Yamaha Raptor 700R 2009 Manuals

Manuals and User Guides for Yamaha Raptor 700R 2009. We have 1 Yamaha Raptor 700R 2009 manual available for free PDF download: Service Manual

Yamaha Raptor 700R 2009 Service Manual

Yamaha Raptor 700R 2009 Service Manual (374 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 15.21 MB

Table of Contents

Table of Contents

7
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    Self-Adjusting Parking Brake Mechanism
    13
    
    Parking Brake Operation
    14
    
    Instrument Functions
    16
  - Important Information
    17
    
    Preparation for Removal and Disassembly
    17
    
    Replacement Parts
    17
    
    Gaskets, Oil Seals and O-Rings
    17
    
    Lock Washers/Plates and Cotter Pins
    17
    
    Bearings and Oil Seals
    18
    
    Circlips
    18
  - Checking the Connections
    19
  - Special Tools
    20
Specifications

27
- General Specifications
  28
- Engine Specifications
  29
- Chassis Specifications
  36
- Electrical Specifications
  39
- Tightening Torques
  42
- Lubrication Points and Lubricant Types
  49
  - Engine
    49
- Lubrication System Chart and Diagrams
  50
  - Engine Oil Lubrication Chart
    50
  - Lubrication Diagrams
    52
- Cooling System Diagrams
  62
- Cable Routing
  68
Periodic Checks and Adjustments

81
- Periodic Maintenance
  
  84
- Engine
  
  87
- Chassis
  
  104
  - Adjusting the Front Disc Brake
    104
    
    Adjusting the Rear Disc Brake
    104
    
    Checking the Brake Fluid Level
    104
    
    Checking the Front Brake Pads
    105
    
    Checking the Rear Brake Pads
    105
    
    Checking the Front Brake Hoses
    105
    
    Checking the Rear Brake Hose
    106
    
    Adjusting the Parking Brake
    106
    
    Adjusting the Rear Brake Light Switch
    107
    
    Bleeding the Hydraulic Brake System
    107
    
    Adjusting the Shift Pedal
    108
    
    Adjusting the Reverse Control Cable
    108
    
    Adjusting the Drive Chain Slack
    109
    
    Checking the Steering System
    110
    
    Adjusting the Toe-In
    110
    
    Checking the Front Shock Absorber Assemblies
    111
    
    Adjusting the Front Shock Absorber Assemblies
    112
    
    Checking the Rear Shock Absorber Assembly
    114
    
    Adjusting the Rear Shock Absorber Assembly
    114
    
    Checking the Tires
    117
    
    Checking the Wheels
    118
    
    Checking and Lubricating the Cables
    118
    
    Lubricating the Clutch Lever
    119
    
    Lubricating the Brake Lever
    119
    
    Lubricating the Pedal
    119
    
    Lubricating the Rear Suspension
    119
- Electrical System
  
  120
  - Checking and Charging the Battery
    120
  - Checking the Fuses
    120
  - Replacing the Headlight Bulbs
    120
  - Adjusting the Headlight Beams
    120
Chassis

123
- General Chassis
  
  126
- Front Wheels
  
  130
  - Removing the Front Wheels
    131
  - Checking the Front Wheels
    131
  - Checking the Front Wheel Hubs
    131
  - Installing the Front Wheel Hub Bearings
    132
  - Installing the Front Brake Discs
    132
  - Installing the Front Wheel Hubs
    132
  - Installing the Front Wheels
    133
- Rear Wheels
  
  134
  - Removing the Rear Wheels
    135
  - Checking the Rear Wheels
    135
  - Checking the Rear Wheel Hubs
    135
  - Installing the Rear Wheel Hubs
    135
  - Installing the Rear Wheels
    136
- Rear Axle and Rear Axle Hub
  
  137
  - Removing the Rear Axle
    139
  - Checking the Rear Axle
    139
  - Checking the Rear Wheel Sprocket
    140
  - Checking the Rear Brake Disc
    140
  - Installing the Rear Wheel Sprocket
    140
  - Installing the Rear Axle
    140
- Front Brakes
  
