2005-2006 Yamaha Raptor 700 Repair Manual

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Stichworte: 2005 2006 ATV Powersports Raptor 700 Raptor Models Yamaha

Produktvarianten

Beschreibung

The Yamaha Raptor 700, produced for the 2005-2006 model years, is a high-performance sport ATV engineered for enthusiasts and competitive off-road riders. Building on a motorsports legacy, this model emphasizes power, torque, and agile handling, making it a formidable machine for sport riding. Key features include a potent liquid-cooled, DOHC, 4-stroke engine with electronic fuel injection for enhanced throttle response and efficiency, a robust steel frame for durability, and hydraulic disc brakes for reliable stopping power. Its design prioritizes performance and rider engagement in demanding off-road conditions. This comprehensive Factory Service Manual provides detailed guidance for the maintenance and repair of the Yamaha Raptor 700. It covers all major systems, including the engine, fuel system, transmission, drivetrain, brakes, suspension, steering, and electrical systems. The manual includes step-by-step instructions for scheduled maintenance, troubleshooting common issues, complete system overhauls, and detailed technical specifications. Owners, mechanics, and technicians will find this manual an indispensable resource for ensuring the optimal performance, reliability, and longevity of their Raptor 700.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

Raptor 700

Model Variant:

Raptor 700

Codes

Model Year Code:

2005-2006

👋 Introduction

Market Position

Vehicle Type:

High-performance sport ATV

Target Audience:

Enthusiasts, off-road riders, competitive racers.

Competitive Analysis

Key Competitors:

Suzuki QuadRacer 450, Honda TRX450R, Polaris Outlaw 525.

Key Features

Engine Architecture:

DOHC, 4-valve, single-cylinder, liquid-cooled.

Performance Focus:

Emphasis on power, torque, and handling for off-road sport riding.

Technological Advancements:

Electronic fuel injection (EFI) for improved throttle response and efficiency.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Downloadable Digital Format (PDF)

Page Count

Estimated Page Count:

Refer to actual document for exact count (typically 300-600 pages for this type of vehicle)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, inspection, and repair of all internal components including cylinder, piston, crankshaft, camshaft, valve train, lubrication system, and cooling system.

Fuel System:

Fuel injection system components (injector, fuel pump, regulator, throttle body), fuel tank, fuel lines, and fuel filter service and troubleshooting.

Transmission:

Clutch assembly, transmission gears, shift mechanism, and lubrication system.

Drivetrain:

Shaft drive, universal joints, final drive housing, and bearings.

Brakes:

Front and rear hydraulic disc brake systems, master cylinders, calipers, brake pads, rotors, and brake lines. Bleeding procedures and specifications.

Suspension:

Front A-arm suspension, rear swingarm, shock absorbers, springs, bushings, and alignment procedures.

Steering:

Handlebar assembly, steering stem, bearings, and tie rod ends.

Electrical System:

Ignition system, starting system (starter motor, starter solenoid), charging system (stator, voltage regulator/rectifier), battery, lighting system (headlight, taillight, brake lights), and wiring diagrams.

Frame And Bodywork:

Chassis inspection, frame integrity, plastic body panels, seats, and skid plates.

Procedures Included

Maintenance:

Scheduled maintenance tasks, lubrication points, filter replacement (air, oil), spark plug service, chain adjustment, and general cleaning procedures.

Troubleshooting:

Diagnostic charts and symptom-based troubleshooting for common issues across all systems.

Repair:

Step-by-step disassembly and reassembly instructions for all major components and systems.

Rebuild:

Complete engine and transmission rebuild procedures with detailed specifications and tolerances.

Diagnostic Procedures:

Specific diagnostic tests for electrical components, fuel system sensors, and engine performance.

Technical Depth

Depth Level:

Comprehensive, covering basic maintenance to complete engine and transmission overhauls.

Detail Level:

Detailed diagrams, torque specifications, tolerances, and diagnostic flowcharts.

