Yamaha YF70GPHE Manuals

Manuals and User Guides for Yamaha YF70GPHE. We have 1 Yamaha YF70GPHE manual available for free PDF download: Service Manual

Yamaha YF70GPHE Service Manual (454 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 17 MB

Important Manual Information
3
How to Use this Manual
4
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
OUTLINE of the EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS Models)
14
EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM (for EPS Models)
16
Instrument Functions
18
Important Information
20
Preparation for Removal and Disassembly
20
Replacement Parts
20
Gaskets, Oil Seals and O-Rings
20
Lock Washers/Plates and Cotter Pins
20
Bearings and Oil Seals
21
Circlips
21
Rubber Parts
21
Basic Service Information
22
Quick Fasteners
22
Electrical System
23
Special Tools
27
Specifications
35
General Specifications
36
Engine Specifications
37
Chassis Specifications
44
Electrical Specifications
47
Tightening Torques
50
General Tightening Torque Specifications
50
Engine Tightening Torques
51
Chassis Tightening Torques
54
Lubrication Points and Lubricant Types
58
Engine
58
Lubrication System Chart and Diagrams
60
Lubrication Diagrams
60
Cooling System Diagrams
64
Cable Routing
66
Periodic Checks and Adjustments
81
Periodic Maintenance
84
Introduction
84
Periodic Maintenance Chart for the Emission Control System
84
General Maintenance and Lubrication Chart
85
Engine
87
Adjusting the Valve Clearance
87
ADJUSTING the EXHAUST GAS VOLUME (for Europe and Oceania)
89
Adjusting the Throttle Lever Free Play
89
Adjusting the Speed Limiter
90
Checking the Spark Plug
90
Measuring the Compression Pressure
91
Checking the Engine Oil Level
92
Changing the Engine Oil
92
Cleaning the Air Filter Element
94
Checking the V-Belt
95
Replacing the V-Belt
95
Checking the Throttle Body Joint
96
Checking the Fuel Line
96
Checking the Breather Hoses
96
Checking the Exhaust System
97
Cleaning the Spark Arrester
97
Checking the Coolant Level
98
Checking the Cooling System
98
Changing the Coolant
99
Chassis
102
Adjusting the Front Disc Brake
102
Adjusting the Rear Disc Brake
102
Checking the Brake Fluid Level
103
Checking the Front Brake Pads
103
Checking the Rear Brake Pads
104
Checking the Front Brake Hoses
104
Checking the Rear Brake Hoses
104
Bleeding the Hydraulic Brake System
105
Adjusting the Drive Select Lever Control Cable and Shift Rod
106
Checking the Final Gear Oil Level
107
Changing the Final Gear Oil
107
Checking the Differential Gear Oil Level
108
Changing the Differential Gear Oil
108
Checking the Constant Velocity Shaft Assembly Dust Boots
109
Checking the Steering System
109
Adjusting the Toe-In
111
Checking the Front Shock Absorber Assemblies
112
Adjusting the Front Shock Absorber Assemblies
112
Checking the Rear Shock Absorber Assemblies
113
Adjusting the Rear Shock Absorber Assemblies
113
Checking the Tires
114
Checking the Wheels
115
Checking and Lubricating the Cables
116
Lubricating the Levers
116
Lubricating the Pedal
116
Electrical System
117
Checking and Charging the Battery
117
Checking the Fuses
117
Replacing the Headlight Bulbs
117
Adjusting the Headlight Beams
117
General Chassis
122
Installing the Rear Fender
127
Installing the Footrest Boards
133
Front Wheels
135
Removing the Front Wheels
136
Removing the Front Wheel Hubs
136
Checking the Front Wheels
136
Checking the Front Wheel Hubs
136
Installing the Front Brake Discs
137
Installing the Front Wheel Hubs
137
Installing the Front Wheels
137
Rear Wheels
