Yamaha YFM7FGX Service Manual

2008SUPPLEMENTARYSERVICE MANUAL3B4-28197-E1YFM7FGPXYFM7FGX

– 4 –SPECENGINE SPECIFICATIONSEBS01002ENGINE SPECIFICATIONSItem Standard LimitValve springFree lengthIntake 40.38 mm (1.59 in) 38.36 mm (1.51 in)Exhau

– 5 –SPECCHASSIS SPECIFICATIONSEBS01003CHASSIS SPECIFICATIONSItem Standard LimitFront wheelType Panel wheel ----Rim size 12 × 6.0 AT ----Rim material

– 6 –SPECELECTRICAL SPECIFICATIONSEBS01004ELECTRICAL SPECIFICATIONSItem Standard LimitECUModel/manufacturer F8T83472/MITSUBISHI ----Ignition coilModel

– 7 –SPECEBS01005TIGHTENING TORQUESENGINE TIGHTENING TORQUESEBS01006CHASSIS TIGHTENING TORQUESItem Part nameThread sizeQ’tyTightening torqueRemarksNm

– 8 –SPECCABLE ROUTINGEBS00028CABLE ROUTING1Coolant reservoir hose2Radiator fan motor breather hose3Differential gear case breather hose4EPS motor bre

– 9 –SPECCABLE ROUTINGI Shift control cableJ Starter motor leadÈ Face the end of the coolant reservoir breatherhose downward.É Route the ground lead,

– 10 –SPECCABLE ROUTINGÏ Place the EPS torque sensor lead and differen-tial gear motor lead in the holder, and then insertthe ends of the holder into

– 11 –SPECCABLE ROUTING× Pass the speed sensor lead, AC magneto lead,and final gear case breather hose through theguide in the order listed.Ø Route th

– 12 –SPECCABLE ROUTING1 Wire harness2 Fuel injector lead3 Fuel hose4 Intake air temperature sensor lead5 Final gear case breather hose6 Ground lead7

– 13 –SPECCABLE ROUTINGM Speed sensor leadN Coolant temperature sensor leadO EPS motor lead coupler (YFM7FGPX only)P EPS torque sensor lead coupler (Y

FOREWORDThis Supplementary Service Manual has been prepared to introduce new service and data for theYFM7FGPX/YFM7FGX. For complete service informatio

– 14 –SPECCABLE ROUTINGÍ Route the fuel tank drain hose to the inside ofthe leads and fuel hose, making sure to positionthe end of the drain hose as s

– 15 –SPECCABLE ROUTINGÓ Face the end of the plastic band inward.Ô Fasten the spark plug lead with the larger diam-eter section of each holder.Õ YFM7F

– 16 –SPECCABLE ROUTING1 Left headlight lead2 Negative battery lead3 Right headlight lead4 EPS (electric power steering) control unit (YFM7FGPX only)5

– 17 –SPECCABLE ROUTINGL Differential gear case breather hoseM Radiator fan motor breather hoseN Ground leadO Relay leadP Wire harnessQ Joint coupler

– 18 –SPECCABLE ROUTINGÏ Fasten the joint coupler lead and horn switchlead (for Europe and Oceania) with the clamp.Ð Pass the coolant reservoir breath

– 19 –SPECCABLE ROUTING1 Throttle cable2 Rear brake hose3 Rear brake cable4 Front brake hose5 Negative battery lead6 Final gear case breather hose7 St

– 20 –SPECCABLE ROUTINGK Fast idle plunger outlet hoseL Wire harnessÈ Route the final gear case breather hose on topof the leads.É Route the intake ai

– 21 –SPECCABLE ROUTINGÑ Pass the throttle cable through the guide on theplastic cover.Ò Insert the projection on the wire harness holderinto the hole

– 22 –CHKADJEBS00029PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjus

– 23 –CHKADJGENERAL MAINTENANCE AND LUBRICATION CHARTEBU21863GENERAL MAINTENANCE AND LUBRICATION CHARTNO. ITEMCHECK OR MAINTE-NANCE JOBINITIAL EVERYWh

EBS00002NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealersand their qualified mechanics. It is not possibl

– 24 –CHKADJGENERAL MAINTENANCE AND LUBRICATION CHARTEBU23070NOTE:• The air filter needs more frequent service if you are riding in unusually wet or d

– 25 –CHKADJAIR FILTER CASENewNew123894765Order Job/Part Q’ty RemarksRemoving the air filter caseRemove the parts in the order listed.Seat/side panels

– 26 –CHKADJEBS00110ADJUSTING THE FRONT SHOCK ABSORBERSWARNING_ Always adjust the spring preload for bothfront shock absorbers to the same setting.Une

– 27 –CHKADJADJUSTING THE REAR SHOCK ABSORBERSDirection aSpring preload is increased (suspension is harder).Direction bSpring preload is decreased (su

