Yamaha YFM700RV 2009 Manuals

Yamaha YFM700RV 2009 Manuals

Manuals and User Guides for Yamaha YFM700RV 2009. We have 1 Yamaha YFM700RV 2009 manual available for free PDF download: Service Manual

Yamaha YFM700RV 2009 Service Manual

Yamaha YFM700RV 2009 Service Manual (409 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 19.59 MB

Table of Contents

Table of Contents

6
- Chassis
  5
- Cooling System
  5
- Electrical
  5
- Engine
  5
- Fuel Injection System
  5
- General Information
  5
- Periodic Checks and Adjustments
  5
- Specifications
  5
- Troubleshooting
  5
  - Table of Contents
    6
- Chapter 1 General Information
  8
- Vehicle Identification
  8
  - Vehicle Identification Number
    8
  - Model Label
    8
- Features
  9
- Important Information
  14
  - Preparation for Removal and Disassembly
    14
  - Replacement Parts
    14
  - Gaskets, Oil Seals and O-Rings
    14
  - Lock Washers/Plates and Cotter Pins
    15
  - Bearings and Oil Seals
    15
  - Circlips
    15
  - Checking the Connections
    16
- Special Tools
  17
Chapter 2 Specifications

23
- Spec
  23
- General Specifications
  24
- Engine Specifications
  27
- Chassis Specifications
  35
- Electrical Specifications
  37
- Tightening Torques
  39
  - Engine Tightening Torques
    39
  - Chassis Tightening Torques
    42
- General Tightening Torque Specifications
  45
- How to Use the Conversion Table
  45
- Lubrication Points and Lubricant Types
  46
  - Engine
    46
- Coolant Flow Diagrams
  47
- Oil Flow Diagrams
  51
- Cable Routing
  56
Chapter 3 Periodic Checks and Adjustments

77
- Chk Adj
  77
- Introduction
  79
- Periodic Maintenance Chart for the Emission Control System
  79
- General Maintenance and Lubrication Chart
  80
- Periodic Maintenance/Lubrication
  81
- Seat, Fenders and Fuel Tank
  83
  - Removing the Fuel Tank
    89
  - Removing the Fuel Pump
    89
  - Installing the Fuel Pump
    90
  - Installing the Fuel Hose
    90
- Engine
  91
  - Adjusting the Valve Clearance
    91
  - ADJUSTING the EXHAUST GAS VOLUME (for Europe and Oceania Only)
    94
  - Adjusting the Engine Idling Speed
    96
  - Adjusting the Throttle Lever Free Play
    96
  - Adjusting the Speed Limiter
    97
  - Checking the Spark Plug
    98
  - Checking the Ignition Timing
    99
  - Measuring the Compression Pressure
    100
  - Checking the Engine Oil Level
    102
  - Changing the Engine Oil
    104
  - Adjusting the Clutch Cable
    107
  - Cleaning the Air Filter Element
    107
  - Checking the Throttle Body Joint
    109
  - Checking the Fuel Hose
    110
  - Checking the Breather Hoses
    110
  - Checking the Coolant Level
    111
  - Changing the Coolant
    111
  - Checking the Cooling System
    114
  - Checking the Coolant Temperature Warning Light
    115
  - Checking the Exhaust System
    116
  - Cleaning the Spark Arrester
    116
- Chassis
  118
  - Adjusting the Front Brake
    118
  - Adjusting the Rear Brake
    118
  - Adjusting the Parking Brake
    119
  - Checking the Brake Fluid Level
    120
  - Checking the Front Brake Pads
    121
  - Checking the Rear Brake Pads
    121
  - Adjusting the Rear Brake Light Switch
    122
  - Checking the Brake Hoses
    122
  - Bleeding the Hydraulic Brake System
    123
  - Adjusting the Shift Pedal
    125
  - Adjusting the Reverse Control Cable
    125
  - Adjusting the Drive Chain Slack
    126
  - Checking the Steering System
    128
  - Adjusting the Toe-In
    128
  - Checking the Front and Rear Shock Absorbers
    130
  - Adjusting the Front Shock Absorbers
    131
  - Adjusting the Rear Shock Absorber
    131
  - Checking the Tires
    134
  - Checking the Wheels
    136
  - Checking and Lubricating the Cables
    136
  - Lubricating the Levers and Pedals
    137
- Electrical System
  138
  - Checking and Charging the Battery
    138
  - Checking the Fuses
    144
  - Adjusting the Headlight Beams
    146
  - Replacing a Headlight Bulb
    147
Chapter 4 Engine

