential gear oil filler bolt 2 Correct oil level 3 Differential gear oil 3 Reinstall the differential gear oil filler bolt and then tighten it to the specified torque Changing the differential gear oil 1 Park the vehicle on a level surface 2 Remove the differential gear case guard by removing the bolts and the collars 1 Differential gear case guard 2...

Page 117: ...he recommended oil NOTICE Be sure no foreign material enters the differential gear case 7 Reinstall the differential gear oil filler bolt and then tighten it to the specified torque 8 Check for oil leakage If oil leakage is found check for the cause Tightening torque Differential gear oil drain bolt 9 8 Nm 0 98 m kgf 7 1 ft lbf 1 Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 18 L ...

Page 118: ...evel 1 Park the vehicle on a level surface 2 Check the coolant level in the coolant reservoir when the engine is cold as the coolant level varies with engine tempera ture The coolant should be between the minimum and maximum level marks 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark Tightening torque Differential gear case guard bolt 7 Nm 0 7 m kgf 5 1 ft lbf 1 2 3 EE book Page ...

Page 119: ... the coolant If water is used instead of coolant have a Yamaha deal er check the antifreeze content of the 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 120: ...ots Check the protective boots for holes or tears If any damage is found have them replaced by a Yamaha dealer 1 Front axle boot 2 each side 1 Rear axle boot 2 each side 1 1 EE book Page 23 Thursday September 6 2007 4 28 PM ...

Page 121: ...ole 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 Spark plug wrench 1 1 EE book Page 24 Thursday September 6 2007 4 28 PM ...

Page 122: ... 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 Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification a Spark plug gap 2 Clean the surface of the spark plug gas ket and its mating su...

Page 123: ... torque as soon as possible 4 Install the spark plug cap 5 Reinstall the console 5B410016 Cleaning the air filter element There is a check hose at the bottom of the 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 Tightening torque Spark plug 1...

Page 124: ...e hood See pages 8 7 8 8 for hood opening and closing procedures 2 Remove the air intake duct shroud by re moving the quick fastener screws 1 Quick fastener screw 2 2 Air intake duct shroud 1 1 2 EE book Page 27 Thursday September 6 2007 4 28 PM ...

Page 125: ...e air filter case cover by un hooking the holders 1 Air filter case cover holder 5 2 Air filter case cover 4 Remove the air filter element 1 Air filter element 1 1 2 1 EE book Page 28 Thursday September 6 2007 4 28 PM ...

Page 126: ...parts cleaning solvent WARNING Using gasoline or other flammable solvents to clean the air fil ter element can cause a fire or explo sion which could lead to serious injury 7 Squeeze the excess solvent out of the sponge material NOTICE Do not twist the sponge material when squeezing it 2 1 EE book Page 29 Thursday September 6 2007 4 28 PM ...

Page 127: ...aha foam air filter oil or other quality liquid foam air filter oil not spray type to the sponge material The sponge material should be wet but not dripping 12 Pull the sponge material over its frame 13 Reinstall the air filter element 14 Insert the projections on the air filter case cover into the holders on the air filter case and then install the air filter case cover by hooking the holders ont...

Page 128: ...e NOTICE Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally op eration without the air filter element will af fect the fuel injection system with subsequent poor performance and possi ble engine overheating 2P512001 Drive select lever box check hose The drive select lever box check h...

Page 129: ...elt case drain plug is located under the driver seat See pages 4 16 4 17 for seat removal and installation procedures After riding in water deep enough to allow wa ter to enter the V belt case remove the drain plug to drain any water from the case If water drains from the V belt case after re moving the drain plug have a Yamaha dealer inspect the vehicle as the water may affect other engine parts ...

Page 130: ...2 Remove the tailpipe by pulling it out of the muffler and then remove the gasket 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon depos its from the spark arrester portion of the tailpipe and inside of the tailpipe housing 1 Tailpipe 2 Spark arrester 3 Gasket 4 Install the gasket and then insert the tailpipe into the muffler and align the bolt holes 5 Install the bolts an...

Page 131: ...g with improperly serviced or ad justed brakes could lead to a loss in brak ing ability and an accident 5B410019 Checking the front and rear brake pads Each brake pad is provided with 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 ...

Page 132: ...d is provided with two wear in dicator 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 a wear indicator groove almost appears have a Yamaha deal er replace the brake pads as a set 1 Brake pad wear indicator groove 1 1 EE book Page 35 Thursday September...

Page 133: ... under the hood See pages 8 7 8 8 for hood opening and closing procedures Observe these precautions When checking the fluid level make sure the top of the brake fluid reservoir is level Use only the recommended quality brake fluid Otherwise the rubber seals may de teriorate causing leakage and poor braking performance Refill with the same type of brake fluid Mix ing fluids may result in a harmful ...

Page 134: ...ance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every four years EVU01220 Checking the brake pedal Have a Yamaha dealer check the brakes at the intervals specified in the periodic mainte nance and lubrication chart There should be no free play in the brake pedal The brakes should operate smoothly and there should be no brake drag If the brakes...

