Yamaha Raptor 700 2005-2009 Service Repair Workshop Manual
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This manual covers the Raptor 700, a high-performance sport ATV, including Standard and SE models from the 2005 through 2009 production years. Renowned for its powerful 686cc fuel-injected engine, lightweight aluminum frame, and long-travel suspension, the Raptor 700 is engineered for agility, robust power delivery, and exceptional handling across demanding off-road terrains. Its design prioritizes performance and rider control, making it a benchmark in the sport ATV segment and a popular choice for enthusiasts and racers alike. This comprehensive service repair workshop manual provides detailed guidance for all aspects of maintaining and repairing your Raptor 700. It encompasses routine maintenance procedures, in-depth troubleshooting guides, complete engine and transmission disassembly/reassembly instructions, and coverage of all major systems, including fuel, ignition, cooling, brakes, suspension, and electrical components. With clear step-by-step instructions, technical specifications, and detailed wiring diagrams, this manual is an essential resource for owners and technicians seeking to ensure the optimal performance, reliability, and longevity of their vehicle. 🏷️ Basic Information Identification Make: Yamaha Model: Raptor 700 Model Variant: Standard/SE Vehicle Type: ATV (All-Terrain Vehicle) Generation Generation: 1st Generation Codes Chassis Code: Various (e.g., YFM700) 👋 Introduction Market Position Market Segment: High-performance sport ATV Target Audience: Sport ATV enthusiasts, recreational riders, off-road racers, mechanics Competitive Analysis Key Competitors: Honda TRX450R, Suzuki LT-R450, Polaris Outlaw 500/525 Key Features Engine Technology: Yamaha's fuel-injected, liquid-cooled, DOHC, 4-valve, 4-stroke engine Chassis Design: Lightweight and durable aluminum frame, long-travel suspension Performance Focus: Designed for agility, power, and handling in demanding off-road conditions Manual Value Proposition Benefit: Enables owners and technicians to perform all necessary maintenance and repairs, ensuring optimal performance and longevity of the vehicle 📋 Manual Details Coverage Areas Years Covered: 2005, 2006, 2007, 2008, 2009 Regions Covered: Global (assuming North American specifications are primary) Page Count Estimated Page Count: 500+ Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, repair, and reassembly of engine components (cylinder, piston, crankshaft, camshaft, valve train, etc.) Fuel System: Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), carburetor (if applicable to early models), fuel tank, lines, and filters Ignition System: CDI unit, ignition coil, spark plug, wiring diagrams Cooling System: Radiator, fan, water pump, thermostat, coolant passages, hoses Transmission Drivetrain: Clutch, gearbox, final drive, driveshafts, differential (if applicable), chain and sprockets Brakes: Front and rear brake systems (calipers, rotors, master cylinders, brake lines, fluid, parking brake) Suspension: Front and rear suspension components (shocks, springs, A-arms, linkages, bushings), steering system (handlebars, steering stem, tie rods) Electrical System: Battery, charging system (stator, rectifier/regulator), starter motor, lighting, instrumentation, wiring harnesses, fuses, relays Body Chassis: Frame, body panels, fenders, plastics, seat, grab bars, footwells Wheels Tires: Wheel specifications, tire pressures, mounting procedures Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement, brake fluid changes, coolant flushes Troubleshooting: Diagnostic procedures for common problems, fault codes (if applicable), electrical diagnostics Repair Procedures: Step-by-step guides for all major mechanical and electrical component repairs Disassembly Reassembly: Detailed instructions for taking apart and putting back together all major systems Technical Data Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values Wiring Diagrams: Comprehensive electrical schematics for all model years and configurations Special Tools: Identification and usage of Yamaha-specific or recommended tools Technical Depth Depth: Comprehensive (from basic maintenance to full engine rebuilds and advanced electrical diagnostics) 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes Printable: Yes Print Quality Image Resolution: High-resolution for clear diagrams and illustrations Binding Type Binding: N/A (Digital) Paper Type Paper Quality: N/A (Digital) Completeness Completeness: Full workshop manual, covering all aspects of service and repair ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Liquid-cooled, DOHC, 4-valve, Single-cylinder Displacement: 686 cc Bore X Stroke: 100.0 mm x 83.0 mm Compression Ratio: 9.0:1 (typical) Fuel Delivery: Fuel Injection (YFI) with 44mm throttle body Ignition: Digital CDI Starter: Electric Lubrication: Wet sump with oil cooler Performance Horsepower: Approximately 45-50 HP (crankshaft, estimated) Torque: Approximately 40-45 lb-ft (crankshaft, estimated) Fuel System Fuel Type: Unleaded gasoline, minimum 87 octane Fuel Tank Capacity: 2.4 gallons (9 liters) 🔧 Transmission Standard Transmission Type: 5-speed manual with Reverse Clutch Type: Wet, multiple-disc Final Drive: O-ring sealed chain, Drive Sprocket, Driven Sprocket Features Gear Ratios: Detailed in manual (e.g., 1st: 2.714, 2nd: 1.750, 3rd: 1.333, 4th: 1.125, 5th: 0.917) Transmission Oil Type: Yamaha Motorcycle Gear Oil 10W-30 or equivalent SAE 10W-30 API SE type motor oil Transmission Oil Capacity: Approx. 0.90 liters (0.95 US qt) 📐 Dimensions Exterior Length: 70.3 inches (1785 mm) Width: 43.5 inches (1105 mm) Height: 44.3 inches (1125 mm) Wheelbase: 50.0 inches (1270 mm) Ground Clearance: 10.1 inches (257 mm) Weights Dry Weight: 421 lbs (191 kg) Curb Weight: Approx. 452 lbs (205 kg) with all necessary fluids Towing Capacity:...
