Summary of 2003 AG200F
Page 1
Ag200f supplementary service manual 2003 3gx-ae2.
Page 2: Foreword
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 ...
Page 3: Notice
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 yama...
Page 4: Gen
Eas00009 symbols the following symbols are not relevant to every 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 7 electrical system 8 troubleshooting symbols 9 to y indicate the...
Page 5: Contents
Contents specifications...................................................................................................1 general specifications ..........................................................................1 maintenance specifications .....................................................
Page 6: Spec
– 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 cm 3 ) bore × stroke 67.0 × 55.7 mm compression ratio 9.5 : 1 compression pressure (std) 900 kpa (9.0 kg/cm 2 ...
Page 7: Spec
– 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 ••...
Page 8: Spec
– 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 4j...
Page 9: Spec
– 4 – spec cable routing 1 clutch cable 2 cable guide 3 front brake cable 4 throttle cable 5 front brake switch lead 6 clutch switch lead 7 clamp å pass the throttle cable behind the main switch. ∫ clamp the handlebar switch lead and the front brake switch lead. ç clamp the handlebar switch lead and...
Page 10: Spec
– 5 – spec cable routing å ∫ ç ∂ ´ ƒ © 1 2 3 4 5 6 7 8 9 0 q w e a a 4 0 9 1 high-tension cord 2 ignition coil 3 ignition coil lead (primary side) 4 starting motor lead 5 breather hose 6 magneto lead 7 over flow hose 8 rectifier/regulator lead 9 brake switch lead 0 battery positive lead q starter re...
Page 11: Spec
– 6 – spec cable routing å ∫ ç ∂ ´ ƒ © ˙ ˆ ∆ ˚ ¬ µ 1 2 3 4 5 6 7 8 9 0 1 starter (choke) cable 2 handlebar switch lead 3 throttle cable 4 starter circuit cut-off relay 5 cdi unit 6 cdi unit lead 7 starting motor lead 8 magneto lead (charge, neutral) 9 magneto lead (pickup coil) 0 cable guide å clamp...
Page 12: Spec
– 7 – spec cable routing å ∫ ç ∂ ´ ƒ © ˙ ˆ ∆ ˚ ¬ µ 1 2 3 4 5 6 7 8 9 0 © pass the wireharness to the far- thest left side. ˙ clamp the wireharness, cdi unit lead, magneto lead, throttle cable, and starter (choke) cable on the center of the engine mount stay. ˆ clamp the wireharness. ∆ clamp the hand...
Page 13: Chk
– 8 – chk adj introduction/ periodic maintenance and lubrication intervals eas00036 periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliab...
Page 14: Chk
– 9 – chk adj periodic maintenance and lubrication intervals *: 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. 21 * engine oil strainer • clean. √ 22 * front and rear brake switche...
Page 15: Electrical
B b or or w/r w/l l/y br w/r w/l b (g) b b b b b b br w/r w /l l/y or b r r w b b b w w w w w r w w w r w w/r w/l pu+ ign pu- gnd stop on off on off low high nl l r nr 10a ww w ww w (b) +v b (b) b b b b 20a r r r r on off (r) (r) push free off run b b p br br/w br dg y b r/w br p br p l br/w l b b g...
Page 16: Elec
– 11 – elec ignition system eas00736 troubleshooting check: 1. Main fuse 2. Battery 3. Spark plug 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Main switch 8. Engine stop switch 9. Pickup coil resistance 10.Wiring connections (of the entire ignition sys- tem) note...
Page 17: Elec
– 12 – elec ignition system 9is the spark plug cap ok? Yes no replace the spark plug cap. Eas00746 6. Ignition coil resistance 9disconnect the ignition coil connectors from the ignition coil terminals. 9connect the pocket tester ( Ω x 1) to the igni- tion coil as shown. Positive tester probe → orang...
Page 18: Elec
– 13 – elec ignition system eas00749 7. Main switch 9check the main switch for continuity. Refer to “checking the switches”. 9is the main switch ok? Yes no replace the main switch. Eas00750 8. Engine stop switch 9check the engine stop switch for continuity. Refer to “checking the switches”. 9is the ...
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Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan.
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Ag200f 2002 wiring diagram 1 cdi magneto 2 neutral switch 3 rectifier regulator 4 fuse (20a) 5 positive wire lead 6 battery 7 negative wire lead 8 starter relay 9 starting motor 0 main switch q start switch w engine stop switch e cdi unit r ignition coil t spark plug y meter light u neutral indicato...