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Yamaha RAPTOR YFM700RF 2015 Service Manual

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2015
SERVICE MANUAL
YFM700RF
YFM700RSF
LIT-11616-28-28
2LS-F8197-10

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Summary of Contents for Yamaha RAPTOR YFM700RF 2015

  • Page 1 2015 SERVICE MANUAL YFM700RF YFM700RSF LIT-11616-28-28 2LS-F8197-10...
  • Page 2 EAS20050 YFM700RF/YFM700RSF SERVICE MANUAL ©2014 by Yamaha Motor Corporation, U.S.A. First edition, July 2014 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-11616-28-28...
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
  • Page 4 EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.

  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: General Information

    GENERAL INFORMATION 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 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION ................. 1-5 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-5 REPLACEMENT PARTS................1-5 GASKETS, OIL SEALS AND O-RINGS ............ 1-5 LOCK WASHERS/PLATES AND COTTER PINS ........

  • Page 10: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the left side of the frame. EAS20150 MODEL LABEL The model label “1” is affixed to the air filter case cover. This information will be needed to order spare parts.

  • Page 11: Features

    FEATURES EAS20170 FEATURES EAS1S3L001 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.

  • Page 12: Fi System

    FEATURES EAS1S3L002 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 kgf/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.

  • Page 13: Instrument Functions

    FEATURES The electrical circuit of the warning light can be EAS1S3L005 INSTRUMENT FUNCTIONS checked by turning the main switch to “ON”. The warning light should come on for a few seconds, Indicator lights and warning lights and then go off. If the warning light does not come on initially when the main switch is turned to “ON”, or if the warning light remains on, check the electrical cir-...

  • Page 14: Important Information

    5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...

  • Page 15: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 EAS2LS1001 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals “2”, lubricate the oil seal to gasoline, flammable oil, grease, etc.

  • Page 16: Basic Service Information

    BASIC SERVICE INFORMATION EAS30380 BASIC SERVICE INFORMATION EAS30390 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.

  • Page 17: Electrical System

    BASIC SERVICE INFORMATION ECA16760 EAS30402 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
  • Page 18 BASIC SERVICE INFORMATION ECA16620 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V. shocks. ECA14371 ECA16630 NOTICE NOTICE...
  • Page 19 BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
  • Page 20 BASIC SERVICE INFORMATION • As a quick remedy, use a contact revitalizer available at most part stores. 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or connector, push both sections of the coupler or connector to- gether until they are connected securely.
  • Page 21 SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.

  • Page 22: Special Tools

    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Crankshaft installer pot 5-63 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-63 90890-01275 Bolt YU-90060 Piston pin puller set 5-27 90890-01304 Piston pin puller YU-01304 YU-01304 Spacer 5-63 ø35 90890-01309 Pot spacer YU-90059 Tappet adjusting tool 90890-01311...
  • Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Damper rod holder (30 mm) 4-47, 4-47 90890-01327 Damper rod holder (30 mm) YM-01327 Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 YU-33984 Flywheel puller...
  • Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Ball joint remover attachment set 4-53 90890-01480 Ball joint adapter set YM-01480 Axle nut wrench (46 mm) 4-14, 4-15 90890-01498 Rear axle nut wrench 46 mm YM-37134 Sheave holder 5-33, 5-35 90890-01701 Primary clutch holder YS-01880-A Compression gauge...
  • Page 25 YU-03153 Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Fuel pressure adapter 90890-03176 Fuel pressure adapter YM-03176 Yamaha diagnostic tool (US) 8-34 90890-03234 Valve spring compressor 5-20, 5-25 90890-04019 Valve spring compressor YM-04019 Middle driven shaft bearing driver 90890-04058 Middle drive bearing installer 40 &...
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Spacer (crankshaft installer) 5-63 90890-04081 Pot spacer YM-91044 YM-91044 Extension 90890-04082 Universal clutch holder 5-44, 5-48 90890-04086 Universal clutch holder YM-91042 Adapter (M16) 5-63 90890-04130 Adapter #13 YM-04059 Mechanical seal installer 90890-04132 Water pump seal installer YM-33221-A Ignition checker...
  • Page 27 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha bond No. 1215 5-35, 5-60 90890-85505 (Three bond No.1215®) 1-18...
  • Page 28 SPECIAL TOOLS 1-19...

  • Page 29: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-9 ELECTRICAL SPECIFICATIONS ..............2-12 TIGHTENING TORQUES ................2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-14 ENGINE TIGHTENING TORQUES............2-15 CHASSIS TIGHTENING TORQUES............2-18 LUBRICATION POINTS AND LUBRICANT TYPES ........2-21 ENGINE....................2-21 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-23 ENGINE OIL LUBRICATION CHART .............2-23 LUBRICATION DIAGRAMS ..............

  • Page 30: General Specifications

    GENERAL SPECIFICATIONS EAS29110 GENERAL SPECIFICATIONS Model Model YFM700RF 2LS1 YFM700RSF B461 Dimensions Overall length 1845 mm (72.6 in) Overall width 1155 mm (45.5 in) Overall height 1115 mm (43.9 in) Seat height 830 mm (32.7 in) Wheelbase 1280 mm (50.4 in) Ground clearance 240 mm (9.4 in) Minimum turning radius...

  • Page 31: Engine Specifications

    ENGINE SPECIFICATIONS EAS29120 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, SOHC Displacement 686.0 cm³ Cylinder arrangement Single cylinder Bore × stroke 102.0 × 84.0 mm (4.02 × 3.31 in) Compression ratio 10.0 : 1 Standard compression pressure (at sea level) 570 kPa (5.7 kgf/cm², 81.1 psi) Minimum-maximum 500–640 kPa (5.0–6.4 kgf/cm², 71.1–91.0 psi)
  • Page 32 ENGINE SPECIFICATIONS Valve full open temperature 85°C (185°F) Valve lift (full open) 8.0 mm (0.31 in) Radiator core Width 198.0 mm (7.80 in) Height 300.0 mm (11.81 in) Depth 24.0 mm (0.94 in) Water pump Water pump type Single suction centrifugal pump Reduction ratio 27/28 (0.964) Impeller shaft tilt limit...
  • Page 33 ENGINE SPECIFICATIONS Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in) Rocker arm shaft outside diameter 11.981–11.991 mm (0.4717–0.4721 in) Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.037 mm (0.0004–0.0015 in) Valve, valve seat, valve guide Valve clearance (cold) Intake 0.09–0.13 mm (0.0035–0.0051 in) Exhaust 0.16–0.20 mm (0.0063–0.0079 in) Valve dimensions...
  • Page 34 ENGINE SPECIFICATIONS Installed compression spring force (intake) 169.00–199.00 N (17.23–20.29 kgf, 37.99– 44.73 lbf) Installed compression spring force (exhaust) 169.00–199.00 N (17.23–20.29 kgf, 37.99– 44.73 lbf) Spring tilt (intake) 2.5°/1.70 mm (2.5°/0.07 in) Spring tilt (exhaust) 2.5°/1.70 mm (2.5°/0.07 in) Winding direction (intake) Clockwise Winding direction (exhaust)
  • Page 35 ENGINE SPECIFICATIONS End gap (installed) 0.20–0.35 mm (0.008–0.014 in) Limit 0.60 mm (0.024 in) Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in) Limit 0.12 mm (0.0047 in) 2nd ring Ring type Taper Dimensions (B × T) 1.20 × 4.00 mm (0.05 × 0.16 in) End gap (installed) 0.75–0.90 mm (0.03–0.04 in) Limit...
  • Page 36 ENGINE SPECIFICATIONS Friction plate 2 thickness 2.90–3.10 mm (0.11–0.12 in) Wear limit 2.8 mm (0.11 in) Plate quantity 1 pcs Clutch plate thickness 1.50–1.60 mm (0.059–0.063 in) Plate quantity 7 pcs Warpage limit 0.20 mm (0.0079 in) Clutch spring free length 50.0 mm (1.97 in) Minimum length 48.0 mm (1.89 in)
  • Page 37 ENGINE SPECIFICATIONS Manufacturer DENSO Idling condition Engine idling speed 1500–1700 r/min CO% (air induction system ON) 1.0 % CO% (air induction system OFF) 1.5-8.5 % Intake vacuum 33.0 kPa (248 mmHg, 9.7 inHg) Water temperature 80 °C (176 °F) Oil temperature 55–65 °C (131–149 °F) Throttle lever free play 2.0–4.0 mm (0.08–0.16 in)

  • Page 38: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS29130 CHASSIS SPECIFICATIONS Chassis Frame type Aluminum die-cast and steel tube frame Caster angle 5.0° Camber angle -1.0° Kingpin angle 14.8° Kingpin offset 5.2 mm (0.20 in) Trail 22.0 mm (0.87 in) Tread rear (STD) 900.0 mm (35.43 in) Tread front (STD) 940.0 mm (37.01 in) Toe-in (with tires touching the ground)
  • Page 39 CHASSIS SPECIFICATIONS Front disc brake Disc outside diameter × thickness 161.0 × 3.5 mm (6.34 × 0.14 in) Brake disc thickness limit 3.0 mm (0.12 in) Brake disc deflection limit 0.15 mm (0.006 in) Brake pad lining thickness (inner) 4.3 mm (0.17 in) Limit 1.0 mm (0.04 in) Brake pad lining thickness (outer)
  • Page 40 CHASSIS SPECIFICATIONS Standard 2 (YFM700RF) 262.0 mm (10.31 in) (YFM700RSF) Maximum 5 (YFM700RF) 253.0 mm (9.96 in) (YFM700RSF) Rebound damping adjusting positions Minimum 30 (YFM700RSF) Standard 18 (YFM700RSF) Maximum 1 (YFM700RSF) Compression damping setting (for fast compression damping) Minimum 2 (YFM700RSF) Standard 1.5 (YFM700RSF) Maximum...

  • Page 41: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS29140 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Digital Ignition timing (B.T.D.C.) 9.0 °/1600 r/min Engine control unit Model/manufacturer F8T85971/MITSUBISHI Fuel injection sensor 192.0–288.0 Ω Crankshaft position sensor resistance Intake air pressure sensor output voltage 3.57 –...
  • Page 42 ELECTRICAL SPECIFICATIONS Indicator light Neutral indicator light Fuel level warning light Reverse indicator light Coolant temperature warning light Engine trouble warning light Electric starting system System type Constant mesh Starter motor Power output 0.80 kW 0.025–0.035 Ω Armature coil resistance Brush overall length 12.5 mm (0.49 in) Limit...

  • Page 43: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 44: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kg, 11 ft·lb) pipe) l =135 Cylinder head bolt 35 Nm (3.5 m·kg, 25 ft·lb) (5.31 in) l =145 Cylinder head bolt 35 Nm (3.5 m·kg, 25 ft·lb) (5.71 in)
  • Page 45 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Timing chain tensioner cap bolt 20 Nm (2 m·kg, 14 ft·lb) Timing chain tensioner bolt 10 Nm (1 m·kg, 7.2 ft·lb) Water pump outlet hose clamp 2 Nm (0.2 m·kg, 1.4 ft·lb) screw Water pump bolt 10 Nm (1 m·kg, 7.2 ft·lb)
  • Page 46 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil seal retainer bolt (clutch cov- 10 Nm (1 m·kg, 7.2 ft·lb) Timing mark accessing screw 2 Nm (0.2 m·kg, 1.4 ft·lb) Crankshaft end accessing screw 2 Nm (0.2 m·kg, 1.4 ft·lb) Crankcase bearing retainer 10 Nm (1 m·kg, 7.2 ft·lb) screw...

