Yamaha Raptor 90 Yfm90 RY 2009 2010 Service Repair Manual – PDF Download

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Yamaha Raptor 90 Yfm90 RY 2009 2010 Service Repair Manual

LANGUAGE:ENGLISH
PAGES:228
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FILE TYPE:PDF

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

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Yamaha Raptor 90 Yfm90 RY 2009 2010 Service Repair Manual

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

TABLE OF CONTENTS:

Yamaha Raptor 90 Yfm90 RY 2009 2010 Service Repair Manual

CHAPTER 1
GENERAL INFORMATION
MACHINE IDENTIFICATION 1-1
VEHICLE IDENTIFICATION NUMBER 1-1
MODEL LABEL 1-1
IMPORTANT INFORMATION 1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY 1-2
REPLACEMENT PARTS 1-2
GASKETS, OIL SEALS AND O-RINGS 1-2
LOCK WASHERS/PLATES AND COTTER PINS 1-3
BEARINGS AND OIL SEALS 1-3
CIRCLIPS 1-3
CHECKING THE CONNECTIONS 1-4
SPECIAL TOOLS 1-5
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS 2-1
ENGINE SPECIFICATIONS 2-4
CHASSIS SPECIFICATIONS 2-11
ELECTRICAL SPECIFICATIONS 2-13
TIGHTENING TORQUES 2-15
ENGINE TIGHTENING TORQUES 2-15
CHASSIS TIGHTENING TORQUES 2-16
HOW TO USE THE CONVERSION TABLE 2-18
GENERAL TIGHTENING TORQUE SPECIFICATIONS 2-18
LUBRICATION POINTS AND LUBRICANT TYPES 2-19
ENGINE 2-19
OIL FLOW DIAGRAMS 2-21
CABLE ROUTING 2-22
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION 3-1
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 TANK 3-7
ENGINE 3-8
ADJUSTING THE VALVE CLEARANCE 3-8
ADJUSTING THE ENGINE IDLING SPEED 3-10
ADJUSTING THE THROTTLE LEVER FREE PLAY 3-11
ADJUSTING THE SPEED LIMITER 3-12
CHECKING THE SPARK PLUG 3-13
CHECKING THE IGNITION TIMING 3-14
MEASURING THE COMPRESSION PRESSURE 3-15
CHECKING THE ENGINE OIL LEVEL 3-17
CHANGING THE ENGINE OIL 3-18
CLEANING THE AIR FILTER ELEMENT 3-19
CLEANING THE SPARK ARRESTER 3-20
CHASSIS 3-22
CHECKING THE FRONT BRAKE SHOES 3-22
ADJUSTING THE FRONT BRAKE 3-22
CHECKING THE REAR BRAKE FLUID LEVEL 3-23
CHECKING THE REAR BRAKE PADS 3-24
CHECKING THE BRAKE HOSE 3-24
BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-24
CHANGING THE FINAL TRANSMISSION OIL 3-26
ADJUSTING THE DRIVE CHAIN SLACK 3-26
CHECKING THE STEERING SYSTEM 3-28
ADJUSTING THE TOE-IN 3-29
CHECKING THE FRONT AND REAR SHOCK ABSORBERS 3-30
CHECKING THE TIRES 3-32
ADJUSTING THE SHOCK ABSORBERS 3-31
CHECKING THE WHEELS 3-34
CHECKING AND LUBRICATING THE CABLES 3-35
LUBRICATING THE LEVERS, STEERING SHAFT
AND STEERING KNUCKLES 3-35
ELECTRICAL SYSTEM 3-36
CHECKING AND CHARGING THE BATTERY 3-36
CHECKING THE FUSES 3-43
CHAPTER 4
ENGINE
ENGINE 4-1
EXHAUST PIPE/MUFFLER, BREATHER HOSE AND LEADS 4-1
ENGINE MOUNTING BOLTS 4-2
REMOVING THE ENGINE 4-3
INSTALLING THE ENGINE 4-3
CYLINDER HEAD 4-4
REMOVING THE CYLINDER HEAD 4-6
