Yamaha Raptor 700 2006-2009 Workshop Service Manual

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Stichworte: 2006 2007 2008 2009 ATV Powersports Raptor 700 Raptor Models Yamaha

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Beschreibung

Introducing the Raptor 700, a high-performance sport All-Terrain Vehicle (ATV) designed for demanding off-road use. Covering model years 2006 through 2009, this ATV is engineered with a powerful 686cc liquid-cooled, four-stroke, single-cylinder engine, featuring a DOHC and 4-valve configuration. Its robust build is complemented by independent front double wishbone suspension with adjustable piggyback shock absorbers and a rear swingarm with a fully adjustable shock, providing exceptional control and comfort. The Raptor 700 is recognized for its strong performance, building on a rich motorsports heritage, and competes in the high-performance sport ATV segment with its sophisticated chassis and powerful engine. This comprehensive workshop service manual provides detailed instructions and technical specifications essential for the maintenance, repair, and overhaul of your Raptor 700 (2006-2009). It covers all major systems, including complete engine overhauls, fuel and ignition systems, cooling, transmission, drivetrain, suspension, braking, steering, and electrical systems. The manual offers guidance on routine maintenance, troubleshooting common issues, and component replacement, along with critical torque specifications and clearance adjustments. Designed for technicians and owners with a good understanding of ATV mechanics, this English-language resource ensures optimal performance and longevity of your vehicle.

🏷️ 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:

📖 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:

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 (Anti-lock Braking System not standard on these models).

Connectivity

Connectivity Features:

🔧 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.