Yamaha rhino 700fi 2008 Manuals

Manuals and User Guides for Yamaha rhino 700fi 2008. We have 1 Yamaha rhino 700fi 2008 manual available for free PDF download: Service Manual

Yamaha rhino 700fi 2008 Service Manual (497 pages)

Off-road motorcycle

Brand: Yamaha | Category: Offroad Vehicle | Size: 55.94 MB

How to Use this Manual
4
Periodic Checks and
5
Table of Contents
8
Chapter 1 General Information

20
Vehicle Identification

20
- Vehicle Identification Number
  20
- Model Label
  20
Features

21
- Outline of the Fi System
  21
- Fi System
  22
- Instrument Functions
  23
Important Information

26
- Preparation for Removal and Disassembly
  26
- Replacement Parts
  26
- Gaskets, Oil Seals and O-Rings
  26
- Lock Washers/Plates and Cotter Pins
  27
- Bearings and Oil Seals
  27
- Circlips
  27
- Checking the Connections
  28
Special Tools

29
Chapter 2 Specifications

36
General Specifications

36
Engine Specifications

40
Chassis Specifications

47
Electrical Specifications

50
Tightening Torques

52
- Engine Tightening Torques
  52
- Chassis Tightening Torques
  55
General Tightening Torque Specifications

59
How to Use the Conversion Table

59
Lubrication Points and Lubricant Types

60
- Engine
  60
Coolant Flow Diagrams

62
Oil Flow Diagrams

64
Cable Routing

67
Chapter 3 Periodic Checks and Adjustments

85
Introduction

85
Periodic Maintenance Chart for the Emission Control System

85
General Maintenance and Lubrication Chart

86
Engine

87
- Adjusting the Valve Clearance
  87
- Adjusting the Throttle Cable
  90
- Checking the Spark Plug
  91
- Checking the Ignition Timing
  93
- Measuring the Compression Pressure
  94
- Checking the Engine Oil Level
  97
- Changing the Engine Oil
  98
- Cleaning the Air Filter Element
  100
- Checking the Throttle Body Joint
  103
- Checking the Fuel Hose
  103
- Checking the Breather Hoses
  104
- Checking the Coolant Level
  104
- Changing the Coolant
  105
- Checking the Cooling System
  109
- Checking the Coolant Temperature Warning Light
  110
- Checking and Replacing the V-Belt
  111
- Checking the Exhaust System
  112
- Cleaning the Spark Arrester
  113
Chassis

114
- Adjusting the Brake Pedal
  114
- Adjusting the Parking Brake
  115
- Checking the Brake Fluid Level
  116
- Checking the Front Brake Pads
  117
- Checking the Rear Brake Pads
  118
- Checking the Parking Brake Pads
  118
- Checking the Brake Hoses and Brake Pipes
  119
- Bleeding the Hydraulic Brake System
  120
- Adjusting the Select Lever Shift Rod
  121
- Adjusting the Brake Light Switch
  122
- Checking the Final Gear Oil Level
  122
- Changing the Final Gear Oil
  123
- Checking the Differential Gear Oil
  124
- Changing the Differential Gear Oil
  125
- Checking the Constant Velocity Joint Dust Boots
  127
- Checking the Steering System
  127
- Adjusting the Toe-In
  128
- Adjusting the Front Shock Absorbers
  130
- Adjusting the Rear Shock Absorbers
  132
- Checking the Tires
  135
- Checking the Wheels
  137
- Checking and Lubricating the Cables
  138
- Lubricating the Pedal, Etc
  138
Electrical System

139
- Checking and Charging the Battery
  139
- Checking the Fuses
  145
- Adjusting the Headlight Beams
  148
- Changing the Headlight Bulbs
  148
- Changing the Tail/Brake Light Bulb
  149
Chapter 4 Engine

151
Engine Removal

151
- V-Belt Cooling Ducts, Muffler and Exhaust Pipes
  151
- Installing the V-Belt Cooling Ducts
  154
- Shift Arm
  155
- Hoses and Leads
  156
- Engine Mounting Bolts
  158
- Installing the Engine
  160
Cylinder Head

161
- Removing the Cylinder Head
  164
- Checking the Camshaft Sprocket
  165
- Checking the Tappet Covers
  165
- Checking the Timing Chain Tensioner
  165
- Checking the Cylinder Head
  166
- Installing the Cylinder Head
  167
Rocker Arms and Camshaft

170
Valves and Valve Springs

177
Cylinder and Piston

186
- Removing the Piston
  187
- Checking the Cylinder and Piston
  187
- Checking the Piston Rings
  189
- Checking the Piston Pin
  190
- Installing the Piston and Cylinder
  191
Ac Magneto

