Yamaha Raptor 700 Service Manual Repair 2013 – 2014 Yfm700 – PDF DOWNLOAD

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Yamaha Raptor 700 Service Manual Repair 2013 – 2014 Yfm700

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LANGUAGE:ENGLISH
PAGES:378
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FILE TYPE:PDF

YAMAHA RAPTOR 700 SERVICE MANUAL REPAIR 2013 – 2014 YFM700 – PDF DOWNLOAD:

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DESCRIPTION:

Yamaha Raptor 700 Service Manual Repair 2013 – 2014 Yfm700

 IMPORTANT :

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.

• This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model.
• This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all of its models.
• Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title “1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each removal and disassembly section.

TABLE OF CONTENTS:

Yamaha Raptor 700 Service Manual Repair 2013 – 2014 Yfm700

IDENTIFICATION 1-1
VEHICLE IDENTIFICATION NUMBER1-1
MODEL LABEL1-1
FEATURES1-2
OUTLINE OF THE FI SYSTEM1-2
FI SYSTEM1-3
INSTRUMENT FUNCTIONS1-4
IMPORTANT INFORMATION 1-5
PREPARATION FOR REMOVAL AND DISASSEMBLY1-5
REPLACEMENT PARTS1-5
GASKETS, OIL SEALS AND O-RINGS 1-5
LOCK WASHERS/PLATES AND COTTER PINS1-5
BEARINGS AND OIL SEALS1-6
CIRCLIPS1-6
CHECKING THE CONNECTIONS 1-7
SPECIAL TOOLS 1-8
GENERAL SPECIFICATIONS 2-1
ENGINE SPECIFICATIONS 2-2
CHASSIS SPECIFICATIONS2-9
ELECTRICAL SPECIFICATIONS 2-13
TIGHTENING TORQUES 2-16
GENERAL TIGHTENING TORQUE SPECIFICATIONS2-16
ENGINE TIGHTENING TORQUES2-17
CHASSIS TIGHTENING TORQUES2-20
LUBRICATION POINTS AND LUBRICANT TYPES 2-23
ENGINE2-23
LUBRICATION SYSTEM CHART AND DIAGRAMS2-25
ENGINE OIL LUBRICATION CHART 2-25
LUBRICATION DIAGRAMS 2-27
COOLING SYSTEM DIAGRAMS2-37
CABLE ROUTING 2-43
PERIODIC MAINTENANCE 3-1
INTRODUCTION3-1
PERIODIC MAINTENANCE CHART FOR THE
EMISSION CONTROL SYSTEM3-1
GENERAL MAINTENANCE AND LUBRICATION CHART3-1
ENGINE 3-4
ADJUSTING THE VALVE CLEARANCE 3-4
ADJUSTING THE ENGINE IDLING SPEED3-6
ADJUSTING THE THROTTLE LEVER FREE PLAY 3-6
ADJUSTING THE SPEED LIMITER3-7
CHECKING THE SPARK PLUG 3-7
CHECKING THE IGNITION TIMING3-8
MEASURING THE COMPRESSION PRESSURE3-9
CHECKING THE ENGINE OIL LEVEL3-10
CHANGING THE ENGINE OIL 3-11
ADJUSTING THE CLUTCH LEVER FREE PLAY3-12
CLEANING THE AIR FILTER ELEMENT3-13
CHECKING THE THROTTLE BODY JOINT3-14
CHECKING THE FUEL LINE 3-14
CHECKING THE CRANKCASE BREATHER HOSE 3-14
CHECKING THE EXHAUST SYSTEM3-15
CLEANING THE SPARK ARRESTER 3-15
CHECKING THE COOLANT LEVEL3-16
CHECKING THE COOLING SYSTEM3-16
CHANGING THE COOLANT3-17
GENERAL CHASSIS4-1
FRONT WHEELS 4-5