  142
- Rear Brake
  
  159
  - Introduction
    159
  - Checking the Rear Brake Disc
    159
  - Replacing the Rear Brake Pads
    159
  - Removing the Rear Brake Caliper
    160
  - Disassembling the Rear Brake Caliper
    161
  - Checking the Rear Brake Caliper
    161
  - Assembling the Rear Brake Caliper
    161
  - Installing the Rear Brake Caliper
    162
  - Checking the Rear Brake Master Cylinder
    164
  - Assembling the Rear Brake Master Cylinder
    164
  - Installing the Rear Brake Master Cylinder
    164
- Handlebar
  
  166
  - Removing the Clutch Switch
    167
  - Removing the Handlebar
    167
  - Checking the Handlebar
    167
  - Installing the Handlebar
    167
- Steering Stem
  
  170
  - Removing the Bearing Retainer
    171
  - Checking the Steering Stem
    171
  - Installing the Bearing Retainer
    171
  - Installing the Lock Washer
    171
  - Installing the Pitman Arm
    171
- Tie-Rods and Steering Knuckles
  
  173
  - Removing the Steering Knuckles
    173
  - Checking the Tie-Rods
    173
  - Checking the Steering Knuckles
    173
  - Installing the Tie-Rods
    173
- Front Arms and Front Shock Absorber Assemblies
  
  175
- Rear Shock Absorber Assembly
  
  180
- Swingarm
  
  184
  - Removing the Swingarm
    186
  - Checking the Swingarm
    186
  - Installing the Swingarm
    186
- Chain Drive
  
  188
  - Checking the Drive Chain
    189
  - Installing the Drive Chain
    190
Engine

191
- Engine Removal
  
  194
  - Installing the Exhaust Pipes and Muffler
    195
  - Installing the Engine
    200
- Cylinder Head
  
  201
- Camshaft
  
  207
- Valves and Valve Springs
  
  213
  - Removing the Valves
    213
  - Checking the Valves and Valve Guides
    213
  - Checking the Valve Seats
    215
  - Checking the Valve Springs
    216
  - Installing the Valves
    217
- Cylinder and Piston
  
  219
  - Removing the Piston
    220
  - Checking the Cylinder and Piston
    220
  - Checking the Piston Rings
    221
  - Checking the Piston Pin
    222
  - Installing the Piston and Cylinder
    222
- Ac Magneto and Starter Clutch
  
  224
- Electric Starter
  
  229
  - Checking the Starter Motor
    231
  - Assembling the Starter Motor
    232
- Clutch
  
  233
  - Removing the Clutch
    237
  - Removing the Primary Drive Gear and Balancer Driven Gear
    237
  - Checking the Friction Plates
    237
  - Checking the Clutch Plates
    238
  - Checking the Clutch Springs
    238
  - Checking the Clutch Housing
    238
  - Checking the Clutch Boss
    238
  - Checking the Pressure Plate
    239
  - Checking the Primary Drive Gears
    239
  - Checking the Balancer Drive Gears
    239
  - Checking the Pull Lever Shaft and Pull Rod
    239
  - Installing the Primary Drive Gear and Balancer Driven Gears
    239
  - Installing the Clutch
    240
- Oil Pump
  
  243
  - Checking the Oil Pump
    245
  - Assembling the Oil Pump
    245
- Shift Shaft
  
  246
  - Checking the Shift Shaft
    247
  - Checking the Stopper Lever
    247
  - Checking the Shift Guide
    247
  - Checking the Shift Drum Segment
    247
  - Installing the Shift Lever
    247
  - Installing the Shift Shaft
    248
- Crankcase
  
  251
  - Separating the Crankcase
    252
  - Checking the Timing Chain and Timing Chain Guide
    252
  - Checking the Oil Strainer
    252
  - Checking the Bearings and Oil Seals
    252
  - Checking the Crankcase
    253
  - Assembling the Crankcase
    253
- Crankshaft
  
