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RAPTOR YFM700RF 2015
Yamaha RAPTOR YFM700RF 2015 User Manual
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2015
SERVICE MANUAL
YFM700RF
YFM700RSF
LIT-11616-28-28
2LS-F8197-10
2
Table of Contents
Table of Contents
7
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Features
11
Outline of the Fi System
11
Fi System
12
Instrument Functions
13
Lock Washers/Plates and Cotter Pins
14
Gaskets, Oil Seals and O-Rings
14
Replacement Parts
14
Preparation for Removal and Disassembly
14
Important Information
14
Bearings and Oil Seals
15
Circlips
15
Rubber Parts
15
Basic Service Information
16
Quick Fasteners
16
Electrical System
17
Special Tools
22
Specifications
29
General Specifications
30
Engine Specifications
31
Chassis Specifications
38
Electrical Specifications
41
General Tightening Torque Specifications
43
Tightening Torques
43
Engine Tightening Torques
44
Chassis Tightening Torques
47
Engine
50
Lubrication Points and Lubricant Types
50
Engine Oil Lubrication Chart
52
Lubrication System Chart and Diagrams
52
Lubrication Diagrams
54
Cooling System Diagrams
64
Cable Routing
70
Periodic Checks and Adjustments
89
General Maintenance and Lubrication Chart
92
Introduction
92
Periodic Maintenance
92
Periodic Maintenance Chart for the Emission Control System
92
Adjusting the Valve Clearance
95
Engine
95
Adjusting the Engine Idling Speed
97
Adjusting the Throttle Lever Free Play
97
Adjusting the Speed Limiter
98
Checking the Spark Plug
98
Measuring the Compression Pressure
99
Checking the Engine Oil Level
100
Changing the Engine Oil
101
Adjusting the Clutch Lever Free Play
103
Cleaning the Air Filter Element
103
Checking the Air Induction System
104
Checking the Throttle Body Joint
104
Checking the Crankcase Breather Hose
105
Checking the Exhaust System
105
Checking the Fuel Line
105
Checking the Coolant Level
106
Cleaning the Spark Arrester
106
Changing the Coolant
107
Checking the Cooling System
107
Adjusting the Front Disc Brake (Yfm700Rsf)
110
Adjusting the Rear Disc Brake
110
Chassis
110
Checking the Brake Fluid Level
110
Checking the Front Brake Hoses
111
Checking the Front Brake Pads
111
Checking the Rear Brake Pads
111
Adjusting the Parking Brake
112
Checking the Rear Brake Hose
112
Adjusting the Rear Brake Light Switch
113
Bleeding the Hydraulic Brake System
113
Adjusting the Reverse Control Cable
114
Adjusting the Shift Pedal
114
Adjusting the Drive Chain Slack
115
Adjusting the Toe-In
116
Checking the Steering System
116
Checking the Front Shock Absorber Assemblies
117
Adjusting the Front Shock Absorber Assemblies
118
Checking the Rear Shock Absorber Assembly
120
Adjusting the Rear Shock Absorber Assembly
121
Checking the Tires
123
Checking and Lubricating the Cables
124
Checking the Wheels
124
Lubricating the Brake Lever
125
Lubricating the Clutch Lever
125
Lubricating the Pedal
125
Lubricating the Rear Suspension
125
Adjusting the Headlight Beams
126
Checking and Charging the Battery
126
Checking the Fuses
126
Electrical System
126
Replacing the Headlight Bulbs
126
Chassis
129
General Chassis
132
Front Wheels
136
Checking the Front Wheel Hubs
137
Checking the Front Wheels
137
Removing the Front Wheels
137
Installing the Front Brake Discs
138
Installing the Front Wheel Hub Bearings
138
Installing the Front Wheel Hubs
138
Installing the Front Wheels
139
Rear Wheels
140
Checking the Rear Wheel Hubs
141
Checking the Rear Wheels
141
Installing the Rear Wheel Hubs
141
Installing the Rear Wheels
141
Removing the Rear Wheels
141
Rear Axle and Rear Axle Hub
143
Checking the Rear Axle
145
Removing the Rear Axle
145
Checking the Rear Brake Disc
146
Checking the Rear Wheel Sprocket
146
Installing the Rear Axle
146
Installing the Rear Wheel Sprocket
146
Front Brakes
148
