2004-2006 Yamaha Pro Hauler 700 Service & Repair Manual

LIT-11616-17-54 JW4-F8197-10 YXP700 YXP1000 SERVICE MANUAL

EBS00001 YXP700/YXP1000 SERVICE MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. First Edition, January 2004 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-11616-17-54

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 vehicles 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, passenger, a bystander, or a person checking or repairing the vehicle. A CAUTION indicates special precautions that must be taken to avoid dam- age 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 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 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 7 accompanies 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 8 are given in addition to the exploded diagram and the job instruction chart.

EBS00005 SYMBOLS The following symbols are not relevant to every machine. Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Fuel system 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting Symbols 0 to G indicate the following. 0 Serviceable with engine mounted A Filling fluid B Lubricant C Special tool D 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 locking agent N and when to install a new part O. N Apply the locking agent (LOCTITE ® ) O Replace 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O GEN INFO SPEC CHK ADJ ENG FUEL DRIV CHAS – + ELEC TRBL SHTG T R . . E G M B LS M LT New

EBS00007 TABLE OF CONTENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 ENGINE ENG 4 FUEL SYSTEM FUEL 5 DRIVE TRAIN DRIV 6 CHASSIS CHAS 7 ELECTRICAL ELEC 8 TROUBLESHOOTING TRBL SHTG 9 – +

CONTENTS CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION............................................................................ 1-1 UTILITY VEHICLE SERIAL NUMBER ...................................................... 1-1 ENGINE SERIAL NUMBER ...................................................................... 1-1 IMPORTANT INFORMATION ......................................................................... 1-2 PREPARATION FOR REMOVAL PROCEDURES ................................... 1-2 REPLACEMENT PARTS........................................................................... 1-2 GASKETS, OIL SEALS AND O-RINGS .................................................... 1-2 LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-3 BEARINGS AND OIL SEALS .................................................................... 1-3 CIRCLIPS .................................................................................................. 1-3 CHECKING OF CONNECTIONS .................................................................... 1-4 SPECIAL TOOLS ............................................................................................ 1-5 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ........................................................................ 2-1 ENGINE SPECIFICATIONS ............................................................................ 2-5 TRANSMISSION SPECIFICATIONS ............................................................ 2-10 CHASSIS SPECIFICATIONS ........................................................................ 2-11 ELECTRICAL SPECIFICATIONS ................................................................. 2-12 TIGHTENING TORQUES .............................................................................. 2-13 ENGINE TIGHTENING TORQUES ......................................................... 2-13 CHASSIS TIGHTENING TORQUES ....................................................... 2-14 HOW TO USE THE CONVERSION TABLE.................................................. 2-17 GENERAL TIGHTENING TORQUE SPECIFICATIONS ............................... 2-17

MAIN METERING SYSTEM .......................................................................... 2-18 FLOAT SYSTEM ........................................................................................... 2-19 CABLE ROUTING (YXP700)......................................................................... 2-20 CABLE ROUTING (YXP1000)....................................................................... 2-27 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION.............................................................................................. 3-1 PERIODIC MAINTENANCE/LUBRICATION .................................................. 3-1 ENGINE ........................................................................................................... 3-3 ADJUSTING THE VALVE CLEARANCE .................................................. 3-3 ADJUSTING THE CARBURETOR ............................................................ 3-5 CHECKING THE ACCELERATOR STOP SWITCH/ADJUSTING THE ACCELERATOR PEDAL POSITION ................................................ 3-6 ADJUSTING THE THROTTLE CABLES ................................................... 3-7 ADJUSTING THE SPEED LIMITER.......................................................... 3-9 ADJUSTING THE STARTER CABLE ..................................................... 3-10 CHECKING THE SPARK PLUG ............................................................. 3-12 MEASURING THE COMPRESSION PRESSURE .................................. 3-12 CHECKING THE ENGINE OIL LEVEL.................................................... 3-14 CHANGING THE ENGINE OIL ............................................................... 3-15 CLEANING THE AIR FILTER.................................................................. 3-16 CHECKING THE FUEL FILTER .............................................................. 3-18 CHECKING THE FUEL HOSES.............................................................. 3-18 CHECKING THE CYLINDER HEAD BREATHER HOSE ....................... 3-18 CHECKING THE V-BELT ........................................................................ 3-18 CHECKING THE PRIMARY SHEAVE AND SECONDARY SHEAVE .... 3-19 LUBRICATING THE PRIMARY SHEAVE AND SECONDARY SHEAVE .................................................................................................. 3-20

