Yamaha YFM700RV Service Manual Download | Manualshive

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LIT-11616-19-13

1S3-28197-10

YFM700RV

SERVICE MANUAL

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Summary of Contents for YFM700RV

Page 1: ...LIT 11616 19 13 1S3 28197 10 YFM700RV SERVICE MANUAL ...

Page 2: ...5 by Yamaha Motor Corporation U S A First Edition May 2005 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A LIT 11616 19 13 ...

Page 3: ...tions and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE _ Designs and specifications are subject to change without notice EBS00003 IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol...

Page 4: ...parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read...

Page 5: ...torque E Wear limit clearance F Engine speed G Electrical data Ω V A Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points H Apply engine oil I Apply gear oil J Apply molybdenum disulfide oil K Apply wheel bearing grease L Apply lithium soap based grease M Apply molybdenum disulfide grease Symbols N to O in the exploded diagrams indicate where to apply a l...

Page 6: ...TENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 ENGINE ENG 4 COOLING SYSTEM COOL 5 FUEL INJECTION SYSTEM FI 6 CHASSIS CHAS 7 ELECTRICAL ELEC 8 TROUBLESHOOTING TRBL SHTG 9 ...

Page 7: ...PLACEMENT PARTS 1 7 GASKETS OIL SEALS AND O RINGS 1 7 LOCK WASHERS PLATES AND COTTER PINS 1 8 BEARINGS AND OIL SEALS 1 8 CIRCLIPS 1 8 CHECKING THE CONNECTIONS 1 9 SPECIAL TOOLS 1 10 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 4 CHASSIS SPECIFICATIONS 2 12 ELECTRICAL SPECIFICATIONS 2 14 TIGHTENING TORQUES 2 16 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES...

Page 8: ...LEARANCE 3 11 ADJUSTING THE ENGINE IDLING SPEED 3 13 ADJUSTING THE THROTTLE LEVER FREE PLAY 3 14 ADJUSTING THE SPEED LIMITER 3 15 CHECKING THE SPARK PLUG 3 16 CHECKING THE IGNITION TIMING 3 17 MEASURING THE COMPRESSION PRESSURE 3 18 CHECKING THE ENGINE OIL LEVEL 3 20 CHANGING THE ENGINE OIL 3 22 ADJUSTING THE CLUTCH CABLE 3 25 CLEANING THE AIR FILTER ELEMENT 3 25 CHECKING THE THROTTLE BODY JOINT 3...

Page 9: ...3 48 ADJUSTING THE REAR SHOCK ABSORBER 3 49 CHECKING THE TIRES 3 52 CHECKING THE WHEELS 3 54 CHECKING AND LUBRICATING THE CABLES 3 54 LUBRICATING THE LEVERS AND PEDALS 3 55 ELECTRICAL SYSTEM 3 56 CHECKING AND CHARGING THE BATTERY 3 56 CHECKING THE FUSES 3 62 ADJUSTING THE HEADLIGHT BEAMS 3 64 REPLACING A HEADLIGHT BULB 3 64 CHAPTER 4 ENGINE ENGINE REMOVAL 4 1 MUFFLER AND EXHAUST PIPES 4 1 INSTALLI...

Page 10: ...GNETO 4 41 REMOVING THE A C MAGNETO ROTOR 4 43 CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR 4 43 CHECKING THE STARTER CLUTCH 4 44 CHECKING THE TORQUE LIMITER 4 45 INSTALLING THE A C MAGNETO ROTOR 4 45 CLUTCH 4 47 REMOVING THE CLUTCH 4 51 REMOVING THE PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR 4 52 CHECKING THE FRICTION PLATES 4 52 CHECKING THE CLUTCH PLATES 4 53 CHECKING THE CLUTCH SPR...

Page 11: ... CRANKSHAFT 4 74 CRANKSHAFT AND BALANCER 4 74 REMOVING THE CRANKSHAFT 4 75 CHECKING THE CRANKSHAFT 4 75 INSTALLING THE CRANKSHAFT 4 76 TRANSMISSION 4 77 MAIN AXLE 4 79 DRIVE AXLE 4 80 COUNTER AXLE 4 82 CHECKING THE SHIFT FORKS 4 83 CHECKING THE SHIFT DRUM ASSEMBLY 4 83 CHECKING THE TRANSMISSION 4 83 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 4 84 INSTALLING THE TRANSMISSION 4 85 CHAPTER 5 COOLING SYS...

Page 12: ... AND PRESSURE REGULATOR OPERATION 6 32 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 6 33 CHAPTER 7 CHASSIS FRONT AND REAR WHEELS 7 1 FRONT WHEELS 7 1 REAR WHEELS 7 3 CHECKING THE WHEELS 7 4 CHECKING THE WHEEL HUBS 7 4 CHECKING THE BRAKE DISCS 7 5 INSTALLING THE FRONT WHEEL HUB BEARINGS 7 6 INSTALLING THE FRONT BRAKE DISCS 7 6 INSTALLING THE FRONT WHEELS 7 6 INSTALLING THE FRONT WHEEL HUBS 7...