148
- Eng
  148
- Engine Removal
  151
  - Muffler and Exhaust Pipes
    151
  - Installing the Exhaust Pipes and Muffler
    152
  - Oil Tank
    153
  - Leads, Cables and Hoses
    154
  - Engine Mounting Bolts
    156
  - Engine Assembly
    157
  - Installing the Engine
    158
- Cylinder Head
  159
- Rocker Arms and Camshaft
  167
- Valves and Valve Springs
  174
- Cylinder and Piston
  183
  - Removing the Piston
    184
  - Checking the Cylinder and Piston
    184
  - Checking the Piston Rings
    186
  - Checking the Piston Pin
    187
  - Installing the Piston and Cylinder
    188
- A.C. Magneto
  191
- Clutch
  197
  - Removing the Clutch
    201
  - Removing the Primary Drive Gear and Balancer Driven Gear
    202
  - Checking the Friction Plates
    202
  - Checking the Clutch Plates
    203
  - Checking the Clutch Springs
    203
  - Checking the Clutch Housing
    204
  - Checking the Clutch Boss
    204
  - Checking the Pressure Plate
    204
  - Checking the Pull Lever Shaft and Pull Rod
    204
  - Checking the Primary Drive Gears
    205
  - Installing the Primary Drive Gear and Balancer Driven Gears
    205
  - Installing the Clutch
    206
- Oil Pump
  209
  - Checking the Oil Pump
    211
  - Assembling the Oil Pump
    212
- Shift Shaft
  213
  - Checking the Shift Shaft
    215
  - Checking the Stopper Lever
    215
  - Checking the Shift Guide
    215
  - Checking the Shift Drum Segment
    215
  - Installing the Shift Lever
    215
  - Installing the Shift Shaft
    216
- Crankcase
  217
  - Crankcase Bearings
    219
  - Separating the Crankcase
    220
  - Checking the Oil Strainer
    220
  - Checking the Timing Chain and Guide
    221
  - Checking the Bearings and Oil Seals
    221
  - Checking the Crankcase
    221
  - Assembling the Crankcase
    222
- Crankshaft
  224
  - Crankshaft and Balancer
    224
  - Removing the Crankshaft
    225
  - Checking the Crankshaft
    225
  - Installing the Crankshaft
    226
- Transmission
  227
  - Main Axle
    229
  - Counter Axle
    232
  - Checking the Shift Forks
    233
  - Checking the Shift Drum Assembly
    233
  - Checking the Transmission
    233
  - Assembling the Main Axle and Drive Axle
    234
  - Installing the Transmission
    235
Cool

236
- Chapter 5 Cooling System
  237
- Radiator
  237
  - Checking the Radiator
    239
  - Installing the Radiator
    240
- Thermostat
  241
  - Checking the Thermostat
    242
  - Installing the Thermostat
    242
- Water Pump
  243
  - Disassembling the Water Pump
    245
  - Checking the Water Pump
    245
  - Assembling the Water Pump
    246
Chapter 6 Fuel Injection System

247
- Circuit Diagram
  249
- Ecu's Self-Diagnostic Function
  251
- Self-Diagnostic Function Table
  252
- Troubleshooting Chart
  253
- Diagnostic Mode
  254
- Troubleshooting Details
  258
- Checking the Speed Sensor
  272
- Checking the Intake Air Pressure Sensor
  273
- Checking the Intake Air Temperature Sensor
  274
- Throttle Body
  275
- Checking the Injector
  278
- Checking the Throttle Body
  278
- Installing the Throttle Body Assembly
  278
- Checking the Fuel Pump and Pressure Regulator Operation
  279
- Checking and Adjusting the Throttle Position Sensor
  280
Chapter 7 Chassis

