Yamaha 2003 AG200F Manual

AG200F
SUPPLEMENTARY
SERVICE MANUAL
2003
3GX-AE2

AG200F 2003
SUPPLEMENTARY
SERVICE MANUAL
©2002 by Yamaha Motor Co., Ltd.
First Edition, March 2002
All rights reserved.
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.

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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
12
34
56
78
90
qw
er
ty
ui o
pas
df
GEN
INFO SPEC
CHK
ADJ ENG
CARB CHAS
ELEC TRBL
SHTG
LT
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
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
å
∫
ç∂
´
ƒ
123
4
5
6
7

– 5 –
SPEC
CABLE ROUTING
å
∫
ç∂
´
ƒ
©
1
2
3
4
5
6
7
890
q
w
e
A
A
4
0
9
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.