2006 Yamaha YFM700RV Raptor 700 ATV Service Repair Manual (P/N LIT-11616-19-13)

This Yamaha YFM700RV Raptor 700 service manual covers model code 1S31, with factory repair procedures and specifications under manual part number LIT-11616-19-13.

• Engine repair: Engine removal, cylinder-head overhaul, valve-clearance adjustment, piston inspection, timing-chain replacement, and crankcase separation.

• Clutch and transmission: Wet-clutch inspection, shift-shaft service, gear and shift-fork checks, and transmission disassembly and reassembly.

• Fuel injection: ECU self-diagnosis, sensor and actuator tests, fuel-pump pressure checks, and throttle-position-sensor adjustment.

• Cooling system: Radiator removal, cap pressure testing, thermostat checks, water-pump disassembly, seal replacement, and coolant filling and bleeding.

• Brake repair: Front and rear caliper rebuilding, master-cylinder service, hydraulic bleeding, and self-adjusting parking-brake mechanism coverage.

• Steering and suspension: Steering-knuckle and front-arm service, shock-absorber inspection and adjustment, rear linkage service, and swingarm and drive-chain checks.

• Electrical troubleshooting: Ignition, starting, charging, lighting, signaling, and cooling-fan diagnosis, supported by circuit diagrams and component test charts.

Written primarily for Yamaha dealers and qualified mechanics, this manual assumes an existing understanding of vehicle maintenance and repair.

Engine Overhaul and Powertrain Service

The engine sections cover the cylinder head, rocker arms, camshaft, valves, piston, and crankshaft. Exploded assembly views accompany removal and disassembly tables, with cylinder-head bolt tightening sequences, wear limits, and reassembly notes.

Lubrication and drive components: Dry-sump oil-tank service and oil-pump inspection are supported by oil flow diagrams. Separate procedures address the A.C. magneto, starter clutch, balancer gears, and clutch damper assembly.

Transmission repair extends to the main, drive, and counter axles, including reverse gearing. The instructions identify shift-fork positions and explain the gear-operation checks required before the crankcase is closed.

Fuel Injection and Electrical Fault Diagnosis

ECU diagnostics: The FI troubleshooting chart links symptoms and fault codes to sensor tests, actuator checks, and fault-history clearing. Procedures use Yamaha FI diagnostic tool 90890-03182 / YU-03182.

The intake-air-pressure diagnostics distinguish an electrical sensor fault from a blocked or disconnected sensor hose. That distinction helps a technician investigate the source of a fault before replacing the sensor.

Throttle body: Injector removal, fuel-pump and pressure-regulator testing, and throttle-position-sensor adjustment are documented. The throttle body itself is not intended for internal disassembly.

Ignition and electric-starting circuit diagrams support checks of the coils, relays, neutral switch, and clutch interlock. Connector views and the full wiring diagram identify wire colors and circuit connections.

The radiator-fan relay test warns that reversed polarity can damage the relay; reinstalling that damaged relay can then damage the ECU when power is applied. Follow the manual's precautions for pressurized fuel and electrical testing.

Brakes, Steering, and Rear Suspension

Brake assemblies: The rear-caliper instructions address piston alignment and the parking-brake shaft and arm positions. This complements the explanation of how the self-adjusting parking-brake mechanism works.

Steering coverage includes tie-rod and steering-knuckle inspection, toe-in adjustment, and front-arm ball-joint service. The manual distinguishes replacement of a defective upper-arm ball joint with the arm assembly from separate lower-arm ball-joint replacement.

Rear chassis: Front and rear shock-absorber procedures are accompanied by relay-arm, connecting-arm, and swingarm bearing and bushing checks. Drive-chain wear measurement and sprocket inspection are also covered.

Rear-axle removal cautions identify direct hammering as a risk to the axle threads and splines. Shock-absorber coverage concerns removal, inspection, adjustment, and replacement; it does not provide an internal damper rebuild procedure.

Cooling-System Inspection and Assembly

Coolant flow diagrams and cable-routing drawings show hose paths and their relationship to the wiring harness. Water-pump repair covers the impeller shaft, bearing, oil seal, and mechanical seal, with the required seal-installation tools identified.

A Preview of Valve, Cooling, and Sensor Specifications

These examples represent a small selection of the manual's adjustment and test data.

For the covered engine, intake valve clearance is 0.09–0.13 mm cold. Cooling specifications list 1.61 L for the radiator circuit, including all routes, with the coolant reservoir specified separately.

Ignition diagnostics specify crankshaft-position-sensor resistance of 192–288 ohms at 20 °C (68 °F), providing the reference range for that component's resistance check.

PDF Search, Navigation, and Page Count

Text navigation and wiring detail: Searchable text and 80 embedded bookmarks provide access to the chapters and major repair sections. Small wire-color codes and connector labels in the dense circuit diagrams require enlargement.

One printable English PDF contains 401 pages total: 400 pages of Yamaha manual material, including the contents, wiring diagram, and back cover, plus one additional introductory page. That introductory page is already included in the total.