Yamaha YFM700RV Raptor Service Manual
YFM700RV
SERVICE MANUAL
LIT-11616-19-13 1S3-28197-10
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 significant 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
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death
the vehicle operator, a bystander or a person checking or repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
to
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 accompanied 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.
12
GEN
SPEC
INFO
34
CHK
ENG
ADJ
56
COOL
78
FI
EBS00006
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
General information
1
Specifications
2
Periodic checks and adjustments
3
Engine
4
Cooling system
5
Fuel injection system
6
Chassis
7
Electrical
8
Troubleshooting
9
CHAS
90
ELEC
–+
TRBL
SHTG
AB
CD
T
.
R
.
EFG
HIJ
LS
G
M
M
E
KLM
B
Symbols 0 to G indicate the following.
Serviceable with engine mounted
0
Filling fluid
A
Lubricant
B
Special tool
C
Tightening torque
D
Wear limit, clearance
E
Engine speed
F
Electrical data (Ω, V, A)
G
Symbols H to M in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Apply engine oil
H
Apply gear oil
I
Apply molybdenum disulfide oil
J
Apply wheel bearing grease
K
Apply lithium-soap-based grease
L
Apply molybdenum disulfide grease
M
NO
LT
New
Symbols N to O in the exploded diagrams
indicate where to apply a locking agent N and
when to install a new part O.
Apply the locking agent (LOCTITE
N
Replace
O
®
)
EBS00008
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
ENGINE
COOLING SYSTEM
GEN
INFO
SPEC
CHK
ADJ
ENG
COOL
1
2
3
4
5
FUEL INJECTION SYSTEM
CHASSIS
ELECTRICAL
TROUBLESHOOTING
FI
CHAS
– +
ELEC
TRBL
SHTG
6
7
8
9
CONTENTS
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
FEATURES
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................ 1-3
SELF-ADJUSTING PARKING BRAKE MECHANISM...............................1-4
IMPORTANT INFORMATION
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
......................................................................................................1-2
..........................................................................................1-10
............................................................................1-1
.........................................................................1-7
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS
ENGINE SPECIFICATIONS
CHASSIS SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES ........................................................2-16
CHASSIS TIGHTENING TORQUES ......................................................2-19
HOW TO USE THE CONVERSION TABLE
GENERAL TIGHTENING TORQUE SPECIFICATIONS
........................................................................2-1
............................................................................2-4
........................................................................2-12
.................................................................2-14
..............................................................................2-16
..................................................2-22
...............................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
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
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
.........................................................................................6-28
............................................................................6-1
CHAPTER 7
CHASSIS
FRONT AND REAR WHEELS
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
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
........................................................................7-1
.............................................................7-8
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
1
VEHICLE IDENTIFICATION
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.
GEN
INFO
1 - 1
GEN
FEATURES
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 optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. 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
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 conditions 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 manner. 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.
INFO
1
Engine trouble warning light
1
Ignition coil
2
Fuel tank
3
4
Fuel hose
5
Fuel pump
6
Intake air pressure sensor
7
Lean angle sensor
8
Battery
9
Intake air temperature sensor
12
345 6 78
D
EFGH
C
ECU (electronic control unit)
0
A
Air filter case
B
Relay unit (fuel pump relay)
C
Speed sensor
D
Throttle position sensor
E
Crankshaft position sensor
F
Fuel injector
G
Coolant temperature sensor
H
Spark plug
9
0A B
1 - 2
GEN
FEATURES
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/cm
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 temperature 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 position 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.
INFO
2
, 46.1 psi). Accord-
0
Fuel pump
1
Fuel injector
2
Ignition coil
3
ECU (electronic control unit)
4
Coolant temperature sensor
5
Crankshaft position sensor
6
Intake air pressure sensor
7
Throttle body
8
1
9
É
A
7
È
8
2
Ê
4
B
3
5
6
Intake air temperature sensor
9
Air filter case
0
Throttle position sensor
A
Speed sensor
B
Fuel system
È
Air system
É
Control system
Ê
1 - 3
GEN
FEATURES
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.
INFO
1
2
Parking brake arm
1
Parking brake shaft
2
Adjusting bolt
3
Adjusting bolt sleeve
4
4567
Adjusting bolt
5
Nut
6
Brake caliper piston
7
3
1 - 4
Parking Brake Operation
FEATURES
GEN
INFO
1
2
3
456
1 Parking brake arm
2 Parking brake shaft
3 Adjusting bolt
When the parking brake is operated, the parking brake cable turns the parking brake arm 1. The
rotation of the parking brake arm is changed to axial thrust in the parking brake shaft 2 and the
adjusting bolt 3 is pushed against the adjusting bolt sleeve 4.
