2008 SUPPLEMENTARY SERVICE MANUAL YFM7FGPX YFM7FGX 3B4-28197-E1
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YFM7FGPX/YFM7FGX. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. YFM7FGPW SERVICE MANUAL: 3B4-28197-E0 YFM7FGPX/YFM7FGX SUPPLEMENTARY SERVICE MANUAL ©2007 by Yamaha Motor Co., Ltd. First edition, March 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co.
EBS00002 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe and unfit for use.
EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “SYMBOLS”.) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.
1 EBS00006 2 GEN INFO SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 0 indicate the subject of each chapter.
CONTENTS GENERAL INFORMATION ................................................................................ 1 SPECIAL TOOLS ......................................................................................... 1 SPECIFICATIONS .............................................................................................. 2 GENERAL SPECIFICATIONS ..................................................................... 2 ENGINE SPECIFICATIONS..................................................................
SPECIAL TOOLS GEN INFO EBS00021 GENERAL INFORMATION SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided. When placing an order, refer to the list provided below to avoid any mistakes. For US and CDN P/N.
GENERAL SPECIFICATIONS SPEC EBS01001 SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code 3B4E, 3B4J, 3B4N, 3B4S (YFM7FGPX) (for CDN) 3B4F, 3B4K, 3B4P (YFM7FGPX) (for Europe) 3B4G, 3B4R (YFM7FGPX) (for Oceania) 5C02, 5C06 (YFM7FGX) (for CDN) 5C04 (YFM7FGX) (for Oceania) Oil type or grade Engine oil For CDN 0° 10° 30° 50° 70° 90° 110° 130°F API service, SG type or higher, JASO standard MA YAMALUBE4 (20W40) or SAE 20W40 YAMALUBE4 (10W30) or SAE 10W30 YAMALUBE 4-CW (5W30) or SAE 5W30
GENERAL SPECIFICATIONS Item Transmission Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Single speed automatic Sub transmission ratio SPEC Standard low high Reverse gear Bulb voltage/wattage × quantity Headlight Tail/brake light Indicator light Neutral indicator light Reverse indicator light Coolant temperature warning light Engine trouble warning light EPS warning light Park indicator light On-command four-wheel drive/differential gear lock ind
ENGINE SPECIFICATIONS SPEC EBS01002 ENGINE SPECIFICATIONS Item Valve spring Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Standard 40.38 mm (1.59 in) 40.38 mm (1.59 in) Limit 38.36 mm (1.51 in) 38.36 mm (1.51 in) 35.00 mm (1.38 in) 35.00 mm (1.38 in) ------- 171 ~ 197 N (17.44 ~ 20.09 kgf, 38.44 ~ 44.29 lb) 171 ~ 197 N (17.44 ~ 20.09 kgf, 38.44 ~ 44.
CHASSIS SPECIFICATIONS SPEC EBS01003 CHASSIS SPECIFICATIONS Item Front wheel Type Rim size Rim material Standard Maximum radial wheel runout Panel wheel 12 × 6.0 AT Aluminum (YFM7FGPX) Steel (YFM7FGX) ---- Maximum lateral wheel runout ---- Rear wheel Type Rim size Rim material Maximum radial wheel runout Panel wheel 12 × 7.5 AT Aluminum (YFM7FGPX) Steel (YFM7FGX) ---- Maximum lateral wheel runout ---- –5– Limit ---------2.0 mm (0.08 in) 2.0 mm (0.08 in) ---------2.0 mm (0.08 in) 2.0 mm (0.
ELECTRICAL SPECIFICATIONS SPEC EBS01004 ELECTRICAL SPECIFICATIONS Item ECU Model/manufacturer Ignition coil Model/manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance Circuit breaker Circuit breaker type Fuses Main fuse Headlight fuse Signaling system fuse Ignition fuse Auxiliary DC jack fuse Fuel injection system fuse Four-wheel-drive motor fuse EPS fuse Radiator fan motor fuse Spare fuse Standard Limit F8T83472/MITSUBISHI ---- 2JN/YAMAHA 6.0 mm (0.24 in) 2.
TIGHTENING TORQUES SPEC EBS01005 TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Item Oil filter cartridge union bolt Exhaust pipe Middle drive pinion gear nut Part name Union bolt Nut Nut Thread Q’ty size M20 M8 M22 1 4 1 Tightening torque Nm m · kg ft · lb 30 14 190 3.0 1.4 19.0 22 10 140 Remarks LT Stake.