Checking the Front Brake Discs
153
Introduction
153
Disassembling the Front Brake Calipers
154
Replacing the Front Brake Pads
154
Assembling the Front Brake Calipers
155
Checking the Front Brake Caliper
155
Installing the Front Brake Calipers
156
Assembling the Front Brake Master Cylinder
157
Checking the Front Brake Master Cylinder
157
Installing the Front Brake Master Cylinder
157
Rear Brake
159
Checking the Rear Brake Disc
166
Introduction
166
Replacing the Rear Brake Pads
166
Disassembling the Rear Brake Caliper
167
Removing the Rear Brake Caliper
167
Assembling the Rear Brake Caliper
168
Checking the Rear Brake Caliper
168
Installing the Rear Brake Caliper
169
Checking the Rear Brake Master Cylinder
170
Assembling the Rear Brake Master Cylinder
171
Installing the Rear Brake Master Cylinder
171
Handlebar
173
Checking the Handlebar
174
Installing the Handlebar
174
Removing the Clutch Switch
174
Removing the Handlebar
174
Steering Stem
177
Checking the Steering Stem
178
Installing the Bearing Retainer
178
Installing the Lock Washer
178
Installing the Pitman Arm
178
Removing the Bearing Retainer
178
Checking the Steering Knuckles
180
Checking the Tie-Rods
180
Installing the Tie-Rods
180
Removing the Steering Knuckles
180
Tie-Rods and Steering Knuckles
180
Front Arms and Front Shock Absorber Assemblies
181
Checking the Front Arms
183
Disposing of a Front Shock Absorber Assembly (Yfm700Rsf)
183
Handling the Front Shock Absorber Assemblies (Yfm700Rsf)
183
Removing the Front Arms
183
Checking the Front Arm Ball Joints
184
Checking the Front Shock Absorber Assemblies
184
Installing the Front Arms and Front Shock Absorber Assemblies
185
Rear Shock Absorber Assembly
186
Checking the Rear Shock Absorber Assembly
188
Checking the Relay Arm and Connecting Arm
188
Disposing of a Rear Shock Absorber Assembly
188
Handling the Rear Shock Absorber Assembly
188
Removing the Rear Shock Absorber Assembly
188
Installing the Rear Shock Absorber Assembly
189
Swingarm
190
Checking the Swingarm
192
Installing the Swingarm
192
Removing the Swingarm
192
Chain Drive
194
Checking the Drive Chain
195
Installing the Drive Chain
196
Engine
197
Engine Removal
200
Installing the Exhaust Pipe and Muffler
201
Installing the Engine
206
Cylinder Head
207
Checking the Cylinder Head
209
Removing the Cylinder Head
209
Checking the Camshaft Sprocket
210
Checking the Tappet Covers and Camshaft Sprocket Cover
210
Checking the Timing Chain Tensioner
210
Installing the Cylinder Head
211
Camshaft
213
Checking the Camshaft
214
Removing the Rocker Arms and Camshaft
214
Checking the Decompression System
215
Checking the Rocker Arms and Rocker Arm Shafts
215
Installing the Camshaft and Rocker Arms
215
Checking the Valves and Valve Guides
219
Removing the Valves
219
Valves and Valve Springs
219
Checking the Valve Seats
221
Checking the Valve Springs
222
Installing the Valves
223
Cylinder and Piston
225
Checking the Cylinder and Piston
226
Removing the Piston
226
Checking the Piston Rings
227
Checking the Piston Pin
228
Installing the Piston and Cylinder
228
Ac Magneto and Starter Clutch
230
Checking the Starter Clutch
232
Checking the Stator Coil and Crankshaft Position Sensor
232
Removing the Ac Magneto Rotor
232
Checking the Torque Limiter
233
Installing the Ac Magneto
233
Electric Starter
235
Checking the Starter Motor
237
Assembling the Starter Motor
238
Clutch
239
Checking the Friction Plates
243
Removing the Clutch
243
Removing the Primary Drive Gear and Balancer Driven Gear
243
Checking the Clutch Boss
244
Checking the Clutch Housing
244
Checking the Clutch Plates
244
Checking the Clutch Springs
244
Checking the Balancer Drive Gears
245
Checking the Pressure Plate
245
Checking the Primary Drive Gears
245
Checking the Pull Lever Shaft and Pull Rod
245
Installing the Primary Drive Gear and Balancer Driven Gears
