Yamaha 2008 Rhino YXR45FX Manual

2008
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-21-21 2P5-F8197-12
YXR45FX

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
YXR45FX. For complete service information procedures it is necessary to use this Supplementary
Service Manual together with the following manual.
YXR45FAV SERVICE MANUAL: LIT-11616-19-43 (2P5-F8197-10)
YXR45FW SUPPLEMENTARY SERVICE MANUAL: LIT-11616-20-50 (2P5-F8197-11)
YXR45FX
SUPPLEMENTARY
SERVICE MANUAL
©2007 by Yamaha Motor Corporation, U.S.A.
First edition, August 2007
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-11616-21-21

EBS00002
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle
repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe
and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
TIP:
_
• This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EBS00003
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to
the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP:

EBS00004
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “symbols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram 4is provided for removal and disassembly jobs.
2. Numbers 5are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8are given in addition
to the exploded diagram and the job instruction chart.

EBS00006
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1to 0indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Cooling system
6Carburetion
7Drive train
8Chassis
9Electrical
0Troubleshooting
Symbols Ato Hindicate the following
ACan be serviced with engine mounted
BFilling fluid
CLubricant
DSpecial tool
ETorque
FWear limit, clearance
GEngine speed
HElectrical data (Ω, V, A)
Symbols Ito Pin the exploded diagrams
indicate the types of lubricants and lubrication
points.
IApply engine oil
JApply gear oil
KApply molybdenum disulfide oil
LApply brake fluid
MApply wheel bearing grease
NApply lithium-soap-based grease
OApply molybdenum disulfide grease
PApply silicone grease
Symbols Qto Rin the exploded diagrams
indicate where to apply a locking agent Qand
when to install a new part R.
QApply the locking agent (LOCTITE®)
RReplace
12
34
56
78
90
ABC
DEF
GH
IJKL
MNOP
QR
GEN
INFO SPEC
CHK
ADJ ENG
COOL CARB
DRIV
CHAS
–+
ELEC TRBL
SHTG
T
R
.
.
EGM
BF
BLS MS
LT
New

CONTENTS
SPECIFICATIONS.............................................................................................. 1
GENERAL SPECIFICATIONS ..................................................................... 1
TIGHTENING TORQUES............................................................................. 1
CHASSIS TIGHTENING TORQUES ..................................................... 1
CHASSIS ............................................................................................................ 2
SEATS, ENCLOSURE, HOOD AND CARGO BED ..................................... 2
SEATS, CONSOLE AND INSTRUMENT PANELS ............................... 2
SIDE DOORS......................................................................................... 4

–1 –
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES
Item Standard
Model code 2P5A, 2P5C, 2P5D
Part to be tightened Thread size Tightening torque Remarks
Nm m ·kg ft ·lb
Passenger seat and passenger handhold bracket M6 8 0.8 5.8 LT
Passenger handhold strap and passenger hand-
hold bracket M6 7 0.7 5.1 LT
Handle latch and side door M5 5 0.5 3.6
Side door bracket and side door M6 7 0.7 5.1
Frame and hinge M8 23 2.3 17 LT
Frame and latch M6 8 0.8 5.8 LT
GENERAL SPECIFICATIONS/TIGHTENING TORQUES

–2 –
CHAS
CHASSIS
SEATS, ENCLOSURE, HOOD AND CARGO BED
SEATS, CONSOLE AND INSTRUMENT PANELS
(16)
(5)
(8)
(4)
(4)
LT
LT
1
4
5
6
7
2
16
17
18
15
14
13
13
10
11
98
12
3
T
R
.
.
7 Nm (0.7 m •kg, 5.1 ft •Ib)
T
R
.
.
7 Nm (0.7 m •kg, 5.1 ft •Ib)
T
R
.
.
35 Nm (3.5 m •kg, 25 ft •Ib)
T
R
.
.
8 Nm (0.8 m •kg, 5.8 ft •Ib)
Order Job/Part Q’ty Remarks
Removing the seats, console and
instrument panels
Remove the parts in the order listed.
1 Driver seat 1
2 Passenger seat 1
3 Air intake duct 1
4 Console 1
5 Steering wheel cover 1
6 Steering wheel 1
7 Pedal cover 1
8 Light switch coupler 1 Disconnect.
9 Main switch coupler 1 Disconnect.
10 On-Command four-wheel drive switch
and differential gear lock switch
2 Disconnect.
11 Indicator/warning light coupler 2 Disconnect.
SEATS, ENCLOSURE, HOOD AND CARGO BED

–3 –
CHAS
SEATS, ENCLOSURE, HOOD AND CARGO BED
(16)
(5)
(8)
(4)
(4)
LT
LT
1
4
5
6
7
2
16
17
18
15
14
13
13
10
11
98
12
3
T
R
.
.
7 Nm (0.7 m •kg, 5.1 ft •Ib)
T
R
.
.
7 Nm (0.7 m •kg, 5.1 ft •Ib)
T
R
.
.
35 Nm (3.5 m •kg, 25 ft •Ib)
T
R
.
.
8 Nm (0.8 m •kg, 5.8 ft •Ib)
Order Job/Part Q’ty Remarks
12 Auxiliary DC jack connector 2 Disconnect.
13 Nut/starter cable 1/1
14 Upper instrument panel 1
15 Lower instrument panel 1
16 Passenger handhold strap 1
17 Passenger handhold grip 1
18 Passenger handhold bracket 1
For installation, reverse the removal pro-
cedure.

– 4 –
CHAS
SIDE DOORS
LT
T
R
.
.
8 Nm (0.8 m •kg, 5.8 ft •Ib)
T
R
.
.
23 Nm (2.3 m •kg, 17 ft •Ib)
2
3
(4)
(4)
5
1
6
T
R
.
.
5 Nm (0.5 m •kg, 3.6 ft •Ib)
T
R
.
.
7 Nm (0.7 m •kg, 5.1 ft •Ib)
New
1
4
New
4
1
LT
Order Job/Part Q’ty Remarks
Removing the side doors Remove the parts in order listed.
The following procedure applies to both
of the side doors.
1 Rubber protector 2
2 Side door 1
3 Handle latch 1
4 Side door bracket 2
5 Hinge 1
6 Latch 1
For installation, reverse the removal pro-
cedure.
SEATS, ENCLOSURE, HOOD AND CARGO BED

YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
PRINTED IN U.S.A.