Yamaha Yfm700rv Raptor Service Manual

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YFM700RV

SERVICE MANUAL

LIT-11616-19-13 1S3-28197-10

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EBS00001

YFM700RV
SERVICE MANUAL
©2005 by Yamaha Motor Corporation, U.S.A.
First Edition, May 2005
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-11616-19-13
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.

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.

NOTE:
_

Designs and specifications are subject to change without notice.

EBS00003

IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING Failure to follow WARNING instructions could result in severe injury or death to
the vehicle operator, a bystander or a person checking or repairing the vehicle.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the vehicle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
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 4 is provided for removal and disassembly jobs.
2. Numbers 5 are 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 7 accompanies 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 8 are given in addition
to the exploded diagram and the job instruction chart.
 EBS00006
1 2 SYMBOLS
GEN The following symbols are not relevant to
INFO SPEC every vehicle.
Symbols 1 to 9 indicate the subject of each
3 4 chapter.
1 General information
CHK ENG 2 Specifications
ADJ 3 Periodic checks and adjustments
4 Engine
5 6 5 Cooling system
6 Fuel injection system
7 Chassis
COOL FI 8 Electrical
9 Troubleshooting
7 8

– +
CHAS ELEC
9 0
Symbols 0 to G indicate the following.
0 Serviceable with engine mounted
TRBL A Filling fluid
B Lubricant
SHTG C Special tool
D Tightening torque
A B
E Wear limit, clearance
F Engine speed
G Electrical data (Ω, V, A)

C D
T.
R.

E F G

H I J Symbols H to M in the exploded diagrams

indicate the types of lubricants and lubrication
points.
E G M H Apply engine oil
I Apply gear oil
K L M J Apply molybdenum disulfide oil
K Apply wheel bearing grease
B LS M L Apply lithium-soap-based grease
M Apply molybdenum disulfide grease

N O
Symbols N to O in the exploded diagrams
indicate where to apply a locking agent N and
LT
New when to install a new part O.
N Apply the locking agent (LOCTITE®)
O Replace
EBS00008

TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC CHECKS AND
CHK
ADJUSTMENTS ADJ 3
ENGINE ENG
4
COOLING SYSTEM COOL
5
FUEL INJECTION SYSTEM FI
6
CHASSIS CHAS 7
– +

ELECTRICAL ELEC 8
TROUBLESHOOTING TRBL
SHTG 9
 CONTENTS

CHAPTER 1
GENERAL INFORMATION

VEHICLE IDENTIFICATION............................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1

FEATURES...................................................................................................... 1-2
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................1-3
SELF-ADJUSTING PARKING BRAKE MECHANISM............................... 1-4

IMPORTANT INFORMATION ......................................................................... 1-7

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-7
REPLACEMENT PARTS...........................................................................1-7
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-7
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-8
BEARINGS AND OIL SEALS .................................................................... 1-8
CIRCLIPS ..................................................................................................1-8
CHECKING THE CONNECTIONS............................................................ 1-9

SPECIAL TOOLS .......................................................................................... 1-10

CHAPTER 2
SPECIFICATIONS

GENERAL SPECIFICATIONS ........................................................................ 2-1

ENGINE SPECIFICATIONS ............................................................................2-4

CHASSIS SPECIFICATIONS ........................................................................2-12

ELECTRICAL SPECIFICATIONS .................................................................2-14

TIGHTENING TORQUES .............................................................................. 2-16

ENGINE TIGHTENING TORQUES ........................................................ 2-16
CHASSIS TIGHTENING TORQUES ......................................................2-19

HOW TO USE THE CONVERSION TABLE.................................................. 2-22

GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-22

LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-23
ENGINE................................................................................................... 2-23

COOLANT FLOW DIAGRAMS ..................................................................... 2-24

OIL FLOW DIAGRAMS ................................................................................. 2-28

CABLE ROUTING ......................................................................................... 2-33

CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION.............................................................................................. 3-1

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

SYSTEM ......................................................................................................... 3-1

GENERAL MAINTENANCE AND LUBRICATION CHART............................ 3-2

SEAT, FENDERS AND FUEL TANK .............................................................. 3-3

REMOVING THE FUEL TANK ..................................................................3-9
REMOVING THE FUEL PUMP .................................................................3-9
INSTALLING THE FUEL PUMP..............................................................3-10
INSTALLING THE FUEL HOSE ..............................................................3-10

