Yamaha GRIZZLY 700 FI YFM7FGPX Operating and installation instructions

YFM7FGPX
YFM7FGX
SERVICE
INFORMATION
3B4-28197-E1-SI

FOREWORD
This Service Information has been prepared to introduce new service and data for the YFM7FGPX/
YFM7FGX. For complete service information procedures it is necessary to use this Service Informa-
tion together with the following manual.
YFM7FGPX/YFM7FGX SUPPLEMENTARY SERVICE MANUAL: 3B4-28197-E1
YFM7FGPW SERVICE INFORMATION: 3B4-28197-E0-SI
YFM7FGPX/YFM7FGX
SERVICE INFORMATION
©2007 by Yamaha Motor Co., Ltd.
First edition, March 2007
All rights reserved.
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 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 4is provided for removal and disassembly jobs.
2. Numbers 5are 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 7accompanies 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 8are given in addition
to the exploded diagram and the job instruction chart.

EBS00006
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1to 0indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Cooling system
6Fuel injection system
7Drive train
8Chassis
9Electrical
0Troubleshooting
Symbols Ato Hindicate the following
ACan be serviced with engine mounted
BFilling fluid
CLubricant
DSpecial tool
ETorque
FWear limit, clearance
GEngine speed
HElectrical data (Ω, V, A)
Symbols Ito Pin the exploded diagrams
indicate the types of lubricants and lubrication
points.
IApply engine oil
JApply gear oil
KApply molybdenum disulfide oil
LApply brake fluid
MApply wheel bearing grease
NApply lithium-soap-based grease
OApply molybdenum disulfide grease
PApply silicone grease
Symbols Qto Rin the exploded diagrams
indicate where to apply a locking agent Qand
when to install a new part R.
QApply the locking agent (LOCTITE®)
RReplace
12
34
56
78
90
ABC
DEF
GH
IJKL
MNOP
QR
GEN
INFO SPEC
CHK
ADJ ENG
COOL
FI
DRIV
CHAS
–+
ELEC TRBL
SHTG
T
R
.
.
EGM
BF
BLS MS
LT
New

CONTENTS
SPECIFICATIONS.............................................................................................. 1
GENERAL SPECIFICATIONS..................................................................... 1
ENGINE SPECIFICATIONS......................................................................... 3
CHASSIS SPECIFICATIONS ...................................................................... 4
ELECTRICAL SPECIFICATIONS................................................................ 5
TIGHTENING TORQUES............................................................................. 6
ENGINE TIGHTENING TORQUES ....................................................... 6
CHASSIS TIGHTENING TORQUES ..................................................... 6
CABLE ROUTING........................................................................................ 7
PERIODIC CHECKS AND ADJUSTMENTS.................................................... 21
INTRODUCTION ........................................................................................ 21
PERIODIC MAINTENANCE CHART FOR
THE EMISSION CONTROL SYSTEM ...................................................... 21
GENERAL MAINTENANCE AND LUBRICATION CHART ...................... 22
YFM7FGPX/YFM7FGX 2008 WIRING DIAGRAM (for CDN)
YFM7FGPX/YFM7FGX 2008 WIRING DIAGRAM (for Europe and Oceania)

–2 –
SPEC
EBS01001
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model code 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)
Oil type or grade
Engine oil
For CDN
For Europe and Oceania
API service, SG type or higher, JASO standard
MA
Final gear oil SAE 80 API GL-4 Hypoid gear oil
Differential gear oil SAE 80 API GL-4 Hypoid gear oil
0°10°30°50°70°90°110°
-20°-10°0°10°20°30°40°
130°F
50°C
YAMALUBE4 (20W40) or SAE 20W40
YAMALUBE4 (10W30) or SAE 10W30
YAMALUBE 4-CW (5W30) or SAE 5W30
GENERAL SPECIFICATIONS
–1 –

–3 –
SPEC
GENERAL SPECIFICATIONS
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
LCD
High-range indicator light LED
Low-range indicator light LED
Differential gear lock indicator light LED
Item Standard
–2 –

–4 –
SPEC
ENGINE SPECIFICATIONS
EBS01002
ENGINE SPECIFICATIONS
Item Standard Limit
Valve spring
Free length
Intake 40.38 mm (1.59 in) 38.36 mm
(1.51 in)
Exhaust 40.38 mm (1.59 in) 38.36 mm
(1.51 in)
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
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 ----
–3 –

–5 –
SPEC
CHASSIS SPECIFICATIONS
EBS01003
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)
–4 –

–6 –
SPEC
ELECTRICAL SPECIFICATIONS
EBS01004
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 Ωat 20 °C (68 °F) ----
Secondary coil resistance 8.64 ~ 12.96 kΩat 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
----
----
----
----
–5 –

