differential YAMAHA RHINO 700 2012 Owners Manual

EVU00050
1 -CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ....................... 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION ........................................ 3-1
INSTRUMENT AND CONTROL
FUNCTIONS ............................................ 4-1
Main switch........................................... 4-1
Indicator lights and warning lights ........ 4-3
Multi-function meter unit ..................... 4-13
Light switch......................................... 4-25
Accelerator pedal ............................... 4-29
Brake pedal ........................................ 4-31
Parking brake lever ............................ 4-31
Drive select lever ................................ 4-33
Fuel tank cap ...................................... 4-33
Doors .................................................. 4-35
Seats .................................................. 4-37
Seat belts ........................................... 4-39
Glove compartment ............................ 4-39
Cup holders ........................................ 4-41
Cargo bed........................................... 4-43
1234
Adjusting the front and rear shock
absorber assemblies (YXR7FB/
YXR700FAB) ................................... 4-49
Adjusting the front shock absorber
assemblies (YXR7FSPB)................. 4-53
Adjusting the rear shock absorber
assemblies (YXR7FSPB)................. 4-67
Trailer hitch bracket and receiver....... 4-79
Auxiliary DC jack ................................ 4-79
FOR YOUR SAFETY –
PRE-OPERATION CHECKS ................... 5-1
Front and rear brakes .......................... 5-7
Fuel .................................................... 5-11
Engine oil ........................................... 5-19
Coolant............................................... 5-21
Final gear oil ...................................... 5-23
Differential gear oil ............................. 5-23
Accelerator pedal ............................... 5-25
Seat belts ........................................... 5-25
Steering.............................................. 5-27
Fittings and fasteners......................... 5-27
Instruments, lights and switches ........ 5-29
Control cables .................................... 5-29
5
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Tires ....................................................5-29
OPERATION ............................................6-1
Engine break-in .....................................6-3
Starting the engine ................................6-7
Drive select lever operation and
reverse driving ..................................6-11
On-Command four-wheel-drive
switch and differential gear lock
switch ................................................6-19
Parking ................................................6-23
Loading ...............................................6-25
BASIC GUIDE FOR SAFE USE ...............7-1
KNOW YOUR VEHICLE .......................7-3
Driver requirements ..............................7-7
Passenger requirements .......................7-9
Occupant protection system ...............7-11
Protective structure .............................7-13
Seat belts ............................................7-17
Doors ..................................................7-25
Passenger handholds .........................7-27
Seat and hip restraints ........................7-29
Floorboard...........................................7-29
Steering wheel ....................................7-31
LEARNING TO OPERATE YOUR
VEHICLE ..........................................7-33
67
Personal protective equipment ........... 7-33
Practice for new Rhino users.............. 7-35
Getting ready to ride ........................... 7-37
Turning ............................................... 7-39
Accelerating ........................................ 7-43
Braking ............................................... 7-45
Engine braking.................................... 7-45
Leaving the vehicle ............................. 7-47
Parking on a flat area ......................... 7-47
Parking on a slope .............................. 7-49
Loading ............................................... 7-51
Operation on different surfaces and
terrains ............................................. 7-53
Hills ..................................................... 7-55
Uphill................................................... 7-57
Downhill .............................................. 7-61
Rough terrain ...................................... 7-65
Pavement ........................................... 7-65
Water .................................................. 7-67
Loose terrain/slippery terrain .............. 7-71
Brush or wooded areas ...................... 7-73
Encountering obstacles ...................... 7-75
1RB60-EE.book Page 2 Thursday, April 7, 2011 10:43 AM