SPEC CABLE ROUTING EBS00028 CABLE ROUTING 1 Coolant reservoir hose 2 Radiator fan motor breather hose 3 Differential gear case breather hose 4 EPS motor breather hose (YFM7FGPX only) 5 Ground lead 6 Coolant reservoir breather hose 7 Throttle cable 8 Fuel injector lead 9 Final gear case breather hose 0 Speed sensor lead A Crankshaft position sensor lead B Differential gear motor lead C EPS torque sensor lead (YFM7FGPX only) D Fast idle plunger outlet hose E Horn switch lead (for Europe and Oceania) F Radi
SPEC CABLE ROUTING Ë Route the coolant reservoir breather hose to the outside of the fast idle plunger outlet hose. Ì Route the fuel injector lead under the fuel hose. Í Fasten the radiator outlet hose to the frame with the plastic band, making sure to face the end of the band inward. Î Route the EPS motor breather hose under the coolant reservoir hose. I Shift control cable J Starter motor lead È Face the end of the coolant reservoir breather hose downward.
SPEC CABLE ROUTING Ó Route the radiator fan motor breather hose, differential gear case breather hose, and horn switch lead to the inside of the fast idle plunger outlet hose and radiator outlet hose. Ô Make sure that the catch of the holder is facing outward. Õ Face the end of the plastic band inward. Ö Route the fuel tank drain hose and position the end of the hose as shown in the illustration.
SPEC CABLE ROUTING Û YFM7FGPX Ü YFM7FGX × Pass the speed sensor lead, AC magneto lead, and final gear case breather hose through the guide in the order listed. Ø Route the speed sensor lead, AC magneto lead, and final gear case breather hose to the right of the reverse switch. Ù Route the final gear case breather hose above the reverse switch lead and ground leads. Ú Route the shift control cable under the gear position switch lead, speed sensor lead, and crankshaft position sensor lead.
CABLE ROUTING 1 Wire harness 2 Fuel injector lead 3 Fuel hose 4 Intake air temperature sensor lead 5 Final gear case breather hose 6 Ground lead 7 Starter motor lead 8 Air filter case breather hose 9 Main switch lead 0 Auxiliary DC jack lead A EPS motor lead (YFM7FGPX only) SPEC B Differential gear motor lead C EPS torque sensor lead (YFM7FGPX only) D Radiator fan motor lead E Radiator inlet hose F EPS motor breather hose (YFM7FGPX only) G Spark plug lead H Rear brake cable I Shift control cable J Fuel ta
CABLE ROUTING SPEC Ê Route the final gear case breather hose above the V-belt cooling duct 1. Ë Route the radiator fan motor lead between the electrical components tray and the radiator inlet hose. Ì Fasten the radiator fan motor lead to the frame with the plastic band, making sure to face the end of the band inward.
CABLE ROUTING SPEC Ï Route the fuel injector lead and coolant temperature sensor lead to the inside of the ground lead, starter motor lead, final gear case breather hose, and wire harness. Ð Face the end of the plastic band inward. Ñ Pass the plastic band through the hole in the plastic cover, and then fasten the leads and hose with the band, making sure to face the end of the band downward. Ò Insert the projection on the coupler into the hole in the frame from the inside of the frame.
CABLE ROUTING SPEC Ó Face the end of the plastic band inward. Ô Fasten the spark plug lead with the larger diameter section of each holder.
SPEC CABLE ROUTING 1 Left headlight lead 2 Negative battery lead 3 Right headlight lead 4 EPS (electric power steering) control unit (YFM7FGPX only) 5 Radiator fan motor lead 6 EPS control unit lead (YFM7FGPX only) 7 Auxiliary DC jack lead 8 Main switch lead 9 Final gear case breather hose 0 Starter motor lead A Differential gear motor lead B Ignition coil lead C Meter lead D Lean angle sensor lead E Coolant reservoir breather hose F Main fuse G EPS fuse (YFM7FGPX only) H Positive battery lead I Horn swit
SPEC CABLE ROUTING Ê Route the negative battery lead along the guide on the electrical components tray. Ë To right headlight Ì Place the couplers on the inside of the electrical components tray. Í To main switch and auxiliary DC jack Î Fasten the left handlebar switch lead, on-command four-wheel-drive motor switch and differential gear lock switch lead, front brake light switch lead, and rear brake light switch lead with the clamp.
