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Free Yamaha Raptor workshop service manual!
Do not add any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slippage. Do not allow foreign material to enter the crankcase. Stop the engine and inspect the oil level again. NOTE: Wait a few minutes until the oil settles before inspecting the oil level. Stop the engine and place a container under the engine oil drain bolt. Stop the engine, and then pour in the remainder of the specified amount.
Warm up the engine for a few minutes, then stop the engine. If no engine oil comes out after one minute, turn the engine off so that it will not seize. NOTE: If the specified clutch lever free play cannot be obtained on it, use the adjusting bolt 3. This will allow unfiltered air to enter, causing rapid wear and possible engine damage.
Additionally, operation without the filter element will affect carburetor tuning with subsequent poor performance and possible engine overheating. Never use gasoline or low flash point solvents as they may cause a fire or explosion. Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check and if necessary, correct the antifreeze concentration of the coolant.
Use only distilled water. However, soft water may be used if distilled water is not available. Start the engine, warm it up for several minutes, and then turn it off. Therefore, do not remove the radiator cap when the engine is hot.
Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, turn the radiator cap counterclockwise while pressing down on it and then remove it.
If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor. If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. If coolant is swallowed, induce vomiting and get immediate medical attention.
If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant. If coolant comes into contact with painted surfaces, immediately wash them with water.
Do not mix different types of antifreeze. NOTE: Before inspecting the coolant level, wait a few minutes until the coolant has settled. Select a well-ventilated area free of combustible materials. Always let the exhaust system cool before performing this operation. Do not start the engine when removing the tailpipe from the muffler. Brake lever free play at the brake lever end : 0 mm 0 in. Rear brake pedal height: 4 mm 0. Brake pedal height: 4 mm 0.
NOTE: When adjusting the brake pedal height make sure the locknut-to-adjusting bolt clearance a does not exceed 2. WARNING After this adjustment is performed, lift the rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake drag.
If any brake drag is noticed perform the above steps again. Free play parking brake cable : 0 mm 0 in at parking brake lever pivot. NOTE: When inspecting the brake fluid level, make sure that the top of the brake fluid reservoir top is horizontal. Always clean up spilled fluid immediately. Use only the designated quality brake fluid: Otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.
Refill with the same type of brake fluid: Mixing fluids may result in a harmful chemical reaction and lead to poor performance. Be careful that water does not enter the master cylinder when refilling.
Water will significantly lower the boiling point of the fluid and may result in a vapor lock. Brake pad wear limit a: 1 mm 0. Operate the brake lever. Operate the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. Hold the machine in an upright position and apply the front or rear brake. A loss of braking performance may occur if the brake system is not properly bled. Add the proper brake fluid to the reservoir.
Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. Connect the clear plastic hose 1 tightly to the caliper bleed screw 2. Place the other end of the hose into a container. Slowly apply the brake lever or pedal several times. Pull the lever in or push down on the pedal and hold it. Loosen the bleed screw and allow the lever or pedal to travel towards its limit.
Tighten the bleed screw when the lever or pedal limit has been reached, then release the lever or pedal. Repeat steps e to h until all the air bubbles have disappeared from the fluid. NOTE: If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. Add brake fluid to the proper level. Shift pedal height: 22 mm 0.
Direction a. Reverse knob free play: 0 mm 0 in. NOTE: Be sure to hold the reverse shift lever 6 when make this adjustment so that it does not move. CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident.
Therefore, keep the drive chain slack within the specified limits. Elevate the rear wheels by placing the suitable stand under the frame. Rotate the rear wheel several times and check the drive chain to locate its tightest point. NOTE: To maintain the proper axle alignment, adjust both sides evenly. There are marks c on each side of hub. Raise the front end of the machine so that there is no weight on the front wheels.
Be sure that both tie-rods are turned the same amount. If not, the machine will drift right or left even though the handlebar is positioned straight. This may lead to mishandling and an accident. After setting the toe-in to specification, run the machine slowly for some distance with both hands lightly holding the handlebar and check that the handlebar responds correctly.
If not, turn either the right or left tierod within the toe-in specification. This reference point will be needed during adjustment.
This is to keep the length of the rods the same. Uneven adjustment can cause poor handling and loss of stability. Adjusting length c: Standard: mm 9. From the fully turned-in position: Standard: 10 clicks out Minimum: 20 clicks out Maximum: 3 clicks out. The adjuster may be damaged. From the fully turned-out position: Standard: 7 clicks in Minimum: 1 click in Maximum: 12 clicks in. It is important that they be inflated correctly and maintained at the proper pressures.