PERIODIC MAINTENANCE AND
ADJUSTMENT ......................................... 8-1
Owner’s manual and tool kit ................. 8-5
Periodic maintenance chart for the
emission control system ..................... 8-7
General maintenance and lubrication
chart ................................................... 8-8
Hood ................................................... 8-17
Console .............................................. 8-21
Engine oil and oil filter cartridge ......... 8-25
Final gear oil ....................................... 8-39
Differential gear oil ............................. 8-47
Coolant ............................................... 8-55
Axle boots........................................... 8-59
Spark plug inspection ......................... 8-61
Cleaning the air filter element............. 8-67
Drive select lever box check hose ...... 8-79
V-belt cooling duct check hose........... 8-79
V-belt case drain plug......................... 8-81
Cleaning the spark arrester ................ 8-83
Valve clearance .................................. 8-85
Brakes ................................................ 8-87
Checking the front and rear brake
pads ................................................. 8-89
Checking the parking brake pads ....... 8-91
Checking the brake fluid level ............ 8-93
Brake fluid replacement...................... 8-99
8
Checking the brake pedal .................. 8-99
Parking brake lever free play
adjustment ..................................... 8-101
Brake light switch adjustment .......... 8-105
Cable inspection and lubrication ...... 8-107
Brake pedal and accelerator pedal
lubrication ...................................... 8-109
Rear knuckle upper and lower pivot
lubrication (left and right) ............... 8-111
Steering shaft lubrication ................. 8-115
Wheel removal ................................. 8-115
Tire replacement .............................. 8-117
Wheel installation ............................. 8-119
Battery.............................................. 8-121
Jump-starting ................................... 8-131
Fuse replacement ............................ 8-137
Replacing a headlight bulb............... 8-143
Headlight beam adjustment ............. 8-149
Tail/brake light bulb replacement ..... 8-151
Troubleshooting ............................... 8-157
Troubleshooting charts .................... 8-159
CLEANING AND STORAGE ................... 9-1
A. Cleaning .......................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS................................. 10-1
910
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3-2
3
26. Light switch
27. Steering wheel
28. Main switch
29. On-Command four-wheel-drive and differential gear lock switches
30. Multi-function 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 switchThe vehicle you have purchased may differ slightly
from those shown in the figures of this manual.
R
S P
QT
Y Z
X
H W
[
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V
1RB60-EE.book Page 2 Thursday, April 7, 2011 10:43 AM

4-3
1. On-Command differential gear lock indicator light “DIFF. LOCK”
2. Low-range indicator light “L”3. High-range indicator light “H”
4. Neutral indicator light “N”5. Reverse indicator light “R”
6. Parking brake indicator light “P”
7. On-Command four-wheel-drive/differential gear lock indicator
“”/“”
8. Coolant temperature warning light “”
9. Engine trouble warning light “”
1. Témoin de blocage du différentiel “DIFF. LOCK”
2. Témoin de la gamme basse “L”3. Témoin de la gamme haute “H”
4. Témoin de point mort “N”5. Témoin de la marche arrière “R”
6. Témoin du frein de stationnement “P”
7. Indicateur de la commande du mode de traction/du système de
blocage du différentiel “”/“”
8. Témoin d’alerte de la température du liquide de refroidissement “”
9. Témoin d’alerte de panne du moteur “”
1. Testigo de bloqueo del diferencial On-Command “DIFF. LOCK”
2. Testigo de marcha corta “L”3. Testigo de marcha larga “H”
4. Testigo de punto muerto “N”5. Testigo de marcha atrás “R”
6. Testigo del freno de estacionamiento “P”
7. Indicador de tracción a las cuatro ruedas/bloqueo del diferencial
On-Command “”/“”
8. Luz de aviso de la temperatura del líquido refrigerante “”
9. Luz de aviso de avería del motor “”
1
2
3
4
5
6
8
9 7
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
EVU00150
Indicator lights and warning lights
EVU01131
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.
EVU00170
Neutral indicator light “N”
This indicator light comes on when the drive select
lever is in the “N” position.
5B410001
Reverse indicator light “R”
This indicator light comes on when the drive select
lever is in the “R” position.
EVU00210
Parking brake indicator light “P”
This indicator light comes on when the parking
brake is applied.
1RB60-EE.book Page 3 Thursday, April 7, 2011 10:43 AM