This manual covers the Raptor 700, a high-performance sport ATV, including Standard and SE models from the 2005 through 2009 production years. Renowned for its powerful 686cc fuel-injected engine, lightweight aluminum frame, and long-travel suspension, the Raptor 700 is engineered for agility, robust power delivery, and exceptional handling across demanding off-road terrains. Its design prioritizes performance and rider control, making it a benchmark in the sport ATV segment and a popular choice for enthusiasts and racers alike.
This comprehensive service repair workshop manual provides detailed guidance for all aspects of maintaining and repairing your Raptor 700. It encompasses routine maintenance procedures, in-depth troubleshooting guides, complete engine and transmission disassembly/reassembly instructions, and coverage of all major systems, including fuel, ignition, cooling, brakes, suspension, and electrical components. With clear step-by-step instructions, technical specifications, and detailed wiring diagrams, this manual is an essential resource for owners and technicians seeking to ensure the optimal performance, reliability, and longevity of their vehicle.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Raptor 700
Model Variant:
Standard/SE
Vehicle Type:
ATV (All-Terrain Vehicle)
Generation
Generation:
1st Generation
Codes
Chassis Code:
Various (e.g., YFM700)
👋 Introduction
Market Position
Market Segment:
High-performance sport ATV
Target Audience:
Sport ATV enthusiasts, recreational riders, off-road racers, mechanics
Yamaha Motorcycle Gear Oil 10W-30 or equivalent SAE 10W-30 API SE type motor oil
Transmission Oil Capacity:
Approx. 0.90 liters (0.95 US qt)
📐 Dimensions
Exterior
Length:
70.3 inches (1785 mm)
Width:
43.5 inches (1105 mm)
Height:
44.3 inches (1125 mm)
Wheelbase:
50.0 inches (1270 mm)
Ground Clearance:
10.1 inches (257 mm)
Weights
Dry Weight:
421 lbs (191 kg)
Curb Weight:
Approx. 452 lbs (205 kg) with all necessary fluids
Towing Capacity:
N/A (not designed or rated for towing)
Wheels Tires
Front Tire Size:
AT22x7-10
Rear Tire Size:
AT20x10-9
Front Wheel Type:
Aluminum alloy
Rear Wheel Type:
Aluminum alloy
Suspension Travel
Front Suspension Travel:
9.1 inches (231 mm)
Rear Suspension Travel:
10.1 inches (257 mm)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (ATVs are not subject to automotive crash testing standards)
Active Features
Braking System:
Hydraulic disc brakes front and rear
Parking Brake:
Yes
Engine Braking:
Utilizes engine compression for downhill control
Passive Features
Operator Presence:
Thumb throttle with safety interlock
Kill Switch:
Engine stop switch on handlebars
Chain Guard:
Yes
💡 Technology Features
Infotainment
Instrumentation:
Digital LCD meter (speedometer, odometer, trip meter, clock, diagnostic indicators).
Driver Assistance
Throttle Control:
Ergonomic thumb throttle design for precise control.
Connectivity
Diagnostic Ports:
Diagnostic connectors for accessing engine data and fault codes (covered in manual).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 1000 km (600 miles) or 6 months, whichever comes first. Also after every 100 hours of operation.
Oil Filter Replacement:
At every engine oil change.
Air Filter Cleaning:
Every 300 km (200 miles) or 20 hours. Replace if necessary.
Spark Plug Inspection/Replacement:
Inspect every 1000 km (600 miles) or 6 months. Replace as needed.
Chain Lubrication/Adjustment:
Lubricate every 300 km (200 miles) or 20 hours. Adjust chain slack as needed (refer to manual for specific slack measurement).
Brake Fluid Change:
Every 2 years or as needed based on inspection.
Coolant Flush:
Every 2 years or 3000 km (1800 miles).
Fluid Specifications
Engine Oil Type:
Yamaha Genuine Motor Oil 10W-40 API SG or higher, JASO Standard MA
Engine Oil Capacity:
Approx. 2.10 liters (2.22 US qt) without filter change; 2.30 liters (2.43 US qt) with filter change
Coolant Type:
High-quality ethylene glycol based coolant with antifreeze protection: 50% mixture with deionized water.
Brake Fluid Type:
SAE J1703 or FMVSS 116 DOT 3
Known Issues
Common Wear Items:
Front A-arm bushings, tie rod ends, wheel bearings, brake pads, chain and sprockets, rear shock absorber.
Engine Performance:
Some users report a need for ECU remapping or aftermarket performance modifications to optimize power delivery. Ensure proper maintenance of the fuel injection system.
Electrical:
Occasional issues with rectifier/regulator failures or battery charging system components, especially under heavy use.
Suspension:
Standard suspension may require adjustment or upgrades for aggressive riding or heavier riders. Shock seals can wear over time.
📚 Vehicle History
Brand Heritage
Brand Focus:
Yamaha Corporation is a Japanese multinational corporation known for its wide range of products, including motorcycles, musical instruments, and powersports vehicles. Yamaha has a strong reputation for innovation and performance in the powersports industry.
Model Evolution
Raptor Lineage:
The Raptor 700 is the successor to the highly popular Raptor 660. It was introduced to offer increased performance, broader usability, and modern features like fuel injection.