  • Page 47: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine upper bracket bolt 33 Nm (3.3 m·kg, 24 ft·lb) Engine mounting nut (upper) 40 Nm (4 m·kg, 29 ft·lb) Engine lower bracket bolt/nut 41 Nm (4.1 m·kg, 30 ft·lb) Engine mounting nut (middle) 66 Nm (6.6 m·kg, 48 ft·lb) Engine mounting nut (lower)
  • Page 48 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Steering knuckle and tie-rod ball 25 Nm (2.5 m·kg, 18 ft·lb) joint nut Pitman arm and tie-rod ball joint 25 Nm (2.5 m·kg, 18 ft·lb) Front brake disc guard (inner) 7 Nm (0.7 m·kg, 5.1 ft·lb) screw Bearing retainer nut 65 Nm (6.5 m·kg, 47 ft·lb)
  • Page 49 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake caliper union bolt 30 Nm (3 m·kg, 22 ft·lb) Parking brake case bolt 22 Nm (2.2 m·kg, 16 ft·lb) Rear brake master bolt 20 Nm (2 m·kg, 14 ft·lb) Rear brake master cylinder union 30 Nm (3 m·kg, 22 ft·lb) bolt...

  • Page 50: Lubrication Points And Lubricant Types

    Transmission gears (wheel and pinion) Shift drum Shift forks Shift fork guide bar Shift lever assembly Shift shaft Reverse shift shaft Yamaha bond No. Crankcase mating surface 1215 (Three bond No.1215®) Yamaha bond No. AC magneto lead grommet (AC magneto cover) 1215 (Three bond No.1215®)
  • Page 51 LUBRICATION POINTS AND LUBRICANT TYPES 2-22...

  • Page 52: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-23...
  • Page 53 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Right crankcase 4. Left crankcase 5. AC magneto cover 6. Oil tank inlet hose 7. To oil tank 8. Main axle 9. Drive axle 10. Counter axle 11. From oil tank 12.

  • Page 54: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-25...
  • Page 55 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil tank breather hose 2. Oil tank outlet hose 3. Oil tank inlet hose 4. Oil tank 2-26...
  • Page 56 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil delivery pipe 2. Oil filter 3. Oil pump 2-28...
  • Page 58 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter 2. Oil pump driven gear 3. Oil pump rotor 1 4. Oil pump rotor 2 5. Oil tank outlet hose joint 6. Main axle 7. Counter axle 2-30...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump rotor 2 3. Oil pump rotor 1 4. Oil pump driven gear A. To oil tank 2-32...
  • Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Balancer 1 2. Crankshaft 2-34...

  • Page 64: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-35...
  • Page 65 COOLING SYSTEM DIAGRAMS 1. Thermostat cover 2. Fast idle plunger outlet hose 3. Radiator inlet hose 4. Radiator 5. Radiator outlet hose 6. Water pump breather hose 7. Water pump A. Install the radiator inlet hose onto the thermostat cover pipe, making sure that it contacts the cover and its yellow paint mark is facing outward.
  • Page 66 COOLING SYSTEM DIAGRAMS 2-37...
  • Page 67 COOLING SYSTEM DIAGRAMS 1. Radiator 2. Radiator fan motor breather hose 3. Fuel tank shield 4. Coolant reservoir breather hose 5. Coolant reservoir 6. Coolant reservoir hose 7. Drain hose A. Pass the radiator fan motor breather hose through the guide. B.
  • Page 68 COOLING SYSTEM DIAGRAMS 2-39...
  • Page 69 COOLING SYSTEM DIAGRAMS 1. Water pump outlet hose 2. Water pump 3. Water pump breather hose 4. Water jacket inlet housing A. From radiator B. Install the water pump outlet hose onto the water jacket inlet housing, making sure to align the yellow paint mark on the hose with the projection on the water jacket inlet housing.

  • Page 70: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING Handlebar (top and front view) 2-41...
  • Page 71 CABLE ROUTING 1. Handlebar switch L. Route the throttle cable in front of the clutch cable and parking brake cable, then above the fuel tank 2. Handlebar switch lead shield. 3. Clutch switch lead M. Pass the throttle cable, clutch cable, parking brake 4.
  • Page 72 CABLE ROUTING Engine (left side view) 2-43...
  • Page 73 CABLE ROUTING 1. Headlight lead (left) K. Secure the plastic band by inserting the projection on the band into the hole in the frame, and then 2. Resistor fasten the wire harness at the center of its 3. Radiator positioning tape with the band, making sure that 4.
  • Page 74 CABLE ROUTING Electrical components tray (left side view) 2-45...
  • Page 75 CABLE ROUTING 1. Starter relay lead 2. Fuel pump relay 3. Yamaha diagnostic tool coupler 4. Fuse box lead 5. Radiator fan motor relay 6. Headlight relay 7. Tail/brake light 8. Tail/brake light lead 9. Fuel pump relay lead 10. ECU (engine control unit) 11.
  • Page 76 CABLE ROUTING Electrical components tray (top view) 2-47...
  • Page 77 CABLE ROUTING 1. Parking brake cable N. Fasten the indicator light assembly lead with the holder on the radiator grill. 2. Radiator fan motor coupler O. Fasten the leads with the holder at the section 3. Ignition coil leads before the intake air temperature sensor lead 4.
  • Page 78 CABLE ROUTING Rear fender (top view) 2-49...
  • Page 79 14. Tail/brake light lead A. Route the starter motor lead under the starter relay lead. B. Route the Yamaha diagnostic tool lead over the fuel pump relay lead, fuse box lead, headlight relay lead, and radiator fan motor relay lead.
  • Page 80 CABLE ROUTING Engine (right side view) 2-51...
  • Page 81 CABLE ROUTING 1. Throttle position sensor lead 2. Fast idle plunger outlet hose 3. Air induction system hose (air filter case joint to air cut-off valve) 4. Fuel injector lead 5. Intake air pressure sensor 6. Coolant temperature sensor lead 7.
  • Page 82 CABLE ROUTING Front brake hose (front and top view) 2-53...
  • Page 83 CABLE ROUTING 1. Front brake pipe 2. Front brake hose 3. Front brake hose holder A. Face the mark on the front brake pipe upward. B. Fasten the front brake pipe with the holder. C. Route the front brake hose over the upper front arm.
  • Page 84 CABLE ROUTING Rear brake hose (right side view) 2-55...
  • Page 85 CABLE ROUTING 1. Parking brake cable 2. Rear brake hose 3. Brake fluid reservoir hose 4. Rear brake light switch lead A. Make sure that the ends of the hose clamp are not pointing outward. B. Face the white paint marks on both ends of the brake fluid reservoir hose rearward.
  • Page 86 CABLE ROUTING Throttle body (left and right side view) 2-57...
  • Page 87 CABLE ROUTING 1. Throttle body 2. Air induction system hose (air filter case joint to air cut-off valve) 3. Air filter case 4. Air filter case joint 5. Crankcase breather hose 6. Idle air hose 7. Cylinder head 8. Brake fluid reservoir 9.
  • Page 88 CABLE ROUTING 2-59...

  • Page 89: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 ENGINE ......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 ADJUSTING THE ENGINE IDLING SPEED ..........3-6 ADJUSTING THE THROTTLE LEVER FREE PLAY ........3-6 ADJUSTING THE SPEED LIMITER............
  • Page 90 CHASSIS ....................... 3-19 ADJUSTING THE FRONT DISC BRAKE (YFM700RSF)......3-19 ADJUSTING THE REAR DISC BRAKE ..........3-19 CHECKING THE BRAKE FLUID LEVEL..........3-19 CHECKING THE FRONT BRAKE PADS ..........3-20 CHECKING THE REAR BRAKE PADS ..........3-20 CHECKING THE FRONT BRAKE HOSES ..........3-20 CHECKING THE REAR BRAKE HOSE ..........

  • Page 92: Periodic Maintenance

    However, keep in mind that if the ATV isn’t used for a long period of time, the month mainte- nance intervals should still be followed. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 93 PERIODIC MAINTENANCE INITIAL EVERY month CHECK OR MAINTENANCE Whichever ITEM 1300 2500 2500 5000 comes first km (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element • Clean and replace if necessary. dusty areas) √...
  • Page 94 PERIODIC MAINTENANCE INITIAL EVERY month CHECK OR MAINTENANCE Whichever ITEM 1300 2500 2500 5000 comes first km (mi) (200) (800) (1600) (1600) (3200) hours Reverse lock release √ √ √ • Check operation and adjust or replace if necessary. cable •...

  • Page 95: Engine

    ENGINE EAS20472 ENGINE EAS20520 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or 6.
  • Page 96 ENGINE • Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica- tion. Locknut 14 Nm (1.4 m·kg, 10 ft·lb) d. Measure the valve clearance again. e. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjust- ment steps until the specified clearance is ▲...

  • Page 97: Adjusting The Engine Idling Speed

    ENGINE • Front fender EAS1S3L006 ADJUSTING THE THROTTLE LEVER FREE • Seat PLAY Refer to “GENERAL CHASSIS” on page 4-1. EAS20620 Prior to adjusting the throttle lever free play, the ADJUSTING THE ENGINE IDLING SPEED engine idling speed should be adjusted. 1.

  • Page 98: Adjusting The Speed Limiter

    ENGINE If the specified throttle lever free play cannot be obtained on the throttle body side of the cable, use the adjusting nut on the throttle lever side. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 99: Measuring The Compression Pressure

    ENGINE ECA13330 NOTICE Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb) Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling Before installing the spark plug, clean the spark into the cylinder.

  • Page 100: Checking The Engine Oil Level

    ENGINE Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without Piston ring(s) wear or damage → Repair. Piston, valves, cylin- der head gasket or Same as without oil piston ring(s) possi- bly defective → Re- pair. 6.

  • Page 101: Changing The Engine Oil

    ENGINE 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check the engine oil level again. Before checking the engine oil level, wait a few minutes until the oil has settled. EAS20800 CHANGING THE ENGINE OIL 1.
  • Page 102 ENGINE 6. Remove: • Oil filter element drain bolt • Oil filter element drain bolt “1” (along with the gasket) Oil filter element drain bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) 11.Fill: • Oil tank • Crankcase (with the specified amount of the recom- mended engine oil) Engine oil quantity Total amount...

  • Page 103: Adjusting The Clutch Lever Free Play

    ENGINE b. Start the engine and keep it idling until engine oil starts to seep from the oil check bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. c. Check the engine oil passages, the oil filter element and the oil pump for damage or leak- age.

  • Page 104: Checking The Air Induction System

    ENGINE 1. Remove: EWA13020 WARNING • Seat Never use low flash point solvents, such as Refer to “GENERAL CHASSIS” on page 4-1. gasoline, to clean the air filter element. Such 2. Remove: solvents may cause a fire or an explosion. •...

  • Page 105: Checking The Fuel Line

    ENGINE ECA13450 EAS21030 NOTICE CHECKING THE FUEL LINE Make sure the crankcase breather hose is 1. Remove: routed correctly. • Seat • Front fender • Fuel tank EAS21080 CHECKING THE EXHAUST SYSTEM Refer to “GENERAL CHASSIS” on page 4-1. The following procedure applies to all of the ex- 2.

  • Page 106: Cleaning The Spark Arrester

    ENGINE f. Tap the tailpipe lightly with a soft-face ham- mer or suitable tool, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler. EAS28970 CLEANING THE SPARK ARRESTER 1.

