Yamaha 2003 AG200F Manuel

AG200F

SUPPLEMENTARY

SERVICE MANUAL

2003

3GX-AE2

AG200F 2003

SUPPLEMENTARY

SERVICE MANUAL

First Edition, March 2002

Any reprinting or unauthorized use with-

out the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

EAS00000

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

AG200F 2003. For complete service information procedures it is necessary to use this Supplementary

Service Manual together with the following manual.

AG200F ’97 SERVICE MANUAL: 3GX-AE1

EAS00003

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-

ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles

should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-

cle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of 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:

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT MANUAL INFORMATION

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

QThe Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED!

wFailure to follow WARNING instructions could result in severe injury or death to the

motorcycle operator, a bystander or a person checking or repairing the motorcycle.

cCA CAUTION indicates special precautions that must be taken to avoid damage to

the motorcycle.

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

EAS00009

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 1to 8indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Engine

5Carburetor(s)

6Chassis

7Electrical system

8Troubleshooting

Symbols 9to yindicate the following.

9Serviceable with engine mounted

0Filling fluid

qLubricant

wSpecial tool

eTightening torque

rWear limit, clearance

tEngine speed

yElectrical data

Symbols uto sin the exploded diagrams indi-

cate the types of lubricants and lubrication

points.

uEngine oil

iGear oil

oMolybdenum-disulfide oil

pWheel-bearing grease

aLithium-soap-based grease

sMolybdenum-disulfide grease

Symbols dto fin the exploded diagrams indi-

cate the following.

dApply locking agent (LOCTITE®)

fReplace the part

ui o

pas

GEN

INFO SPEC

CHK

ADJ ENG

CARB CHAS

ELEC TRBL

SHTG

New

CONTENTS

SPECIFICATIONS...................................................................................................1

GENERAL SPECIFICATIONS ..........................................................................1

MAINTENANCE SPECIFICATIONS .................................................................2

CHASSIS .....................................................................................................2

ELECTRICAL...............................................................................................2

TIGHTENING TORQUES..................................................................................3

ENGINE .......................................................................................................3

CABLE ROUTING.............................................................................................4

PERIODIC CHECKS AND ADJUSTMENTS...........................................................8

INTRODUCTION ...............................................................................................8

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS.......................8

ELECTRICAL........................................................................................................10

IGNITION SYSTEM .........................................................................................10

CIRCUIT DIAGRAM ..................................................................................10

TROUBLESHOOTING ..............................................................................11

AG200F 2002 WIRING DIAGRAM

– 1 –

SPEC

GENERAL SPECIFICATIONS

Model AG200F

Model code: 3GXF

Engine:

Engine type Air-cooled 4-stroke, SOHC

Cylinder arrangement Forward-inclined single cylinder

Displacement 0.196 L (196 cm3

)

Bore ×stroke 67.0 ×55.7 mm

Compression ratio 9.5 : 1

Compression pressure (STD)

900 kPa (9.0 kg/cm2, 130.5 psi) at 1,000 r/min

Starting system Electric and kick starter

Lubrication system: Wet sump

Chassis:

Frame type Diamond

Caster angle 27.42°

Trail 87 mm

Tire:

Type With tube

Size front 80/100-21 51M

rear 4.10-18 59M

Manufacturer front IRC

rear IRC

Type front VE-32

rear FARM SPECIAL - Z2

Tire pressure (cold tire):

Maximum load-except motorcycle 112 kg

Loading condition A * 0~112 kg

(off road riding)

front 120 kPa (1.2 kgf/cm2, 17.4 psi)

rear 150 kPa (1.5 kgf/cm2, 21.8 psi)

Electrical:

Ignition system DC-CDI

Generator system AC magneto

Battery type GT6B-3

Battery capacity 12V 6 Ah

*Load is the total weight of cargo, rider, passenger, and accessories.