CHASSIS ....................................................................................................... 3-21 ADJUSTING THE BRAKE CABLES........................................................ 3-21 ADJUSTING THE PARKING BRAKE...................................................... 3-22 CHECKING THE FRONT AND REAR BRAKE SHOE LINING ............... 3-23 ADJUSTING THE SHIFTING CABLE ..................................................... 3-25 CHECKING THE TRANSMISSION OIL LEVEL ...................................... 3-26 CHANGING THE TRANSMISSION OIL .................................................. 3-26 CHECKING THE STEERING SYSTEM (YXP700) .................................. 3-27 CHECKING THE STEERING SYSTEM (YXP1000) ................................ 3-28 ADJUSTING THE TOE-IN ....................................................................... 3-31 CHECKING THE REAR AXLE ................................................................ 3-32 CHECKING THE FRONT AND REAR SHOCK ABSORBERS ............... 3-33 CHECKING THE TIRES .......................................................................... 3-33 CHECKING THE WHEELS ..................................................................... 3-35 CHECKING AND LUBRICATING THE CABLES .................................... 3-36 LUBRICATING THE PEDAL, ETC. ......................................................... 3-36 ELECTRICAL ................................................................................................ 3-37 CHECKING AND CHARGING THE BATTERY ....................................... 3-37 CHECKING THE FUSES ........................................................................ 3-42 ADJUSTING THE STARTER BELT ........................................................ 3-43 ADJUSTING THE HEADLIGHT BEAM ................................................... 3-44 CHANGING THE HEADLIGHT BULB ..................................................... 3-45 CHAPTER 4 ENGINE ENGINE REMOVAL ........................................................................................ 4-1 MUFFLER.................................................................................................. 4-1 LEADS AND ENGINE MOUNTING BOLTS .............................................. 4-2 CYLINDER HEAD AND ROCKER ARMS....................................................... 4-3 REMOVING THE ROCKER ARMS ........................................................... 4-5 REMOVING THE CYLINDER HEAD......................................................... 4-5 CHECKING THE PUSH RODS ................................................................. 4-5 CHECKING THE CYLINDER HEAD ......................................................... 4-6 CHECKING THE ROCKER ARMS............................................................ 4-7 INSTALLING THE CYLINDER HEAD ....................................................... 4-8 INSTALLING THE ROCKER ARMS.......................................................... 4-8 VALVES AND VALVE SPRINGS .................................................................... 4-9 REMOVING THE VALVES AND VALVE SPRINGS ............................... 4-10 CHECKING THE VALVES AND VALVE SPRINGS ................................ 4-10 INSTALLING THE VALVES AND VALVE SPRINGS .............................. 4-15 FLYWHEEL MAGNETO ................................................................................ 4-16 REMOVING THE FLYWHEEL MAGNETO ............................................. 4-17 INSTALLING THE FLYWHEEL MAGNETO ............................................ 4-17

CRANKCASE COVER, CAMSHAFT, AND BALANCER ............................. 4-19 REMOVING THE CRANKCASE COVER................................................ 4-21 CHECKING THE CAMSHAFT................................................................. 4-21 CHECKING THE VALVE LIFTER ........................................................... 4-22 CHECKING THE BALANCER SHAFT .................................................... 4-22 CHECKING THE BEARINGS .................................................................. 4-23 INSTALLING THE BALANCER AND CAMSHAFT.................................. 4-23 INSTALLING THE CRANKCASE COVER .............................................. 4-23 PISTON, CONNECTING ROD, CRANKSHAFT, AND CRANKCASE .......... 4-24 REMOVING THE PISTON ...................................................................... 4-26 CHECKING THE CYLINDER AND PISTON ........................................... 4-26 CHECKING THE PISTON RINGS........................................................... 4-28 CHECKING THE PISTON PIN ................................................................ 4-29 CHECKING THE CRANKSHAFT ............................................................ 4-30 INSTALLING THE PISTON ..................................................................... 4-31 CHAPTER 5 FUEL SYSTEM FUEL PUMP AND FUEL TANK ...................................................................... 5-1 (YXP700) ................................................................................................... 5-1 (YXP1000) ................................................................................................. 5-2 CHECKING THE FUEL PUMP FUEL SUPPLY ........................................ 5-3 CHECKING THE FUEL PUMP .................................................................. 5-3 CARBURETOR................................................................................................ 5-6 DISASSEMBLING THE CARBURETOR ................................................. 5-10 CHECKING THE CARBURETOR ........................................................... 5-11 ASSEMBLING THE CARBURETOR ....................................................... 5-12 CHAPTER 6 DRIVE TRAIN PRIMARY SHEAVE......................................................................................... 6-1 REMOVING THE PRIMARY SHEAVE ...................................................... 6-3 DISASSEMBLING THE PRIMARY SHEAVE ............................................ 6-4 CHECKING THE PRIMARY SHEAVE ...................................................... 6-5 ASSEMBLING THE PRIMARY SHEAVE .................................................. 6-5 INSTALLING THE PRIMARY SHEAVE .................................................... 6-7 SECONDARY SHEAVE .................................................................................. 6-8 REMOVING THE SECONDARY SHEAVE ............................................... 6-9 CHECKING THE SECONDARY SHEAVE .............................................. 6-10 INSTALLING THE SECONDARY SHEAVE ............................................ 6-11

2004-2006 Yamaha Pro Hauler 700 Service & Repair Manual

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