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Raptor 90 YFM90RA 2011
Yamaha Raptor 90 YFM90RA 2011 User Manual
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SERVICE MANUAL
YFM90R
A
43D-F8197-1
2
LIT-11616-2
4
-1
6
201
1
2
Table of Contents
Default Chapter
8
Table of Contents
8
Chapter 1 General Information
16
Machine Identification
16
Vehicle Identification Number
16
Model Label
16
Important Information
17
Preparation for Removal and Disassembly
17
Replacement Parts
17
Gaskets, Oil Seals and O-Rings
17
Lock Washers/Plates and Cotter Pins
18
Bearings and Oil Seals
18
Circlips
18
Checking the Connections
19
Special Tools
20
Specifications
23
General Specifications
23
Engine Specifications
26
Chapter 2 Specifications
30
Engine
32
Chassis Specifications
33
Chapter 6 Chassis
34
Electrical Specifications
35
Tightening Torques
37
Engine Tightening Torques
37
Chassis Tightening Torques
38
How to Use the Conversion Table
40
General Tightening Torque Specifications
40
Lubrication Points and Lubricant Types
41
Engine
41
Oil Flow Diagrams
43
Cable Routing
44
Chapter 3 Periodic Checks and Adjustments
53
Introduction
53
Periodic Maintenance/Lubrication
53
Seat, Fenders and Fuel Tank
55
Seat and Front Panel
55
Front Fender
56
Rear Fender and Footrest Boards
57
Fuel Tank
59
Engine
60
Adjusting the Valve Clearance
60
Adjusting Valve Clearance
60
Adjusting the Engine Idling Speed
62
Adjusting the Throttle Lever Free Play
63
Adjusting the Speed Limiter
64
Checking the Spark Plug
65
Checking the Ignition Timing
66
Measuring the Compression Pressure
67
Checking the Engine Oil Level
69
Changing the Engine Oil
70
Cleaning the Air Filter Element
71
Cleaning the Spark Arrester
72
Chassis
74
Checking the Front Brake Shoes
74
Adjusting the Front Brake
74
Adjusting the Parking Brake
75
Checking the Rear Brake Fluid Level
76
Checking the Rear Brake Pads
77
Checking the Brake Hose
77
Bleeding the Hydraulic Brake System
77
Changing the Final Transmission Oil
79
Adjusting the Drive Chain Slack
79
Checking the Steering System
81
Adjusting the Toe-In
82
Checking the Front and Rear Shock Absorbers
83
Adjusting the Shock Absorbers
84
Checking the Tires
85
Checking the Tires
86
Checking the Wheels
87
Checking and Lubricating the Cables
88
Lubricating the Levers, Steering Shaft and Steering Knuckles
88
Electrical System
89
Checking and Charging the Battery
89
Checking the Fuses
96
Chapter 4 Engine
98
Exhaust Pipe/Muffler, Breather Hose and Leads
98
Engine Mounting Bolts
99
Removing the Engine
100
Installing the Engine
100
Cylinder Head
101
Removing the Cylinder Head
101
Checking the Camshaft Sprocket
104
Checking the Cyl. Head Cover Assy
104
Checking the Timing Chain Guides
104
Checking the Timing Chain Tensioner Assembly
104
Checking the Cylinder Head
105
Installing the Cylinder Head
106
Camshaft, Rocker Arms and Valves
108
Removing the Rocker Arms and Camshaft
109
Removing the Valves and Valve Springs
109
Checking the Camshaft
110
Checking the Rocker Arms and Rocker Arm Shafts
110
Checking the Valves and Valve Springs
112
Installing the Valves and Valve Springs
116
Installing the Camshaft and Rocker Arms
117
Cylinder and Piston
118
Removing the Piston
119
Checking the Cylinder and Piston
119
Checking the Piston Rings
121
Checking the Piston Pin
122
Installing the Piston
123
Installing the Cylinder
124
C.D.I. Magneto
125
Removing the C.D.I. Magneto Rotor
126
Checking the Pickup Coil/Stator Assembly
127
Installing the C.D.I. Magneto Rotor
127
Belt Drive
128
Crankcase Cover
128
Kickstarter
128
Installing the Kickstarter
130
V-Belt, Clutch, Primary and Secondary Sheave
131
Disassembling the Secondary Sheave
132
Removing the Primary Sheave
133
Removing the Secondary Sheave and V-Belt
133
Disassembling the Secondary Sheave
134
Checking the Clutch Shoe
134
Checking the V-Belt
135
Checking the Primary Sheave
135
Checking the Primary Sheave Weights
135
Checking the Slider
136
Checking the Secondary Sheave
136
Assembling the Primary Sheave
137