SPEC CABLE ROUTING Ó Fasten the coolant reservoir hose with the holder on the electrical components tray. Ô Pass the hoses, ground lead, and horn switch lead through the opening in the electrical components tray. Õ Route the coolant reservoir breather hose above the other hoses. Ö Route the hoses to the inside of the bolt. × YFM7FGPX Ø YFM7FGX Ï Fasten the joint coupler lead and horn switch lead (for Europe and Oceania) with the clamp.
CABLE ROUTING 1 Throttle cable 2 Rear brake hose 3 Rear brake cable 4 Front brake hose 5 Negative battery lead 6 Final gear case breather hose 7 Starter motor lead 8 Throttle body breather hose 9 Engine idling speed adjusting cable 0 Intake air pressure sensor lead SPEC A Breather hose (air filter case to fast idle plunger unit) B TPS lead C Intake air temperature sensor lead D Fuel injector lead E Coolant temperature sensor lead F Rectifier/regulator lead G AC magneto lead H Fuel hose I Tail/brake light
CABLE ROUTING Ì Route the fuel injector lead and coolant temperature sensor lead to the outside of the frame. Í Pass the tail/brake light lead through the hole in the rear fender. Î Fasten the tail/brake light lead with the holder, making sure that the coupler is positioned to the rear of the holder. Ï Route the throttle cable under the plastic cover. Ð Route the fast idle plunger outlet hose above the plastic cover.
CABLE ROUTING SPEC Ñ Pass the throttle cable through the guide on the plastic cover. Ò Insert the projection on the wire harness holder into the hole in the plastic cover.
INTRODUCTION/PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM CHK ADJ EBS00029 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced.
GENERAL MAINTENANCE AND LUBRICATION CHART CHK ADJ EBU21863 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) 20 80 160 160 320 hours 1 2 * Air filter element • Clean and replace if necessary. Front brake • Check operation and correct if necessary. • Check fluid level and ATV for fluid leakage, and correct if necessary.
GENERAL MAINTENANCE AND LUBRICATION CHART CHK ADJ INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first EVERY month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 • Change. • Check ATV for oil leakage, and correct if necessary. √ • Check coolant level and ATV for coolant leakage, and correct if necessary. √ 21 Final gear oil 22 Cooling system 23 * Moving parts and cables • Lubricate.
AIR FILTER CASE CHK ADJ AIR FILTER CASE 2 3 1 8 New 9 New 4 5 6 7 Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the air filter case Seat/side panels Q’ty Air filter case cover Air filter element Air filter element frame Air filter case joint clamp screw Intake air temperature sensor coupler Breather hose (air filter case to fast idle plunger unit) Cylinder head breather hose Intake air temperature sensor Air filter case 1 1 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed.
ADJUSTING THE FRONT SHOCK ABSORBERS/ ADJUSTING THE REAR SHOCK ABSORBERS CHK ADJ EBS00110 ADJUSTING THE FRONT SHOCK ABSORBERS WARNING _ Always adjust the spring preload for both front shock absorbers to the same setting. Uneven adjustment can cause poor handling and loss of stability. 1 2 3 4 1. Adjust: • spring preload Turn the adjuster 1 in direction a or b. 5 Steering nut wrench 90890-01443 Spanner wrench YU-33975 1 a b Direction a Spring preload is increased (suspension is harder).
ADJUSTING THE REAR SHOCK ABSORBERS Direction a Spring preload is increased (suspension is harder). Direction b Spring preload is decreased (suspension is softer).
ENG CRANKCASE EBS00319 ENGINE CRANKCASE TIMING CHAIN AND OIL FILTER T. 17 Nm (1.7 m • kg, 12 ft • Ib) R. 9 E 6 8 New LS T. New R. T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) R. LS T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) New LS 5 T. R. New 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 LS LT LT New 4 LT LS LT LT 3 New 2 New 7 LT T. R. New 30 Nm (3.0 m • kg, 22 ft • Ib) LT T. R. 17 Nm (1.7 m • kg, 12 ft • Ib) T. R.
ENG CRANKCASE T. 17 Nm (1.7 m • kg, 12 ft • Ib) R. 9 E 6 8 New LS T. New R. T. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) R. LS T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) New LS 5 T. R. New 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 LS LT LT New 4 LT LS LT LT 3 New 2 New 7 LT T. R. New 30 Nm (3.0 m • kg, 22 ft • Ib) LT T. R. 17 Nm (1.7 m • kg, 12 ft • Ib) T. R.
