2008 Yamaha Rhino 700 FI / YXR70FX UTV Service Manual Set (P/N LIT-11616-21-58)

This Yamaha Service Manual Set pairs the 2008 Rhino 700 FI (YXR70FX) manual, P/N LIT-11616-21-58, first edition September 2007, with the 2009 supplementary service manual, P/N LIT-11616-22-14, first edition May 2008.

• Engine and CVT repair: Engine removal, cylinder-head and crankcase service, balancer-gear inspection, clutch repair, and primary and secondary sheave overhaul.

• Fuel injection: ECU self-diagnosis, sensor and actuator testing, throttle-body service, fuel-pump checks, and throttle position sensor adjustment.

• Cooling system: Radiator inspection, thermostat testing, water-pump disassembly and seal replacement, coolant bleeding, and oil-cooler inspection.

• Drive train: Front differential and rear final-drive service, constant velocity joint repair, middle-gear shim selection, and gear-lash adjustment.

• Brakes and chassis: Brake-caliper and master-cylinder repair, hydraulic-brake bleeding, parking-brake adjustment, steering-knuckle inspection, and suspension service.

• Electrical troubleshooting: Ignition, starting, charging, lighting, signaling, and 2WD/4WD circuit diagnosis, supported by wiring diagrams and troubleshooting charts.

Yamaha wrote these publications primarily for dealer mechanics and assumes an understanding of vehicle mechanics and repair procedures.

Engine, CVT, and Internal Transmission Repair

Cylinder-head coverage includes valve-stem-to-valve-guide clearance checks, camshaft runout limits, decompression-system inspection, and timing-chain installation. Lower-engine sections cover crankshaft installation, oil-pump inspection, balancer-gear alignment, and shift-fork, shift-drum, and transmission checks.

CVT exploded views show both sheave assemblies. The clutch instructions identify the carrier nut's left-hand threads and the one-way bearing's installation orientation. Camshaft-installation cautions address incorrect valve timing and potential damage from crankshaft movement during assembly.

Emission-control and general maintenance charts organize routine service, including valve-clearance checks, V-belt inspection, lubrication, and fluid changes.

FI Diagnostics and Cooling-System Tests

The ECU diagnostic-mode section connects fault codes with sensor readings, actuator tests, wiring checks, and reinstatement methods. Its troubleshooting chart also addresses poor running without a warning light, helping distinguish sensor or actuator faults from problems requiring internal engine inspection.

Throttle-body procedures include fuel-injector inspection, fuel-pressure testing, and TPS checking and adjustment. Cooling-system instructions cover thermostat operation, radiator condition, water-pump seals, and the oil cooler.

Fuel-system and electrical diagnosis involve pressurized fuel and energized circuits. Follow the safety precautions in the relevant sections before testing.

Drive Gears, CV Joints, and Chassis

Front differential and rear final-drive service are treated separately, with CV-joint disassembly, inspection, and boot installation. Middle-gear and final-drive sections include shim-selection calculations and backlash checks, with required tools identified, including the YM-01467 gear-lash measurement tool.

The differential lash procedure warns that excessive force on the ring-gear holding bolt can damage the ring gear.

Chassis instructions extend to steering shafts, tie-rods, steering knuckles, suspension arms and linkages, shock absorbers, and the rear stabilizer. Brake sections distinguish front and rear caliper work from parking-brake service and include master-cylinder inspection and assembly.

Wiring Diagrams and Circuit Tracing

System-specific circuit diagrams accompany electrical checks, including fuel-pump operation, cooling-fan control, and 2WD/4WD selection. The full wiring sheets provide component keys and wire-color codes.

Coolant-flow and oil-flow diagrams show the fluid paths. Cable-routing views document harness, hose, and cable placement, while exploded assembly views identify parts and their relationship during disassembly and installation.

Supplement Models and Service Updates

The supplement applies to YXR7FY, YXR7FDUY, YXR7FHY, YXR7FSEY, YXR7FSPY, and YXR7FSP2Y. It adds revised specifications, seat and instrument-panel removal information, helmet/seat belt indicator-light diagnosis, and the corresponding wiring diagram.

This is a supplementary publication intended for use with the included base manual for complete service procedures.

A Selection of Fluid and Electrical Reference Values

These examples show a small portion of the service data provided for the YXR70FX.

Engine-oil quantities are 2.00 L without oil-filter cartridge replacement and 2.10 L with replacement. Radiator capacity, including all routes, is 2.35 L.

The FI-system description specifies regulated fuel pressure of 324 kPa. Electrical specifications give crankshaft position sensor resistance as 459–561 ohms at 20 °C (68 °F).

Searchable PDF, Bookmarks, and Page Breakdown

Text search and diagram detail: The PDF contains searchable native text and embedded bookmarks covering the main manual and supplement. Small connector and wire-color labels on the wiring sheets require zooming.

Supplied as one printable, English-language PDF totaling 516 pages.

These totals include the covers, introductory material, wiring sheets, two publisher back covers, and five blank separator pages.