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Yamaha Manuals
Offroad Vehicle
YFM70RY
Service manual
Yamaha YFM70RY Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
General Information
Identification
Vehicle Identification Number
Model Label
Features
Outline of the Fi System
Fi System
Self-Adjusting Parking Brake Mechanism
Parking Brake Operation
Instrument Functions
Important Information
Preparation for Removal and Disassembly
Replacement Parts
Gaskets, Oil Seals and O-Rings
Lock Washers/Plates and Cotter Pins
Bearings and Oil Seals
Circlips
Checking the Connections
Special Tools
Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Tightening Torques
General Tightening Torque Specifications
Engine Tightening Torques
Chassis Tightening Torques
Lubrication Points and Lubricant Types
Engine
Lubrication System Chart and Diagrams
Engine Oil Lubrication Chart
Lubrication Diagrams
Cooling System Diagrams
Cable Routing
Periodic Checks and Adjustments
Periodic Maintenance
General Maintenance and Lubrication Chart
Introduction
Periodic Maintenance Chart for the Emission Control System
Engine
Adjusting the Valve Clearance
Adjusting the Engine Idling Speed
ADJUSTING the EXHAUST GAS VOLUME (for Europe and Oceania)
Adjusting the Throttle Lever Free Play
Adjusting the Speed Limiter
Checking the Spark Plug
Checking the Ignition Timing
Measuring the Compression Pressure
Checking the Engine Oil Level
Changing the Engine Oil
Adjusting the Clutch Lever Free Play
Cleaning the Air Filter Element
Checking the Throttle Body Joint
Checking the Fuel Line
Checking the Crankcase Breather Hose
Checking the Exhaust System
Cleaning the Spark Arrester
Checking the Coolant Level
Checking the Cooling System
Changing the Coolant
Chassis
Adjusting the Front Disc Brake
Adjusting the Rear Disc Brake
Checking the Brake Fluid Level
Checking the Front Brake Pads
Checking the Rear Brake Pads
Checking the Front Brake Hoses
Checking the Rear Brake Hose
Adjusting the Parking Brake
Adjusting the Rear Brake Light Switch
Bleeding the Hydraulic Brake System
Adjusting the Shift Pedal
Adjusting the Reverse Control Cable
Adjusting the Drive Chain Slack
Checking the Steering System
Adjusting the Toe-In
Checking the Front Shock Absorber Assemblies
Adjusting the Front Shock Absorber Assemblies
Checking the Rear Shock Absorber Assembly
Adjusting the Rear Shock Absorber Assembly
Checking the Tires
Checking the Wheels
Checking and Lubricating the Cables
Lubricating the Clutch Lever
Lubricating the Brake Lever
Lubricating the Pedal
Lubricating the Rear Suspension
Electrical System
Checking and Charging the Battery
Checking the Fuses
Replacing the Headlight Bulbs
Adjusting the Headlight Beams
Chassis
General Chassis
Front Wheels
Removing the Front Wheels
Checking the Front Wheels
Checking the Front Wheel Hubs
Installing the Front Wheel Hub Bearings
Installing the Front Brake Discs
Installing the Front Wheel Hubs
Installing the Front Wheels
Rear Wheels
Removing the Rear Wheels
Checking the Rear Wheels
Checking the Rear Wheel Hubs
Installing the Rear Wheel Hubs
Installing the Rear Wheels
Rear Axle and Rear Axle Hub
Removing the Rear Axle
Checking the Rear Axle
Checking the Rear Wheel Sprocket
Checking the Rear Brake Disc
Installing the Rear Wheel Sprocket
Installing the Rear Axle
Front Brakes
Introduction
Checking the Front Brake Discs
Replacing the Front Brake Pads
Disassembling the Front Brake Calipers
Checking the Front Brake Caliper
Assembling the Front Brake Calipers
Installing the Front Brake Calipers
Checking the Front Brake Master Cylinder
Assembling the Front Brake Master Cylinder
Installing the Front Brake Master Cylinder
Rear Brake
Introduction
Checking the Rear Brake Disc
Replacing the Rear Brake Pads
Removing the Rear Brake Caliper
Disassembling the Rear Brake Caliper
Checking the Rear Brake Caliper
Assembling the Rear Brake Caliper
Installing the Rear Brake Caliper
Checking the Rear Brake Master Cylinder
Assembling the Rear Brake Master Cylinder
Installing the Rear Brake Master Cylinder
Handlebar
Removing the Clutch Switch
Removing the Handlebar
Checking the Handlebar
Installing the Handlebar
Steering Stem
Removing the Bearing Retainer
Checking the Steering Stem
Installing the Bearing Retainer
Installing the Lock Washer
Installing the Pitman Arm
Tie-Rods and Steering Knuckles
Removing the Steering Knuckles
Checking the Tie-Rods
Checking the Steering Knuckles
Installing the Tie-Rods
Front Arms and Front Shock Absorber Assemblies
Handling the Front Shock Absorber Assemblies
Disposing of a Front Shock Absorber Assembly
Removing the Front Arms
Checking the Front Arms
Checking the Front Shock Absorber Assemblies
Checking the Front Arm Ball Joints
Installing the Front Arms and Front Shock Absorber Assemblies
Rear Shock Absorber Assembly
Handling the Rear Shock Absorber Assembly
Disposing of a Rear Shock Absorber Assembly
Removing the Rear Shock Absorber Assembly
Checking the Relay Arm and Connecting Arm
Checking the Rear Shock Absorber Assembly
