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Yahama Raptor YFM700RV Service Manual
YFM700RV
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CONTENTS
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
MODEL LABEL
FEATURES
OUTLINE OF THE FI SYSTEM
FI SYSTEM
SELF ADJUSTING PARKING BRAKE MECHANISM
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
REPLACEMENT PARTS
GASKETS, OIL SEALS AND O RINGS
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
SYSTEM
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 COOLANT TEMPERATURE WARNING LIGHT
CHECKING THE EXHAUST SYSTEM
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 TOE IN
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 4
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
CHECKING THE CAMSHAFT SPROCKET
INSTALLING THE CYLINDER HEAD
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
A C MAGNETO
REMOVING THE A C MAGNETO ROTOR
CHECKING THE STATOR COIL
AND CRANKSHAFT POSITION SENSOR
CHECKING THE STARTER CLUTCH
CHECKING THE TORQUE LIMITER
INSTALLING THE A C 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
CRANKCASE 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
CRANKSHAFT 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 5
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 6
FUEL INJECTION SYSTEM
CIRCUIT DIAGRAM
ECUS SELF DIAGNOSTIC FUNCTION
SELF DIAGNOSTIC 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 7
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
CHECKING THE BRAKE DISC
INSTALLING THE DRIVEN SPROCKET
INSTALLING THE REAR AXLE
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
TIE RODS AND STEERING KNUCKLES
REMOVING THE STEERING KNUCKLES
CHECKING THE TIE RODS
CHECKING THE STEERING KNUCKLES
INSTALLING THE TIE RODS
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
REMOVING THE FRONT ARMS
CHECKING THE FRONT ARMS
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES
CHECKING THE BALL JOINTS
INSTALLING THE FRONT ARMS
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 8
ELECTRICAL
ELECTRICAL COMPONENTS
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 CUT OFF 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 9
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING
FUEL SYSTEM
ELECTRICAL SYSTEM
COMPRESSION SYSTEM
POOR IDLE SPEED PERFORMANCE
POOR IDLE SPEED PERFORMANCE
POOR MEDIUM AND HIGH SPEED PERFORMANCE
POOR MEDIUM AND HIGH SPEED 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
Tags: 700
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