  • Page 107: Checking The Cooling System

    ENGINE ECA13470 NOTICE • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used.
  • Page 108 ENGINE 3. Drain: • Coolant (from the coolant reservoir) 7. Drain: • Coolant (from the engine and radiator) 4. Connect: 8. Check: • Coolant reservoir hose • Coolant drain bolt “1” 5. Remove: Damage → Replace. • Radiator cap “1” 9.
  • Page 109 ENGINE Recommended antifreeze High-quality ethylene glycol anti- freeze containing corrosion in- hibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Radiator capacity (including all routes) 1.68 L (1.78 US qt, 1.48 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 15.Install: 0.25 L (0.26 US qt, 0.22 Imp.qt) •...

  • Page 110: Chassis

    CHASSIS b. Turn the adjusting bolt “2” until the brake ped- EAS29360 CHASSIS al height is within the specified limits. EAS21170 Brake pedal position (from foot- ADJUSTING THE FRONT DISC BRAKE rest) (YFM700RSF) 15.3 mm (0.60 in) 1. Adjust: • Brake lever position “a” ▼...

  • Page 111: Checking The Front Brake Pads

    CHASSIS 1. Remove: • Front wheel Refer to “FRONT WHEELS” on page 4-5. 2. Check: • Front brake pad Wear indicator grooves “a” have almost dis- appeared → Replace the brake pads as a set. Refer to “FRONT BRAKES” on page 4-17. 3.

  • Page 112: Checking The Rear Brake Hose

    CHASSIS 2. Check: EAS29210 ADJUSTING THE PARKING BRAKE • Brake hose “1” 1. Check: Cracks/damage/wear → Replace. • Parking brake cable end length “a” Out of specification → Adjust. Parking brake cable end length 47.0–51.0 mm (1.85–2.01 in) 3. Check: •...

  • Page 113: Adjusting The Rear Brake Light Switch

    CHASSIS caution could allow air to enter the hydraulic EAS21330 ADJUSTING THE REAR BRAKE LIGHT brake system, considerably lengthening the SWITCH bleeding procedure. • If bleeding is difficult, it may be necessary to let The rear brake light switch is operated by move- the brake fluid settle for a few hours.

  • Page 114: Adjusting The Shift Pedal

    CHASSIS j. Tighten the bleed screw to specification. Shift pedal bolt 16 Nm (1.6 m·kg, 11 ft·lb) Bleed screw 6 Nm (0.6 m·kg, 4.3 ft·lb) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 115: Adjusting The Drive Chain Slack

    CHASSIS Loosen the rear axle pinch bolts in the proper se- quence as shown. b. Insert an appropriate shaft “2” in the hole “4” of rear axle hub “3” so that the sprocket bracket “5” does not move. d. Tighten the locknut. e.

  • Page 116: Checking The Steering System

    CHASSIS EAS29280 CHECKING THE STEERING SYSTEM 1. Place the vehicle on a level surface. 2. Check: • Steering assembly bushings Move the handlebar up and down, and back and forth. Excessive play → Replace the steering stem bushings. EAS29290 ADJUSTING THE TOE-IN 1.

  • Page 117: Checking The Front Shock Absorber Assemblies

    CHASSIS d. Tighten the rod end locknuts of both tie-rods. Locknut (tie-rod end) 18 Nm (1.8 m·kg, 13 ft·lb) Adjust the tie-rod ends so that “A” and “B” are equal. C. Forward ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 118: Adjusting The Front Shock Absorber Assemblies

    CHASSIS Refer to “FRONT ARMS AND FRONT Spring preload adjusting positions SHOCK ABSORBER ASSEMBLIES” on Minimum page 4-50. 3. Check: Standard • Operation Pump the front shock absorber assembly up Maximum and down several times. Unsmooth operation → Replace front shock absorber assembly.
  • Page 119 CHASSIS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. Direction “a” Rebound damping force is increased (suspension is harder). Direction “b”...

  • Page 120: Checking The Rear Shock Absorber Assembly

    CHASSIS ECA1S3L003 NOTICE Compression damping setting (for fast compression damping) Do not force the adjuster past the minimum Minimum or maximum extent of adjustment. The ad- 2 turn(s) out* juster may be damaged. Standard 1.5 turn(s) out* Maximum Adjusting bolt fully turned in * With the adjusting bolt fully turned in ECA1S3L003 NOTICE...

  • Page 121: Adjusting The Rear Shock Absorber Assembly

    CHASSIS Spring preload adjusting length “c” Minimum 238.5 mm (9.39 in) Standard 228.5 mm (9.00 in) Maximum 223.5 mm (8.80 in) EAS1S3L008 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 1. Remove: • Seat • Air filter case Refer to “GENERAL CHASSIS” on page 4-1. 2.
  • Page 122 CHASSIS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting bolt “1” in direction “a” or “b”. Direction “a” Compression damping force is in- creased (suspension is harder). Direction “b”...

  • Page 123: Checking The Tires

    Rear 24.5 kPa (0.245 kgf/cm², 3.6 vehicles. The tires listed below have been psi) approved by Yamaha Motor Co., Ltd. for this model. If other tire combinations are used, they can adversely affect your vehicle’s han- Maximum loading limit dling characteristics and are therefore not...

  • Page 124: Checking The Wheels

    CHASSIS EWA1S3L015 WARNING Maximum loading limit 100.0 kg (220 lb) It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit * Total weight of the cargo, trailer hitch “a”, replace the tire immediately. vertical load, rider, and accessories.

  • Page 125: Lubricating The Clutch Lever

    CHASSIS 1. Check: • Outer cable Damage → Replace. 2. Check: • Cable operation Rough movement → Lubricate. Recommended lubricant Engine oil or a suitable cable lu- bricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device.

  • Page 126: Electrical System

    ELECTRICAL SYSTEM EAS21750 ECA13690 ELECTRICAL SYSTEM NOTICE Avoid touching the glass part of the head- EAS21760 light bulb to keep it free from oil, otherwise CHECKING AND CHARGING THE BATTERY the transparency of the glass, the life of the Refer to “ELECTRICAL COMPONENTS” on bulb and the luminous flux will be adversely page 8-59.
  • Page 127 ELECTRICAL SYSTEM ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3-36...
  • Page 128 ELECTRICAL SYSTEM 3-37...
  • Page 129 CHASSIS GENERAL CHASSIS..................4-1 FRONT WHEELS .................... 4-5 REMOVING THE FRONT WHEELS ............4-6 CHECKING THE FRONT WHEELS............4-6 CHECKING THE FRONT WHEEL HUBS ..........4-6 INSTALLING THE FRONT WHEEL HUB BEARINGS ......4-7 INSTALLING THE FRONT BRAKE DISCS..........4-7 INSTALLING THE FRONT WHEEL HUBS ..........4-7 INSTALLING THE FRONT WHEELS............4-8 REAR WHEELS....................
  • Page 130 REAR BRAKE ....................4-28 INTRODUCTION ..................4-35 CHECKING THE REAR BRAKE DISC............4-35 REPLACING THE REAR BRAKE PADS..........4-35 REMOVING THE REAR BRAKE CALIPER ..........4-36 DISASSEMBLING THE REAR BRAKE CALIPER ........4-36 CHECKING THE REAR BRAKE CALIPER..........4-37 ASSEMBLING THE REAR BRAKE CALIPER ........4-37 INSTALLING THE REAR BRAKE CALIPER...........4-38 CHECKING THE REAR BRAKE MASTER CYLINDER ......
  • Page 131 REAR SHOCK ABSORBER ASSEMBLY ............4-55 HANDLING THE REAR SHOCK ABSORBER ASSEMBLY....4-57 DISPOSING OF A REAR SHOCK ABSORBER ASSEMBLY ....4-57 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....4-57 CHECKING THE RELAY ARM AND CONNECTING ARM.....4-57 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....4-57 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ....

  • Page 132: General Chassis

    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat, front panel, foot protectors and engine skid plate 4 Nm (0.4 m kg, 2.9 ft • • 16 Nm (1.6 m kg, 11 ft • • 12 Nm (1.2 m kg, 8.7 ft •...
  • Page 133 GENERAL CHASSIS Removing the headlights and front fender 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 134 GENERAL CHASSIS Removing the rear fender 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 135 GENERAL CHASSIS Removing the rear fender 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 9 Nm (0.9 m kg, 6.5 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 136: Front Wheels

    FRONT WHEELS EAS21870 FRONT WHEELS Removing the front wheels and brake discs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front wheels. Place the vehicle on a level surface. Front wheel Brake disc guard (outer) Cotter pin Front wheel axle nut Do not squeeze the brake lever when the...

  • Page 137: Removing The Front Wheels

    FRONT WHEELS EAS21890 REMOVING THE FRONT WHEELS 1. Place the vehicle on a level surface. 2. Elevate: • Front wheels Place the vehicle on a suitable stand so that the front wheels are elevated. 3. Remove: • Front brake calipers Do not apply the brake lever when removing the brake calipers.

  • Page 138: Installing The Front Wheel Hub Bearings

    FRONT WHEELS Face the oil seal side of the bearing inward. 2. Check: • Wheel bearings Wheel hub play/wheel turns roughly → Re- place. EAS1S3L013 INSTALLING THE FRONT BRAKE DISCS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 139: Installing The Front Wheels

    FRONT WHEELS Wheel nut 45 Nm (4.5 m·kg, 32 ft·lb) 2. Check: • Brake disc Refer to “CHECKING THE FRONT BRAKE DISCS” on page 4-22. EAS29420 INSTALLING THE FRONT WHEELS The following procedure applies to both of the front wheels. 1.

  • Page 140: Rear Wheels

    REAR WHEELS EAS22020 REAR WHEELS Removing the rear wheels Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the rear wheels. Place the vehicle on a level surface. Rear wheel Cotter pin Rear wheel axle nut Rear wheel hub For installation, reverse the removal proce- dure.

  • Page 141: Removing The Rear Wheels

    REAR WHEELS EAS1S3L014 REMOVING THE REAR WHEELS 1. Place the vehicle on a level surface. 2. Elevate: • Rear wheels Place the vehicle on a suitable stand so that the rear wheels are elevated. EAS29430 CHECKING THE REAR WHEELS EAS29450 The following procedure applies to both of the INSTALLING THE REAR WHEEL HUBS rear wheels.
  • Page 142 REAR WHEELS 1. Install: • Wheel The arrow mark “1” on the tire must point in the direction of rotation “A” of the wheel. 2. Tighten: • Wheel nut Wheel nut 45 Nm (4.5 m·kg, 32 ft·lb) 4-11...

  • Page 143: Rear Axle And Rear Axle Hub

    REAR AXLE AND REAR AXLE HUB EAS29470 REAR AXLE AND REAR AXLE HUB Removing the rear axle and rear axle hub 34 Nm (3.4 m kg, 24 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 21 Nm (2.1 m kg, 15 ft •...
  • Page 144 REAR AXLE AND REAR AXLE HUB Removing the rear axle and rear axle hub 34 Nm (3.4 m kg, 24 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 21 Nm (2.1 m kg, 15 ft • •...

  • Page 145: Removing The Rear Axle

    REAR AXLE AND REAR AXLE HUB EAS29490 ECA16180 REMOVING THE REAR AXLE NOTICE 1. Place the vehicle on a level surface. • Never directly tap the axle end with a ham- 2. Remove: mer, since this will result in damage to the •...

  • Page 146: Checking The Rear Wheel Sprocket

    REAR AXLE AND REAR AXLE HUB 2. Install: EAS29510 CHECKING THE REAR WHEEL SPROCKET • Rear wheels 1. Check: Refer to “REAR WHEELS” on page 4-9. • Rear wheel sprocket 3. Tighten: Refer to “CHAIN DRIVE” on page 4-63. • Rear axle ring nut “1” •...
  • Page 147 REAR AXLE AND REAR AXLE HUB 4. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-24. 4-16...

