2009 And 2011-2012 Yamaha Yxr700 Rhino Side X Side Service Repair Manual
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2009 And 2011-2012 Yamaha Yxr700 Rhino Side X Side Service Repair Manual
- 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 significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
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 accompanied by corresponding illustrations.
TABLE OF CONTENTS:
2009 And 2011-2012 Yamaha Yxr700 Rhino Side X Side Service Repair Manual
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION1-1
VEHICLE IDENTIFICATION NUMBER1-1
MODEL LABEL1-1
FEATURES1-2
OUTLINE OF THE FI SYSTEM1-2
FI SYSTEM1-3
INSTRUMENT FUNCTIONS1-4
IMPORTANT INFORMATION 1-7
PREPARATION FOR REMOVAL AND DISASSEMBLY1-7
REPLACEMENT PARTS1-7
GASKETS, OIL SEALS AND O-RINGS 1-7
LOCK WASHERS/PLATES AND COTTER PINS1-8
BEARINGS AND OIL SEALS1-8
CIRCLIPS1-8
CHECKING THE CONNECTIONS1-9
SPECIAL TOOLS 1-10
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS 2-1
ENGINE SPECIFICATIONS 2-5
CHASSIS SPECIFICATIONS2-12
ELECTRICAL SPECIFICATIONS 2-15
TIGHTENING TORQUES 2-17
ENGINE TIGHTENING TORQUES2-17
CHASSIS TIGHTENING TORQUES2-20
HOW TO USE THE CONVERSION TABLE2-24
GENERAL TIGHTENING TORQUE SPECIFICATIONS2-24
LUBRICATION POINTS AND LUBRICANT TYPES 2-25
ENGINE2-25
COOLANT FLOW DIAGRAMS 2-27
OIL FLOW DIAGRAMS2-29
CABLE ROUTING 2-32
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART3-2
ENGINE 3-3
ADJUSTING THE VALVE CLEARANCE 3-3
ADJUSTING THE THROTTLE CABLE 3-6
CHECKING THE SPARK PLUG 3-7
CHECKING THE IGNITION TIMING3-9
MEASURING THE COMPRESSION PRESSURE3-10
CHECKING THE ENGINE OIL LEVEL3-13
CHANGING THE ENGINE OIL 3-14
CLEANING THE AIR FILTER ELEMENT3-16
CHECKING THE THROTTLE BODY JOINT3-19
CHECKING THE FUEL HOSE3-19
CHECKING THE BREATHER HOSES 3-19
CHECKING THE COOLANT LEVEL3-20
CHANGING THE COOLANT3-21
CHECKING THE COOLING SYSTEM3-25
CHECKING THE COOLANT TEMPERATURE WARNING LIGHT3-26
CHECKING AND REPLACING THE V-BELT 3-27
CHECKING THE EXHAUST SYSTEM3-28
CLEANING THE SPARK ARRESTER 3-29
CHASSIS 3-30
ADJUSTING THE BRAKE PEDAL3-30
ADJUSTING THE PARKING BRAKE3-31
CHECKING THE BRAKE FLUID LEVEL3-32
CHECKING THE FRONT BRAKE PADS3-33
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 ROD3-37
ADJUSTING THE BRAKE LIGHT SWITCH3-38
CHECKING THE FINAL GEAR OIL LEVEL3-38
CHANGING THE FINAL GEAR OIL3-39
CHECKING THE DIFFERENTIAL GEAR OIL3-40
CHANGING THE DIFFERENTIAL GEAR OIL 3-41
CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS3-43
CHECKING THE STEERING SYSTEM 3-43
ADJUSTING THE TOE-IN3-44
ADJUSTING THE FRONT SHOCK ABSORBERS 3-45
ADJUSTING THE REAR SHOCK ABSORBERS3-48
CHECKING THE TIRES3-51
CHECKING THE WHEELS 3-53
CHECKING AND LUBRICATING THE CABLES 3-54
LUBRICATING THE PEDAL, ETC 3-54
ELECTRICAL SYSTEM3-55
CHECKING AND CHARGING THE BATTERY3-55
CHECKING THE FUSES 3-61
ADJUSTING THE HEADLIGHT BEAMS3-64
CHANGING THE HEADLIGHT BULBS3-64
CHANGING THE TAIL/BRAKE LIGHT BULB 3-65
CHAPTER 4
ENGINE