Assembling the Secondary Sheave
138
Installing the Belt Drive
139
Starter Clutch and Starter Motor
141
Checking the Starter Wheel Gear
142
Oil Pump
143
Checking the Oil Pump
144
Installing the Oil Pump
145
Crankcase and Crankshaft
146
Separating the Crankcase
146
Removing the Crankshaft Assembly
146
Checking the Timing Chain and Timing Chain Guides
148
Checking the Crankshaft and Connecting Rod
149
Installing the Crankshaft
150
Assembling the Crankcase
151
Transmission
152
Checking the Transmission
153
Chapter 5 Carburetor
154
Disassembling the Carburetor
155
Checking the Carburetor
157
Assembling the Carburetor
159
Installing the Carburetor
160
Measuring and Adjusting the Fuel Level
161
Front and Rear Wheels
162
Front Wheels
162
Rear Wheels
163
Checking the Wheels
164
Checking the Front Wheel Hubs
164
Checking the Rear Wheel Hubs
165
Installing the Wheel Hubs
165
Installing the Front Wheels
166
Installing the Rear Wheels
166
Front Brakes
167
Removing the Front Brakes
168
Checking the Front Brake Shoe Plates
168
Checking the Front Brake Shoes
168
Checking the Front Brake Drums
169
Installing the Front Brakes
170
Rear Axle and Rear Axle Hub
172
Removing the Rear Axle
174
Checking the Rear Axle
175
Checking the Driven Sprocket
175
Checking the Brake Disc
175
Installing the Driven Sprocket
175
Installing the Rear Axle
176
Rear Brakes
177
Rear Brake Pads
177
Replacing the Rear Brake Pads
178
Rear Brake Master Cylinder
180
Checking the Master Cylinder
181
Assembling the Rear Brake Master Cylinder
181
Installing the Rear Brake Master Cylinder
182
Rear Brake Caliper
184
Removing the Parking Brake Cable
186
Checking the Rear Brake Caliper
186
Installing the Rear Brake Caliper
187
Steering System
189
Handlebar
189
Removing the Handlebar Grips
191
Removing the Rear Brake Switch
191
Checking the Handlebar
191
Installing the Handlebar
192
Installing the Handlebar Grips
192
Installing the Rear Brake Master Cylinder
193
Installing the Front Brake Lever Assembly
193
Installing the Parking Brake Lever
194
Steering Stem
195
Removing the Steering Stem
195
Checking the Steering Stem
196
Installing the Lower Handlebar Holder
197
Installing the Steering Stem
197
Installing the Lock Washer
197
Tie-Rods and Steering Knuckles
198
Removing the Tie-Rods
198
Removing the Steering Knuckles
199
Checking the Tie-Rods
199
Checking the Steering Knuckles
199
Installing the Tie-Rods
200
Front Arms and Front Shock Absorber Assemblies
201
Front Arms and Front Shock Absorber
201
Assemblies
201
Removing the Front Arms
202
Checking the Front Arms
202
Checking the Front Shock Absorbers
202
Checking the Ball Joints
203
Installing the Front Arms
203
Rear Shock Absorber, Swingarm and Drive Chain
204
Drive Chain
205
Checking the Rear Shock Absorber
206
Removing the Rear Shock Absorber
206
Removing the Swingarm
206
Checking the Swingarm
207
Checking the Drive Chain
208
Installing the Drive Chain
209
Installing the Drive Sprocket
209
Chapter 7
210
Electrical Components
210
Checking Switch Continuity
211
Checking the Switches
212
Ignition System
213
Circuit Diagram
213
Troubleshooting
214
Electric Starting System
218
Circuit Diagram
218
Starting Circuit Operation
219
Starter Motor
219
Checking the Starter Motor
223
Assembling the Starter Motor
224
Charging System
225
Circuit Diagram
225
Troubleshooting
228
Starting Failure/Hard Starting
228
Chapter 8
228
Fuel System
228
Electrical System
228
Compression System
229
Poor Idle Speed Performance
229
Poor Medium and High-Speed Performance
229
Faulty Clutch
230
Engine Operates but Vehicle will Not Move
230
Poor Starting Performance
230
Poor Speed Performance
230
Overheating
230
Faulty Brake
231
Poor Braking Effect
231
Shock Absorber Malfunction
231
Malfunction
231
Unstable Handling
231
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Yamaha Raptor 90 YFM90RA 2011 Specifications
General
Brand
Yamaha
Model
Raptor 90 YFM90RA 2011
Category
Offroad Vehicle
Language
English
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