Page 135: ...cedures 3 Remove the console See page 8 9 for console removal and installation proce dures 4 Check the parking brake lever free play The maximum free play is equal to one click of the parking brake lever If neces sary adjust the free play as follows a Parking brake lever free play 5 The parking brake lever must be re leased when checking and adjusting the parking brake lever free play 6 Loosen the...

Page 136: ...s properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch 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 t...

Page 137: ... control cables frequently and re place damaged cables Corrosion can result when 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 1 a b 2 Recommended lubricant Lithium soap based grease EE book Page 40 Thursday September 6 2007 4 28 PM ...

Page 138: ...ate the pivoting parts 5B410021 Rear knuckle upper and lower pivot lubrication 1 Remove the lower arm protector by re moving the bolts 1 Bolt 3 2 Lower arm protector Recommended lubricant Lithium soap based grease 1 2 EE book Page 41 Thursday September 6 2007 4 28 PM ...

Page 139: ...gun 3 Install the lower arm protector by install ing the bolts and tightening them to the specified torque Recommended lubricant Lithium soap based grease Tightening torque Lower arm protector 7 Nm 0 7 m kgf 5 1 ft lbf EE book Page 42 Thursday September 6 2007 4 28 PM ...

Page 140: ...EVU00930 Wheel removal 1 Loosen the wheel nuts 2 Elevate the vehicle and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Nut 4 Recommended lubricant Lithium soap based grease EE book Page 43 Thursday September 6 2007 4 28 PM ...

Page 141: ... 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 handling and stability This can cause a loss of control The tires listed below have been approved by Yamaha Motor Manufacturing Corporation of America for this model Manufacturer Size ...

Page 142: ... 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 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 1 Arrow mark 1 Tapered nut EE book Page 45 Thursday September 6 2007 4 28 PM ...

Page 143: ...e or add distilled water in the bat tery If the battery seems to have discharged con sult a Yamaha dealer NOTICE Do not try to remove the sealing caps of the battery cells You may damage the bat tery Wheel nut torque Front 55 Nm 5 5 m kgf 40 ft lbf Rear 55 Nm 5 5 m kgf 40 ft lbf EE book Page 46 Thursday September 6 2007 4 28 PM ...

Page 144: ...RNING Batteries may produce explosive gases Ventilate when charging or using in a closed space Keep batteries away from sparks flames cigarettes or other sourc es of ignition EVU00960 Battery maintenance 1 If the vehicle will not be used for a month or longer remove the battery and store it in a cool dark place Completely re charge the battery before reinstallation NOTICE _ A special battery charg...

Page 145: ...ARNING To avoid battery explosion and or serious damage to the electrical system Do not connect the negative lead of the jumper cable to the negative termi nal of the battery Do not touch the positive lead of the jumper cable to the negative lead Do not reverse the polarity of the jumper cables when connecting to the batteries 2 1 EE book Page 48 Thursday September 6 2007 4 28 PM ...

Page 146: ... removal and installation proce dures 5 Using a charged 12 volt battery connect the positive lead of the jumper cable to the positive terminal of the battery in the vehicle and the other end of the positive lead to the positive terminal of the charged battery 1 Jumper cable positive lead 6 Connect the negative lead of the jumper cable to the negative terminal of the charged battery and the other e...

Page 147: ...nect 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 9 Reinstall the console 10 Reinstall the battery compartment cover 11 Close the hood 1 EE book Page 50 Thursday September 6 2007 4 28 PM ...

Page 148: ... by lifting it up and pulling it out 1 Quick fastener screw 2 2 Battery compartment cover Turn the key to OFF and turn off the electri cal circuit in question NOTICE To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 3 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Always use a fuse of the specified amperage Never ...

Page 149: ...cal circuit in question to check if the device operates 5 If the fuse blows again immediately have a Yamaha dealer check the electrical system 6 Reinstall the battery compartment cover by installing the quick fastener screws 7 Close the hood 1 2 3 7 9 4 56 8 A 0 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...

Page 150: ...hood up 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 3 Remove the headlight bulb holder cover by pulling it off 1 Headlight bulb holder cover EE book Page 53 Thursday September 6 2007 4 28 PM ...

Page 151: ...se 1 Headlight bulb holder 5 Wait for the headlight bulb to cool before touching or removing it Remove the bulb by pulling it out 6 Insert a new headlight bulb into the bulb holder by pushing it in 1 Do not touch the glass part of the bulb EE book Page 54 Thursday September 6 2007 4 28 PM ...

Page 152: ...ly fitted over the bulb holder and seated properly 8 Close the hood 9 Adjust the headlight beam if necessary EVU00990 Headlight beam adjustment NOTICE It is advisable to have a Yamaha dealer make this adjustment To raise the beam turn the adjusting screw in direction a To lower the beam turn the adjusting screw in direction b 1 Headlight beam adjusting screw EE book Page 55 Thursday September 6 20...

Page 153: ...ace it as follows 1 Remove the quick fastener screws and bolts from panel A if replacing the left tail brake light bulb or panel B if replac ing the right tail brake light bulb 1 Panel A 1 Panel B 1 Quick fastener screw 8 2 Bolt 2 3 Panel A EE book Page 56 Thursday September 6 2007 4 28 PM ...

