Yamaha_YFM_700RV_Raptor_Servic e_Repair _Manual


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Yamaha_YFM_700RV_Raptor_Service_Repair _Manual
Pages 402
CONTENTS

CHAPTER 1 GENERAL INFORMATION
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER MODEL LABEL
FEATURES
OUTLINE OF THE FI SYSTEM FI SYSTEM SELFADJUSTING PARKING BRAKE MECHANISM
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY REPLACEMENT PARTS GASKETS, OIL SEALS AND ORINGS LOCK WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS CIRCLIPS CHECKING THE CONNECTIONS
SPECIAL TOOLS


CHAPTER 2 SPECIFICATIONS
GENERAL SPECIFICATIONS
ENGINE SPECIFICATIONS
CHASSIS SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES
HOW TO USE THE CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
COOLANT FLOW DIAGRAMS
OIL FLOW DIAGRAMS
CABLE ROUTING

CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYS TEM
GENERAL MAINTENANCE AND LUBRICATION CHART
SEAT, FENDERS AND FUEL TANK
REMOVING THE FUEL TANK
REMOVING THE FUEL PUMP
INSTALLING THE FUEL PUMP
INSTALLING THE FUEL HOSE
ENGINE
ADJUSTING THE VALVE CLEARANCE
ADJUSTING THE ENGINE IDLING SPEED
ADJUSTING THE THROTTLE LEVER FREE PLAY
ADJUSTING THE SPEED LIMITER
CHECKING THE SPARK PLUG
CHECKING THE IGNITION TIMING
MEASURING THE COMPRESSION PRESSURE
CHECKING THE ENGINE OIL LEVEL
CHANGING THE ENGINE OIL
ADJUSTING THE CLUTCH CABLE
CLEANING THE AIR FILTER ELEMENT
CHECKING THE THROTTLE BODY JOINT
CHECKING THE FUEL HOSE
CHECKING THE BREATHER HOSES
CHECKING THE COOLANT LEVEL
CHANGING THE COOLANT
CHECKING THE COOLING SYSTEM
CHECKING THE EXHAUST SYSTEM
CHECKING THE COOLANT TEMPERATURE WARNING LIGHT
CLEANING THE SPARK ARRESTER
CHASSIS
ADJUSTING THE FRONT BRAKE ADJUSTING THE REAR BRAKE ADJUSTING THE PARKING BRAKE CHECKING THE BRAKE FLUID LEVEL CHECKING THE FRONT BRAKE PADS CHECKING THE REAR BRAKE PADS ADJUSTING THE REAR BRAKE LIGHT SWITCH CHECKING THE BRAKE HOSES BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJUSTING THE SHIFT PEDAL ADJUSTING THE REVERSE CONTROL CABLE ADJUSTING THE DRIVE CHAIN SLACK CHECKING THE STEERING SYSTEM ADJUSTING THE TOEIN CHECKING THE FRONT AND REAR SHOCK ABSORBERS ADJUSTING THE FRONT SHOCK ABSORBERS ADJUSTING THE REAR SHOCK ABSORBER CHECKING THE TIRES CHECKING THE WHEELS CHECKING AND LUBRICATING THE CABLES LUBRICATING THE LEVERS AND PEDALS
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY CHECKING THE FUSES ADJUSTING THE HEADLIGHT BEAMS REPLACING A HEADLIGHT BULB

