Market Segment:
High-performance sport ATV segment.
Target Audience:
Experienced riders and off-road enthusiasts seeking high-performance sport ATV capability.
Key Competitors:
Honda TRX450R, Suzuki LT-R450, Kawasaki KFX450R.
Competitive Advantage:
Larger-displacement 686cc DOHC single-cylinder engine and a sophisticated chassis delivering strong performance in its class.
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 4-valve, single-cylinder.
Engine Displacement:
686cc
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.
Transmission Type:
5-speed constant mesh with wet multi-disc clutch and reverse.
Systems Covered:
Engine, fuel and ignition, cooling, transmission, drivetrain, suspension, braking, steering, electrical, chassis and body.
Manual Type:
Workshop Service Manual
Delivery Method:
Instant digital download
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.
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.
Depth Of Coverage:
Comprehensive. Covers everything from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics.
Skill Level Assumption:
Assumes a fully qualified technician with a good understanding of ATV mechanics and diagnostic tools.
Parts Information:
Part identification and replacement procedures for wear items and critical components; includes torque specs and clearance data required for correct reassembly.
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
Engine Configuration:
Single-cylinder, four-stroke, DOHC, 4-valve
Engine Displacement:
686cc
Engine Code:
Typically referred to by model designation, e.g., 35B for the Raptor 700.
Bore X Stroke:
100.0 mm x 84.0 mm
Compression Ratio:
9.2:1 (for many models)
Horsepower Approx:
Approximately 45-50 HP (peak, subject to exhaust and tuning)
Torque Approx:
Approximately 40-45 lb-ft (peak)
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)
Standard Transmission:
5-speed manual with constant mesh and wet multi-disc clutch
Reverse Gear:
Yes, integrated into the transmission.
Final Drive:
O-ring sealed chain
Clutch Type:
Wet, multiple-disc
Transmission Oil Type:
Yamalube 4 (or equivalent API SG, SAE 10W-40) motorcycle oil.
Transmission Oil Capacity:
Approx. 1.40 US qt (1.3 L) for engine oil/transmission oil.
Wheelbase:
Approx. 50.0 inches (1270 mm)
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)
Ground Clearance:
Approx. 10.0 inches (254 mm)
Dry Weight:
Approx. 390 lbs (177 kg)
Curb Weight:
Approx. 412 lbs (187 kg) (with all necessary operating fluids)
Atv Safety Standards:
Adheres to industry safety guidelines for ATVs, user must follow operating instructions.
Crash Test Ratings:
N/A - ATVs are not subject to standardized crash test ratings.
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.
Footwells:
Aggressively designed footpegs with heel guards for secure foot placement.
Throttle Limiter:
Thumb throttle with adjustable tension for controlled acceleration.
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.
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.
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.
Manufacturer:
Yamaha Motor Co., Ltd.
Yamaha Motorsports Legacy:
Yamaha has a long and successful history in motorsports, particularly in off-road and ATV racing, known for innovation and reliability.
Raptor Lineage:
The Raptor 700 builds upon the legacy of the popular Raptor 660, introducing a larger displacement engine, updated chassis, and improved ergonomics.
Model Years Impact:
The 2006-2009 generation represents the initial introduction of the 700cc engine for many markets, offering significant performance gains over previous models.
Manufacturing Location:
Generally manufactured in Japan, with assembly potentially occurring in other locations.
