Yamaha 2002 YFS200 Manual

YFS200(P)
SUPPLEMENTARY
SERVICE MANUAL
2XJ-AE2
2002

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and new data for
the YFS200(P) 2002. For complete information on service procedures, it is necessary to use this
Supplementary Service Manual together with the following manual.
YFS200U SERVICE MANUAL: 2XJ-ME1
YFS200A(’90) SUPPLEMENTARY SERVICE MANUAL: 2XJ-AE1
YFS200(P) 2002
SUPPLEMENTARY
SERVICE MANUAL
 2001 by Yamaha Motor Co., Ltd.
First Edition, May 2001
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

EB001000
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 machine has a basic understanding of the mechanical ideas and the procedures of
machine repair. Repairs attempted by anyone without this knowledge are likely to render the
machine unsafe and unfit for use.
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.
N
OTE:
Designs and specifications are subject to change without notice.
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 machine operator, a bystander or a person inspecting or repairing the
machine.
A CAUTION indicates special precautions that must be taken to avoid dam-
age to the machine.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
N
O
TE:

HOW TO USE THIS MANUAL
CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1: This is a chapter with its symbol on the upper right of each page.
2nd title 2: This title appears on the upper of each page on the left of the chapter sym-
bol. (For the chapter “Periodic inspection and adjustment” the 3rd title
appears.)
3rd title 3: This is a final title.
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 inspections.
A set of particularly important procedure 4is placed between a line of asterisks “*” with each proce-
dure preceded by “●”.
IMPORTANT FEATURES
●Data and a special tool are framed in a box preceded by a relevant symbol 5.
●An encircled numeral 6indicates a part name, and an encircled alphabetical letter data or an
alignment mark 7, the others being indicated by an alphabetical letter in a box 8.
●A condition of a faulty component will precede an arrow symbol 9and the course of action will fol-
low it.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying
correct disassembly and assembly procedures.

EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1to 9are printed on the
top right of each page and indicate the subject
of each chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Carburetion
6Drive train
7Chassis
8Electrical
9Troubleshooting
Illustrated symbols 0to Fare used to identify
the specifications appearing in the text.
0Filling fluid
ALubricant
BSpecial tool
CTorque
DWear limit, clearance
EEngine speed
FΩ, V, A
Illustrated symbols Gto Min the exploded
diagrams indicate the types of lubricants and
lubrication points.
GApply engine oil
HApply gear oil
IApply molybdenum disulfide oil
JApply wheel bearing grease
KApply lightweight lithium soap base grease
LApply molybdenum disulfide grease
MApply silicon grease
Illustrated symbols Nto Oin the exploded
diagrams indicate where to apply a locking
agent Nand when to install a new part O.
NApply the locking agent (LOCTITE)
OReplace
12
34
56
78
90
AB
CD
EF
GHI
J
NO
GEN
INFO SPEC
CHK
ADJ ENG
CARB
DRIV
CHAS
–+
ELEC
TRBL
SHTG
T
R
.
.
EGM
BLS MS
KLM
LT New

CONTENTS
GENERAL INFORMATION ...............................................................................1
MACHINE IDENTIFICATION .....................................................................1
MODEL LABEL ......................................................................................1
SPECIFICATIONS .............................................................................................2
GENERAL SPECIFICATIONS ...................................................................2
MAINTENANCE SPECIFICATIONS ..........................................................3
ENGINE .................................................................................................3
CHASSIS ...............................................................................................5
ELECTRICAL.........................................................................................5
CABLE ROUTING ......................................................................................6
PERIODIC CHECKS AND ADJUSTMENTS...................................................11
INTRODUCTION......................................................................................11
PERIODIC MAINTENANCE/LUBRICATION INTERVALS.......................11
CHASSIS..................................................................................................12
ADJUSTING THE REAR BRAKE LIGHT SWITCH..............................12
ELECTRICAL ..................................................................................................13
CHECKING THE SWITCH .......................................................................13
CHECKING THE SWITCH...................................................................13
CHECKING A SWITCH SHOWN IN THE MANUAL ............................13
SIGNAL SYSTEM ....................................................................................14
CIRCUIT DIAGRAM.............................................................................14
CHECKING THE SIGNAL SYSTEM....................................................15
YFS200(P) 2002 WIRING DIAGRAM

–1 –
GEN
INFO
MACHINE IDENTIFICATION
GENERAL INFORMATION
MACHINE IDENTIFICATION
MODEL LABEL
The model label 1is affixed to the frame. This
information will be needed to order spare
parts.

–2 –
SPEC
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model YFS200(P) 2002
Model code number 5KJ8 (CDN, Europe, Oceania)
Spark plug:
Type/manufacturer BR8ES/NGK
Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Tire:
Type Tubeless
Size: Front AT21 ×7 –10 DUNLOP KT851A
CHENG SHIN C873N
Rear AT21 ×10 –8 DUNLOP KT895A
CHENG SHIN C874N
Electrical:
Ignition system C.D.I.
Generator system C.D.I. magneto
Headlight type Bulb type
Headlight bulb type Incandescence
Bulb wattage ×quantity:
Headlight 12 V 45 W/45 W ×1
Tail/brake light 12 V 5 W/21 W ×1
Indicator light “OIL LEVEL”12 V 3.4 W ×1