  • Page 148: Front Brakes

    FRONT BRAKES EAS22210 FRONT BRAKES Removing the front brake pads 17 Nm (1.7 m kg, 12 ft • • 28 Nm (2.8 m kg, 20 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 149 FRONT BRAKES Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake fluid Drain. Brake fluid reservoir cap Brake fluid reservoir diaphragm Front brake light switch connector Disconnect. Front brake light switch Brake lever Union bolt Copper washer Brake hose Disconnect.
  • Page 150 FRONT BRAKES Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-19...
  • Page 151 FRONT BRAKES Removing the front brake calipers 17 Nm (1.7 m kg, 12 ft • • 28 Nm (2.8 m kg, 20 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 152 FRONT BRAKES Disassembling the front brake calipers 17 Nm (1.7 m kg, 12 ft • • 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake caliper retaining bolt Brake pad/pad shim Brake pad spring...

  • Page 153: Introduction

    FRONT BRAKES EAS22220 INTRODUCTION Brake disc deflection limit EWA14100 0.15 mm (0.006 in) WARNING Disc brake components rarely require disas- ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the dial gauge at a right angle against sembly.

  • Page 154: Replacing The Front Brake Pads

    FRONT BRAKES e. If out of specification, repeat the adjustment ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the steps until the brake disc deflection is within bleed screw “2”.

  • Page 155: Checking The Front Brake Caliper

    FRONT BRAKES Recommended brake component replace- Before disassembling the brake caliper, drain ment schedule the brake fluid from the entire brake system. Brake hoses Every four years 1. Remove: Every two years and • Brake caliper pistons Brake fluid whenever the brake •...

  • Page 156: Installing The Front Brake Calipers

    FRONT BRAKES EWA13530 WARNING Specified brake fluid DOT 4 Proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “CABLE 1. Install: ROUTING” on page 2-41. • Brake caliper piston seals “1” ECA1S3L011 NOTICE • Brake caliper piston dust seals “2” When installing the brake hose onto the brake caliper, make sure the brake pipe “a”...

  • Page 157: Checking The Front Brake Master Cylinder

    FRONT BRAKES 4. Check: • Brake fluid level Below the minimum level mark → Add the specified brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-19. 5. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem.
  • Page 158 FRONT BRAKES 2. Install: • When refilling, be careful that water does not enter the brake master cylinder reser- • Copper washers voir. Water will significantly lower the boil- • Brake hose ing point of the brake fluid and could cause •...

  • Page 159: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 17 Nm (1.7 m kg, 12 ft • • 43 Nm (4.3 m kg, 31 ft • • Order Job/Parts to remove Q’ty Remarks Brake caliper bolt Brake pad retaining bolt Brake pad Brake pad spring For installation, reverse the removal proce-...
  • Page 160 REAR BRAKE Removing the rear brake master cylinder 4 Nm (0.4 m kg, 2.9 ft • • 20 Nm (2.0 m kg, 14 ft • • 30 Nm (3.0 m kg, 22 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 161 REAR BRAKE Removing the rear brake master cylinder 4 Nm (0.4 m kg, 2.9 ft • • 20 Nm (2.0 m kg, 14 ft • • 30 Nm (3.0 m kg, 22 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 162 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Hose joint Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly pro- cedure. 4-31...
  • Page 163 REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 43 Nm (4.3 m kg, 31 ft • • Order Job/Parts to remove Q’ty Remarks Brake fluid Drain. Parking brake cable Disconnect. Union bolt Copper washer Brake hose Disconnect.
  • Page 164 REAR BRAKE Disassembling the rear brake caliper 22 Nm (2.2 m kg, 16 ft • • 17 Nm (1.7 m kg, 12 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 22 Nm (2.2 m kg, 16 ft •...
  • Page 165 REAR BRAKE Disassembling the rear brake caliper 22 Nm (2.2 m kg, 16 ft • • 17 Nm (1.7 m kg, 12 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 22 Nm (2.2 m kg, 16 ft •...

  • Page 166: Introduction

    REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 3.5 mm (0.14 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...

  • Page 167: Removing The Rear Brake Caliper

    REAR BRAKE 6. Check: • Brake pedal operation Always install new brake pads and brake pad Soft or spongy feeling → Bleed the brake sys- spring as a set. tem. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 168: Checking The Rear Brake Caliper

    REAR BRAKE EWA1PE1003 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston seals and dust seals. EAS22660 ASSEMBLING THE REAR BRAKE CALIPER EWA1PE1004 WARNING • Before installation, all internal brake com- b. Remove the brake caliper piston dust seals ponents should be cleaned and lubricated and caliper piston seals.

  • Page 169: Installing The Rear Brake Caliper

    REAR BRAKE ECA1S3L012 NOTICE When installing the parking brake shaft, the When installing the brake hose onto the punch mark “a” should be between the marks “b” brake caliper, make sure the brake pipe “a” with the parking brake shaft fully turned in. touches the projection “b”...

  • Page 170: Checking The Rear Brake Master Cylinder

    REAR BRAKE 5. Check: EWA1S3L010 WARNING • Brake pedal operation Soft or spongy feeling → Bleed the brake sys- After this adjustment is performed, lift the rear wheels off the ground by placing a block tem. under the engine, and spin the rear wheels to Refer to “BLEEDING THE HYDRAULIC ensure there is no brake drag.

  • Page 171: Assembling The Rear Brake Master Cylinder

    REAR BRAKE 4. Check: 2. Fill: • Brake hoses • Brake fluid reservoir Cracks/damage/wear → Replace. (to the maximum level mark) EAS22730 Specified brake fluid ASSEMBLING THE REAR BRAKE MASTER DOT 4 CYLINDER EWA1S3L011 EWA13090 WARNING WARNING • Before installation, all internal brake com- •...
  • Page 172 REAR BRAKE Brake pedal position (from foot- rest) 15.3 mm (0.60 in) 6. Adjust: • Rear brake light operation timing Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH” on page 3-22. 4-41...

  • Page 173: Handlebar

    HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft •...

  • Page 174: Removing The Clutch Switch

    HANDLEBAR EAS1S3L016 REMOVING THE CLUTCH SWITCH 1. Remove: • Clutch switch “1” EAS22911 INSTALLING THE HANDLEBAR 1. Place the vehicle on a level surface. 2. Install: • Handlebar Push the fastener when removing the clutch • Upper handlebar holders switch out of the clutch lever holder. Upper handlebar holder bolt 23 Nm (2.3 m·kg, 17 ft·lb) EAS22860...
  • Page 175 HANDLEBAR Install the clutch lever bracket as shown. a. 53–54 mm (2.09–2.13 in) 5. Install: • Brake master cylinder “1” Brake master cylinder bracket bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) 3. Install: • Handlebar grip “1” • Install the brake master cylinder holder with the ▼...
  • Page 176 HANDLEBAR 7. Install: • Clutch cable 8. Connect: • Clutch switch coupler Lubricate the end of the clutch cable with a thin coat of lithium-soap-based grease. 9. Adjust: • Clutch cable free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-12. Clutch lever free play (lever end) 8.0–13.0 mm (0.31–0.51 in) 10.Adjust:...

  • Page 177: Steering Stem

    STEERING STEM EAS29540 STEERING STEM Removing the steering stem Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Front fender/fuel tank 4-1. Pitman arm Lock washer Steering stem bushing Spacer Oil seal Steering stem Oil seal Oil seal Bearing retainer Bearing For installation, reverse the removal proce-...

  • Page 178: Removing The Bearing Retainer

    STEERING STEM EAS29550 REMOVING THE BEARING RETAINER Damper rod holder (30 mm) 1. Remove: 90890-01327 • Bearing retainer Damper rod holder (30 mm) YM-01327 Damper rod holder (30 mm) 90890-01327 EAS29580 Damper rod holder (30 mm) INSTALLING THE LOCK WASHER YM-01327 1.
  • Page 179 TIE-RODS AND STEERING KNUCKLES EAS29660 TIE-RODS AND STEERING KNUCKLES Removing the tie-rods and steering knuckles Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the tie-rods and steering knuckles. Front wheel/brake disc Refer to “FRONT WHEELS” on page 4-5. Front brake caliper Refer to “FRONT BRAKES”...

  • Page 180: Tie-Rods And Steering Knuckles

    TIE-RODS AND STEERING KNUCKLES EAS29670 REMOVING THE STEERING KNUCKLES The following procedure applies to both of the steering knuckles. 1. Remove: • Steering knuckle “1” Use a general puller to separate the ball joints “2” from the steering knuckle “1”. EAS29700 INSTALLING THE TIE-RODS The following procedure applies to both of the...

  • Page 181: Front Arms And Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES EAS29710 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Removing the front arms and front shock absorber assemblies 40 Nm (4.0 m kg, 29 ft 55 Nm (5.5 m kg, 40 ft • • •...
  • Page 182 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Removing the front arms and front shock absorber assemblies 40 Nm (4.0 m kg, 29 ft 55 Nm (5.5 m kg, 40 ft • • • • 50 Nm (5.0 m kg, 36 ft •...

  • Page 183: Handling The Front Shock Absorber Assemblies (Yfm700Rsf)

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES EAS1PE1002 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ HANDLING THE FRONT SHOCK ABSORBER a. Check the front arm side play “A” by moving ASSEMBLIES (YFM700RSF) it from side to side.

  • Page 184: Checking The Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES c. Remove the ball joint assembly with the spe- EAS29760 CHECKING THE FRONT SHOCK ABSORBER cial tools. ASSEMBLIES The following procedure applies to both of the Ball joint remover front shock absorber assemblies. 90890-01474 1.

  • Page 185: Installing The Front Arms And Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES h. Attach the assembled special tools, ball joint assembly “10”, installer spacer “6” and install- er washer “7” to the front arm “9”. • Do not tap or damage the top of the ball joint. •...

  • Page 186: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS1S3L019 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 55 Nm (5.5 m kg, 40 ft • • 43 Nm (4.3 m kg, 31 ft • • 43 Nm (4.3 m kg, 31 ft •...
  • Page 187 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 55 Nm (5.5 m kg, 40 ft • • 43 Nm (4.3 m kg, 31 ft • • 43 Nm (4.3 m kg, 31 ft • • 55 Nm (5.5 m kg, 40 ft •...

  • Page 188: Handling The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS1S3L045 EAS23230 HANDLING THE REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ASSEMBLY EWA1S3L016 1. Place the vehicle on a level surface. WARNING This rear shock absorber assembly contains Place the vehicle on a suitable stand so that the highly compressed nitrogen gas.

  • Page 189: Installing The Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY • Gas cylinder Damage/gas leaks → Replace the rear shock absorber assembly. 3. Install: • Connecting arm • Relay arm • Rear shock absorber EAS1S3L021 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY When installing the rear shock absorber, lift up 1.

  • Page 190: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm 100 Nm (10.0 m kg, 72 ft 7 Nm (0.7 m kg, 5.1 ft • • • • (4) 1 7 Nm (0.7 m kg, 5.1 ft • • 55 Nm (5.5 m kg, 40 ft •...
  • Page 191 SWINGARM Removing the swingarm 100 Nm (10.0 m kg, 72 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 12 9 10 10 7 Nm (0.7 m kg, 5.1 ft • • 55 Nm (5.5 m kg, 40 ft •...

