Yamaha RAPTOR 700R Manual

READ THIS MANUAL CAREFULLY!

It contains important safety information.

OWNER’S MANUAL

YFM700RV

wThis ATV should not be ridden by anyone under 16 years of age.

LIT-11626-19-59

1S3-28199-11

EBU13320

INTRODUCTION

Congratulations on your purchase of the Yamaha YFM700R. It represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.

This manual will provide you with a good basic understanding of the features and operation of this ATV.

This manual includes important safety information. It provides information about special techniques and skills necessary to ride your ATV.

It also includes basic maintenance and inspection procedures.

If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer.

AN IMPORTANT SAFETY MESSAGE:

8READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.

8PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.

8NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMATION.

8THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE.

8THIS ATV IS A HIGH PERFORMANCE ATV FOR OFF-ROAD USE ONLY, FOR SPORT TYPE RECREATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS.

EBU08010

IMPORTANT MANUAL INFORMATION

FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.

Particularly important information is distinguished in this manual by the following notations:

Q

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

wFailure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the

machine.

cC A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE: A NOTE provides key information to make procedures easier or clearer.

EBU15000

IMPORTANT NOTICE

This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway.

This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.

Please check your local riding laws and regulations before operating this ATV.

EBU13330

AFFIX DEALER

LABEL HERE

YFM700RV

OWNER’S MANUAL

©2005 by Yamaha Motor Corporation, U.S.A.

1st edition, June 2005 All rights reserved.

Any reprinting or unauthorized use without the written permission

of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in Japan.

P/N LIT-11626-19-59

	EBU00140
	w					CONTROL FUNCTIONS	4-1
					4
	Indicates a potential hazard that could result
						Main switch	4-1
	in serious injury or death.
						Indicator and warning lights	4-2
						Handlebar switches ............................	4-4
			CONTENTS			Throttle lever ......................................	4-6
						Speed limiter ......................................	4-7
						Clutch lever ........................................	4-8
			LOCATION OF THE WARNING AND			Brake lever .........................................	4-8
	1					Brake pedal	4-9
			SPECIFICATION LABELS ...................	1-1
						Parking brake lever	4-10
			SAFETY INFORMATION	2-1		Shift pedal ........................................	4-11
	2
						Reverse knob	4-12
			DESCRIPTION AND MACHINE IDENTIFI-			Fuel tank cap	4-12
	3					Seat	4-13
			CATION ................................................	3-1
						Front shock absorber adjustment	4-14
			Identification number records	3-2
						Adjusting the rear shock absorber	4-16
			Key identification number	3-2
			Vehicle identification number .............	3-3
			Model label .........................................	3-3

5

6

				Engine break-in ..................................		6-7
	PRE-OPERATION CHECKS ................	5-1		Parking ...............................................		6-8
	Front and rear brakes .........................	5-3		Parking on a slope ..............................		6-8
	Fuel ....................................................	5-4		Accessories and loading ..................		6-10
	Engine oil ............................................	5-6
	Coolant	5-6		RIDING YOUR ATV		7-1
			7
	Chain ..................................................	5-7		GETTING TO KNOW YOUR ATV ......		7-3
	Throttle lever ......................................	5-7		RIDE WITH CARE AND GOOD
	Tires ...................................................	5-8		JUDGEMENT ...................................		7-4
	How to measure tire pressure ............	5-9		BE CAREFUL WHERE YOU RIDE ..		7-16
	Tire wear limit ...................................	5-10		TURNING YOUR ATV ......................		7-23
	Fittings and fasteners .......................	5-10		CLIMBING UPHILL ..........................		7-25
	Lights ................................................	5-10		RIDING DOWNHILL .........................		7-30
	Switches ...........................................	5-10		CROSSING A SLOPE ......................		7-32
				CROSSING THROUGH SHALLOW
	OPERATION ........................................	6-1		WATER ..........................................		7-34
	Starting the engine .............................	6-1		RIDING OVER ROUGH TERRAIN ...		7-36
	Reverse knob operation and reverse			SLIDING AND SKIDDING ................		7-38
	driving ...............................................	6-3		WHAT TO DO IF ...	.......................... 7-40
	Shifting ...............................................	6-4		WHAT TO DO ...	.............................. 7-40
	To start out and accelerate: ................	6-5
	To decelerate: ....................................	6-6

8	PERIODIC MAINTENANCE AND
	....................................ADJUSTMENT	8-1
	Owner’s manual and tool kit .................	8-1
	Periodic maintenance chart for the
	emission control system ....................	8-3
	General maintenance and lubrication
	chart ...................................................	8-4
	Panel removal and installation .............	8-7
	Engine oil and oil filter element ............	8-8
	Cooling system ..................................	8-13
	Changing the coolant .........................	8-14
	Spark plug inspection ........................	8-17
	Air filter element cleaning ..................	8-19
	Spark arrester cleaning ......................	8-22
	Idle speed adjustment ........................	8-25
	Valve clearance adjustment ...............	8-26
	Throttle lever adjustment ...................	8-26
	Front and rear brake pad inspection .....	8-27
	Brake fluid level inspection ................	8-28
	Brake fluid replacement .....................	8-30
	Front brake lever free play .................	8-30
	Brake pedal height adjustment ..........	8-32