ENGINE REMOVAL 4-1
V-BELT COOLING DUCTS, MUFFLER AND EXHAUST PIPES4-1
INSTALLING THE V-BELT COOLING DUCTS4-4
SHIFT ARM 4-5
HOSES AND LEADS4-6
ENGINE MOUNTING BOLTS 4-8
INSTALLING THE ENGINE4-10
CYLINDER HEAD4-11
REMOVING THE CYLINDER HEAD4-14
CHECKING THE CAMSHAFT SPROCKET4-15
CHECKING THE TAPPET COVERS 4-15
CHECKING THE TIMING CHAIN TENSIONER4-15
CHECKING THE CYLINDER HEAD 4-16
INSTALLING THE CYLINDER HEAD 4-17
ROCKER ARMS AND CAMSHAFT4-20
REMOVING THE ROCKER ARMS AND CAMSHAFT4-22
CHECKING THE CAMSHAFT4-22
CHECKING THE DECOMPRESSION SYSTEM4-23
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 4-23
INSTALLING THE CAMSHAFT AND ROCKER ARMS 4-24
VALVES AND VALVE SPRINGS4-27
REMOVING THE VALVES AND VALVE SPRINGS 4-28
CHECKING THE VALVES AND VALVE SPRINGS4-29
INSTALLING THE VALVES AND VALVE SPRINGS4-33
CYLINDER AND PISTON4-36
REMOVING THE PISTON 4-37
CHECKING THE CYLINDER AND PISTON 4-37
CHECKING THE PISTON RINGS4-39
CHECKING THE PISTON PIN 4-40
INSTALLING THE PISTON AND CYLINDER 4-41
AC MAGNETO4-44
REMOVING THE AC MAGNETO ROTOR4-47
CHECKING THE STATOR COIL AND CRANKSHAFT POSITION
SENSOR 4-48
CHECKING THE STARTER CLUTCH4-48
CHECKING THE TORQUE LIMITER4-49
INSTALLING THE AC MAGNETO ROTOR 4-49
BALANCER GEARS AND OIL PUMP GEARS 4-51
REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP
DRIVEN GEAR4-53
CHECKING THE OIL PUMP DRIVE 4-53
CHECKING THE BALANCER DRIVE4-53
INSTALLING THE BALANCER DRIVE GEAR, BALANCER DRIVEN
GEAR, AND OIL PUMP DRIVEN GEAR4-54
PRIMARY AND SECONDARY SHEAVES4-55
PRIMARY SHEAVE4-57
SECONDARY SHEAVE 4-58
REMOVING THE PRIMARY AND SECONDARY SHEAVES4-59
DISASSEMBLING THE SECONDARY SHEAVE4-59
CHECKING THE PRIMARY SHEAVE 4-60
CHECKING THE SECONDARY SHEAVE4-60
ASSEMBLING THE PRIMARY SHEAVE4-61
ASSEMBLING THE SECONDARY SHEAVE4-62
INSTALLING THE PRIMARY AND SECONDARY SHEAVES4-64
CLUTCH 4-65
REMOVING THE CLUTCH 4-67
CHECKING THE CLUTCH4-68
INSTALLING THE CLUTCH4-69
CRANKCASE 4-70
TIMING CHAIN AND OIL FILTER 4-70
CRANKCASE 4-72
CRANKCASE BEARINGS4-73
SEPARATING THE CRANKCASE4-74
CHECKING THE TIMING CHAIN AND GUIDE4-74
CHECKING THE RELIEF VALVE 4-74
CHECKING THE BEARINGS4-75
CHECKING THE CRANKCASE4-75
ASSEMBLING THE CRANKCASE4-75
INSTALLING THE SHIFT LEVER 4-76
CRANKSHAFT AND OIL PUMP4-77
OIL PUMP 4-78
REMOVING THE CRANKSHAFT 4-79
CHECKING THE OIL PUMP 4-79
CHECKING THE OIL STRAINER 4-80
CHECKING THE CRANKSHAFT4-80
ASSEMBLING THE OIL PUMP4-81
INSTALLING THE CRANKSHAFT4-81
TRANSMISSION4-83
DRIVE AXLE 4-85
REMOVING THE TRANSMISSION 4-87
CHECKING THE SHIFT FORKS4-87
CHECKING THE SHIFT DRUM 4-88
CHECKING THE TRANSMISSION4-88
CHECKING THE SECONDARY SHAFT4-89
ASSEMBLING THE SHIFT FORK ASSEMBLY 4-89
INSTALLING THE TRANSMISSION4-89
MIDDLE GEAR4-91
MIDDLE DRIVE SHAFT 4-91
MIDDLE DRIVEN SHAFT4-92
REMOVING THE MIDDLE DRIVE SHAFT 4-94
REMOVING THE MIDDLE DRIVEN SHAFT4-95
CHECKING THE PINION GEARS 4-98
SELECTING MIDDLE DRIVE AND DRIVEN GEAR SHIMS4-98
INSTALLING THE BEARING AND OIL SEALS 4-102
INSTALLING THE MIDDLE DRIVEN SHAFT 4-103
