2004 Yamaha Raptor 350 ATV Service & Repair Manual Set (P/N LIT-11616-07-50)

This Yamaha service manual set combines the YFM350XA base manual, P/N LIT-11616-07-50, first edition May 1990, with five supplementary service manuals for the Warrior 350 and Raptor 350. The YFM350S Raptor supplement is designed to be used with the included base manual and preceding supplements.

• Engine overhaul: Engine removal, cylinder-head and valve service, piston and crankshaft inspection, cam-chain installation, and oil-pump inspection.

• Clutch and transmission: Wet-clutch disassembly, friction-plate inspection, shift-fork and shaft checks, reverse-drive components, and transmission assembly.

• Carburetor service: Mikuni BTM36SH and BSR36 removal and disassembly, float and fuel-level specifications, throttle-cable adjustment, and carburetor section views.

• Brakes and chassis: Master-cylinder and caliper service, hydraulic bleeding, steering inspection, toe-in adjustment, rear-axle removal, and swingarm service.

• Electrical diagnosis: Starting, charging, ignition, lighting, and signal-system troubleshooting, with circuit diagrams, switch-continuity charts, and model-specific wiring diagrams.

Written primarily for Yamaha dealer mechanics, these publications assume an understanding of mechanical principles and machine repair procedures.

Engine, Clutch, and Transmission Repair

The eight-chapter base manual covers internal engine inspection and repair, including valve-seat refacing, valve-guide replacement, piston-ring checks, crankcase separation, and crankshaft installation. Lubrication Diagrams show the oil paths serving the engine and transmission.

Clutch coverage includes plate wear, spring condition, housing damage, and release-mechanism alignment. Transmission sections examine gear teeth, engagement dogs, shift forks, guide bars, and shaft runout before reassembly.

The special-tool references identify equipment for these jobs, including crankcase separator YU-01135 and crankshaft installer set YU-90050.

Carburetors and Raptor-Specific Changes

Fuel-system differences: The base publication covers the Mikuni BTM36SH. Its Carburetor Section View identifies the pilot, starter, float, and accelerator-pump circuits, supported by inspection and adjustment procedures.

The YFM350S supplement covers the Mikuni BSR36, including its vacuum chamber, piston valve, coasting enricher, and jet assemblies. Earlier supplements distinguish California carburetor settings and identifiers. These sections keep the applicable component data separate when selecting parts or checking adjustments.

Raptor service updates: Additional material addresses bodywork and fuel-tank removal, revised engine mounting, clutch-release alignment, parking-brake adjustment, and sealed-battery testing and charging.

Brakes, Steering, and Rear-Axle Service

Brake coverage extends beyond pad replacement to caliper and master-cylinder disassembly, component inspection, and hydraulic-system bleeding. Steering sections cover shaft bearings, tie-rod joints, assembly orientation, and toe-in.

The rear-axle instructions distinguish the base manual’s paired ring nuts from the YFM350S nut and locking-bolt arrangement. The Raptor supplement also provides revised front-arm, rear-shock, linkage, and swingarm assembly drawings.

The axle sections warn that direct hammer blows can damage shaft threads and splines. Rear-shock precautions explain how damage to the nitrogen cylinder reduces damping performance.

Always review the detailed factory precautions before disassembly, particularly when working on hydraulic brakes or the nitrogen-pressurized rear shock absorber.

Starting, Charging, and Ignition Fault Tracing

The Electric Starting System Circuit Diagram and its troubleshooting charts cover the starter motor, relays, clutch switch, neutral switch, and drive-select interlock. This helps distinguish an interlock fault from a starter-motor problem.

The Charging System and Ignition System circuit diagrams accompany output, resistance, and continuity checks. Later supplements introduce DC CDI information and rotor-rotation-direction detection-coil tests. The YFM350S Wiring Diagram adds the Raptor’s connector layouts and wire-color codes, while cable-routing drawings show harness and hose placement.

Examples of Engine Inspection and Float-Height Data

These are a few examples of the inspection and adjustment specifications included in the set.

For the YFM350XA base engine, the tables list a camshaft runout limit of 0.03 mm and cold intake-valve clearance of 0.06–0.10 mm. Installed end gaps for both the top and second piston rings are 0.20–0.40 mm.

For the YFM350S BSR36 carburetor, the specified float height is 13.0 mm.

Bookmarks, Text Search, and Included Publications

Search and diagram detail: Embedded bookmarks provide access to the base manual and supplements. PDF text search is available on pages 308–402; pages 1–307 have no searchable text layer. Small wire-color and connector labels in the checked wiring diagrams are readable with magnification.

The set is supplied as one printable, 402-page PDF containing the following publications.

Covers, introductory material, wiring diagrams, back covers, and three nearly blank chapter-ending pages are already included in these totals.