Yamaha YXR7FD Owner'S Manual Download

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5-2

Final gear oil/
Differential gear oil

• Check for leakage.

5-7, 8-15–8-21

Accelerator pedal

• Check for proper accelerator pedal operation.

5-7

Seat belts

• Check for proper operation and belt 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

1RB7A_EE.book Page 2 Tuesday, April 24, 2012 9:07 AM

Summary of Contents for YXR7FD

Page 1: ...1RB F8199 7A YXR7FD YXR7FSPD YXR700FAD OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information DIC183 ...

Page 2: ...nlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Eiji Kato Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application of the essential health and safety requirements stated in the Directives of EEC the following standards and or technical specifications were consulted Title and or number an...

Page 3: ...anding 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 ...

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: ...n force before choosing where to operate this vehicle It is illegal to operate this vehicle on public lands where vehicles its size are prohibited YXR7FD YXR7FSPD YXR700FAD OWNER S MANUAL 2012 by Yamaha Motor Co Ltd 1st edition March 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in U S A 1RB7A_EE bo...

Page 6: ...cap 4 17 Doors 4 17 Seats 4 18 1 2 3 4 Seat belts 4 19 Glove compartment 4 19 Cup holders 4 20 Cargo bed 4 21 Adjusting the front and rear shock absorber assemblies YXR7FD YXR700FAD 4 23 Adjusting the front shock absorber assemblies YXR7FSPD 4 25 Adjusting the rear shock absorber assemblies YXR7FSPD 4 30 Trailer hitch bracket and receiver 4 36 Auxiliary DC jack 4 36 FOR YOUR SAFETY PRE OPERATION C...

Page 7: ... requirements 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...

Page 8: ...8 Coolant 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 replace...

Page 9: ...p starting 8 51 Fuse replacement 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 9 10 11 1RB7A_EE book Page 4 Tuesday April 24 2012 9 07 AM ...

Page 10: ...1 1 EVU00060 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 2 5 3 4 6 8 7 1 B 187 9 C I L J K D A 0 32 1 F G H E 1RB7A_EE book Page 1 Tuesday April 24 2012 9 07 AM ...

Page 11: ...ontain important 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 1YXR7FSPD 3 2For Europe 1RB7A_EE book Page 2 Tuesday April 24 2012 9 07 AM ...

Page 12: ...orboards 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 5YXR7FD YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN 2012 YXR700F 30 0 kW 540 kg 1RB F155A 10 5YXR7FSPD YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN 2012 YXR700F 30 0 kW 548 kg 1RB F155A 00 6For Europe 1RB7A_EE book Page 3 Tuesday April 24 2012 9 07 AM ...

Page 13: ...1 4 7 8For Europe 9For Europe 0For Europe 1RB7A_EE book Page 4 Tuesday April 24 2012 9 07 AM ...

Page 14: ...rushed 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 1RB7A_EE book Page 5 Tuesday April 24 2012 9 07 AM ...

Page 15: ...1 6 CFor Europe D 1RB7A_EE book Page 6 Tuesday April 24 2012 9 07 AM ...

Page 16: ...1 7 EFor Europe F YAMAHA 5UG F151J 00 MAX 7 3 INCH 185MM 1RB7A_EE book Page 7 Tuesday April 24 2012 9 07 AM ...

Page 17: ...1 8 GFor Europe H 1RB7A_EE book Page 8 Tuesday April 24 2012 9 07 AM ...

Page 18: ...1 9 IFor Europe J K 1RB7A_EE book Page 9 Tuesday April 24 2012 9 07 AM ...

Page 19: ...1 10 LFor Europe 1RB7A_EE book Page 10 Tuesday April 24 2012 9 07 AM ...

Page 20: ...e 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 y...

Page 21: ...lts properly Both driver and passenger must 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 g...

Page 22: ...ects 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 23: ...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 24: ...ing 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 1RB7A_EE...

Page 25: ... 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 l...

Page 26: ...vels 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 in...

Page 27: ...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 28: ...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 1RB7A_EE book Page 9 Tuesday April 24 2012 9 07 AM ...

