Yamaha 2002 YFA1 Supplementary Service Manual Download Page 1 | Manualshive

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YFA1

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P

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SUPPLEMENTARY

SERVICE MANUAL

3FA-AE1

2002

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Summary of Contents for 2002 YFA1

Page 1: ...YFA1 P SUPPLEMENTARY SERVICEMANUAL 3FA AE1 2002 ...

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Page 3: ...rocedures it is necessary to use this Sup plementary Service Manual together with the following manual YFA1W SERVICE MANUAL 3FA ME1 YFA1 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 ...

Page 4: ...fications 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 NOTE 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 ...

Page 5: ...nic with an easy to read handy reference that contains comprehensive explanations of all disassembly repair assembly and inspections A set of particularly important procedure 4 is 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 6 indicates a part name and an encir...

Page 6: ...clearance E Engine speed F Ω V A Illustrated symbols G to M in the exploded diagrams indicate the types of lubricants and lubrication points G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply wheel bearing grease K Apply lightweight lithium soap base grease L Apply molybdenum disulfide grease M Apply silicon grease Illustrated symbols N to O in the exploded diagrams indic...

Page 7: ...ABLE ROUTING 8 PERIODIC CHECKS AND ADJUSTMENTS 14 INTRODUCTION 14 PERIODIC MAINTENANCE LUBRICATION INTERVALS 14 CHASSIS 15 ADJUSTING THE FRONT BRAKE 15 CHASSIS 16 STEERING SYSTEM 16 ELECTRICAL 17 CHECKING THE SWITCH 17 CHECKING THE SWITCH 17 CHECKING A SWITCH SHOWN IN THE MANUAL 17 SIGNAL SYSTEM 18 CIRCUIT DIAGRAM 18 CHECKING THE SIGNAL SYSTEM 19 YFA1 P 2002 WIRING DIAGRAM ...

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Page 9: ... 1 GEN INFO MACHINE IDENTIFICATION GENERAL INFORMATION MACHINE IDENTIFICATION MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 10: ... Chain drive Secondary reduction ratio 32 12 2 666 Clutch type Dry centrifugal automatic Transmission type Single speed automatic V belt Operation Centrifugal automatic type Single speed automatic 2 303 0 821 Reverse ratio 49 14 49 15 40 17 26 902 Tire Type Tubeless Size Front AT20 7 8 Rear AT22 10 8 Manufacturer type Front DUNLOP KT536A Rear DUNLOP KT537A Wear limit 3 0 mm 0 12 in Electrical Igni...

Page 11: ...Inside diameter rocker arm 10 000 10 015 mm 0 3937 0 3943 in Outside diameter shaft 9 981 9 991 mm 0 3930 0 3933 in Arm to shaft clearance 0 009 0 034 mm 0 0004 0 0013 in Valve valve seat valve guide Valve clearance cold Intake 0 08 0 12 mm 0 0031 0 0047 in Exhaust 0 10 0 14 mm 0 0039 0 0055 in Valve dimensions A head diameter Intake 25 9 26 1 mm 1 02 1 03 in Exhaust 21 9 22 1 mm 0 86 0 87 in B fa...

Page 12: ...8 0 0016 in Wear limit 0 15 mm 0 006 in Over size 2nd 49 5 mm 1 95 in 4th 50 0 mm 1 97 in Piston off set 0 5 mm 0 02 in Piston off set direction Intake side Inside diameter piston pin bore 13 002 13 013 mm 0 5119 0 5123 in Outside diameter piston pin 12 996 13 000 mm 0 5117 0 5118 in Piston pin to piston clearance 0 002 0 017 mm 0 0001 0 0006 in Limit 0 07 mm 0 003 in Piston ring Type Top ring Bar...

Page 13: ...t size V S 1 8 Starter jet G S 45 Float height F H 21 8 mm 0 858 in Fuel level F L 4 0 6 0 mm 0 16 0 24 in With special tool Engine idling speed 1 650 1 750 r min Intake vacuum 26 7 kPa 200 mm Hg 7 88 in Hg Model YFA1 P 2002 Suspension Suspension travel Front 41 mm 1 614 in Rear 60 mm 2 362 in Free length spring Front 148 mm 5 827 in Rear 205 mm 8 071 in Installed length Rear 180 mm 7 09 in Spring...

Page 14: ...AHA Minimum spark gap 6 0 mm 0 24 in Primary coil resistance 0 18 0 28 Ω at 20 C 68 F Secondary coil resistance 6 32 9 48 kΩ at 20 C 68 F Spark plug cap Material Resin Resistance 10 kΩ at 20 C 68 F Charging system Type A C magneto generator Magneto model manufacturer F3FA YAMAHA Charging coil resistance 0 96 1 44 Ω at 20 C 68 F lead color Black White Charging current Day Minimum 0 8 A at 3 000 r m...

