LIT-11616-20-11

3B4-28197-10

YFM7FGPW

SERVICE MANUAL

EBS00001

YFM7FGPW

SERVICE MANUAL

©2006 by Yamaha Motor Corporation, U.S.A.

First Edition, May 2006

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-11616-20-11

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 sig-

nificant 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!

Failure to follow WARNING instructions could result in severe injury or death to

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.

WARNING

CAUTION:

NOTE:

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 accompa-

nied 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

6. 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.

EBS00006

SYMBOLS

The following symbols are not relevant to

every vehicle.

Symbols 1 to 0 indicate the subject of each

chapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 Engine

5 Cooling system

6 Fuel injection system

7 Drive train

8 Chassis

9 Electrical

0 Troubleshooting

Symbols A to H indicate the following

A Can be serviced with engine mounted

B Filling fluid

C Lubricant

D Special tool

E Torque

F Wear limit, clearance

G Engine speed

H Electrical data (Ω, V, A)

Symbols I to N in the exploded diagrams

indicate the types of lubricants and lubrication

points.

I Apply engine oil

J Apply gear oil

K Apply molybdenum disulfide oil

L Apply wheel bearing grease

M Apply lithium-soap-based grease

N Apply molybdenum disulfide grease

Symbols O to P in the exploded diagrams

indicate where to apply a locking agent O and

when to install a new part P.

O Apply the locking agent (LOCTITE^®)

P Replace

1

2

3

4

5

6

7

8

9

0

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

GEN

INFO

SPEC

CHK

ADJ

ENG

COOL

FI

DRIV

CHAS

–

+

ELEC

TRBL

SHTG

T R

.

.

E

G

M

B

LS

M

LT

New

EBS00008 TABLE OF CONTENTS

GENERAL INFORMATION

GEN

INFO 1

SPECIFICATIONS

SPEC 2

PERIODIC CHECKS AND

ADJUSTMENTS

CHK

ADJ 3

ENGINE

ENG 4

COOLING SYSTEM

COOL 5

FUEL INJECTION SYSTEM

FI

6

DRIVE TRAIN

DRIV 7

CHASSIS

CHAS 8

ELECTRICAL

ELEC 9

TROUBLESHOOTING

TRBL

SHTG 10

–

+

CONTENTS

CHAPTER 1

GENERAL INFORMATION

VEHICLE 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......1-4

EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM .....1-5

INSTRUMENT FUNCTIONS.....................................................................1-6

IMPORTANT INFORMATION .........................................................................1-9

PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-9

REPLACEMENT PARTS...........................................................................1-9

GASKETS, OIL SEALS AND O-RINGS ....................................................1-9

LOCK WASHERS/PLATES AND COTTER PINS...................................1-10

BEARINGS AND OIL SEALS..................................................................1-10

CIRCLIPS................................................................................................1-10

CHECKING THE CONNECTIONS..........................................................1-11

SPECIAL TOOLS ..........................................................................................1-12

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS ........................................................................2-1

ENGINE SPECIFICATIONS ............................................................................2-5

CHASSIS SPECIFICATIONS........................................................................2-12

ELECTRICAL SPECIFICATIONS .................................................................2-14

TIGHTENING TORQUES ..............................................................................2-16

ENGINE TIGHTENING TORQUES.........................................................2-16

CHASSIS TIGHTENING TORQUES.......................................................2-19

HOW TO USE THE CONVERSION TABLE..................................................2-22

GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-22

LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-23

ENGINE...................................................................................................2-23

COOLANT FLOW DIAGRAMS .....................................................................2-25

OIL FLOW DIAGRAMS.................................................................................2-26

CABLE ROUTING .........................................................................................2-28

CHAPTER 3

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION..............................................................................................3-1

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

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

GENERAL MAINTENANCE AND LUBRICATION CHART............................3-2

ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS .......................3-4