139
Removing the Rear Wheels
140
Removing the Rear Wheel Hubs
140
Checking the Rear Wheels
140
Checking the Rear Wheel Hubs
140
Installing the Rear Brake Discs
140
Installing the Rear Wheel Hubs
140
Installing the Rear Wheels
141
Front Brake
142
Introduction
147
Checking the Front Brake Discs
147
Replacing the Front Brake Pads
148
Disassembling the Front Brake Calipers
148
Checking the Front Brake Calipers
149
Assembling the Front Brake Calipers
149
Installing the Front Brake Calipers
150
Checking the Front Brake Master Cylinder
150
Assembling the Front Brake Master Cylinder
151
Installing the Front Brake Master Cylinder
151
Rear Brake
153
Introduction
159
Checking the Rear Brake Discs
159
Replacing the Rear Brake Pads
159
Removing the Rear Brake Master Cylinder
160
Disassembling the Rear Brake Calipers
160
Checking the Rear Brake Calipers
161
Assembling the Rear Brake Calipers
161
Installing the Rear Brake Calipers
161
Checking the Rear Brake Master Cylinder
162
Assembling the Rear Brake Master Cylinder
162
Installing the Rear Brake Master Cylinder
162
Handlebar
167
Removing the Handlebar
167
Checking the Handlebar
167
Installing the Handlebar
167
Steering Stem
170
REMOVING the BEARING RETAINER (Except for EPS Models)
174
Checking the Steering Stem
174
INSTALLING the STEERING STEM (Except for EPS Models)
174
INSTALLING the STEERING STEM (for EPS Models)
175
INSTALLING the PITMAN ARM (Except for EPS Models)
176
INSTALLING the PITMAN ARM (for EPS Models)
176
Tie-Rods and Steering Knuckles
177
Removing the Steering Knuckles
178
Checking the Tie-Rods
178
Checking the Steering Knuckles and Front Wheel Bearings
178
Checking the Steering Knuckle Ball Joints
178
Installing the Tie-Rods
180
Installing the Front Arm Protectors
180
Front Arms and Front Shock Absorber Assemblies
181
Checking the Front Arms
183
Checking the Front Shock Absorber Assemblies
183
Checking the Front Arm Ball Joints
183
Installing the Front Arms and Front Shock Absorber Assemblies
184
Installing the Front Arm Protectors
185
Rear Knuckles and Stabilizer
186
Checking the Rear Knuckles and Rear Wheel Bearings
187
Checking the Stabilizer
187
Installing the Rear Arm Protectors
187
Rear Arms and Rear Shock Absorber Assemblies
188
Checking the Rear Arms
189
Checking the Rear Shock Absorber Assemblies
189
Installing the Rear Arms and Rear Shock Absorber Assemblies
189
Engine
191
Engine Removal
194
Installing the Muffler
195
Installing the V-Belt Cooling Ducts
195
Installing the Drive Select Lever Unit
198
Installing the Engine
202
Cylinder Head
203
Removing the Cylinder Head
205
Checking the Cylinder Head
205
Checking the Camshaft Sprocket
206
Checking the Tappet Covers and Camshaft Sprocket Cover
206
Checking the Timing Chain Tensioner
206
Installing the Cylinder Head
207
Rocker Arms and Camshaft
210
Removing the Rocker Arms and Camshaft
211
Checking the Camshaft
211
Checking the Decompression System
212
Checking the Rocker Arms and Rocker Arm Shafts
212
Installing the Camshaft and Rocker Arms
212
Valves and Valve Springs
214
Removing the Valves
215
Checking the Valves and Valve Guides
215
Checking the Valve Seats
217
Checking the Valve Springs
218
Installing the Valves
219
Cylinder and Piston
221
Removing the Piston
222
Checking the Cylinder and Piston
222
Checking the Piston Rings
223
Checking the Piston Pin
224
Installing the Piston and Cylinder
224
Ac Magneto and Starter Clutch
226
Removing the Ac Magneto Rotor
228
Removing the Starter Clutch
228
Checking the Stator Coil and Crankshaft Position Sensor