Page 29: ...Tail brake lights 10 Rear shock absorber assembly 11 Cargo bed release levers 12 Spark plug 13 Door 14 Spark arrester 15 Passenger seat belt 16 Sun top YXR7FSPD 17 Passenger seat 18 Passenger handholds 19 Engine oil dipstick 20 Battery 21 Fuses 22 Coolant reservoir 23 Radiator cap 24 Oil filter cartridge 25 Fuel tank cap C BA 0 8 9 I H G F E J K L M A C N O D 1RB7A_EE book Page 1 Tuesday April 24 ...

Page 30: ...n meter unit 31 Helmet Seat belt indicator light 32 Auxiliary DC jack 33 Drive select lever 34 Parking brake lever 35 Accelerator pedal 36 Brake pedal 37 Horn switch The vehicle you have purchased may differ slightly from those shown in the figures of this manual R S P Q T Y Z X H W U V 1RB7A_EE book Page 2 Tuesday April 24 2012 9 07 AM ...

Page 31: ...pplied with power 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 1RB7A_EE book Page 1 Tuesday April 24 2...

Page 32: ...or 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 6 8 9 7 DIFF LOC...

Page 33: ...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 34: ...ng 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 of...

Page 35: ...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 36: ...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 37: ...play 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 1RB7A_EE book Page 7 Tuesday April 24 2012 9 07 AM ...

Page 38: ...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 39: ... 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 1RB7A_EE book Page 9 Tuesday April 24 2012 9 07 AM ...

Page 40: ...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 1RB7A_EE book Page 10 Tuesday April 24 2012 9 07 AM ...

Page 41: ...ice 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 dea...

Page 42: ...er 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 1RB7A_EE book Page 12 Tuesday April 24 2012 9 07 AM ...

Page 43: ...mand 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 wheels...

Page 44: ...differen tial gear locked Power is supplied to the rear and front wheels with the differential gear locked Unlike the 4WD mode all wheels turn at the same speed regardless of traction EVU01280 Horn switch Press the switch to sound the horn 1 Horn switch 1 1RB7A_EE book Page 14 Tuesday April 24 2012 9 07 AM ...

Page 45: ...sion 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 EVU00270 Brake pedal Press the brake pedal to slow or stop the ve hicle 1 Brake pedal 1RB7A_EE book Page 15 Tuesday April 24 2012 9 07 AM ...

Page 46: ...ng 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 EVU00290 Drive select lever The drive select lever is used to shift the vehi 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 sel...

Page 47: ...ise To close Install the fuel tank cap by turning it clockwise Doors To open a door pull the latch outward To close a door push or pull the door inward until it is securely latched Be sure the door is SE CURELY LATCHED AFTER CLOSING IT 1 Latch 2 Door 1 2 1RB7A_EE book Page 17 Tuesday April 24 2012 9 07 AM ...

Page 48: ...nger seat 3 Seat lock lever 2 To install a seat insert the projections on the rear of the seat into the seat holders and push down on the seat at the front Make sure the seats are securely latched WARNING A loose seat could cause the operator to lose control or cause the operator or pas senger to fall 1 3 1RB7A_EE book Page 18 Tuesday April 24 2012 9 07 AM ...

Page 49: ... riding in the vehicle See pages 7 6 7 9 for more information 1 Seat belt 2 EVU01191 Glove compartment NOTICE To protect from damage do not put metal items like tools or sharply edged items directly in the glove compartment If they must be stored wrap them in appropriate cushioning material a Unlock b Open 1 1RB7A_EE book Page 19 Tuesday April 24 2012 9 07 AM ...

Page 50: ...p 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 otherwise they may be thrown about and possibly injure peo ple in the vehicle during sudden brak ing or an accident 1 Storage cup holder 1 2 C...

