Yamaha XC200T User manual

1987
MOTORCYCLE
SERVICE MANUAL
Model : XC200T
1YA281972000 *1YA281972000*

_i_I___I_!_I_,,_i!iill
i!ili_i
_i!iil

×C200T
SERVUCE MANUAL
©1986 by Yamaha Motor Co., Ltd.
1st Edition, June1986
ARIrights reserved,Any reprinting or
...... unauthorized use withoutthe written
permission of Yamaha Motor Co., Ltd.
is e×pressBy prohibited.
Printed in Japan

NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and ....
their qualified mechanics,tt is not possible to put an entire mechanic's education into one manual,
so it is assumed that persons using this book to perform maintenance and repairs on Yamaha scooter
have a basic understanding of the mechanical concepts and procedures inherent in scooter repair tech-
nology_ Without such knowledge,attempted repairs or service to this model may render it unfit to
use and/or unsafe.
Yamaha Motor Company,Ltd.is continually striving to improve all models manufactured by Yamaha.
Modifications and significant changes in specifications or procedures will be forwarded to all Autho-
rized Yamaha dealers and will,where applicable,appear in future editions of this manual.
TECHNICAL PUBLiCATiONS
SERVICE DiViSiON
MOTORCYCLES OPERATIONS
YAMAHA MOTOR CO., LTD.
HOW TO USE TH IS MAN UAL
PARTICULARLYiMPORTANT INFORMATmON
This material is distinguished by the following notation.
NOTE: A NOTE provides key information to make procedures easier or clearer.
ii!!i_i_i_ii_iii!i_i:i_i A CAUTION indicates special procedures that must be foltowed to avoid
damage to the scooter.
A WARNING indicates special procedures that must be followed to avoid injury
to a scooter operator or person inspecting or repairing the scooter.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential,step-by-step format. The informa-
tion has been compiled to provide the mechanic with an easy to read,handy reference that contains
comprehensive explanations of all disassembly,repair,assembly,and inspection operations.
In this revised format,the condition of a faulty component will precede an arrow symbol and the course
of action required will follow the symbol,e.g.,
® Bearings
Pitting/Damage--* Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying cor-
rect disassembly and assembly procedures.

-_ ® iLLUSTRATED SYMBOLS
(Referto theimlustration)
Illustrated symbols (_ to _) are designed as
thumb tabs to indicate thechapter's number and
_content.
I General information
ENG Periodic inspection and adjustment
............... _ EngineCooling system
_ _ Carburetion
Chassis
[C_B _il [CHAS_ _) ,_ppter'ndaIces
_ ®
_ _ Illustrated symbols(_ to (_ are used toidentify
6_)_the specifications appearing in the text.
(_) Filling fluid
(_ Lubricant
(_ Tightening
Wear limit, clearanceEngine speed
@ @
@ @
(_ _ Illustrated symbols (_ to (_ in the exploded
_= _ _,diagram indicate grade of lubricant and location
= = of lubrication point.
_ _ (_ Apply engine oil
(_ Apply gear oil
_ (_ _ Apply molybdenum disulfide oil
Apply wheel bearing grease
(_ Apply lightweight lithium-soap base grease
®Apply molybdenum disulfide grease
(_ Apply locking agent (LOCTITE®)
®±

_ii_iii_!i_i_i__
iiiiii!i_i_,
i_i_!i__ _ __
!_i_ii_iii_!_i_!i_i_
_i_iii_i!iii_iii_I_
_ _i,_,_

.... mNDEX
GENERALNFORMA'r oN IJ]
PERmODmCINSPEONS
AND ADJUSTMENTS UNSP
ADJ
ENGmNEOVERHAUL _
ENG
CARSUREYION CAR8
CHASSMS CHAS_
ELECTRICAL ELEC
APPENDmCES APPX

iilliii_iiiii_i_i_i_iii_i__
_i_iiiii_ii_i_i__
__i_i_iiii_i!ili_'

GEN
CHAPTER 1.
......... GENERAL mNFORMATiON
SCOOTERIDENTIFICATION ....................................... 1-1
VEHICLE IDENTIFICATION NUMBER .............................. 1-1
ENGINE SERIAL NUMBER ....................................... 1-1
INPORTANT iNFORMATiON ....................................... 1-2 I_
ALL REPLACEMENT PARTS ..................................... 1-2
GASKETS, OILSEALS, AND O-RINGS ............................ 1-2
LOCK WASHERS/PLATES AND COTTER PINS .................... 1-2
BEARINGS AND OIL SEALS ..................................... 1-2
CIRCLIPS...................................................... 1=3
...... SPECIALTOOLS .................................................. 1-3
FOR TUNE-UP .................................................. 1-3
FOR ENGINE SERVICE .......................................... 1-4
FOR CHASSIS SERVICE ......................................... 1-8
FOR ELECTRICALCOMPONENTS ................................ 1-8

[ GEN SCOOTER iDENTiFICATION
GENERAL INFORMATmON
SCOOTER IDENTIFICATION
VEHICLE IDENTmF_CATION NUMBER
The vehicleidentification number _.-_is stamped
h_to the steering head pipe.
_i_ NOTE:
The vehicle identification number is used to iden-
tify your scooter and may be used to register your
scooter with the licensing authority in your state.
Starting Seriam Number:
JYA1YA00_ HA000101
ENGINE SERIAL NUMBER
The engine sedaf number/1_ is stamped into the
elevated part of the left rear section of the trans-
mission case.
NOTE:
The first three digits of these numbers are for
: model identifications; the remaining digits are the
unit production number,
Starting SeriaJ Number:
1YA-000101
NOTE:
Designs and specifications are subject to change
without notice.
1-1