CHAPTER ENGINE
ENGINE REMOVAL
MUFFLER AND EXHAUST PIPES INSTALLING THE EXHAUST PIPES AND MUFFLER OIL TANK LEADS, CABLES AND HOSES ENGINE MOUNTING BOLTS INSTALLING THE ENGINE
CYLINDER HEAD
REMOVING THE CYLINDER HEAD CHECKING THE CYLINDER HEAD CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET
COVER CHECKING THE TIMING CHAIN TENSIONER
ROCKER ARMS AND CAMSHAFT
REMOVING THE ROCKER ARMS AND CAMSHAFT CHECKING THE CAMSHAFT CHECKING THE DECOMPRESSION SYSTEM CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS INSTALLING THE CAMSHAFT AND ROCKER ARMS
VALVES AND VALVE SPRINGS
REMOVING THE VALVES AND VALVE SPRINGS CHECKING THE VALVES AND VALVE SPRINGS INSTALLING THE VALVES AND VALVE SPRINGS
CYLINDER AND PISTON
REMOVING THE PISTON CHECKING THE CYLINDER AND PISTON CHECKING THE PISTON RINGS CHECKING THE PISTON PIN INSTALLING THE PISTON AND CYLINDER
AC MAGNETO
REMOVING THE AC MAGNETO ROTOR CHECKING THE STATOR COIL
AND CRANKSHAFT POSITION SENSOR CHECKING THE STARTER CLUTCH CHECKING THE TORQUE LIMITER INSTALLING THE AC MAGNETO ROTOR
CLUTCH
REMOVING THE CLUTCH REMOVING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEAR CHECKING THE FRICTION PLATES CHECKING THE CLUTCH PLATES CHECKING THE CLUTCH SPRINGS CHECKING THE CLUTCH HOUSING CHECKING THE CLUTCH BOSS CHECKING THE PRESSURE PLATE CHECKING THE PULL LEVER SHAFT AND PULL ROD CHECKING THE PRIMARY DRIVE GEARS CHECKING THE BALANCER DRIVE GEARS INSTALLING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEARS INSTALLING THE CLUTCH
OIL PUMP
CHECKING THE OIL PUMP ASSEMBLING THE OIL PUMP
SHIFT SHAFT CHECKING THE SHIFT SHAFT CHECKING THE STOPPER LEVER CHECKING THE SHIFT GUIDE CHECKING THE SHIFT DRUM SEGMENT INSTALLING THE SHIFT LEVER INSTALLING THE SHIFT SHAFT
CRANKCASE CRANK CASE BEARINGS SEPARATING THE CRANKCASE CHECKING THE OIL STRAINER CHECKING THE TIMING CHAIN AND GUIDE CHECKING THE BEARINGS AND OIL SEALS CHECKING THE CRANKCASE ASSEMBLING THE CRANKCASE
CRANKSHAFT CRANK SHAFT AND BALANCER REMOVING THE CRANKSHAFT CHECKING THE CRANKSHAFT INSTALLING THE CRANKSHAFT
TRANSMISSION MAIN AXLE DRIVE AXLE COUNTER AXLE CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY CHECKING THE TRANSMISSION ASSEMBLING THE MAIN AXLE AND DRIVE AXLE INSTALLING THE TRANSMISSION

CHAPTER 4 COOLING SYSTEM
RADIATOR CHECKING THE RADIATOR INSTALLING THE RADIATOR
THERMOSTAT CHECKING THE THERMOSTAT INSTALLING THE THERMOSTAT
WATER PUMP DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP ASSEMBLING THE WATER PUMP

CHAPTER 5 FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
CIRCUIT DIAGRAM ECU‘S SELFDIAGNOSTIC FUNCTION SELFDIAGNOSTIC FUNCTION TABLE TROUBLESHOOTING CHART DIAGNOSTIC MODE TROUBLESHOOTING DETAILS CHECKING THE SPEED SENSOR CHECKING THE INTAKE AIR PRESSURE SENSOR CHECKING THE INTAKE AIR TEMPERATURE SENSOR
THROTTLE BODY
CHECKING THE INJECTOR CHECKING THE THROTTLE BODY INSTALLING THE THROTTLE BODY ASSEMBLY CHECKING THE FUEL PUMP
AND PRESSURE REGULATOR OPERATION CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR

CHAPTER 6 CHASSIS
FRONT AND REAR WHEELS
FRONT WHEELS REAR WHEELS CHECKING THE WHEELS CHECKING THE WHEEL HUBS CHECKING THE BRAKE DISCS INSTALLING THE FRONT WHEEL HUB BEARINGS INSTALLING THE FRONT BRAKE DISCS INSTALLING THE FRONT WHEELS INSTALLING THE FRONT WHEEL HUBS INSTALLING THE REAR WHEEL HUBS
REAR AXLE AND REAR AXLE HUB
REMOVING THE REAR BRAKE CALIPER REMOVING THE REAR AXLE CHECKING THE REAR AXLE CHECKING THE DRIVEN SPROCKET FRONT AND REAR BRAKES
FRONT BRAKE PADS REAR BRAKE PADS REPLACING THE FRONT BRAKE PADS REPLACING THE REAR BRAKE PADS FRONT BRAKE MASTER CYLINDER REAR BRAKE MASTER CYLINDER REMOVING THE FRONT BRAKE LIGHT SWITCH CHECKING THE MASTER CYLINDERS ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ASSEMBLING THE REAR BRAKE MASTER CYLINDER INSTALLING THE FRONT BRAKE MASTER CYLINDER INSTALLING THE REAR BRAKE MASTER CYLINDER FRONT BRAKE CALIPERS REAR BRAKE CALIPER REMOVING THE REAR BRAKE CALIPER DISASSEMBLING THE FRONT BRAKE CALIPERS DISASSEMBLING THE REAR BRAKE CALIPER CHECKING THE FRONT AND REAR BRAKE CALIPERS ASSEMBLING THE FRONT BRAKE CALIPERS ASSEMBLING THE REAR BRAKE CALIPER INSTALLING THE FRONT BRAKE CALIPERS INSTALLING THE REAR BRAKE CALIPER
STEERING SYSTEM
HANDLEBAR REMOVING THE FRONT BRAKE LIGHT SWITCH
AND CLUTCH SWITCH REMOVING THE HANDLEBAR GRIPS CHECKING THE HANDLEBAR INSTALLING THE HANDLEBAR INSTALLING THE HANDLEBAR GRIPS INSTALLING THE CLUTCH LEVER INSTALLING THE BRAKE MASTER CYLINDER STEERING STEM REMOVING THE BEARING RETAINER CHECKING THE STEERING STEM INSTALLING THE BEARING RETAINER INSTALLING THE LOCK WASHER INSTALLING THE PITMAN ARM TIERODS AND STEERING KNUCKLES REMOVING THE STEERING KNUCKLES CHECKING THE TIERODS CHECKING THE STEERING KNUCKLES INSTALLING THE TIERODS
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
REMOVING THE FRONT ARMS CHECKING THE FRONT ARMS CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES
REAR SHOCK ABSORBER AND RELAY ARM HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER REMOVING THE REAR SHOCK ABSORBER CHECKING THE REAR SHOCK ABSORBER CHECKING THE RELAY ARM AND CONNECTING ARM INSTALLING THE RELAY ARM AND CONNECTING ARM INSTALLING THE REAR SHOCK ABSORBER
SWINGARM AND DRIVE CHAIN REMOVING THE SWINGARM CHECKING THE SWINGARM CHECKING THE DRIVE CHAIN INSTALLING THE SWINGARM INSTALLING THE DRIVE SPROCKET

CHAPTER 7 ELECTRICAL
ELECTRICAL COMPONENTSC
CHECKING SWITCH CONTINUITY
CHECKING THE SWITCHES
CHECKING THE BULBS AND BULB SOCKETS TYPES OF BULBS CHECKING THE CONDITION OF THE BULBS CHECKING THE CONDITION OF THE BULB SOCKETS
IGNITION SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING
ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM STARTING CIRCUIT CUTOFF SYSTEM OPERATION TROUBLESHOOTING
STARTER MOTOR CHECKING THE STARTER MOTOR ASSEMBLING THE STARTER MOTOR
CHARGING SYSTEM
CIRCUIT DIAGRAM TROUBLESHOOTING
LIGHTING SYSTEM
CIRCUIT DIAGRAM TROUBLESHOOTING CHECKING THE LIGHTING SYSTEM
SIGNALING SYSTEM
CIRCUIT DIAGRAM TROUBLESHOOTING CHECKING THE SIGNALING SYSTEM
COOLING SYSTEM
CIRCUIT DIAGRAM TROUBLESHOOTING

CHAPTER 8 TROUBLESHOOTING
STARTING FAILURE/HARD STARTING FUEL SYSTEM ELECTRICAL SYSTEM COMPRESSION SYSTEM
POOR IDLE SPEED PERFORMANCE
POOR IDLE SPEED PERFORMANCE
POOR MEDIUM AND HIGHSPEED PERFORMANCE
POOR MEDIUM AND HIGHSPEED PERFORMANCE
FAULTY GEAR SHIFTING HARD SHIFTING SHIFT PEDAL DOES NOT MOVE JUMPS OUT GEAR
CLUTCH SLIPPING/DRAGGING CLUTCH SLIPPING CLUTCH DRAGGING
OVERHEATING
OVERHEATING
OVERCOOLING
COOLING SYSTEM
FAULTY BRAKE
POOR BRAKING EFFECT
SHOCK ABSORBER MALFUNCTION
MALFUNCTION
UNSTABLE HANDLING
UNSTABLE HANDLING
LIGHTING SYSTEM HEADLIGHT DOES NOT COME ON TAIL/BRAKE LIGHT DOES NOT COME ON HEADLIGHT BULB BURNT OUT

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