REMOVING THE FRONT WHEELS 4-6
CHECKING THE FRONT WHEELS4-6
CHECKING THE FRONT WHEEL HUBS 4-6
INSTALLING THE FRONT WHEEL HUB BEARINGS4-7
INSTALLING THE FRONT BRAKE DISCS4-7
INSTALLING THE FRONT WHEEL HUBS 4-7
INSTALLING THE FRONT WHEELS4-8
REAR WHEELS4-9
REMOVING THE REAR WHEELS4-10
CHECKING THE REAR WHEELS 4-10
CHECKING THE REAR WHEEL HUBS4-10
INSTALLING THE REAR WHEEL HUBS4-10
INSTALLING THE REAR WHEELS 4-10
REAR AXLE AND REAR AXLE HUB4-12
REMOVING THE REAR AXLE4-14
CHECKING THE REAR AXLE 4-14
CHECKING THE REAR WHEEL SPROCKET4-15
CHECKING THE REAR BRAKE DISC4-15
INSTALLING THE REAR WHEEL SPROCKET4-15
INSTALLING THE REAR AXLE 4-15
FRONT BRAKES4-17
INTRODUCTION4-22
CHECKING THE FRONT BRAKE DISCS4-22
REPLACING THE FRONT BRAKE PADS 4-23
DISASSEMBLING THE FRONT BRAKE CALIPERS4-23
CHECKING THE FRONT BRAKE CALIPER 4-24
ASSEMBLING THE FRONT BRAKE CALIPERS4-24
INSTALLING THE FRONT BRAKE CALIPERS4-25
CHECKING THE FRONT BRAKE MASTER CYLINDER4-26
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4-26
INSTALLING THE FRONT BRAKE MASTER CYLINDER4-26
REAR BRAKE4-28
INTRODUCTION4-34
CHECKING THE REAR BRAKE DISC4-34
REPLACING THE REAR BRAKE PADS4-34
REMOVING THE REAR BRAKE CALIPER 4-35
DISASSEMBLING THE REAR BRAKE CALIPER 4-35
CHECKING THE REAR BRAKE CALIPER4-36
ASSEMBLING THE REAR BRAKE CALIPER 4-36
INSTALLING THE REAR BRAKE CALIPER4-37
CHECKING THE REAR BRAKE MASTER CYLINDER4-38
ASSEMBLING THE REAR BRAKE MASTER CYLINDER4-39
INSTALLING THE REAR BRAKE MASTER CYLINDER4-39
HANDLEBAR 4-41
REMOVING THE CLUTCH SWITCH4-42
REMOVING THE HANDLEBAR4-42
CHECKING THE HANDLEBAR 4-42
INSTALLING THE HANDLEBAR 4-42
STEERING STEM4-45
REMOVING THE BEARING RETAINER 4-46
CHECKING THE STEERING STEM4-46
INSTALLING THE BEARING RETAINER4-46
INSTALLING THE LOCK WASHER4-46
INSTALLING THE PITMAN ARM4-46
TIE-RODS AND STEERING KNUCKLES4-47
REMOVING THE STEERING KNUCKLES4-48
CHECKING THE TIE-RODS 4-48
CHECKING THE STEERING KNUCKLES4-48
INSTALLING THE TIE-RODS 4-48
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES4-49
HANDLING THE FRONT SHOCK ABSORBER
ASSEMBLIES (YFM7RSE) 4-51
DISPOSING OF A FRONT SHOCK ABSORBER
ASSEMBLY (YFM7RSE)4-51
REMOVING THE FRONT ARMS4-51
CHECKING THE FRONT ARMS4-51
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES 4-52
CHECKING THE FRONT ARM BALL JOINTS 4-52
INSTALLING THE FRONT ARMS AND FRONT
SHOCK ABSORBER ASSEMBLIES 4-53
REAR SHOCK ABSORBER ASSEMBLY 4-54
HANDLING THE REAR SHOCK ABSORBER ASSEMBLY4-56
DISPOSING OF A REAR SHOCK ABSORBER ASSEMBLY4-56
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY4-56
CHECKING THE RELAY ARM AND CONNECTING ARM4-56
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4-56