When the adjusting bolt sleeve receives the force, the dark shaded area in the above illustration is
pushed and the brake pad 6 is pushed against the brake disc.
When the brake pad wears, the clearance between the brake caliper piston 5 and the brake pad
becomes larger and the force applied to the brake pad becomes weaker.
If this occurs, the self-adjusting parking brake mechanism adjusts automatically to achieve the
proper clearance.
4 Adjusting bolt sleeve
5 Brake caliper piston
6 Brake pad
1 - 5
Parking Brake Operation
FEATURES
GEN
INFO
12
È
É
4
3
Ê
1 Brake caliper piston
2 Nut
When the brake pedal is operated, the brake fluid pressure in the master cylinder increases and the
brake caliper piston 1 and the nut 2 are pushed.
When there is proper clearance between the brake caliper piston and the brake pad, no other parts
move because the movement of the brake caliper piston and the nut is absorbed by the backlash of
the threads of the nut and the adjusting bolt 3.
When the movement of the nut is greater than the backlash between the nut and the adjusting bolt,
the parking brake adjusts automatically.
The amount of the adjustment varies with brake fluid pressure. Operating the parking brake makes
no adjustment.
The adjustment operation is as follows.
1. When the brake pedal is operated, the brake fluid pressure increases and the brake caliper piston and the nut move.
2. When the movement of the brake caliper piston and the nut is greater than the backlash of the
threads of the nut and the adjusting bolt, the force È will be required to pull the adjusting bolt.
The force to pull the adjusting bolt will be turned into the rotation torque É by the shape of the
threads of the nut and the adjusting bolt.
3. At this time, the clutch torque Ê between the adjusting bolt and the adjusting bolt sleeve 4 will
decrease depending on the force required to pull the adjusting bolt.
When the rotation torque exceeds the clutch torque, the adjusting bolt rotates and the clearance
between the brake caliper piston and the brake pad decreases by the movement of the threads of
the nut and the adjusting bolt.
3 Adjusting bolt
4 Adjusting bolt sleeve
1 - 6
IMPORTANT INFORMATION
EBS00013
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
GEN
INFO
EBS00014
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use oil and grease recommended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EBS00015
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be
cleaned.
2. During reassembly properly oil all mating
parts and bearings, and lubricate the oil
seal lips with grease.
1 - 7
IMPORTANT INFORMATION
EBS00016
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1
and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
EBS00017
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appropriate.
Oil seal
1
GEN
INFO
CAUTION:
_
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
Bearing
1
EBS00018
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.
Shaft
4
1 - 8
IMPORTANT INFORMATION
EBS00019
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect several times.
3. Check:
• all connections
Loose connection → Connect properly.
NOTE:
_
If the pin 1 on the terminal is flattened, bend it
up.
GEN
INFO
4. Connect:
• lead
• coupler
• connector
NOTE:
_
Make sure all connections are tight.
5. Check:
• continuity (with the pocket tester)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
_
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
1 - 9
GEN
SPECIAL TOOLS
EBS00021
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools; this will help prevent damage caused by the use of inappropriate
tools or improvised techniques. Special tools may differ by shape and part number from country to
country. In such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
For US and CDN
P/N. YM-, YU-, YS-, YK-, ACC-
Except for US and CDN
P/N. 90890-
Tool No. Tool name/Function Illustration
Slide hammer bolt
Slide hammer bolt (6 mm)
90890-01083
YU-01083-1
This tool is used to remove the rocker arm
shaft.
INFO
90890-01084
YU-01083-3
90890-01135
YU-01135-B
90890-01268
YU-01268
90890-01274
YU-90058
YU-90059
Weight
This tool is used to remove the rocker arm
shaft.
Crankcase separating tool
Crankcase separator
This tool is used to separate the crankcase.
Ring nut wrench
Spanner wrench
This tool is used to loosen or tighten the
rear shock absorber locknuts.
Crankshaft installer pot
Installer pot
Pot installer
90890-01275
YU-90060
This tool is used to install the crankshaft.
Crankshaft installer bolt
Bolt
This tool is used to install the crankshaft.
