Yamaha Raptor 90 2011–2013 Service & Owner’s Manual Set (P/N LIT-11616-24-16)

The service manual covers diagnosis and component repair. The owner’s manual explains how to operate the ATV and what to check before and between rides.

Factory repair procedures apply to the YFM90RA (43D7). Some specifications differ between the two publications, so use the values for your model.

Searchable Text, Bookmarks, and Wiring Detail

Finding information in the PDFs: Both files have searchable text and embedded bookmarks. The owner’s warranty card is included as two page images without searchable text. Small connector labels and wire-color codes in the service manual’s circuit and wiring diagrams are legible when zoomed in.

The ZIP contains two printable PDFs with 363 pages total. The count includes both manuals’ covers, three blank pages and the landscape wiring diagram in the service manual, and two warranty card pages and three supplemental information pages in the owner’s manual.

Engine and Belt-Drive Repair, Electrical Checks, and ATV Care

These are selected topics from the two manuals. The owner’s manual also covers engine break-in and storage.

• Engine repair: Step-by-step procedures for engine removal and installation, cylinder head and valve train service, piston and cylinder inspection, and crankshaft and transmission checks.

• Belt drive and starter clutch: Kickstarter service, primary and secondary sheave disassembly and reassembly, V-belt and clutch shoe inspection, and starter clutch checks.

• Carburetor service: Removal, disassembly, and inspection of the TK SVR 22-1G carburetor, with procedures for measuring and adjusting the float chamber fuel level.

• Chassis and brakes: Front drum brake service, rear hydraulic disc brake repair and bleeding, rear axle and wheel hub work, and steering and suspension inspection.

• Electrical troubleshooting: Switch continuity and AC-CDI ignition tests, electric-start circuit diagnosis, starter motor inspection and reassembly, and charging-system checks.

• Owner operation and maintenance: Cold and warm starting, rider controls and speed limiters, pre-ride inspections, and scheduled maintenance.

Yamaha wrote the service manual primarily for dealers and qualified mechanics, and the owner’s manual guides riders and supervising parents through safe operation and routine upkeep.

Engine, Carburetor, and Belt Drive

The engine chapter covers C.D.I. magneto removal, oil pump inspection, timing chain service, and connecting rod checks on the wet-sump single-cylinder engine. The crankcase procedure explains how to separate the halves evenly to protect the mating surfaces from damage that can cause oil leaks.

Exploded carburetor views accompany checks of the float, needle valve, and jets. The V-belt automatic drive section covers the dry centrifugal clutch, primary sheave weights, slider, and secondary sheave torque cam and guide pins. It specifies an oil seal guide to protect the secondary sheave seal lip during assembly. The troubleshooting chapter identifies oil or grease on the belt as a cause of slipping and poor speed performance.

Chassis Setup and Workshop References

The chassis chapter covers driven sprocket removal, rear master cylinder and caliper overhaul, and service of the steering stem, tie rods, knuckles, front arms, shocks, and swingarm. Setup checks include steering play, toe-in, shock spring preload, drive chain alignment and slack, and wheel and tire condition.

Factory tables cover engine and chassis torques, lubrication points, fluid grades and capacities, wear limits, and inspection clearances. The tool list pairs U.S. and Canadian numbers with 90890-series equivalents, including the flywheel puller (90890-01189 / YM-01189), tappet adjusting tool (90890-01311 / YM-08035), and fuel-level gauge (90890-01312 / YM-01312-A). It also lists the valve spring compressor (90890-04019 / YM-04019), clutch spring holder (90890-01337 / YM-33285), and axle nut wrench (90890-01422 / YM-37132).

Wiring and Fault Finding

Separate ignition, electric starting, and charging circuit diagrams accompany the electrical tests. The full YFM90R wiring diagram shows connector layouts and wire-color codes. The oil flow diagram and cable routing views provide references for engine and chassis work.

The starting-circuit checks help distinguish a rear brake switch or starter relay fault from a starter motor fault when the engine will not crank. Symptom-based troubleshooting also covers hard starting, poor idle or high-speed performance, a running engine with no drive, overheating, weak braking, shock faults, and unstable handling.

Riding and Routine Maintenance

The owner’s manual explains the main switch, handlebar controls, fuel cock, choke, and electric and kick starting. It treats the vehicle speed-limiter screw and the removable engine speed-limiter plate separately so parents can identify the two controls used when setting up the ATV for a beginning rider. Riding guidance covers turns, hills, side slopes, shallow water, rough terrain, and skidding.

Pre-ride checks cover fuel, oil, brakes, throttle action, chain, tires, fasteners, and switches. Maintenance covers spark plug checks, engine and final transmission oil changes, both air filter elements, spark arrester cleaning, idle and throttle free play, brake wear and fluid, chain service, cables and levers, wheel hub bearings, battery and fuse service, and wheel removal. The manual directs owners to a Yamaha dealer for valve-clearance adjustment and brake component replacement. It also includes a basic no-start chart, vehicle identification, maintenance records, and warranty information.

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.

Selected Belt and Clutch Wear Limits

The YFM90RA service manual lists a standard V-belt width of 18.0 mm and a wear limit of 17.0 mm. The width check helps determine when belt wear warrants replacement.

For the same drive assembly, the clutch housing inspection gives a maximum inside diameter of 107.5 mm. This gives the technician a separate wear check when inspecting the centrifugal clutch.