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Yamaha Raptor 700 2006-2009 Workshop Service Manual

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🏷️ Basic Information Identification Make: Yamaha Model: Raptor 700 Model Years Covered: 2006, 2007, 2008, 2009 Vehicle Type: ATV (All-Terrain Vehicle) 👋 Introduction Market Position Market Segment: High-performance sport ATV segment. Competitive Analysis Key Competitors: Honda TRX450R, Suzuki LT-R450, Kawasaki KFX450R. Key Features Vehicle Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve, single-cylinder. Engine Displacement: 686cc Fuel Induction: Mikuni 44mm carburetor (for most 2006-2009 models, some variations may exist). Transmission Type: 5-speed constant mesh with wet multi-disc clutch and reverse. Suspension Front: Independent double wishbone with piggyback shock absorbers, 5-way preload adjustable, 8.1-inch travel. Suspension Rear: Swingarm with fully adjustable piggyback shock absorber, 9.5-inch travel. Brakes Front: Dual hydraulic disc Brakes Rear: Hydraulic disc Tires Front: AT21x7R10 Tires Rear: AT20x10R9 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual Language: English Format: PDF Download Page Count Page Count: 401 📖 Manual Coverage Systems Covered Engine Overhaul: Complete engine disassembly, inspection, repair, and reassembly procedures. Fuel System: Carburetor/fuel injection system diagnosis and repair, fuel pump, fuel lines. Ignition System: Ignition coil, spark plug, CDI unit, timing checks. Cooling System: Radiator, coolant, water pump, fan operation. Transmission And Drivetrain: Clutch operation, gear shifting mechanisms, final drive, axle maintenance. Suspension System: Front and rear suspension geometry, shock absorber service, bushing replacement. Braking System: Brake caliper overhaul, hydraulic lines, master cylinder, brake pad replacement, bleeding procedures. Steering System: Steering column, tie rods, ball joint inspection and replacement. Electrical System: Wiring diagrams, battery service, starter motor, lighting, charging system, fuses, relays. Chassis And Body: Frame inspection, body panel removal and installation, seat, handlebars. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug checks, air filter cleaning/replacement. Troubleshooting: Diagnostic flowcharts and common problem identification for various systems. Repair And Rebuild: Detailed step-by-step instructions for component repair and full system overhauls. Part Replacement: Instructions for replacing common wear items and critical components. Torque Specifications: Precise torque values for critical fasteners and assembly points. Clearances And Adjustments: Specifications for valve clearances, chain slack, and other critical adjustments. Technical Depth Depth Of Coverage: Comprehensive. Covers everything from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics. Assumed Technician Skill Skill Level Assumption: Assumes a fully qualified technician with a good understanding of ATV mechanics and diagnostic tools. 📊 Manual Specifications File Format File Format: PDF Print Quality Image Resolution: High resolution, suitable for clear viewing of diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Searchable Text: Likely searchable, depending on the original PDF's OCR quality. ⚙️ Engine Specifications Primary Engine Engine Code: Typically referred to by model designation, e.g., 35B for the Raptor 700. Engine Configuration: Single-cylinder, four-stroke Bore X Stroke: 100.0 mm x 84.0 mm Compression Ratio: 9.2:1 (for many models) Performance Horsepower Approx: Approximately 45-50 HP (peak, subject to exhaust and tuning) Torque Approx: Approximately 40-45 lb-ft (peak) Fuel System Fuel Delivery: Mikuni BSR42 (42mm) carburetor for early models, later models may feature different carburetor sizes or EFI systems. This manual likely covers the prevalent 42mm BSR carburetor. Fuel Type: Unleaded gasoline, minimum 87 octane. Fuel Tank Capacity: Approx. 2.9 gallons (11 Liters) 🔧 Transmission Standard Transmission Type: 5-speed manual with constant mesh and wet multi-disc clutch Optional Reverse Gear: Yes, integrated into the transmission. Features Final Drive: O-ring sealed chain Clutch Type: Wet, multiple-disc Fluid Specifications Transmission Oil Type: Yamalube 4 (or equivalent API SG, SAE 10W-40) motorcycle oil. Fluid Capacities Transmission Oil Capacity: Approx. 