ENGINE .........................................................................................................3-11
ADJUSTING THE VALVE CLEARANCE ................................................ 3-11
ADJUSTING THE ENGINE IDLING SPEED ...........................................3-13
ADJUSTING THE THROTTLE LEVER FREE PLAY ..............................3-14
ADJUSTING THE SPEED LIMITER........................................................ 3-15
CHECKING THE SPARK PLUG ............................................................. 3-16
CHECKING THE IGNITION TIMING.......................................................3-17
MEASURING THE COMPRESSION PRESSURE..................................3-18
CHECKING THE ENGINE OIL LEVEL....................................................3-20
CHANGING THE ENGINE OIL ...............................................................3-22
ADJUSTING THE CLUTCH CABLE........................................................ 3-25
CLEANING THE AIR FILTER ELEMENT................................................ 3-25
CHECKING THE THROTTLE BODY JOINT...........................................3-27
CHECKING THE FUEL HOSE ................................................................3-28
CHECKING THE BREATHER HOSES ...................................................3-28
CHECKING THE COOLANT LEVEL.......................................................3-29
CHANGING THE COOLANT................................................................... 3-29
CHECKING THE COOLING SYSTEM ....................................................3-32
CHECKING THE COOLANT TEMPERATURE WARNING LIGHT.........3-33
CHECKING THE EXHAUST SYSTEM....................................................3-34
CLEANING THE SPARK ARRESTER ....................................................3-34
CHASSIS ....................................................................................................... 3-36
ADJUSTING THE FRONT BRAKE ......................................................... 3-36
ADJUSTING THE REAR BRAKE............................................................ 3-36
ADJUSTING THE PARKING BRAKE......................................................3-37
CHECKING THE BRAKE FLUID LEVEL................................................. 3-38
CHECKING THE FRONT BRAKE PADS ................................................ 3-39
CHECKING THE REAR BRAKE PADS .................................................. 3-39
ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................3-40
CHECKING THE BRAKE HOSES........................................................... 3-40
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-41
ADJUSTING THE SHIFT PEDAL............................................................ 3-43
ADJUSTING THE REVERSE CONTROL CABLE ..................................3-43
ADJUSTING THE DRIVE CHAIN SLACK ............................................... 3-44
CHECKING THE STEERING SYSTEM .................................................. 3-46
ADJUSTING THE TOE-IN....................................................................... 3-46
CHECKING THE FRONT AND REAR SHOCK ABSORBERS ............... 3-48
ADJUSTING THE FRONT SHOCK ABSORBERS .................................3-48
ADJUSTING THE REAR SHOCK ABSORBER ...................................... 3-49
CHECKING THE TIRES..........................................................................3-52
CHECKING THE WHEELS ..................................................................... 3-54
CHECKING AND LUBRICATING THE CABLES .................................... 3-54
LUBRICATING THE LEVERS AND PEDALS .........................................3-55

ELECTRICAL SYSTEM................................................................................. 3-56

CHECKING AND CHARGING THE BATTERY....................................... 3-56
CHECKING THE FUSES ........................................................................3-62
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-64
REPLACING A HEADLIGHT BULB ........................................................ 3-64

CHAPTER 4
ENGINE

ENGINE REMOVAL ........................................................................................4-1

MUFFLER AND EXHAUST PIPES ........................................................... 4-1
INSTALLING THE EXHAUST PIPES AND MUFFLER ............................. 4-2
OIL TANK ..................................................................................................4-3
LEADS, CABLES AND HOSES ................................................................4-4
ENGINE MOUNTING BOLTS ...................................................................4-6
INSTALLING THE ENGINE....................................................................... 4-8

CYLINDER HEAD............................................................................................ 4-9

REMOVING THE CYLINDER HEAD.......................................................4-11
CHECKING THE CYLINDER HEAD .......................................................4-12
CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET
COVER ................................................................................................... 4-13
CHECKING THE TIMING CHAIN TENSIONER...................................... 4-13
CHECKING THE CAMSHAFT SPROCKET............................................4-13
INSTALLING THE CYLINDER HEAD .....................................................4-13
ROCKER ARMS AND CAMSHAFT ..............................................................4-17
REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 4-19
CHECKING THE CAMSHAFT.................................................................4-19
CHECKING THE DECOMPRESSION SYSTEM..................................... 4-20
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 4-21
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 4-22

