YAMAHA YFM7FGPX, YFM7FGX SERVICE MANUAL SUPPLEMENTARY

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

First edition, March 2007

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

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.

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 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.

NOTE:

• 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.

EBS00003

IMPORTANT INFORMATION

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

CAUTION:

NOTE:

Failure to follow WARNING instructions could result in severe injury or death the vehicle operator, a bystander or a person checking or repairing the vehicle.

A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle.

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

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. 3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.

2. 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.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

. The meanings of the symbol marks are given on the next page.

4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

5. 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.

GEN

INFO

SPEC

CHK

ENG

ADJ

COOL

DRIV

CHAS

EBS00006

SYMBOLS

The following symbols are not relevant to every vehicle. Symbols 1 to 0 indicate the subject of each chapter.

General information

Specifications

Periodic checks and adjustments

Engine

Cooling system

Fuel injection system

Drive train

Chassis

Electrical

Troubleshooting

ELEC

–+

ABC

DEF

IJKL

MNOP

TRBL

SHTG

New

Symbols A to H indicate the following

Can be serviced with engine mounted

Filling fluid

Lubricant

Special tool

Torque

Wear limit, clearance

Engine speed

Electrical data (Ω, V, A)

Symbols I to P in the exploded diagrams indicate the types of lubricants and lubrication points.

Apply engine oil

Apply gear oil

Apply molybdenum disulfide oil

Apply brake fluid

Apply wheel bearing grease

Apply lithium-soap-based grease

Apply molybdenum disulfide grease

Apply silicone grease

Symbols Q to R in the exploded diagrams indicate where to apply a locking agent Q and when to install a new part R.

Apply the locking agent (LOCTITE

Replace

)

CONTENTS

GENERAL INFORMATION

SPECIAL TOOLS .........................................................................................1

SPECIFICATIONS

GENERAL SPECIFICATIONS .....................................................................2

ENGINE SPECIFICATIONS......................................................................... 4

CHASSIS SPECIFICATIONS....................................................................... 5

ELECTRICAL SPECIFICATIONS ................................................................ 6

TIGHTENING TORQUES............................................................................. 7

ENGINE TIGHTENING TORQUES ....................................................... 7

CHASSIS TIGHTENING TORQUES ..................................................... 7

CABLE ROUTING ........................................................................................8

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION ........................................................................................ 22

PERIODIC MAINTENANCE CHART FOR

THE EMISSION CONTROL SYSTEM.......................................................22

GENERAL MAINTENANCE AND LUBRICATION CHART ........................23

AIR FILTER CASE ..................................................................................... 25

ADJUSTING THE FRONT SHOCK ABSORBERS .............................. 26

ADJUSTING THE REAR SHOCK ABSORBERS ................................ 26

..............................................................................................2

................................................................................1

.................................................... 22

ENGINE

FUEL INJECTION SYSTEM

CHASSIS

ELECTRICAL

YFM7FGPX/YFM7FGX 2008 WIRING DIAGRAM (for CDN)

YFM7FGPX/YFM7FGX 2008 WIRING DIAGRAM (for Europe and Oceania)

............................................................................................................28

CRANKCASE .............................................................................................28

TIMING CHAIN AND OIL FILTER........................................................ 28

.............................................................................30

THROTTLE BODY ..................................................................................... 30

..........................................................................................................33

STEERING SYSTEM ................................................................................. 33

STEERING STEM (YFM7FGX only)....................................................33

INSTALLING THE PITMAN ARM (YFM7FGX only) ............................ 35

INSTALLING THE LOCK WASHER (YFM7FGX only) ........................35

INSTALLING THE STEERING STEM (YFM7FGPX only) ................... 36

...................................................................................................37

ELECTRICAL COMPONENTS................................................................... 37

GEN

SPECIAL TOOLS

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. YM-, YU-, YS-, YK-, ACC-

Except for US and CDN

P/N. 90890-

Tool No. Tool name/How to use Illustration

Steering nut wrench Spanner wrench

90890-01443

YU-33975

This tool is needed to loosen and tighten the front shock absorber and rear shock absorber locknuts.

INFO

– 1 –

GENERAL SPECIFICATIONS

EBS01001

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

Model code

Oil type or grade

Engine oil

For CDN

0° 10° 30° 50° 70° 90° 110°

YAMALUBE4 (20W40) or SAE 20W40

YAMALUBE4 (10W30) or SAE 10W30

130°F

SPEC

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)

API service, SG type or higher, JASO standard MA

YAMALUBE 4-CW (5W30) or SAE 5W30

-20° -10° 0° 10° 20° 30° 40°

50°C

For Europe and Oceania

Final gear oil SAE 80 API GL-4 Hypoid gear oil Differential gear oil SAE 80 API GL-4 Hypoid gear oil

– 2 –

GENERAL SPECIFICATIONS

Item Standard

Transmission

Primary reduction system V-belt Secondary reduction system Shaft drive Secondary reduction ratio 41/21 × 24/18 × 33/9 (9.544) Transmission type V-belt automatic Operation Left hand operation Single speed automatic 2.380 ~ 0.700 : 1 Sub transmission ratio low 31/16 (1.938)

high 31/27 (1.148)

Reverse gear 23/14 × 28/23 (2.000)

Bulb voltage/wattage × quantity

Headlight 12 V 35.0 W/35.0 W × 2 Tail/brake light 12 V 5.0/21.0 W × 1 Indicator light

Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light LED Engine trouble warning light LED EPS warning light LED (YFM7FGPX only) Park indicator light LED On-command four-wheel drive/differential gear lock indicator High-range indicator light LED Low-range indicator light LED Differential gear lock indicator light LED

LCD

SPEC

– 3 –

ENGINE SPECIFICATIONS

EBS01002

SPEC

ENGINE SPECIFICATIONS

Item Standard Limit

Valve spring

Free length

Intake 40.38 mm (1.59 in) 38.36 mm

Exhaust 40.38 mm (1.59 in) 38.36 mm

Installed length (valve closed)

Intake 35.00 mm (1.38 in) ---Exhaust 35.00 mm (1.38 in) ----

Compressed spring force (installed)

Intake 171 ~ 197 N

(17.44 ~ 20.09 kgf, 38.44 ~ 44.29 lb)

Exhaust 171 ~ 197 N

(17.44 ~ 20.09 kgf, 38.44 ~ 44.29 lb)

Spring tilt

(1.51 in)

----

Intake ---- 2.5°/1.80 mm

(2.5°/0.071 in)

Exhaust ---- 2.5°/1.80 mm

(2.5°/0.071 in)

Winding direction (top view)

Intake Clockwise ---Exhaust Clockwise ----

– 4 –

CHASSIS SPECIFICATIONS

EBS01003

SPEC

CHASSIS SPECIFICATIONS

Item Standard Limit

Front wheel

Type Panel wheel ---Rim size 12 × 6.0 AT ---Rim material Aluminum (YFM7FGPX)

Steel (YFM7FGX)

Maximum radial wheel runout ---- 2.0 mm

(0.08 in)

Maximum lateral wheel runout ---- 2.0 mm

(0.08 in)

Rear wheel

Type Panel wheel ---Rim size 12 × 7.5 AT ---Rim material Aluminum (YFM7FGPX)

Steel (YFM7FGX)

Maximum radial wheel runout ---- 2.0 mm

(0.08 in)

Maximum lateral wheel runout ---- 2.0 mm

(0.08 in)

----

– 5 –

ELECTRICAL SPECIFICATIONS

EBS01004

SPEC

ELECTRICAL SPECIFICATIONS

Item Standard Limit

ECU

Model/manufacturer F8T83472/MITSUBISHI ----

Ignition coil

Model/manufacturer 2JN/YAMAHA ---Minimum ignition spark gap 6.0 mm (0.24 in) ---Primary coil resistance 2.16 ~ 2.64 Ω at 20 °C (68 °F) ---Secondary coil resistance 8.64 ~ 12.96 kΩ at 20 °C (68 °F) ----

Circuit breaker

Circuit breaker type Fuse ---Fuses

Main fuse 40.0 A ---Headlight fuse 15.0 A ---Signaling system fuse 5.0 A ---Ignition fuse 10.0 A ---Auxiliary DC jack fuse 15.0 A ---Fuel injection system fuse 15.0 A ---Four-wheel-drive motor fuse 10.0 A ---EPS fuse 40.0 A (YFM7FGPX only) ---Radiator fan motor fuse 15.0 A ---Spare fuse 40.0 A

15.0 A

10.0 A

5.0 A

----

– 6 –

EBS01005

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES

TIGHTENING TORQUES

SPEC

Item Part name

Thread

size

Q’ty

Oil filter cartridge union bolt Union bolt M20 1 30 3.0 22

Tightening torque

Remarks

Nm m · kg ft · lb

Exhaust pipe Nut M8 4 14 1.4 10 Middle drive pinion gear nut Nut M22 1 190 19.0 140 Stake.

EBS01006

CHASSIS TIGHTENING TORQUES

Tightening torque

Part to be tightened Thread size

Remarks

Nm m · kg ft · lb

Steering stem bracket and frame M10 51 5.1 37 Steering stem support and frame

(YFM7FGX only)

M8 30 3.0 22

EPS control unit and frame (YFM7FGPX only) M8 30 3.0 22

Pitman arm nut (YFM7FGX) M14 190 19.0 140 Pitman arm nut (YFM7FGPX) M16 210 21.0 150 Steering stem joint bolt (YFM7FGPX only) M8 35 3.5 25 Steering stem bearing and frame

(YFM7FGPX only)

M10 51 5.1 37

Steering stem bearing nut (YFM7FGPX only) M22 125 12.5 90 EPS motor cover (YFM7FGPX only) M6 7 0.7 5.1

– 7 –

EBS00028

CABLE ROUTING

Coolant reservoir hose

Radiator fan motor breather hose

Differential gear case breather hose

EPS motor breather hose (YFM7FGPX only)

Ground lead

Coolant reservoir breather hose

Throttle cable

Fuel injector lead

Final gear case breather hose

CABLE ROUTING

Speed sensor lead

Crankshaft position sensor lead

Differential gear motor lead

EPS torque sensor lead (YFM7FGPX only)

Fast idle plunger outlet hose

Horn switch lead (for Europe and Oceania)

Radiator outlet hose

Gear position switch lead

Reverse switch lead

SPEC

ÎÍ

A-A

B-B

C-C

E-E

– 8 –

CABLE ROUTING

SPEC

I Shift control cable J Starter motor lead

È Face the end of the coolant reservoir breather

hose downward.

É Route the ground lead, radiator fan motor

breather hose, differential gear case breather hose, and EPS motor breather hose to the inside of the fast idle plunger outlet hose.

Ê Pass the radiator fan motor breather hose

through the larger diameter guide.

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.

A-A

ÎÍ

B-B

C-C

B-B

C-C

E-E

– 9 –

+ 35 hidden pages