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Yamaha AG200FZ Owner's Manual

Yamaha AG200FZ Owner's Manual

Table of Contents




Table of Contents

Summary of Contents for Yamaha AG200FZ

  • Page 1 OWNER’S MANUAL AG200FZ 53C-28199-20...
  • Page 2 EAU46090 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
  • Page 3 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.
  • Page 4 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.
  • Page 5 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.
  • Page 6: Table Of Contents

    TABLE OF CONTENTS LOCATION OF IMPORTANT Auxiliary DC jack ......4-13 Adjusting the throttle cable free LABELS ..........1-1 play ........... 7-14 FOR YOUR SAFETY – Valve clearance ......7-15 SAFETY INFORMATION ....2-1 PRE-OPERATION CHECKS ..... 5-1 Tires ..........7-15 Spoke wheels ......
  • Page 7 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 ........
  • Page 8: Location Of Important Labels

    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.
  • Page 9 LOCATION OF IMPORTANT LABELS Before you operate this vehicle, read the owner’s manual. 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.
  • Page 10: Safety Information

    SAFETY INFORMATION EAU35132 Safe Riding Therefore: Perform the pre-operation checks each Wear a brightly colored jacket. time you use the vehicle to make sure it Use extra caution when you are Be a Responsible Owner is in safe operating condition. Failure to approaching passing As the vehicle’s owner, you are respon-...
  • Page 11 Genuine Wear a face shield or goggles. any engine exhaust. Deadly levels of Yamaha accessories, which are avail- Wind in your unprotected eyes carbon monoxide can collect rapidly able only from a Yamaha dealer, have...
  • Page 12 Yamaha for use on your vehicle. You are responsible for injuries related stable in cross winds. Many companies with no connection to to changes in the vehicle.
  • Page 13: Description

    DESCRIPTION EAU10410 Left view 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)
  • Page 14: Right View

    DESCRIPTION EAU10420 Right view 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)
  • Page 15: Controls And Instruments

    DESCRIPTION EAU10430 Controls and instruments 1. Clutch lever (page 4-3) 8. Throttle grip (page 7-14) 2. Left handlebar switches (page 4-2) 9. Main switch (page 4-1) 3. Speedometer unit (page 4-2) 10.Fuel tank cap (page 4-5) 4. Auxiliary DC jack (page 4-13) 5.
  • Page 16: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS EAU10450 electrical systems will be switched EAU11010 Main switch Indicator light off, which may result in loss of con- trol or an accident. The main switch controls the ignition 1. Neutral indicator light “NEUTRAL” and lighting systems. The various main switch positions are described below.
  • Page 17: Speedometer Unit

    INSTRUMENT AND CONTROL FUNCTIONS EAU11621 EAU12348 Right Speedometer unit Handlebar switches Left 1. Engine stop switch “ ” 2. Start switch “START” 1. Speedometer 2. Odometer 1. Light switch “ / ” EAU12400 2. Dimmer switch “ ” The speedometer unit is equipped with Dimmer switch “...
  • Page 18: Clutch Lever

    INSTRUMENT AND CONTROL FUNCTIONS EAU12500 EAU35000 Horn switch “ ” Clutch lever 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.
  • Page 19: Shift Pedal

    INSTRUMENT AND CONTROL FUNCTIONS EAU12870 EAU12890 EAU12941 Shift pedal Brake lever Brake pedal 1. Shift pedal 1. Brake lever 1. Brake pedal The shift pedal is located on the left The brake lever is located at the right The brake pedal is on the right side of side of the engine and is used in com- handlebar grip.
  • Page 20: Fuel Tank Cap

    INSTRUMENT AND CONTROL FUNCTIONS EAU13182 EAU13212 Fuel tank cap Fuel Make sure there is sufficient gasoline in the tank. EWA10881 WARNING Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions.
  • Page 21: Fuel Cock

    Always return the lever to this as well as to the exhaust system. position when the engine is not running. Your Yamaha engine has been de- signed to use regular unleaded gaso- line with a research octane number of 91 or higher.
  • Page 22: Starter (Choke) Knob