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4-57
SWINGARM4-58
REMOVING THE SWINGARM4-60
CHECKING THE SWINGARM 4-60
INSTALLING THE SWINGARM 4-60
CHAIN DRIVE4-62
CHECKING THE DRIVE CHAIN 4-63
INSTALLING THE DRIVE CHAIN 4-64
NGINE REMOVAL 5-1
INSTALLING THE EXHAUST PIPES AND MUFFLER 5-2
INSTALLING THE ENGINE5-7
CYLINDER HEAD5-8
REMOVING THE CYLINDER HEAD5-9
CHECKING THE CYLINDER HEAD 5-9
CHECKING THE CAMSHAFT SPROCKET5-10
CHECKING THE TAPPET COVERS AND CAMSHAFT
SPROCKET COVER5-10
CHECKING THE TIMING CHAIN TENSIONER5-10
INSTALLING THE CYLINDER HEAD 5-11
CAMSHAFT5-13
REMOVING THE ROCKER ARMS AND CAMSHAFT5-14
CHECKING THE CAMSHAFT5-14
CHECKING THE DECOMPRESSION SYSTEM5-15
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 5-15
INSTALLING THE CAMSHAFT AND ROCKER ARMS 5-15
VALVES AND VALVE SPRINGS5-18
REMOVING THE VALVES5-19
CHECKING THE VALVES AND VALVE GUIDES 5-19
CHECKING THE VALVE SEATS5-21
CHECKING THE VALVE SPRINGS5-22
INSTALLING THE VALVES 5-23
CYLINDER AND PISTON5-25
REMOVING THE PISTON 5-26
CHECKING THE CYLINDER AND PISTON 5-26
CHECKING THE PISTON RINGS5-27
CHECKING THE PISTON PIN 5-28
INSTALLING THE PISTON AND CYLINDER 5-28
AC MAGNETO AND STARTER CLUTCH5-30
REMOVING THE AC MAGNETO ROTOR5-32
CHECKING THE STATOR COIL AND CRANKSHAFT
POSITION SENSOR 5-32
CHECKING THE STARTER CLUTCH5-32
CHECKING THE TORQUE LIMITER5-33
INSTALLING THE AC MAGNETO 5-33
ELECTRIC STARTER5-35
CHECKING THE STARTER MOTOR 5-37
ASSEMBLING THE STARTER MOTOR5-38
CLUTCH 5-39
REMOVING THE CLUTCH 5-43
REMOVING THE PRIMARY DRIVE GEAR AND
BALANCER DRIVEN GEAR 5-43
CHECKING THE FRICTION PLATES5-43
CHECKING THE CLUTCH PLATES5-44
CHECKING THE CLUTCH SPRINGS5-44
CHECKING THE CLUTCH HOUSING5-44
CHECKING THE CLUTCH BOSS5-44
CHECKING THE PRESSURE PLATE 5-45
CHECKING THE PRIMARY DRIVE GEARS 5-45
CHECKING THE BALANCER DRIVE GEARS 5-45
CHECKING THE PULL LEVER SHAFT AND PULL ROD 5-45
INSTALLING THE PRIMARY DRIVE GEAR AND
BALANCER DRIVEN GEARS5-45
INSTALLING THE CLUTCH5-46
OIL PUMP5-49
CHECKING THE OIL PUMP 5-51
ASSEMBLING THE OIL PUMP5-51
SHIFT SHAFT5-52
CHECKING THE SHIFT SHAFT 5-53
CHECKING THE STOPPER LEVER 5-53
CHECKING THE SHIFT GUIDE5-53
CHECKING THE SHIFT DRUM SEGMENT 5-53
INSTALLING THE SHIFT LEVER 5-53
INSTALLING THE SHIFT SHAFT 5-54
CRANKCASE 5-55
SEPARATING THE CRANKCASE5-58
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE5-58
CHECKING THE OIL STRAINER 5-58
CHECKING THE BEARINGS AND OIL SEALS5-58
CHECKING THE CRANKCASE5-59
ASSEMBLING THE CRANKCASE5-59
CRANKSHAFT 5-61
REMOVING THE CRANKSHAFT 5-62
CHECKING THE CRANKSHAFT5-62
INSTALLING THE CRANKSHAFT5-62
TRANSMISSION5-64
CHECKING THE SHIFT FORKS5-69
CHECKING THE SHIFT DRUM ASSEMBLY5-69