VALVES AND VALVE SPRINGS.................................................................. 4-24

REMOVING THE VALVES AND VALVE SPRINGS ...............................4-25
CHECKING THE VALVES AND VALVE SPRINGS ................................4-26
INSTALLING THE VALVES AND VALVE SPRINGS ..............................4-31

CYLINDER AND PISTON.............................................................................. 4-33

REMOVING THE PISTON ...................................................................... 4-34
CHECKING THE CYLINDER AND PISTON ...........................................4-34
CHECKING THE PISTON RINGS........................................................... 4-36
CHECKING THE PISTON PIN ................................................................4-37
INSTALLING THE PISTON AND CYLINDER .........................................4-38

A.C. MAGNETO............................................................................................. 4-41

REMOVING THE A.C. MAGNETO ROTOR............................................4-43
CHECKING THE STATOR COIL
AND CRANKSHAFT POSITION SENSOR ............................................4-43
CHECKING THE STARTER CLUTCH ....................................................4-44
CHECKING THE TORQUE LIMITER......................................................4-45
INSTALLING THE A.C. MAGNETO ROTOR ..........................................4-45

CLUTCH ........................................................................................................4-47
REMOVING THE CLUTCH ..................................................................... 4-51
REMOVING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEAR .......................................................... 4-52
CHECKING THE FRICTION PLATES.....................................................4-52
CHECKING THE CLUTCH PLATES .......................................................4-53
CHECKING THE CLUTCH SPRINGS.....................................................4-53
CHECKING THE CLUTCH HOUSING ....................................................4-54
CHECKING THE CLUTCH BOSS........................................................... 4-54
CHECKING THE PRESSURE PLATE ....................................................4-54
CHECKING THE PULL LEVER SHAFT AND PULL ROD ......................4-54
CHECKING THE PRIMARY DRIVE GEARS ..........................................4-55
CHECKING THE BALANCER DRIVE GEARS ....................................... 4-55
INSTALLING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEARS .......................................................4-55
INSTALLING THE CLUTCH.................................................................... 4-56

OIL PUMP...................................................................................................... 4-59

CHECKING THE OIL PUMP ................................................................... 4-61
ASSEMBLING THE OIL PUMP...............................................................4-62
SHIFT SHAFT................................................................................................4-63
CHECKING THE SHIFT SHAFT ............................................................. 4-65
CHECKING THE STOPPER LEVER ......................................................4-65
CHECKING THE SHIFT GUIDE..............................................................4-65
CHECKING THE SHIFT DRUM SEGMENT ...........................................4-65
INSTALLING THE SHIFT LEVER ........................................................... 4-65
INSTALLING THE SHIFT SHAFT ........................................................... 4-66

CRANKCASE ................................................................................................4-67
CRANKCASE BEARINGS....................................................................... 4-69
SEPARATING THE CRANKCASE.......................................................... 4-70
CHECKING THE OIL STRAINER ........................................................... 4-70
CHECKING THE TIMING CHAIN AND GUIDE....................................... 4-71
CHECKING THE BEARINGS AND OIL SEALS...................................... 4-71
CHECKING THE CRANKCASE ..............................................................4-71
ASSEMBLING THE CRANKCASE.......................................................... 4-72

CRANKSHAFT ..............................................................................................4-74
CRANKSHAFT AND BALANCER ........................................................... 4-74
REMOVING THE CRANKSHAFT ........................................................... 4-75
CHECKING THE CRANKSHAFT ............................................................ 4-75
INSTALLING THE CRANKSHAFT .......................................................... 4-76

TRANSMISSION............................................................................................ 4-77
MAIN AXLE ............................................................................................. 4-79
DRIVE AXLE ........................................................................................... 4-80
COUNTER AXLE.....................................................................................4-82
CHECKING THE SHIFT FORKS............................................................. 4-83
CHECKING THE SHIFT DRUM ASSEMBLY..........................................4-83
CHECKING THE TRANSMISSION ......................................................... 4-83
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ..............................4-84
INSTALLING THE TRANSMISSION .......................................................4-85

CHAPTER 5
COOLING SYSTEM

RADIATOR ...................................................................................................... 5-1

CHECKING THE RADIATOR.................................................................... 5-3
INSTALLING THE RADIATOR..................................................................5-4

THERMOSTAT ................................................................................................5-5
CHECKING THE THERMOSTAT.............................................................. 5-6
INSTALLING THE THERMOSTAT............................................................ 5-6

