Yamaha AG200FZ User manual

OWNER’S MANUAL
53C-28199-20
AG200FZ
✦✰✥✣❉❖❊ ✤  

Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
EAU46090
Q
✦✰✥✣❉❖❊ ✥  

INTRODUCTION
EAU10102
Welcome to the Yamaha world of motorcycling!
As the owner of the AG200FZ, you are benefiting from Yamaha’s vast experience and newest technology regarding the de-
sign and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your AG200FZ. The Owner’s Manual
does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and
others from trouble and injury.
In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any
further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most cur-
rent product information available at the time of printing, there may be minor discrepancies between your motorcycle and this
manual. If there is any question concerning this manual, please consult a Yamaha dealer.
WARNING
EWA10031
Please read this manual carefully and completely before operating this motorcycle.
✼✦✰✥✣✲✣ ✤  

IMPORTANT MANUAL INFORMATION
EAU10132
Particularly important information is distinguished in this manual by the following notations:
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury
or death.
A WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the
vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP
✼✦✰✥✣✲✣ ✤  

IMPORTANT MANUAL INFORMATION
EAU10200
AG200FZ
OWNER’S MANUAL
©2009 by Yamaha Motor Co., Ltd.
1st edition, December 2009
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
✼✦✰✥✣✲✣ ✥  

TABLE OF CONTENTS
LOCATION OF IMPORTANT
LABELS ............................................. 1-1
SAFETY INFORMATION .................. 2-1
DESCRIPTION .................................. 3-1
Left view .......................................... 3-1
Right view ........................................ 3-2
Controls and instruments................. 3-3
INSTRUMENT AND CONTROL
FUNCTIONS ....................................... 4-1
Main switch ..................................... 4-1
Indicator light .................................. 4-1
Speedometer unit ........................... 4-2
Handlebar switches ........................ 4-2
Clutch lever ..................................... 4-3
Shift pedal ....................................... 4-4
Brake lever ..................................... 4-4
Brake pedal .................................... 4-4
Fuel tank cap .................................. 4-5
Fuel ................................................. 4-5
Fuel cock ........................................ 4-6
Starter (choke) knob
“”
............... 4-7
Kickstarter ....................................... 4-8
Seat ................................................ 4-8
Adjusting the shock absorber
assembly ..................................... 4-9
Front and rear carriers .................. 4-10
Sidestands .................................... 4-11
Starting circuit cut-off system ....... 4-11
Auxiliary DC jack .......................... 4-13
FOR YOUR SAFETY –
PRE-OPERATION CHECKS ............. 5-1
OPERATION AND IMPORTANT
RIDING POINTS ................................. 6-1
Starting and warming up a cold
engine ......................................... 6-1
Starting a warm engine .................. 6-2
Shifting ........................................... 6-2
Tips for reducing fuel
consumption ............................... 6-3
Engine break-in .............................. 6-3
Parking ........................................... 6-4
PERIODIC MAINTENANCE AND
ADJUSTMENT ................................... 7-1
Owner’s tool kit ............................... 7-1
Periodic maintenance chart for the
emission control system ............. 7-3
General maintenance and
lubrication chart .......................... 7-4
Removing and installing panels ..... 7-7
Checking the spark plug ................. 7-8
Engine oil and oil filter element ...... 7-9
Cleaning the air filter element ...... 7-12
Adjusting the carburetor ............... 7-13
Adjusting the engine idling
speed ........................................ 7-13
Adjusting the throttle cable free
play ........................................... 7-14
Valve clearance ........................... 7-15
Tires ............................................. 7-15
Spoke wheels .............................. 7-16
Adjusting the clutch lever free
play ........................................... 7-17
Adjusting the brake lever free
play ........................................... 7-18
Adjusting the brake pedal position
and free play ............................. 7-19
Checking the shift pedal .............. 7-20
Brake light switches ..................... 7-21
Checking the front and rear brake
shoes ........................................ 7-21
Drive chain slack .......................... 7-22
Cleaning and lubricating the drive
chain ......................................... 7-23
Checking and lubricating the
cables ....................................... 7-24
Checking and lubricating the
throttle grip and cable ............... 7-24
Checking and lubricating the
brake and clutch levers ............. 7-24
Checking and lubricating the
brake pedal ............................... 7-25
Checking and lubricating the
sidestands ................................ 7-25
Lubricating the rear suspension ... 7-25
Checking the front fork ................. 7-26
Checking the steering .................. 7-26
✼✦✰✥✣✲✣ ✤  

