Yamaha YFM700RV 2009 User manual

YFM700RV
SERVICE MANUAL
1S3-28197-E0

EBS00000
YFM700RV
SERVICE MANUAL
©2005 by Yamaha Motor Co., Ltd.
First edition, May 2005
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

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. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe
and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications 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 means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the vehicle operator, a bystander or a person checking or repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

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. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify 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 4is provided for removal and disassembly jobs.
2. Numbers 5are 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 way by the use of symbol marks
6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8are given in addition
to the exploded diagram and the job instruction chart.

EBS00006
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1to 9indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Cooling system
6Fuel injection system
7Chassis
8Electrical
9Troubleshooting
Symbols 0to Gindicate the following.
0Serviceable with engine mounted
AFilling fluid
BLubricant
CSpecial tool
DTightening torque
EWear limit, clearance
FEngine speed
GElectrical data (Ω, V, A)
Symbols Hto Min the exploded diagrams
indicate the types of lubricants and lubrication
points.
HApply engine oil
IApply gear oil
JApply molybdenum disulfide oil
KApply wheel bearing grease
LApply lithium-soap-based grease
MApply molybdenum disulfide grease
Symbols Nto Oin the exploded diagrams
indicate where to apply a locking agent Nand
when to install a new part O.
NApply the locking agent (LOCTITE®)
OReplace
12
34
56
78
90
AB
CD
EFG
HIJ
KLM
NO
GEN
INFO SPEC
CHK
ADJ ENG
COOL
FI
CHAS
–+
ELEC
TRBL
SHTG
T
R
.
.
EGM
BLS M
LT
New

EBS00008
TABLE OF CONTENTS
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
–+

GEN
INFO
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 ....................................................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

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

1 - 2
GEN
INFO
FEATURES
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. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the
combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies with the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating con-
ditions of the engine.
As the requirements 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 engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions.
1Engine trouble warning light
2Ignition coil
3Fuel tank
4Fuel hose
5Fuel pump
6Intake air pressure sensor
7Lean angle sensor
8Battery
9Intake air temperature sensor
0ECU (electronic control unit)
AAir filter case
BRelay unit (fuel pump relay)
CSpeed sensor
DThrottle position sensor
ECrankshaft position sensor
FFuel injector
GCoolant temperature sensor
HSpark plug
12 345 6 7890A B
C
D
EFGH

1 - 3
GEN
INFO
FEATURES
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/cm2, 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. Therefore, the longer the length of time the fuel injector is energized (injection duration), the
greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector
is energized (injection duration), the lesser the volume of fuel that is supplied.
The 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 sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times
in accordance with the driving conditions.
Illustration is for reference only.
1Fuel pump
2Fuel injector
3Ignition coil
4ECU (electronic control unit)
5Coolant temperature sensor
6Crankshaft position sensor
7Intake air pressure sensor
8Throttle body
9Intake air temperature sensor
0Air filter case
AThrottle position sensor
BSpeed sensor
ÈFuel system
ÉAir system
ÊControl system
0
2
1
3
B
5
6
7
8
9
È
É
Ê
A
4

1 - 4
GEN
INFO
FEATURES
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 5to 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. The proper clearance is automatically maintained at all times, ensuring stable braking
performance when parking the vehicle.
1Parking brake arm
2Parking brake shaft
3Adjusting bolt
4Adjusting bolt sleeve
5Adjusting bolt
6Nut
7Brake caliper piston
1
2
3
4567

1 - 5
GEN
INFO
FEATURES
Parking Brake Operation
1Parking brake arm
2Parking brake shaft
3Adjusting bolt
4Adjusting bolt sleeve
5Brake caliper piston
6Brake 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 2and the
adjusting bolt 3is 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 6is pushed against the brake disc.
When the brake pad wears, the clearance between the brake caliper piston 5and the brake pad
becomes larger and the force applied to the brake pad becomes weaker.
If this occurs, the self-adjusting parking brake mechanism adjusts automatically to achieve the
proper clearance.
1
2
3
456

1 - 6
GEN
INFO
FEATURES
Parking Brake Operation
1Brake caliper piston
2Nut
3Adjusting bolt
4Adjusting bolt sleeve
When the brake pedal is operated, the brake fluid pressure in the master cylinder increases and the
brake caliper piston 1and the nut 2are 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.
When the movement of the nut is greater than the backlash between the nut and the adjusting bolt,
the parking brake adjusts automatically.
The amount of the adjustment varies with brake fluid pressure. Operating the parking 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 Èwill be required to pull the adjusting bolt.
The force to pull the adjusting bolt will be turned into the rotation torque Éby the shape of the
threads of the nut and the adjusting bolt.
3. At this time, the clutch torque Êbetween the adjusting bolt and the adjusting bolt sleeve 4will
decrease depending on the force required to pull the adjusting bolt.
When the rotation torque exceeds the clutch torque, the adjusting bolt rotates and the clearance
between the brake caliper piston and the brake pad decreases by the movement of the threads of
the nut and the adjusting bolt.
12
3
4
È
É
Ê

1 - 7
GEN
INFO
IMPORTANT INFORMATION
EBS00013
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
“mated”through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassembly, clean 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, but inferior in quality.
EBS00015
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly properly oil all mating
parts and bearings, and lubricate the oil
seal lips with grease.

