Table of Contents
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Table of Contents
Related Manuals for Yamaha 2003 AG200F
Summary of Contents for Yamaha 2003 AG200F
- Page 1 2003 AG200F 3GX-AE2 SUPPLEMENTARY SERVICE MANUAL...
- Page 2 Service Manual together with the following manual. AG200F ’97 SERVICE MANUAL: 3GX-AE1 EAS00000 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.
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Page 3: Important Manual Information
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. - Page 4 EAS00009 SYMBOLS The following symbols are not relevant to every SPEC INFO vehicle. Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetor(s) 6 Chassis CARB CHAS 7 Electrical system 8 Troubleshooting...
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Page 5: Table Of Contents
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... -
Page 6: Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS 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 cm Bore × stroke 67.0 × 55.7 mm Compression ratio 9.5 : 1 Compression pressure (STD) 900 kPa (9.0 kg/cm , 130.5 psi) at 1,000 r/min Starting system... -
Page 7: Maintenance Specifications
No. of links ••• Chain free play 30~45 mm ••• ELECTRICAL Item Standard Limit CDI: CDI magneto model/manufacturer 3GX/YAMAHA ••• 656~984 Ω at 20°C/ Pickup coil resistance/color ••• Red — White Ignition coil: Model/manufacturer 2JN/YAMAHA ••• Minimum spark gap 6 mm •••... -
Page 8: Tightening Torques
SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Electric starter system: Type Constant mesh type Starter motor: Model/manufacturer 4JG/YAMAHA ••• Output 0.4 kW ••• 0.0126~0.0154 Ω at 20°C Armature coil resistance ••• Brush overall length 10 mm 3.5 mm Brash spring pressure 5.52~8.28 N (563~844g) -
Page 9: Cable Routing
SPEC CABLE ROUTING EAS00035 CABLE ROUTING 1 Clutch cable å Pass the throttle cable behind pler, speedometer lead and 2 Cable guide front turn signal light lead (left). the main switch. ´ Insert the front fork breather 3 Front brake cable ∫... - Page 10 SPEC CABLE ROUTING 1 High-tension cord å Tighten with the ignition coil and ƒ Clamp the battery positive lead 2 Ignition coil the earth lead. (bypass from the and wireharness. 3 Ignition coil lead (primary side) © Insert the fuse holder into the wireharness) 4 Starting motor lead ∫...
- Page 11 SPEC CABLE ROUTING 1 Starter (choke) cable å Clamp the throttle cable, starter ∂ Clamp the wireharness, CDI 2 Handlebar switch lead (choke) cable and handlebar unit lead, magneto (pickup coil) 3 Throttle cable switch lead (left). lead and starting motor lead. 4 Starter circuit cut-off relay ∫...
- Page 12 SPEC CABLE ROUTING © Pass the wireharness to the far- ˚ Pass the starter (choke) cable thest left side. and handlebar switch lead ˙ Clamp the wireharness, CDI through the outside of the cable unit lead, magneto lead, throttle guide. ¬...
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Page 13: Periodic Checks And Adjustments
√ √ √ √ Engine oil • Check oil level and vehicle for oil leakage. Engine oil filter √ √ √ • Clean. element *: It is recommended that these items be serviced by a Yamaha dealer. – 8 –... - Page 14 √ switches • Adjust headlight beam. *: It is recommended that these items be serviced by a Yamaha dealer. NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. – 9 –...
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Page 15: Electrical
ELEC IGNITION SYSTEM EAS00734 ELECTRICAL IGNITION SYSTEM CIRCUIT DIAGRAM 1 CDI magneto 3 Rectifier regulator 5 Positive wire lead 6 Battery 7 Negative wire lead 0 Main switch w Engine stop switch e CDI unit r Ignition coil t Spark plug –... -
Page 16: Troubleshooting
ELEC IGNITION SYSTEM EAS00736 EAS00739 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no 9Check the condition of the battery. spark or intermittent spark). Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: Minimum open-circuit voltage 1. Main fuse 12.8 V or more at 20 °C (68 °F) 2. - Page 17 ELEC IGNITION SYSTEM EAS00743 Spark plug cap resistance 4. Ignition spark gap 10 kΩ at 20°C (68°F) The following procedure applies to all of the 9Is the spark plug cap OK? spark plug. 9Disconnect the spark plug cap from the spark plug.
- Page 18 ELEC IGNITION SYSTEM 9Measure the pickup coil resistance. 9Measure the secondary coil resistance. Pickup coil resistance Secondary coil resistance 656 ~ 984 Ω at 20°C (68°F) 5.68 ~ 8.52 kΩ at 20°C (68°F) (between red and white) 9Is the ignition coil OK? 9Is the pickup coil OK? Replace the ignition Replace the pick up...
- Page 19 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
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Page 20: Ag200F 2002 Wiring Diagram
AG200F 2002 WIRING DIAGRAM 1 CDI magneto 2 Neutral switch 3 Rectifier regulator 4 Fuse (20A) W/R W/L 5 Positive wire lead 6 Battery 7 Negative wire lead 8 Starter relay 9 Starting motor 0 Main switch STOP q Start switch w Engine stop switch e CDI unit r Ignition coil...