1.40 US qt (1.3 L) for engine oil/transmission oil. 📐 Dimensions Exterior Overall Length: Approx. 70.5 inches (1790 mm) Overall Width: Approx. 45.2 inches (1150 mm) Overall Height: Approx. 43.9 inches (1115 mm) Seat Height: Approx. 32.3 inches (820 mm) Wheelbase: Approx. 50.0 inches (1270 mm) Weights Dry Weight: Approx. 390 lbs (177 kg) Curb Weight: Approx. 412 lbs (187 kg) (with all necessary operating fluids) Ground Clearance: Approx. 10.0 inches (254 mm) 🛡️ Safety Features Ratings Atv Safety Standards: Adheres to industry safety guidelines for ATVs, user must follow operating instructions. Active Features Braking Performance: Dual front disc and single rear disc brakes for robust stopping power. Chassis Stability: Wide stance and well-tuned suspension contribute to stability. Passive Features Footwells: Aggressively designed footpegs with heel guards for secure foot placement. Throttle Limiter: Thumb throttle with adjustable tension for controlled acceleration. 💡 Technology Features Infotainment Infotainment System: N/A (Performance ATV, not designed for infotainment features). Driver Assistance Traction Control: N/A ABS: N/A (Anti-lock Braking System not standard on these models). Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Engine Oil Change: Every 1000 km (600 miles) or 6 months, whichever comes first. Air Filter Cleaning: Every 1000 km (600 miles) or more frequently in dusty conditions. Spark Plug Replacement: Recommended every 4000 km (2400 miles) or as per inspection. Valve Clearance Check: Every 4000 km (2400 miles)....
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Yamaha Raptor 700 2006-2009 Workshop Service Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Raptor 700
Model Years Covered:
2006, 2007, 2008, 2009
Vehicle Type:
ATV (All-Terrain Vehicle)
👋 Introduction
Market Position
Market Segment:
High-performance sport ATV segment.
Competitive Analysis
Key Competitors:
Honda TRX450R, Suzuki LT-R450, Kawasaki KFX450R.
Key Features Vehicle
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 4-valve, single-cylinder.
Engine Displacement:
686cc
Fuel Induction:
Mikuni 44mm carburetor (for most 2006-2009 models, some variations may exist).
Transmission Type:
5-speed constant mesh with wet multi-disc clutch and reverse.
Suspension Front:
Independent double wishbone with piggyback shock absorbers, 5-way preload adjustable, 8.1-inch travel.
Suspension Rear:
Swingarm with fully adjustable piggyback shock absorber, 9.5-inch travel.
Brakes Front:
Dual hydraulic disc
Brakes Rear:
Hydraulic disc
Tires Front:
AT21x7R10
Tires Rear:
AT20x10R9
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Manual
Language:
English
Format:
PDF Download
Page Count
Page Count:
401
📖 Manual Coverage
Systems Covered
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly procedures.
Fuel System:
Carburetor/fuel injection system diagnosis and repair, fuel pump, fuel lines.
Ignition System:
Ignition coil, spark plug, CDI unit, timing checks.
Cooling System:
Radiator, coolant, water pump, fan operation.
Transmission And Drivetrain:
Clutch operation, gear shifting mechanisms, final drive, axle maintenance.
Suspension System:
Front and rear suspension geometry, shock absorber service, bushing replacement.
Braking System:
Brake caliper overhaul, hydraulic lines, master cylinder, brake pad replacement, bleeding procedures.
Steering System:
Steering column, tie rods, ball joint inspection and replacement.
Electrical System:
Wiring diagrams, battery service, starter motor, lighting, charging system, fuses, relays.
Chassis And Body:
Frame inspection, body panel removal and installation, seat, handlebars.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug checks, air filter cleaning/replacement.
Troubleshooting:
Diagnostic flowcharts and common problem identification for various systems.
Repair And Rebuild:
Detailed step-by-step instructions for component repair and full system overhauls.
Part Replacement:
Instructions for replacing common wear items and critical components.
Torque Specifications:
Precise torque values for critical fasteners and assembly points.
Clearances And Adjustments:
Specifications for valve clearances, chain slack, and other critical adjustments.
Technical Depth
Depth Of Coverage:
Comprehensive. Covers everything from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics.