Page 13: ...CALIPER 7 39 INSTALLING THE FRONT BRAKE CALIPERS 7 40 INSTALLING THE REAR BRAKE CALIPER 7 41 STEERING SYSTEM 7 44 HANDLEBAR 7 44 REMOVING THE FRONT BRAKE LIGHT SWITCH AND CLUTCH SWITCH 7 46 REMOVING THE HANDLEBAR GRIPS 7 46 CHECKING THE HANDLEBAR 7 46 INSTALLING THE HANDLEBAR 7 47 INSTALLING THE HANDLEBAR GRIPS 7 47 INSTALLING THE CLUTCH LEVER 7 48 INSTALLING THE BRAKE MASTER CYLINDER 7 48 STEERIN...

Page 14: ...NG THE SWINGARM 7 67 CHECKING THE DRIVE CHAIN 7 68 INSTALLING THE SWINGARM 7 70 INSTALLING THE DRIVE SPROCKET 7 70 CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS 8 1 CHECKING SWITCH CONTINUITY 8 2 CHECKING THE SWITCHES 8 3 CHECKING THE BULBS AND BULB SOCKETS 8 5 TYPES OF BULBS 8 5 CHECKING THE CONDITION OF THE BULBS 8 5 CHECKING THE CONDITION OF THE BULB SOCKETS 8 7 IGNITION SYSTEM 8 8 CIRCUIT DIAGRAM...

Page 15: ...OOTING 8 43 CHAPTER 9 TROUBLESHOOTING STARTING FAILURE HARD STARTING 9 1 FUEL SYSTEM 9 1 ELECTRICAL SYSTEM 9 1 COMPRESSION SYSTEM 9 1 POOR IDLE SPEED PERFORMANCE 9 2 POOR IDLE SPEED PERFORMANCE 9 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 HARD SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT GEAR 9 2 CLUTCH SLIPPING DRAGGING...

Page 16: ...AKING EFFECT 9 4 SHOCK ABSORBER MALFUNCTION 9 4 MALFUNCTION 9 4 UNSTABLE HANDLING 9 4 UNSTABLE HANDLING 9 4 LIGHTING SYSTEM 9 5 HEADLIGHT DOES NOT COME ON 9 5 TAIL BRAKE LIGHT DOES NOT COME ON 9 5 HEADLIGHT BULB BURNT OUT 9 5 ...

Page 17: ...LE IDENTIFICATION EBS00010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame 1 EBS00011 MODEL LABEL The model label 1 is affixed to the air filter case cover This information will be needed to order spare parts 1 ...

Page 18: ...irements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engi...

Page 19: ...he injection duration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air tem perature sensor coolant temperature sensor and speed sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft posi tion senso...

Page 20: ...en the brake caliper piston 7 and the adjusting bolt 5 This adjustment procedure is unnecessary for vehicles equipped with a self adjusting parking brake mechanism The proper clearance is automatically maintained at all times ensuring stable braking performance when parking the vehicle 1 Parking brake arm 2 Parking brake shaft 3 Adjusting bolt 4 Adjusting bolt sleeve 5 Adjusting bolt 6 Nut 7 Brake...

Page 21: ...ng brake shaft 2 and the adjusting bolt 3 is pushed against the adjusting bolt sleeve 4 When the adjusting bolt sleeve receives the force the dark shaded area in the above illustration is pushed and the brake pad 6 is pushed against the brake disc When the brake pad wears the clearance between the brake caliper piston 5 and the brake pad becomes larger and the force applied to the brake pad become...

Page 22: ...ing brake makes no adjustment The adjustment operation is as follows 1 When the brake pedal is operated the brake fluid pressure increases and the brake caliper pis ton and the nut move 2 When the movement of the brake caliper piston and the nut is greater than the backlash of the threads of the nut and the adjusting bolt the force È will be required to pull the adjusting bolt The force to pull th...

Page 23: ...all of the parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EBS00014 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance bu...

Page 24: ...sible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate 1 Oil seal CAUTION _ Do not spin the bearing with compressed air because this will damage the bearing surfaces 1 Bearing EBS00018 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always rep...

Page 25: ...l times 3 Check all connections Loose connection Connect properly NOTE _ If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE _ Make sure all connections are tight 5 Check continuity with the pocket tester NOTE _ If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer availab...

Page 26: ...S and CDN P N 90890 Tool No Tool name Function Illustration 90890 01083 YU 01083 1 Slide hammer bolt Slide hammer bolt 6 mm This tool is used to remove the rocker arm shaft 90890 01084 YU 01083 3 Weight This tool is used to remove the rocker arm shaft 90890 01135 YU 01135 B Crankcase separating tool Crankcase separator This tool is used to separate the crank case 90890 01268 YU 01268 Ring nut wren...

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