282
- Chas
  282
  - Front and Rear Wheels
    284
- Front Wheels
  284
- Rear Wheels
  286
- Checking the Wheel Hubs
  287
- Checking the Wheels
  287
- Checking the Brake Discs
  288
- Installing the Front Brake Discs
  289
- Installing the Front Wheel Hub Bearings
  289
- Installing the Front Wheels
  289
- Installing the Front Wheel Hubs
  290
- Installing the Rear Wheel Hubs
  290
- Rear Axle and Rear Axle Hub
  291
  - Removing the Rear Brake Caliper
    293
  - Removing the Rear Axle
    293
  - Checking the Rear Axle
    294
  - Checking the Driven Sprocket
    294
  - Checking the Brake Disc
    295
  - Installing the Driven Sprocket
    295
  - Installing the Rear Axle
    295
- Front and Rear Brakes
  297
  - Front Brake Pads
    297
  - Rear Brake Pads
    298
  - Replacing the Front Brake Pads
    299
  - Replacing the Rear Brake Pads
    301
  - Front Brake Master Cylinder
    303
  - Rear Brake Master Cylinder
    305
  - Removing the Front Brake Light Switch
    308
  - Checking the Master Cylinders
    308
  - Assembling the Front Brake Master Cylinder
    309
  - Assembling the Rear Brake Master Cylinder
    309
  - Installing the Front Brake Master Cylinder
    310
  - Installing the Rear Brake Master Cylinder
    312
  - Front Brake Calipers
    314
  - Rear Brake Caliper
    316
  - Removing the Rear Brake Caliper
    319
  - Disassembling the Front Brake Calipers
    319
  - Disassembling the Rear Brake Caliper
    320
  - Checking the Front and Rear Brake Calipers
    320
  - Assembling the Front Brake Calipers
    321
  - Assembling the Rear Brake Caliper
    322
  - Installing the Front Brake Calipers
    323
  - Installing the Rear Brake Caliper
    324
- Steering System
  327
  - Handlebar
    327
  - Removing the Front Brake Light Switch and Clutch Switch
    329
  - Removing the Handlebar Grips
    329
  - Checking the Handlebar
    329
  - Installing the Handlebar
    330
  - Installing the Handlebar Grips
    330
  - Installing the Clutch Lever
    331
  - Installing the Brake Master Cylinder
    331
  - Steering Stem
    332
  - Removing the Bearing Retainer
    334
  - Checking the Steering Stem
    334
  - Installing the Bearing Retainer
    334
  - Installing the Lock Washer
    334
  - Installing the Pitman Arm
    335
  - Tie-Rods and Steering Knuckles
    336
  - Removing the Steering Knuckles
    337
  - Checking the Tie-Rods
    337
  - Checking the Steering Knuckles
    337
  - Installing the Tie-Rods
    337
- Front Arms and Front Shock Absorber Assemblies
  338
  - Removing the Front Arms
    340
  - Checking the Front Arms
    340
  - Checking the Front Shock Absorber Assemblies
    340
  - Checking the Ball Joints
    341
  - Front Arms and Front Shock Absorber
    341
  - Installing the Front Arms
    342
- Rear Shock Absorber and Relay Arm
  343
- Swingarm and Drive Chain
  348
  - Removing the Swingarm
    350
  - Checking the Swingarm
    350
  - Checking the Drive Chain
    351
  - Installing the Swingarm
    353
  - Installing the Drive Sprocket
    353
Chapter 8 Electrical

354
- Elec
  354
- Electrical Components
  355
- Checking Switch Continuity
  356
- Checking the Switches
  357
- Checking the Bulbs and Bulb Sockets
  359
- Ignition System
  362
  - Circuit Diagram
    362
  - Troubleshooting
    363
- Electric Starting System
  368
  - Circuit Diagram
    368
  - Starting Circuit Cut-Off System Operation
    369
  - Troubleshooting
    370
- Starter Motor
  374
  - Checking the Starter Motor
    376
  - Assembling the Starter Motor
    377
- Charging System
  379
  - Circuit Diagram
    379
  - Troubleshooting
    380
- Lighting System
  382
  - Circuit Diagram
    382
  - Troubleshooting
    383
  - Checking the Lighting System
    384
- Signaling System
  387
  - Circuit Diagram
    387
  - Troubleshooting
    388
  - Checking the Signaling System
    389
- Cooling System
  396
  - Circuit Diagram
    396
Trbl Shtg

401
- Troubleshooting
  401
- Chapter 9
  402
- Compression System
  402
- Electrical System
  402
- Fuel System
  402
- Starting Failure/Hard Starting
  402
- Faulty Gear Shifting
  403
  - Hard Shifting
    403
  - Shift Pedal Does Not Move
    403
  - Jumps out Gear
    403
- Poor Idle Speed Performance
  403
- Poor Medium and High-Speed Performance
  403
- Clutch Slipping/Dragging
  404
  - Clutch Slipping
    404
  - Clutch Dragging
    404
- Overcooling
  404
  - Cooling System
    404
- Overheating
  404
- Faulty Brake
  405
  - Poor Braking Effect
    405
- Shock Absorber Malfunction
  405
  - Malfunction
    405
- Unstable Handling
  405
- Lighting System
  406
  - Headlight Does Not Come on
    406
  - Tail/Brake Light Does Not Come on
    406
  - Headlight Bulb Burnt out
    406

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