1 - 8
GEN
INFO
IMPORTANT INFORMATION
EBS00016
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1and 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-
facturer’s marks or numbers are visible. 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.
1Oil seal
CAUTION:
_
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
1Bearing
EBS00018
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2is positioned opposite
the thrust 3that the circlip receives.
4Shaft

1 - 9
GEN
INFO
IMPORTANT INFORMATION
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 →Connect and disconnect sev-
eral times.
3. Check:
•all connections
Loose connection →Connect properly.
NOTE:
_
If the pin 1on 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
available at most part stores.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

1 - 10
GEN
INFO
SPECIAL TOOLS
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. In such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
For US and CDN
P/N. YM-, YU-, YS-, YK-, ACC-
Except for US 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 wrench
Spanner wrench
This tool is used to loosen or tighten the
rear shock absorber locknuts.
90890-01274
YU-90058
YU-90059
Crankshaft installer pot
Installer pot
Pot installer
This tool is used to install the crankshaft.
90890-01275
YU-90060
Crankshaft installer bolt
Bolt
This tool is used to install the crankshaft.

1 - 11
GEN
INFO
SPECIAL TOOLS
90890-04130
YM-04059
Adapter (M16)
Adapter #13
This tool is used to install the crankshaft.
90890-04081
YM-91044
Spacer (crankshaft installer)
Pot spacer
This tool is used to install the crankshaft.
90890-01304
YU-01304
Piston pin puller set
Piston pin puller
This tool is used to remove the piston pin.
90890-01311
YM-08035-A
Tappet adjusting tool
Valve adjuster (3 mm & 4 mm)
This tool is necessary for adjusting the
valve clearance.
90890-01325
YU-24460-01
Radiator cap tester
Radiator pressure tester
This tool is used to check the cooling sys-
tem.
90890-01352
YU-33984
Radiator cap tester adapter
Radiator pressure tester adapter
This tool is used to check the cooling sys-
tem.
90890-01327
YM-01327
Damper rod holder (30 mm)
This tool is needed to loosen and tighten
the steering stem bearing retainer.
90890-01404
YM-01404
Flywheel puller
This tool is used to remove the A.C.mag-
neto rotor.
Tool No. Tool name/Function Illustration

1 - 12
GEN
INFO
SPECIAL TOOLS
90890-01443
YU-33975
Steering nut wrench
Spanner wrench
This tool is needed to loosen and tighten
the front shock absorber and rear shock
absorber locknuts.
90890-01474
YM-01474
Ball joint remover
This tool is used to remove or install the
ball joints.
90890-01480
YM-01480
Ball joint remover attachment set
Ball joint adapter set
These tools are used to remove or install
the ball joints.
90890-01498
YM-37134
Rear axle nut wrench (46 mm)
Axle nut wrench (46 mm)
This tool is needed to loosen or tighten the
rear axle nut.
90890-01701
YS-01880-A
Sheave holder
Primary clutch holder
This tool is used to hold the A.C. magneto
rotor when loosen or tighten the A.C. mag-
neto rotor nut.
90890-03079
YM-34483
Thickness gauge
Narrow gauge set
This tool is used to measure the valve
clearance.
90890-03081
YU-33223
Compression gauge
Engine compression tester
This tool is used to measure engine com-
pression.
90890-04082
Extension
This tool is used to measure engine com-
pression.
Tool No. Tool name/Function Illustration

1 - 13
GEN
INFO
SPECIAL TOOLS
90890-03112
YU-03112-C
Pocket tester
Analog pocket tester
This instrument is needed for checking the
electrical system.
90890-03141
YU-03141
Timing light
Inductive clamp timing light
This tool is necessary for checking ignition
timing.
90890-03153
YU-03153
Pressure gauge
This tool is used to measure fuel pressure.
90890-03176
YM-03176
Fuel pressure adapter
This tool is used to measure fuel pressure.
90890-03174
YU-A1927
Digital circuit tester
Model 88 Multimeter with tachometer
This tool is used to check the electrical
system.
90890-03182
YU-03182
FI diagnostic tool
This tool is used to check the diagnosis.
90890-04019
YM-04019
Valve spring compressor
This tool is needed to remove and install
the valve assemblies.
90890-01243
YM-01253-1
Valve spring compressor attachment
Valve spring compressor adapter (26 mm)
This tool is needed to remove and install
the valve assemblies.
Tool No. Tool name/Function Illustration