2009 yamaha rhino 700 efi owners manual free download

The Yamaha Rhino or SxS repair manual will be arranged in a clear and logical manner. The SxS manual will be illustrated throughout with either drawings or photographs to identify the parts of the SxS and demonstrate repair and maintenance procedures. Some manuals contain both. All manuals should have a table of contents. Some manuals may also include an index. A good manual will also have a general information section near the beginning that describes service rules, safety precautions, and any symbols and abbreviations used in the manual.

In this section the manual will also describe specifications for the SxS; torque values; lubrication and seal points; cable and harness routing; and the emission control systems. The manual may contain a schedule for routine maintenance in the general information section or this information might be contained in its own section. After the general information section, the manual will be divided into sections or chapters for different areas or systems within the SxS.

For example, the first section might cover general information on the frame and body. Other sections will cover the engine, including the drive train and electrical system; the chassis, including the driving mechanism, suspension, and steering; and the frame and electrical system associated with it, such as the battery.

The manual may also contain a section with wiring diagrams. If the manual covers more than one variation of the model of SxS, the wiring diagrams for each variation should be included. Within each section or chapter for a system of the Yamaha Rhino SxS will be found detailed information on that system.

For example, some of the subsections in the chapter on the engine will be for the ignition system, the fuel system, the electric starter, the transmission, and the crankcase and crankshaft. Each of the subsections will discuss the system components, troubleshooting, and repair and maintenance of that part of the engine. See page Yamaha dealer.

Page Fuel Never refuel while smoking, or while in the vicinity of sparks, open flames, or oth- Your Yamaha engine has been designed to er sources of ignition such as the pilot use regular unleaded gasoline with a pump Page 73 Always place a portable fuel container on the Gasohol containing methanol is not recom- ground before filling it.

Before removing the mended by Yamaha because it may cause container cap, touch the container with the fuel system damage or vehicle performance fuel dispenser nozzle. Add oil as necessary. See pages — voir when the engine is cold the coolant level Page Final Gear Oil It must operate smoothly and for details. Have a Yamaha dealer repair as nec- Recommended oil: essary for proper operation. Page Steering Yamaha dealer repair as necessary for proper operation.

EVU 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.

Page Tires EVU Tires Set tire pressures to the following specifica- Check tire pressure regularly to make sure it tions: is at the recommended specifications. Tire pressure gauge a. Tire wear limit Page Operation If there is a and 20 hours. For this reason, we ask that you read the fol- lowing material carefully. Page Starting The Engine The coolant temperature warning light and build-up of heat.

If any abnormality is noticed engine trouble warning light should come during this period, consult a Yamaha dealer. If a warning light does not go off, see pag- 0—10 hours However, hard when the engine is cold! Apply the brake pedal, then shift by mov- driving ing the drive select lever along the shift guide. Do not shift without coming to a complete stop and waiting for the engine to return to normal idle speed.

Ap- cause the engine speed to be limited until ply the parking brake to help prevent the vehi- the differential gear is completely engaged Page 88 You can measure tongue weight with a bath- Operating when loaded with cargo or tow- room scale. Put the tongue of the loaded trail- ing a trailer er on the scale with the tongue at hitch height. Drive more slowly than you would without a Adjust the load in the trailer, if necessary, to load.

Page 89 Pulling something other than a trailer Yamaha recommends that loads be transport- ed in the bed or in a trailer. The safe and proper operation of this vehicle. Rhino has higher ground clearance and other Read this chapter and review the safety in- features to handle rugged terrain, and, as a Page 91 Doing things with a Rhino that some people do for thrills in other vehicles such as side- ways sliding, skidding, fishtailing, or donuts have led to side rollovers. These rollovers can result in crushed limbs and other serious inju- ries or death to drivers or passengers.

These requirements are in response to the disproportionately high rate of crashes involving youthful drivers.

Allowing passengers to ride Do not make changes to the occupant pro- improperly can lead to serious injury or death. If you install aftermarket As the operator, you are responsible for your products or have your vehicle modified, passenger.

Page 94 The Rhino comes with a variety of features to help reduce the risk of driver and passenger injury. These features work together, and when properly used, these features will help protect the occupants in the event of an acci- dent. If these features are not used properly, they can cause injury. Driver must be sure that the pas- es or other objects and may reduce your risk senger is belted before driving.

Page 96 An unbelted occupant may strike the interior of the vehicle, the protective structure, or oth- er objects in an accident or during operation. You may also fall completely out or be partial- ly ejected from the vehicle, which may lead to being crushed between the ground and the vehicle. Page 97 2. If the latch plate is not positioned in the correct location along the seat belt, squeeze the latch plate ends together along its long edges in order to more eas- ily adjust its location up or down along the length of the belt.