Page 51: ...argo bed 2 Tailgate 3 Cargo hook 4 For additional loading information see pages 6 9 6 11 Opening and closing the tailgate 1 Tailgate 2 Latch 2 To open Unhook the latches and then lower the tail gate To close Lift the tailgate to the original position and then hook the latches Maximum load limit 181 kg 400 lb 1RB7A_EE book Page 21 Tuesday April 24 2012 9 07 AM ...

Page 52: ... lapse if you put heavy cargo or sit on it 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 1RB7A_EE book Page 22 Tuesday April 24 2012 9 07 AM ...

Page 53: ...er assemblies YXR7FD YXR700FAD 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 The spring preload can be adjusted to suit the operating conditions You can reduce preload for a softer ride or increase preload if frequent bottoming occurs or when carrying loads N...

Page 54: ...ring in direction a To decrease the spring preload turn the spring preload adjusting ring in direction b Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber 1 Spring preload adjusting ring 2 Position indicator TIP 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 ...

Page 55: ...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 front shock abso...

Page 56: ...eload 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 0...

Page 57: ... 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 62 mm 2 44 in Standard Distance A 67 mm 2 64 in Maximum hard Distance A 77 mm 3 03 in Tightening torque Locknut 12 5 Nm 1 25 m kgf 9 04 ft...

Page 58: ...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 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 ...

Page 59: ...n 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 10 click s in direction b Maximum hard 9 click s in direction b ...

Page 60: ... poor handling and loss of stability which could lead to an acci dent 5UG1B002 Adjusting the rear shock absorber assemblies YXR7FSPD WARNING These shock absorber assemblies contain highly pressurized nitrogen gas Read and understand the following information be fore handling the shock absorber assem blies Do not tamper with or attempt to open the cylinder assemblies Do not subject the shock absorb...

Page 61: ... of the rear shock absorber assemblies can be adjusted 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 ...

Page 62: ...ith 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 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 t...

Page 63: ...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 a b 1 2 3 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 di...

Page 64: ...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 7 click s in direction b Maximum hard 2 click s in direction b With the adjusting screw fully tur...

Page 65: ...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 66: ...iler hitch bracket 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 and the headlights are turned off 1 Auxiliary DC jack cap 1 Set the light switch to OFF 2 Turn the accessory off 3 Start the engine Se...

Page 67: ...sories requiring more than the maximum capacity stat ed above This may 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 Maximum rated capacity for the auxiliary DC jack DC 12 V 10 A 120 W 1RB7A_EE boo...

Page 68: ...nnot 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 Check fuel level Fi...

Page 69: ...peration and belt 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 1RB7A_EE book Page 2 Tuesday April 24 2012 9 0...

Page 70: ...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 th...

Page 71: ...the 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 an...

Page 72: ...ozzle 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 discharge of this build up while refueling can cause a spark and ignite the gasoline Recommended fuel UNLEADED GASOLINE ONLY For Europe Regular unleaded gasoline only with a research octane number of...

Page 73: ...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 74: ...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 75: ...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 76: ...rol 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 incorre...

Page 77: ...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 1RB7A_EE book Page 10 Tuesday April 24 2012 9 07 AM ...

Page 78: ...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 or any condition...

Page 79: ...tle position 10 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 Ap...

Page 80: ...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 81: ...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 82: ... 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 83: ...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 1RB7A_...

Page 84: ...fferential 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 85: ...imited 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 1RB7A_EE book Page 8 Tuesday April 24 2012 9 07 AM ...

Page 86: ... 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 87: ...er 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 clines Turn gradually and go s...

Page 88: ...tructions 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 chan...

Page 89: ...ons WARNING Follow 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 overtu...

Page 90: ...death to drivers or passen gers 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 features 1RB...

Page 91: ... the ignition key when the vehicle is not in use to prevent unauthorized use of the machine Parents Many countries 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 con...

Page 92: ... 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 93: ...ures 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 1RB7A_EE book Page 5 Tuesday April 24 2012 9 07 AM ...

Page 94: ...e 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 driving...

Page 95: ...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 96: ...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 97: ...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 98: ...at 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 1RB7A_EE book Page 10 Tuesday April 24 2012 9 07 AM ...

