YAMAHA YFM5FGY, YFM5FGPY, YFM7FGY, YFM7FGPY User Manual

2009

SERVICE MANUAL

YFM5FGY

YFM5FGPY

YFM7FGY

YFM7FGPY

LIT-11616-22-19 34D-28197-10

EAS20050

YFM5FGY/YFM5FGPY/YFM7FGY/YFM7FGPY

SERVICE MANUAL

©2008 by Yamaha Motor Corporation, U.S.A.

First edition, May 2008

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

LIT-11616-22-19

EAS20071

T

IMPORTANT

This manual was produced by the Yamaha Motor Company, Ltd. 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. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi­cle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi­cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. 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.

IP

• This Service Manual contains information regarding periodic maintenance to the emission control sys­tem. Please read this material carefully.

• Designs and specifications are subject to change without notice.

EAS20081

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.

This is the safety alert symbol. It is used to alert you to potential person­al injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.

WARNING

NOTICE

TIP

A WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

EAS20090

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.

• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.

• Sub-section titles “2” appear in smaller print than the section title.

• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each

removal and disassembly section.

• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas­sembly step.

• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.

• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.

• Jobs “7” requiring more information (such as special tools and technical data) are described sequen­tially.

1

3

NOTICE

7

2

4

5

6

EAS20100

T

SYMBOLS

The following symbols are used in this manual
for easier understanding.

IP

The following symbols are not relevant to every
vehicle.

1 2 3

4 5 6

T

.

R

.

78

1. Serviceable with engine mounted

2. Filling fluid

3. Lubricant

4. Special tool

5. Tightening torque

6. Wear limit, clearance

7. Engine speed

8. Electrical data

9. Engine oil

10.Gear oil

11.Molybdenum disulfide oil

12.Brake fluid

13.Wheel bearing grease

14.Lithium-soap-based grease

15.Molybdenum disulfide grease

16.Silicone grease

17.Apply locking agent (LOCTITE®).

18.Replace the part with a new one.

9 10

E

11 12

M

13 14

B

15 16

M

17 18

LT

G

BF

LS

S

New

EAS20110

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND
ADJUSTMENTS

CHASSIS

ENGINE

1

2

3

4

5

COOLING SYSTEM

FUEL SYSTEM

DRIVE TRAIN

ELECTRICAL SYSTEM

TROUBLESHOOTING

6

7

8

9

10

GENERAL INFORMATION

IDENTIFICATION ............................................................................................1-1

VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1

MODEL LABEL..........................................................................................1-1

FEATURES...................................................................................................... 1-2

OUTLINE OF THE FI SYSTEM................................................................. 1-2

FI SYSTEM................................................................................................ 1-3

OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM

(YFM5FGP/YFM7FGP only)..................................................................... 1-5

EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM

(YFM5FGP/YFM7FGP only)..................................................................... 1-7

INSTRUMENT FUNCTIONS ..................................................................... 1-9

IMPORTANT INFORMATION .......................................................................1-11

PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-11

REPLACEMENT PARTS......................................................................... 1-11

GASKETS, OIL SEALS AND O-RINGS .................................................. 1-11

LOCK WASHERS/PLATES AND COTTER PINS ...................................1-11

BEARINGS AND OIL SEALS ..................................................................1-12

CIRCLIPS ................................................................................................1-12

1

CHECKING THE CONNECTIONS ................................................................ 1-13

SPECIAL TOOLS .......................................................................................... 1-14

EAS20130

IDENTIFICATION

EAS20140

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the front left side of the frame.

EAS20150

MODEL LABEL

The model label “1” is affixed to the location
shown in the illustration. This information will be
needed to order spare parts.

IDENTIFICATION

1-1

FEATURES

EAS20170

FEATURES

EAS28P1031

OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies with the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter
the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum
air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the
engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom­modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by
the engine at all times by using a microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions.