TABLE OF CONTENTS
Checking the wheel bearings ....... 7-27
Battery .......................................... 7-27
Replacing the fuses ...................... 7-29
Replacing the headlight bulb ........ 7-30
Replacing the tail/brake light
bulb ........................................... 7-31
Replacing a turn signal light
bulb ........................................... 7-31
Supporting the motorcycle ............ 7-32
Front wheel ................................... 7-32
Rear wheel ................................... 7-34
Troubleshooting ............................ 7-36
Troubleshooting chart ................... 7-37
MOTORCYCLE CARE AND
STORAGE .......................................... 8-1
Matte color caution ......................... 8-1
Care ................................................ 8-1
Storage ........................................... 8-3
SPECIFICATIONS ............................. 9-1
CONSUMER INFORMATION ........... 10-1
Identification numbers .................. 10-1
Motorcycle noise regulation
(for Australia) ............................. 10-2
✼✦✰✥✣✲✣ ✥  

1-1
1
LOCATION OF IMPORTANT LABELS
EAU10384
Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of
your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label
is available from your Yamaha dealer.
123
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LOCATION OF IMPORTANT LABELS
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Before you operate this vehicle, read the owner’s manual.
5PA-21568-01
Prima di usare il veicolo, leggete il manuale di istruzioni.
Lire le manuel du propri étaire avant d ’utiliser ce v éhicule.
Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.
Antes de conducir este vehículo, lea el Manual del Propietario.
follows.
FRONT :
:REAR
3GX-21668-00
Cold tire normal pressure should be set as
125 kPa,{1.25 kgf/cm2}, 18 psi
150 kPa,{1.50 kgf/cm2}, 22 psi
3
1
2
✼✦✰✥✣✲✣ ✥  

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7
8
9
SAFETY INFORMATION
EAU35132
Be a Responsible Owner
As the vehicle’s owner, you are respon-
sible for the safe and proper operation
of your motorcycle.
Motorcycles are single-track vehicles.
Their safe use and operation are de-
pendent upon the use of proper riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements before
riding this motorcycle.
He or she should:
● Obtain thorough instructions from
a competent source on all aspects
of motorcycle operation.
● Observe the warnings and mainte-
nance requirements in this Own-
er’s Manual.
● Obtain qualified training in safe
and proper riding techniques.
● Obtain professional technical ser-
vice as indicated in this Owner’s
Manual and/or when made neces-
sary by mechanical conditions.
Safe Riding
Perform the pre-operation checks each
time you use the vehicle to make sure it
is in safe operating condition. Failure to
inspect or maintain the vehicle properly
increases the possibility of an accident
or equipment damage. See page 5-1
for a list of pre-operation checks.
● This motorcycle is designed for
off-road use only, therefore, it is il-
legal to operate it on public streets,
roads, or highways, even a dirt or
gravel one. Off-road use on public
lands may be illegal. Please check
local regulations before riding.
● This motorcycle is designed to car-
ry the operator only. No passen-
gers.
● The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.
Therefore:
● Wear a brightly colored jacket.
● Use extra caution when you are
approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.
● Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
● Many accidents involve inexperi-
enced operators.
● Make sure that you are qualified
and that you only lend your mo-
torcycle to other qualified opera-
tors.
● Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
● We recommend that you prac-
tice riding your motorcycle until
you have become thoroughly fa-
miliar with the motorcycle and all
of its controls.
● Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
✼✦✰✥✣✲✣ ✤  