194
Balancer Gears and Oil Pump Gears

201
Primary and Secondary Sheaves

205
- Primary Sheave
  207
- Secondary Sheave
  208
- Removing the Primary and Secondary Sheaves
  209
- Disassembling the Secondary Sheave
  209
- Checking the Primary Sheave
  210
- Checking the Secondary Sheave
  210
- Assembling the Primary Sheave
  211
- Assembling the Secondary Sheave
  212
- Installing the Primary and Secondary Sheaves
  214
Clutch

215
- Removing the Clutch
  217
- Checking the Clutch
  218
- Installing the Clutch
  219
Crankcase

220
- Timing Chain and Oil Filter
  220
- Crankcase
  221
- Crankcase Bearings
  223
- Separating the Crankcase
  224
- Checking the Timing Chain and Guide
  224
- Checking the Relief Valve
  224
- Checking the Bearings
  225
- Checking the Crankcase
  225
- Assembling the Crankcase
  225
- Installing the Shift Lever
  226
Crankshaft and Oil Pump

227
- Oil Pump
  228
- Removing the Crankshaft
  229
- Checking the Oil Pump
  229
- Checking the Oil Strainer
  230
- Checking the Crankshaft
  230
- Assembling the Oil Pump
  231
- Installing the Crankshaft
  231
Transmission

233
- Drive Axle
  235
- Removing the Transmission
  237
- Checking the Shift Forks
  237
- Checking the Shift Drum
  238
- Checking the Transmission
  238
- Checking the Secondary Shaft
  239
- Assembling the Shift Fork Assembly
  239
- Installing the Transmission
  239
Middle Gear

241
- Middle Drive Shaft
  241
- Middle Driven Shaft
  242
- Removing the Middle Drive Shaft
  244
- Removing the Middle Driven Shaft
  245
- Checking the Pinion Gears
  248
- Selecting Middle Drive and Driven Gear Shims
  248
- Installing the Bearing and Oil Seals
  252
- Installing the Middle Driven Shaft
  253
- Installing the Middle Drive Shaft
  255
- Measuring the Middle Gear Backlash
  256
Chapter 5 Cooling System

257
Radiator and Coolant Reservoir

257
- Checking the Radiator
  259
- Installing the Radiator
  260
Thermostat

261
- Checking the Thermostat
  262
- Installing the Thermostat
  262
Water Pump

263
- Disassembling the Water Pump
  265
- Checking the Water Pump
  265
- Assembling the Water Pump
  266
Oil Cooler

268
- Checking the Oil Cooler
  270
Chapter 6 Fuel Injection System

271
- Circuit Diagram
  272
- Ecu Self-Diagnostic Function
  274
- Self-Diagnostic Function Table
  275
- Troubleshooting Chart
  276
- Diagnostic Mode
  277
- Troubleshooting Details
  281
- Checking the Intake Air Pressure Sensor
  296
- Checking the Intake Air Temperature Sensor
  296
- Installing the Air Intake Duct and Air Filter Case
  301
Fuel Pump and Fuel Tank

302
- Removing the Fuel Tank
  304
- Removing the Fuel Pump
  304
- Checking the Fuel Pump Body
  305
- Checking the Rollover Valve
  305
- Installing the Fuel Pump
  305
- Installing the Fuel Hose
  306
Throttle Body

307
Chapter 7 Drive Train

316
Troubleshooting

316
- Checking Noises
  316
- Troubleshooting Chart
  318
Front Constant Velocity Joints, Differential Gear and Drive Shaft

319
Rear Constant Velocity Joints, Final Drive Gear and Drive Shaft

335
Chapter 8

358
- Front Guard and Hood
  358
- Seats, Rear Console and Instrument Panels
  359
- Removing the Steering Wheel
  361
- Installing the Steering Wheel
  361
- Side Doors
  362
- Panels and Front Console
  363
- Removing the Side Panels
  365
- Install the Side Panels
  365
- Cargo Bed
  366
- Skid Plates
  368
- Installing the Rear Skid Plate
  369
- Enclosure and Seat Belts
  370
- Installing the Enclosure
  371
Seats, Enclosure, Hood and Cargo Bed

358
Front and Rear Wheels

372
- Front Wheels
  372
- Rear Wheels
  374
- Checking the Wheels
  376
- Checking the Wheel Hubs
  376
- Checking the Brake Discs
  377
- Installing the Wheel Hubs
  377
- Installing the Wheels
  377
Front and Rear Brakes

378
- Front Brake Pads
  378
- Rear Brake Pads
  379
- Replacing the Front and Rear Brake Pads
  380
- Brake Master Cylinder
  382
- Checking the Master Cylinder
  384
- Assembling the Brake Master Cylinder
  384
- Installing the Brake Master Cylinder
  385
- Front Brake Caliper
  387
- Rear Brake Calipers
  389
- Checking the Front and Rear Brake Calipers
  391
- Assembling the Front and Rear Brake Calipers
  392
- Installing the Front and Rear Brake Calipers
  393
Parking Brake