–7 –
SPEC
EBS01005
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
EBS01006
CHASSIS TIGHTENING TORQUES
Item Part name Thread
size Q’ty Tightening torque Remarks
Nm m ·kg ft ·lb
Oil filter cartridge union bolt Union bolt M20 1 30 3.0 22 LT
Exhaust pipe Nut M8 4 14 1.4 10
Middle drive pinion gear nut Nut M22 1 190 19.0 140 Stake.
Part to be tightened Thread size Tightening torque Remarks
Nm m ·kg ft ·lb
Steering stem bracket and frame M10 51 5.1 37 LT
Steering stem support and frame
(YFM7FGX only) M8 30 3.0 22 LT
EPS control unit and frame (YFM7FGPX only) M8 30 3.0 22 LT
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 LT
Steering stem bearing and frame
(YFM7FGPX only) M10 51 5.1 37 LT
Steering stem bearing nut (YFM7FGPX only) M22 125 12.5 90
EPS motor cover (YFM7FGPX only) M6 7 0.7 5.1
TIGHTENING TORQUES
–6 –

–8 –
SPEC
CABLE ROUTING
EBS00028
CABLE ROUTING
1Coolant reservoir hose
2Radiator fan motor breather hose
3Differential gear case breather hose
4EPS motor breather hose (YFM7FGPX only)
5Ground lead
6Coolant reservoir breather hose
7Throttle cable
8Fuel injector lead
9Final gear case breather hose
0Speed sensor lead
ACrankshaft position sensor lead
BDifferential gear motor lead
CEPS torque sensor lead (YFM7FGPX only)
DFast idle plunger outlet hose
EHorn switch lead (for Europe and Oceania)
FRadiator outlet hose
GGear position switch lead
HReverse switch lead
Ó
Ò
Ñ
Ð
Ï
Ô
Ú
×
Ø
Ø
Ù
Ö
ÎÍ
ÈÉ
ÊË
Ì
1
D
E
C
B
D5
G
0
9
A
H
5
J
I
A
23567
8
9
0
A
4
E
E
A
A
B
B
C
C
D
A-A
E-E
D
Õ
ÛÜ
ÛÜ
F1
B-B
Õ
F1
1
B-B
Õ
C
4
F
C-C
Õ
C-C
1
F
4
–7 –

–9 –
SPEC
CABLE ROUTING
IShift control cable
JStarter motor lead
ÈFace the end of the coolant reservoir breather
hose downward.
ÉRoute 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.
ÊPass the radiator fan motor breather hose
through the larger diameter guide.
ËRoute the coolant reservoir breather hose to the
outside of the fast idle plunger outlet hose.
ÌRoute the fuel injector lead under the fuel hose.
ÍFasten the radiator outlet hose to the frame with
the plastic band, making sure to face the end of
the band inward.
ÎRoute the EPS motor breather hose under the
coolant reservoir hose.
Ó
Ò
Ñ
Ð
Ï
Ô
Ú
×
Ø
Ø
Ù
Ö
ÎÍ
ÈÉ
ÊË
Ì
1
D
E
C
B
D5
G
0
9
A
H
5
J
I
A
23567
8
9
0
A
4
E
E
A
A
B
B
C
C
D
A-A
E-E
D
Õ
ÛÜ
ÛÜ
F1
B-B
Õ
F1
1
B-B
Õ
C
4
F
C-C
Õ
C-C
1
F
4
–8 –

–10 –
SPEC
CABLE ROUTING
ÏPlace the EPS torque sensor lead and differen-
tial gear motor lead in the holder, and then insert
the ends of the holder into the hole in the stay on
the frame.
ÐRoute the differential gear case breather hose to
the inside of the frame.
ÑFasten the differential gear case breather hose
to the frame with the plastic band, making sure
to face the end of the band inward.
ÒAttach the ground lead terminal to the frame
using the bolt.
ÓRoute the radiator fan motor breather hose, dif-
ferential gear case breather hose, and horn
switch lead to the inside of the fast idle plunger
outlet hose and radiator outlet hose.
ÔMake sure that the catch of the holder is facing
outward.
ÕFace the end of the plastic band inward.
ÖRoute the fuel tank drain hose and position the
end of the hose as shown in the illustration.
Ó
Ò
Ñ
Ð
Ï
Ô
Ú
×
Ø
Ø
Ù
Ö
ÎÍ
ÈÉ
ÊË
Ì
1
D
E
C
B
D5
G
0
9
A
H
5
J
I
A
23567
8
9
0
A
4
E
E
A
A
B
B
C
C
D
A-A
E-E
D
Õ
ÛÜ
ÛÜ
F1
B-B
Õ
F1
1
B-B
Õ
C
4
F
C-C
Õ
C-C
1
F
4
–9 –