  • Page 192: Removing The Swingarm

    SWINGARM 2. Check: EAS23350 REMOVING THE SWINGARM • Pivot shaft 1. Place the vehicle on a level surface. Roll the pivot shaft on a flat surface. 2. Check: Bends → Replace. • Swingarm side play EWA13770 • Swingarm vertical movement WARNING ▼...
  • Page 193 SWINGARM 3. Install: • Relay arm • Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER AS- SEMBLY” on page 4-55. 4. Install: • Rear wheels Refer to and “REAR WHEELS” on page 4-9. 5. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...

  • Page 194: Chain Drive

    CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain 10 Nm (1.0 m kg, 7.2 ft • • 85 Nm (8.5 m kg, 61 ft • • 32 Nm (3.2 m kg, 23 ft • • Order Job/Parts to remove Q’ty Remarks Swingarm...

  • Page 195: Checking The Drive Chain

    CHAIN DRIVE c. Remove the drive chain from the kerosene EAS23441 CHECKING THE DRIVE CHAIN and completely dry it. 1. Measure: ECA14290 • 15-link section of the drive chain NOTICE Out of specification → Replace the drive • This motorcycle has a drive chain with chain.

  • Page 196: Installing The Drive Chain

    CHAIN DRIVE While applying the rear brake, tighten the drive sprocket nut. Drive sprocket nut 85 Nm (8.5 m·kg, 61 ft·lb) 4. Lubricate: • Drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 5. Check: 3. Bend the lock washer tab along a flat side of •...

  • Page 197: Engine

    ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE EXHAUST PIPE AND MUFFLER........5-2 INSTALLING THE ENGINE............... 5-7 CYLINDER HEAD.................... 5-8 REMOVING THE CYLINDER HEAD............5-10 CHECKING THE CYLINDER HEAD ............5-10 CHECKING THE CAMSHAFT SPROCKET..........5-11 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER ................5-11 CHECKING THE TIMING CHAIN TENSIONER........
  • Page 198 CLUTCH ......................5-40 REMOVING THE CLUTCH ..............5-44 REMOVING THE PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR ..............5-44 CHECKING THE FRICTION PLATES.............5-44 CHECKING THE CLUTCH PLATES ............5-45 CHECKING THE CLUTCH SPRINGS.............5-45 CHECKING THE CLUTCH HOUSING ............5-45 CHECKING THE CLUTCH BOSS............5-45 CHECKING THE PRESSURE PLATE ............5-46 CHECKING THE PRIMARY DRIVE GEARS ..........5-46 CHECKING THE BALANCER DRIVE GEARS ........

  • Page 200: Engine Removal

    ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the muffler and exhaust pipe 38 Nm (3.8 m kg, 27 ft • • 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 20 Nm (2.0 m kg, 14 ft •...

  • Page 201: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL EAS2LS1003 INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • Gasket “1” (to muffler) Install the gasket with the chamfer “a”, located on an inner rim of the gasket, and the chamfer “b”, located on an outer rim of the gasket, as shown.
  • Page 202 ENGINE REMOVAL Removing the oil tank 16 Nm (1.6 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 203 ENGINE REMOVAL Disconnecting the leads, cables and hoses Order Job/Parts to remove Q’ty Remarks Coolant Drain. Right foot protector/air filter case/battery/fuel Refer to “GENERAL CHASSIS” on page tank 4-1. Rear brake light switch/right footrest Refer to “REAR BRAKE” on page 4-28. Radiator inlet hose Refer to “THERMOSTAT”...
  • Page 204 ENGINE REMOVAL Disconnecting the leads, cables and hoses Order Job/Parts to remove Q’ty Remarks Negative battery sub-wire harness coupler Disconnect. Speed sensor coupler Disconnect. AC magneto coupler Disconnect. Crankshaft position sensor coupler Disconnect. Rear brake light switch coupler Rear brake light switch lead Neutral switch and reverse switch sub-wire har- ness Ground lead...
  • Page 205 ENGINE REMOVAL Removing the engine 33 Nm (3.3 m kg, 24 ft • • 40 Nm (4.0 m kg, 29 ft • • 100 Nm (10.0 m kg, 72 ft • • 66 Nm (6.6 m kg, 48 ft • •...

  • Page 206: Installing The Engine

    ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE Engine upper bracket bolt “1” ECA1S3L015 33 Nm (3.3 m·kg, 24 ft·lb) NOTICE Engine upper bracket bolt “2” Install all of the bolts/nuts and then tighten 33 Nm (3.3 m·kg, 24 ft·lb) them to full torque specifications. Engine mounting bolt (upper)/nut “3”...

  • Page 207: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 20 Nm (2.0 m kg, 14 ft • • 33 Nm (3.3 m kg, 24 ft 13 Nm (1.3 m kg, 9.4 ft • • • • 35 Nm (3.5 m kg, 25 ft •...
  • Page 208 CYLINDER HEAD Removing the cylinder head 20 Nm (2.0 m kg, 14 ft • • 33 Nm (3.3 m kg, 24 ft 13 Nm (1.3 m kg, 9.4 ft • • • • 35 Nm (3.5 m kg, 25 ft •...

  • Page 209: Removing The Cylinder Head

    CYLINDER HEAD • Camshaft sprocket EAS24130 REMOVING THE CYLINDER HEAD • Timing chain 1. Align: • “I” mark “a” on the AC magneto rotor To prevent the timing chain from falling into the (with the stationary pointer “b” on the AC crankcase, fasten it with a wire.

  • Page 210: Checking The Camshaft Sprocket

    CYLINDER HEAD 3. Measure: • Cylinder head warpage Out of specification → Resurface the cylinder head. Warpage limit 0.03 mm (0.0012 in) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.

  • Page 211: Installing The Cylinder Head

    CYLINDER HEAD • Timing chain ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft counterclockwise. b. Align the “I” mark “a” on the AC magneto rotor with the stationary pointer “b” on the AC mag- neto cover.
  • Page 212 CYLINDER HEAD b. Release the timing chain tensioner one-way Refer to the installation steps above. cam “4” and push the timing chain tensioner rod “5” all the way into the timing chain ten- sioner housing. c. Install the timing chain tensioner and gasket “6”...

  • Page 213: Camshaft

    CAMSHAFT EAS23730 CAMSHAFT Removing the rocker arms and camshaft 14 Nm (1.4 m kg, 10 ft • • 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Cylinder head...

  • Page 214: Removing The Rocker Arms And Camshaft

    CAMSHAFT EAS23770 EAS23840 REMOVING THE ROCKER ARMS AND CHECKING THE CAMSHAFT CAMSHAFT 1. Check: 1. Loosen: • Camshaft lobes Blue discoloration/pitting/scratches → Re- • Locknuts • Valve clearance adjusting screws place the camshaft. 2. Remove: 2. Measure: • Camshaft retainer “1” •...

  • Page 215: Checking The Decompression System

    CAMSHAFT Camshaft runout limit Rocker arm inside diameter 0.030 mm (0.0012 in) 12.000–12.018 mm (0.4724– 0.4731 in) EAS1S3L025 4. Measure: CHECKING THE DECOMPRESSION SYSTEM • Rocker arm shaft outside diameter 1. Check: Out of specification → Replace. • Decompression system ▼...
  • Page 216 CAMSHAFT • Apply engine oil to the bearing. Install the camshaft so that the camshaft sprock- • Install the bearing so that the seal “a” is facing et mounting pins “a” can be aligned with the the camshaft. camshaft sprocket cover bolt holes “b”. Installed depth “b”...
  • Page 217 CAMSHAFT Camshaft retainer bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) 5-18...
  • Page 218 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-8. Rocker arms/rocker arm shafts/camshaft Refer to “CAMSHAFT” on page 5-14. Valve cotter Valve spring retainer Valve spring...

  • Page 219: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 220 VALVES AND VALVE SPRINGS b. Install the new valve guide with the valve Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover ance (intake) “1”. 0.010–0.037 mm (0.0004–0.0015 Limit 0.080 mm (0.0031 in) Valve-stem-to-valve-guide clear- ance (exhaust) 0.025–0.052 mm (0.0010–0.0020 Limit 0.100 mm (0.0039 in) c.

  • Page 221: Checking The Valve Seats

    VALVES AND VALVE SPRINGS • Valve stem end Mushroom shape or diameter larger than the body of the valve stem → Replace the valve. 5. Measure: • Valve stem runout Out of specification → Replace the valve. • When installing a new valve, always replace the valve guide.

  • Page 222: Checking The Valve Springs

    VALVES AND VALVE SPRINGS b. Apply molybdenum disulfide oil onto the h. Install the valve into the cylinder head. valve stem. i. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. j.

  • Page 223: Installing The Valves

    VALVES AND VALVE SPRINGS 2. Measure: EAS24340 INSTALLING THE VALVES • Compressed valve spring force “a” Out of specification → Replace the valve The following procedure applies to all of the valves and related components. spring. 1. Deburr: • Valve stem end (with an oil stone) b.
  • Page 224 VALVES AND VALVE SPRINGS • Make sure each valve is installed in its original place. • Install the valve springs with the larger pitch “a” facing up. 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.

  • Page 225: Cylinder And Piston

    CYLINDER AND PISTON EAS24350 CYLINDER AND PISTON Removing the cylinder and piston 1st 15Nm (1.5 m kg, 11 ft • • 2nd 50Nm (5.0m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 226: Removing The Piston

    CYLINDER AND PISTON EAS24380 REMOVING THE PISTON When removing a piston ring, open the end gap 1. Remove: with your fingers and lift the other side of the ring • Piston pin clips “1” over the piston crown. • Piston pin “2” •...

  • Page 227: Checking The Piston Rings

    CYLINDER AND PISTON EAS24430 CHECKING THE PISTON RINGS Bore 1. Measure: 102.000–102.010 mm (4.0157– • Piston ring side clearance 4.0161 in) Out of specification → Replace the piston Wear limit 102.080 mm (4.0189 in) and piston rings as a set. Taper limit 0.05 mm (0.002 in) Before measuring the piston ring side clearance,...

  • Page 228: Checking The Piston Pin

    CYLINDER AND PISTON 3. Measure: Piston pin bore inside diameter • Piston ring end gap 23.004–23.015 mm (0.9057– Out of specification → Replace the piston 0.9061 in) ring. Limit 23.045 mm (0.9073 in) The oil ring expander spacer’s end gap cannot be measured.
  • Page 229 CYLINDER AND PISTON 2. Install: 6. Install: • Piston “1” • Cylinder “1” • Piston pin “2” • Timing chain guide (exhaust side) • Piston pin clips “3” • While compressing the piston rings with one hand, install the cylinder with the other hand. •...

  • Page 230: Ac Magneto And Starter Clutch

    AC MAGNETO AND STARTER CLUTCH EAS1S3L026 AC MAGNETO AND STARTER CLUTCH Removing the AC magneto and starter clutch 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (14) 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 231 AC MAGNETO AND STARTER CLUTCH Removing the AC magneto and starter clutch 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (14) 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft •...

  • Page 232: Removing The Ac Magneto Rotor

    AC MAGNETO AND STARTER CLUTCH EAS24490 ECA13880 REMOVING THE AC MAGNETO ROTOR NOTICE 1. Remove: To protect the end of the crankshaft, place an • AC magneto cover appropriate sized socket between the fly- wheel puller set center bolt and the crank- Loosen each bolt 1/4 of a turn at a time, in stag- shaft.