395
- Parking Brake Pads
  395
- Replacing the Parking Brake Pads
  396
- Parking Brake
  397
- Parking Brake Disc
  400
- Checking the Parking Brake
  401
- Checking the Parking Brake Disc
  401
- Assembling the Parking Brake
  401
Pedal Assembly

404
Steering System

406
- Steering Shaft and Steering Assembly
  406
- Disassembling the Steering Assembly
  409
- Checking the Steering Joint
  409
- Checking the Steering Assembly
  409
- Assembling the Steering Assembly
  410
- Installing the Steering System
  411
- Tie-Rod and Steering Knuckle
  412
- Removing the Steering Knuckles
  413
- Checking the Tie-Rods
  413
- Checking the Steering Knuckles
  413
Front Arms and Front Shock Absorbers

417
Rear Knuckle and Stabilizer

424
- Checking the Rear Knuckles
  425
- Checking the Stabilizer
  425
Rear Arms and Rear Shock Absorber

426
Chapter 9 Electrical

431
Electrical Components

431
Checking Switch Continuity

433
Checking the Switches

434
Checking the Bulbs and Bulb Sockets

436
Ignition System

439
- Circuit Diagram
  439
- Troubleshooting
  440
Electric Starting System

444
- Circuit Diagram
  444
- Starting Circuit Operation
  445
- Troubleshooting
  446
Starter Motor

449
- Checking the Starter Motor
  451
- Assembling the Starter Motor
  453
Charging System

454
- Circuit Diagram
  454
- Troubleshooting
  455
Lighting System

457
- Circuit Diagram
  457
- Troubleshooting
  458
- Checking the Lighting System
  460
Signaling System

462
- Circuit Diagram
  462
- Troubleshooting
  464
- Checking the Signaling System
  466
Cooling System

475
- Circuit Diagram
  475
- Troubleshooting
  476
Fuel Pump System

480
- Circuit Diagram
  480
- Troubleshooting
  481
2Wd/4Wd Selecting System

483
- Circuit Diagram
  483
- Troubleshooting
  488
Chapter 10

488
- Fuel System
  488
- Electrical System
  488
- Compression System
  489
Starting Failure/Hard Starting

488
Poor Idle Speed Performance

489
Poor Medium and High-Speed Performance

489
Faulty Drive Train

490
Faulty Gear Shifting

491
- Hard Shifting
  491
- Shift Lever Does Not Move
  491
- Jumps out of Gear
  491
  - Faulty Brake
    492
  - Unstable Handling
    493

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Yamaha rhino 700fi 2008 Manuals

Yamaha rhino 700fi 2008 Service Manual (497 pages)

Table of Contents

Chapter 1 General Information

Vehicle Identification

Features

Important Information

Special Tools

Chapter 2 Specifications

General Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Tightening Torques

General Tightening Torque Specifications

How to Use the Conversion Table

Lubrication Points and Lubricant Types

Coolant Flow Diagrams

Oil Flow Diagrams

Cable Routing

Chapter 3 Periodic Checks and Adjustments

Introduction

Periodic Maintenance Chart for the Emission Control System

General Maintenance and Lubrication Chart

Engine

Chassis

Electrical System

Chapter 4 Engine

Engine Removal

Cylinder Head

Rocker Arms and Camshaft

Valves and Valve Springs

Cylinder and Piston

Ac Magneto

Balancer Gears and Oil Pump Gears

Primary and Secondary Sheaves

Clutch

Crankcase

Crankshaft and Oil Pump

Transmission

Middle Gear

Chapter 5 Cooling System

Radiator and Coolant Reservoir

Thermostat

Water Pump

Oil Cooler

Chapter 6 Fuel Injection System

Fuel Pump and Fuel Tank

Throttle Body

Chapter 7 Drive Train

Troubleshooting

Front Constant Velocity Joints, Differential Gear and Drive Shaft

Rear Constant Velocity Joints, Final Drive Gear and Drive Shaft

Chapter 8

Seats, Enclosure, Hood and Cargo Bed

Front and Rear Wheels

Front and Rear Brakes

Parking Brake

Pedal Assembly

Steering System

Front Arms and Front Shock Absorbers

Rear Knuckle and Stabilizer

Rear Arms and Rear Shock Absorber

Chapter 9 Electrical

Electrical Components

Checking Switch Continuity

Checking the Switches

Checking the Bulbs and Bulb Sockets

Ignition System

Electric Starting System

Starter Motor

Charging System

Lighting System

Signaling System

Cooling System

Fuel Pump System

2Wd/4Wd Selecting System

Chapter 10

Starting Failure/Hard Starting

Poor Idle Speed Performance