Page 15: ... Armature coil resistance 0 019 0 023 Ω at 20 C 68 F Overall length brush 10 0 mm 0 39 in Limit 3 5 mm 0 14 in Brush spring pressure 552 828 g Commutator diameter 22 0 mm 0 87 in Wear limit 21 0 mm 0 83 in Mica undercut 1 5 mm 0 06 in Starter relay Model manufacturer MS5D 611 JIDECO Amperage rating 100 A Coil resistance 3 87 4 73 Ω at 20 C 68 F Starting circuit cut off relay Model manufacturer ACA...

Page 16: ... 8 SPEC CABLE ROUTING 1 Throttle cable 2 Band 3 Breather hose 4 Rear brake switch lead 5 Rear brake cable 6 Front brake cable 7 Front brake switch lead CABLE ROUTING ...

Page 17: ...leads in front of the brake cable and con nect them inside the headlight body É Pass the inlet and outlet hoses between the brake cables Ê Clamp the front brake switch lead rear brake switch lead main switch lead handlebar switch lead and wire sub leads with a plastic clamp Ë Pass the leads between the throttle cable and front brake cable CABLE ROUTING ...

Page 18: ...le cable 2 Rectifier regulator 3 Starting motor 4 CDI magneto lead 5 Clamp 6 Ignition coil È Fasten the wire harness starting motor lead and transmission case breather hose to the frame with a plastic band CABLE ROUTING ...

Page 19: ...smission case 8 Neutral switch lead 9 Select lever switch 0 Overflow hose A Battery breather hose B Band C Battery negative lead D Reverse switch lead È Hold the clamp and ground lead to the crank case with a screw É Pass the overflow hose between the engine and swingarm Ê Pass the battery breather hose through the guides CABLE ROUTING ...

Page 20: ... brake cable 8 Front brake cable left 9 Front brake cable right 0 CDI unit A Band È Pass the breather hose through the hole of han dlebar cover and then between the steering col umn and fuel tank É Pass the overflow hose left side of the engine stay Ê Pass the brake cable inside the swingarm CABLE ROUTING ...

Page 21: ...e transmission case 6 Ignition coil 7 Battery positive lead 8 Battery negative lead 9 Breather hose crankcase 0 Throttle cable A Fuse holder B Starting circuit cut off relay C Reverse relay È Pass the breather hose between the throttle cable and starter cable CABLE ROUTING ...

Page 22: ...rtment Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor Check idle speed starter operation Adjust if necessary Cylinderhead cover breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check leakage Retighten if necessary Replace gasket if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary Engi...

Page 23: ...brake lever free play Loosen the locknut 1 Turn the adjuster 2 in or out until the speci fied brake lever free play is obtained Tighten the locknut CAUTION After adjusting the brake lever free play make sure there is no drag Front brake lever free play 5 8 mm 0 20 0 3 in at lever pivot Turning in Free play is increased Turning out Free play is decreased ...

Page 24: ...YSTEM CHASSIS STEERING SYSTEM 1 Handlebar holder upper 2 Handlebar holder lower 3 Steering column 4 Cable joint 5 Cable joint bracket 6 Collar 7 Steering bracket 8 Oil seal 9 Steering bracket 0 Steering knuckle A Tie rod ...

Page 25: ...e switch on and off a few times when checking it Pocket tester P N YU 03112 90890 03112 CHECKING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches main switch handlebar switch engine stop switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the column and the switch lead colors in the top row For each switch position ...

Page 26: ...D GRAY B B B W R W L G W R B B O G Y R W L W R W L W B B L W L W Sb R B Br R W B B R R R R R R B B B W Y W B Y Br B Y L Y 1 2 3 5 6 8 7 0 A Br Sb B L L L Br G L E C F H G Y Br G L G W B G I K J N L M Br R GRAY 4 G W B B Br Y D 9 Sb L W Br R B G W B Br G L 3 Main switch 4 Fuse 5 Battery 9 CDI unit B Neutral indicator light C Neutral switch D Select lever switch E Reverse indicator light F Reverse r...

Page 27: ...es Refer to CHECKING THE SWITCH NO CONTINUITY Replace the brake switch 3 Voltage Connect the pocket tester DC 20V to the bulb socket connector Tester lead Yellow terminal 1 Tester lead Black terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V of the Yellow lead on the bulb socket connector This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main...

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Page 29: ... Y D 9 Sb L W Br R B G W B Br G L 1 AC magneto 2 Rectifier regulator 3 Main switch 4 Fuse 5 Battery 6 Starter relay 7 Starter motor 8 Starting circuit cut off relay 9 CDI unit 0 Ignition coil A Spark plug B Neutral indicator light C Neutral switch D Reverse switch E Reverse indicator light F Reverse relay G Brake lever switch H Front brake light switch I Tail brake light J Handlebar switch left K ...

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