INSTALLING THE MIDDLE DRIVE SHAFT4-105
MEASURING THE MIDDLE GEAR BACKLASH4-106
CHAPTER 5
COOLING SYSTEM
RADIATOR AND COOLANT RESERVOIR 5-1
CHECKING THE RADIATOR5-3
INSTALLING THE RADIATOR5-4
THERMOSTAT 5-5
CHECKING THE THERMOSTAT5-6
INSTALLING THE THERMOSTAT5-6
WATER PUMP5-7
DISASSEMBLING THE WATER PUMP5-9
CHECKING THE WATER PUMP5-9
ASSEMBLING THE WATER PUMP5-10
OIL COOLER5-12
CHECKING THE OIL COOLER 5-14
CHAPTER 6
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM6-1
CIRCUIT DIAGRAM 6-2
ECU SELF-DIAGNOSTIC FUNCTION6-4
SELF-DIAGNOSTIC FUNCTION TABLE6-5
TROUBLESHOOTING CHART6-6
DIAGNOSTIC MODE 6-7
TROUBLESHOOTING DETAILS 6-11
CHECKING THE INTAKE AIR PRESSURE SENSOR 6-26
CHECKING THE INTAKE AIR TEMPERATURE SENSOR6-26
AIR FILTER CASE AND AIR INTAKE DUCT6-28
INSTALLING THE AIR INTAKE DUCT AND AIR FILTER CASE6-31
FUEL PUMP AND FUEL TANK 6-32
REMOVING THE FUEL TANK6-34
REMOVING THE FUEL PUMP 6-34
CHECKING THE FUEL PUMP BODY6-35
CHECKING THE ROLLOVER VALVE 6-35
INSTALLING THE FUEL PUMP6-35
INSTALLING THE FUEL HOSE6-36
THROTTLE BODY6-37
REMOVING THE THROTTLE BODY ASSEMBLY 6-40
CHECKING THE FUEL INJECTOR 6-40
CHECKING THE THROTTLE BODY 6-40
INSTALLING THE THROTTLE BODY ASSEMBLY6-41
CHECKING THE FUEL PUMP AND PRESSURE REGULATOR
OPERATION 6-43
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR 6-44
CHAPTER 7
DRIVE TRAIN
TROUBLESHOOTING7-1
CHECKING NOISES7-1
TROUBLESHOOTING CHART7-3
FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND
DRIVE SHAFT 7-4
DISASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS 7-10
DISASSEMBLING THE UNIVERSAL JOINT 7-11
REMOVING THE DIFFERENTIAL GEAR ASSEMBLY7-11
CHECKING THE FRONT CONSTANT VELOCITY JOINTS7-12
CHECKING THE DIFFERENTIAL GEARS 7-12
CHECKING THE DIFFERENTIAL GEAR MOTOR 7-13
ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS 7-13
ASSEMBLING THE DIFFERENTIAL GEARS7-15
ASSEMBLING THE UNIVERSAL JOINT 7-17
MEASURING THE DIFFERENTIAL GEAR LASH 7-17
ADJUSTING THE DIFFERENTIAL GEAR LASH7-18
CHECKING THE DIFFERENTIAL GEAR OPERATION 7-19
REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND
DRIVE SHAFT 7-20
DISASSEMBLING THE REAR CONSTANT VELOCITY JOINTS7-28
ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS7-29
DISASSEMBLING THE FINAL GEAR CASE7-31
REMOVING THE FINAL DRIVE ROLLER BEARINGS7-32
INSTALLING THE FINAL DRIVE ROLLER BEARINGS 7-32
POSITIONING THE FINAL DRIVE PINION GEAR AND RING
GEAR 7-33
CHECKING THE DRIVE SHAFT7-38
CHECKING THE FINAL GEAR CASE 7-38
MEASURING AND ADJUSTING THE FINAL GEAR LASH7-38
ASSEMBLING THE FINAL GEAR CASE7-40
CHAPTER 8
CHASSIS
SEATS, ENCLOSURE, HOOD AND CARGO BED8-1
FRONT GUARD AND HOOD8-1
SEATS, REAR CONSOLE AND INSTRUMENT PANELS8-2
REMOVING THE STEERING WHEEL8-4
INSTALLING THE STEERING WHEEL 8-4
SIDE DOORS8-5
PANELS AND FRONT CONSOLE8-6
REMOVING THE SIDE PANELS 8-8
INSTALL THE SIDE PANELS 8-8
CARGO BED8-9
SKID PLATES 8-11
INSTALLING THE REAR SKID PLATE8-12
ENCLOSURE AND SEAT BELTS8-13
INSTALLING THE ENCLOSURE8-14
