2011–2013 Yamaha Raptor 90 YFM90RB Owner's Manual (P/N LIT-11616-24-16, LIT-11626-25-15)

• 363-page Yamaha factory-manual PDF set: a 235-page YFM90RA Service Manual, P/N LIT-11616-24-16, and a 128-page YFM90RB Owner’s Manual, P/N LIT-11626-25-15.
• The service volume documents the 43D-series / model code 43D7 configuration with an air-cooled SOHC single-cylinder engine, TK SVR 22-1G carburetor, electric and kick starting, centrifugal clutch, V-belt automatic drive, front drum brake, and rear hydraulic disc brake.
• Covers engine removal and installation, cylinder-head and valve-train repair, piston and cylinder inspection, C.D.I. magneto service, oil-pump work, crankcase separation, crankshaft checks, timing-chain service, and transmission inspection.
• Details kickstarter, starter-clutch, V-belt, clutch-shoe, primary- and secondary-sheave repair, including disassembly, wear inspection, reassembly, and installation procedures.
• Documents brake-system repair and bleeding, wheel-hub and rear-axle service, steering-stem and tie-rod work, suspension and swingarm inspection, drive-chain setup, toe-in adjustment, and wheel checks.
• Provides ignition, electric-start, and charging circuit diagrams; switch-continuity tests; starter-motor service; troubleshooting charts; oil-flow and cable-routing diagrams; special-tool numbers; factory specification tables; and a full YFM90R wiring diagram.

Factory Repair Coverage

The 235-page service volume is Yamaha’s 2011 YFM90RA manual for model code 43D7. Its cover code is 43D-F8197-12, and the manual is the first edition dated July 2010. The machine configuration is the 88cc air-cooled four-stroke SOHC engine with wet-sump lubrication, AC-CDI ignition, TK SVR 22-1G carburetor, electric and kick starters, a dry centrifugal clutch, and V-belt automatic transmission. It starts with machine identification, special tools, specifications, cable routing, and scheduled service before moving into full repair procedures.

Engine coverage includes removal and installation, cylinder-head and timing-chain work, camshaft, rocker-arm and valve inspection, piston and cylinder service, C.D.I. magneto removal, starter-clutch service, oil-pump inspection, crankcase splitting, crankshaft and connecting-rod checks, and internal transmission inspection. The belt-drive chapter handles the kickstarter, clutch shoes, primary and secondary sheaves, sheave weights, slider, V-belt condition, reassembly, and final installation. Troubleshooting links those systems to hard starting, poor idle or high-speed performance, clutch slip, a no-move condition, overheating, weak braking, shock problems, and unstable handling.

Two shop cautions show the level of detail. Yamaha specifies separating the crankcase halves evenly and striking only reinforced areas, not the sealing faces; damage there can lead to leaks after reassembly. The belt-drive procedure keeps grease off the V-belt and secondary sheave and protects the secondary-sheave oil-seal lip with the correct guide. The troubleshooting section identifies belt contamination as a cause of slipping and poor speed performance.

Chassis, Electrical, and Shop Reference

Chassis repair covers front and rear wheels and hubs, front drum brakes, the rear axle and driven sprocket, rear brake pads, master cylinder and caliper, hydraulic bleeding, steering stem, tie rods and knuckles, front arms and shocks, rear shock, swingarm, and drive chain. Setup and inspection material includes brake adjustment, rear brake-fluid checks, steering play, toe-in, shock preload, tire and wheel condition, and chain alignment and slack.

Electrical sections provide component locations, switch-continuity checks, ignition diagnosis, electric-start operating logic, starter-motor inspection and assembly, charging-system diagnosis, and system-specific electrical test data. Key visual references include the oil-flow diagram, cable-routing views, ignition-system circuit diagram, electric-starting-system circuit diagram, charging-system circuit diagram, and separate YFM90R wiring diagram, with exploded assembly views throughout the engine, carburetor, and chassis chapters.

The special-tool list cross-references Yamaha’s US/Canada numbers with 90890-series equivalents. Examples include flywheel puller 90890-01189/YM-01189, tappet adjusting tool 90890-01311/YM-08035, fuel-level gauge 90890-01312/YM-01312-A, valve-spring compressor 90890-04019/YM-04019, clutch-spring holder 90890-01337/YM-33285, and axle-nut wrench 90890-01422/YM-37132. Factory data covers engine and chassis torque tables, lubrication points, approved fluids and capacities, carburetor settings, wear limits, inspection clearances, brake and wheel limits, steering and chain adjustments, ignition and charging values, and battery and starter specifications.

Operation and Maintenance Overview

The 128-page YFM90RB Owner’s Manual carries cover code 43D-F8199-13 and is the first edition dated July 2011. It explains the main switch, handlebar controls, fuel cock, choke, electric and kick starting, cold- and warm-engine procedures, and the two-stage speed-control system. The vehicle speed-limiter screw and removable engine speed-limiter plate are treated separately, an important distinction when setting up the ATV for a beginning rider.

Pre-operation checks cover fuel, engine and final-transmission oil, brakes, throttle action, drive chain, tires, fasteners, and switches. Maintenance sections address the NGK CR7HSA spark plug specification, engine and final-drive oil, the left and right air-box filter elements, spark-arrester cleaning, carburetor and idle adjustment, throttle free play, valve clearance, brake wear and fluid, chain service, cables and levers, wheel-hub bearings, battery, fuse, wheel removal, and a basic starting-system troubleshooting chart.

Riding chapters cover turns, hills, side slopes, shallow water, rough terrain, sliding and skidding. Cleaning, storage, vehicle identification, maintenance records, and warranty information are also included.

Internal engine repair, hydraulic brake work, and electrical diagnosis require the mechanical knowledge and test equipment Yamaha assumes in the service manual. Safety-critical systems should be fully checked before the ATV is ridden.