Parking brake adjustment .................	8-33
Adjusting the rear brake light switch ....	8-35
Clutch lever free play adjustment .....	8-36
Drive chain slack check ....................	8-38
Adjusting the drive chain slack .........	8-39
Lubricating the drive chain ...............	8-40
Cable inspection and lubrication ......	8-42
Brake and shift pedal/brake and
clutch lever lubrication ....................	8-42
Front upper and lower arm pivot
lubrication .......................................	8-43
Rear arm pivot lubrication ................	8-44
Wheel removal .................................	8-46
Wheel installation .............................	8-47
Battery ..............................................	8-48
Battery maintenance ........................	8-49
Fuse replacement .............................	8-50
Replacing a headlight bulb ...............	8-52
Headlight beam adjustment ..............	8-55
Tail/brake light ..................................	8-55
Troubleshooting ................................	8-56
Troubleshooting charts .....................	8-57

9	................CLEANING AND STORAGE	9-1
	.....................................A. CLEANING	9-1
	B. STORAGE .....................................	9-3

10

11

12

13

14

SPECIFICATIONS ..............................	10-1
NOISE REGULATION ........................	11-1
MAINTENANCE RECORD .................	12-1
ATV LIMITED WARRANTY ................	13-1
YAMAHA EXTENDED SERVICE
(Y.E.S.) ..............................................	14-1

EBU04640

LOCATION OF THE WARNING AND

SPECIFICATION LABELS

3

1	4
2

5

1-1

Read and understand all of the labels on your

w

1

machine. They contain important information for safe and proper operation of your ATV.

Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.

q

5FE-21697-01

5FE-21568-01

1-2

e

r

qWARNING

NEVER ride as a passenger.

Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.

5FE5FE-2151H- 1H-40 -01

t

1-3

EBU15760

qSAFETY INFORMATION

2

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.

An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions.

SEVERE INJURY OR DEATH can result if you do not follow these instructions:

8Read this manual and all labels carefully and follow the operating procedures described.

8Never operate an ATV without proper training or instruction.Take a Training Course.

Beginners should receive training from a certified instructor. Contact an authorized ATV dealer or call 1-800-887-2887 to find out about the training courses nearest you.

8Always follow the age recommendation:

- A child under 16 years old should never operate an ATV with engine size greater than 90cc.

8Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely.

8Never carry a passenger on an ATV.

2-1

8Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.

8Never operate an ATV on any public street, road or highway, even a dirt or gravel one.

8Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants.

8Never consume alcohol or drugs before or while operating this ATV.

8Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience.

8Never attempt wheelies, jumps, or other stunts.

8Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

8Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation.

8Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

8Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

2-2

8Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

8Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

8Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

8Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

8Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

2-3

8Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual.

8Always check for obstacles before operating in a new area.

Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

8Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

8Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.

8Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly.

2-4

8Always use the size and type of tires specified in this manual.

8Always maintain proper tire pressure as described in this manual.

8Never modify an ATV through improper installation or use of accessories.

8Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s Safety Hotline at 1-800-852-5344.

2-5

qWARNING

POTENTIAL HAZARD

Improper handling of gasoline.

WHAT CAN HAPPEN

Gasoline can catch fire and you could be burned.

HOW TO AVOID THE HAZARD

Always turn off the engine when refueling. Do not refuel immediately after the engine has been running and is still very hot.

Do not spill gasoline on the engine or exhaust pipe/muffler when refueling. Never refuel while smoking, or in the vicinity of sparks, open flames, or other sources of ignition such as the pilot lights of water heaters and clothes dryers.

When transporting the ATV in another vehicle, be sure it is kept upright. Otherwise, fuel may leak out of the fuel tank.

WHAT CAN HAPPEN

Gasoline is poisonous and can cause injuries.

HOW TO AVOID THE HAZARD

If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately.

If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

2-6

qWARNING

POTENTIAL HAZARD

Starting or running the engine in a closed area.

WHAT CAN HAPPEN

Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.

HOW TO AVOID THE HAZARD

Always operate your ATV in an area with adequate ventilation.

2-7

EBU00320

DESCRIPTION AND MACHINE IDENTIFICATION

1

2

3

5 6

7

8

	4				9
0 q	w	e	1.	Spark arrester	10.	Clutch lever
			2. Seat		11.	Parking brake lever
			3.	Headlight	12.	Main switch
			4.	Brake pedal	13.	Brake lever
			5.	Engine oil tank	14.	Throttle lever
			6.	Coolant reservoir	15.	Reverse knob
			7.	Idle adjusting screw	16.	Fuel tank cap
			8.	Tail/brake light	17.	Handlebar switches
			9.	Shift pedal

NOTE:

The machine you have purchased may differ slightly from those shown in the figures of this manual.

u y t r

3-1

EBU06000

Identification number records

Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen.