FI THROTTLE BODY EAS00909 FUEL INJECTION SYSTEM THROTTLE BODY LS 4 8 New 10 7 1 3 2 12 11 13 6 9 T. R. Order 5 9 3 Nm (0.3 m • kg, 2.
FI THROTTLE BODY LS 4 8 New 10 7 1 3 2 12 11 13 9 T. R. Order 9 10 Job/Part Throttle body joint clamp screw Throttle body assembly 5 6 9 3 Nm (0.3 m • kg, 2.2 ft • Ib) Q’ty 2 Loosen. 1 11 Fuel hose 1 12 13 Fuel injector coupler Throttle body joint 1 1 – 31 – Remarks Refer to “INSTALLING THE THROTTLE BODY ASSEMBLY” in chapter 6. (Manual No.: 3B4-28197-E0) Disconnect. Refer to “REMOVING THE THROTTLE BODY ASSEMBLY” and “INSTALLING THE THROTTLE BODY ASSEMBLY” in chapter 6.
FI THROTTLE BODY 6 4 New 3 5 New New 7 1 2 Order 1 2 3 4 5 6 7 Job/Part Disassembling the throttle body assembly Intake air pressure sensor Intake air pressure sensor hose Throttle position sensor Injector fuel rail Fuel injector Fast idle plunger unit Throttle body Q’ty 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. CAUTION: The throttle body should not be disassembled. For assembly, reverse the disassembly procedure.
STEERING SYSTEM CHAS EBS00454 CHASSIS STEERING SYSTEM STEERING STEM (YFM7FGX only) T. 10 R. 51 Nm (5.1 m • kg, 37 ft • Ib) T. LS R. 5 New 23 Nm (2.3 m • kg, 17 ft • Ib) LS New 1 2 4 3 16 3 LT LT 5 New LS LS New 12 T. 30 Nm (3.0 m • kg, 22 ft • Ib) R. New 14 LS 15 New (4) 6 11 LT 6 LS Job/Part Removing the steering stem Front fender R. Order T.
STEERING SYSTEM T. 10 R. 51 Nm (5.1 m • kg, 37 ft • Ib) T. LS R. 5 New 23 Nm (2.3 m • kg, 17 ft • Ib) CHAS LS New 1 2 4 3 16 3 LT LT 5 New LS LS New 12 T. 30 Nm (3.0 m • kg, 22 ft • Ib) R. New 14 LS 15 New (4) 6 11 LT 6 LS Job/Part Tie rod end nut Tie rod Pitman arm nut Pitman arm Steering stem Steering stem support Oil seal Oil seal Circlip Bearing Steering stem bracket R. Order 6 7 8 9 10 11 12 13 14 15 16 T. 8 R. 9 T. New 13 7 25 Nm (2.
STEERING SYSTEM CHAS INSTALLING THE PITMAN ARM (YFM7FGX only) 1. Install: • pitman arm 1 • washer • pitman arm nut b a 1 T. 190 Nm (19.0 m · kg, 140 ft · lb) R. • clip NOTE: Align the groove a in the pitman arm with the steering stem spline b that is indented. INSTALLING THE LOCK WASHER (YFM7FGX only) 1. Install: • cable guide • lock washer New • steering stem bushing bolts a T. R. a 23 Nm (2.3 m · kg, 17 ft · lb) NOTE: • Bend the lock washer tab a along a flat side of the bolt.
STEERING SYSTEM 3 A 0 8 9 7 B G INSTALLING THE STEERING STEM (YFM7FGPX only) 1. Install: • EPS unit 1 • washers • EPS unit bolts 2 7 H C 9 H T. UP R. 5 6 D E 4 2 F 2. • • • • EPS unit bolt 30 Nm (3.0 m · kg, 22 ft · lb) LOCTITE® Install: steering stem 3 steering stem bearing 4 collar 5 bearing nut 6 T. (4) R. 1 CHAS 125 Nm (12.5 m · kg, 90 ft · lb) NOTE: Install the steering stem bearing with the “UP” mark facing up. 3.