1 - 10
GEN
SPECIAL TOOLS
Tool No. Tool name/Function Illustration
Adapter (M16)
Adapter #13
90890-04130
YM-04059
This tool is used to install the crankshaft.
Spacer (crankshaft installer)
Pot spacer
90890-04081
YM-91044
This tool is used to install the crankshaft.
Piston pin puller set
Piston pin puller
90890-01304
YU-01304
This tool is used to remove the piston pin.
INFO
90890-01311
YM-08035-A
90890-01325
YU-24460-01
90890-01352
YU-33984
90890-01327
YM-01327
Tappet adjusting tool
Valve adjuster (3 mm & 4 mm)
This tool is necessary for adjusting the
valve clearance.
Radiator cap tester
Radiator pressure tester
This tool is used to check the cooling system.
Radiator cap tester adapter
Radiator pressure tester adapter
This tool is used to check the cooling system.
Damper rod holder (30 mm)
This tool is needed to loosen and tighten
the steering stem bearing retainer.
90890-01404
YM-01404
Flywheel puller
This tool is used to remove the A.C.magneto rotor.
1 - 11
GEN
SPECIAL TOOLS
Tool No. Tool name/Function Illustration
Steering nut wrench
Spanner wrench
90890-01443
YU-33975
90890-01474
YM-01474
90890-01480
YM-01480
This tool is needed to loosen and tighten
the front shock absorber and rear shock
absorber locknuts.
Ball joint remover
This tool is used to remove or install the
ball joints.
Ball joint remover attachment set
Ball joint adapter set
These tools are used to remove or install
the ball joints.
INFO
90890-01498
YM-37134
90890-01701
YS-01880-A
90890-03079
YM-34483
90890-03081
YU-33223
Rear axle nut wrench (46 mm)
Axle nut wrench (46 mm)
This tool is needed to loosen or tighten the
rear axle nut.
Sheave holder
Primary clutch holder
This tool is used to hold the A.C. magneto
rotor when loosen or tighten the A.C. magneto rotor nut.
Thickness gauge
Narrow gauge set
This tool is used to measure the valve
clearance.
Compression gauge
Engine compression tester
This tool is used to measure engine compression.
90890-04082
Extension
This tool is used to measure engine compression.
1 - 12
GEN
SPECIAL TOOLS
Tool No. Tool name/Function Illustration
Pocket tester
Analog pocket tester
90890-03112
YU-03112-C
This instrument is needed for checking the
electrical system.
Timing light
Inductive clamp timing light
90890-03141
YU-03141
This tool is necessary for checking ignition
timing.
Pressure gauge
90890-03153
YU-03153
This tool is used to measure fuel pressure.
INFO
90890-03176
YM-03176
90890-03174
YU-A1927
90890-03182
YU-03182
90890-04019
YM-04019
Fuel pressure adapter
This tool is used to measure fuel pressure.
Digital circuit tester
Model 88 Multimeter with tachometer
This tool is used to check the electrical
system.
FI diagnostic tool
This tool is used to check the diagnosis.
Valve spring compressor
This tool is needed to remove and install
the valve assemblies.
90890-01243
YM-01253-1
Valve spring compressor attachment
Valve spring compressor adapter (26 mm)
This tool is needed to remove and install
the valve assemblies.
1 - 13
GEN
SPECIAL TOOLS
Tool No. Tool name/Function Illustration
Middle driven shaft bearing driver
Bearing driver (40 mm)
90890-04058
YM-04058
This tool is used to install the water pump
seal.
Mechanical seal installer
Water pump seal installer
90890-04132
YM-33221-A
This tool is used to install the water pump
seal.
Valve guide remover (ø6)
Valve guide remover (6.0 mm)
90890-04064
YM-4064-A
This tool is needed to remove and install
the valve guides.
INFO
90890-04065
YM-4065-A
90890-04066
YM-04066
90890-04086
YM-91042
90890-06754
YM-34487
Valve guide installer (ø6)
Valve guide installer (6.0 mm)
This tool is needed to install the valve
guides.
Valve guide reamer (ø6)
Valve guide reamer (6.0 mm)
This tool is needed to rebore the new
valve guides.
Universal clutch holder
This tool is needed to hold the clutch boss
when removing or installing the clutch
boss nut.
Ignition checker
Opama pet-4000 spark checker
This tool is used to check the ignition system components.
90890-06760
YU-39951-B
Digital tachometer
This tool is needed to observe engine rpm.
1 - 14
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