Yamaha YFM7FGPW 2007 Manuals

Manuals and User Guides for Yamaha YFM7FGPW 2007. We have 1 Yamaha YFM7FGPW 2007 manual available for free PDF download: Service Manual

Yamaha YFM7FGPW 2007 Service Manual (485 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 17.18 MB

How to Use this Manual
4
Periodic Checks and Adjustments

5
- Table of Contents
  6
Engine

5
Cooling System

5
Fuel Injection System

5
Drive Train

5
Chassis

14
Electrical

16
Troubleshooting

17
Chapter 1 General Information

19
Vehicle Identification

19
- Vehicle Identification Number
  19
- Model Label
  19
Features

20
Important Information

27
- Preparation for Removal and Disassembly
  27
- Replacement Parts
  27
- Gaskets, Oil Seals and O-Rings
  27
- Lock Washers/Plates and Cotter Pins
  28
- Bearings and Oil Seals
  28
- Circlips
  28
- Checking the Connections
  29
Special Tools

30
Chapter 2 Specifications

37
Spec

37
General Specifications

37
Engine Specifications

41
Chassis Specifications

48
Electrical Specifications

50
Tightening Torques

52
- Engine Tightening Torques
  52
- Chassis Tightening Torques
  55
General Tightening Torque Specifications

58
How to Use the Conversion Table

58
Lubrication Points and Lubricant Types

59
- Engine
  59
Coolant Flow Diagrams

61
Oil Flow Diagrams

62
Cable Routing

64
Chapter 3 Periodic Checks and Adjustments

82
Introduction

82
Periodic Maintenance Chart for the Emission Control System

82
Chk Adj

82
General Maintenance and Lubrication Chart

83
Engine Skid Plates, Seat, Carriers and Fenders

85
- Engine Skid Plates
  85
- Seat and Side Panels
  86
- Front Carrier and Front Guard
  87
- Front Fenders and Front Grill
  89
- Rear Carrier and Rear Fender
  90
Electrical Components Tray

91
- Electrical Components Tray 1/2
  91
- Electrical Components Tray 2/2
  92
Footrest Boards

95
Air Filter Case

96
Engine

97
- Adjusting the Valve Clearance
  97
- Adjusting the Engine Idling Speed
  100
- Adjusting the Throttle Lever Free Play
  101
- Adjusting the Speed Limiter
  103
- Checking the Spark Plug
  104
- Checking the Ignition Timing
  105
- Measuring the Compression Pressure
  106
- Checking the Engine Oil Level
  109
- Changing the Engine Oil
  110
- Cleaning the Air Filter Element
  112
- Checking the Throttle Body Joint
  114
- Checking the Fuel Hose
  115
- Checking the Breather Hoses
  115
- Checking the Coolant Level
  116
- Changing the Coolant
  116
- Checking the Cooling System
  120
- Checking the Coolant Temperature Warning Light
  121
- Checking the V-Belt
  122
- Checking the Exhaust System
  123
- Cleaning the Spark Arrester
  124
Chassis

125
- Adjusting the Front Brake
  125
- Adjusting the Rear Brake
  125
- Checking the Brake Fluid Level
  127
- Checking the Front Brake Pads
  128
- Checking the Rear Brake Pads
  129
- Checking the Rear Brake Hose Protectors
  129
- Checking the Brake Hoses
  130
- Bleeding the Hydraulic Brake System
  130
- Adjusting the Select Lever Control Cable and Shift Rod
  133
- Checking the Final Gear Oil Level
  134
- Changing the Final Gear Oil
  134
- Checking the Differential Gear Oil Level
  136
- Changing the Differential Gear Oil
  136
- Checking the Constant Velocity Joint Dust Boots
  137
- Checking the Steering System
  138
- Adjusting the Toe-In
  140
- Checking the Front and Rear Shock Absorbers
  141
- Adjusting the Front Shock Absorbers
  142
- Adjusting the Rear Shock Absorbers
  143
- Checking the Tires
  143
- Checking the Wheels
  146
- Checking and Lubricating the Cables
  146
- Lubricating the Levers and Pedals
  147
Electrical System

148
- Checking and Charging the Battery
  148
- Checking the Fuses
  154
- Adjusting the Headlight Beams
  157
- Replacing the Headlight Bulbs
  157
Chapter 4 Engine

159
Engine Removal

159
- Air Ducts, Muffler and Exhaust Pipe
  159
- Select Lever Unit
  161
- Leads, Cables and Hoses
  162
- Engine Mounting Bolts
  164
- Installing the Engine
  166
- Installing the Select Lever Unit
  167
Eng

159
Cylinder Head

168
- Removing the Cylinder Head
  170
- Checking the Camshaft Sprocket
  171
- Checking the Tappet Covers
  171
- Checking the Timing Chain Tensioner
  171
- Checking the Cylinder Head
  172
- Installing the Cylinder Head
  173
Rocker Arms and Camshaft