1 2 3 4 6 7 8 9 10

1. ECU (engine control unit)

2. Lean angle sensor

3. Fuel injection system relay

4. Engine trouble warning light

5. ISC (idle speed control) unit

6. Intake air pressure sensor

7. TPS (throttle position sensor)

8. Intake air temperature sensor

5

1112131415

9. Fuel injector

10.Fuel pump

11.Speed sensor

12.Crankshaft position sensor

13.Coolant temperature sensor

14.Spark plug

15.Ignition coil

1-2

FEATURES

EAS28P1032

FI SYSTEM

The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm², 46.1 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing
the fuel to be injected into the intake manifold only during the time the passage remains open. There­fore, the longer the length of time the fuel injector is energized (injection duration), the greater the vol­ume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized
(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature
sensor, coolant temperature sensor, lean angle sensor and speed sensor enable the ECU to determine
the injection duration. The injection timing is determined through the signals from the crankshaft posi­tion sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in
accordance with the driving conditions.

Illustration is for reference only.

1

14

B

13

1. Fuel pump

2. Fuel injector

3. Ignition coil

4. ECU (engine control unit)

5. Speed sensor

6. Lean angle sensor

7. Coolant temperature sensor

8. Crankshaft position sensor

9. Intake air pressure sensor

10.Throttle body

11.ISC (idle speed control) unit

12.Throttle position sensor

12

11

C

5

4

6

2

A

7

3

10

9

8

13.Intake air temperature sensor

14.Air filter case

A. Fuel system
B. Air system
C. Control system

1-3

FEATURES

1-4

FEATURES

EAS28P1033

OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (YFM5FGP/YFM7FGP only)

12

3 d a

e

f

5

c

4

b

6

8

7

1-5

FEATURES

1. Speed information from speed sensor

2. Engine starting RPM information from ECU

3. Battery

4. Steering stem

5. EPS control unit

6. EPS motor

7. Torque sensor

8. EPS unit
a. Operates steering

ECA28P1027

NOTICE

b. Twists torsion bar
c. Sends the torque sensor signal
d. EPS control unit calculates assist power
e. Electricity output switched by EPS control unit
f. Activates EPS motor

To prevent accidental damage to the EPS unit, it must not be disassembled.

1-6

FEATURES

EAS28P1034

EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM (YFM5FGP/YFM7FGP only)

1

2

4

5

3

7

8

9

6

11

12

13

18

10

17

16

15

14

1-7

1. EPS unit

2. Torque sensor

3. EPS motor

4. EPS control unit

5. Battery

6. Engine rpm signal

7. Coolant temperature sensor signal

8. Crankshaft position sensor signal

9. Speed sensor signal

10.ECU (engine control unit)

11.Intake air temperature sensor signal

12.Throttle position sensor signal

13.Intake air pressure sensor signal

14.Lean angle sensor signal

15.Ignition coil

16.Fuel pump

17.Fuel injector

18.Meter assembly

• Multifunction display:
Speedometer/Odometer/Tripmeter A/Trip
meter B/Clock/Fuel meter/Gear position

• Indicator and warning lights: EPS
warning/Engine trouble warning/Coolant
temperature warning/Reverse
indicator/Neutral indicator/Park
indicator/High-range indicator/Low-range
indicator/Differential lock

• FI and EPS self-diagnostic fault codes

FEATURES

1-8

FEATURES

T

T

EAS28P1035

INSTRUMENT FUNCTIONS

Multifunction display

45

3

2

1

67

1. “CLOCK” button

2. “RESET” button

3. “SELECT” button

4. Speedometer

5. Fuel meter

6. Clock/Hour meter

7. Odometer/Tripmeter A/Tripmeter B

The multifunction display is equipped with the
following:

• a speedometer (which shows the riding speed)

• an odometer (which shows the total distance

traveled)

• two tripmeters (which show the distance trav­eled since they were last set to zero)

• a clock

• an hour meter (which shows the total time the

engine has been running)

• a fuel meter

• a self-diagnosis device

Odometer and tripmeter modes

Pushing the “SELECT” button switches the dis­play between the odometer mode “ODO” and
the tripmeter modes “A” and “B” in the following
order:
ODO → TRIP A → TRIP B → ODO
To reset a tripmeter, select it by pushing the “SE-
LECT” button, and then push the “RESET” but-
ton for at least three seconds. The tripmeters
can be used to estimate the distance that can be
traveled with a full tank of fuel. This information
will enable you to plan future fuel stops.

IP

Pushing and holding in the “SELECT” button,
and turning the key to “ON” while the button is
pushed, switches the display between “mph”
and “km/h”.