WATER PUMP.................................................................................................5-7
DISASSEMBLING THE WATER PUMP.................................................... 5-9
CHECKING THE WATER PUMP .............................................................. 5-9
ASSEMBLING THE WATER PUMP........................................................ 5-10
 CHAPTER 6
FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEM............................................................................6-1

CIRCUIT DIAGRAM .................................................................................. 6-2
ECU’S SELF-DIAGNOSTIC FUNCTION................................................... 6-4
SELF-DIAGNOSTIC FUNCTION TABLE .................................................. 6-5
TROUBLESHOOTING CHART .................................................................6-6
DIAGNOSTIC MODE ................................................................................ 6-7
TROUBLESHOOTING DETAILS ............................................................ 6-11
CHECKING THE SPEED SENSOR ........................................................ 6-25
CHECKING THE INTAKE AIR PRESSURE SENSOR ........................... 6-26
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....................6-27

THROTTLE BODY......................................................................................... 6-28

CHECKING THE INJECTOR .................................................................. 6-31
CHECKING THE THROTTLE BODY ......................................................6-31
INSTALLING THE THROTTLE BODY ASSEMBLY................................6-31
CHECKING THE FUEL PUMP
AND PRESSURE REGULATOR OPERATION...................................... 6-32
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR ................................................................................................6-33

CHAPTER 7
CHASSIS

FRONT AND REAR WHEELS ........................................................................ 7-1

FRONT WHEELS ......................................................................................7-1
REAR WHEELS ........................................................................................7-3
CHECKING THE WHEELS ....................................................................... 7-4
CHECKING THE WHEEL HUBS............................................................... 7-4
CHECKING THE BRAKE DISCS .............................................................. 7-5
INSTALLING THE FRONT WHEEL HUB BEARINGS .............................. 7-6
INSTALLING THE FRONT BRAKE DISCS............................................... 7-6
INSTALLING THE FRONT WHEELS........................................................7-6
INSTALLING THE FRONT WHEEL HUBS ............................................... 7-7
INSTALLING THE REAR WHEEL HUBS.................................................. 7-7

REAR AXLE AND REAR AXLE HUB ............................................................. 7-8

REMOVING THE REAR BRAKE CALIPER ............................................7-10
REMOVING THE REAR AXLE................................................................7-10
CHECKING THE REAR AXLE ................................................................7-11
CHECKING THE DRIVEN SPROCKET .................................................. 7-11
CHECKING THE BRAKE DISC...............................................................7-12
INSTALLING THE DRIVEN SPROCKET ................................................ 7-12
INSTALLING THE REAR AXLE ..............................................................7-12
FRONT AND REAR BRAKES....................................................................... 7-14
FRONT BRAKE PADS ............................................................................7-14
REAR BRAKE PADS............................................................................... 7-15
REPLACING THE FRONT BRAKE PADS .............................................. 7-16
REPLACING THE REAR BRAKE PADS................................................. 7-18
FRONT BRAKE MASTER CYLINDER....................................................7-20
REAR BRAKE MASTER CYLINDER ......................................................7-22
REMOVING THE FRONT BRAKE LIGHT SWITCH ...............................7-25
CHECKING THE MASTER CYLINDERS................................................ 7-25
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 7-26
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................7-26
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................7-27
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 7-29
FRONT BRAKE CALIPERS .................................................................... 7-31
REAR BRAKE CALIPER .........................................................................7-33
REMOVING THE REAR BRAKE CALIPER ............................................7-36
DISASSEMBLING THE FRONT BRAKE CALIPERS..............................7-36
DISASSEMBLING THE REAR BRAKE CALIPER ..................................7-37
CHECKING THE FRONT AND REAR BRAKE CALIPERS ....................7-37
ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 7-38
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 7-39
INSTALLING THE FRONT BRAKE CALIPERS ...................................... 7-40
INSTALLING THE REAR BRAKE CALIPER...........................................7-41