    INSTRUMENT AND CONTROL FUNCTIONS This indicates reserve. If you run out of EAU13600 Starter (choke) knob “ ” fuel while riding, move the lever to this position. Fill the tank at the first oppor- tunity. Be sure to set the lever back to “ON”...
  • Page 23: Kickstarter

    INSTRUMENT AND CONTROL FUNCTIONS EAU13650 EAU14001 Kickstarter Seat To remove the seat 1. Remove panels A and B. (See page 7-7.) 2. Remove the bolts and pull the seat off. 1. Bolt 1. Kickstarter To install the seat 1. Insert the projections on the front To start the engine, fold out the kick- of the seat into the seat holders as starter lever, move it down lightly with...
  • Page 24: Adjusting The Shock Absorber Assembly

    INSTRUMENT AND CONTROL FUNCTIONS 2. Place the seat in the original posi- EAU14842 Adjusting the shock absorber tion, and then tighten the bolts. assembly 3. Install the panels. This shock absorber assembly is equipped with a spring preload adjust- Make sure that the seat is properly se- ing ring.
  • Page 25: Front And Rear Carriers

    Cylinder damage will result in poor 1. Rear carrier damping performance. Do not dispose of a damaged or worn-out shock absorber as- sembly yourself. Take the shock absorber assembly to a Yamaha dealer for any service. 1. Front carrier 4-10...
  • Page 26: Sidestands

    INSTRUMENT AND CONTROL FUNCTIONS EAU48860 EWA15410 EAU15391 Sidestands Starting circuit cut-off system WARNING The starting circuit cut-off system (com- The vehicle must not be ridden with prising the clutch switch and the neutral either sidestand down, or if a side- switch) prevents starting when the stand cannot be properly moved up transmission is in gear and the clutch...
  • Page 27 With the engine turned off: 1. Make sure that the engine stop switch is set to “ ”. If a malfunction is noted, have a Yamaha 2. Turn the key to “ON”. dealer check the system before riding. 3. Shift the transmission into the neutral position.
  • Page 28: Auxiliary Dc Jack

    INSTRUMENT AND CONTROL FUNCTIONS EAU15402 when the engine is running. Auxiliary DC jack Refer to the following chart for correct usage. Amperage chart Idling speed Headlight/taillight “ON” 12 V, 3 A Headlight/taillight “OFF” 12 V, 6 A To use the auxiliary DC jack 1.
  • Page 29: For Your Safety - Pre-Operation Checks

    Lubricate cable if necessary. Clutch 7-17 Check lever free play. Adjust if necessary. Make sure that operation is smooth. Check cable free play. Throttle grip 7-14, 7-24 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing.
  • Page 30 FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM CHECKS PAGE Make sure that operation is smooth. Control cables 7-24 Lubricate if necessary. Check chain slack. Adjust if necessary. Drive chain 7-22, 7-23 Check chain condition. Lubricate if necessary. Check for damage. Check tire condition and tread depth.
  • Page 31: Operation And Important Riding Points

    (See page 6-2.) The neutral indicator light should come The engine is warm when it responds on. If not, ask a Yamaha dealer to quickly to the throttle with the starter check the electrical circuit. (choke) turned off.
  • Page 32: Starting A Warm Engine

    OPERATION AND IMPORTANT RIDING POINTS EAU16640 EAU16671 ECA10260 Starting a warm engine Shifting NOTICE Follow the same procedure as for start- Even with the transmission in ing a cold engine with the exception the neutral position, do not that the starter (choke) is not required coast for long periods of time when the engine is warm.
  • Page 33: Tips For Reducing Fuel Consumption

    If any engine trouble should occur during the engine break-in pe- riod, immediately have a Yamaha dealer check the vehicle. [ECA10362]...
  • Page 34: Parking

    OPERATION AND IMPORTANT RIDING POINTS EAU17171 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”. EWA10311 WARNING Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them and be burned.
  • Page 35: Periodic Maintenance And Adjustment

    If The owner’s tool kit is located inside the you are not familiar with vehicle ser- tool box. vice, have a Yamaha dealer perform The service information included in this service. manual and the tools provided in the...
  • Page 36 If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you.
  • Page 37: Periodic Maintenance Chart For The Emission Control System

    From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi). Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 38: General Maintenance And Lubrication Chart