CHECKING THE TRANSMISSION5-69
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5-70
INSTALLING THE TRANSMISSION5-70
RADIATOR 6-1
CHECKING THE RADIATOR6-2
INSTALLING THE RADIATOR6-2
THERMOSTAT 6-3
CHECKING THE THERMOSTAT6-4
INSTALLING THE THERMOSTAT6-4
WATER PUMP6-5
DISASSEMBLING THE WATER PUMP6-7
CHECKING THE WATER PUMP6-7
ASSEMBLING THE WATER PUMP6-7
FUEL TANK7-1
REMOVING THE FUEL TANK7-2
REMOVING THE FUEL PUMP 7-2
CHECKING THE FUEL PUMP BODY7-2
INSTALLING THE FUEL PUMP7-2
INSTALLING THE FUEL HOSE7-3
THROTTLE BODY7-4
CHECKING THE INJECTOR 7-7
CHECKING THE THROTTLE BODY 7-7
CHECKING THE PRESSURE REGULATOR OPERATION7-7
ADJUSTING THE THROTTLE POSITION SENSOR7-7
INSTALLING THE THROTTLE BODY 7-8
IGNITION SYSTEM 8-1
CIRCUIT DIAGRAM 8-1
TROUBLESHOOTING 8-3
ELECTRIC STARTING SYSTEM8-5
CIRCUIT DIAGRAM 8-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION8-7
TROUBLESHOOTING 8-8
CHARGING SYSTEM8-11
CIRCUIT DIAGRAM 8-11
TROUBLESHOOTING 8-13
LIGHTING SYSTEM 8-15
CIRCUIT DIAGRAM 8-15
TROUBLESHOOTING 8-17
SIGNALING SYSTEM 8-19
CIRCUIT DIAGRAM 8-19
TROUBLESHOOTING 8-21
COOLING SYSTEM8-25
CIRCUIT DIAGRAM 8-25
TROUBLESHOOTING 8-27
FUEL INJECTION SYSTEM8-29
CIRCUIT DIAGRAM 8-29
ECU SELF-DIAGNOSTIC FUNCTION8-31
SELF-DIAGNOSTIC FUNCTION TABLE8-33
TROUBLESHOOTING METHOD8-35
DIAGNOSTIC MODE 8-36
TROUBLESHOOTING DETAILS 8-41
FUEL PUMP SYSTEM8-55
CIRCUIT DIAGRAM 8-55
TROUBLESHOOTING 8-57
ELECTRICAL COMPONENTS8-59
CHECKING THE SWITCHES 8-61
CHECKING THE BULBS AND BULB SOCKETS 8-64
CHECKING THE FUSES 8-65
CHECKING AND CHARGING THE BATTERY8-66
CHECKING THE RELAYS 8-69
CHECKING THE DIODES8-70
CHECKING THE SPARK PLUG CAP 8-70
CHECKING THE IGNITION COIL 8-71
CHECKING THE IGNITION SPARK GAP8-71
CHECKING THE CRANKSHAFT POSITION SENSOR8-72
CHECKING THE LEAN ANGLE SENSOR8-72
CHECKING THE STARTER MOTOR OPERATION8-73
CHECKING THE STATOR COIL 8-73
CHECKING THE RECTIFIER/REGULATOR8-74
CHECKING THE FUEL SENDER 8-74
CHECKING THE SPEED SENSOR8-75
CHECKING THE RADIATOR FAN MOTOR 8-75
CHECKING THE RADIATOR FAN MOTOR CIRCUIT BREAKER 8-75
CHECKING THE COOLANT TEMPERATURE SENSOR8-76
CHECKING THE THROTTLE POSITION SENSOR 8-77
CHECKING THE INTAKE AIR PRESSURE SENSOR 8-77
CHECKING THE INTAKE AIR TEMPERATURE SENSOR8-77
TROUBLESHOOTING9-1
GENERAL INFORMATION 9-1
STARTING FAILURES9-1
INCORRECT ENGINE IDLING SPEED 9-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE9-2
FAULTY GEAR SHIFTING9-2
SHIFT PEDAL DOES NOT MOVE9-2
JUMPS OUT OF GEAR9-2
FAULTY CLUTCH 9-2
OVERHEATING 9-2
OVERCOOLING9-3
POOR BRAKING PERFORMANCE9-3
FAULTY SHOCK ABSORBER ASSEMBLY9-3
UNSTABLE HANDLING9-3
FAULTY LIGHTING OR SIGNALING SYSTEM9-4

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]