Yamaha Raptor 90 Service Manual Repair 2009 – 2010 Yfm90 – PDF DOWNLOAD

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Yamaha Raptor 90 Service Manual Repair 2009 – 2010 Yfm90

FILE DETAILS:

LANGUAGE:ENGLISH
PAGES:228
DOWNLOADABLE:YES
FILE TYPE:PDF

TABLE OF CONTENTS:

Yamaha Raptor 90 Service Manual Repair 2009 – 2010 Yfm90

CHAPTER 1
GENERAL INFORMATION
MACHINE IDENTIFICATION1-1
VEHICLE IDENTIFICATION NUMBER1-1
MODEL LABEL1-1
IMPORTANT INFORMATION 1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY1-2
REPLACEMENT PARTS1-2
GASKETS, OIL SEALS AND O-RINGS 1-2
LOCK WASHERS/PLATES AND COTTER PINS1-3
BEARINGS AND OIL SEALS1-3
CIRCLIPS1-3
CHECKING THE CONNECTIONS1-4
SPECIAL TOOLS 1-5
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS 2-1
ENGINE SPECIFICATIONS 2-4
CHASSIS SPECIFICATIONS2-11
ELECTRICAL SPECIFICATIONS 2-13
TIGHTENING TORQUES 2-15
ENGINE TIGHTENING TORQUES2-15
CHASSIS TIGHTENING TORQUES2-16
HOW TO USE THE CONVERSION TABLE2-18
GENERAL TIGHTENING TORQUE SPECIFICATIONS2-18
LUBRICATION POINTS AND LUBRICANT TYPES 2-19
ENGINE2-19
OIL FLOW DIAGRAMS2-21
CABLE ROUTING 2-22
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION3-1
PERIODIC MAINTENANCE/LUBRICATION 3-1
SEAT, FENDERS AND FUEL TANK 3-3
SEAT AND FRONT PANEL 3-3
FRONT FENDER 3-4
REAR FENDER AND FOOTREST BOARDS 3-5
FUEL TANK3-7
ENGINE 3-8
ADJUSTING THE VALVE CLEARANCE 3-8
ADJUSTING THE ENGINE IDLING SPEED3-10
ADJUSTING THE THROTTLE LEVER FREE PLAY 3-11
ADJUSTING THE SPEED LIMITER3-12
CHECKING THE SPARK PLUG 3-13
CHECKING THE IGNITION TIMING3-14
MEASURING THE COMPRESSION PRESSURE3-15
CHECKING THE ENGINE OIL LEVEL3-17
CHANGING THE ENGINE OIL 3-18
CLEANING THE AIR FILTER ELEMENT3-19
CLEANING THE SPARK ARRESTER 3-20
CHASSIS3-22
CHECKING THE FRONT BRAKE SHOES3-22
ADJUSTING THE FRONT BRAKE3-22
CHECKING THE REAR BRAKE FLUID LEVEL3-23
CHECKING THE REAR BRAKE PADS3-24
CHECKING THE BRAKE HOSE3-24
BLEEDING THE HYDRAULIC BRAKE SYSTEM3-24
CHANGING THE FINAL TRANSMISSION OIL3-26
ADJUSTING THE DRIVE CHAIN SLACK3-26
CHECKING THE STEERING SYSTEM3-28
ADJUSTING THE TOE-IN3-29
CHECKING THE FRONT AND REAR SHOCK ABSORBERS 3-30
CHECKING THE TIRES3-32
ADJUSTING THE SHOCK ABSORBERS3-31
CHECKING THE WHEELS 3-34
CHECKING AND LUBRICATING THE CABLES 3-35
LUBRICATING THE LEVERS, STEERING SHAFT
AND STEERING KNUCKLES 3-35
ELECTRICAL SYSTEM3-36
CHECKING AND CHARGING THE BATTERY3-36
CHECKING THE FUSES3-43
CHAPTER 4
ENGINE
ENGINE 4-1
EXHAUST PIPE/MUFFLER, BREATHER HOSE AND LEADS 4-1
ENGINE MOUNTING BOLTS 4-2
REMOVING THE ENGINE4-3
INSTALLING THE ENGINE4-3
CYLINDER HEAD4-4
REMOVING THE CYLINDER HEAD4-6
CHECKING THE CAMSHAFT SPROCKET4-7
CHECKING THE CYL HEAD COVER ASSY4-7
CHECKING THE TIMING CHAIN GUIDES4-7
CHECKING THE TIMING CHAIN TENSIONER ASSEMBLY 4-7
CHECKING THE CYLINDER HEAD 4-8
INSTALLING THE CYLINDER HEAD 4-9
CAMSHAFT, ROCKER ARMS AND VALVES4-11
REMOVING THE ROCKER ARMS AND CAMSHAFT4-12
REMOVING THE VALVES AND VALVE SPRINGS 4-12
