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.

WARNING

CAUTION:

NOTE:

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

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.

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.

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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.

1			2
GEN			SPEC
INFO
3			4
CHK			ENG
ADJ
5			6
COOL			FI
7			8
CHAS			ELEC –	+
9			0
TRBL
SHTG
A			B
C			D
			T
			.
			R
			.
E	F		G
H	I		J
E		G	M
K	L		M
B		LS	M
N			O
LT			New

EBS00006

SYMBOLS

The following symbols are not relevant to every vehicle.

Symbols 1 to 9 indicate the subject of each chapter.

1 General information

2Specifications

3Periodic checks and adjustments

4Engine

5Cooling system

6Fuel injection system

7Chassis

8Electrical

9Troubleshooting

Symbols 0 to G indicate the following.

0 Serviceable with engine mounted A Filling fluid

BLubricant

CSpecial tool

DTightening torque

EWear limit, clearance

FEngine speed

GElectrical data (Ω, V, A)

Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points.

H Apply engine oil I Apply gear oil

J Apply molybdenum disulfide oil K Apply wheel bearing grease

LApply lithium-soap-based grease

MApply molybdenum disulfide grease

Symbols N to O in the exploded diagrams indicate where to apply a locking agent N and when to install a new part O.

NApply the locking agent (LOCTITE®)

OReplace

EBS00008

TABLE OF CONTENTS

	GENERAL INFORMATION
		INFOGEN	1
	SPECIFICATIONS
		SPEC	2
	PERIODIC CHECKS AND
	ADJUSTMENTS	CHKADJ	3

ENGINE

ENG 4

COOLING SYSTEM

COOL 5

FUEL INJECTION SYSTEM

FI 6

CHASSIS

CHAS 7

–	+
ELECTRICAL	8
ELEC

TROUBLESHOOTING SHTGTRBL 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

1

1

EBS00009

GENERAL INFORMATION

VEHICLE IDENTIFICATION

EBS00010

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped into the left side of the frame.

EBS00011

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 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.

1 2	3 4 5 6 7 8 9 0 A B

1

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

FEATURES

FI SYSTEM

GEN INFO

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). Accordingly, 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.

	Ê	B
		4
1	2
È
		3
A
0
É
9
	8
7		5
		6

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

1 - 3

FEATURES

SELF-ADJUSTING PARKING BRAKE MECHANISM

GEN INFO

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.

			1
			2
			3
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

1 - 4

FEATURES

Parking Brake Operation

GEN INFO

		1
		2
		3
6	5	4

1 Parking brake arm	4 Adjusting bolt sleeve
2 Parking brake shaft	5 Brake caliper piston
3 Adjusting bolt	6 Brake pad

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.

1 - 5

FEATURES

Parking Brake Operation

GEN INFO

1	2	È
		É
		4
		3
		Ê

1 Brake caliper piston	3 Adjusting bolt
2 Nut	4 Adjusting bolt sleeve

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.

1 - 6

IMPORTANT INFORMATION

EBS00013

GEN INFO

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.

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

GEN INFO

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.

1 Oil seal

CAUTION:

Do not spin the bearing with compressed air because this will damage the bearing surfaces.

1 Bearing

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.

4 Shaft

1 - 8

GEN

IMPORTANT INFORMATION INFO

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 sev-

eral times.

3.Check:

•all connections

Loose connection → Connect properly.

NOTE:

If the pin 1 on the terminal is flattened, bend it up.

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

SPECIAL TOOLS

EBS00021

SPECIAL TOOLS

GEN INFO

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-, ACCExcept 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.
	Weight
90890-01084
YU-01083-3
	This tool is used to remove the rocker arm
	shaft.
	Crankcase separating tool
	Crankcase separator
90890-01135
YU-01135-B
	This tool is used to separate the crank-
	case.
	Ring nut wrench
	Spanner wrench
90890-01268
YU-01268
	This tool is used to loosen or tighten the
	rear shock absorber locknuts.
	Crankshaft installer pot
90890-01274	Installer pot
	Pot installer
YU-90058
YU-90059
	This tool is used to install the crankshaft.
	Crankshaft installer bolt
	Bolt
90890-01275
YU-90060
	This tool is used to install the crankshaft.

1 - 10

	SPECIAL TOOLS				GEN
					INFO
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.
	Tappet adjusting tool
	Valve adjuster (3 mm & 4 mm)
90890-01311
YM-08035-A
	This tool is necessary for adjusting the
	valve clearance.
	Radiator cap tester
	Radiator pressure tester
90890-01325
YU-24460-01
	This tool is used to check the cooling sys-
	tem.
	Radiator cap tester adapter
	Radiator pressure tester adapter
90890-01352
YU-33984
	This tool is used to check the cooling sys-
	tem.
	Damper rod holder (30 mm)
90890-01327
YM-01327
	This tool is needed to loosen and tighten
	the steering stem bearing retainer.
	Flywheel puller

90890-01404 YM-01404

This tool is used to remove the A.C.magneto rotor.

1 - 11

	SPECIAL TOOLS				GEN
					INFO
Tool No.	Tool name/Function	Illustration
	Steering nut wrench
	Spanner wrench
90890-01443
YU-33975	This tool is needed to loosen and tighten
	the front shock absorber and rear shock
	absorber locknuts.
	Ball joint remover
90890-01474
YM-01474
	This tool is used to remove or install the
	ball joints.
	Ball joint remover attachment set
	Ball joint adapter set
90890-01480
YM-01480
	These tools are used to remove or install
	the ball joints.
	Rear axle nut wrench (46 mm)
	Axle nut wrench (46 mm)
90890-01498
YM-37134
	This tool is needed to loosen or tighten the
	rear axle nut.
	Sheave holder
	Primary clutch holder
90890-01701
YS-01880-A	This tool is used to hold the A.C. magneto
	rotor when loosen or tighten the A.C. mag-
	neto rotor nut.
	Thickness gauge
	Narrow gauge set
90890-03079
YM-34483
	This tool is used to measure the valve
	clearance.
	Compression gauge
	Engine compression tester
90890-03081
YU-33223
	This tool is used to measure engine com-
	pression.
	Extension

90890-04082

This tool is used to measure engine compression.

1 - 12

		SPECIAL TOOLS		GEN
				INFO
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.

Fuel pressure adapter

90890-03176 YM-03176

This tool is used to measure fuel pressure.

Digital circuit tester

Model 88 Multimeter with tachometer

90890-03174 YU-A1927

This tool is used to check the electrical system.

FI diagnostic tool

90890-03182 YU-03182

This tool is used to check the diagnosis.

Valve spring compressor

90890-04019 YM-04019

This tool is needed to remove and install the valve assemblies.

Valve spring compressor attachment Valve spring compressor adapter (26 mm)

90890-01243 YM-01253-1

This tool is needed to remove and install the valve assemblies.

1 - 13

	SPECIAL TOOLS				GEN
					INFO
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.
	Valve guide installer (ø6)
	Valve guide installer (6.0 mm)
90890-04065
YM-4065-A
	This tool is needed to install the valve
	guides.
	Valve guide reamer (ø6)
	Valve guide reamer (6.0 mm)
90890-04066
YM-04066
	This tool is needed to rebore the new
	valve guides.
	Universal clutch holder
90890-04086
YM-91042	This tool is needed to hold the clutch boss
	when removing or installing the clutch
	boss nut.
	Ignition checker
	Opama pet-4000 spark checker
90890-06754
YM-34487
	This tool is used to check the ignition sys-
	tem components.
	Digital tachometer

90890-06760 YU-39951-B

This tool is needed to observe engine rpm.

1 - 14