  • Page 233: Checking The Torque Limiter

    AC MAGNETO AND STARTER CLUTCH • Bolts “2” b. When turning the starter wheel gear counter- Loose → Replace with a new one, and clinch clockwise “A”, the starter clutch and the start- the end of the bolt. er wheel gear should engage, otherwise the starter clutch is faulty and must be replaced.
  • Page 234 90890-01701 Primary clutch holder YS-01880-A 2. Apply: • Sealant “1” (onto the crankshaft position sensor/stator assembly lead grommet) Yamaha bond No. 1215 5. Install: 90890-85505 (Three bond No.1215®) • Gasket • AC magneto cover • AC magneto cover bolts AC magneto cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)

  • Page 235: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 5 Nm (0.5 m kg, 3.6 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1. Starter motor lead Disconnect.
  • Page 236 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Square ring Lock washer Shim Armature assembly Starter motor yoke Brush holder assembly Square ring Shim Starter motor rear cover For assembly, reverse the disassembly pro- cedure.

  • Page 237: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ CHECKING THE STARTER MOTOR a. Measure the armature assembly resistances 1. Check: with the pocket tester. • Commutator Dirt → Clean with 600 grit sandpaper. Pocket tester 90890-03112 2.

  • Page 238: Assembling The Starter Motor

    ELECTRIC STARTER Brush spring force 7.65–10.01 N (780–1021 gf, 27.54–36.03 oz) 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bushing • Bearing • Oil seal Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1.

  • Page 239: Clutch

    CLUTCH EAS25061 CLUTCH Removing the clutch cover 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (14) 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 240 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Bearing For installation, reverse the removal proce- dure. 5-41...
  • Page 241 CLUTCH Removing the clutch 8 Nm (0.8 m kg, 5.8 ft • • 60 Nm (6.0 m kg, 43 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 110 Nm (11.0 m kg, 80 ft • • 60 Nm (6.0 m kg, 43 ft 95 Nm (9.5 m...
  • Page 242 CLUTCH Removing the clutch 8 Nm (0.8 m kg, 5.8 ft • • 60 Nm (6.0 m kg, 43 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 110 Nm (11.0 m kg, 80 ft • • 60 Nm (6.0 m kg, 43 ft 95 Nm (9.5 m...

  • Page 243: Removing The Clutch

    CLUTCH EAS25070 REMOVING THE CLUTCH 1. Remove: • Clutch cover Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EAS1S3L030 REMOVING THE PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR 1.

  • Page 244: Checking The Clutch Plates

    CLUTCH 1. Check: • Clutch spring Measure the friction plate at four places. Damage → Replace the clutch springs as a set. Friction plate 1 thickness 2. Measure: 2.92–3.08 mm (0.11–0.12 in) • Clutch spring free length “a” Wear limit Out of specification →...

  • Page 245: Checking The Pressure Plate

    CLUTCH • Water pump drive gear “4” Damage/wear → Replace the balancer drive gear and balancer driven gear as a set. Replace the water pump drive gear and water pump driven gear as a set. Excessive noise during operation → Replace the balancer drive gear and balancer driven gear as a set.

  • Page 246: Installing The Clutch

    CLUTCH 3. Bend the lock washer tabs along a flat side of the nut. • Align the punch mark “a” on the balancer drive gear with the punch mark “b” on the balancer EAS25240 driven gear 2. INSTALLING THE CLUTCH •...
  • Page 247 CLUTCH • While holding the clutch boss “1” with the uni- versal clutch holder “4”, tighten the clutch boss nut. • Stake the clutch boss nut “3” at a cutout “b” in the main axle. Universal clutch holder 90890-04086 Universal clutch holder YM-91042 6.
  • Page 248 CLUTCH 9. Adjust: • Clutch cable length Move the pull lever a notch until the cable length is within specification. 10.Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-12. 5-49...

  • Page 249: Oil Pump

    OIL PUMP EAS24911 OIL PUMP Removing the oil pump Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH” on page 5-40. Oil baffle plate 1 Circlip Oil pump driven gear Oil baffle plate 2 Oil pump Oil pump gasket O-ring For installation, reverse the removal proce- dure.
  • Page 250 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing 1/oil seal Oil pump outer rotor 1 Dowel pin Oil pump inner rotor 1 Oil pump housing cover/oil seal Dowel pin Oil pump shaft Dowel pin Oil pump inner rotor 2 Oil pump outer rotor 2 Oil pump housing 2...

  • Page 251: Checking The Oil Pump

    OIL PUMP EAS24960 CHECKING THE OIL PUMP 1. Check: • Oil pump driven gear “1” • Oil pump housing 1 “2” • Oil pump housing cover “3” • Oil pump housing 2 “4” Cracks/damage/wear → Replace the defec- tive part(s). EAS25000 ASSEMBLING THE OIL PUMP 1.

  • Page 252: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH” on page 5-40. Shift pedal Shift shaft Shift shaft spring Stopper lever/washer Stopper lever spring Roller Shift guide Shift lever assembly Pawl holder Pawl...

  • Page 253: Checking The Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear → Replace. • Shift lever spring “2” Damage/wear → Replace. EAS1S3L034 CHECKING THE SHIFT DRUM SEGMENT 1. Check: • Shift drum segment Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1.

  • Page 254: Installing The Shift Shaft

    SHIFT SHAFT 3. Install: • Shift lever assembly “1” • Shift guide “2” Shift guide bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) LOCTITE® The shift lever assembly is installed at the same time as the shift guide. 2. Install: • Shift pedal Refer to “ADJUSTING THE SHIFT PEDAL”...

  • Page 255: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine assembly Refer to “ENGINE REMOVAL” on page 5-1. Refer to “CYLINDER AND PISTON” on page Piston 5-26. Refer to “AC MAGNETO AND STARTER AC magneto CLUTCH” on page 5-31. Balancer driven gears Refer to “CLUTCH”...
  • Page 256 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Oil pipe joint Reverse shift lever Reverse shift lever spring Circlip Right crankcase Left crankcase Dowel pin Dowel pin/O-ring Oil strainer For installation, reverse the removal proce- dure. 5-57...
  • Page 257 CRANKCASE Removing the crankcase bearings 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Crankshaft Refer to “CRANKSHAFT” on page 5-62. Transmission Refer to “TRANSMISSION”...

  • Page 258: Separating The Crankcase

    CRANKCASE EAS1S3L036 SEPARATING THE CRANKCASE 1. Remove: • Crankcase bolts Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Check: •...

  • Page 259: Checking The Crankcase

    • Sealant “1” (onto the crankcase mating surfaces) • Install the bearing by pressing its outer race evenly. Yamaha bond No. 1215 • To prevent the bearing retainer screws “2” from 90890-85505 becoming loose, flatten the edge “a” of each (Three bond No.1215®)
  • Page 260 CRANKCASE 5. Fit the right crankcase onto the left crank- case. Tap lightly on the case with a soft ham- mer. ECA1S3L018 NOTICE Before installing and torquing the crankcase holding bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both di- rections.

  • Page 261: Crankshaft

    CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-56. Balancer 1 Balancer 2 Crankshaft For installation, reverse the removal proce- dure. 5-62...

  • Page 262: Removing The Crankshaft

    CRANKSHAFT EAS1S3L038 REMOVING THE CRANKSHAFT 1. Remove: • Crankshaft “1” • Remove the crankshaft with the crankcase separating tool “2”. • Make sure the crankcase separating tool is centered over the crankshaft. Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B EAS1S3L040 INSTALLING THE CRANKSHAFT 1.
  • Page 263 CRANKSHAFT ECA1S3L019 NOTICE Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier. Hold the connecting rod at top dead center (TDC) with one hand while turning the nut of the crankshaft installer bolt with the other. Turn the crankshaft installer bolt until the crankshaft as- sembly bottoms against the bearing.

  • Page 264: Transmission

    TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-56. Spacer Circlip Washer Reverse wheel gear 2 Spacer Counter axle assembly Shift drum Shift fork “R” Shift fork “C”...
  • Page 265 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Drive axle assembly Main axle assembly Reverse shift shaft For installation, reverse the removal proce- dure. 5-66...
  • Page 266 TRANSMISSION Disassembling the main axle Order Job/Parts to remove Q’ty Remarks Circlip 2nd pinion gear Toothed lock washer Toothed washer retainer 4th pinion gear Toothed spacer Toothed washer Circlip 3rd pinion gear 5th pinion gear Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure.
  • Page 267 TRANSMISSION Disassembling the drive axle Order Job/Parts to remove Q’ty Remarks Circlip Washer Reverse wheel gear 2 Spacer Dog clutch Circlip Toothed washer 1st wheel gear Toothed spacer 5th wheel gear Toothed lock washer Toothed washer retainer 3rd wheel gear Toothed spacer 5-68...
  • Page 268 TRANSMISSION Disassembling the drive axle Order Job/Parts to remove Q’ty Remarks Toothed washer Circlip 4th wheel gear Circlip Toothed washer 2nd wheel gear Spacer Drive axle For assembly, reverse the disassembly pro- cedure. 5-69...
  • Page 269 TRANSMISSION Disassembling the counter axle Order Job/Parts to remove Q’ty Remarks Circlip Washer Spacer Reverse wheel gear 1 Counter axle For assembly, reverse the disassembly pro- cedure. 5-70...

  • Page 270: Checking The Shift Forks

    TRANSMISSION EAS26260 EAS26270 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks. • Shift drum grooves Damage/scratches/wear → Replace the shift 1. Check: • Shift fork cam follower “1” drum assembly.

  • Page 271: Assembling The Main Axle And Drive Axle

    TRANSMISSION 3. Check: • Shift fork-C “4” • Transmission gear engagement (to main axle) (each pinion gear to its respective wheel • Shift fork-R “5” gear) (to drive axle) Incorrect → Reassemble the transmission • Shift drum “6” axle assemblies. 4.
  • Page 272 TRANSMISSION 5-73...

  • Page 273: Cooling System

    COOLING SYSTEM RADIATOR ...................... 6-1 CHECKING THE RADIATOR..............6-2 INSTALLING THE RADIATOR..............6-2 THERMOSTAT ....................6-3 CHECKING THE THERMOSTAT.............. 6-4 INSTALLING THE THERMOSTAT............6-4 WATER PUMP....................6-5 DISASSEMBLING THE WATER PUMP............ 6-7 CHECKING THE WATER PUMP .............. 6-7 ASSEMBLING THE WATER PUMP............6-7...

  • Page 274: Radiator

    RADIATOR EAS26380 RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Front fender 4-1. Coolant Drain.

  • Page 275: Checking The Radiator

    RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.

  • Page 276: Thermostat

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Front fender 4-1. Coolant Drain.

  • Page 277: Checking The Thermostat

    THERMOSTAT 2. Check: EAS26450 CHECKING THE THERMOSTAT • Thermostat cover 1. Check: • Thermostat housing (cylinder head) • Thermostat “1” Cracks/damage → Replace. Does not open at 69–73 °C (156.2–163.4 °F) → Replace. EAS1S3L009 INSTALLING THE THERMOSTAT 1. Install: • Thermostat “1” •...

  • Page 278: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the water pump 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks It is not necessary to remove the water...
  • Page 279 WATER PUMP Disassembling the water pump 11 Nm (1.1 m kg, 8.0 ft • • Order Job/Parts to remove Q’ty Remarks Water pump housing cover Gasket Circlip Impeller shaft gear Washer Impeller shaft assembly Water pump seal Oil seal Bearing Water pump housing For assembly, reverse the disassembly pro- cedure.

  • Page 280: Disassembling The Water Pump

    WATER PUMP 2. Check: EAS26510 DISASSEMBLING THE WATER PUMP • Bearing 1. Remove: Rough movement → Replace. • Water pump seal “1” • Impeller shaft gear Pitting/wear → Replace. Remove the water pump seal from the inside of EAS26560 the water pump housing “2”. ASSEMBLING THE WATER PUMP 1.
  • Page 281 WATER PUMP 3. Mechanical seal installer 4. Middle driven shaft bearing driver A. Push down 3. Measure: • Impeller shaft tilt Impeller shaft tilt limit 0.15 mm (0.006 in) 1. Straightedge 2. Impeller...
  • Page 282 WATER PUMP...