Page Doors 6. Check if the seat belt shoulder position Doors suits the size of the driver and passen- The doors are designed to reduce the likeli- ger. Page Passenger Handholds Passenger handholds Handholds are provided to grip during opera- tion to maintain proper position and balance. Holding onto the handholds helps to reduce the likelihood that the passenger puts a hand outside the vehicle if the vehicle begins to tip.

Page Seat And Hip Restraints Seat and hip restraints Floorboard The seat and hip restraints are designed to The floorboard allows you to brace your feet, help keep you in the vehicle. Do not hold onto which helps you keep your body in the vehicle hip restraint when the vehicle is moving. Do not hold the steering wheel with your thumbs inside the rim. Keep your palms on the out- side of the steering wheel.

Similar to other off- road vehicles, if the Rhino hits a deep rut or large obstacle, the steering wheel could brief- ly jerk in one direction or back and forth as the tires and vehicle respond to the obstacle. Page Practice For New Rhino Users Wear eye protection when operating or riding the vehicle to reduce the risk of a serious ac- cident or injury. Eye protection, such as a face shield or goggles, may reduce the risk of for- eign material getting in your eyes and help prevent loss of vision.

Follow the instructions starting on too far or too fast can result in loss of control pages — to start the engine. Page Braking Braking Engine braking When slowing down or stopping, take your Engine compression braking is designed to foot off the accelerator pedal and press the assist you when operating your Rhino off- brake pedal smoothly.

Improper use of the road. With this feature, the engine helps slow brakes can cause the tires to lose traction, re- the vehicle down after you take your foot off ducing control of the vehicle and increasing Page Leaving The Vehicle Leaving the vehicle Parking on a flat area Do not get out of the vehicle while the engine When parking on a flat area, stop the engine is running and the drive select lever is in any and shift the drive select lever into the neutral gear.

Page Loading 4. With the brake pedal applied, set the Operation on different surfaces and parking brake. Block the front and rear wheels with Go slowly and proceed with caution when op- rocks or other objects. This vehicle may handle differently in certain Loading types of terrains or on certain surfaces. Page Hills Hills Choose carefully which hills you attempt to climb or descend. Avoid hills with slippery sur- faces or those where you will not be able to see far enough ahead of you.

Use common sense and remember that some hills are too steep for you to climb or descend. Page Uphill Uphill Slow down when you reach the crest of the hill Do not attempt to climb hills until you have if you cannot see clearly what is on the other mastered basic maneuvers on flat ground.

Page Downhill Downhill If you are sliding or skidding, try to steer in the Check the terrain carefully before going direction the vehicle is sliding, to regain con- downhill. When possible, choose a path that trol. For example, if you feel the back of the lets you drive your vehicle straight downhill.

Page Rough Terrain Rough terrain Water Operation over rough terrain should be done If you must cross shallow, slow-moving water with caution. Page Brush Or Wooded Areas Brush or wooded areas Encountering obstacles When operating in areas with brush or trees, If you cannot go around an obstacle, such as watch carefully on both sides and above the a fallen tree or a ditch, stop the vehicle where vehicle for obstacles such as branches that it is safe to do so.

If you are not familiar with vehicle Brake discs, calipers, drums, and linings service, have a Yamaha dealer perform can become very hot during use. To avoid service. Page If you do not 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.

Hood 1. Secure pro- are in place when closing the hood. Page Console 5B Console To install 1. Place the console in its original position. To remove 2. Install the parking brake lever boot. Remove the seats. See pages — 3. Install the seats. In addition, change the oil and the oil filter car- tridge at the intervals specified in the periodic maintenance and lubrication chart.

To check the engine oil level 1. Page 5. Insert the dipstick completely into the oil 7. Insert the dipstick completely into the oil filler hole, and then remove it again to filler hole.

Install the console. The engine oil should be between the mini- mum and maximum level marks. Page To change the engine oil with or without oil filter cartridge replacement 1. Park the vehicle on a level surface. Remove the console. See page for console removal and installation proce- dures. Start the engine, warm it up for several minutes, and then turn it off.

Page If the O-ring remains attached to the crankcase, oil leakage may occur. An oil filter wrench is available from a Yamaha dealer. 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. Page Refill with the specified amount of recom- mended engine oil, and then insert the dipstick completely into the oil filler hole.

Recommended engine oil: See pages — Oil quantity: Without oil filter cartridge replacement: 2. Remove the final gear oil filler bolt and its additives with oil. Page 3. If the oil is below the brim of the filler hole, Changing the final gear oil add sufficient oil of the recommended 1. Place an oil pan under the final gear case 6. Refill with the recommended final gear oil to collect the used oil. Remove the final gear oil filler bolt and its Be sure no foreign material enters the O-ring, the final gear oil drain bolt and its final gear case.