STEERING SYSTEM .....................................................................................7-44

HANDLEBAR........................................................................................... 7-44
REMOVING THE FRONT BRAKE LIGHT SWITCH
AND CLUTCH SWITCH .........................................................................7-46
REMOVING THE HANDLEBAR GRIPS.................................................. 7-46
CHECKING THE HANDLEBAR ..............................................................7-46
INSTALLING THE HANDLEBAR ............................................................ 7-47
INSTALLING THE HANDLEBAR GRIPS ................................................ 7-47
INSTALLING THE CLUTCH LEVER .......................................................7-48
INSTALLING THE BRAKE MASTER CYLINDER ................................... 7-48
STEERING STEM ...................................................................................7-49
REMOVING THE BEARING RETAINER ................................................ 7-51
CHECKING THE STEERING STEM .......................................................7-51
INSTALLING THE BEARING RETAINER ............................................... 7-51
INSTALLING THE LOCK WASHER........................................................ 7-51
INSTALLING THE PITMAN ARM............................................................ 7-52
TIE-RODS AND STEERING KNUCKLES ............................................... 7-53
REMOVING THE STEERING KNUCKLES ............................................. 7-54
CHECKING THE TIE-RODS ................................................................... 7-54
CHECKING THE STEERING KNUCKLES.............................................. 7-54
INSTALLING THE TIE-RODS .................................................................7-54

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ............. 7-55

REMOVING THE FRONT ARMS ............................................................ 7-57
CHECKING THE FRONT ARMS............................................................. 7-57
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ............. 7-57
CHECKING THE BALL JOINTS..............................................................7-58
INSTALLING THE FRONT ARMS........................................................... 7-59
REAR SHOCK ABSORBER AND RELAY ARM ..........................................7-60
HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER.... 7-62
DISPOSING OF A REAR SHOCK ABSORBER
AND GAS CYLINDER ............................................................................7-62
REMOVING THE REAR SHOCK ABSORBER ....................................... 7-63
CHECKING THE REAR SHOCK ABSORBER........................................ 7-63
CHECKING THE RELAY ARM AND CONNECTING ARM.....................7-63
INSTALLING THE RELAY ARM AND CONNECTING ARM................... 7-64
INSTALLING THE REAR SHOCK ABSORBER...................................... 7-64

SWINGARM AND DRIVE CHAIN.................................................................. 7-65

REMOVING THE SWINGARM................................................................7-67
CHECKING THE SWINGARM ................................................................7-67
CHECKING THE DRIVE CHAIN ............................................................. 7-68
INSTALLING THE SWINGARM ..............................................................7-70
INSTALLING THE DRIVE SPROCKET...................................................7-70

CHAPTER 8
ELECTRICAL

ELECTRICAL COMPONENTS........................................................................ 8-1

CHECKING SWITCH CONTINUITY................................................................8-2

CHECKING THE SWITCHES..........................................................................8-3

CHECKING THE BULBS AND BULB SOCKETS .......................................... 8-5

TYPES OF BULBS .................................................................................... 8-5
CHECKING THE CONDITION OF THE BULBS ....................................... 8-5
CHECKING THE CONDITION OF THE BULB SOCKETS .......................8-7

IGNITION SYSTEM ......................................................................................... 8-8

CIRCUIT DIAGRAM .................................................................................. 8-8
TROUBLESHOOTING ..............................................................................8-9

ELECTRIC STARTING SYSTEM .................................................................. 8-14

CIRCUIT DIAGRAM ................................................................................ 8-14
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................ 8-15
TROUBLESHOOTING ............................................................................8-16

STARTER MOTOR........................................................................................ 8-20

CHECKING THE STARTER MOTOR .....................................................8-22
ASSEMBLING THE STARTER MOTOR................................................. 8-23
CHARGING SYSTEM....................................................................................8-25
CIRCUIT DIAGRAM ................................................................................ 8-25
TROUBLESHOOTING ............................................................................8-26

LIGHTING SYSTEM ......................................................................................8-28

CIRCUIT DIAGRAM ................................................................................ 8-28
TROUBLESHOOTING ............................................................................8-29
CHECKING THE LIGHTING SYSTEM....................................................8-30

SIGNALING SYSTEM ...................................................................................8-33

CIRCUIT DIAGRAM ................................................................................ 8-33
TROUBLESHOOTING ............................................................................8-34
CHECKING THE SIGNALING SYSTEM ................................................. 8-35

COOLING SYSTEM....................................................................................... 8-42

CIRCUIT DIAGRAM ................................................................................ 8-42
TROUBLESHOOTING ............................................................................8-43

CHAPTER 9
TROUBLESHOOTING

STARTING FAILURE/HARD STARTING .......................................................9-1

FUEL SYSTEM.......................................................................................... 9-1
ELECTRICAL SYSTEM.............................................................................9-1
COMPRESSION SYSTEM........................................................................ 9-1