229
Checking the Starter Clutch
229
Checking the Torque Limiter
229
Installing the Starter Clutch
229
Installing the Ac Magneto
230
Electric Starter
232
Checking the Starter Motor
234
Assembling the Starter Motor
235
Balancer Gears and Oil Pump Gears
236
Removing the Balancer Driven Gear and Oil Pump Driven Gear
237
Checking the Oil Pump Drive
237
Checking the Balancer Drive
237
Installing the Balancer Drive Gear, Balancer Driven Gear, and Oil Pump Driven Gear
237
Primary and Secondary Sheaves
239
Removing the Primary and Secondary Sheaves
242
Disassembling the Secondary Sheave
242
Checking the V-Belt
242
Checking the Primary Sheave
243
Checking the Primary Sheave Weights
243
Checking the Primary Sheave Sliders
243
Checking the Secondary Sheave
243
Assembling the Primary Sheave
244
Assembling the Secondary Sheave
244
Installing the Primary and Secondary Sheaves
245
Clutch
247
Removing the Clutch
249
Checking the Clutch
249
Checking the Clutch Shoe
249
Assembling the Clutch Housing
250
Installing the Clutch
250
Crankcase
252
Separating the Crankcase
256
Checking the Timing Chain and Timing Chain Guide
256
Checking the Relief Valve
256
Checking the Bearings
256
Checking the Crankcase
257
Assembling the Crankcase
257
Installing the Shift Lever
258
Crankshaft and Oil Pump
259
Removing the Crankshaft
261
Checking the Oil Pump
261
Checking the Oil Strainer
262
Checking the Crankshaft
262
Assembling the Oil Pump
262
Installing the Crankshaft
263
Transmission
264
Removing the Transmission
268
Checking the Shift Forks
268
Checking the Shift Drum
268
Checking the Transmission
268
Checking the Secondary Shaft
269
Checking the Stopper Lever and Stopper Wheel
269
Assembling the Shift Fork Assembly
269
Installing the Shift Forks and Shift Drum
269
Middle Gear
271
Removing the Middle Drive Shaft
274
Removing the Middle Driven Shaft
274
Checking the Pinion Gears
275
Installing the Bearing and Oil Seals
276
Installing the Middle Driven Shaft
276
Installing the Middle Drive Shaft
277
Measuring the Middle Gear Backlash
278
Aligning the Middle Gear
279
Cooling System
283
Radiator
284
Checking the Radiator
286
Installing the Radiator
286
Thermostat
287
Checking the Thermostat
288
Installing the Thermostat
288
Water Pump
290
Disassembling the Water Pump
292
Checking the Water Pump
292
Assembling the Water Pump
292
Fuel System
295
Fuel Tank
296
Removing the Fuel Tank
297
Removing the Fuel Pump
297
Checking the Fuel Pump Body
297
Checking the Fuel Tank Breather Hose Joint
297
Installing the Fuel Pump
297
Installing the Fuel Tank
298
Throttle Body
299
Removing the Throttle Body Assembly
301
Checking the Injector
301
Checking the Throttle Body
301
Installing the Throttle Body Assembly
301
Checking the Fuel Pressure
302
Adjusting the Throttle Position Sensor
302
Air Induction System
304
Checking the Air Induction System
308
Installing the Air Induction System
308
Drive Train
309
Troubleshooting
310
Checking Noises
310
Troubleshooting Chart
311
Front Constant Velocity Shaft Assemblies, Differential Assembly and Front Drive Shaft
312
Disassembling the Front Constant Velocity Shaft Assemblies
318
Checking the Front Constant Velocity Shaft Assemblies
318
Front Constant Velocity Shaft Assemblies, Differen- Tial Assembly and Front Drive Shaft
319
Assembling the Front Constant Velocity Shaft Assemblies
319
Removing the Differential Gear Assembly
320
Checking the Differential Assembly
320
Checking the Differential Motor
320
Assembling the Differential Assembly
321
