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Rhino 2005
Yamaha Rhino 2005 Manuals
Manuals and User Guides for Yamaha Rhino 2005. We have
1
Yamaha Rhino 2005 manual available for free PDF download: Service Manual
Yamaha Rhino 2005 Service Manual (506 pages)
Brand:
Yamaha
| Category:
Offroad Vehicle
| Size: 23.6 MB
Table of Contents
Table of Contents
4
Specifications
2
Table of Contents
4
Chapter 1 General Information
14
Vehicle Identification
14
Model Label
14
Vehicle Identification Number
14
Features
15
Self-Adjusting Parking Brake Mechanism
15
Important Information
18
Gaskets, Oil Seals and O-Rings
18
Preparation for Removal Procedures
18
Replacement Parts
18
Bearings and Oil Seals
19
Circlips
19
Lock Washers/Plates and Cotter Pins
19
Checking of Connections
20
Special Tools
21
Chapter 2 Specifications
26
General Specifications
26
Engine Specifications
29
Chassis Specifications
37
Electrical Specifications
39
Tightening Torques
41
Engine Tightening Torques
41
Chassis Tightening Torques
44
General Tightening Torque Specifications
47
How to Use the Conversion Table
47
Lubrication Points and Lubricant Types
48
Engine
48
Coolant Flow Diagrams
49
Oil Flow Diagrams
52
Cable Routing
57
Chapter 3 Periodic Checks and Adjustments
74
Introduction
74
Periodic Maintenance/Lubrication
74
Engine
76
Adjusting the Valve Clearance
76
Adjusting the Idling Speed
79
Adjusting the Timing Chain
79
Adjusting the Throttle Cable
80
Adjusting the Starter Cable
81
Checking the Spark Plug
82
Checking the Ignition Timing
83
Measuring the Compression Pressure
84
Checking the Engine Oil Level
86
Changing the Engine Oil
87
Cleaning the Air Filter
89
Checking the Coolant Level
91
Changing the Coolant
92
Cooling System
94
Checking the Coolant Temperature Warning Light
96
Checking the V-Belt
97
Cleaning the Spark Arrester
98
Chassis
99
Adjusting the Brake Pedal
99
Adjusting the Parking Brake
100
Checking the Brake Fluid Level
101
Checking the Front Brake Pads
102
Checking the Rear Brake Pads
102
Bleeding the Hydraulic Brake System
103
Checking the Brake Hoses and Brake Pipes
103
Adjusting the Brake Light Switch
105
Adjusting the Select Lever Shift Rod
105
Checking the Final Gear Oil Level
106
Changing the Final Gear Oil
107
Checking the Differential Gear Oil
107
Changing the Differential Gear Oil
108
Checking the Constant Velocity Joint Dust Boots
109
Adjusting the Toe-In
110
Checking the Steering System
110
Adjusting the Front Shock Absorbers
112
Adjusting the Rear Shock Absorbers
112
Checking the Tires
113
Checking and Lubricating the Cables
115
Checking the Wheels
115
Lubricating the Pedal, Etc
116
Electrical
117
Checking and Charging the Battery
117
Checking the Fuses
122
Adjusting the Headlight Beam
124
Changing the Headlight Bulb
124
Changing the Tail/Brake Light Bulb
125
Chapter 4 Engine
127
Engine Removal
127
Air Ducts, Muffler and Exhaust Pipe
127
Select Lever Unit and Coolant Reservoir
129
Hoses and Leads
130
Engine Mounting Bolts
132
Installing the Engine
134
Cylinder Head Cover
135
Checking the Cylinder Head Cover
137
Checking the Tappet Covers
137
Removing the Cylinder Head Cover
137
Installing the Cylinder Head Cover
138
Rocker Arms
139
Checking the Rocker Arms
141
Removing the Rocker Arms
141
Installing the Rocker Arms
142
Camshaft and Cylinder Head
143
Checking the Camshaft
145
Removing the Camshaft and Cylinder Head
145
Checking the Camshaft Sprocket
146
Checking the Decompression System
146
Checking the Timing Chain Guide (Exhaust Side)
146
Checking the Timing Chain Tensioner
146
Checking the Cylinder Head
147
Installing the Camshaft and Cylinder Head
148
Valves and Valve Springs
151
Removing the Valves and Valve Springs
152
Checking the Valves and Valve Springs
153
Installing the Valves and Valve Springs
157
Cylinder and Piston
159
Checking the Cylinder and Piston
160
Removing the Piston
160
Checking the Piston Rings
162
Checking the Piston Pin
163
Installing the Piston
163
Installing the Cylinder
165
Engine Cooling Fan and A.C. Magneto
166
Checking the A.C. Magneto
169
Removing the A.C. Magneto
169
Checking the Starter Clutch
170
Checking the Engine Cooling Fan
171
Installing the A.C. Magneto
171
Balancer Gears and Oil Pump Gears
174
Checking the Balancer Drive Gear and Balancer Driven Gear
176
Checking the Oil Pump Drive Gear and Oil Pump Driven Gear
176
Removing the Balancer Drive Gear and Balancer Driven Gear
176