CHECKING THE CAMSHAFT4-13
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 4-13
CHECKING THE VALVES AND VALVE SPRINGS4-15
INSTALLING THE VALVES AND VALVE SPRINGS4-19
INSTALLING THE CAMSHAFT AND ROCKER ARMS 4-20
CYLINDER AND PISTON4-21
REMOVING THE PISTON 4-22
CHECKING THE CYLINDER AND PISTON 4-22
CHECKING THE PISTON RINGS4-24
CHECKING THE PISTON PIN 4-25
INSTALLING THE PISTON4-26
INSTALLING THE CYLINDER 4-27
CDI MAGNETO4-28
REMOVING THE CDI MAGNETO ROTOR 4-29
CHECKING THE PICKUP COIL/STATOR ASSEMBLY4-29
INSTALLING STATOR COIL ASSEMBLY 4-30
INSTALLING THE CDI MAGNETO ROTOR4-30
BELT DRIVE 4-31
CRANKCASE COVER4-31
KICKSTARTER4-32
INSTALLING THE KICKSTARTER4-33
V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE4-34
DISASSEMBLING THE SECONDARY SHEAVE4-35
REMOVING THE PRIMARY SHEAVE4-36
REMOVING THE SECONDARY SHEAVE AND V-BELT4-36
DISASSEMBLING THE SECONDARY SHEAVE4-37
CHECKING THE CLUTCH SHOE4-37
CHECKING THE V-BELT4-38
CHECKING THE PRIMARY SHEAVE4-38
CHECKING THE PRIMARY SHEAVE WEIGHTS4-38
CHECKING THE SLIDER4-39
CHECKING THE SECONDARY SHEAVE4-39
ASSEMBLING THE PRIMARY SHEAVE4-40
ASSEMBLING THE SECONDARY SHEAVE4-41
INSTALLING THE BELT DRIVE4-42
TRANSMISSION 4-55
CHECKING THE TRANSMISSION4-56
CRANKCASE AND CRANKSHAFT 4-49
SEPARATING THE CRANKCASE4-50
REMOVING THE CRANKSHAFT ASSEMBLY4-51
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES4-51
CHECKING THE CRANKSHAFT AND CONNECTING ROD4-52
INSTALLING THE CRANKSHAFT4-53
ASSEMBLING THE CRANKCASE4-54
STARTER CLUTCH AND STARTER MOTOR 4-44
CHECKING THE STARTER WHEEL GEAR4-45
OIL PUMP 4-46
CHECKING THE OIL PUMP4-47
INSTALLING THE OIL PUMP4-48
CHAPTER 5
CARBURETOR
CARBURETOR5-1
DISASSEMBLING THE CARBURETOR5-4
CHECKING THE CARBURETOR 5-4
ASSEMBLING THE CARBURETOR5-6
INSTALLING THE CARBURETOR 5-7
MEASURING AND ADJUSTING THE FUEL LEVEL 5-8
CHAPTER 6
CHASSIS
FRONT AND REAR WHEELS 6-1
FRONT WHEELS6-1
REAR WHEELS 6-2
CHECKING THE WHEELS 6-3
CHECKING THE FRONT WHEEL HUBS 6-3
CHECKING THE REAR WHEEL HUBS6-4
INSTALLING THE WHEEL HUBS6-4
INSTALLING THE FRONT WHEELS6-5
INSTALLING THE REAR WHEELS6-5
FRONT BRAKES 6-6
FRONT BRAKES6-6
REMOVING THE FRONT BRAKES 6-7
CHECKING THE FRONT BRAKE SHOE PLATES 6-7
CHECKING THE FRONT BRAKE SHOES6-7
CHECKING THE FRONT BRAKE DRUMS6-8
INSTALLING THE FRONT BRAKES 6-9
REAR AXLE AND REAR AXLE HUB
6-11
REAR AXLE AND REAR AXLE HUB6-11
REMOVING THE REAR AXLE6-13
CHECKING THE REAR AXLE6-14
CHECKING THE DRIVEN SPROCKET6-14
CHECKING THE BRAKE DISC6-14
INSTALLING THE DRIVEN SPROCKET6-14
INSTALLING THE REAR AXLE6-15
STEERING SYSTEM6-28
HANDLEBAR6-28
REMOVING THE HANDLEBAR GRIPS6-30
REMOVING THE REAR BRAKE SWITCH 6-30
CHECKING THE HANDLEBAR 6-30
INSTALLING THE HANDLEBAR 6-31
INSTALLING THE HANDLEBAR GRIPS 6-31
INSTALLING THE REAR BRAKE MASTER CYLINDER6-32
INSTALLING THE FRONT BRAKE LEVER ASSEMBLY6-32
STEERING STEM 6-33
REMOVING THE STEERING STEM 6-34
CHECKING THE STEERING STEM6-34
INSTALLING THE STEERING STEM6-35