– 28 –ENGCRANKCASEEBS00319ENGINECRANKCASE TIMING CHAIN AND OIL FILTERLTNewNewNewNewNewNewNewNewLSLSLSLSLTELTLTLTLTLSLT256981743T R..7 Nm (0.7 m • kg,

– 29 –ENGLTNewNewNewNewNewNewNewNewLSLSLSLSLTELTLTLTLTLSLT256981743T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)T R..17 Nm (1.7 m • kg, 12 ft • Ib)T R..10 Nm (1

– 30 –FITHROTTLE BODYEAS00909FUEL INJECTION SYSTEMTHROTTLE BODY569913NewLST R..3 Nm (0.3 m • kg, 2.2 ft • Ib)472131112108Order Job/Part Q’ty RemarksRe

– 31 –FITHROTTLE BODY569913NewLST R..3 Nm (0.3 m • kg, 2.2 ft • Ib)472131112108Order Job/Part Q’ty Remarks9 Throttle body joint clamp screw 2 Loosen.

– 32 –FINewNewNew1234567Order Job/Part Q’ty RemarksDisassembling the throttle body assemblyRemove the parts in the order listed.1 Intake air pressure

– 33 –CHASSTEERING SYSTEMEBS00454CHASSIS STEERING SYSTEMSTEERING STEM (YFM7FGX only)81396743310165521NewNewNewNewNewNewNewLTLTLS(4)T R..23 Nm (2.3 m •

EBS00004HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “SYMBOLS”.)1st title 1: Th

– 34 –CHAS81396743310165521NewNewNewNewNewNewNewLTLTLS(4)T R..23 Nm (2.3 m • kg, 17 ft • Ib)T R..30 Nm (3.0 m • kg, 22 ft • Ib)T R..25 Nm (2.5 m • kg,

– 35 –CHASSTEERING SYSTEMINSTALLING THE PITMAN ARM (YFM7FGX only)1. Install:• pitman arm 1• washer• pitman arm nut• clipNOTE:Align the groove a in the

– 36 –CHASSTEERING SYSTEMINSTALLING THE STEERING STEM (YFM7FGPX only)1. Install:• EPS unit 1• washers• EPS unit bolts 22. Install:• steering stem 3• s

– 37 –– +ELECEBS00500ELECTRICALELECTRICAL COMPONENTS1Four-wheel-drive motor relay 32Rear brake relay3Four-wheel-drive motor relay 24Four-wheel-drive m

– 38 –– +ELECELECTRICAL COMPONENTSC Reverse switchD Gear position switchE Auxiliary DC jackF Main switchG Differential gear motorH EPS motor (YFM7FGPX

– 39 –– +ELECELECTRICAL COMPONENTS1 Lean angle sensor2 Radiator fan motor relay3 Fuel injection system relay4 Starting circuit cut-off relay5 Front br

YFM7FGPX/YFM7FGX 2008 WIRING DIAGRAM (for CDN)1 Crankshaft position sensor2 AC magneto3 Rectifier/regulator4 Main switch5 Frame ground6 Main fuse7 EPS

YFM7FGPX/YFM7FGX 2008 WIRING DIAGRAM (for Europe and Oceania)1 Crankshaft position sensor2 AC magneto3 Rectifier/regulator4 Main switch5 Frame ground6

YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPAN

YFM7FGPX/YFM7FGX 2008 WIRING DIAGRAM (for CDN)YFM7FGPX/YFM7FGX 2008 SCHÉMA DE CÂBLAGE (Canada)G/YBB/LGyBLLBBrR/B(GRAY)R/BR/W(GRAY)PBGW/BBrL/WG/Y(GREEN

EBS00006SYMBOLSThe following symbols are not relevant toevery vehicle. Symbols 1 to 0 indicate the subject of eachchapter.1General information 2Specif

YFM7FGPX/YFM7FGX 2008 WIRING DIAGRAM (for Europe and Oceania)YFM7FGPX/YFM7FGX 2008 SCHÉMA DE CÂBLAGE(Europe et Océanie)G/YBB/LGyBrR/B(GRAY)R/BR/W(GRAY

CONTENTSGENERAL INFORMATION... 1SPECIAL TOOLS ...

– 1 –GENINFOSPECIAL TOOLSEBS00021GENERAL INFORMATION SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and asse

– 2 –SPECEBS01001SPECIFICATIONSGENERAL SPECIFICATIONSItem StandardModel code3B4E, 3B4J, 3B4N, 3B4S (YFM7FGPX) (for CDN)3B4F, 3B4K, 3B4P (YFM7FGPX) (fo

– 3 –SPECGENERAL SPECIFICATIONSTransmissionPrimary reduction system V-beltSecondary reduction system Shaft driveSecondary reduction ratio 41/21 × 24/1