Measuring the Differential Gear Backlash
322
Adjusting the Differential Gear Backlash
322
Rear Constant Velocity Shaft Assemblies, Final Drive Assembly and Rear Drive Shaft
324
Disassembling the Rear Constant Velocity Shaft Assemblies
331
Checking the Rear Constant Velocity Shaft Assemblies
331
Rear Constant Velocity Shaft Assemblies, Final Drive Assembly and Rear Drive Shaft
332
Assembling the Rear Constant Velocity Shaft Assemblies
332
Disassembling the Final Drive Pinion Gear Assembly
333
Checking the Rear Drive Shaft
333
Checking the Final Drive Assembly
333
Assembling the Final Drive Case
334
Assembling the Final Drive Pinion Gear Assembly
334
Selecting the Final Drive Pinion Gear Shim(S)
334
Selecting the Final Driven Pinion Gear Shim (Final Drive Case Side) and Thrust Washer
335
Selecting the Final Driven Pinion Gear Shim (Final Drive Case Cover Side)
337
Selecting the Wheel Gear Shim(S)
338
Measuring the Final Gear Backlash
338
Adjusting the Final Gear Backlash
339
Ignition System
344
Circuit Diagram
344
Troubleshooting
346
Electric Starting System
348
Circuit Diagram
348
Starting Circuit Cut-Off System Operation
350
Troubleshooting
351
Charging System
354
Circuit Diagram
354
Troubleshooting
356
Lighting System
358
Circuit Diagram
358
Troubleshooting
360
Signaling System
362
CIRCUIT DIAGRAM (for CDN)
362
CIRCUIT DIAGRAM (for Europe and Oceania)
364
Troubleshooting
366
Cooling System
372
Circuit Diagram
372
Troubleshooting
374
Fuel Injection System
376
Circuit Diagram
376
Ecu Self-Diagnostic Function
378
Self-Diagnostic Function Table
378
Troubleshooting Method
380
Yamaha Diagnostic Tool
381
Troubleshooting Details
386
Fuel Pump System
400
Circuit Diagram
400
Troubleshooting
402
2Wd/4Wd Selecting System
404
Circuit Diagram
404
Troubleshooting
406
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS Models)
408
Circuit Diagram
408
Eps Control Unit's Self-Diagnostic Function
410
Eps Warning Light During Normal Operation
410
Diagnostic Mode
411
Self-Diagnostic Function Table (Eps System)
413
Troubleshooting Details (Eps System)
414
Electrical Components
418
Checking the Switches
422
Checking the Bulbs and Bulb Sockets
425
Checking the Fuses
426
Checking and Charging the Battery
427
Checking the Relays
430
Checking the Diode
432
Checking the Spark Plug Cap
433
Checking the Ignition Coil
433
Checking the Ignition Spark Gap
434
Checking the Crankshaft Position Sensor
434
Checking the Lean Angle Sensor
434
Checking the Starter Motor Operation
435
Checking the Stator Coil
435
Checking the Rectifier/Regulator
436
Checking the Fuel Sender
436
Checking the Speed Sensor
437
Checking the Radiator Fan Motor
437
Checking the Radiator Fan Motor Circuit Breaker
437
Checking the Coolant Temperature Sensor
438
Checking the Throttle Position Sensor
438
Checking the Air Induction System Solenoid
439
Checking the Intake Air Pressure Sensor
439
Checking the Intake Air Temperature Sensor
440
CHECKING the EPS MOTOR (for EPS Models)
440
CHECKING the EPS TORQUE SENSOR (for EPS Models)
441
Troubleshooting
444
General Information
444
Starting Failures
444
Incorrect Engine Idling Speed
444
Poor Medium-And-High-Speed Performance
445
Faulty Drive Train
445
Faulty Gear Shifting
445
Shift Lever Does Not Move
445
Jumps out of Gear
445
Faulty Clutch
446
Overheating
446
Overcooling
446
Poor Braking Performance
447
Faulty Shock Absorber Assembly
447
Unstable Handling
447
Faulty Lighting or Signaling System
447
Wiring Diagram
449
Color Code
449

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