245
Installing the Clutch
246
Oil Pump
249
Assembling the Oil Pump
251
Checking the Oil Pump
251
Shift Shaft
252
Checking the Shift Drum Segment
253
Checking the Shift Guide
253
Checking the Shift Shaft
253
Checking the Stopper Lever
253
Installing the Shift Lever
253
Installing the Shift Shaft
254
Crankcase
255
Checking the Bearings and Oil Seals
258
Checking the Oil Strainer
258
Checking the Timing Chain and Timing Chain Guide
258
Separating the Crankcase
258
Assembling the Crankcase
259
Checking the Crankcase
259
Crankshaft
261
Checking the Crankshaft
262
Installing the Crankshaft
262
Removing the Crankshaft
262
Transmission
264
Checking the Shift Drum Assembly
270
Checking the Shift Forks
270
Checking the Transmission
270
Assembling the Main Axle and Drive Axle
271
Installing the Transmission
271
Cooling System
273
Radiator
274
Checking the Radiator
275
Installing the Radiator
275
Thermostat
276
Checking the Thermostat
277
Installing the Thermostat
277
Water Pump
278
Assembling the Water Pump
280
Checking the Water Pump
280
Disassembling the Water Pump
280
Fuel System
283
Fuel Tank
284
Checking the Fuel Pump Body
285
Installing the Fuel Pump
285
Removing the Fuel Pump
285
Removing the Fuel Tank
285
Installing the Fuel Hose
286
Throttle Body
289
Adjusting the Throttle Position Sensor
290
Checking the Injector
290
Checking the Pressure Regulator Operation
290
Checking the Throttle Body
290
Installing the Throttle Body
291
Air Induction System
292
Checking the Air Induction System
296
Installing the Air Induction System
296
Electrical System
297
Circuit Diagram
300
Ignition System
300
Troubleshooting
302
Circuit Diagram
304
Electric Starting System
304
Starting Circuit Cut-Off System Operation
306
Troubleshooting
307
Charging System
310
Circuit Diagram
310
Troubleshooting
312
Circuit Diagram
314
Lighting System
314
Troubleshooting
316
Circuit Diagram
318
Signaling System
318
Troubleshooting
320
Circuit Diagram
324
Cooling System
324
Troubleshooting
326
Circuit Diagram
328
Fuel Injection System
328
Ecu Self-Diagnostic Function
330
Troubleshooting Method
332
Yamaha Diagnostic Tool
333
Troubleshooting Details
336
Circuit Diagram
354
Fuel Pump System
354
Troubleshooting
356
Electrical Components
358
Checking the Switches
360
Checking the Bulbs and Bulb Sockets
363
Checking the Fuses
364
Checking and Charging the Battery
365
Checking the Relays
368
Checking the Diode
369
Checking the Ignition Coil
369
Checking the Spark Plug Cap
369
Checking the Ignition Spark Gap
370
Checking the Crankshaft Position Sensor
371
Checking the Lean Angle Sensor
371
Checking the Starter Motor Operation
371
Checking the Rectifier/Regulator
372
Checking the Stator Coil
372
Checking the Fuel Sender
373
Checking the Speed Sensor
373
Checking the Coolant Temperature Sensor
374
Checking the Radiator Fan Motor
374
Checking the Radiator Fan Motor Circuit Breaker
374
Checking the Throttle Position Sensor
375
Checking the Air Induction System Solenoid
376
Checking the Intake Air Pressure Sensor
376
Checking the Intake Air Temperature Sensor
376
Troubleshooting
379
General Information
380
Incorrect Engine Idling Speed
380
Starting Failures
380
Troubleshooting
380
Faulty Clutch
381
Faulty Gear Shifting
381
Jumps out of Gear
381
Poor Medium-And-High-Speed Performance
381
Shift Pedal Does Not Move
381
Faulty Shock Absorber Assembly
382
Overcooling
382
Overheating
382
Poor Braking Performance
382
Unstable Handling
382
Faulty Lighting or Signaling System
383
Self-Diagnostic Function and Diagnostic Code Table
384
4
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Yamaha RAPTOR YFM700RF 2015 Specifications
General
Brand
Yamaha
Model
RAPTOR YFM700RF 2015
Category
Offroad Vehicle
Language
English
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