Page 154: ...b 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 7 Reinstall the bulb holder together with the bulb by turning it clockwise 8 Install the panel 9 Lower the cargo bed 10 Reinstall the quick fastener screws and bolts and then tighten the bolts to the specified torque Tightening torque Panel bolt 7 Nm 0 7 m kg...

Page 155: ...s 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 but they are often inferior Consequently they have a shorter service life and can lead to ex pensive repair bills WARNING When checking the fuel system do not smoke and make sure there are no open flames or spark...

Page 156: ...er to inspect 3 Ignition 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 En...

Page 157: ...ed 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 t...

Page 158: ... 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 159: ...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 160: ... prevent moisture 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 st...

Page 161: ...heelbase 1 910 mm 75 2 in Ground clearance 280 mm 11 0 in Minimum turning radius 3 900 mm 154 in Basic weight With oil and full fuel tank 540 0 kg 1 190 lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 686 0 cm3 Bore stroke 102 0 84 0 mm 4 02 3 31 in Compression ratio 9 20 1 Starting system Electric starter Lubrication system Wet ...

Page 162: ...0 90 110 130 F 20 10 0 10 20 30 40 50 C YAMALUBE 4 10W 40 or SAE 10W 40 YAMALUBE 4 CW 5W 30 or SAE 5W 30 YAMALUBE 4 20W 50 or SAE 20W 50 NOTICE In order to prevent clutch slippage since the en gine oil also lubricates the clutch do not mix any chemical additives with oil Do not use oils with a diesel specification of CD or oils of a higher qual ity than specified In addition do not use oils la bel...

Page 163: ...ty including all routes 2 35 L 2 07 Imp qt 2 48 US qt Air filter Air filter element Wet element Fuel Type Unleaded gasoline only Fuel tank capacity 30 0 L 6 60 lmp gal 7 93 US gal Throttle body Type quantity 41EHS 1 Manufacturer MIKUNI Spark plug Type manufacturer CPR7EA 9 NGK Spark plug gap 0 8 0 9 mm 0 031 0 035 in Clutch type Wet centrifugal automatic Model YXR70FX EE book Page 3 Thursday Septe...

Page 164: ...hand operation Reverse gear 23 14 28 23 2 000 Sub transmission ratio low 31 16 1 938 high 31 21 1 476 Chassis Frame type Steel tube frame Caster angle 5 0 Trail 26 0 mm 1 02 in Tire Type Tubeless Size front 25 8 12NHS rear 25 10 12NHS Wheel Type Panel wheel Cast wheel Special Edition model Rim size front 12 6 0AT rear 12 7 5AT Model YXR70FX EE book Page 4 Thursday September 6 2007 4 28 PM ...

Page 165: ...rber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 185 mm 7 3 in Rear wheel travel 185 mm 7 3 in Electrical Ignition system Transistorized coil ignition digital Generator system AC magneto Battery type U1L 11 Battery capacity 12 V 28 0 Ah Headlight type Krypton bulb Model YXR70FX EE book Page 5 Thursday September 6 2007 4 28 ...

Page 166: ...ator 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 indicator LCD On Command differential gear lock indicator light LED High range indicator light LED Low range indicator light LED Model YXR70FX EE book Page 6 Thursday September 6 2007 4 28 PM ...

Page 167: ...em fuse 10 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 10 0 A Four wheel drive motor fuse 10 0 A Signaling system fuse 10 0 A Backup fuse 10 0 A Radiator fan fuse 25 0 A Model YXR70FX EE book Page 7 Thursday September 6 2007 4 28 PM ...

Page 168: ... 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 EE book Page 1 Thursday September 6 2007 4 28 PM ...

Page 169: ...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 EE book Page 2 Thursday September 6 2007 4 28 PM ...

Page 170: ...s affixed to the frame under the driver seat Record the information on this label in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label 1 EE book Page 3 Thursday September 6 2007 4 28 PM ...

Page 171: ...pose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system Mu...

Page 172: ...ance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1 200 750 75 6 2 400 1 500 150 12 4 800 3 000 300 18 7 200 4 500 450 24 9 600 6 000 600 30 12 000 7 500 750 36 14 400 9 000 900 42 16 800 10 500 1 050 48 19 200 12 000 1 200 54 21 600 13 500 1 350 60 24 000 15 0...

Page 173: ... any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corporation U S A SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance such as spark ...

Page 174: ...11 7 EVU01090 YAMAHA EXTENDED SERVICE Y E S EE book Page 7 Thursday September 6 2007 4 28 PM ...

Page 175: ...11 8 EE book Page 8 Thursday September 6 2007 4 28 PM ...

Page 176: ...B6 yoko fm Page 1 Wednesday March 8 2006 10 46 AM ...

Page 177: ...B6 yoko fm Page 1 Wednesday March 8 2006 10 46 AM ...

Page 178: ...PRINTED IN USA 2007 09 6 5 1 CR E DIC2342 YAMAHA MOTOR CO LTD ...

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