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Yes (typically)

Printability:

Printable

Print Quality

Image Resolution:

High-resolution for clear diagrams and illustrations.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, DOHC, 4-stroke, 5-valve

Displacement:

686 cc

Bore X Stroke:

100.0 mm x 83.9 mm

Compression Ratio:

9.0:1

Performance

Horsepower Estimate:

Approx. 53 hp @ 6,000 rpm (manufacturer claims may vary, actual dyno results can differ)

Torque Estimate:

Approx. 50 lb-ft @ 5,500 rpm (manufacturer claims may vary)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Mikuni 44mm throttle body

Fuel Type:

Unleaded gasoline, minimum 87 octane

Ignition

Ignition System:

TCI (Transistor Controlled Ignition)

Cooling System

Cooling Method:

Liquid-cooled

Lubrication System

Oil Type:

Yamalube 4 (or equivalent) 10W-40 motorcycle oil (check manual for specific API service classification)

Oil Capacity:

Refer to manual for precise capacity with filter change (typically around 2.0-2.5 liters)

🔧 Transmission

Standard

Transmission Type:

5-speed, constant mesh, wet multi-disc clutch

Drive Type:

Chain drive

Features

Reverse Gear:

Clutch Operation:

Hydraulic

📐 Dimensions

Exterior

Overall Length:

7,140 mm (71.4 inches)

Overall Width:

1,170 mm (46.1 inches)

Overall Height:

1,065 mm (41.9 inches)

Wheelbase:

1,280 mm (50.4 inches)

Ground Clearance:

230 mm (9.1 inches)

Weights

Dry Weight:

193 kg (425 lbs)

Fuel Capacity:

10 Liters (2.6 US gal)

🛡️ Safety Features

Ratings

Rollover Protection:

N/A (ATV inherently lacks typical automotive safety ratings)

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Parking Brake:

Rear disc parking brake (lever operated).

Passive Features

Chassis Design:

Reinforced steel frame for durability and rigidity.

Lighting:

Dual 30W headlights, 8W taillight/brake light.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic instrumentation)

Driver Assistance

Traction Control:

Connectivity

Connectivity Features:

Instrumentation

Instrument Cluster:

Digital LCD display with speedometer, odometer, trip meter, clock, and warning lights.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 1,000 km (600 miles) or 6 months, whichever comes first (refer to manual for exact conditions).

Air Filter Cleaning:

Every 500 km (300 miles) or after dusty riding conditions.

Spark Plug Replacement:

Every 3,000 km (1,800 miles) or as needed (inspect at 1,000 km).

Chain Adjustment:

Every 500 km (300 miles) or as needed.

Fluid Specifications

Engine Oil Specification:

Yamalube 4 (or equivalent) 10W-40, API SG or higher.

Coolant Type:

Permanent type antifreeze coolant (e.g., 50/50 mix of ethylene glycol and distilled water).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Wheel bearings, tie rod ends, brake pads, chain and sprockets due to off-road use and high performance.

Efi System:

Occasional sensitivity to fuel quality or sensor issues, often addressed through ECU resets or sensor cleaning/replacement.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Corporation

Motorsports Legacy:

Yamaha has a long and successful history in motorsports, including ATV racing, which heavily influenced the development of the Raptor line.

Model Evolution

Predecessor:

Yamaha Warrior 350, Yamaha Raptor 660R.

Introduction Of 700:

The Raptor 700 was introduced as a successor to the popular Raptor 660R, incorporating a larger displacement engine and updated chassis technology.

Production

Production Start Year:

Manufacturing Location:

Japan (primary assembly/components)

🏆 Awards & Recognition

Recognitions

Industry Awards:

Praised by ATV enthusiasts and media for its power and handling, contributing to Yamaha's strong presence in the sport ATV market.

Ratings

Performance Reviews:

Consistently received high ratings for its class-leading engine performance and chassis dynamics upon release.