Clock mode

Pushing the “CLOCK” button switches the dis­play between the clock mode “CLOCK” and the
hour meter mode “HOUR” in the following order:
CLOCK → HOUR → CLOCK
To set the clock:

1. Set the display to the clock mode.

2. Push the “SELECT” button and “RESET” but-
ton together for at least three seconds.

3. When the hour digits start flashing, push the
“RESET” button to set the hours.

4. Push the “SELECT” button, and the minute
digits will start flashing.

5. Push the “RESET” button to set the minutes.

6. Push the “SELECT” button and then release
it to start the clock.

Fuel meter

1

2

3

1. Fuel level warning indicator

2. Fuel meter

3. “E” segment

The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear from “F” (full) towards “E” (empty) as
the fuel level decreases. When the “E” segment
disappears and the fuel level warning indicator
flashes, refuel as soon as possible.

IP

This fuel meter is equipped with a self-diagnosis
system. If the electrical circuit is defective, all the
display segments and fuel level warning indica­tor will start flashing. If this occurs, check the
electrical circuit.
Refer to “SIGNALING SYSTEM” on page 9-19.

1-9

Self-diagnosis device

1

1. Fault code display

This model is equipped with a self-diagnosis de­vice for various electrical circuits.
If any of those circuits are defective, the multi­function display will indicate a two-digit fault
code. If the multifunction display indicates such
a fault code, note the code number, and check
the vehicle.

ECA28P1028

NOTICE

If the multifunction display indicates a fault
code, the vehicle should be checked as soon
as possible in order to avoid engine damage.

FEATURES

1-10

EAS20180

IMPORTANT INFORMATION

EAS20190

PREPARATION FOR REMOVAL AND
DISASSEMBLY

1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning equip­ment.
Refer to “SPECIAL TOOLS” on page 1-14.

3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat­ed” through normal wear. Mated parts must
always be reused or replaced as an assem­bly.

IMPORTANT INFORMATION

EAS20210

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac­es, oil seal lips and O-rings must be cleaned.

2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.

4. During disassembly, clean all of the 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.

5. Keep all parts away from any source of fire.

EAS20200

REPLACEMENT PARTS

Use only genuine Yamaha parts for all replace­ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.

1. Oil

2. Lip

3. Spring

4. Grease

EAS20220

LOCK WASHERS/PLATES AND COTTER
PINS

After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.

1-11

EAS20230

BEARINGS AND OIL SEALS

Install bearings “1” and oil seals “2” so that the
manufacturer marks or numbers are visible.
When installing oil seals “2”, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.

ECA13300

NOTICE

Do not spin the bearing with compressed air
because this will damage the bearing surfac­es.

IMPORTANT INFORMATION

EAS20240

CIRCLIPS

Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al­ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.

1-12

EAS20250

T

T

T

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for
stains, rust, moisture, etc.

1. Disconnect:

• Lead

• Coupler

• Connector

2. Check:

• Lead

• Coupler

• Connector

Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect sev-
eral times.

CHECKING THE CONNECTIONS

Pocket tester

90890-03112

IP

• If there is no continuity, clean the terminals.

• When checking the wire harness, perform

steps (1) to (3).

• As a quick remedy, use a contact revitalizer
available at most part stores.

Analog pocket tester

YU-03112-C

3. Check:

• All connections

Loose connection → Connect properly.

IP

If the pin “1” on the terminal is flattened, bend it
up.

4. Connect:

• Lead

• Coupler

• Connector

IP

Make sure all connections are tight.

5. Check:

• Continuity
(with the pocket tester)

1-13

SPECIAL TOOLS

T

EAS20260

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.

IP

• For U.S.A. and Canada, use part numbers starting with “YM-”, “YU-”, or “ACC-”.

• For others, use part numbers starting with “90890-”.

Tool name/Tool No. Illustration

Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

Thickness gauge
90890-03079
Narrow gauge set
YM-34483

Tappet adjusting tool
90890-01311
Six piece tappet set
YM-A5970

Reference

pages

1-13, 9-81,
9-82, 9-83,
9-87, 9-89,
9-90, 9-91,
9-92, 9-93,
9-94, 9-95,
9-96, 9-97,
9-98