Page 99: ...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 1RB7A_EE book Page 11 Tuesday April 24 2012 9 07 AM ...

Page 100: ...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 101: ...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 102: ...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 103: ... or hard accelera tion Driving aggressively or making abrupt maneuvers even on flat open areas can cause side rollovers Avoid sideways sliding skidding or back wheel sliding and never do donuts If you feel the Rhino begin to slide sideways or the back wheels slide during a turn steer into the direction of the slide if pos sible and gradually let off the accelerator ped al to regain directional con...

Page 104: ...oot 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 ac...

Page 105: ...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 106: ...ing 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 out...

Page 107: ... 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 vehic...

Page 108: ... 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 h...

Page 109: ... 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 110: ... 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 carefully...

Page 111: ...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 112: ...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 the back wheels slide during a turn steer into the directio...

Page 113: ...ter 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 you...

Page 114: ... 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 fire or carbon m...

Page 115: ... 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 116: ... 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 1RB7A_EE book Page 3 Tuesday April 24 2012 9 07 AM ...

Page 117: ...ed 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 ne...

Page 118: ...essary 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 balan...

Page 119: ...oses 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 Stabilizer bushings Check for cracks or damage Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary ITEM ROUTINE Whichever comes ...

Page 120: ...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 1RB7A_EE book Page 7 Tuesday April 24 2012 9 07 AM ...

Page 121: ... 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 1RB7A_EE book Page 8 Tuesday April 24 2012 9 07 AM ...

Page 122: ...ear 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 fits ...

Page 123: ...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 124: ...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 1RB7A_EE book Page 11 Tuesday April 24 2012 9 07 AM ...

Page 125: ...es 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 pages 4 22 4 23 for cargo bed lifting and lowering procedures 2 1 1R...

Page 126: ... 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 127: ...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 128: ... 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 129: ...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 1RB7A_EE book Page 16 Tuesday April 24 2012 9 07...

Page 130: ...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 qu...

Page 131: ...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 1RB7A_EE boo...

Page 132: ... 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 1RB7A_EE book Page 19 Tuesday April 24 2012 9 07 AM ...

Page 133: ... 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 1RB7A_EE book Page 20 Tuesday April 24 2...

Page 134: ... 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 2...

Page 135: ...ngine 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 1...

Page 136: ...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 fou...

Page 137: ...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 1RB7A_EE book Page 24 Tuesday April 24 2012 9 07 AM ...

Page 138: ...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 139: ...rk 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 140: ... 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 1RB7A_EE book Page 27 Tuesday April 24 2012 9 07 AM ...

Page 141: ... 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 1RB7A_EE book Page 28 Tuesday April 24 2012 9 07 AM ...

Page 142: ...9 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 1RB7A_EE book Page 29 Tuesday April 24 2012 9 07 AM ...

Page 143: ... 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 spon...

Page 144: ...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 air...

Page 145: ...lects 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 1RB7A_EE book Page 32 Tuesday April 24 2012 9 07 AM ...

Page 146: ...elt 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 the ...

Page 147: ... 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 148: ...th 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 wh...

Page 149: ... 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 150: ...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 151: ...essary 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 page 4 18 for seat removal and installation proce dures 3 Remove the console See page 8 9 for console removal and installation proce dures 4 Check the p...

Page 152: ...ocknut 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 1RB7A_EE book Page 39 Tuesday April 24 2012 9 07 AM ...

Page 153: ...tch 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 1RB7A_EE book Page 40 ...

Page 154: ...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 1RB7A_EE book Page 41 Tuesd...

Page 155: ... 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 1RB7A_EE book Page 42 Tuesday April 24 2012 9 07 AM ...

Page 156: ...ightening 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 1RB7A_EE book Page 43 Tuesday April 24 2012 9 07 AM ...

Page 157: ...r 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 158: ... 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 159: ...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 1RB7A_EE book Page 46 Tuesday April 24 2012 9 07 AM ...

Page 160: ...ies 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 atten...

Page 161: ...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 1RB7A...

Page 162: ...tional 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 t...