INSTALLING THE LOWER HANDLEBAR HOLDER6-35
INSTALLING THE LOCK WASHER6-35
TIE-RODS AND STEERING KNUCKLES6-36
REMOVING THE STEERING KNUCKLES6-37
REMOVING THE TIE-RODS6-37
CHECKING THE TIE-RODS 6-37
CHECKING THE STEERING KNUCKLES6-37
INSTALLING THE TIE-RODS 6-38
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES6-39
REMOVING THE FRONT ARMS6-40
FRONT ARMS AND FRONT SHOCK ABSORBER
ASSEMBLIES6-39
CHECKING THE FRONT ARMS6-40
CHECKING THE FRONT SHOCK ABSORBERS6-40
REAR BRAKES 6-16
REAR BRAKE PADS6-16
REPLACING THE REAR BRAKE PADS6-17
REAR BRAKE MASTER CYLINDER6-19
CHECKING THE MASTER CYLINDER6-20
ASSEMBLING THE REAR BRAKE MASTER CYLINDER6-20
INSTALLING THE REAR BRAKE MASTER CYLINDER6-21
REAR BRAKE CALIPER6-23
CHECKING THE REAR BRAKE CALIPER6-25
INSTALLING THE REAR BRAKE CALIPER6-26
CHECKING THE BALL JOINTS6-41
INSTALLING THE FRONT ARMS6-41
CHAPTER 7
ELECTRICAL
ELECTRICAL COMPONENTS7-1
CHECKING SWITCH CONTINUITY7-2
CHECKING THE SWITCHES7-3
IGNITION SYSTEM 7-4
CIRCUIT DIAGRAM 7-4
TROUBLESHOOTING 7-5
ELECTRIC STARTING SYSTEM7-9
CIRCUIT DIAGRAM 7-9
STARTING CIRCUIT OPERATION7-10
TROUBLESHOOTING 7-11
STARTER MOTOR7-13
CHECKING THE STARTER MOTOR 7-14
ASSEMBLING THE STARTER MOTOR7-15
CHARGING SYSTEM7-16
CIRCUIT DIAGRAM 7-16
TROUBLESHOOTING 7-17
REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN6-42
REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN6-42
REMOVING THE REAR SHOCK ABSORBER6-44
CHECKING THE REAR SHOCK ABSORBER6-44
REMOVING THE SWINGARM6-44
CHECKING THE SWINGARM6-45
CHECKING THE DRIVE CHAIN6-46
INSTALLING THE DRIVE SPROCKET6-47
INSTALLING THE DRIVE CHAIN6-47
CHAPTER 8
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING 8-1
FUEL SYSTEM8-1
ELECTRICAL SYSTEM8-1
COMPRESSION SYSTEM8-2
POOR IDLE SPEED PERFORMANCE8-2
POOR IDLE SPEED PERFORMANCE8-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE8-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE 8-2
FAULTY CLUTCH 8-3
ENGINE OPERATES BUT VEHICLE WILL NOT MOVE8-3
POOR STARTING PERFORMANCE8-3
POOR SPEED PERFORMANCE8-3
OVERHEATING8-3
OVERHEATING 8-3
FAULTY BRAKE8-4
POOR BRAKING EFFECT8-4
SHOCK ABSORBER MALFUNCTION 8-4
MALFUNCTION8-4
UNSTABLE HANDLING8-4
UNSTABLE HANDLING8-4

DESCRIPTION:

Yamaha Raptor 90 Service Manual Repair 2009 – 2010 Yfm90

FOREWORD:

This manual was produced by the Yamaha Motor Company 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, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all 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
MANUAL ORGANIZATION:

This manual consists of chapters for the main categories of subjects. (See “symbols”)
1st title : This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title : This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.
3rd title : This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.

YAMAHA RAPTOR 90 SERVICE MANUAL REPAIR 2009 – 2010 YFM90 – PDF DOWNLOAD:

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