Yamaha 3FA-AE2 Service Manual Download | Manualshive

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– 7 –

SPEC

CABLE ROUTING

Ë

Cross the front brake cables behind the steering
shaft. Route the right front brake cable in front of
the left front brake cable.

Ì

Put the cover on the couplers, and then fasten a
plastic band around the middle of the cover.

Í

Route the rear brake switch lead and the handle-
bar switch lead behind the throttle cable and the
rear brake cable.

Î

Route the horn switch lead behind the coupler
cover, throttle cable, front brake cable, and rear
brake cable. (for Europe)

1 2

3

4

8

5
6

Î

È

É

Ê

Í

Ë

Ì

7

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13
14
15
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17
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Summary of Contents for 3FA-AE2

Page 1: ...YFM125S3FA AE2 SUPPLEMENTARY SERVICE MANUAL ...

Page 2: ......

Page 3: ...se this Supplementary Service Manual together with the following manual YFA1W SERVICE MANUAL 3FA ME1 YFA1 P 2002 SUPPLEMENTARY SERVICE MANUAL 3FA AE1 YFM125S SUPPLEMENTARY SERVICE MANUAL 2004 by Yamaha Motor Co Ltd First edition January 2004 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...ions 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 EBS00003 IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol ...

Page 5: ...parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read...

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

Page 7: ...T BUMPER AND CENTER COVER 17 FRONT GRILL ASSEMBLY AND FRONT FENDER 19 REAR CARRIER AND REAR FENDER 20 ELECTRICAL 22 ADJUSTING THE HEADLIGHT BEAMS 22 REPLACING A HEADLIGHT BULB 22 ELECTRICAL 24 IGNITION SYSTEM 24 CIRCUIT DIAGRAM 24 CHARGING SYSTEM 25 CIRCUIT DIAGRAM 25 LIGHTING SYSTEM 26 CIRCUIT DIAGRAM 26 TROUBLESHOOTING 27 SIGNAL SYSTEM 29 CIRCUIT DIAGRAM 29 CHECKING THE SIGNALING SYSTEM 30 YFM12...

Page 8: ......

Page 9: ... kg 220 lb Fuel Type Regular unleaded gasoline only for CDN and Europe Unleaded gasoline only for Oceania Fuel tank capacity 7 6 L 1 67 Imp gal 2 01 US gal Reserve amount 1 3 L 0 28 Imp gal 0 34 US gal Spark plug Type manufacturer CR7HS NGK Spark plug gap 0 6 0 7 mm 0 024 0 028 in Electrical Ignition system DC C D I Generator system A C magneto generator Battery capacity 12V 12Ah Battery type 12N1...

Page 10: ...B P 1 1 1 Pilot screw P S 2 and 1 2 turns out for Europe and Oceania Valve seat size V S 1 8 Starter jet G S 45 Fuel level F L 3 5 4 5 mm 0 14 0 18 in With special tool Engine idling speed 1 650 1 750 r min Intake vacuum 26 7 kPa 200 mmHg 7 88 inHg Part to be tightened Thread size Tightening torque Remarks Nm m kg ft lb Footrest board and footrest bracket M5 7 0 7 5 1 Footrest and footrest bracket...

Page 11: ...Semi conductor short circuit type No load regulated voltage DC 14 0 15 0 V Rectifier capacity 14 0 A Withstand voltage 200 V Electric starting system Type Constant mesh Starter motor Model manufacturer 3FA YAMAHA Output 0 4 kW 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 8...

Page 12: ...nk breather hose 7 Horn switch lead for Europe 8 Horn switch for Europe 9 Headlight lead left 0 Headlight lead right A Neutral reverse indicator light lead B Main switch lead C Coupler cover D Steering shaft OFF RUN EN G STO P LO HI 0FF LIGHTS LIGHTS 0FF HI LO EN G STO P OFF RUN 1 4 2 3 É 1 2 0 9 DC Ì Ë Í A B Ê 7 8 6 5 È For CDN and Oceania For Europe ...

Page 13: ...r switch lead and horn switch lead with two plas tic bands for Europe Ë Do not pull the wire harness after fastening it Ì When installing the front fender do not pinch the coupler cover Í Pass the leads and wire harness through the guides on the front fender as shown OFF RUN EN G STO P LO HI 0FF LIGHTS LIGHTS 0FF HI LO EN G STO P OFF RUN 1 4 2 3 É 1 2 0 9 DC Ì Ë Í A B Ê 7 8 6 5 È For CDN and Ocean...

Page 14: ... brake switch lead È Pass the front brake cable and rear brake cable through the cable guide for CDN and Oceania Pass the front brake cable rear brake cable and horn switch lead through the cable guide for Europe É Route the rear brake cable to the inside of the front fender bracket Ê Pass the air duct inlet and outlet hoses between the brake cables 1 2 3 4 8 5 6 Î È É Ê Í Ë Ì 7 ...