  255
  - Removing the Crankshaft
    256
  - Checking the Crankshaft
    256
  - Installing the Crankshaft
    256
- Transmission
  
  258
  - Checking the Shift Forks
    263
  - Checking the Shift Drum Assembly
    263
  - Checking the Transmission
    263
  - Assembling the Main Axle and Drive Axle
    264
  - Installing the Transmission
    264
Cooling System

267
- Radiator
  
  269
  - Checking the Radiator
    269
  - Installing the Radiator
    269
- Thermostat
  
  270
  - Checking the Thermostat
    271
  - Installing the Thermostat
    271
- Water Pump
  
  272
  - Disassembling the Water Pump
    274
  - Checking the Water Pump
    274
  - Assembling the Water Pump
    274
Fuel System

277
- Fuel Tank
  
  279
  - Checking the Fuel Pump Body
    279
  - Installing the Fuel Pump
    279
  - Removing the Fuel Pump
    279
  - Removing the Fuel Tank
    279
  - Installing the Fuel Hose
    280
- Throttle Body
  
  281
  - Checking the Injector
    284
  - Checking the Throttle Body
    284
  - Checking the Pressure Regulator Operation
    284
  - Adjusting the Throttle Position Sensor
    284
  - Installing the Throttle Body
    285
Electrical System

287
- Ignition System
  
  290
  - Circuit Diagram
    290
  - Troubleshooting
    292
- Electric Starting System
  
  294
  - Circuit Diagram
    294
  - Starting Circuit Cut-Off System Operation
    296
  - Troubleshooting
    298
- Charging System
  
  300
  - Circuit Diagram
    300
  - Troubleshooting
    302
- Lighting System
  
  304
  - Circuit Diagram
    304
  - Troubleshooting
    306
- Signaling System
  
  308
  - Circuit Diagram
    308
  - Troubleshooting
    310
- Cooling System
  
  314
  - Circuit Diagram
    314
  - Troubleshooting
    316
- Fuel Injection System
  
  318
  - Circuit Diagram
    318
  - Ecu Self-Diagnostic Function
    320
  - Self-Diagnostic Function Table
    320
  - Troubleshooting Method
    322
  - Diagnostic Mode
    322
  - Troubleshooting Details
    327
- Fuel Pump System
  
  340
  - Circuit Diagram
    340
  - Troubleshooting
    342
- Electrical Components
  
  344
  - Checking the Switches
    346
  - Checking the Bulbs and Bulb Sockets
    349
  - Checking the Fuses
    350
  - Checking and Charging the Battery
    351
  - Checking the Relays
    354
  - Checking the Diodes
    355
  - Checking the Spark Plug Cap
    355
  - Checking the Ignition Coil
    356
  - Checking the Ignition Spark Gap
    356
  - Checking the Crankshaft Position Sensor
    357
  - Checking the Lean Angle Sensor
    357
  - Checking the Starter Motor Operation
    358
  - Checking the Stator Coil
    358
  - Checking the Rectifier/Regulator
    359
  - Checking the Fuel Sender
    359
  - Checking the Speed Sensor
    360
  - Checking the Radiator Fan Motor
    360
  - Checking the Radiator Fan Motor Circuit Breaker
    360
  - Checking the Coolant Temperature Sensor
    361
  - Checking the Throttle Position Sensor
    362
  - Checking the Intake Air Pressure Sensor
    362
  - Checking the Intake Air Temperature Sensor
    362
Troubleshooting

365
- General Information
  365
- General Information
  366
- Incorrect Engine Idling Speed
  366
- Starting Failures
  366
- Troubleshooting
  366
- Faulty Clutch
  367
- Faulty Gear Shifting
  367
- Jumps out of Gear
  367
- Overheating
  367
- Poor Medium-And-High-Speed Performance
  367
- Shift Pedal Does Not Move
  367
- Faulty Shock Absorber Assembly
  368
- Overcooling
  368
- Poor Braking Performance
  368
- Unstable Handling
  368
- Faulty Lighting or Signaling System
  369

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