Assumed Technician Skill
Skill Level Assumption:
Assumes a fully qualified technician with a good understanding of ATV mechanics and diagnostic tools.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Image Resolution:
High resolution, suitable for clear viewing of diagrams and text.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Searchability
Searchable Text:
Likely searchable, depending on the original PDF's OCR quality.
⚙️ Engine Specifications
Primary Engine
Engine Code:
Typically referred to by model designation, e.g., 35B for the Raptor 700.
Engine Configuration:
Single-cylinder, four-stroke
Bore X Stroke:
100.0 mm x 84.0 mm
Compression Ratio:
9.2:1 (for many models)
Performance
Horsepower Approx:
Approximately 45-50 HP (peak, subject to exhaust and tuning)
Torque Approx:
Approximately 40-45 lb-ft (peak)
Fuel System
Fuel Delivery:
Mikuni BSR42 (42mm) carburetor for early models, later models may feature different carburetor sizes or EFI systems. This manual likely covers the prevalent 42mm BSR carburetor.
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Fuel Tank Capacity:
Approx. 2.9 gallons (11 Liters)
🔧 Transmission
Standard
Transmission Type:
5-speed manual with constant mesh and wet multi-disc clutch
Optional
Reverse Gear:
Yes, integrated into the transmission.
Features
Final Drive:
O-ring sealed chain
Clutch Type:
Wet, multiple-disc
Fluid Specifications
Transmission Oil Type:
Yamalube 4 (or equivalent API SG, SAE 10W-40) motorcycle oil.
Fluid Capacities
Transmission Oil Capacity:
Approx. 1.40 US qt (1.3 L) for engine oil/transmission oil.
📐 Dimensions
Exterior
Overall Length:
Approx. 70.5 inches (1790 mm)
Overall Width:
Approx. 45.2 inches (1150 mm)
Overall Height:
Approx. 43.9 inches (1115 mm)
Seat Height:
Approx. 32.3 inches (820 mm)
Wheelbase:
Approx. 50.0 inches (1270 mm)
Weights
Dry Weight:
Approx. 390 lbs (177 kg)
Curb Weight:
Approx. 412 lbs (187 kg) (with all necessary operating fluids)
Ground Clearance:
Approx. 10.0 inches (254 mm)
🛡️ Safety Features
Ratings
Atv Safety Standards:
Adheres to industry safety guidelines for ATVs, user must follow operating instructions.
Active Features
Braking Performance:
Dual front disc and single rear disc brakes for robust stopping power.
Chassis Stability:
Wide stance and well-tuned suspension contribute to stability.
Passive Features
Footwells:
Aggressively designed footpegs with heel guards for secure foot placement.
Throttle Limiter:
Thumb throttle with adjustable tension for controlled acceleration.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Performance ATV, not designed for infotainment features).
Driver Assistance
Traction Control:
N/A
ABS:
N/A (Anti-lock Braking System not standard on these models).
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 1000 km (600 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 1000 km (600 miles) or more frequently in dusty conditions.
Spark Plug Replacement:
Recommended every 4000 km (2400 miles) or as per inspection.
Valve Clearance Check:
Every 4000 km (2400 miles).
Chain Lubrication Adjustment:
Every 500 km (300 miles) or as needed.
Fluid Specifications
Engine Oil:
Yamalube 4 (or equivalent API SG, SAE 10W-40).
Coolant:
Permanent type antifreeze coolant (50% solution) mixed with distilled water.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Known Issues
Common Wear Items:
Wheel bearings, steering stem bearings, suspension bushings, brake pads, chain and sprockets, clutch plates.
Engine Characteristics:
Some owners report occasional carburetor jetting issues or minor overheating in extreme conditions, both of which this manual would provide solutions for.
Electrical Components:
While generally robust, typical electrical maintenance might involve checking grounds and connections.
📚 Vehicle History
Brand Heritage
Yamaha Motorsports Legacy:
Yamaha has a long and successful history in motorsports, particularly in off-road and ATV racing, known for innovation and reliability.
Model Evolution
Raptor Lineage:
The Raptor 700 builds upon the legacy of the popular Raptor 660, introducing a larger displacement engine, updated chassis, and improved ergonomics.
Production
Manufacturing Location:
Generally manufactured in Japan, with assembly potentially occurring in other locations.
Model Years Impact:
The 2006-2009 generation represents the initial introduction of the fuel-injected 700cc engine for many markets, offering significant performance gains over previous models.
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