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SAFETY INFORMATION
erator is veering wide on a turn
due to excessive speed or under-
cornering (insufficient lean angle
for the speed). Never travel faster
than warranted by conditions.
● Ride cautiously in unfamiliar ar-
eas. You may encounter hidden
obstacles that could cause an ac-
cident.
● The posture of the operator is im-
portant for proper control. The op-
erator should keep both hands on
the handlebar and both feet on the
operator footrests during operation
to maintain control of the motorcy-
cle.
● Never ride under the influence of
alcohol or other drugs.
Protective apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the preven-
tion or reduction of head injuries.
● Always wear an approved helmet.
● Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
● The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
● Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
● Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or af-
ter operation and can cause burns.
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing car-
bon monoxide can cause headaches,
dizziness, drowsiness, nausea, confu-
sion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be
present even if you do not see or smell
any engine exhaust. Deadly levels of
carbon monoxide can collect rapidly
and you can quickly be overcome and
unable to save yourself. Also, deadly
levels of carbon monoxide can linger
for hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poison-
ing, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
● Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
● Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
● Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail-
able only from a Yamaha dealer, have
✼✦✰✥✣✲✣ ✥  

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SAFETY INFORMATION
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection to
Yamaha manufacture parts and acces-
sories or offer other modifications for
Yamaha vehicles. Yamaha is not in a
position to test the products that these
aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories,
and Modifications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accessories
or modifications are not suitable be-
cause of potential safety hazards to you
or others. Installing aftermarket prod-
ucts or having other modifications per-
formed to your vehicle that change any
of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or death.
You are responsible for injuries related
to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
● Never install accessories that
would impair the performance of
your motorcycle. Carefully inspect
the accessory before using it to
make sure that it does not in any
way reduce ground clearance or
cornering clearance, limit suspen-
sion travel, steering travel or con-
trol operation, or obscure lights or
reflectors.
● Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution. If accesso-
ries are added to the handlebar
or front fork area, they must be
as lightweight as possible and
should be kept to a minimum.
● Bulky or large accessories may
seriously affect the stability of
the motorcycle. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds.
● Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.
● Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match the
performance capabilities and to provide
the best combination of handling, brak-
ing, and comfort. Other tires, rims, siz-
es, and combinations may not be
appropriate. Refer to page 7-15 for tire
specifications and more information on
replacing your tires.
✼✦✰✥✣✲✣ ✦  

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DESCRIPTION
EAU10410
Left view
123 4
56
1. Headlight (page 7-30)
2. Fuel cock (page 4-6)
3. Main fuse (page 7-29)
4. Owner’s tool kit (page 7-1)
5. Air filter element (page 7-12)
6. Shift pedal (page 4-4)
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DESCRIPTION
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EAU10420
Right view
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4
56 2
1. Shock absorber assembly spring preload adjusting ring (page 4-9)
2. Engine oil filter element (page 7-9)
3. Brake pedal (page 4-4)
4. Kickstarter (page 4-8)
5. Battery (page 7-27)
6. Auxiliary DC jack fuse (page 7-29)
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DESCRIPTION
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EAU10430
Controls and instruments
12 3 45 6 7
8910
1. Clutch lever (page 4-3)
2. Left handlebar switches (page 4-2)
3. Speedometer unit (page 4-2)
4. Auxiliary DC jack (page 4-13)
5. Starter (choke) knob (page 4-7)
6. Right handlebar switches (page 4-2)
7. Brake lever (page 4-4)
8. Throttle grip (page 7-14)
9. Main switch (page 4-1)
10.Fuel tank cap (page 4-5)
✼✦✰✥✣✲✣ ✦  