–11 –
SPEC
CABLE ROUTING
×Pass the speed sensor lead, AC magneto lead,
and final gear case breather hose through the
guide in the order listed.
ØRoute the speed sensor lead, AC magneto lead,
and final gear case breather hose to the right of
the reverse switch.
ÙRoute the final gear case breather hose above
the reverse switch lead and ground leads.
ÚRoute the shift control cable under the gear posi-
tion switch lead, speed sensor lead, and crank-
shaft position sensor lead.
ÛYFM7FGPX
ÜYFM7FGX
Ó
Ò
Ñ
Ð
Ï
Ô
Ú
×
Ø
Ø
Ù
Ö
ÎÍ
ÈÉ
ÊË
Ì
1
D
E
C
B
D5
G
0
9
A
H
5
J
I
A
23567
8
9
0
A
4
E
E
A
A
B
B
C
C
D
A-A
E-E
D
Õ
ÛÜ
ÛÜ
F1
B-B
Õ
F1
1
B-B
Õ
C
4
F
C-C
Õ
C-C
1
F
4
–10 –

–12 –
SPEC
CABLE ROUTING
1Wire harness
2Fuel injector lead
3Fuel hose
4Intake air temperature sensor lead
5Final gear case breather hose
6Ground lead
7Starter motor lead
8Air filter case breather hose
9Main switch lead
0Auxiliary DC jack lead
AEPS motor lead (YFM7FGPX only)
BDifferential gear motor lead
CEPS torque sensor lead (YFM7FGPX only)
DRadiator fan motor lead
ERadiator inlet hose
FEPS motor breather hose (YFM7FGPX only)
GSpark plug lead
HRear brake cable
IShift control cable
JFuel tank drain hose
KGear position switch lead
LAC magneto lead
A
A
B
B
F
F
E
ED
C
C
D
A-A B-B C-C
D-D E-E F-F
È
Ï
Î
Í
É
3
2
1
N
M
L
K
J
L
5
2
N
6
1
B
A
C
G
I
HI
O
B
P
7
1
7
56
Ð
Ó
ÕÖ
D-D
B
Ó
Ô
Ñ
Ò
Ì
Ê
Ë
IHG
F
E
90ABCD
4
5678
–11 –

–13 –
SPEC
CABLE ROUTING
MSpeed sensor lead
NCoolant temperature sensor lead
OEPS motor lead coupler (YFM7FGPX only)
PEPS torque sensor lead coupler
(YFM7FGPX only)
ÈRoute the fuel hose between the wire harness
and the fuel tank drain hose.
ÉRoute the coolant temperature sensor lead
above the fast idle plunger inlet hose.
ÊRoute the final gear case breather hose above
the V-belt cooling duct 1.
ËRoute the radiator fan motor lead between the
electrical components tray and the radiator inlet
hose.
ÌFasten the radiator fan motor lead to the frame
with the plastic band, making sure to face the
end of the band inward.
A
A
B
B
F
F
E
ED
C
C
D
A-A B-B C-C
D-D E-E F-F
È
Ï
Î
Í
É
3
2
1
N
M
L
K
J
L
5
2
N
6
1
B
A
C
G
I
HI
O
B
P
7
1
7
56
Ð
Ó
ÕÖ
D-D
B
Ó
Ô
Ñ
Ò
Ì
Ê
Ë
IHG
F
E
90ABCD
4
5678
–12 –

–14 –
SPEC
CABLE ROUTING
ÍRoute the fuel tank drain hose to the inside of
the leads and fuel hose, making sure to position
the end of the drain hose as shown in the illus-
tration.
ÎFasten the final gear case breather hose,
ground lead, starter motor lead, fuel injector
lead, coolant temperature sensor lead, AC mag-
neto lead, and wire harness with the plastic
band, making sure to position the band near the
split in the wire harness.
ÏRoute the fuel injector lead and coolant temper-
ature sensor lead to the inside of the ground
lead, starter motor lead, final gear case breather
hose, and wire harness.
ÐFace the end of the plastic band inward.
ÑPass the plastic band through the hole in the
plastic cover, and then fasten the leads and
hose with the band, making sure to face the end
of the band downward.
ÒInsert the projection on the coupler into the hole
in the frame from the inside of the frame.
A
A
B
B
F
F
E
ED
C
C
D
A-A B-B C-C
D-D E-E F-F
È
Ï
Î
Í
É
3
2
1
N
M
L
K
J
L
5
2
N
6
1
B
A
C
G
I
HI
O
B
P
7
1
7
56
Ð
Ó
ÕÖ
D-D
B
Ó
Ô
Ñ
Ò
Ì
Ê
Ë
IHG
F
E
90ABCD
4
5678
–13 –

–15 –
SPEC
CABLE ROUTING
ÓFace the end of the plastic band inward.
ÔFasten the spark plug lead with the larger diam-
eter section of each holder.
ÕYFM7FGPX
ÖYFM7FGX
A
A
B
B
F
F
E
ED
C
C
D
A-A B-B C-C
D-D E-E F-F
È
Ï
Î
Í
É
3
2
1
N
M
L
K
J
L
5
2
N
6
1
B
A
C
G
I
HI
O
B
P
7
1
7
56
Ð
Ó
ÕÖ
D-D
B
Ó
Ô
Ñ
Ò
Ì
Ê
Ë
IHG
F
E
90ABCD
4
5678
–14 –