Yamaha RAPTOR YFM700RF 2015 Manuals

Manuals and User Guides for Yamaha RAPTOR YFM700RF 2015. We have 1 Yamaha RAPTOR YFM700RF 2015 manual available for free PDF download: Service Manual

Yamaha RAPTOR YFM700RF 2015 Service Manual

Yamaha RAPTOR YFM700RF 2015 Service Manual (394 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 10.98 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
- Instrument Functions
  13
- Lock Washers/Plates and Cotter Pins
  14
- Gaskets, Oil Seals and O-Rings
  14
- Replacement Parts
  14
- Preparation for Removal and Disassembly
  14
- Important Information
  14
- Bearings and Oil Seals
  15
- Circlips
  15
- Rubber Parts
  15
- Basic Service Information
  16
- Quick Fasteners
  16
- Electrical System
  17
- Special Tools
  22
Specifications

29
- General Specifications
  30
- Engine Specifications
  31
- Chassis Specifications
  38
- Electrical Specifications
  41
- General Tightening Torque Specifications
  43
- Tightening Torques
  43
- Engine Tightening Torques
  44
- Chassis Tightening Torques
  47
- Engine
  50
- Lubrication Points and Lubricant Types
  50
- Engine Oil Lubrication Chart
  52
- Lubrication System Chart and Diagrams
  52
- Lubrication Diagrams
  54
- Cooling System Diagrams
  64
- Cable Routing
  70
Periodic Checks and Adjustments

89
- General Maintenance and Lubrication Chart
  92
- Introduction
  92
- Periodic Maintenance
  92
- Periodic Maintenance Chart for the Emission Control System
  92
- Adjusting the Valve Clearance
  95
- Engine
  95
- Adjusting the Engine Idling Speed
  97
- Adjusting the Throttle Lever Free Play
  97
- Adjusting the Speed Limiter
  98
- Checking the Spark Plug
  98
- Measuring the Compression Pressure
  99
- Checking the Engine Oil Level
  100
- Changing the Engine Oil
  101
- Adjusting the Clutch Lever Free Play
  103
- Cleaning the Air Filter Element
  103
- Checking the Air Induction System
  104
- Checking the Throttle Body Joint
  104
- Checking the Crankcase Breather Hose
  105
- Checking the Exhaust System
  105
- Checking the Fuel Line
  105
- Checking the Coolant Level
  106
- Cleaning the Spark Arrester
  106
- Changing the Coolant
  107
- Checking the Cooling System
  107
- Adjusting the Front Disc Brake (Yfm700Rsf)
  110
- Adjusting the Rear Disc Brake
  110
- Chassis
  110
- Checking the Brake Fluid Level
  110
- Checking the Front Brake Hoses
  111
- Checking the Front Brake Pads
  111
- Checking the Rear Brake Pads
  111
- Adjusting the Parking Brake
  112
- Checking the Rear Brake Hose
  112
- Adjusting the Rear Brake Light Switch
  113
- Bleeding the Hydraulic Brake System
  113
- Adjusting the Reverse Control Cable
  114
- Adjusting the Shift Pedal
  114
- Adjusting the Drive Chain Slack
  115
- Adjusting the Toe-In
  116
- Checking the Steering System
  116
- Checking the Front Shock Absorber Assemblies
  117
- Adjusting the Front Shock Absorber Assemblies
  118
- Checking the Rear Shock Absorber Assembly
  120
- Adjusting the Rear Shock Absorber Assembly
  121
- Checking the Tires
  123
- Checking and Lubricating the Cables
  124
- Checking the Wheels
  124
- Lubricating the Brake Lever
  125
- Lubricating the Clutch Lever
  125
- Lubricating the Pedal
  125
- Lubricating the Rear Suspension
  125
- Adjusting the Headlight Beams
  126
- Checking and Charging the Battery
  126
- Checking the Fuses
  126
- Electrical System
  126
- Replacing the Headlight Bulbs
  126
Chassis