Page Differential Gear Oil 5B 9. Install the final gear case guard by install- Differential gear oil ing the bolts and the collars, and then tightening the bolts to the specified Checking the differential gear oil level torque. Page 4. Check the gasket for damage, and re- place it if necessary. Install the differential gear oil filler bolt and its gasket, and then tighten the bolt to the specified torque.

Tightening torque: Differential gear oil filler bolt: 23 Nm 2. Page Changing the differential gear oil 3. Place an oil pan under the differential 1. Remove the differential gear case guard 4. Remove the differential gear oil filler bolt, by removing the bolts and the collars.

Page 9. Check for oil leakage. If oil leakage is Tightening torque: found, check for the cause. Differential gear oil drain bolt: Install the differential gear case guard by 9. Page Coolant 5B Coolant The coolant level should be checked before each ride.

Checking the coolant level 1. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level varies with engine tempera- ture. Remove the spark plug cap. Spark plug cap 3. Use the spark plug wrench in the tool kit to remove the spark plug as shown. Page Inspection The spark plug is an important engine compo- nent and is easy to inspect.

The condition of the spark plug can indicate the condition of the engine. The ideal color of the porcelain insulator around the center electrode is a medium-to- light tan for a vehicle that is being ridden nor- mally. Page Measure the spark plug gap with a wire thick- 2. Install the spark plug and tighten it to the ness gauge and, if necessary, adjust the gap specified torque. If a torque wrench is not to specification. Page Cleaning The Air Filter Element 5B Cleaning the air filter element There is a check hose at the bottom of the air filter case and at the bottom of the air duct un- der the case.

If dust or water collects in a check hose, empty the hose and clean the air filter element and air filter case. Page 1.

Open the hood. See pages — for 3. Remove the air filter case cover by un- hood opening and closing procedures. Remove the air intake duct shroud by re- moving the quick fastener screws. Remove the air filter element. Remove the sponge material from the air filter frame. Air filter element 1. Air filter frame 2. Sponge material Thoroughly apply Yamaha foam air filter oil or other quality liquid foam air filter oil not spray type to the sponge material.

The sponge material should be wet but not dripping. Insert the projections on the air filter case The air filter element should be cleaned every cover into the holders on the air filter 20—40 hours. It should be cleaned and lubri- case, and then install the air filter case cated more often if the vehicle is operated in cover by hooking the holders onto the extremely dusty areas.

Page Drive Select Lever Box Check Hose 2P 5B Drive select lever box check hose V-belt cooling duct check hose The drive select lever box check hose is locat- The V-belt cooling duct check hose is located ed under the console. See page for con- under the cargo bed. If dust or water collects sole removal and installation procedures. If in the V-belt cooling duct check hose, remove dust or water collects in the drive select lever Remove the tailpipe bolts.

Page Valve Clearance To prevent this, the valve clear- ance must be adjusted regularly. This adjust- ment however, should be left to a professional Yamaha service technician. Tailpipe 2. Spark arrester 3. Gasket 4. Page Brakes 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.

Page Checking The Parking Brake Pads Check the pad has worn to a wear indicator groove, have brake fluid level with the top of the reservoir a Yamaha dealer replace the brake pads as a level. Replenish the brake fluid if necessary. If the brake fluid erwise, the rubber seals may deterio- level goes down suddenly, have a Yamaha rate, causing leakage.

Page Checking The Brake Pedal EVU EVU Checking the brake pedal Parking brake lever free play adjustment Have a Yamaha dealer check the brakes at Periodically check the parking brake lever free the intervals specified in the periodic mainte- play and adjust it if necessary.

Page a. Parking brake lever free play 1. Rubber cover 2. Locknut 3. Adjusting nut 8. Turn the adjusting nut in direction a to 5. Release the parking brake lever. Slide the rubber cover back on the park- ing brake cable.

Page Brake Light Switch Adjustment EVU Brake light switch adjustment The brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. See pages — for hood opening and closing procedures. Lubricate the cable ends. If the cables do not operate smoothly, ask a Yamaha dealer to re- place them.

Recommended lubricant: Lithium-soap-based grease Lubricate the knuckle upper and lower lubrication left and right pivots with a grease gun. Remove the lower arm protector by re- moving the bolts. Recommended lubricant: 1.

Install the lower arm protector by install- Steering shaft lubrication ing the bolts and tightening them to the Lubricate the pivot points. Recommended lubricant: Tightening torque: Lithium-soap-based grease Lower arm protector bolt: 7 Nm 0.

Loosen the wheel nuts. Always use the same size and type of tires 2. The stand under the frame. Install the wheel and the nuts.