SPECIFICATIONS

GENERAL SPECIFICATIONS

– 2 –

SPEC

MAINTENANCE SPECIFICATIONS

CHASSIS

Item Standard Limit

Rear suspension:

Shock absorber stroke 82 mm •••

Spring free length 279 mm 276 mm

Fitting length 265 mm •••

Spring rate (K1) 44.3 N/mm (4.52 kg/mm) •••

(K2) 70.8N/mm (7.22 kg/mm) •••

Stroke (K1) 0 ~ 42 mm •••

(K2) 42 ~ 82 mm •••

Drive chain:

Type/manufacturer 428HG/DAIDO •••

No. of links 122 •••

Chain free play 30~45 mm •••

Item Standard Limit

CDI:

CDI magneto model/manufacturer 3GX/YAMAHA •••

Pickup coil resistance/color 656~984 Ωat 20°C/ •••

Red — White

Ignition coil:

Model/manufacturer 2JN/YAMAHA •••

Minimum spark gap 6 mm •••

Primary winding resistance 0.24~0.36 Ωat 20°C •••

Secondary winding resistance 5.68~8.52 kΩat 20°C •••

Charging system:

Type CDI magneto •••

Model/manufacturer F5MP/YAMAHA •••

Standard output 14 V, 175W @5,000 r/min •••

Stator coil resistance/color 0.56~0.84 Ωat 20°C/ •••

White — White •••

Rectifier/regulator:

Model/manufacturer SH629A-12/SHINDENGEN •••

Type (regulator) Semi conductor - short circuit type •••

No load regulated voltage 14.1~14.9 V •••

Capacity (rectifier) 10 A •••

Withstand voltage 200 V •••

ELECTRICAL

– 3 –

SPEC

MAINTENANCE SPECIFICATIONS

Part to be tightened

Carburetor joint and carburetor

Part name

Bolt

Thread

size Q’ty

M6 2 12 1.2

Tightening

torque Remarks

Nm m•kg

TIGHTENING TORQUES

ENGINE

Item Standard Limit

Electric starter system:

Type Constant mesh type

Starter motor:

Model/manufacturer 4JG/YAMAHA •••

Output 0.4 kW •••

Armature coil resistance 0.0126~0.0154 Ωat 20°C •••

Brush overall length 10 mm 3.5 mm

Brash spring pressure 5.52~8.28 N (563~844g) •••

Starter relay:

Model/manufacturer MS5F-431/JIDECO •••

Amperage rating 180 A •••

Coil winding resistance 4.18~4.62 Ωat 20°C •••

Flasher relay:

Type Full transistor type •••

Model/manufacturer FE218BH/DENSO •••

Flasher frequency 75~95 cycle/min •••

– 4 –

SPEC

CABLE ROUTING

1Clutch cable

2Cable guide

3Front brake cable

4Throttle cable

5Front brake switch lead

6Clutch switch lead

7Clamp

åPass the throttle cable behind

the main switch.

∫Clamp the handlebar switch

lead and the front brake switch

lead.

çClamp the handlebar switch

lead and the clutch lead.

∂From the left, front turn signal

light lead (right), handlebar

switch lead (right), main switch

lead, auxiliary DC terminal cou-

pler, speedometer lead and

front turn signal light lead (left).

´Insert the front fork breather

hose into the headlight body

under hole.

ƒTo the headlight.

EAS00035

CABLE ROUTING

∫

ç∂

123

– 5 –

SPEC

CABLE ROUTING

∫

ç∂

890

1High-tension cord

2Ignition coil

3Ignition coil lead (primary side)

4Starting motor lead

5Breather hose

6Magneto lead

7Over flow hose

8Rectifier/regulator lead

9Brake switch lead

0Battery positive lead

qStarter relay lead

wWireharness

eBattery negative lead

åTighten with the ignition coil and

the earth lead. (bypass from the

wireharness)

∫Clamp the wireharness and the

starting motor lead behind the

air cleaner duct.

çTo the regulator earth lead.

∂Black coupler. (to the regulator

coupler)

´White coupler. (to the starter

relay)

ƒClamp the battery positive lead

and wireharness.

©Insert the fuse holder into the

guard flap projection.

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