3-5

3-5

YM-A5970

ø9ø8 ø10

ø3 ø4

Digital tachometer

3-8
90890-06760
YU-39951-B

Timing light

3-8
90890-03141
Inductive clamp timing light
YU-03141

1-14

SPECIAL TOOLS

Tool name/Tool No. Illustration

Compression gauge
90890-03081
Engine compression tester
YU-33223

Extension
90890-04082

Oil filter wrench
90890-01426
YU-38411

Belt tension gauge
90890-03170
Rear drive belt tension gauge
YM-03170

Reference

pages

3-9

3-9

3-11

3-28

Ring nut wrench
90890-01268
Spanner wrench
YU-01268

Ball joint remover
90890-01474
YM-01474

Ball joint remover attachment set
90890-01480
Ball joint adapter set
YM-01480

Ball joint remover short shaft set
90890-01514
YM-01514

3-31, 3-32

4-57, 4-61

4-57, 4-61

4-57

Slide hammer bolt
90890-01083
Slide hammer bolt 6 mm
YU-01083-1

5-18, 5-20

1-15

SPECIAL TOOLS

Tool name/Tool No. Illustration

Weight
90890-01084
YU-01083-3

Valve spring compressor
90890-04019
YM-04019

Valve spring compressor attachment
90890-01243
Valve spring compressor adapter (26 mm)
YM-01253-1

Reference

pages

5-18

YU-01083-3

5-22, 5-27

5-22, 5-27

Valve guide remover (ø6)
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A

Valve guide installer (ø6)
90890-04065
Valve guide installer (6.0 mm)
YM-04065-A

Valve guide reamer (ø6)
90890-04066
Valve guide reamer (6.0 mm)
YM-04066

5-23

5-23

5-23

1-16

SPECIAL TOOLS

Tool name/Tool No. Illustration

Piston pin puller set
90890-01304
Piston pin puller
YU-01304

Sheave holder
90890-01701
Primary clutch holder
YS-01880-A

Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B

Reference

pages

5-29

YU-01304

5-36, 5-37,

5-38, 5-50,

5-54

5-36

Yamaha bond No. 1215
90890-85505
(Three Bond No.1215®)

Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927

Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135

5-38, 5-66

5-42, 7-7

5-50, 5-53

1-17

SPECIAL TOOLS

Tool name/Tool No. Illustration

Locknut wrench
90890-01348
YM-01348

Sheave spring compressor
90890-04134
YM-04134

Reference

pages

5-50, 5-53

5-50, 5-53

Universal clutch holder
90890-04086
YM-91042

Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B

5-58, 5-59

5-70

1-18

SPECIAL TOOLS

Tool name/Tool No. Illustration

Crankshaft installer pot
90890-01274
Installing pot
YU-90058

Crankshaft installer bolt
90890-01275
Bolt
YU-90060

Adapter (M16)
90890-04130
Adapter #13
YM-04059

Reference

pages

5-72

YU-90058/YU-90059

5-72

5-72

Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044

Spacer
90890-01309
Pot spacer
YU-90059

Coupling gear/middle shaft tool
90890-01229
Gear holder
YM-01229

YM-91044

ø35

5-72

5-72

5-82, 5-85

1-19

SPECIAL TOOLS

Tool name/Tool No. Illustration

Bearing retainer wrench
90890-04128
Middle gear bearing retainer
YM-04128

Ring nut wrench
90890-01430
YM-38404

Final gear backlash band
90890-01511
Middle drive gear lash tool
YM-01230

Radiator cap tester
90890-01325
Radiator pressure tester
YU-24460-01

Reference

pages

5-83, 5-84

5-83, 5-84

5-86, 8-29

6-3

Radiator cap tester adapter
90890-01352
Radiator pressure tester adapter
YU-33984

Mechanical seal installer
90890-04132
Water pump seal installer
YM-33221-A

YU-24460-01

6-3

YU-33984

6-9

1-20

SPECIAL TOOLS

Tool name/Tool No. Illustration

Middle driven shaft bearing driver
90890-04058
Bearing driver 40 mm
YM-04058

Pressure gauge
90890-03153
YU-03153

Fuel pressure adapter
90890-03176
YM-03176

Boots band installation tool
90890-01526
YM-01526

Reference

pages

6-9

7-7

7-7

8-9, 8-11, 8-22,

8-24

Ring gear fix bolt (M10)
90890-01527
YM-01527

Gear lash measurement tool
90890-01475
Middle drive gear lash tool
YM-01475

Ring gear fix bolt (M14)
90890-01524
YM-01524

Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487

8-13

M10×P1.25

8-13

8-29

M14×P1.5

9-91

1-21