The tires listed below have been approved by Yamaha Motor Co. The following are minimums: Front Higher pressures may cause the tire to burst. Inflate the tires slowly and carefully. Fast inflation could cause the tire to burst. Cold tire pressure Standard.
Tire wear limit a: Front and rear: 3. When tire wear is out of specification, replace the tire immediately. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. Never attempt even small repairs to the wheel.
Ride conservatively after installing a tire to allow it to seat itself properly on the rim. An unsafe condition may result so replace a damaged cable as soon as possible. Recommended lubricant: Yamaha chain and cable lube or Engine oil NOTE: Hold the cable end up and apply several drops of lubricant to the cable.
Lubricate the pivoting parts. Recommended lubricant: Lithium soap base grease. Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals. Never remove the sealing caps. If the sealing caps have been removed, the balance will not be maintained and battery performance will deteriorate.
If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery. Get immediate medical attention. Batteries generate explosive hydrogen gas.
If it is impossible to set the standard charging current, be careful not to overcharge. When charging the battery, be sure to remove it from the motorcycle. If charging has to be done with the battery mounted on the motorcycle, be sure to disconnect the wire at the negative terminal. Never remove the sealing caps of an MF battery.
Make sure that the charging clips are in full contact with the terminal and that they are not shorted together. A corroded clip on the charger may cause the battery to generate heat in the contact area. A weak clip spring may cause sparks. Downloading a Yamaha Raptor repair manual is easy. And no special software is needed to download the manual and view it.
Once downloaded, the manual can be saved to your computer, tablet or smartphone forever. So what are you waiting for? Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE: Designs and specifications are subject to change without notice. Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine. A NOTE provides key information to make procedures easier or clearer. It is located in the upper left corner of the page.
An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6.
The meanings of the symbol marks are given on the next page. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart. Illustrated symbols H to N in the exploded diagrams indicate the types of lubricants and lubrication points.
Illustrated symbols O to P in the exploded diagrams indicate where to apply a locking agent O and when to install a new part P. This information will be needed to order spare parts. Remove all dirt, mud, dust and foreign material before removal and disassembly.
Use proper tools and cleaning equipment. When disassembling the machine, always keep mated parts together. Mated parts must always be reused or replaced as an assembly.
During machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. Page Chapter 8. Wheel runout limit: Radial 2: 2. Check: Wheel balance If wheel runout is within the limits, replace the brake disc. Brake disc maximum deflection: 0. Install each nut with its tapered side towards the wheel. Wheel runout limit: Radial: 2. Install: Wheel Put the other end of this hose into an open container.
Brake fluid reservoir cap Brake fluid reservoir diaphragm Brake lever Union bolt Brake master cylinder kit For assembly, reverse the disassembly procedure. For assembly, reverse the disassembly procedure. Water will significantly lower the boiling point of the brake fluid and may result in vapor lock. Always clean up spilled brake fluid immediately. Brake fluid Drain. Union bolt Copper washer Brake hose Disconnect. Bend the lock washer tab along a flat side of the bolt.
NOTE: Pass the cables and hoses through the cable guide. NOTE: Install the outside bearing first. Contact should be made only with the outer race. If side play is noticeable, check the bushings. Nut 6: 45 Nm 4. Nut 7: 45 Nm 4.
Page Chapter 9. If the continuity is faulty at any point, replace the switch. The coupler locations are circled. Fuse main, ignition 7.
Engine stop switch 2. Battery 8. Main switch 3. Spark plug 9. Pickup coil resistance 4. Ignition spark gap Spark plug cap resistance coil resistance 6.
Ignition coil resistance Properly connect the ignition system. If the main switch is on and the engine stop switch is in the RUN position, the starter motor can be operated only if: The transmission is in neutral the neutral Rear brake switch 1. Fuse main, ignition 9. Start switch 2. Battery Diode 3. Starter motor Wiring connection the entire starting sys- 4.
Starter relay tem 5. Main switch 6. Engine stop switch 7. Diode Remove the diode from the coupler. Check the diode for continuity as follows. Bracket 1 Washer kit Bracket Outside diameter: 28 mm 1. Measure: Mica undercut b Brush length: Fuse main 4.
Charging coil resistance 2. Battery 5. Wiring connections 3. YUA shooting: Engine tachometer: 1 Seat The charging circuit is not faulty. Light switch 1. Fuse main, headlight 5. Wiring connections 2. Battery the entire lighting system 3. EB 5. Fuse main, ignition, signaling system 2. Battery 3. Main switch 4.
Properly connect the signal system.
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