ENGINE SKID PLATES.............................................................................3-4

SEAT AND SIDE PANELS........................................................................3-5

FRONT CARRIER AND FRONT GUARD.................................................3-6

FRONT FENDERS AND FRONT GRILL...................................................3-8

REAR CARRIER AND REAR FENDER....................................................3-9

ELECTRICAL COMPONENTS TRAY...........................................................3-10

ELECTRICAL COMPONENTS TRAY 1/2...............................................3-10

ELECTRICAL COMPONENTS TRAY 2/2...............................................3-12

FOOTREST BOARDS...................................................................................3-14

AIR FILTER CASE ........................................................................................3-15

ENGINE .........................................................................................................3-16

ADJUSTING THE VALVE CLEARANCE ................................................3-16

ADJUSTING THE ENGINE IDLING SPEED...........................................3-19

ADJUSTING THE THROTTLE LEVER FREE PLAY ..............................3-20

ADJUSTING THE SPEED LIMITER........................................................3-22

CHECKING THE SPARK PLUG .............................................................3-23

CHECKING THE IGNITION TIMING.......................................................3-24

MEASURING THE COMPRESSION PRESSURE..................................3-25

CHECKING THE ENGINE OIL LEVEL....................................................3-28

CHANGING THE ENGINE OIL ...............................................................3-29

CLEANING THE AIR FILTER ELEMENT................................................3-31

CHECKING THE THROTTLE BODY JOINT...........................................3-33

CHECKING THE FUEL HOSE................................................................3-34

CHECKING THE BREATHER HOSES ...................................................3-34

CHECKING THE COOLANT LEVEL.......................................................3-35

CHANGING THE COOLANT...................................................................3-35

CHECKING THE COOLING SYSTEM....................................................3-39

CHECKING THE COOLANT TEMPERATURE WARNING LIGHT.........3-40

CHECKING THE V-BELT........................................................................3-41

CHECKING THE EXHAUST SYSTEM....................................................3-42

CLEANING THE SPARK ARRESTER ....................................................3-43

CHASSIS .......................................................................................................3-44

ADJUSTING THE FRONT BRAKE .........................................................3-44

ADJUSTING THE REAR BRAKE............................................................3-44

CHECKING THE BRAKE FLUID LEVEL.................................................3-46

CHECKING THE FRONT BRAKE PADS................................................3-47

CHECKING THE REAR BRAKE PADS ..................................................3-48

CHECKING THE REAR BRAKE HOSE PROTECTORS........................3-48

CHECKING THE BRAKE HOSES...........................................................3-49

BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-49

ADJUSTING THE SELECT LEVER CONTROL CABLE AND

SHIFT ROD ............................................................................................3-51

CHECKING THE FINAL GEAR OIL LEVEL............................................3-53

CHANGING THE FINAL GEAR OIL........................................................3-53

CHECKING THE DIFFERENTIAL GEAR OIL LEVEL.............................3-55

CHANGING THE DIFFERENTIAL GEAR OIL ........................................3-55

CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS ..........3-56

CHECKING THE STEERING SYSTEM ..................................................3-57

ADJUSTING THE TOE-IN.......................................................................3-59

CHECKING THE FRONT AND REAR SHOCK ABSORBERS ...............3-60

ADJUSTING THE FRONT SHOCK ABSORBERS .................................3-61

ADJUSTING THE REAR SHOCK ABSORBERS....................................3-62

CHECKING THE TIRES..........................................................................3-62

CHECKING THE WHEELS .....................................................................3-65

CHECKING AND LUBRICATING THE CABLES ....................................3-65

LUBRICATING THE LEVERS AND PEDALS .........................................3-66

ELECTRICAL SYSTEM.................................................................................3-67

CHECKING AND CHARGING THE BATTERY.......................................3-67

CHECKING THE FUSES ........................................................................3-73

ADJUSTING THE HEADLIGHT BEAMS.................................................3-76

REPLACING THE HEADLIGHT BULBS .................................................3-76

CHAPTER 4

ENGINE

ENGINE REMOVAL ........................................................................................4-1

AIR DUCTS, MUFFLER AND EXHAUST PIPE ........................................4-1

SELECT LEVER UNIT ..............................................................................4-3

LEADS, CABLES AND HOSES ................................................................4-4

ENGINE MOUNTING BOLTS ...................................................................4-6

INSTALLING THE ENGINE.......................................................................4-8

INSTALLING THE SELECT LEVER UNIT ................................................4-9

CYLINDER HEAD..........................................................................................4-10

REMOVING THE CYLINDER HEAD.......................................................4-12

CHECKING THE CAMSHAFT SPROCKET............................................4-13

CHECKING THE TAPPET COVERS ......................................................4-13

CHECKING THE TIMING CHAIN TENSIONER......................................4-13

CHECKING THE CYLINDER HEAD .......................................................4-14

INSTALLING THE CYLINDER HEAD .....................................................4-15

ROCKER ARMS AND CAMSHAFT..............................................................4-18

REMOVING THE ROCKER ARMS AND CAMSHAFT............................4-20

CHECKING THE CAMSHAFT.................................................................4-20

CHECKING THE DECOMPRESSION SYSTEM.....................................4-21

CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........4-21

INSTALLING THE CAMSHAFT AND ROCKER ARMS ..........................4-22

VALVES AND VALVE SPRINGS..................................................................4-25

REMOVING THE VALVES AND VALVE SPRINGS ...............................4-26

CHECKING THE VALVES AND VALVE SPRINGS................................4-27

INSTALLING THE VALVES AND VALVE SPRINGS..............................4-31

CYLINDER AND PISTON..............................................................................4-34

REMOVING THE PISTON ......................................................................4-35

