2008-2011 Yamaha Rhino 700 FI (YXR70FX) Service & Repair Manual

SERVICE MANUAL 2008 LIT-11616-21-58 5B4-F8197-10 YXR70FX

EBS00001 YXR70FX SERVICE MANUAL ©2007 by Yamaha Motor Corporation, U.S.A. First edition, September 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-21-58

EBS00002 IMPORTANT This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig- nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. TIP: _ • This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. • Designs and specifications are subject to change without notice. EBS00003 IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations. This is the safety 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. A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property. A TIP provides key information to make procedures easier or clearer. WARNING NOTICE TIP:

EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page. 3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa- nied by corresponding illustrations. EXPLODED DIAGRAMS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs. 2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6. The meanings of the symbol marks are given on the next page. 4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart. 2 3 1 4 5 6 7 8

EBS00006 SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 0 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Fuel injection system 7 Drive train 8 Chassis 9 Electrical 0 Troubleshooting Symbols A to H indicate the following A Can be serviced with engine mounted B Filling fluid C Lubricant D Special tool E Torque F Wear limit, clearance G Engine speed H Electrical data (Ω, V, A) Symbols I to P in the exploded diagrams indicate the types of lubricants and lubrication points. I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply brake fluid M Apply wheel bearing grease N Apply lithium-soap-based grease O Apply molybdenum disulfide grease P Apply silicone grease Symbols Q to R in the exploded diagrams indicate where to apply a locking agent Q and when to install a new part R. Q Apply the locking agent (LOCTITE ® ) R Replace 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R GEN INFO SPEC CHK ADJ ENG COOL FI DRIV CHAS – + ELEC TRBL SHTG T R . . E G M BF B LS M S LT New

EBS00008 TABLE OF CONTENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 ENGINE ENG 4 COOLING SYSTEM COOL 5 FUEL INJECTION SYSTEM FI 6 DRIVE TRAIN DRIV 7 CHASSIS CHAS 8 ELECTRICAL ELEC 9 TROUBLESHOOTING TRBL SHTG 10 – +

CONTENTS CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION............................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1 MODEL LABEL.......................................................................................... 1-1 FEATURES ...................................................................................................... 1-2 OUTLINE OF THE FI SYSTEM ................................................................. 1-2 FI SYSTEM................................................................................................ 1-3 INSTRUMENT FUNCTIONS ..................................................................... 1-4 IMPORTANT INFORMATION ......................................................................... 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-7 REPLACEMENT PARTS........................................................................... 1-7 GASKETS, OIL SEALS AND O-RINGS .................................................... 1-7 LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-8 BEARINGS AND OIL SEALS .................................................................... 1-8 CIRCLIPS .................................................................................................. 1-8 CHECKING THE CONNECTIONS ............................................................ 1-9 SPECIAL TOOLS .......................................................................................... 1-10 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ........................................................................ 2-1 ENGINE SPECIFICATIONS ............................................................................ 2-5 CHASSIS SPECIFICATIONS ........................................................................ 2-12 ELECTRICAL SPECIFICATIONS ................................................................. 2-15 TIGHTENING TORQUES .............................................................................. 2-17 ENGINE TIGHTENING TORQUES ......................................................... 2-17 CHASSIS TIGHTENING TORQUES ....................................................... 2-20 HOW TO USE THE CONVERSION TABLE.................................................. 2-24

