Yamaha Raptor 90 (YFM90RY) ATV Service Manual, 2009 (P/N LIT-11616-22-13)

This Yamaha service manual (P/N LIT-11616-22-13 / 43D-F8197-10) covers the 2009 Raptor 90 (YFM90RY), model code 43D1, with factory procedures for engine, drivetrain, chassis, and electrical repair.

Searchable PDF and Chapter Bookmarks

Search and circuit detail: The PDF has searchable text and nine embedded bookmarks for the contents and eight main chapters. Small connector labels and wire-color codes in the ignition, starting, and charging circuit diagrams are readable when zoomed.

One printable, English-language PDF contains 228 pages, including the cover, introductory material, contents, and two blank pages.

Engine, CVT and Chassis Service

These coverage highlights are a selection from the manual, which also includes speed-limiter adjustment and spark-arrester cleaning.

• Engine repair: Step-by-step engine removal and installation, cylinder-head service, valve-train inspection, piston and ring checks, crankcase separation, and crankshaft inspection.

• CVT and transmission: V-belt replacement, centrifugal-clutch inspection, primary and secondary sheave service, kickstarter assembly, and reduction-gear and transmission-shaft checks.

• Carburetor service: Disassembly, cleaning, component inspection, reassembly, fuel-level measurement, and idle-speed and throttle-free-play adjustments.

• Brake service: Front drum-brake inspection and adjustment, rear pad replacement, master-cylinder and caliper service, and hydraulic rear-brake bleeding.

• Steering and suspension: Steering-stem, tie-rod, and steering-knuckle service, toe-in adjustment, front-arm inspection, rear-axle removal, and swingarm and drive-chain checks.

• Electrical diagnosis: Ignition and starter fault charts, switch-continuity checks, starter-motor inspection, charging-system circuit diagrams, and battery testing and charging guidance.

Written primarily for Yamaha dealers and qualified mechanics, this manual assumes a working knowledge of machine repair.

Internal Engine and Belt-Drive Work

For the air-cooled SOHC four-stroke engine, inspection sections distinguish standard dimensions from wear limits for valve guides, rocker arms, pistons, and rings. Timing-mark illustrations accompany cylinder-head installation.

The trochoid oil-pump section provides rotor-clearance checks. Belt-drive detail extends to primary-sheave weights, secondary-sheave torque-cam grooves, and clutch-spring handling.

Periodic maintenance charts, component-specific torque tables, and lubricant references connect scheduled service with the relevant workshop procedures. Exploded views and job instruction charts show component order and lubrication points, while oil flow diagrams trace engine lubrication.

Carburetor Inspection and Fuel-Level Setup

Carburetor inspection covers the needle valve, float, piston-valve diaphragm, and jets. Disassembly and reassembly also include the accelerator pump.

Fuel-level procedures identify gauge 90890-01312 (YM-01312-A) and explain the relationship between float adjustment and the measured fuel level.

Brakes, Wheel Bearings and Suspension

Brake coverage includes master-cylinder assembly notes, caliper inspection, and hose-routing requirements. Wheel-hub procedures address bearing replacement; suspension checks cover bushings, ball joints, pivot play, and replacement of leaking or damaged shock-absorber assemblies.

The rear-axle instructions warn that direct hammer blows can damage the axle threads and splines. The bearing notes also warn that spinning bearings with compressed air damages their running surfaces.

Always maintain standard workshop safety protocols and verify your equipment setup before undertaking brake work or working with the ATV raised.

Electrical Fault Isolation

Circuit diagrams are supported by switch-continuity charts and cable-routing drawings for the wiring harness, throttle, choke, and brake controls.

The starting-circuit explanation includes the rear-brake interlock, so its fault chart helps trace a no-crank complaint through the switch, relay, motor, and wiring. Starter-motor inspection goes down to commutator wear, brush length, and armature resistance.

Charging-system limitation: Troubleshooting is incomplete in this file: it ends after the fuse and battery checks, followed by a blank page.

A Preview of Engine and Final-Drive Service Values

The valve-adjustment section specifies 0.07–0.10 mm for both intake and exhaust valves on a cold engine at room temperature. For a warmed engine at sea level, the compression test lists a standard 1,250 kPa at 1,000 rpm with the throttle fully open.

Drive-chain slack is specified at 10–25 mm with the ATV unloaded and all tires on the ground. The total final-transmission oil quantity is listed as 0.30 L.