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Yamaha YFM7FGPW User Manual

Yamaha YFM7FGPW
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LIT-11616-20-11 3B4-28197-10
YFM7FGPW
SERVICE MANUAL

Table of Contents

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Yamaha YFM7FGPW Specifications

General IconGeneral
BrandYamaha
ModelYFM7FGPW
CategoryOffroad Vehicle
LanguageEnglish

Summary

CHAPTER 1 GENERAL INFORMATION

VEHICLE IDENTIFICATION

Details about identifying the vehicle's VIN and model label.

FEATURES

Overview of the model's key features, including the FI system.

IMPORTANT INFORMATION

Crucial guidelines for preparation, parts, and general handling.

SPECIAL TOOLS

Lists necessary specialized tools for maintenance and assembly.

CHAPTER 2 SPECIFICATIONS

GENERAL SPECIFICATIONS

Technical data on dimensions, weight, engine, lubrication, and chassis.

ENGINE SPECIFICATIONS

Detailed specifications for engine components like cylinder head, bore, and valves.

CHASSIS SPECIFICATIONS

Technical data for chassis components like suspension, wheels, and brakes.

ELECTRICAL SPECIFICATIONS

Specifications for the vehicle's electrical system components.

TIGHTENING TORQUES

Torque specifications for engine and chassis fasteners.

HOW TO USE THE CONVERSION TABLE

Guide on converting metric units to imperial units for specifications.

CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

Schedule for emission control system maintenance tasks.

GENERAL MAINTENANCE AND LUBRICATION CHART

Comprehensive schedule for general maintenance and lubrication.

ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS

Procedures for removing and inspecting body panels and skid plates.

ELECTRICAL COMPONENTS TRAY

Details on removing and installing electrical component trays.

FOOTREST BOARDS

Procedure for removing and installing footrest boards.

AIR FILTER CASE

Steps for accessing and servicing the air filter case.

ENGINE

Maintenance and adjustment procedures for engine components.

CHASSIS

Maintenance and adjustment procedures for chassis components.

ELECTRICAL SYSTEM

Troubleshooting and maintenance for the vehicle's electrical systems.

CHAPTER 4 ENGINE

ENGINE REMOVAL

Procedures for removing engine components like air ducts and exhaust.

CYLINDER HEAD

Steps for removing, checking, and installing the cylinder head.

ROCKER ARMS AND CAMSHAFT

Procedures for inspecting and installing rocker arms and camshaft.

VALVES AND VALVE SPRINGS

Steps for removing, checking, and installing valves and springs.

CYLINDER AND PISTON

Procedures for removing, checking, and installing the cylinder and piston.

AC MAGNETO

Procedures for removing, checking, and installing the AC magneto.

BALANCER GEARS AND OIL PUMP GEARS

Steps for removing and installing balancer and oil pump gears.

PRIMARY AND SECONDARY SHEAVES

Procedures for removing, disassembling, and assembling the primary and secondary sheaves.

CLUTCH

Steps for removing, checking, and installing the clutch.

CRANKCASE

Procedures for separating, checking, and assembling the crankcase.

CRANKSHAFT AND OIL PUMP

Procedures for removing, checking, and installing the crankshaft and oil pump.

TRANSMISSION

Procedures for removing, checking, and installing transmission components.

MIDDLE GEAR

Procedures for removing, checking, and installing middle gear components.

CHAPTER 5 COOLING SYSTEM

RADIATOR

Procedures for checking and installing the radiator.

THERMOSTAT

Steps for checking and installing the thermostat.

WATER PUMP

Procedures for disassembling, checking, and assembling the water pump.

CHAPTER 6 FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEM

Overview and troubleshooting of the fuel injection system.

FUEL TANK

Procedures for removing and installing the fuel tank and related components.

THROTTLE BODY

Procedures for removing, checking, and installing the throttle body assembly.

CHAPTER 7 DRIVE TRAIN

TROUBLESHOOTING

Troubleshooting guide for drive train issues and noises.

FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR

Procedures for removing, disassembling, and assembling CV joints and differential gear.

REAR CONSTANT VELOCITY JOINTS AND FINAL DRIVE GEAR

Steps for removing, disassembling, and assembling rear CV joints and final drive gear.

CHAPTER 8 CHASSIS

FRONT AND REAR WHEELS

Procedures for removing, checking, and installing front and rear wheels.

FRONT AND REAR BRAKES

Procedures for checking and replacing brake pads, and master cylinders.

STEERING SYSTEM

Procedures for checking and installing the handlebar, steering stem, and related parts.

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES

Procedures for removing, checking, and installing front suspension components.

REAR KNUCKLES AND STABILIZER

Procedures for checking rear knuckles and stabilizer.

REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES

Procedures for removing, checking, and installing rear suspension components.

CHAPTER 9 ELECTRICAL

ELECTRICAL COMPONENTS

Overview of electrical components and their locations.

CHECKING SWITCH CONTINUITY

Method for testing switch continuity using a pocket tester.

CHECKING THE SWITCHES

Procedures for checking various switches for damage, connections, and continuity.

CHECKING THE BULBS AND BULB SOCKETS

Guide to checking bulbs and sockets for damage, wear, and continuity.

IGNITION SYSTEM

Troubleshooting and circuit diagrams for the ignition system.

ELECTRIC STARTING SYSTEM

Circuit diagram and troubleshooting for the electric starting system.

STARTER MOTOR

Procedures for checking and assembling the starter motor.

CHARGING SYSTEM

Circuit diagram and troubleshooting for the charging system.

LIGHTING SYSTEM

Circuit diagram and troubleshooting for the lighting system.

SIGNALING SYSTEM

Circuit diagram and troubleshooting for the signaling system.

COOLING SYSTEM

Troubleshooting and circuit diagrams for the cooling system.

FUEL PUMP SYSTEM

Troubleshooting and circuit diagrams for the fuel pump system.

2WD/4WD SELECTING SYSTEM

Troubleshooting and circuit diagrams for the 2WD/4WD selecting system.

EPS (ELECTRIC POWER STEERING) SYSTEM

Circuit diagram, self-diagnostics, and troubleshooting for the EPS system.

CHAPTER 10 TROUBLESHOOTING

STARTING FAILURE/HARD STARTING

Common causes and checks for engine starting difficulties.

POOR IDLE SPEED PERFORMANCE

Troubleshooting steps for issues with low-speed engine operation.

POOR MEDIUM AND HIGH-SPEED PERFORMANCE

Troubleshooting steps for engine performance issues at higher speeds.

FAULTY DRIVE TRAIN

Symptoms and causes of drive train malfunctions.

FAULTY GEAR SHIFTING

Troubleshooting for hard shifting, non-moving shift levers, and jumping out of gear.

FAULTY CLUTCH PERFORMANCE

Troubleshooting for engine operation issues, clutch slipping, and poor starting performance.

OVERHEATING

Troubleshooting steps for engine overheating issues.

OVERCOOLING

Troubleshooting steps for engine overcooling issues.

FAULTY BRAKE

Troubleshooting for poor braking effect.

SHOCK ABSORBER MALFUNCTION

Troubleshooting for shock absorber malfunctions.

UNSTABLE HANDLING

Troubleshooting for unstable vehicle handling.

LIGHTING SYSTEM

Troubleshooting for lighting system failures like headlights not working or burnt-out bulbs.

BULB BURNT OUT

Troubleshooting for burnt-out bulbs in the lighting system.

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