CHECKING THE CYLINDER AND PISTON ...........................................4-35

CHECKING THE PISTON RINGS...........................................................4-37

CHECKING THE PISTON PIN................................................................4-38

INSTALLING THE PISTON AND CYLINDER .........................................4-39

AC MAGNETO...............................................................................................4-42

REMOVING THE AC MAGNETO ROTOR..............................................4-45

CHECKING THE STATOR COIL AND CRANKSHAFT POSITION

SENSOR ................................................................................................4-46

CHECKING THE STARTER CLUTCH....................................................4-46

CHECKING THE TORQUE LIMITER......................................................4-47

INSTALLING THE AC MAGNETO ROTOR ............................................4-47

BALANCER GEARS AND OIL PUMP GEARS ............................................4-49

REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP

DRIVEN GEAR.......................................................................................4-51

CHECKING THE OIL PUMP DRIVE .......................................................4-51

CHECKING THE BALANCER DRIVE.....................................................4-51

INSTALLING THE BALANCER DRIVE GEAR, BALANCER DRIVEN

GEAR, AND OIL PUMP DRIVEN GEAR................................................4-52

PRIMARY AND SECONDARY SHEAVES....................................................4-53

PRIMARY SHEAVE.................................................................................4-55

SECONDARY SHEAVE ..........................................................................4-56

REMOVING THE PRIMARY AND SECONDARY SHEAVES.................4-57

DISASSEMBLING THE SECONDARY SHEAVE....................................4-57

CHECKING THE PRIMARY SHEAVE ....................................................4-58

CHECKING THE SECONDARY SHEAVE..............................................4-58

ASSEMBLING THE PRIMARY SHEAVE................................................4-59

ASSEMBLING THE SECONDARY SHEAVE..........................................4-60

INSTALLING THE PRIMARY AND SECONDARY SHEAVES................4-62

CLUTCH ........................................................................................................4-63

REMOVING THE CLUTCH .....................................................................4-65

CHECKING THE CLUTCH......................................................................4-66

INSTALLING THE CLUTCH....................................................................4-67

CRANKCASE ................................................................................................4-68

TIMING CHAIN AND OIL FILTER...........................................................4-68

CRANKCASE ..........................................................................................4-70

CRANKCASE BEARINGS.......................................................................4-71

SEPARATING THE CRANKCASE..........................................................4-72

CHECKING THE TIMING CHAIN AND GUIDE.......................................4-72

CHECKING THE RELIEF VALVE ...........................................................4-72

CHECKING THE BEARINGS..................................................................4-73

CHECKING THE CRANKCASE..............................................................4-73

ASSEMBLING THE CRANKCASE..........................................................4-73

INSTALLING THE SHIFT LEVER ...........................................................4-74

CRANKSHAFT AND OIL PUMP...................................................................4-75

OIL PUMP ...............................................................................................4-76

REMOVING THE CRANKSHAFT ...........................................................4-77

CHECKING THE OIL PUMP ...................................................................4-77

CHECKING THE OIL STRAINER ...........................................................4-78

CHECKING THE CRANKSHAFT............................................................4-78

ASSEMBLING THE OIL PUMP...............................................................4-79

INSTALLING THE CRANKSHAFT..........................................................4-79

TRANSMISSION............................................................................................4-81

DRIVE AXLE ...........................................................................................4-83

REMOVING THE TRANSMISSION ........................................................4-85

CHECKING THE SHIFT FORKS.............................................................4-85

CHECKING THE SHIFT DRUM ..............................................................4-86

CHECKING THE TRANSMISSION.........................................................4-86

CHECKING THE SECONDARY SHAFT.................................................4-87

CHECKING THE STOPPER LEVER AND STOPPER WHEEL..............4-87

ASSEMBLING THE SHIFT FORK ASSEMBLY ......................................4-87

INSTALLING THE TRANSMISSION.......................................................4-88

MIDDLE GEAR..............................................................................................4-89

MIDDLE DRIVE SHAFT ..........................................................................4-89

MIDDLE DRIVEN SHAFT........................................................................4-90

REMOVING THE MIDDLE DRIVE SHAFT .............................................4-92

REMOVING THE MIDDLE DRIVEN SHAFT...........................................4-93

CHECKING THE PINION GEARS ..........................................................4-95

SELECTING MIDDLE DRIVE AND DRIVEN GEAR SHIMS...................4-96

INSTALLING THE BEARING AND OIL SEALS ......................................4-99

INSTALLING THE MIDDLE DRIVEN SHAFT .......................................4-100

INSTALLING THE MIDDLE DRIVE SHAFT..........................................4-102

MEASURING THE MIDDLE GEAR BACKLASH...................................4-102

CHAPTER 5

COOLING SYSTEM

RADIATOR ......................................................................................................5-1

CHECKING THE RADIATOR....................................................................5-3

INSTALLING THE RADIATOR..................................................................5-4

THERMOSTAT ................................................................................................5-5

CHECKING THE THERMOSTAT..............................................................5-6

INSTALLING THE THERMOSTAT............................................................5-6

WATER PUMP.................................................................................................5-7

DISASSEMBLING THE WATER PUMP....................................................5-9

CHECKING THE WATER PUMP..............................................................5-9

ASSEMBLING THE WATER PUMP........................................................5-10

CHAPTER 6

FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEM............................................................................6-1