  • Page 283: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL HOSE ..............7-3 THROTTLE BODY................... 7-4 CHECKING THE INJECTOR ..............7-7 CHECKING THE THROTTLE BODY ............7-7 CHECKING THE PRESSURE REGULATOR OPERATION .....

  • Page 284: Fuel Tank

    FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...

  • Page 285: Removing The Fuel Tank

    FUEL TANK 3. Remove: EAS26630 REMOVING THE FUEL TANK • Fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. Do not set the fuel tank down on the installation 2. Remove: surface of the fuel pump.

  • Page 286: Installing The Fuel Hose

    FUEL TANK EAS1S3L011 INSTALLING THE FUEL HOSE 1. Install: • Fuel hose • Fuel hose holder • Fuel pump coupler ECA1S3L007 NOTICE When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holder is in the correct position, other- wise the fuel hose will not be properly in- stalled.
  • Page 287 THROTTLE BODY EAS26970 THROTTLE BODY Removing the throttle body 3 Nm (0.3 m kg, 2.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Fuel tank shield 4-1.
  • Page 288 THROTTLE BODY Removing the throttle body 3 Nm (0.3 m kg, 2.2 ft • • 12 13 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Fast idle plunger outlet hose Disconnect. Intake air pressure sensor hose Intake air pressure sensor Intake manifold clamp screw Loosen.

  • Page 289: Throttle Body

    THROTTLE BODY Disassembling the throttle body Order Job/Parts to remove Q’ty Remarks Throttle position sensor Fuel injection pipe Fuel injector ECA1S3L008 NOTICE Throttle body The throttle body should not be disas- sembled. For assembly, reverse the disassembly pro- cedure.

  • Page 290: Checking The Injector

    THROTTLE BODY d. Connect the pressure gauge “3” and adapter EAS26980 CHECKING THE INJECTOR “4” to the fuel pump and fuel hose. 1. Check: • Injector Pressure gauge Damage → Replace. 90890-03153 Pressure gauge EAS26990 YU-03153 CHECKING THE THROTTLE BODY Fuel pressure adapter 1.

  • Page 291: Installing The Throttle Body

    THROTTLE BODY Digital circuit tester 90890-03174 Model 88 Multimeter with ta- chometer YU-A1927 2. Install: • Throttle cable 3. Adjust: • Throttle lever free play Refer to “ADJUSTING THE THROTTLE LE- VER FREE PLAY” on page 3-6. 4. Adjust: c. Measure the throttle position sensor voltage. •...

  • Page 292: Air Induction System

    AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM...
  • Page 293 AIR INDUCTION SYSTEM 1. Air induction system hose (air filter case joint to air cut-off valve) 2. Air cut-off valve 3. Air induction system hose (air cut-off valve to reed valve) 4. Reed valve A. from the air filter case joint 7-10...
  • Page 294 AIR INDUCTION SYSTEM Removing the air cut-off valve Order Job/Parts to remove Q’ty Remarks Seat/Front panel/Fuel tank top panel/Front fend- Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank shield Refer to “FUEL TANK” on page 7-1. Air cut-off valve coupler Disconnect.
  • Page 295 AIR INDUCTION SYSTEM Removing the reed valve 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Air induction system hose (air cut-off valve to Disconnect. reed valve) Refer to “Removing the air cut-off valve”. Reed valve cover Reed valve assembly Reed valve plate...

  • Page 296: Checking The Air Induction System

    AIR INDUCTION SYSTEM 2. Check: EAS27060 CHECKING THE AIR INDUCTION SYSTEM • Reed valve • Reed valve stopper Air injection • Reed valve seat The air induction system burns unburned ex- Cracks/damage → Replace the reed valve haust gases by injecting fresh air (secondary air) assembly.

  • Page 297: Electrical System

    TROUBLESHOOTING ................8-21 COOLING SYSTEM..................8-25 CIRCUIT DIAGRAM ................8-25 TROUBLESHOOTING ................8-27 FUEL INJECTION SYSTEM................8-29 CIRCUIT DIAGRAM ................8-29 ECU SELF-DIAGNOSTIC FUNCTION............8-31 TROUBLESHOOTING METHOD............8-33 YAMAHA DIAGNOSTIC TOOL ...............8-34 TROUBLESHOOTING DETAILS ............8-37 FUEL PUMP SYSTEM...................8-55 CIRCUIT DIAGRAM ................8-55 TROUBLESHOOTING ................8-57...
  • Page 298 ELECTRICAL COMPONENTS..............8-59 CHECKING THE SWITCHES ..............8-61 CHECKING THE BULBS AND BULB SOCKETS ........8-64 CHECKING THE FUSES ................8-65 CHECKING AND CHARGING THE BATTERY........8-66 CHECKING THE RELAYS ..............8-69 CHECKING THE DIODE .................8-70 CHECKING THE SPARK PLUG CAP .............8-70 CHECKING THE IGNITION COIL ............

  • Page 300: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM...
  • Page 301 IGNITION SYSTEM 1. Crankshaft position sensor 3. Main switch 5. Battery 6. Main fuse 24.ECU (engine control unit) 25.Ignition coil 26.Spark plug 32.Lean angle sensor 33.Joint coupler 35.Handlebar switch 37.Engine stop switch 41.Fuel injection system fuse 43.Ignition fuse A. Wire harness C.

  • Page 302: Troubleshooting

    IGNITION SYSTEM EAS27130 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Fuel tank 4. Front panel 5. Front fender NG → 1.
  • Page 303 IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-61. OK ↓ NG → 9. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the handlebar switch.

  • Page 304: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 305 ELECTRIC STARTING SYSTEM 3. Main switch 5. Battery 6. Main fuse 7. Starter relay 8. Starter motor 16.Diode 17.Clutch switch 19.Neutral switch 24.ECU (engine control unit) 33.Joint coupler 35.Handlebar switch 37.Engine stop switch 38.Start switch 41.Fuel injection system fuse 43.Ignition fuse A.

  • Page 306: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...

  • Page 307: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Front fender NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 308 ELECTRIC STARTING SYSTEM NG → 9. Check the clutch switch. Refer to “CHECKING THE Replace the clutch switch. SWITCHES” on page 8-61. OK ↓ NG → 10.Check the start switch. The start switch is faulty. Replace the han- Refer to “CHECKING THE dlebar switch.
  • Page 309 ELECTRIC STARTING SYSTEM 8-10...

  • Page 310: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11...
  • Page 311 CHARGING SYSTEM 2. AC magneto 4. Rectifier/regulator 5. Battery 6. Main fuse A. Wire harness C. Negative battery sub-wire harness 8-12...

  • Page 312: Troubleshooting

    CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Front panel 4. Front fender NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
  • Page 313 CHARGING SYSTEM 8-14...

  • Page 314: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-15...
  • Page 315 LIGHTING SYSTEM 3. Main switch 5. Battery 6. Main fuse 35.Handlebar switch 36.Light switch 39.Headlight relay 40.Headlight 45.Headlight fuse 48.Tail/brake light A. Wire harness C. Negative battery sub-wire harness 8-16...

  • Page 316: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight or taillight. • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Front panel 4. Front fender NG → 1. Check the condition of each bulb and bulb socket.
  • Page 317 LIGHTING SYSTEM 8-18...

  • Page 318: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-19...
  • Page 319 SIGNALING SYSTEM 3. Main switch 5. Battery 6. Main fuse 10.Indicator light assembly 11.Fuel level warning light 13.Coolant temperature warning light 14.Reverse indicator light 15.Neutral indicator light 19.Neutral switch 20.Fuel pump 23.Reverse switch 24.ECU (engine control unit) 28.Coolant temperature sensor 33.Joint coupler 34.Resistor 41.Fuel injection system fuse...

  • Page 320: Troubleshooting

    SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: warning light, brake light or an indicator light. • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Front panel 4. Front fender NG →...
  • Page 321 SIGNALING SYSTEM NG → 3. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ Replace the tail/brake light assembly. The neutral indicator light fails to come on. NG →...
  • Page 322 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ Replace the indicator light assembly or ECU. The fuel level warning light fails to come on. NG →...
  • Page 323 SIGNALING SYSTEM 8-24...

  • Page 324: Cooling System

    COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-25...
  • Page 325 COOLING SYSTEM 3. Main switch 5. Battery 6. Main fuse 24.ECU (engine control unit) 28.Coolant temperature sensor 33.Joint coupler 41.Fuel injection system fuse 42.Radiator fan motor fuse 43.Ignition fuse 49.Circuit breaker (fan motor) 50.Radiator fan motor relay 51.Radiator fan motor A.

  • Page 326: Troubleshooting

    COOLING SYSTEM EAS27320 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel 3. Front panel 4. Front fender NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s).
  • Page 327 COOLING SYSTEM NG → 8. Check the entire cooling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-25. OK ↓ Replace the ECU. 8-28...

  • Page 328: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-29...
  • Page 329 FUEL INJECTION SYSTEM 1. Crankshaft position sensor 3. Main switch 5. Battery 6. Main fuse 9. Yamaha diagnostic tool coupler 10.Indicator light assembly 12.Engine trouble warning light 16.Diode 17.Clutch switch 18.Fuel pump relay 19.Neutral switch 20.Fuel pump 21.Air induction system solenoid 22.Fuel injector...

  • Page 330: Ecu Self-Diagnostic Function

    • After the engine has been stopped, the lowest fault code number is indicated by the engine trouble warning light (or displayed on the Yamaha diagnostic tool). It remains stored in the memory of the ECU until it is deleted.
  • Page 331 FUEL INJECTION SYSTEM Engine trouble warning light indication and fuel injection system operation Warning light indica- Fuel injection opera- ECU operation Vehicle operation tion tion Warning provided Flashing* when unable to start Operation stopped Cannot be operated engine Operated with substi- tute characteristics in Can or cannot be oper- Remains on...

  • Page 332: Troubleshooting Method

    ▼▼▼ 36: Fuel injector a. Check the fault code number displayed on the Yamaha diagnostic tool. If a malfunction is detected in the sensors or b. Identify the faulty system with the fault code actuators, repair or replace all faulty parts.

  • Page 333: Yamaha Diagnostic Tool

    FUEL INJECTION SYSTEM EAS1XC1028 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool (US) 90890-03234...
  • Page 334 FUEL INJECTION SYSTEM Operation of the Yamaha diagnostic tool (Malfunction mode) Malfunction results are displayed in the top part of the window area. 1. Recovered The item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected The item list of the malfunction currently occurred are displayed.
  • Page 335 FUEL INJECTION SYSTEM 5. Item The item names of the detected malfunction are displayed. 6. Condition The current conditions are displayed. (Detected/Recovered) 7. Symptom The symptoms of the detected malfunction are displayed. 8. Diagnosis code The diagnosis codes related to the detected malfunction are displayed. 9.