FRONT AND REAR WHEELS 8-15
FRONT WHEELS8-15
REAR WHEELS 8-17
CHECKING THE WHEELS 8-19
CHECKING THE WHEEL HUBS8-19
CHECKING THE BRAKE DISCS 8-20
INSTALLING THE WHEEL HUBS8-20
INSTALLING THE WHEELS 8-20
FRONT AND REAR BRAKES8-21
FRONT BRAKE PADS 8-21
REAR BRAKE PADS8-22
REPLACING THE FRONT AND REAR BRAKE PADS8-23
BRAKE MASTER CYLINDER 8-25
CHECKING THE MASTER CYLINDER 8-27
ASSEMBLING THE BRAKE MASTER CYLINDER8-27
INSTALLING THE BRAKE MASTER CYLINDER8-28
FRONT BRAKE CALIPER8-30
REAR BRAKE CALIPERS8-32
DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS8-34
CHECKING THE FRONT AND REAR BRAKE CALIPERS 8-34
ASSEMBLING THE FRONT AND REAR BRAKE CALIPERS8-35
INSTALLING THE FRONT AND REAR BRAKE CALIPERS 8-36
PARKING BRAKE8-38
PARKING BRAKE PADS 8-38
REPLACING THE PARKING BRAKE PADS 8-39
PARKING BRAKE 8-40
PARKING BRAKE DISC8-43
CHECKING THE PARKING BRAKE8-44
CHECKING THE PARKING BRAKE DISC 8-44
ASSEMBLING THE PARKING BRAKE8-44
PEDAL ASSEMBLY8-47
STEERING SYSTEM8-49
STEERING SHAFT AND STEERING ASSEMBLY8-49
DISASSEMBLING THE STEERING ASSEMBLY 8-52
CHECKING THE STEERING JOINT8-52
CHECKING THE STEERING ASSEMBLY8-52
ASSEMBLING THE STEERING ASSEMBLY 8-53
INSTALLING THE STEERING SYSTEM 8-54
TIE-ROD AND STEERING KNUCKLE8-55
REMOVING THE STEERING KNUCKLES8-56
CHECKING THE TIE-RODS 8-56
CHECKING THE STEERING KNUCKLES8-56
FRONT ARMS AND FRONT SHOCK ABSORBERS8-60
REMOVING THE FRONT ARMS8-62
CHECKING THE FRONT ARMS8-62
HANDLING THE FRONT SHOCK ABSORBERS AND GAS CYLINDERS
(For models equipped with gas-oil damper shock absorbers)8-64
DISPOSING OF A FRONT SHOCK ABSORBER AND GAS CYLINDER
(For models equipped with gas-oil damper shock absorbers)8-65
CHECKING THE FRONT SHOCK ABSORBERS8-65
INSTALLING THE FRONT ARMS AND FRONT SHOCK
ABSORBER8-66
REAR KNUCKLE AND STABILIZER 8-67
CHECKING THE REAR KNUCKLES8-68
CHECKING THE STABILIZER8-68
REAR ARMS AND REAR SHOCK ABSORBER8-69
CHECKING THE REAR ARMS8-71
HANDLING THE REAR SHOCK ABSORBERS AND GAS CYLINDERS
(For models equipped with gas-oil damper shock absorbers)8-71
DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER
(For models equipped with gas-oil damper shock absorbers)8-72
CHECKING THE REAR SHOCK ABSORBERS 8-72
INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER8-73
CHAPTER 9
ELECTRICAL
ELECTRICAL COMPONENTS9-1
CHECKING SWITCH CONTINUITY9-3
CHECKING THE SWITCHES9-4
CHECKING THE BULBS AND BULB SOCKETS 9-6
TYPES OF BULBS9-6
CHECKING THE CONDITION OF THE BULBS 9-7
CHECKING THE CONDITION OF THE BULB SOCKETS 9-8
IGNITION SYSTEM 9-9
CIRCUIT DIAGRAM 9-9
TROUBLESHOOTING 9-10
ELECTRIC STARTING SYSTEM9-14
CIRCUIT DIAGRAM 9-14
STARTING CIRCUIT OPERATION9-15
TROUBLESHOOTING 9-16
STARTER MOTOR9-19
CHECKING THE STARTER MOTOR 9-21
ASSEMBLING THE STARTER MOTOR9-23
CHARGING SYSTEM9-24
CIRCUIT DIAGRAM 9-24
TROUBLESHOOTING 9-25
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:516
DOWNLOADABLE:YES
FILE TYPE:PDF
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
Fletcher Jackson –
Great customer service