4-5
1. On-Command differential gear lock indicator light “DIFF. LOCK”
2. Low-range indicator light “L”3. High-range indicator light “H”
4. Neutral indicator light “N”5. Reverse indicator light “R”
6. Parking brake indicator light “P”
7. On-Command four-wheel-drive/differential gear lock indicator
“”/“”
8. Coolant temperature warning light “”
9. Engine trouble warning light “”
1. Témoin de blocage du différentiel “DIFF. LOCK”
2. Témoin de la gamme basse “L”3. Témoin de la gamme haute “H”
4. Témoin de point mort “N”5. Témoin de la marche arrière “R”
6. Témoin du frein de stationnement “P”
7. Indicateur de la commande du mode de traction/du système de
blocage du différentiel “”/“”
8. Témoin d’alerte de la température du liquide de refroidissement “”
9. Témoin d’alerte de panne du moteur “”
1. Testigo de bloqueo del diferencial On-Command “DIFF. LOCK”
2. Testigo de marcha corta “L”3. Testigo de marcha larga “H”
4. Testigo de punto muerto “N”5. Testigo de marcha atrás “R”
6. Testigo del freno de estacionamiento “P”
7. Indicador de tracción a las cuatro ruedas/bloqueo del diferencial
On-Command “”/“”
8. Luz de aviso de la temperatura del líquido refrigerante “”
9. Luz de aviso de avería del motor “”
1
2
3
4
5
6
8
9 7
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
EVU01161
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” position.
The On-Command differential gear lock indicator
“” and the On-Command differential gear lock
indicator light “DIFF. LOCK” come on when the
On-Command differential gear lock switch is set to
the “LOCK” position.TIP

Due to the synchronizing mechanism in the
differential gear case, the four-wheel-drive in-
dicator may not come on until the Rhino
starts moving.


When the On-Command differential gear lock
switch is set to “LOCK” or “4WD”, the indica-
tor “” and the indicator light “DIFF. LOCK”
will flash until the differential gear is com-
pletely locked or unlocked. If the indicator
and the indicator light continue to flash, the
differential is not completely locked or un-
locked. In this case, start moving to allow
time for the differential to lock or unlock.
DIFF.
LOCK
DIFF.
LOCK
1RB60-EE.book Page 5 Thursday, April 7, 2011 10:43 AM

4-7
1. On-Command differential gear lock indicator light “DIFF. LOCK”
2. Low-range indicator light “L”3. High-range indicator light “H”
4. Neutral indicator light “N”5. Reverse indicator light “R”
6. Parking brake indicator light “P”
7. On-Command four-wheel-drive/differential gear lock indicator
“”/“”
8. Coolant temperature warning light “”
9. Engine trouble warning light “”
1. Témoin de blocage du différentiel “DIFF. LOCK”
2. Témoin de la gamme basse “L”3. Témoin de la gamme haute “H”
4. Témoin de point mort “N”5. Témoin de la marche arrière “R”
6. Témoin du frein de stationnement “P”
7. Indicateur de la commande du mode de traction/du système de
blocage du différentiel “”/“”
8. Témoin d’alerte de la température du liquide de refroidissement “”
9. Témoin d’alerte de panne du moteur “”
1. Testigo de bloqueo del diferencial On-Command “DIFF. LOCK”
2. Testigo de marcha corta “L”3. Testigo de marcha larga “H”
4. Testigo de punto muerto “N”5. Testigo de marcha atrás “R”
6. Testigo del freno de estacionamiento “P”
7. Indicador de tracción a las cuatro ruedas/bloqueo del diferencial
On-Command “”/“”
8. Luz de aviso de la temperatura del líquido refrigerante “”
9. Luz de aviso de avería del motor “”
1
2
3
4
5
6
8
9 7
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
5B410002
Coolant temperature warning light “”
If the coolant temperature reaches a specific level,
this light comes on to warn that the coolant tem-
perature 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 8-158.)
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 light remains on,
have a Yamaha dealer check the electrical circuit.NOTICE

The engine may overheat if the vehicle is
overloaded. If this happens, reduce the
load to specification.