Page 163: ...ttery 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 1RB7A_EE book ...

Page 164: ...eries 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 165: ...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 1RB7A_EE book Page 52 Tuesday April 24 2012 9 ...

Page 166: ...wn 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 1RB7A_EE book Page 53 Tuesday Apr...

Page 167: ...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 fus...

Page 168: ... 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 169: ...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 1RB7A_EE book Page 56 Tuesday April 24 2012 9 07 AM ...

Page 170: ...ersely 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 bul...

Page 171: ...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 1RB7A_EE book Page 58 Tuesday April 24 2012...

Page 172: ...the 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 1RB7A_EE book Page 59 Tuesday April 24 2012 9 07 AM ...

Page 173: ...ems 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...

Page 174: ...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 1RB7A_EE book Page 61 Tuesday April 24 2012 9 07 AM ...

Page 175: ...emove 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 Che...

Page 176: ...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 177: ...y degreaser with 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...

Page 178: ...ratch 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 fuel tank with fresh...

Page 179: ...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 180: ...190 lb Noise and vibration level Noise level 77 311 EEC YXR7FD 80 2 dB A YXR7FSPD 80 2 dB A Vibration on seat EN1032 ISO5008 YXR7FD Will not exceed 0 5 m s2 YXR7FSPD Will not exceed 0 5 m s2 Vibration on handlebar EN1032 ISO5008 YXR7FD Will not exceed 2 5 m s2 YXR7FSPD Will not exceed 2 5 m s2 Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Single cylinder Displacement 686 cm B...

Page 181: ...apacity up to the maximum level mark 0 32 L 0 34 US qt 0 28 Imp qt Radiator capacity including all routes 2 35 L 2 48 US qt 2 07 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel YXR7FD Regular unleaded gasoline only YXR7FSPD Regular unleaded gasoline only YXR700FAD Unleaded gasoline only Fuel tank capacity 30 0 L 7 93 US gal 6 60 Imp gal Fuel injection Throttle body ID mark 5...

Page 182: ...ear tire Type Tubeless Size 25 x 10 12NHS Manufacturer model MAXXIS M952Y Loading Maximum loading limit YXR7FD 367 0 kg 809 lb YXR7FSPD 359 0 kg 791 lb YXR700FAD 367 0 kg 809 lb Total weight of rider passenger cargo accessories and tongue Tire air pressure measured on cold tires Recommended Front 70 0 kPa 0 700 kgf cm 10 psi Rear 98 0 kPa 0 980 kgf cm 14 psi Minimum Front 63 0 kPa 0 630 kgf cm 9 p...

Page 183: ...XR700FAD Coil spring oil damper Wheel travel 185 mm 7 3 in Rear suspension Type Double wishbone Spring shock absorber type YXR7FD Coil spring oil damper YXR7FSPD Coil spring gas oil damper YXR700FAD Coil spring oil damper Wheel travel 185 mm 7 3 in Electrical system Ignition system TCI Charging system AC magneto Battery Model U1 H11L Voltage capacity 12 V 28 0 Ah Headlight Bulb type Krypton bulb B...

Page 184: ...25 0 A For Europe only The figures quoted are emission levels and are not necessarily safe working levels Whilst there is a correlation between the emission and exposure levels this cannot be used reliably to determine whether or not further precautions are required Factors that influence the actual level of exposure of work force include the characteristics of the work room the other sources of n...

Page 185: ...n ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 VEHICLE IDENTIFICATION NUMBER ACA 02E 2 MODEL LABEL INFORMATION ACA 01E 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 1RB7A_EE book Page 1 Tuesday April 24...

Page 186: ... 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 1RB7A_EE book Page 2 Tuesday April 24 2012 9 07 AM ...

Page 187: ...1RB7A_EE book Page 3 Tuesday April 24 2012 9 07 AM ...

Page 188: ...PRINTED IN USA 2012 04 0 3 1 CR E 1RB7A_EE book Page 1 Tuesday April 24 2012 9 07 AM ...

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Yamaha YXR7FD, Owner'S Manual

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