    PERIODIC MAINTENANCE AND ADJUSTMENT EAU17717 General maintenance and lubrication chart ODOMETER READING ANNUAL ITEM CHECK OR MAINTENANCE JOB 1000 km 6000 km 12000 km 18000 km 24000 km CHECK (600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi) Clean. √...
  • Page 39 PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER READING ANNUAL ITEM CHECK OR MAINTENANCE JOB 1000 km 6000 km 12000 km 18000 km 24000 km CHECK (600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi) Check bearing play and steering √ √ √...
  • Page 40 PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER READING ANNUAL ITEM CHECK OR MAINTENANCE JOB 1000 km 6000 km 12000 km 18000 km 24000 km CHECK (600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi) Check operation and free play. Adjust the throttle cable free Throttle grip hous- √...
  • Page 41: Removing And Installing Panels

    PERIODIC MAINTENANCE AND ADJUSTMENT EAU18771 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1.
  • Page 42: Checking The Spark Plug

    Spark plug gap: ating improperly. Do not attempt to 0.6–0.7 mm (0.024–0.028 in) diagnose such problems yourself. In- stead, have a Yamaha dealer check 1. Spark plug cap To install the spark plug the vehicle. 1. Clean the surface of the spark plug 2.
  • Page 43: Engine Oil And Oil Filter Element

    PERIODIC MAINTENANCE AND ADJUSTMENT 2. Install the spark plug with the EAU19795 Engine oil and oil filter spark plug wrench, and then tight- element en it to the specified torque. The engine oil level should be checked Tightening torque: before each ride. In addition, the oil Spark plug: must be changed and the oil filter ele- 18 Nm (1.8 m·kgf, 13 ft·lbf)
  • Page 44 PERIODIC MAINTENANCE AND ADJUSTMENT removing the engine oil drain bolt, the O-ring, compression spring, and oil strainer will fall out. Take care not to lose these parts. [ECA11001] 1. Engine oil drain bolt 1. Oil filter element cover bolt 2. O-ring 2.
  • Page 45 PERIODIC MAINTENANCE AND ADJUSTMENT 7. Check the O-rings for damage and addition, do not use oils labeled Tightening torque: replace them if necessary. “ENERGY CONSERVING II” or Engine oil drain bolt: 8. Clean the oil filter element with sol- higher. 43 Nm (4.3 m·kgf, 31 ft·lbf) vent, and then install it.
  • Page 46: Cleaning The Air Filter Element

    PERIODIC MAINTENANCE AND ADJUSTMENT EAU20862 solvent, and then squeeze the re- Cleaning the air filter element maining solvent out. The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more fre- quently if you are riding in unusually wet or dusty areas.
  • Page 47: Adjusting The Carburetor

    Yamaha dealer, who has the neces- and/or cylinder(s) may become periodic maintenance and lubrication sary professional knowledge and expe- excessively worn.
  • Page 48: Adjusting The Throttle Cable Free Play

    If the specified idling speed cannot be play, turn the adjusting nut in direc- sition. obtained as described above, have a tion (a). To decrease the throttle Yamaha dealer make the adjustment. cable free play, turn the adjusting nut in direction (b). 7-14...
  • Page 49: Valve Clearance

    150 kPa (1.50 kgf/cm , 22 psi) from occurring, the valve clearance the specified tires. must be adjusted by a Yamaha dealer EWA10511 at the intervals specified in the periodic Tire air pressure WARNING maintenance and lubrication chart.
  • Page 50: Spoke Wheels

    EAU21941 Front tire: Spoke wheels nail or glass fragments in it, or if the Size: EWA10610 sidewall is cracked, have a Yamaha 80/100-21 51M WARNING Manufacturer/model: dealer replace the tire immediately. IRC/VE-32 The wheels on this model are not de-...
  • Page 51: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE AND ADJUSTMENT Ride at moderate speeds after EAU22043 lever free play, turn the adjusting Adjusting the clutch lever free changing a tire since the tire sur- bolt in direction (b). play face must first be “broken in” for it to develop its optimal characteris- If the specified clutch lever free play tics.
  • Page 52: Adjusting The Brake Lever Free Play