CHECKING THE CAMSHAFT SPROCKET 4-7
CHECKING THE CYL HEAD COVER ASSY 4-7
CHECKING THE TIMING CHAIN GUIDES 4-7
CHECKING THE TIMING CHAIN TENSIONER ASSEMBLY 4-7
CHECKING THE CYLINDER HEAD 4-8
INSTALLING THE CYLINDER HEAD 4-9
CAMSHAFT, ROCKER ARMS AND VALVES 4-11
REMOVING THE ROCKER ARMS AND CAMSHAFT 4-12
REMOVING THE VALVES AND VALVE SPRINGS 4-12
CHECKING THE CAMSHAFT 4-13
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 4-13
CHECKING THE VALVES AND VALVE SPRINGS 4-15
INSTALLING THE VALVES AND VALVE SPRINGS 4-19
INSTALLING THE CAMSHAFT AND ROCKER ARMS 4-20
CYLINDER AND PISTON 4-21
REMOVING THE PISTON 4-22
CHECKING THE CYLINDER AND PISTON 4-22
CHECKING THE PISTON RINGS 4-24
CHECKING THE PISTON PIN 4-25
INSTALLING THE PISTON 4-26
INSTALLING THE CYLINDER 4-27
C D I MAGNETO 4-28
REMOVING THE C D I MAGNETO ROTOR 4-29
CHECKING THE PICKUP COIL/STATOR ASSEMBLY 4-29
INSTALLING STATOR COIL ASSEMBLY 4-30
INSTALLING THE C D I MAGNETO ROTOR 4-30
BELT DRIVE 4-31
CRANKCASE COVER 4-31
KICKSTARTER 4-32
INSTALLING THE KICKSTARTER 4-33
V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE 4-34
DISASSEMBLING THE SECONDARY SHEAVE 4-35
REMOVING THE PRIMARY SHEAVE 4-36
REMOVING THE SECONDARY SHEAVE AND V-BELT 4-36
DISASSEMBLING THE SECONDARY SHEAVE 4-37
CHECKING THE CLUTCH SHOE 4-37
CHECKING THE V-BELT 4-38
CHECKING THE PRIMARY SHEAVE 4-38
CHECKING THE PRIMARY SHEAVE WEIGHTS 4-38
CHECKING THE SLIDER 4-39
CHECKING THE SECONDARY SHEAVE 4-39
ASSEMBLING THE PRIMARY SHEAVE 4-40
ASSEMBLING THE SECONDARY SHEAVE 4-41
INSTALLING THE BELT DRIVE 4-42
TRANSMISSION 4-55
CHECKING THE TRANSMISSION 4-56
CRANKCASE AND CRANKSHAFT 4-49
SEPARATING THE CRANKCASE 4-50
REMOVING THE CRANKSHAFT ASSEMBLY 4-51
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES 4-51
CHECKING THE CRANKSHAFT AND CONNECTING ROD 4-52
INSTALLING THE CRANKSHAFT 4-53
ASSEMBLING THE CRANKCASE 4-54
STARTER CLUTCH AND STARTER MOTOR 4-44
CHECKING THE STARTER WHEEL GEAR 4-45
OIL PUMP 4-46
CHECKING THE OIL PUMP 4-47
INSTALLING THE OIL PUMP 4-48
CHAPTER 5
CARBURETOR
CARBURETOR 5-1
DISASSEMBLING THE CARBURETOR 5-4
CHECKING THE CARBURETOR 5-4
ASSEMBLING THE CARBURETOR 5-6
INSTALLING THE CARBURETOR 5-7
MEASURING AND ADJUSTING THE FUEL LEVEL 5-8
CHAPTER 6
CHASSIS
FRONT AND REAR WHEELS 6-1
FRONT WHEELS 6-1
REAR WHEELS 6-2
CHECKING THE WHEELS 6-3
CHECKING THE FRONT WHEEL HUBS 6-3
CHECKING THE REAR WHEEL HUBS 6-4
INSTALLING THE WHEEL HUBS 6-4
INSTALLING THE FRONT WHEELS 6-5
INSTALLING THE REAR WHEELS 6-5
FRONT BRAKES 6-6
FRONT BRAKES 6-6
REMOVING THE FRONT BRAKES 6-7
CHECKING THE FRONT BRAKE SHOE PLATES 6-7
CHECKING THE FRONT BRAKE SHOES 6-7
CHECKING THE FRONT BRAKE DRUMS 6-8
INSTALLING THE FRONT BRAKES 6-9
REAR AXLE AND REAR AXLE HUB
6-11
REAR AXLE AND REAR AXLE HUB 6-11
REMOVING THE REAR AXLE 6-13