129
- General Chassis
  132
- Front Wheels
  136
- Checking the Front Wheel Hubs
  137
- Checking the Front Wheels
  137
- Removing the Front Wheels
  137
- Installing the Front Brake Discs
  138
- Installing the Front Wheel Hub Bearings
  138
- Installing the Front Wheel Hubs
  138
- Installing the Front Wheels
  139
- Rear Wheels
  140
- Checking the Rear Wheel Hubs
  141
- Checking the Rear Wheels
  141
- Installing the Rear Wheel Hubs
  141
- Installing the Rear Wheels
  141
- Removing the Rear Wheels
  141
- Rear Axle and Rear Axle Hub
  143
- Checking the Rear Axle
  145
- Removing the Rear Axle
  145
- Checking the Rear Brake Disc
  146
- Checking the Rear Wheel Sprocket
  146
- Installing the Rear Axle
  146
- Installing the Rear Wheel Sprocket
  146
- Front Brakes
  148
- Checking the Front Brake Discs
  153
- Introduction
  153
- Disassembling the Front Brake Calipers
  154
- Replacing the Front Brake Pads
  154
- Assembling the Front Brake Calipers
  155
- Checking the Front Brake Caliper
  155
- Installing the Front Brake Calipers
  156
- Assembling the Front Brake Master Cylinder
  157
- Checking the Front Brake Master Cylinder
  157
- Installing the Front Brake Master Cylinder
  157
- Rear Brake
  159
- Checking the Rear Brake Disc
  166
- Introduction
  166
- Replacing the Rear Brake Pads
  166
- Disassembling the Rear Brake Caliper
  167
- Removing the Rear Brake Caliper
  167
- Assembling the Rear Brake Caliper
  168
- Checking the Rear Brake Caliper
  168
- Installing the Rear Brake Caliper
  169
- Checking the Rear Brake Master Cylinder
  170
- Assembling the Rear Brake Master Cylinder
  171
- Installing the Rear Brake Master Cylinder
  171
- Handlebar
  173
- Checking the Handlebar
  174
- Installing the Handlebar
  174
- Removing the Clutch Switch
  174
- Removing the Handlebar
  174
- Steering Stem
  177
- Checking the Steering Stem
  178
- Installing the Bearing Retainer
  178
- Installing the Lock Washer
  178
- Installing the Pitman Arm
  178
- Removing the Bearing Retainer
  178
- Checking the Steering Knuckles
  180
- Checking the Tie-Rods
  180
- Installing the Tie-Rods
  180
- Removing the Steering Knuckles
  180
- Tie-Rods and Steering Knuckles
  180
- Front Arms and Front Shock Absorber Assemblies
  181
- Checking the Front Arms
  183
- Disposing of a Front Shock Absorber Assembly (Yfm700Rsf)
  183
- Handling the Front Shock Absorber Assemblies (Yfm700Rsf)
  183
- Removing the Front Arms
  183
- Checking the Front Arm Ball Joints
  184
- Checking the Front Shock Absorber Assemblies
  184
- Installing the Front Arms and Front Shock Absorber Assemblies
  185
- Rear Shock Absorber Assembly
  186
- Checking the Rear Shock Absorber Assembly
  188
- Checking the Relay Arm and Connecting Arm
  188
- Disposing of a Rear Shock Absorber Assembly
  188
- Handling the Rear Shock Absorber Assembly
  188
- Removing the Rear Shock Absorber Assembly
  188
- Installing the Rear Shock Absorber Assembly
  189
- Swingarm
  190
- Checking the Swingarm
  192
- Installing the Swingarm
  192
- Removing the Swingarm
  192
- Chain Drive
  194
- Checking the Drive Chain
  195
- Installing the Drive Chain
  196
Engine

197
- Engine Removal
  200
- Installing the Exhaust Pipe and Muffler
  201
- Installing the Engine
  206
- Cylinder Head
  207
- Checking the Cylinder Head
  209
- Removing the Cylinder Head
  209
- Checking the Camshaft Sprocket
  210
- Checking the Tappet Covers and Camshaft Sprocket Cover
  210
- Checking the Timing Chain Tensioner
  210
- Installing the Cylinder Head
  211
- Camshaft
  213
- Checking the Camshaft
  214
- Removing the Rocker Arms and Camshaft
  214
- Checking the Decompression System
  215
- Checking the Rocker Arms and Rocker Arm Shafts
  215
- Installing the Camshaft and Rocker Arms
  215
- Checking the Valves and Valve Guides
  219
- Removing the Valves
  219
- Valves and Valve Springs
  219
- Checking the Valve Seats
  221
- Checking the Valve Springs
  222
- Installing the Valves
  223
- Cylinder and Piston
  225
- Checking the Cylinder and Piston
  226
- Removing the Piston
  226
- Checking the Piston Rings
  227
- Checking the Piston Pin
  228
- Installing the Piston and Cylinder
  228
- Ac Magneto and Starter Clutch
  230
- Checking the Starter Clutch
  232
- Checking the Stator Coil and Crankshaft Position Sensor
  232
- Removing the Ac Magneto Rotor
  232
- Checking the Torque Limiter
  233
- Installing the Ac Magneto
  233
- Electric Starter
  235
- Checking the Starter Motor
  237
- Assembling the Starter Motor
  238
- Clutch
  239
- Checking the Friction Plates
  243
- Removing the Clutch
  243
- Removing the Primary Drive Gear and Balancer Driven Gear
  243
- Checking the Clutch Boss
  244
- Checking the Clutch Housing
  244
- Checking the Clutch Plates
  244
- Checking the Clutch Springs
  244
- Checking the Balancer Drive Gears
  245
- Checking the Pressure Plate
  245
- Checking the Primary Drive Gears
  245
- Checking the Pull Lever Shaft and Pull Rod
  245
- Installing the Primary Drive Gear and Balancer Driven Gears
  245
- Installing the Clutch
  246
- Oil Pump
  249
- Assembling the Oil Pump
  251
- Checking the Oil Pump
  251
- Shift Shaft
  252
- Checking the Shift Drum Segment
  253
- Checking the Shift Guide
  253
- Checking the Shift Shaft
  253
- Checking the Stopper Lever
  253
- Installing the Shift Lever
  253
- Installing the Shift Shaft
  254
- Crankcase
  255
- Checking the Bearings and Oil Seals
  258
- Checking the Oil Strainer
  258
- Checking the Timing Chain and Timing Chain Guide
  258
- Separating the Crankcase
  258
- Assembling the Crankcase
  259
- Checking the Crankcase
  259
- Crankshaft
  261
- Checking the Crankshaft
  262
- Installing the Crankshaft
  262
- Removing the Crankshaft
  262
- Transmission
  264
- Checking the Shift Drum Assembly
  270
- Checking the Shift Forks
  270
- Checking the Transmission
  270
- Assembling the Main Axle and Drive Axle
  271
- Installing the Transmission
  271
Cooling System