  • Page 336: Troubleshooting Details

    Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part have been completed, reset the Yamaha diag- nostic tool display according to the reinstatement method.
  • Page 337 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Installed condition of crank- Improperly installed sensor Crank the engine. → Reinstall or replace the shaft position sensor. Fault code number is not dis- played →...
  • Page 338 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Open or short circuit → Re- Wire harness continuity. Turn the main switch to “ ” place the wire harness. (on). Between intake air pressure Fault code number is not dis- played →...
  • Page 339 FUEL INJECTION SYSTEM If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number “13” first. Fault code No. Intake air pressure sensor: hose system malfunction (clogged Item or detached hose). Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 340 FUEL INJECTION SYSTEM If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number “13” first. Fault code No. Item Throttle position sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 341 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Throttle position sensor re- Measure the throttle position Turn the main switch to “ ” sistance. sensor resistance. (on). Refer to “CHECKING THE Fault code number is not dis- played →...
  • Page 342 FUEL INJECTION SYSTEM Fault code No. Throttle position sensor: stuck throttle position sensor is de- Item tected. Defective throttle position Check throttle position sen- Turn the main switch to “ ” sensor. sor signal. (on), then operate the throt- Execute the diagnostic tle.
  • Page 343 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Open or short circuit → Re- Wire harness continuity. Turn the main switch to “ ” place the wire harness. (on). Between coolant tempera- Fault code number is not dis- played →...
  • Page 344 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Improperly connected → Connection of intake air tem- Turn the main switch to “ ” perature sensor coupler. Connect the coupler secure- (on). Check the locking condition ly or replace the wire har- Fault code number is not dis- played →...
  • Page 345 Actuates the ignition coil five times at one-second intervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Check that power is supplied to the ingnition coil.
  • Page 346 FUEL INJECTION SYSTEM Fault code No. Ignition coil: malfunction detected in the primary lead of the Item ignition coil. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Improperly connected → Connection of ignition coil Start the engine and let it idle connector.
  • Page 347 Injector: open or short circuit detected. Actuates injector five times at one-second intervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on each time the fuel injector is actuated. Check that power is supplied to the injector. Procedure Check the injector operation by listening for the operating sound or by confirming the operation visually.
  • Page 348 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Lean angle sensor output voltage Indicated • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Remove the lean angle sensor and incline it more than 65 de- Procedure grees.
  • Page 349 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed Item sensor. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Vehicle speed pulse Indicated 0–999 Check that the number increases when the rear wheels are rotat- Procedure ed.
  • Page 350 Actuation (When the relay is on, the “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen go off. When the relay is off, the “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on.)
  • Page 351 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel in- Item jector and fuel pump. Open or short circuit → Re- Wire harness continuity. Start the engine and let it idle place the wire harness. for approximately 5 seconds.
  • Page 352 FUEL INJECTION SYSTEM Fault code No. Item Charging voltage is abnormal. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Malfunction in charging sys- Check the charging system. Start the engine and let it idle tem.
  • Page 353 FUEL INJECTION SYSTEM 8-54...

  • Page 354: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-55...
  • Page 355 FUEL PUMP SYSTEM 3. Main switch 5. Battery 6. Main fuse 18.Fuel pump relay 20.Fuel pump 24.ECU (engine control unit) 33.Joint coupler 35.Handlebar switch 37.Engine stop switch 41.Fuel injection system fuse 43.Ignition fuse A. Wire harness C. Negative battery sub-wire harness 8-56...

  • Page 356: Troubleshooting

    FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank top panel NG → 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 357 FUEL PUMP SYSTEM 8-58...

  • Page 358: Electrical Components

    ELECTRICAL COMPONENTS EAS27972 ELECTRICAL COMPONENTS 8-59...
  • Page 359 ELECTRICAL COMPONENTS 1. Main switch 2. Indicator light assembly 3. Front brake light switch 4. Clutch switch 5. Handlebar switch 6. Lean angle sensor 7. Battery 8. Starter relay 9. Main fuse 10. Circuit breaker (fan) 11. Fuse box 12. Radiator fan motor relay 13.

  • Page 360: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES Y/R L Y Br R/B L/B B R/B R/L R Br 8-61...
  • Page 361 ELECTRICAL COMPONENTS 1. Light switch 2. Engine stop switch 3. Start switch 4. Main switch 5. Front brake light switch 6. Clutch switch 7. Fuse 8. Reverse switch 9. Neutral switch 10. Rear brake light switch 8-62...
  • Page 362 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 363: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS • Avoid touching the glass part of a headlight EAS27990 CHECKING THE BULBS AND BULB bulb to keep it free from oil, otherwise the SOCKETS transparency of the glass, the life of the bulb, and the luminous flux will be adverse- Do not check any of the lights that use LEDs.

  • Page 364: Checking The Fuses

    ELECTRICAL COMPONENTS Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.

  • Page 365: Checking And Charging The Battery

    ELECTRICAL COMPONENTS specific gravity of the electrolyte. Therefore, the EAS28030 CHECKING AND CHARGING THE BATTERY charge of the battery has to be checked by mea- EWA13290 suring the voltage at the battery terminals. WARNING Batteries generate explosive hydrogen gas 1. Remove: and contain electrolyte which is made of poi- •...
  • Page 366 ELECTRICAL COMPONENTS • To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. • Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.
  • Page 367 ELECTRICAL COMPONENTS Set the charging voltage at 16–17 V. If the set- If the current is lower than the standard charging ting is lower, charging will be insufficient. If too current written on the battery, this type of battery high, the battery will be over-charged. charger cannot charge the VRLA (Valve Regu- lated Lead Acid) battery.

  • Page 368: Checking The Relays

    ELECTRICAL COMPONENTS EAS28040 CHECKING THE RELAYS Result Check each switch for continuity with the pocket Continuity tester. If the continuity reading is incorrect, re- (between “3” and “4”) place the relay. Headlight relay Pocket tester 90890-03112 First step: Analog pocket tester YU-03112-C 1.

  • Page 369: Checking The Diode

    ELECTRICAL COMPONENTS Radiator fan motor relay Lg,Sb B/Y,Sb ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the diode from the wire harness. 1. Positive battery terminal b. Connect the pocket tester (Ω × 1) to the diode 2.

  • Page 370: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS Primary coil resistance 3.40–4.60 Ω ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the ignition coil connectors from the ignition coil terminals. b. Connect the pocket tester (Ω × 1) to the igni- tion coil as shown.

  • Page 371: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS e. Crank the engine by pushing the start switch Lean angle sensor output voltage “ ” and gradually increase the spark gap un- Less than 65°: 0.4–1.4 V til a misfire occurs. More than 65°: 3.7–4.4 V ▲ ▲▲▲...

  • Page 372: Checking The Stator Coil

    ELECTRICAL COMPONENTS • This check is likely to produce sparks, therefore, make sure no flammable gas or fluid is in the vicinity. b. Measure the stator coil resistance. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 373: Checking The Fuel Sender

    ELECTRICAL COMPONENTS EAS28230 CHECKING THE FUEL SENDER 1. Disconnect: • Fuel pump coupler DC 5A (from the wire harness) 2. Drain • Fuel (from the fuel tank) O/G B/W B 3. Remove: • Fuel pump assembly (from the fuel tank) 4.

  • Page 374: Checking The Radiator Fan Motor

    ELECTRICAL COMPONENTS The radiator fan motor circuit breaker “1” is at- tached to the wire harness with white tape near the headlight relay “2”. b. Set the main switch to “ON”. c. Elevate the rear wheels and slowly rotate them. d.

  • Page 375: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS • Never subject the coolant temperature sen- e. Measure the coolant temperature sensor re- sor to strong shocks. If the coolant temper- sistance. ature sensor is dropped, replace it. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 376: Checking The Intake Air Pressure Sensor

    ELECTRICAL COMPONENTS EAS28410 CHECKING THE INTAKE AIR PRESSURE Intake air temperature sensor re- SENSOR sistance 2.21–2.69 Ω 1. Check: • Intake air pressure sensor output voltage Out of specification → Replace. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
  • Page 377 ELECTRICAL COMPONENTS • Positive tester probe → Air induction system solenoid terminal “1” • Negative tester probe → Air induction system solenoid terminal “2” Br/R c. Measure the air induction system solenoid re- sistance. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
  • Page 378 ELECTRICAL COMPONENTS 8-79...

  • Page 379: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ............... 9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED ............ 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING................ 9-2 SHIFT PEDAL DOES NOT MOVE ............9-2 JUMPS OUT OF GEAR................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................9-3 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............

  • Page 380: Troubleshooting

    TROUBLESHOOTING 3. Throttle body EAS28451 TROUBLESHOOTING • Deteriorated or contaminated fuel • Vacuum leak EAS28460 GENERAL INFORMATION Electrical system 1. Battery The following guide for troubleshooting does not • Discharged battery cover all the possible causes of trouble. It should •...

  • Page 381: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING • Improper throttle cable free play Transmission • Flooded throttle body • Seized transmission gear • Faulty air induction system • Foreign object between transmission gears • Improperly assembled transmission Electrical system EAS28550 1. Battery JUMPS OUT OF GEAR •...

  • Page 382: Overheating

    TROUBLESHOOTING EAS28600 EAS28620 OVERHEATING POOR BRAKING PERFORMANCE • Worn brake pad Engine • Worn brake disc 1. Clogged coolant passages • Air in hydraulic brake system • Cylinder head and piston • Leaking brake fluid • Heavy carbon buildup • Faulty brake caliper kit 2.

  • Page 383: Faulty Lighting Or Signaling System

    TROUBLESHOOTING • Damaged frame EAS28710 FAULTY LIGHTING OR SIGNALING SYSTEM Headlight does not come on • Wrong headlight bulb • Too many electrical accessories • Hard charging • Incorrect connection • Improperly grounded circuit • Poor contacts (main or light switch) •...

  • Page 384: Self-Diagnostic Function And Diagnostic Code Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS2LS1004 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Self-diagnostic function table Fault Reference Item code No. pages Crankshaft position sensor: no normal signals are received from the 8-37 crankshaft position sensor. Intake air pressure sensor: open or short circuit detected. 8-38 Intake air pressure sensor: hose system malfunction (clogged or de- 8-40...
  • Page 385 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic code: sensor operation table Diagnostic Item Display Procedure code No. Throttle position sensor signal • Fully closed position 14–20 Check with throttle valve fully closed. Intake air pressure Displays the intake air Push the start switch and pressure.
  • Page 386 Check that power is sup- five times at one-second plied to the ignition coil. intervals. • Check that a spark is The “CHECK” indicator generated. and “ ” on the Yamaha diagnostic tool screen come on each time the ig- nition coil is actuated.
  • Page 387 (When the relay is on, the “CHECK” indicator and “ ” on the Yamaha diag- nostic tool screen go off. When the relay is off, the “CHECK” indicator and “ ” on the Yamaha diag- nostic tool screen come on.)
  • Page 388 (When the relay is on, the “CHECK” indicator and “ ” on the Yamaha diag- nostic tool screen go off. When the relay is off, the “CHECK” indicator and “ ” on the Yamaha diag- nostic tool screen come on.)
  • Page 389 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9-10...
  • Page 390 5. Battery Orange 6. Main fuse Pink 7. Starter relay 8. Starter motor Sky blue White 9. Yamaha diagnostic tool coupler Yellow 10. Indicator light assembly Black/Blue 11. Fuel level warning light Black/White 12. Engine trouble warning light Black/Yellow 13. Coolant temperature warning...
  • Page 393 YFM700RF/YFM700RSF 2015 WIRING DIAGRAM Br/Y Br/Y Y Sb G/W (Gy) (Gy) Br/G Br/W (Gy) Br/W B/L G/Y O/B B/W Br Br/W Br/W W/L G/L Sb P O/R Br/L Br/L L/W L/B Br/G Br/G Br/G Br/R R/B Br/R Br/G Br/G Lg,Sb R/L R/B B/Y ,Sb (Gy)
  • Page 394 YFM700RF/YFM700RSF 2015 WIRING DIAGRAM (Gy) (Gy) (Gy) (Gy) (Gy) (Gy) (Gy)

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