POOR IDLE SPEED PERFORMANCE ........................................................... 9-2

POOR IDLE SPEED PERFORMANCE.....................................................9-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE..................................9-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE ........................... 9-2

FAULTY GEAR SHIFTING..............................................................................9-2

HARD SHIFTING.......................................................................................9-2
SHIFT PEDAL DOES NOT MOVE ............................................................ 9-2
JUMPS OUT GEAR................................................................................... 9-2

CLUTCH SLIPPING/DRAGGING.................................................................... 9-3

CLUTCH SLIPPING .................................................................................. 9-3
CLUTCH DRAGGING ............................................................................... 9-3

OVERHEATING............................................................................................... 9-3
OVERHEATING ........................................................................................9-3

OVERCOOLING .............................................................................................. 9-3

COOLING SYSTEM .................................................................................. 9-3
FAULTY BRAKE ............................................................................................. 9-4
POOR BRAKING EFFECT........................................................................ 9-4

SHOCK ABSORBER MALFUNCTION ........................................................... 9-4

MALFUNCTION......................................................................................... 9-4

UNSTABLE HANDLING.................................................................................. 9-4

UNSTABLE HANDLING ............................................................................9-4

LIGHTING SYSTEM ........................................................................................9-5

HEADLIGHT DOES NOT COME ON ........................................................9-5
TAIL/BRAKE LIGHT DOES NOT COME ON ............................................9-5
HEADLIGHT BULB BURNT OUT.............................................................. 9-5
 GEN
VEHICLE IDENTIFICATION INFO
EBS00009

GENERAL INFORMATION
VEHICLE IDENTIFICATION
EBS00010
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the left side of the frame.

EBS00011

1 MODEL LABEL
The model label 1 is affixed to the air filter
case cover. This information will be needed to
order spare parts.

1-1
 GEN
FEATURES INFO
EAS20170

FEATURES
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-
mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera-
ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the
combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies with the engine operating
1
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating con-
ditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man-
ner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions.

1 2 34 5 6 7890 A B

H G F E D C

1 Engine trouble warning light 0 ECU (electronic control unit)

2 Ignition coil A Air filter case
3 Fuel tank B Relay unit (fuel pump relay)
4 Fuel hose C Speed sensor
5 Fuel pump D Throttle position sensor
6 Intake air pressure sensor E Crankshaft position sensor
7 Lean angle sensor F Fuel injector
8 Battery G Coolant temperature sensor
9 Intake air temperature sensor H Spark plug

1-2
 GEN
FEATURES INFO
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains
the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm2, 46.1 psi). Accord-
ingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens,
causing the fuel to be injected into the intake manifold only during the time the passage remains
open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the
greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector
is energized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air tem-
perature sensor, coolant temperature sensor and speed sensor enable the ECU to determine the
injection duration. The injection timing is determined through the signals from the crankshaft posi-
tion sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times
in accordance with the driving conditions.
Illustration is for reference only.

B
Ê
4
1
2
È
3
A
0
É
9

7 5

1 Fuel pump 9 Intake air temperature sensor

2 Fuel injector 0 Air filter case
3 Ignition coil A Throttle position sensor
4 ECU (electronic control unit) B Speed sensor
5 Coolant temperature sensor
6 Crankshaft position sensor È Fuel system
7 Intake air pressure sensor É Air system
8 Throttle body Ê Control system

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Yamaha Yfm700rv Raptor Service Manual
Full download: http://manualplace.com/download/yamaha-yfm700rv-raptor-service-manual/ GEN
FEATURES INFO
SELF-ADJUSTING PARKING BRAKE MECHANISM
Usually, for vehicles equipped with a parking brake that must be adjusted manually, it is necessary
to adjust the adjusting bolt 5 to achieve the proper clearance between the brake caliper piston 7
and the adjusting bolt 5.
This adjustment procedure is unnecessary for vehicles equipped with a self-adjusting parking brake
mechanism. The proper clearance is automatically maintained at all times, ensuring stable braking
performance when parking the vehicle.

7 6 5 4

1 Parking brake arm 5 Adjusting bolt

2 Parking brake shaft 6 Nut
3 Adjusting bolt 7 Brake caliper piston
4 Adjusting bolt sleeve

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