176
Valves and Valve Springs

183
Cylinder and Piston

192
- Removing the Piston
  193
- Checking the Cylinder and Piston
  193
- Checking the Piston Rings
  195
- Checking the Piston Pin
  196
- Installing the Piston and Cylinder
  197
Ac Magneto

200
Balancer Gears and Oil Pump Gears

207
Primary and Secondary Sheaves

211
- Primary Sheave
  213
- Secondary Sheave
  214
- Removing the Primary and Secondary Sheaves
  215
- Disassembling the Secondary Sheave
  215
- Checking the Primary Sheave
  216
- Checking the Secondary Sheave
  216
- Assembling the Primary Sheave
  217
- Assembling the Secondary Sheave
  218
- Installing the Primary and Secondary Sheaves
  220
Clutch

221
- Removing the Clutch
  223
- Checking the Clutch
  224
- Installing the Clutch
  225
Crankcase

226
- Timing Chain and Oil Filter
  226
- Crankcase
  227
- Crankcase Bearings
  229
- Separating the Crankcase
  230
- Checking the Timing Chain and Guide
  230
- Checking the Relief Valve
  230
- Checking the Bearings
  231
- Checking the Crankcase
  231
- Assembling the Crankcase
  231
- Installing the Shift Lever
  232
Crankshaft and Oil Pump

233
- Oil Pump
  234
- Removing the Crankshaft
  235
- Checking the Oil Pump
  235
- Checking the Oil Strainer
  236
- Checking the Crankshaft
  236
- Assembling the Oil Pump
  237
- Installing the Crankshaft
  237
Transmission

239
- Drive Axle
  241
- Removing the Transmission
  243
- Checking the Shift Forks
  243
- Checking the Shift Drum
  244
- Checking the Transmission
  244
- Checking the Secondary Shaft
  245
- Checking the Stopper Lever and Stopper Wheel
  245
- Assembling the Shift Fork Assembly
  245
- Installing the Transmission
  246
Middle Gear

247
- Middle Drive Shaft
  247
- Middle Driven Shaft
  248
- Removing the Middle Drive Shaft
  250
- Removing the Middle Driven Shaft
  251
- Checking the Pinion Gears
  253
- Selecting Middle Drive and Driven Gear Shims
  254
- Installing the Bearing and Oil Seals
  257
- Installing the Middle Driven Shaft
  258
- Installing the Middle Drive Shaft
  260
- Measuring the Middle Gear Backlash
  260
Chapter 5 Cooling System

262
Cool

262
Radiator

262
- Checking the Radiator
  264
- Installing the Radiator
  265
Thermostat

266
- Checking the Thermostat
  267
- Installing the Thermostat
  267
Water Pump

268
- Disassembling the Water Pump
  270
- Checking the Water Pump
  270
- Assembling the Water Pump
  271
Chapter 6 Fuel Injection System

273
- Circuit Diagram
  275
- Ecu Self-Diagnostic Function
  277
- Self-Diagnostic Function Table
  278
- Troubleshooting Chart
  279
- Diagnostic Mode
  280
- Troubleshooting Details
  284
- Checking the Intake Air Pressure Sensor
  298
- Checking the Intake Air Temperature Sensor
  298
Fuel Tank

300
- Removing the Fuel Tank
  302
- Removing the Fuel Pump
  302
- Checking the Fuel Pump Body
  303
- Checking the Rollover Valve
  303
- Installing the Fuel Pump
  303
- Installing the Fuel Hose
  304
Throttle Body

305
Chapter 7 Drive Train

313
Driv

313
Troubleshooting

313
- Checking Noises
  313
- Troubleshooting Chart
  315
Front Constant Velocity Joints and Differential Gear

316
Rear Constant Velocity Joints and Final Drive Gear

329
Chapter 8

348
- Front Wheels
  348
- Rear Wheels
  350
- Checking the Wheels
  352
- Checking the Wheel Hubs
  352
- Checking the Brake Discs
  353
- Installing the Brake Discs
  353
- Installing the Wheel Hubs
  353
- Installing the Wheels
  354
Chas

348
Front and Rear Wheels

348
Front and Rear Brakes

355
Steering System

378
- Handlebar
  378
- Removing the Handlebar Grips
  380
- Checking the Handlebar
  380
- Installing the Handlebar
  380
- Installing the Handlebar Grips
  381
- Installing the Rear Brake Master Cylinder
  381
- Installing the Front Brake Master Cylinder
  382
- Installing the Throttle Lever Assembly
  382
- Steering Stem
  383
- Checking the Steering Stem
  385
- Installing the Steering Stem
  385
- Installing the Pitman Arm
  387
- Tie-Rods and Steering Knuckles
  388
- Removing the Steering Knuckles
  390
- Checking the Tie-Rods
  390
- Checking the Steering Knuckles
  390
- Installing the Tie-Rods
  393
Front Arms and Front Shock Absorber Assemblies