GENERAL TIGHTENING TORQUE SPECIFICATIONS ............................... 2-24 LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-25 ENGINE ................................................................................................... 2-25 COOLANT FLOW DIAGRAMS ..................................................................... 2-27 OIL FLOW DIAGRAMS ................................................................................. 2-29 CABLE ROUTING ......................................................................................... 2-32 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION.............................................................................................. 3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ......................................................................................................... 3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ............................ 3-2 ENGINE ........................................................................................................... 3-3 ADJUSTING THE VALVE CLEARANCE .................................................. 3-3 ADJUSTING THE THROTTLE CABLE ..................................................... 3-6 CHECKING THE SPARK PLUG ............................................................... 3-7 CHECKING THE IGNITION TIMING ......................................................... 3-9 MEASURING THE COMPRESSION PRESSURE .................................. 3-10 CHECKING THE ENGINE OIL LEVEL.................................................... 3-13 CHANGING THE ENGINE OIL ............................................................... 3-14 CLEANING THE AIR FILTER ELEMENT................................................ 3-16 CHECKING THE THROTTLE BODY JOINT ........................................... 3-19 CHECKING THE FUEL HOSE ................................................................ 3-19 CHECKING THE BREATHER HOSES ................................................... 3-19 CHECKING THE COOLANT LEVEL ....................................................... 3-20 CHANGING THE COOLANT................................................................... 3-21 CHECKING THE COOLING SYSTEM .................................................... 3-25 CHECKING THE COOLANT TEMPERATURE WARNING LIGHT ......... 3-26 CHECKING AND REPLACING THE V-BELT ......................................... 3-27 CHECKING THE EXHAUST SYSTEM.................................................... 3-28 CLEANING THE SPARK ARRESTER .................................................... 3-29

CHASSIS ....................................................................................................... 3-30 ADJUSTING THE BRAKE PEDAL .......................................................... 3-30 ADJUSTING THE PARKING BRAKE...................................................... 3-31 CHECKING THE BRAKE FLUID LEVEL................................................. 3-32 CHECKING THE FRONT BRAKE PADS ................................................ 3-33 CHECKING THE REAR BRAKE PADS .................................................. 3-34 CHECKING THE PARKING BRAKE PADS ............................................ 3-34 CHECKING THE BRAKE HOSES AND BRAKE PIPES ......................... 3-35 BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-36 ADJUSTING THE SELECT LEVER SHIFT ROD .................................... 3-37 ADJUSTING THE BRAKE LIGHT SWITCH ............................................ 3-38 CHECKING THE FINAL GEAR OIL LEVEL ............................................ 3-38 CHANGING THE FINAL GEAR OIL ........................................................ 3-39 CHECKING THE DIFFERENTIAL GEAR OIL ......................................... 3-40 CHANGING THE DIFFERENTIAL GEAR OIL ........................................ 3-41 CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS .......... 3-43 CHECKING THE STEERING SYSTEM .................................................. 3-43 ADJUSTING THE TOE-IN ....................................................................... 3-44 ADJUSTING THE FRONT SHOCK ABSORBERS ................................. 3-45 ADJUSTING THE REAR SHOCK ABSORBERS .................................... 3-48 CHECKING THE TIRES .......................................................................... 3-51 CHECKING THE WHEELS ..................................................................... 3-53 CHECKING AND LUBRICATING THE CABLES .................................... 3-54 LUBRICATING THE PEDAL, ETC. ......................................................... 3-54 ELECTRICAL SYSTEM................................................................................. 3-55 CHECKING AND CHARGING THE BATTERY ....................................... 3-55 CHECKING THE FUSES ........................................................................ 3-61 ADJUSTING THE HEADLIGHT BEAMS ................................................. 3-64 CHANGING THE HEADLIGHT BULBS................................................... 3-64 CHANGING THE TAIL/BRAKE LIGHT BULB ......................................... 3-65 CHAPTER 4 ENGINE ENGINE REMOVAL ........................................................................................ 4-1 V-BELT COOLING DUCTS, MUFFLER AND EXHAUST PIPES .............. 4-1 INSTALLING THE V-BELT COOLING DUCTS ......................................... 4-4 SHIFT ARM ............................................................................................... 4-5 HOSES AND LEADS................................................................................. 4-6 ENGINE MOUNTING BOLTS ................................................................... 4-8 INSTALLING THE ENGINE..................................................................... 4-10