- Ya m a h a R a p t o r 0
I n s ta l l a t i o n I n s t r u c t i o n s
Power Commander USB Cable CD-ROM

Parts List

Button Adjustment Display
Installation Guide Power Adapter Power Commander Decals Dynojet Decals Velcro

Alcohol Swab

Faceplate Buttons USB Port

Expansion Port

The ignition MUST be turned OFF before installation!
You can also download the Power from our web site at:
Commander software and latest maps www.powercommander.com
PLEASE READ ALL DIRECTIONS BEFORE STARTING INSTALLATION
Dynojet Research 2191 Mendenhall Drive North Las Vegas, NV 89081 (800) 992-4993 www.powercommander.com
i416-411 www.powercommander.com 2006-2008 Yamaha Raptor700 - PCIII USB - 1

Remove these bolts

Remove seat. Remove the fuel tank cover and the front shroud over the radiator.

Fig. A

Remove the four fuel tank
mounting bolts and 2 push pins
(Fig. A shows the rear 2 mount-
ing bolts and the two push pins).

Remove these pins

Note: The fuel tank needs to be raised up to access the throttle body. the wiring harness or the fuel line from the fuel tank. You do NOT have to disconnect
Route the PCIII wiring harness throttle body going along the left hand side of the frame.
from the rear of the quad to the

Fig. B

Route the harness behind the air box mounting tab (Fig. B).

PCIII harness

Route the PCIII wiring harness tery bracket (Fig. C).
between the battery and the batrouting the PCIII harness underneath the frame and go to the throttle body. Continue

Fig. C

Ground wire
Attach the ground wire of the battery (Fig. C).
PCIII to the negative side of the

i416-411

www.powercommander.com
2006-2008 Yamaha Raptor700 - PCIII USB - 2

Unplug

Fig. D
Unplug the stock wiring harness from the fuel injector (Fig. D).

Stock.connector

Fig. E
Plug the PCIII wiring harness stock wiring harness (Fig. E).
in-line of the fuel injector and

PCIII.connectors

Unplug the Throttle Position

Fig. F

Sensor connector from the right hand side of the throttle body (Fig. F). This connector is cov-
ered with a BLACK rubber boot.

TPS connector

2006-2008 Yamaha Raptor700 - PCIII USB - 3

Stock connector

Fig. G
Connect the PCIII wiring harwiring harness (Fig. G).
ness in-line of the stock TPS and

connectors

Mount the PCIII into the tail cro.
section using the supplied velswab to clean the surface before Use the supplied alcohol

Fig. H

attaching the unit. 12
Mount the fuel tank back into place.
Make sure the wiring harness is routed in a manner that it will not get damaged.
2006-2008 Yamaha Raptor700 - PCIII USB - 4