CHECKING THE REAR AXLE 6-14
CHECKING THE DRIVEN SPROCKET 6-14
CHECKING THE BRAKE DISC 6-14
INSTALLING THE DRIVEN SPROCKET 6-14
INSTALLING THE REAR AXLE 6-15
STEERING SYSTEM 6-28
HANDLEBAR 6-28
REMOVING THE HANDLEBAR GRIPS 6-30
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 CYLINDER 6-32
INSTALLING THE FRONT BRAKE LEVER ASSEMBLY 6-32
STEERING STEM 6-33
REMOVING THE STEERING STEM 6-34
CHECKING THE STEERING STEM 6-34
INSTALLING THE STEERING STEM 6-35
INSTALLING THE LOWER HANDLEBAR HOLDER 6-35
INSTALLING THE LOCK WASHER 6-35
TIE-RODS AND STEERING KNUCKLES 6-36
REMOVING THE STEERING KNUCKLES 6-37
REMOVING THE TIE-RODS 6-37
CHECKING THE TIE-RODS 6-37
CHECKING THE STEERING KNUCKLES 6-37
INSTALLING THE TIE-RODS 6-38
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 6-39
REMOVING THE FRONT ARMS 6-40
FRONT ARMS AND FRONT SHOCK ABSORBER
ASSEMBLIES 6-39
CHECKING THE FRONT ARMS 6-40
CHECKING THE FRONT SHOCK ABSORBERS 6-40
REAR BRAKES 6-16
REAR BRAKE PADS 6-16
REPLACING THE REAR BRAKE PADS 6-17
REAR BRAKE MASTER CYLINDER 6-19
CHECKING THE MASTER CYLINDER 6-20
ASSEMBLING THE REAR BRAKE MASTER CYLINDER 6-20
INSTALLING THE REAR BRAKE MASTER CYLINDER 6-21
REAR BRAKE CALIPER 6-23
CHECKING THE REAR BRAKE CALIPER 6-25
INSTALLING THE REAR BRAKE CALIPER 6-26
CHECKING THE BALL JOINTS 6-41
INSTALLING THE FRONT ARMS 6-41
CHAPTER 7
ELECTRICAL
ELECTRICAL COMPONENTS 7-1
CHECKING SWITCH CONTINUITY 7-2
CHECKING THE SWITCHES 7-3
IGNITION SYSTEM 7-4
CIRCUIT DIAGRAM 7-4
TROUBLESHOOTING 7-5
ELECTRIC STARTING SYSTEM 7-9
CIRCUIT DIAGRAM 7-9
STARTING CIRCUIT OPERATION 7-10
TROUBLESHOOTING 7-11
STARTER MOTOR 7-13
CHECKING THE STARTER MOTOR 7-14
ASSEMBLING THE STARTER MOTOR 7-15
CHARGING SYSTEM 7-16
CIRCUIT DIAGRAM 7-16
TROUBLESHOOTING 7-17
REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN 6-42
REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN 6-42
REMOVING THE REAR SHOCK ABSORBER 6-44
CHECKING THE REAR SHOCK ABSORBER 6-44
REMOVING THE SWINGARM 6-44
CHECKING THE SWINGARM 6-45
CHECKING THE DRIVE CHAIN 6-46
INSTALLING THE DRIVE SPROCKET 6-47
INSTALLING THE DRIVE CHAIN 6-47
CHAPTER 8
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING 8-1
FUEL SYSTEM 8-1
ELECTRICAL SYSTEM 8-1
COMPRESSION SYSTEM 8-2
POOR IDLE SPEED PERFORMANCE 8-2
POOR IDLE SPEED PERFORMANCE 8-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE 8-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE 8-2
FAULTY CLUTCH 8-3
ENGINE OPERATES BUT VEHICLE WILL NOT MOVE 8-3
POOR STARTING PERFORMANCE 8-3
POOR SPEED PERFORMANCE 8-3
OVERHEATING 8-3
OVERHEATING 8-3
FAULTY BRAKE 8-4
POOR BRAKING EFFECT 8-4
SHOCK ABSORBER MALFUNCTION 8-4
MALFUNCTION 8-4
UNSTABLE HANDLING 8-4
UNSTABLE HANDLING 8-4

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⦁ 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]