ELEC ELECTRICAL COMPONENTS – + EBS00500 ELECTRICAL ELECTRICAL COMPONENTS 1 Four-wheel-drive motor relay 3 2 Rear brake relay 3 Four-wheel-drive motor relay 2 4 Four-wheel-drive motor relay 1 5 Headlight relay 6 Fuel injection system fuse 7 Starter relay 1 2 8 EPS fuse (YFM7FGPX only) 9 Main fuse 0 Fuse box (ignition, headlights, four-wheel-drive motor, radiator fan motor, signaling system, auxiliary DC jack) A Radiator fan motor circuit breaker B Rectifier/regulator 3 4 5 6 7 0 8 K 9 J A H
ELEC ELECTRICAL COMPONENTS – + C Reverse switch D Gear position switch E Auxiliary DC jack F Main switch G Differential gear motor H EPS motor (YFM7FGPX only) I EPS torque sensor (YFM7FGPX only) J Horn (for Europe and Oceania) K Radiator fan motor 1 2 3 4 5 6 7 0 8 K 9 J A H B I C F D G E – 38 –
ELECTRICAL COMPONENTS 1 Lean angle sensor 2 Radiator fan motor relay 3 Fuel injection system relay 4 Starting circuit cut-off relay 5 Front brake light switch 6 Rear brake light switch 7 Intake air temperature sensor 8 Intake air pressure sensor 9 TPS (throttle position sensor) 0 Fuel pump A Speed sensor 1 ELEC – + B Crankshaft position sensor C Coolant temperature sensor D Ignition coil E Battery F ECU (engine control unit) G EPS (electric power steering) control unit (YFM7FGPX only) 2 3 4 5 6 8
YFM7FGPX/YFM7FGX 2008 WIRING DIAGRAM (for CDN) 1 Crankshaft position sensor 2 AC magneto 3 Rectifier/regulator 4 Main switch 5 Frame ground 6 Main fuse 7 EPS fuse 8 Battery 9 Fuel injection system fuse 0 Starter relay A Starter motor B EPS torque sensor C EPS motor D EPS (electric power steering) control unit E EPS self-diagnosis signal connectors F Diode 1 G Starting circuit cut-off relay H Fuel injection system relay I Diode 2 J Reverse switch K ECU (engine control unit) L Ignition coil M Spark plug N Fue
YFM7FGPX/YFM7FGX 2008 WIRING DIAGRAM (for Europe and Oceania) 1 Crankshaft position sensor 2 AC magneto 3 Rectifier/regulator 4 Main switch 5 Frame ground 6 Main fuse 7 EPS fuse 8 Battery 9 Fuel injection system fuse 0 Starter relay A Starter motor B EPS torque sensor C EPS motor D EPS (electric power steering) control unit E EPS self-diagnosis signal connectors F Diode 1 G Starting circuit cut-off relay H Fuel injection system relay I Diode 2 J Reverse switch K ECU (engine control unit) L Ignition coil M S
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YFM7FGPX/YFM7FGX 2008 WIRING DIAGRAM (for CDN) YFM7FGPX/YFM7FGX 2008 SCHÉMA DE CÂBLAGE (Canada) È B B/L Gy 5 B/L Gy 1 G/Y B B 3 R (GRAY) R R G W B B W R G B R B W R G B R B R R R B/W L/B B R/B W G/R O/W L/B L B L/B Br O O/W Br L/B G W G/R G/R W (BLACK) (BLACK) O L O E R/L R/B G/W Y/W R/B L (BLACK) J (GRAY) R/B (BLACK) R Br L/W Br/B R L/W Br/B 4 ON 8 R Br/L OFF 9 B B Br/L R (BLACK) O B/L Br/W Y/W K (GREEN) G/Y Sb B/Y L/R L/B G/Y B/L B/Y I B
YFM7FGPX/YFM7FGX 2008 WIRING DIAGRAM (for Europe and Oceania) YFM7FGPX/YFM7FGX 2008 SCHÉMA DE CÂBLAGE (Europe et Océanie) È B B/L Gy 5 B/L Gy 1 G/Y B B 3 R (GRAY) R R G W B W R G B R B W R G B R B (GRAY) R/W R R R R W Sb Gy Br Y/B Y/L Y/W B/L R/B O R/B W G/R O/W L/B L B O/W Br L/B G W G/R G/R W (BLACK) O E R/B L (BLACK) J (GRAY) R/B Br L/W 8 R Br/L OFF B B Br/L R (BLACK) G F B R/B Y/R B K (GREEN) G/Y Sb B/Y L/R L/B Y/W Y/W B/L P L/B R/L B B/L