Installing the Rear Shock Absorber Assembly
Swingarm
Removing the Swingarm
Checking the Swingarm
Installing the Swingarm
Chain Drive
Checking the Drive Chain
Installing the Drive Chain
Engine
Engine Removal
Installing the Exhaust Pipes and Muffler
Installing the Engine
Cylinder Head
Removing the Cylinder Head
Checking the Cylinder Head
Checking the Camshaft Sprocket
Checking the Tappet Covers and Camshaft Sprocket Cover
Checking the Timing Chain Tensioner
Installing the Cylinder Head
Camshaft
Removing the Rocker Arms and Camshaft
Checking the Camshaft
Checking the Decompression System
Checking the Rocker Arms and Rocker Arm Shafts
Installing the Camshaft and Rocker Arms
Valves and Valve Springs
Removing the Valves
Checking the Valves and Valve Guides
Checking the Valve Seats
Checking the Valve Springs
Installing the Valves
Cylinder and Piston
Removing the Piston
Checking the Cylinder and Piston
Checking the Piston Rings
Checking the Piston Pin
Installing the Piston and Cylinder
Ac Magneto and Starter Clutch
Removing the Ac Magneto Rotor
Checking the Stator Coil and Crankshaft Position Sensor
Checking the Starter Clutch
Checking the Torque Limiter
Installing the Ac Magneto
Electric Starter
Checking the Starter Motor
Assembling the Starter Motor
Clutch
Removing the Clutch
Removing the Primary Drive Gear and Balancer Driven Gear
Checking the Friction Plates
Checking the Clutch Plates
Checking the Clutch Springs
Checking the Clutch Housing
Checking the Clutch Boss
Checking the Pressure Plate
Checking the Primary Drive Gears
Checking the Balancer Drive Gears
Checking the Pull Lever Shaft and Pull Rod
Installing the Primary Drive Gear and Balancer Driven Gears
Installing the Clutch
Oil Pump
Checking the Oil Pump
Assembling the Oil Pump
Shift Shaft
Checking the Shift Shaft
Checking the Stopper Lever
Checking the Shift Guide
Checking the Shift Drum Segment
Installing the Shift Lever
Installing the Shift Shaft
Crankcase
Separating the Crankcase
Checking the Timing Chain and Timing Chain Guide
Checking the Oil Strainer
Checking the Bearings and Oil Seals
Checking the Crankcase
Assembling the Crankcase
Crankshaft
Removing the Crankshaft
Checking the Crankshaft
Installing the Crankshaft
Transmission
Checking the Shift Forks
Checking the Shift Drum Assembly
Checking the Transmission
Assembling the Main Axle and Drive Axle
Installing the Transmission
Cooling System
Radiator
Checking the Radiator
Installing the Radiator
Thermostat
Checking the Thermostat
Installing the Thermostat
Water Pump
Disassembling the Water Pump
Checking the Water Pump
Assembling the Water Pump
Fuel System
Fuel Tank
Checking the Fuel Pump Body
Installing the Fuel Pump
Removing the Fuel Pump
Removing the Fuel Tank
Installing the Fuel Hose
Throttle Body
Checking the Injector
Checking the Throttle Body
Checking the Pressure Regulator Operation
Adjusting the Throttle Position Sensor
Installing the Throttle Body
Electrical System
Ignition System
Circuit Diagram
Troubleshooting
Electric Starting System
Circuit Diagram
Starting Circuit Cut-Off System Operation
Troubleshooting
Charging System
Circuit Diagram
Troubleshooting
Lighting System
Circuit Diagram
Troubleshooting
Signaling System
Circuit Diagram
Troubleshooting
Cooling System
Circuit Diagram
Troubleshooting
Fuel Injection System
Circuit Diagram
Ecu Self-Diagnostic Function
Self-Diagnostic Function Table
Troubleshooting Method
Diagnostic Mode
Troubleshooting Details
Fuel Pump System
Circuit Diagram
Troubleshooting
Electrical Components
Checking the Switches
Checking the Bulbs and Bulb Sockets
Checking the Fuses
Checking and Charging the Battery
Checking the Relays
Checking the Diodes
Checking the Spark Plug Cap
Checking the Ignition Coil
Checking the Ignition Spark Gap
Checking the Crankshaft Position Sensor
Checking the Lean Angle Sensor
Checking the Starter Motor Operation
Checking the Stator Coil
Checking the Rectifier/Regulator
Checking the Fuel Sender
Checking the Speed Sensor
Checking the Radiator Fan Motor
Checking the Radiator Fan Motor Circuit Breaker
Checking the Coolant Temperature Sensor
Checking the Throttle Position Sensor
Checking the Intake Air Pressure Sensor
Checking the Intake Air Temperature Sensor
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2009
SERVICE MANUAL
YFM70RY
1S3-28197-E2
Table of
Contents
Previous
Page
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Page
1
2
3
4
5
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Chapters
Table of Contents
7
Specifications
27
Periodic Checks and Adjustments
81
Chassis
123
Engine
191
Cooling System
267
Fuel System
277
Electrical System
287
Troubleshooting
365
Table of Contents
Troubleshooting
TROUBLESHOOTING
292
TROUBLESHOOTING
298
TROUBLESHOOTING
302
TROUBLESHOOTING
306
TROUBLESHOOTING
310
TROUBLESHOOTING
316
TROUBLESHOOTING METHOD
322
TROUBLESHOOTING DETAILS
327
TROUBLESHOOTING
342
TROUBLESHOOTING
365
TROUBLESHOOTING
366
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Raptor 700r 2009
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