CIRCUIT DIAGRAM ..................................................................................6-3

ECU SELF-DIAGNOSTIC FUNCTION......................................................6-5

SELF-DIAGNOSTIC FUNCTION TABLE..................................................6-6

TROUBLESHOOTING CHART.................................................................6-7

DIAGNOSTIC MODE ................................................................................6-8

TROUBLESHOOTING DETAILS ............................................................6-12

CHECKING THE INTAKE AIR PRESSURE SENSOR ...........................6-26

CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....................6-26

FUEL TANK...................................................................................................6-28

REMOVING THE FUEL TANK................................................................6-30

REMOVING THE FUEL PUMP ...............................................................6-30

CHECKING THE FUEL PUMP BODY.....................................................6-31

CHECKING THE ROLLOVER VALVE ....................................................6-31

INSTALLING THE FUEL PUMP..............................................................6-31

INSTALLING THE FUEL HOSE..............................................................6-32

THROTTLE BODY.........................................................................................6-33

REMOVING THE THROTTLE BODY ASSEMBLY .................................6-36

CHECKING THE FUEL INJECTOR ........................................................6-36

CHECKING THE THROTTLE BODY ......................................................6-36

INSTALLING THE THROTTLE BODY ASSEMBLY................................6-37

CHECKING THE FUEL PUMP AND PRESSURE REGULATOR

OPERATION ..........................................................................................6-38

CHECKING AND ADJUSTING THE THROTTLE POSITION

SENSOR ................................................................................................6-39

CHAPTER 7

DRIVE TRAIN

TROUBLESHOOTING.....................................................................................7-1

CHECKING NOISES.................................................................................7-1

TROUBLESHOOTING CHART.................................................................7-3

FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR........7-4

REMOVING THE FRONT CONSTANT VELOCITY JOINTS..................7-10

REMOVING THE DIFFERENTIAL GEAR ASSEMBLY...........................7-11

CHECKING THE FRONT CONSTANT VELOCITY JOINTS...................7-11

CHECKING THE DIFFERENTIAL GEARS .............................................7-12

CHECKING THE DIFFERENTIAL GEAR MOTOR .................................7-12

ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS ..............7-13

ASSEMBLING THE DIFFERENTIAL GEARS.........................................7-16

MEASURING THE DIFFERENTIAL GEAR LASH ..................................7-17

ADJUSTING THE DIFFERENTIAL GEAR LASH....................................7-18

CHECKING THE DIFFERENTIAL GEAR OPERATION .........................7-19

REAR CONSTANT VELOCITY JOINTS AND FINAL DRIVE GEAR ...........7-20

REMOVING THE REAR CONSTANT VELOCITY JOINTS ....................7-27

ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS.................7-28

DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY.......7-30

POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR ...7-30

ADJUSTING THE FINAL DRIVE PINION GEAR BACKLASH................7-30

ADJUSTING THE FINAL DRIVEN PINION GEAR BACKLASH .............7-32

MEASURING THE FINAL DRIVEN PINION GEAR THRUST

WASHER CLEARANCE.........................................................................7-34

MEASURING THE WHEEL GEAR THRUST CLEARANCE...................7-35

CHECKING THE REAR DRIVE SHAFT..................................................7-36

CHECKING THE FINAL DRIVE ASSEMBLY..........................................7-36

MEASUREMENT THE FINAL GEAR LASH............................................7-37

ADJUSTING THE FINAL GEAR LASH ...................................................7-38

ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY.............7-39

ASSEMBLING THE FINAL GEAR CASE................................................7-40

CHAPTER 8

CHASSIS

FRONT AND REAR WHEELS ........................................................................8-1

FRONT WHEELS......................................................................................8-1

REAR WHEELS ........................................................................................8-3

CHECKING THE WHEELS .......................................................................8-5

CHECKING THE WHEEL HUBS...............................................................8-5

CHECKING THE BRAKE DISCS ..............................................................8-6

INSTALLING THE BRAKE DISCS ............................................................8-6

INSTALLING THE WHEEL HUBS.............................................................8-6

INSTALLING THE WHEELS .....................................................................8-7