394
Rear Knuckles and Stabilizer

399
- Checking the Rear Knuckles
  401
- Checking the Stabilizer
  401
Rear Arms and Rear Shock Absorber Assemblies

402
Chapter 9

406
Electrical Components

406
Elec

406
Checking Switch Continuity

409
Checking the Switches

410
Checking the Bulbs and Bulb Sockets

412
Ignition System

415
- Circuit Diagram
  415
- Troubleshooting
  416
Electric Starting System

421
- Circuit Diagram
  421
- Starting Circuit Operation
  422
- Troubleshooting
  423
Starter Motor

427
- Checking the Starter Motor
  429
- Assembling the Starter Motor
  431
Charging System

432
- Circuit Diagram
  432
- Troubleshooting
  433
Lighting System

435
- Circuit Diagram
  435
- Troubleshooting
  436
- Checking the Lighting System
  437
Signaling System

439
- Circuit Diagram
  439
- Troubleshooting
  441
- Checking the Signaling System
  442
Cooling System

450
- Circuit Diagram
  450
- Troubleshooting
  451
Fuel Pump System

455
- Circuit Diagram
  455
- Troubleshooting
  456
2Wd/4Wd Selecting System

458
- Circuit Diagram
  458
- Troubleshooting
  459
Eps (Electric Power Steering) System

463
- Circuit Diagram
  463
- Eps Control Unit's Self-Diagnostic Function
  464
- Eps Warning Light During Normal Operation
  465
- Diagnostic Mode
  466
- Self-Diagnostic Function Table (Eps System)
  469
- Troubleshooting Details (Eps System)
  470
- Checking the Eps Motor
  474
- Checking the Eps Torque Sensor
  474
Chapter 10

476
- Fuel System
  476
- Electrical System
  476
- Compression System
  477
Trbl Shtg

476
Starting Failure/Hard Starting

476
Poor Idle Speed Performance

477
Poor Medium and High-Speed Performance

477
Faulty Drive Train

478
Faulty Clutch Performance

479
- Engine Operates but Vehicle will Not Move
  479
- Clutch Slipping
  479
- Poor Starting Performance
  479
- Poor Speed Performance
  480
Faulty Gear Shifting

479
- Hard Shifting
  479
- Shift Lever Does Not Move
  479
- Jumps out of Gear
  479
Overheating

480
Overcooling

480
- Cooling System
  480
Faulty Brake

480
- Poor Braking Effect
  480
Shock Absorber Malfunction

481
- Malfunction
  481
Unstable Handling

481
Lighting System

481
- Headlight Does Not Come on
  481
- Bulb Burnt out
  481

Yamaha Categories

Motorcycle Musical Instrument Electronic Keyboard Receiver Amplifier

More Yamaha Manuals

Yamaha YFM7FGPW 2007 Manuals

Yamaha YFM7FGPW 2007 Service Manual (485 pages)

Table of Contents

Periodic Checks and Adjustments

Engine

Cooling System

Fuel Injection System

Drive Train

Chassis

Electrical

Troubleshooting

Chapter 1 General Information

Vehicle Identification

Features

Important Information

Special Tools

Chapter 2 Specifications

Spec

General Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Tightening Torques

General Tightening Torque Specifications

How to Use the Conversion Table

Lubrication Points and Lubricant Types

Coolant Flow Diagrams

Oil Flow Diagrams

Cable Routing

Chapter 3 Periodic Checks and Adjustments

Introduction

Periodic Maintenance Chart for the Emission Control System

Chk Adj

General Maintenance and Lubrication Chart

Engine Skid Plates, Seat, Carriers and Fenders

Electrical Components Tray

Footrest Boards

Air Filter Case

Engine

Chassis

Electrical System

Chapter 4 Engine

Engine Removal

Eng

Cylinder Head

Rocker Arms and Camshaft

Valves and Valve Springs

Cylinder and Piston

Ac Magneto

Balancer Gears and Oil Pump Gears

Primary and Secondary Sheaves

Clutch

Crankcase

Crankshaft and Oil Pump

Transmission

Middle Gear

Chapter 5 Cooling System

Cool

Radiator

Thermostat

Water Pump

Chapter 6 Fuel Injection System

Fuel Tank

Throttle Body

Chapter 7 Drive Train

Driv

Troubleshooting

Front Constant Velocity Joints and Differential Gear

Rear Constant Velocity Joints and Final Drive Gear

Chapter 8

Chas

Front and Rear Wheels

Front and Rear Brakes

Steering System

Front Arms and Front Shock Absorber Assemblies

Rear Knuckles and Stabilizer

Rear Arms and Rear Shock Absorber Assemblies

Chapter 9

Electrical Components

Elec