1.KEY IDENTIFICATION NUMBER:

2.VEHICLE IDENTIFICATION NUMBER:

3.MODEL LABEL INFORMATION:

1

6

EBU00350
Key identification number
The key identification number is stamped on the
key as shown in the following illustration. This
number can be used for ordering a new key.	3

1. Key identification number

3-2

EBU00360

Vehicle identification number

The vehicle identification number is stamped into the frame.

1

1. Vehicle identification number

NOTE:

The vehicle identification number is used to identify your machine.

EBU07870

Model label

The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer.

1

1. Model label

3-3

EBU00390

CONTROL FUNCTIONS

OFF ON w

Indicates a potential hazard that could result

in serious injury or death.

4

EBU09420

Main switch

Functions of the respective switch positions are as follows:

ON:

The engine can be started only at this position and the headlights and taillight come on when the light switch is on.

OFF:

All electrical circuits are switched off. The key can be removed in this position.

4-1

EBU08020

Indicator and warning lights

5

4 3

2 1

1.Neutral indicator light “N”

2.Reverse indicator light “R”

3.Coolant temperature warning light “ ”

4.Engine trouble warning light “ ”

5.Fuel level warning light “ ”

EBU06030

Neutral indicator light “N”

This indicator light comes on when the transmission is in neutral.

EBU06022

Reverse indicator light “R”

This indicator light comes on when the transmission is in reverse.

EBU16010

Coolant temperature warning light “ ”

When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.

The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on, and then go off, have a Yamaha dealer check the electrical cir-

cuit.

cC

8The engine may overheat if the ATV is overloaded. If this happens, reduce the load to specification.

8After restarting, make sure that the light is out. Continuous use while the light is on may cause damage to the engine.

4-2

EBU15881

Engine trouble warning light “ ”

This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the self-diagnosis system.

The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on, and then go off, have a Yamaha dealer check the electrical circuit.

EBU15791

Fuel level warning light “ ”

This fuel level warning light comes on when the fuel level drops below approximately 2.6 L (0.57 Imp.gal, 0.69 US gal). When this occurs, refuel as soon as possible.

The electrical circuit of the warning light can be checked by setting the engine stop switch to “RUN” and turning the key to “ON”.

If the warning light does not come on, and then go off, have a Yamaha dealer check the electrical circuit.

4-3

EBU00530		EBU11560
Handlebar switches		Light switch “LIGHTS”
1		Set the switch to the “LO” position to turn on the
		low beam and the taillight.
		Set the switch to the “HI” position to turn on the
		high beam and the taillight.
		Set the switch to the “OFF” position to turn off all
		of the lights.
		cC
2	3	Do not use the headlights with the engine
		turned off for more than thirty minutes. The
1. Light switch “LIGHTS”		battery may discharge to the point that the
2. Engine stop switch “ENG. STOP”

	3. Start switch “START”	starter motor will not operate properly. If this
		should happen, remove the battery and
		recharge it.

4-4

EBU11580

Engine stop switch “ENG. STOP”

Make sure that the engine stop switch is in the “RUN” position before starting the engine. The engine stop switch controls ignition and can be used at all times to stop the engine, especially in an emergency. The engine will not start or run when the engine stop switch is turned to “OFF”.

EBU06470

Start switch “START”

The starter motor cranks the engine when this

switch is pushed.

cC

See the starting instructions on page 6-1 prior to starting the engine.

4-5

EBU00620

Throttle lever

Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever.

1. Throttle lever

Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released.

qWARNING

POTENTIAL HAZARD

Malfunction of throttle.

WHAT CAN HAPPEN

The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident.

HOW TO AVOID THE HAZARD

Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a Yamaha dealer if you canít find or solve the problem yourself.

4-6

EBU11590

Speed limiter

The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV.

1. Locknut

2. Adjusting screw

a. No more than 12 mm (0.47 in)

qWARNING

POTENTIAL HAZARD

Improper adjustment of the speed limiter and throttle.

WHAT CAN HAPPEN

The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured.

HOW TO AVOID THE HAZARD

Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play is adjusted to 2–4 mm (0.08–0.16 in). See page 8-26.

4-7

EBU00690

Clutch lever

The clutch lever is located on the left handlebar and the ignition circuit cut-off system is incorporated in the clutch lever holder. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. (Refer to “Starting a cold engine” for a description of the ignition circuit cut-off system.)

1. Clutch lever

EBU09880

Brake lever

The brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake.

1. Brake lever

4-8