Installing the Balancer Drive Gear and Balancer Driven Gear
177
Primary and Secondary Sheaves
178
Primary Sheave
180
Secondary Sheave
181
Disassembling the Secondary Sheave
182
Removing the Primary and Secondary Sheaves
182
Checking the Primary Sheave
183
Checking the Secondary Sheave
183
Assembling the Primary Sheave
184
Assembling the Secondary Sheave
184
Installing the Primary and Secondary Sheaves
186
Clutch
187
Checking the Clutch
189
Removing the Clutch
189
Installing the Clutch
190
Crankcase
192
Starter Motor, Timing Chain and Oil Filter
192
Crankcase
193
Crankcase Bearings
195
Checking the Oil Delivery Pipe
196
Checking the Timing Chain and Guides
196
Separating the Crankcase
196
Assembling the Crankcase
197
Checking the Bearings
197
Checking the Crankcase
197
Checking the Relief Valve
197
Installing the Shift Levers
198
Crankshaft and Oil Pump
199
Oil Pump
200
Checking the Oil Pump
201
Removing the Crankshaft
201
Assembling the Oil Pump
202
Checking the Oil Strainer
202
Checking the Relief Valve
202
Checking the Crankshaft
203
Installing the Crankshaft and Balancer
204
Transmission
205
Drive Axle Assembly
206
Checking the Shift Forks
207
Removing the Transmission
207
Checking the Drive Axle
208
Checking the High Wheel Gear and Middle Drive Gear
208
Checking the Shift Drum
208
Checking the Chain
209
Checking the Secondary Shaft and Driven Sprocket
209
Assembling the Shift Fork Assembly
210
Installing the Transmission
210
Middle Gear
211
Middle Drive Shaft
211
Middle Driven Shaft
212
Removing the Middle Drive Shaft
214
Removing the Middle Driven Shaft
214
Checking the Pinion Gears
217
Selecting the Middle Drive and Driven Gear Shims
218
Installing the Middle Driven Shaft
221
Installing the Middle Drive Shaft
223
Measuring the Middle Gear Backlash
224
Chapter 5 Cooling System
225
Radiator and Coolant Reservoir
225
Checking the Radiator
227
Installing the Radiator
228
Water Pump
229
Checking the Water Pump
231
Disassembling the Water Pump
231
Assembling the Water Pump
232
Oil Cooler
234
Checking the Oil Cooler
236
Chapter 6 Fuel System
237
Fuel Pump and Fuel Tank
237
Checking the Fuel Pump Operation
239
Carburetor
240
Checking the Carburetor
244
Disassembling the Carburetor
244
Assembling the Carburetor
246
Adjusting the Fuel Level
247
Chapter 7 Drive Train
248
Troubleshooting
248
Front Constant Velocity Joints, Differential Gear and Drive Shaft
251
Disassembling the Universal Joint
256
Removing the Differential Gear Assembly
256
Checking the Constant Velocity Joints
257
Checking the Differential Gear
257
Assembling the Front Constant Velocity Joints
258
Checking the Gear Motor
258
Assembling the Differential Gear
259
Assembling the Universal Joint
261
Measuring and Adjusting the Differential Gear Lash
261
Checking the Differential Gear Operation
263
Rear Constant Velocity Joints, Final Drive Gear and Drive Shaft
265
Assembling the Rear Constant Velocity Joints
271
Disassembling the Final Gear Case
271
Removing the Final Drive Roller Bearings
272
Installing the Final Drive Roller Bearings
273
Positioning the Final Drive Pinion Gear and Ring Gear
273
Checking the Drive Shaft
278
Checking the Final Gear Case
278
Measuring and Adjusting the Final Gear Lash
279
Assembling the Final Gear Case
280
Seats, Enclosure, Hood and Cargo Bed
283
Chapter 8
283
Chassis
283
Front Bumper and Hood
283
Seats, Console and Instrument Panels
284
Panels and Footrest Cover
286
Cargo Bed
288
Skid Plates
290
Enclosure and Seat Belts
291
Front Wheels and Brake Discs
292
Checking the Front Wheel
294
Checking the Front Wheel Hub
294
Checking the Front Brake Disc
295
Installing the Front Wheel
295
Installing the Front Wheel Hub
295
Rear Wheels and Brake Disc
296
Rear Wheels
296
Rear Brake Disc
297
Checking the Rear Brake Disc
298
Checking the Rear Wheel
298
Checking the Rear Wheel Hub
298
Installing the Rear Wheel
299
Installing the Rear Wheel Hub
299
Front and Rear Brakes
300
Front Brake Pads
300
Rear Brake Pads
301
Replacing the Front Brake Pads
302
Replacing the Rear Brake Pads
303
Brake Master Cylinder
306
Assembling the Brake Master Cylinder
308
Checking the Master Cylinder
308
Installing the Brake Master Cylinder
309
Front Brake Caliper
311
Rear Brake Caliper
313
Disassembling the Front Brake Calipers
317
Disassembling the Rear Brake Caliper
317
Checking the Front and Rear Brake Calipers
318
Assembling the Front Brake Calipers
319
Assembling the Rear Brake Caliper
320