DRI YAMAHA RAPTOR 700/715/727 NATIONAL KIT ASSEMBLY TIPS
2006-2008 Models SPECIAL NOTE: DRI does not recommend working on the engine of your Yamaha Raptor 700 without the assistance of the Genuine OEM Yamaha Service Manual.
ASSEMBLY: It is strongly recommended to follow all instructions in OEM Yamaha Service Manual, specifically for torque values and cam timing set. Also consult the DRI Tech Sheet for 4-Stroke Top End Assembly. SPECIAL NOTE: It is also advisable to read DRI TECH Sheet 4-Stroke Upgrade Components BREAK-IN: Read and follow instructions for DRI TECH Sheet 4-Stroke Engine Break In. *NOTE: Engine will run better after it has 3-5 hours on it. VALVE SETTINGS: Valves should be checked initially every 3-4 hours for first 12-hour period after initial set-up and every 20 hours after that. Consult your camshaft specification card for correct clearances. Stock clearances no longer apply after camshaft has been upgraded to a DRI camshaft. DRI CAM SETTINGS (Clearances must be set and checked with engine cold) Cam Profile Number Intake Exhaust 294 X1.005.X2.005.008 NOTE #1: Both X1 and X2 cams require heavy duty valve springs NOTE #2: X2 camshaft requires shortened valve guides for proper valve spring retainer clearance. NOTE #3: X2 cam requires head and rocker arm modifications. ROCKER ARM MODIFICATION: When installing a #294 X2 camshaft the rocker arms MUST be modified for cam lobe clearance. This modification MUST be performed by a trained professional with the proper equipment. Cylinder head must also be notched to accept the X2 camshaft. PISTON RINGS: Piston ring installation is a very delicate procedure and should be performed by a trained professional. All rings MUST have gap checked. *DRI recommends consulting their 4-STROKE PISTON RING ASSEMBLY TIPS install sheet before attempting to install your rings. **Improper ring gap settings can cause damage to piston and Nikasil coating on cylinder bore. COMPRESSION RELEASE: DRI recommends using the factory compression release system that is attached to the camshaft. Install and adjust exactly as per the instructions in the OEM Yamaha Service Manual. Call DRI Technical support if questions arise. SPARK PLUG: Use NGK CR8E Gap: 028 -.031.
AIR INTAKE: DRI recommends using a Pro Flow Air Cleaner kit, with K&N Filter. For best performance it is recommended to use stock air box with lid removed. Current as of 7/13/2009
EXHAUST: For maximum performance use Fat Boy 4 Complete Stainless Exhaust System. Turndown and /or spark arrestor screen are optional. Always install using new exhaust gaskets. FUEL: Use VP C-12 Fuel. Motor Octane 108 or Sonoco Standard (105 motor 0ctane) OIL: Maxima Premium 4 10W40*Consult Yamaha OEM Service Manual for oil capacity specifications. **BEFORE INSTALLING FRESH OIL IS STRONGLY RECOMMEMDED TO REMOVE OIL COOLER AND OIL TANK FROM MACHINE AND FLUSH THOUROUGHLLY OUT INTERNALS WITH CLEAN PARTS CLEANING SOLVENT CARBURETION: This machine is not carbureted. It is equipped with electronic fuel injection. AIR/FUEL MIXTURE: The air fuel mixture MUST be adjusted when your engine is modified. DRI recommends using the VORTEX EFI Interceptor. The plug in device has a revamped fuel map that corrects the air/fuel mixture for modified engines. The Interceptor is also adjustable for fine tuning in 2% increments too both richen and lean the mixture. TOP END SERVICE For maximum performance top end should be serviced at least every 20 hours. For standard usage top end should be serviced at least every 50 hours. A top end service includes checking, valves, valve sealing, piston clearance, cam chain and tensioner, lower rod bearing etc. Piston clearance should be kept between.003 -.0035 not recommended to exceed.005 Ring end gap should be kept.015 -.020 not to exceed.025 Consult DRI or a qualified technician for additional assistance. CRANKSHAFT: For Standard usage stock rod should be sufficient. Under serious performance conditions an upgraded connecting rod is required. Contact DRI for additional details. GEARING: OEM Gearing 14 x 38. Sand Riding (20 paddles) 14 x 38, MX (18 Tires 15 x 38). Trail Riding (20 Tire) Low Speed 14x38 -Medium Speed 15x38- High Speed 16 x 38 IGNITION: It is recommended to use the stock ignition at this time. *Available in the future from Vortex will be programmable ECU units. CLUTCH: The clutch must be kept in excellent condition for maximum performance to be delivered. DRI recommends installing a Hinson Billet Outer Clutch Basket. Call DR Tech department with any questions regarding clutch performance or upgrades. TRANSMISSION: DRI recommends staying with the stock oem transmission assembly.

Current as of 7/13/2009

RADIATOR: Stock radiator works OK for stock engines. A High capacity radiator is strongly recommended for modified/hi compression 700 engines and all big bore engines. Heating issues will result if radiator is not upgraded HOUR METER: It is recommended to install and hour meter on your machine. This device can come in very handy keeping track of packing life, valve adjustments, oil changes, top end service, etc. A number of manufactures offer them for under $ 50.00. Installation is simple NOTES 1. Valve clearance and Deck height must be checked. Valve to Piston clearance should be minimum.060, Piston to Head clearance should be.040 minimum. 2. Must use special modified DRI steel head gasket for 105.00mm piston and larger. DRI is not responsible for any engine component (gears, rod, etc.) fatigue or failure due to increased horsepower and torque.