Yamaha 2002 YFS200 Supplementary Service Manual Download Page 2 | Manualshive

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Summary of Contents for 2002 YFS200

Page 1: ...YFS200 P SUPPLEMENTARY SERVICEMANUAL 2XJ AE2 2002 ...

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Page 3: ... 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 ...

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: ...ICAL 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 ...

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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: ...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 ...

Page 11: ...ring 0 03 0 05 mm 0 0012 0 0020 in 2nd ring 0 03 0 05 mm 0 0012 0 0020 in Crankshaft Crank width A 57 90 57 95 mm 2 280 2 281 in Runout limit C 0 03 mm 0 0012 in Big end side clearance D 0 2 0 7 mm 0 008 0 028 in Big end radial clearance E 0 021 0 035 mm 0 0008 0 0014 in Small end free play F 0 8 1 0 mm 0 031 0 039 in Clutch Friction plate thickness quantity 2 92 3 08 mm 0 115 0 121 in 7 pcs Wear ...

Page 12: ... 7 Jet needle clip position J N 5J22 2 Needle jet N J P 6 345 Cutaway C A 2 0 Pilot outlet P O 0 6 Pilot jet P J 32 5 Bypass 1 B P 1 0 8 3 75 Pilot air screw P A S 1 and 1 2 turns out Valve seat size V S ø2 8 Starter jet G S 45 Float height F H 20 5 21 5 mm 0 81 0 85 in Fuel level F L 0 5 1 5 mm 0 02 0 06 in Engine idling speed 1 450 1 550 r min Model YFS200 P 2002 ...

Page 13: ...r Clutch lever free play 2 3 mm 0 08 0 12 in at lever pivot Parts to be tightened Thread size Tightening torque Remarks Nm m kg ft lb Front arm lower and upper and frame M10 1 25 32 3 2 23 Steering knuckle and ball joint front lower arm M10 1 25 25 2 5 18 Steering knuckle and ball joint front upper arm M10 1 25 48 4 8 35 Footrest M10 1 25 64 6 4 46 Rear bumper M8 1 25 23 2 3 17 Model YFS200 P 2002...

Page 14: ...itch lead A Oil indicator light lead B Main switch lead C Headlight lead D Control unit E CDI unit F Ground lead G Voltage regulator È The throttle cable should be routed behind the clutch cable and on the left side of the guide É Route all leads behind the cables and through the cable guide Ê Route all leads toward the CDI unit side Ë The ground and voltage regula tor leads should be routed in fr...

Page 15: ...tch lead 4 Fuel breather hose 5 Band 6 Wire harness 7 Crankcase ventilation hose È Route the clutch cable in front of the fender stay É Route the front brake cable through the cable guide behind the front shock absorber and above the tie rod CABLE ROUTING ...

Page 16: ... 7 Clamp 8 Oil hose 9 Carburetor overflow hose 0 Flywheel magneto lead È For installing the wire harness align the posi tioning tape with the wire holder É The leads should be clamped on the inward half of the frame pipe Ê Clamp the oil hose and rear brake light switch lead with the plastic clamp CABLE ROUTING ...

Page 17: ...r brake light switch 6 Band 7 Tail brake light lead 8 Oil level gauge lead 9 Oil hose 0 Wire harness A Clamp B Throttle switch lead C Throttle cable D Clutch cable E Ignition coil lead F Ignition coil G Ground lead È Place the slack of the spark plug lead toward the left side of the frame CABLE ROUTING ...

Page 18: ...10 SPEC 1 Rear brake light switch 2 Oil hose 3 Crankcase ventilation hose 4 Parking brake cable 5 Cable guide 6 Rear brake cable È Route the parking brake cable in front of the fender stay CABLE ROUTING ...

Page 19: ...Adjust if necessary Crankcase breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Retighten if necessary Replace gasket if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary Throttle operation Inspect and adjust free play if necessary Front brake operation Inspect and adjust free play if necessary Front brake sho...

Page 20: ... the brake light comes on just before the braking effect starts 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time Direction a Brake light comes on sooner Direction b...

Page 21: ...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 22: ... B B Y B B W B Br Y Br Y O B 4 5 B B OFF ON B W B B B O B G Y G Y L D F C B A G B Y L L E Y Br BLACK B B Br Y B B Y B 8 6 B Y B Y B B BLACK GRAY GRAY B B Y B Y B 7 B Y B Y B B BLACK BLACK Br 9 G G 0 2 3 1 1 CDI magneto 2 Voltage regulator 9 Oil indicator light 0 Oil level gauge E Tail brake light F Rear brake light switch G Front brake light switch ...

Page 23: ...WITCH NO CONTINUITY Replace the brake switch 3 Voltage Connect the tachometer to the spark plug lead Connect the pocket tester DC 20V to the bulb socket connector Tester lead Yellow terminal 1 Tester lead Black terminal 2 OUT OF SPECIFICATION Start the engine and accelerate to about 5 000 r min CAUTION Do not run the engine in neutral above 6 000 r min for more than 1 or 2 seconds Lighting voltage...

Page 24: ...s Tester lead Yellow Red lead 1 Tester lead Black lead 2 Measure the lighting coil resistance Lighting coil resistance 0 16 0 24 Ω at 20 C 68 F OUT OF SPECIFICATION Replace the stator assembly CORRECT 5 Wiring connections Check the connections of the entire lighting system Refer to CIRCUIT DIAGRAM Replace the voltage regulator POOR CONNECTION Properly connect the lighting system ...

Page 25: ...7 B Y B Y B B BLACK BLACK Br 9 G 0 2 3 1 1 CDI magneto 2 Voltage regulator 3 CDI unit 4 Ignition coil 5 Spark plug 6 Control unit 7 Throttle switch 8 Carburetor switch 9 Oil indicator light 0 Oil level gauge A Main switch B Engine stop switch C Lights switch D Headlight E Tail brake light F Rear brake light switch G Front brake light switch COLOR CODE B Black Br Brown G Green L Blue O Orange Y Yel...

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