Yamaha YFM700RV Service Manual
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Yamaha YFM700RV Service Manual

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YFM700RV
SERVICE MANUAL
LIT-11616-19-13
1S3-28197-10

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Summary of Contents for Yamaha YFM700RV

  • Page 1 YFM700RV SERVICE MANUAL LIT-11616-19-13 1S3-28197-10...
  • Page 2 EBS00001 YFM700RV SERVICE MANUAL ©2005 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: Specifications

    EBS00002 NOTICE 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 vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair.

  • Page 4: How To Use This Manual

    EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.

  • Page 5: Tightening Torques

    EBS00006 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Fuel injection system 7 Chassis COOL 8 Electrical...
  • Page 6 EBS00008 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM CHASSIS CHAS – ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...

  • Page 7: Table Of Contents

    CONTENTS CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION................1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 SELF-ADJUSTING PARKING BRAKE MECHANISM....... 1-4 IMPORTANT INFORMATION ................. 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................1-7 GASKETS, OIL SEALS AND O-RINGS ............

  • Page 8: Periodic Checks And Adjustments

    LUBRICATION POINTS AND LUBRICANT TYPES ........2-23 ENGINE....................2-23 COOLANT FLOW DIAGRAMS ..............2-24 OIL FLOW DIAGRAMS ................. 2-28 CABLE ROUTING ..................2-33 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ......................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART......
  • Page 9 CHASSIS ....................... 3-36 ADJUSTING THE FRONT BRAKE ............3-36 ADJUSTING THE REAR BRAKE............3-36 ADJUSTING THE PARKING BRAKE............3-37 CHECKING THE BRAKE FLUID LEVEL..........3-38 CHECKING THE FRONT BRAKE PADS ..........3-39 CHECKING THE REAR BRAKE PADS ..........3-39 ADJUSTING THE REAR BRAKE LIGHT SWITCH .........3-40 CHECKING THE BRAKE HOSES............
  • Page 10 ROCKER ARMS AND CAMSHAFT ..............4-17 REMOVING THE ROCKER ARMS AND CAMSHAFT......4-19 CHECKING THE CAMSHAFT..............4-19 CHECKING THE DECOMPRESSION SYSTEM........4-20 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ..4-21 INSTALLING THE CAMSHAFT AND ROCKER ARMS ......4-22 VALVES AND VALVE SPRINGS..............4-24 REMOVING THE VALVES AND VALVE SPRINGS .......4-25 CHECKING THE VALVES AND VALVE SPRINGS ........4-26 INSTALLING THE VALVES AND VALVE SPRINGS ......4-31...

  • Page 11: Cooling System

    SHIFT SHAFT....................4-63 CHECKING THE SHIFT SHAFT ............. 4-65 CHECKING THE STOPPER LEVER ............4-65 CHECKING THE SHIFT GUIDE..............4-65 CHECKING THE SHIFT DRUM SEGMENT ...........4-65 INSTALLING THE SHIFT LEVER ............4-65 INSTALLING THE SHIFT SHAFT ............4-66 CRANKCASE ....................4-67 CRANKCASE BEARINGS............... 4-69 SEPARATING THE CRANKCASE............

  • Page 12: Fuel Injection System

    CHAPTER 6 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM................6-1 CIRCUIT DIAGRAM .................. 6-2 ECU’S SELF-DIAGNOSTIC FUNCTION........... 6-4 SELF-DIAGNOSTIC FUNCTION TABLE ..........6-5 TROUBLESHOOTING CHART ..............6-6 DIAGNOSTIC MODE ................6-7 TROUBLESHOOTING DETAILS ............6-11 CHECKING THE SPEED SENSOR ............6-25 CHECKING THE INTAKE AIR PRESSURE SENSOR ......6-26 CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....6-27 THROTTLE BODY..................
  • Page 13 FRONT AND REAR BRAKES............... 7-14 FRONT BRAKE PADS ................7-14 REAR BRAKE PADS................7-15 REPLACING THE FRONT BRAKE PADS ..........7-16 REPLACING THE REAR BRAKE PADS..........7-18 FRONT BRAKE MASTER CYLINDER............7-20 REAR BRAKE MASTER CYLINDER ............7-22 REMOVING THE FRONT BRAKE LIGHT SWITCH .......7-25 CHECKING THE MASTER CYLINDERS..........

  • Page 14: Electrical

    REAR SHOCK ABSORBER AND RELAY ARM ..........7-60 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER..7-62 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER ................7-62 REMOVING THE REAR SHOCK ABSORBER ........7-63 CHECKING THE REAR SHOCK ABSORBER........7-63 CHECKING THE RELAY ARM AND CONNECTING ARM.....7-63 INSTALLING THE RELAY ARM AND CONNECTING ARM....

  • Page 15: Electrical System

    CHARGING SYSTEM..................8-25 CIRCUIT DIAGRAM ................8-25 TROUBLESHOOTING ................8-26 LIGHTING SYSTEM ..................8-28 CIRCUIT DIAGRAM ................8-28 TROUBLESHOOTING ................8-29 CHECKING THE LIGHTING SYSTEM............8-30 SIGNALING SYSTEM ...................8-33 CIRCUIT DIAGRAM ................8-33 TROUBLESHOOTING ................8-34 CHECKING THE SIGNALING SYSTEM ..........8-35 COOLING SYSTEM..................8-42 CIRCUIT DIAGRAM ................8-42 TROUBLESHOOTING ................8-43 CHAPTER 9 TROUBLESHOOTING...
  • Page 16 FAULTY BRAKE ..................... 9-4 POOR BRAKING 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: Vehicle Identification

    VEHICLE IDENTIFICATION INFO EBS00009 GENERAL INFORMATION VEHICLE IDENTIFICATION EBS00010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. EBS00011 MODEL LABEL The model label 1 is affixed to the air filter case cover. This information will be needed to order spare parts.

  • Page 18: Features

    FEATURES INFO EAS20170 FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 19: Fi System

    FEATURES INFO FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm , 46.1 psi). Accord- ingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 20: Self-Adjusting Parking Brake Mechanism

    FEATURES INFO SELF-ADJUSTING PARKING BRAKE MECHANISM Usually, for vehicles equipped with a parking brake that must be adjusted manually, it is necessary to adjust the adjusting bolt 5 to achieve the proper clearance between 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.
  • Page 21 FEATURES INFO Parking Brake Operation 1 Parking brake arm 4 Adjusting bolt sleeve 2 Parking brake shaft 5 Brake caliper piston 3 Adjusting bolt 6 Brake pad When the parking brake is operated, the parking brake cable turns the parking brake arm 1. The rotation of the parking brake arm is changed to axial thrust in the parking brake shaft 2 and the adjusting bolt 3 is pushed against the adjusting bolt sleeve 4.
  • Page 22 FEATURES INFO Parking Brake Operation È É Ê 1 Brake caliper piston 3 Adjusting bolt 2 Nut 4 Adjusting bolt sleeve When the brake pedal is operated, the brake fluid pressure in the master cylinder increases and the brake caliper piston 1 and the nut 2 are pushed. When there is proper clearance between the brake caliper piston and the brake pad, no other parts move because the movement of the brake caliper piston and the nut is absorbed by the backlash of the threads of the nut and the adjusting bolt 3.

  • Page 23: Important Information

    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, but inferior in quality.

  • Page 24: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EBS00016 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EBS00017 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu-...

  • Page 25: Checking The Connections

    IMPORTANT INFORMATION INFO EBS00019 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...

  • Page 26: Special Tools

    SPECIAL TOOLS INFO EBS00021 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country.

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