    PERIODIC MAINTENANCE AND ADJUSTMENT 7. Tighten the locknut at the crank- EAU49300 lever free play, turn the adjusting Adjusting the brake lever free case. bolt in direction (b). play 8. Tighten the locknut at the clutch le- 4. If the specified brake lever free ver and then slide the rubber cover play could be obtained as de- to its original position.
  • Page 53: Adjusting The Brake Pedal Position And Free Play

    PERIODIC MAINTENANCE AND ADJUSTMENT EAU22192 Adjusting the brake pedal position and free play EWA10670 WARNING It is advisable to have a Yamaha dealer make these adjustments. Brake pedal position The top of the brake pedal should be 1. Adjusting nut 1. Locknut positioned approximately 10.0 mm...
  • Page 54: Checking The Shift Pedal

    Checking the shift pedal The operation of the shift pedal should be checked before each ride. If opera- tion is not smooth, have a Yamaha dealer check the vehicle. 1. Brake pedal free play adjusting nut 1. Brake pedal free play 2.
  • Page 55: Brake Light Switches

    To make the brake light reaches the wear limit line, have a come on earlier, turn the adjusting nut Yamaha dealer replace the brake in direction (a). To make the brake light shoes as a set. come on later, turn the adjusting nut in direction (b).
  • Page 56: Drive Chain Slack

    PERIODIC MAINTENANCE AND ADJUSTMENT EAU22760 Drive chain slack: Drive chain slack 20.0–30.0 mm (0.79–1.18 in) The drive chain slack should be checked before each ride and adjusted 6. If the drive chain slack is correct, if necessary. install the check hole cap. If the drive chain slack is incorrect, ad- just it as follows.
  • Page 57: Cleaning And Lubricating The Drive

    For a thorough cleaning, have a (b), and then push the rear wheel After adjusting the brake pedal free Yamaha dealer remove the drive chain forward. NOTICE: Improper drive play, check the operation of the and soak it in solvent.
  • Page 58: Checking And Lubricating The Cables

    Yamaha dealer at the intervals speci- ed if necessary. If a cable is damaged fied in the periodic maintenance chart.
  • Page 59: Checking And Lubricating The Brake Pedal

    The pivoting points of the rear suspen- and the pedal pivot should be lubricat- sidestand pivots and metal-to-metal sion must be lubricated by a Yamaha ed if necessary. contact surfaces should be lubricated if dealer at the intervals specified in the necessary.
  • Page 60: Checking The Front Fork

    Yamaha dealer check or re- tion. WARNING! To avoid injury, of it falling over. [EWA10751] pair it.
  • Page 61: Checking The Wheel Bearings

    If there is play in the wheel The battery is located behind panel B. hub or if the wheel does not turn (See page 7-7.) smoothly, have a Yamaha dealer check This model is equipped with a VRLA the wheel bearings. (Valve Regulated Lead Acid) battery.
  • Page 62 To charge the battery 2. If the battery will be stored for more WARNING Have a Yamaha dealer charge the bat- than two months, check it at least Electrolyte is poisonous and tery as soon as possible if it seems to...
  • Page 63: Replacing The Fuses

    The main fuse is located behind panel check if the device operates. A. (See page 7-7.) 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 1. Auxiliary DC jack fuse 2. Spare fuse If a fuse is blown, replace it as follows.
  • Page 64: Replacing The Headlight Bulb

    8. Install the headlight unit by install- ing the bolt. 9. Have a Yamaha dealer adjust the headlight beam if necessary. 1. Headlight bulb holder 2. Headlight bulb cover 4. Remove the burnt-out bulb by turn- ing it counterclockwise.
  • Page 65: Replacing The Tail/Brake Light Bulb

    PERIODIC MAINTENANCE AND ADJUSTMENT EAU24133 EAU24232 push it in, and then turn it clock- Replacing the tail/brake light Replacing a turn signal light wise until it stops. bulb bulb 4. Install the holder, and then place 1. Remove the tail/brake light lens by 1.
  • Page 66: Supporting The Motorcycle