273
- Radiator
  274
- Checking the Radiator
  275
- Installing the Radiator
  275
- Thermostat
  276
- Checking the Thermostat
  277
- Installing the Thermostat
  277
- Water Pump
  278
- Assembling the Water Pump
  280
- Checking the Water Pump
  280
- Disassembling the Water Pump
  280
Fuel System

283
- Fuel Tank
  284
- Checking the Fuel Pump Body
  285
- Installing the Fuel Pump
  285
- Removing the Fuel Pump
  285
- Removing the Fuel Tank
  285
- Installing the Fuel Hose
  286
- Throttle Body
  289
- Adjusting the Throttle Position Sensor
  290
- Checking the Injector
  290
- Checking the Pressure Regulator Operation
  290
- Checking the Throttle Body
  290
- Installing the Throttle Body
  291
- Air Induction System
  292
- Checking the Air Induction System
  296
- Installing the Air Induction System
  296
Electrical System

297
- Circuit Diagram
  300
- Ignition System
  300
- Troubleshooting
  302
- Circuit Diagram
  304
- Electric Starting System
  304
- Starting Circuit Cut-Off System Operation
  306
- Troubleshooting
  307
- Charging System
  310
- Circuit Diagram
  310
- Troubleshooting
  312
- Circuit Diagram
  314
- Lighting System
  314
- Troubleshooting
  316
- Circuit Diagram
  318
- Signaling System
  318
- Troubleshooting
  320
- Circuit Diagram
  324
- Cooling System
  324
- Troubleshooting
  326
- Circuit Diagram
  328
- Fuel Injection System
  328
- Ecu Self-Diagnostic Function
  330
- Troubleshooting Method
  332
- Yamaha Diagnostic Tool
  333
- Troubleshooting Details
  336
- Circuit Diagram
  354
- Fuel Pump System
  354
- Troubleshooting
  356
- Electrical Components
  358
- Checking the Switches
  360
- Checking the Bulbs and Bulb Sockets
  363
- Checking the Fuses
  364
- Checking and Charging the Battery
  365
- Checking the Relays
  368
- Checking the Diode
  369
- Checking the Ignition Coil
  369
- Checking the Spark Plug Cap
  369
- Checking the Ignition Spark Gap
  370
- Checking the Crankshaft Position Sensor
  371
- Checking the Lean Angle Sensor
  371
- Checking the Starter Motor Operation
  371
- Checking the Rectifier/Regulator
  372
- Checking the Stator Coil
  372
- Checking the Fuel Sender
  373
- Checking the Speed Sensor
  373
- Checking the Coolant Temperature Sensor
  374
- Checking the Radiator Fan Motor
  374
- Checking the Radiator Fan Motor Circuit Breaker
  374
- Checking the Throttle Position Sensor
  375
- Checking the Air Induction System Solenoid
  376
- Checking the Intake Air Pressure Sensor
  376
- Checking the Intake Air Temperature Sensor
  376
Troubleshooting

379
- General Information
  380
- Incorrect Engine Idling Speed
  380
- Starting Failures
  380
- Troubleshooting
  380
- Faulty Clutch
  381
- Faulty Gear Shifting
  381
- Jumps out of Gear
  381
- Poor Medium-And-High-Speed Performance
  381
- Shift Pedal Does Not Move
  381
- Faulty Shock Absorber Assembly
  382
- Overcooling
  382
- Overheating
  382
- Poor Braking Performance
  382
- Unstable Handling
  382
- Faulty Lighting or Signaling System
  383
- Self-Diagnostic Function and Diagnostic Code Table
  384

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