Installing the Front Brake Calipers
322
Installing the Rear Brake Caliper
323
Pedal Assembly
325
Steering System
327
Steering Column and Steering Assembly
327
Checking the Steering Assembly
330
Checking the Steering Joint
330
Disassembling the Steering Assembly
330
Assembling the Steering Assembly
331
Installing the Steering System
332
Tie-Rod and Steering Knuckle
333
Checking the Steering Knuckles
334
Checking the Tie-Rods
334
Removing the Steering Knuckles
334
Front Arms and Front Shock Absorber
338
Checking the Front Arms
340
Removing the Front Arms
340
Checking the Front Shock Absorber
342
Installing the Front Arms and Front Shock Absorber
343
Rear Knuckle and Stabilizer
344
Checking the Rear Knuckle
345
Checking the Stabilizer
345
Rear Arms and Rear Shock Absorber
346
Checking the Rear Arms
347
Checking the Rear Shock Absorber
347
Installing the Rear Arms and Rear Shock Absorber
348
Chapter 9 Electrical
349
Electrical Components
350
Checking the Switch
351
Checking a Switch Shown in the Manual
351
Checking the Switch Continuity
352
Checking the Bulbs and Bulb Sockets
354
Checking the Condition of the Bulbs
354
Types of Bulbs
354
Checking the Condition of the Bulb Sockets
356
Ignition System
357
Circuit Diagram
357
Troubleshooting
358
Electric Starting System
363
Circuit Diagram
363
Starting Circuit Operation
364
Troubleshooting
365
Starter Motor
368
Checking the Starter Motor
369
Assembling the Starter Motor
370
Charging System
371
Circuit Diagram
371
Troubleshooting
372
Lighting System
374
Circuit Diagram
374
Troubleshooting
375
Checking the Lighting System
377
Signaling System
379
Circuit Diagram
379
Troubleshooting
381
Circuit Diagram
382
Checking the Signal System
383
Cooling System
393
Circuit Diagram
393
Troubleshooting
394
Circuit Diagram
397
2Wd/4Wd Selecting System
398
Circuit Diagram
398
Troubleshooting
399
Circuit Diagram
402
Carburetor Heating System
403
Circuit Diagram
403
Troubleshooting
404
Circuit Diagram
406
Troubleshooting
407
Starting Failure/Hard Starting
407
Chapter 10
407
Electrical System
407
Fuel System
407
Compression System
408
Poor Idle Speed Performance
408
Poor Medium and High-Speed Performance
408
Faulty Drive Train
409
Faulty Clutch Performance
410
Clutch Slipping
410
Engine Operates but Vehicle will Not Move
410
Poor Starting Performance
410
Poor Speed Performance
411
Faulty Gear Shifting
410
Hard Shifting
410
Jumps out of Gear
410
Shift Lever Does Not Move
410
Faulty Brake
411
Poor Braking Effect
411
Overheating
411
Shock Absorber Malfunction
411
Malfunction
411
Lighting System
412
Bulb Burnt out
412
Headlight Does Not Come on
412
Unstable Handling
412
Table of Contents
416
Specifications
417
General Specifications
417
Engine Specifications
418
Chassis Specifications
418
Electrical Specifications
418
Tightening Torques
419
Chassis Tightening Torques
419
Engine Tightening Torques
419
Cable Routing
420
Periodic Checks and Adjustments
436
Introduction
436
Periodic Maintenance/Lubrication
436
Engine
438
Cleaning the Air Filter Elements
438
Chassis
441
Adjusting the Parking Brake
441
Engine
442
Engine Removal
442
Air Ducts, Muffler and Exhaust Pipe
442
Fuel System
444
Carburetor
444
Installing the Air Filter Case Joint
446
Chassis
447
Seats, Enclosure, Hood and Cargo Bed
447
Seats, Console and Instrument Panels
447
Panels and Footrest Cover
449
Cargo Bed
450
Enclosure and Seat Belts
451
Yxr660Fat Wiring Diagram
452
Table of Contents
455
Specifications
456
General Specifications
456
Chassis Specifications
457
Electrical Specifications
458
Tightening Torques
458
Chassis Tightening Torques
458
Cable Routing
459
Periodic Checks and Adjustments
476
Electrical
476
Changing a Headlight Bulb
476
Engine
478
Engine Cooling Fan and A.C. Magneto
478
Cooling System
481
Oil Cooler
481
Chassis
483
Seats, Enclosure, Hood and Cargo Bed
483
Front Guard and Hood
483
Panels and Footrest Cover
484
Cargo Bed
485
Skid Plates
487
Installing the Rear Skid Plate
488
Enclosure and Seat Belts
489
Front Wheels and Brake Discs
490
Rear Wheels and Brake Disc
492
Rear Wheels
492
Front Arms and Front Shock Absorbers
493
Rear Knuckle and Stabilizer
495
Electrical
496
Electrical Components
496
Lighting System
498
Circuit Diagram
498
Troubleshooting
499
SIGNALING SYSTEM (for Special Edition Models)
501
Circuit Diagram
501
Checking the Signal System
503
Yxr66Fav 2006 Wiring Diagram
506
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