After restarting, make sure that the warn-
ing light is out. Continuous use while this
warning light is on may cause damage to
the engine.
1RB60-EE.book Page 7 Thursday, April 7, 2011 10:43 AM

4-9
1. On-Command differential gear lock indicator light “DIFF. LOCK”
2. Low-range indicator light “L”3. High-range indicator light “H”
4. Neutral indicator light “N”5. Reverse indicator light “R”
6. Parking brake indicator light “P”
7. On-Command four-wheel-drive/differential gear lock indicator
“”/“”
8. Coolant temperature warning light “”
9. Engine trouble warning light “”
1. Témoin de blocage du différentiel “DIFF. LOCK”
2. Témoin de la gamme basse “L”3. Témoin de la gamme haute “H”
4. Témoin de point mort “N”5. Témoin de la marche arrière “R”
6. Témoin du frein de stationnement “P”
7. Indicateur de la commande du mode de traction/du système de
blocage du différentiel “”/“”
8. Témoin d’alerte de la température du liquide de refroidissement “”
9. Témoin d’alerte de panne du moteur “”
1. Testigo de bloqueo del diferencial On-Command “DIFF. LOCK”
2. Testigo de marcha corta “L”3. Testigo de marcha larga “H”
4. Testigo de punto muerto “N”5. Testigo de marcha atrás “R”
6. Testigo del freno de estacionamiento “P”
7. Indicador de tracción a las cuatro ruedas/bloqueo del diferencial
On-Command “”/“”
8. Luz de aviso de la temperatura del líquido refrigerante “”
9. Luz de aviso de avería del motor “”
1
2
3
4
5
6
8
9 7
DIFF.
LOCK
DIFF.
LOCK
DIFF.
LOCK
5B410003
Engine trouble warning light “”
This warning light comes on or flashes if a problem
is detected in the electrical circuit monitoring the
engine. When this occurs, have a Yamaha dealer
check the self-diagnosis system. (See page 4-23
for an explanation 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 light remains on,
have a Yamaha dealer check the electrical circuit.
1RB60-EE.book Page 9 Thursday, April 7, 2011 10:43 AM

4-27 1. On-Command four-wheel-drive switch “2WD”/“4WD”
2. On-Command differential gear lock switch “4WD”/“LOCK”
1. Commutateur du mode de traction “2WD”/“4WD”
2. Commutateur de blocage du différentiel “4WD”/“LOCK”
1. Conmutador de tracción On-Command “2WD”/“4WD”
2. Conmutador de bloqueo del diferencial On-Command
“4WD”/“LOCK”
EVU01183
On-Command four-wheel-drive and differential
gear lock switches
This vehicle is equipped with an On-Command
four-wheel-drive switch “2WD”/“4WD” and a differ-
ential gear lock switch “4WD”/“LOCK”. Select the
appropriate drive according to terrain and condi-
tions.

“2WD” (two-wheel drive): Power is supplied to
the rear wheels only.


“4WD” (four-wheel drive): Power is supplied to
the rear and front wheels.


“LOCK” (four-wheel drive with the differential
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.
1RB60-EE.book Page 27 Thursday, April 7, 2011 10:43 AM

5-1
EVU01200
1 -FOR YOUR SAFETY – PRE-OPERATION CHECKS
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always fol-
low the inspection and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equip-
ment damage. Do not operate the vehicle if you find any problem. If a problem cannot be corrected
by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEM ROUTINE PAGE
BrakesCheck operation, free play, fluid level, and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-7–5-9, 8-87–8-89,
8-93–8-97, 8-103
Parking brakeCheck for proper operation, condition, and free play. 8-91, 8-99–8-101
FuelCheck fuel level.
Fill with fuel if necessary.5-11–5-17
Engine oilCheck oil level.
Fill with oil to proper level if necessary.5-19, 8-25–8-37
CoolantCheck coolant level.
Fill with coolant if necessary.5-21, 8-55–8-57
Final gear oil/
Differential gear oilCheck for leakage. 5-23, 8-39–8-53
Accelerator pedalCheck for proper accelerator pedal operation. 5-25
Seat beltsCheck for proper operation and belt wear. 5-25
1RB60-EE.book Page 1 Thursday, April 7, 2011 10:43 AM