    PERIODIC MAINTENANCE AND ADJUSTMENT EAU24350 frame in front of the rear wheel or under EAU24360 Supporting the motorcycle Front wheel each side of the swingarm. Since this model is not equipped with a centerstand, follow these precautions EAU35033 To remove the front wheel when removing the front and rear EWA10821 wheel or performing other maintenance...
  • Page 67 PERIODIC MAINTENANCE AND ADJUSTMENT 6. Loosen the axle nut. 7. Lift the front wheel off the ground according to the procedure on page 7-32. 8. Remove the axle nut, pull the wheel axle out, and then remove the wheel. EAU35041 To install the front wheel 1.
  • Page 68: Rear Wheel

    PERIODIC MAINTENANCE AND ADJUSTMENT 9. Slide the rubber cover back to its EAU25080 Rear wheel original position. EAU49021 To remove the rear wheel EWA10821 WARNING To avoid injury, securely support the vehicle so there is no danger of it falling over. 1.
  • Page 69 PERIODIC MAINTENANCE AND ADJUSTMENT 2. Remove the brake pedal free play EAU49030 To install the rear wheel adjusting nut, and then disconnect 1. Install the drive chain adjusting the brake rod from the brake cam- plate and the wheel by inserting shaft lever.
  • Page 70: Troubleshooting

    9. Adjust the brake pedal free play. for checking these vital systems your- (See page 7-19.) self. However, should your motorcycle require any repair, take it to a Yamaha EWA10660 WARNING dealer, whose skilled technicians have After adjusting the brake pedal free...
  • Page 71: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.
  • Page 72: Motorcycle Care And Storage

    Be ble. Rust and corrosion can develop Cleaning sure to consult a Yamaha dealer for even if high-quality components are ECA10772 advice on what products to use be- NOTICE used.
  • Page 73 MOTORCYCLE CARE AND STORAGE off any detergent residue using scratches on the windshield. plenty of water, as it is harmful Test the product on a small hid- Salt sprayed on roads in the winter may to plastic parts. den part of the windshield to remain well into spring.
  • Page 74: Storage

    Contaminants on the brakes or tires Consult a Yamaha dealer for ad- To prevent corrosion, avoid can cause loss of control. vice on what products to use.
  • Page 75 MOTORCYCLE CARE AND STORAGE 3. Drain the carburetor float chamber spark plug electrodes while than 30 °C (90 °F)]. For more in- by loosening the drain bolt; this will turning engine formation on storing the battery, prevent fuel deposits from building over.
  • Page 76: Specifications

    SPECIFICATIONS Dimensions: EAU2633X Engine oil: Fuel reserve amount: 2.0 L (0.53 US gal, 0.44 Overall length: Recommended brand: Carburetor: 2160 mm (85.0 in) YAMALUBE Type × quantity: Overall width: Type: 930 mm (36.6 in) SAE 10W-30, 10W-40, 10W-50, 15W-40, BS26 x 1 Overall height: 20W-40 or 20W-50...
  • Page 77 SPECIFICATIONS 3rd: Front wheel: Electrical system: 30/21 (1.429) Wheel type: Ignition system: 4th: Spoke wheel DC CDI 25/26 (0.962) Rim size: Charging system: 5th: 21x1.60 AC magneto 22/31 (0.710) Rear wheel: Battery: Chassis: Wheel type: Model: Frame type: Spoke wheel YTZ7S Diamond Rim size:...
  • Page 78: Consumer Information

    Record the vehicle identification num- ber and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number 1.
  • Page 79: Motorcycle Noise Regulation (For Australia)

    CONSUMER INFORMATION EAU26570 Motorcycle noise regulation (for Australia) TAMPERING WITH NOISE CON- TROL SYSTEM PROHIBITED: Owners are warned that the law may prohibit: The removal or rendering inopera- tive by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the pur- pose of noise control prior to its...
  • Page 80 INDEX Fuel............4-5 Fuel cock ...........4-6 Air filter element, cleaning....... 7-12 Safety information ........2-1 Fuel consumption, tips for reducing...6-3 Auxiliary DC jack........4-13 Seat ............4-8 Fuel tank cap ..........4-5 Shifting ............6-2 Fuses, replacing ........7-29 Shift pedal ..........4-4 Battery.............
  • Page 81 INDEX Wheel bearings, checking .......7-27 Wheel (front) ..........7-32 Wheel (rear)..........7-34 Wheels.............7-16...

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