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INSTRUMENT AND CONTROL FUNCTIONS
EAU10450
Main switch
The main switch controls the ignition
and lighting systems. The various main
switch positions are described below.
EAU10630
ON
All electrical systems are supplied with
power, and the engine can be started.
The key cannot be removed.
EAU45751
OFF
All electrical systems are off. The key
can be removed.
WARNING
EWA10072
Never turn the key to “OFF”while
the vehicle is moving, otherwise the
electrical systems will be switched
off, which may result in loss of con-
trol or an accident.
EAU11010
Indicator light
EAU11070
Neutral indicator light “NEUTRAL”
This indicator light comes on when the
transmission is in the neutral position.
ON
OFF
1. Neutral indicator light “NEUTRAL”
1
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INSTRUMENT AND CONTROL FUNCTIONS
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EAU11621
Speedometer unit
The speedometer unit is equipped with
a speedometer and an odometer. The
speedometer shows riding speed. The
odometer shows the total distance trav-
eled.
EAU12348
Handlebar switches
Left
Right
EAU12400
Dimmer switch “/”
Set this switch to “ ” for the high
beam and to “ ” for the low beam.
EAU12460
Turn signal switch “/”
To signal a right-hand turn, push this
switch to “ ”. To signal a left-hand
turn, push this switch to “ ”. When re-
leased, the switch returns to the center
position. To cancel the turn signal
lights, push the switch in after it has re-
turned to the center position.
1. Speedometer
2. Odometer
1
2
1. Light switch “ / ”
2. Dimmer switch “ / ”
3. Turn signal switch “ / ”
4. Horn switch “ ”
2
1
3
4
1. Engine stop switch “ / ”
2. Start switch “START”
1
2
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INSTRUMENT AND CONTROL FUNCTIONS
4-3
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EAU12500
Horn switch “”
Press this switch to sound the horn.
EAU12581
Light switch “/”
Set the light switch to “ ” to turn on
the headlight, taillight and meter light-
ing. Set the switch to “ ” to turn off all
the lights.
EAU12660
Engine stop switch “/”
Set this switch to “ ” before starting
the engine. Set this switch to “ ” to
stop the engine in case of an emergen-
cy, such as when the vehicle overturns
or when the throttle cable is stuck.
EAU12691
Start switch “START”
Push this switch to crank the engine
with the starter. See page 6-1 for start-
ing instructions prior to starting the en-
gine.
EAU35000
Clutch lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the start-
ing circuit cut-off system. (See
page 4-11.)
A clutch lever lock is provided to keep
the clutch disengaged. To lock the
clutch lever, push down the clutch lever
lock while holding the clutch lever
pulled towards the handlebar grip. To
release the lever lock, simply pull the
clutch lever.
1. Clutch lever
1
1. Clutch lever lock
1
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INSTRUMENT AND CONTROL FUNCTIONS
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EAU12870
Shift pedal
The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 5-speed con-
stant-mesh transmission equipped on
this motorcycle.
EAU12890
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
EAU12941
Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
1. Shift pedal
1
1. Brake lever
1
1. Brake pedal
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INSTRUMENT AND CONTROL FUNCTIONS
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EAU13182
Fuel tank cap
To remove the fuel tank cap, turn it
counterclockwise, and then pull it off.
To install the fuel tank cap, insert it into
the tank opening, and then turn it clock-
wise.
WARNING
EWA11091
Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a fire hazard.
EAU13212
Fuel
Make sure there is sufficient gasoline in
the tank.
WARNING
EWA10881
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.
1. Before refueling, turn off the en-
gine and be sure that no one is sit-
ting on the vehicle. Never refuel
while smoking, or while in the vi-
cinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters and
clothes dryers.
2. Do not overfill the fuel tank. Stop
filling when the fuel reaches the
bottom of the filler tube. Because
fuel expands when it heats up,
heat from the engine or the sun
can cause fuel to spill out of the
fuel tank.
3. Wipe up any spilled fuel immedi-
ately. NOTICE: Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteri-
orate painted surfaces or plastic
parts. [ECA10071]
4. Be sure to securely close the fuel
tank cap.
WARNING
EWA15151
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gaso-
line by mouth. If you should swallow
some gasoline or inhale a lot of gas-
oline vapor, or get some gasoline in
1. Fuel tank cap
1
1. Fuel tank filler tube
2. Maximum fuel level
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