Page 15: ...ut the cover on the couplers and then fasten a plastic band around the middle of the cover Í Route the rear brake switch lead and the handle bar switch lead behind the throttle cable and the rear brake cable Î Route the horn switch lead behind the coupler cover throttle cable front brake cable and rear brake cable for Europe 1 2 3 4 8 5 6 Î È É Ê Í Ë Ì 7 ...

Page 16: ...ope 8 Horn for Europe 9 Starter motor lead 0 A C magneto lead A Starter motor È Fasten the wire harness starter motor lead and transmission case breather hose to the frame with a plastic band É Route the wire harness starter motor lead and the transmission case breather hose under the frame cross member A B B 7 7 Ô 1 È 2 3 4 Ë 5 6 Ì Í Î 7 8 É 9 Ñ Ð 0 A Ò Ó Ò Ê B A B Ï ...

Page 17: ...eave any slack in the main switch lead and wire har ness under the front fender Ì Face the end of the transmission case breather hose down Í Fasten the wire harness starter motor lead and rectifier regulator lead to the frame with a plastic band for CDN and Oceania Fasten the wire harness starter motor lead rec tifier regulator lead and horn lead to the frame with a plastic band for Europe Î Faste...

Page 18: ... should be toward the rear of the vehicle facing inward Ñ Fasten the starter motor lead and A C magneto lead with a plastic locking tie Ò Fasten the A C magneto lead with the holders Ó Route the A C magneto lead on top of the crankcase Ô Face the end of the plastic band inward for Europe A B B 7 7 Ô 1 È 2 3 4 Ë 5 6 Ì Í Î 7 8 É 9 Ñ Ð 0 A Ò Ó Ò Ê B A B Ï ...

Page 19: ...t cut off relay 5 Starter relay 6 Positive battery lead 7 Negative battery lead 8 Transmission case breather hose 9 Reverse switch 0 Neutral switch lead A Reverse switch lead B Starter motor lead C Battery breather hose D Fuse holder 1 7 A 0 2 È Õ 3 D C B Ó Ñ Ò Ñ 4 5 É 6 Ê Ë 7 Ì 8 A A Ô Ï Ð Î A 0 9 Í ...

Page 20: ... the front end of the frame support as shown Í Route the fuel overflow hose in front of the trans mission case breather hose Î Install both the holder and the negative battery lead terminal to the crankcase with the screw so that the holder is in front of the terminal Fasten the neutral switch lead and reverse switch lead with the holder Ï Pass the fuel overflow hose between the swing arm and cran...

Page 21: ... neutral switch lead reverse switch lead and starter motor lead to the frame with a plastic band The end of the plastic band should be toward the rear of the vehicle facing inward Ô 60 mm 2 36 in Õ Do not straighten the negative battery lead ter minal The negative battery lead should be bent as shown 1 7 A 0 2 È Õ 3 D C B Ó Ñ Ò Ñ 4 5 É 6 Ê Ë 7 Ì 8 A A Ô Ï Ð Î A 0 9 Í ...

Page 22: ...ke cable to the outside of the frame É Place the end of the fuel tank breather hose in the rubber fuel overflow tray Ê Pass the fuel tank breather hose through the hole in the handlebar cover Ë Route the fuel overflow hose to the outside of the engine bracket Keep the hose as far away as possible from the exhaust pipe Ì Pass the rear brake cable through the swingarm Í Pass the rear brake cable thr...

Page 23: ... Wire harness 5 Transmission case breather hose 6 Ignition coil 7 Negative battery leads 8 Positive battery lead 9 Air vent hose 0 Crankcase breather hose A Starter cable B Starting circuit cut off relay C Reverse relay D Fuse holder 1 2 3 4 5 6 É 7 8Ê È ÎA Í0 Ì9 Ë 4 B D C A A ...

Page 24: ...Pass the air vent hose through the hole in the fuel tank from the top The end of the air vent hose should extend 15 20 mm 0 59 0 79 in from the hole Ì Do not kink the air vent hose Í Pass the crankcase breather hose between the starter cable and throttle cable Î Route the starter cable over the crankcase breather hose and under the throttle cable 1 2 3 4 5 6 É 7 8Ê È ÎA Í0 Ì9 Ë 4 B D C A A ...

Page 25: ... 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib 4 3 2 1 7 5 6 4 Order Job Part Q ty Remarks Removing the seat front carrier front bumper and center cover Remove the parts in the order listed 1 Seat 1 NOTE Pull the seat lock lever backward then pull up the seat at the rear 2 Handlebar cover 1 3 Front carrier 1 4 Front bumper 1 5 Neutral reverse indicator light coupler 1 Disconnect 6 Front fend...

Page 26: ... 2 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib 4 3 2 1 7 5 6 4 Order Job Part Q ty Remarks 7 Center cover 1 NOTE Install the fuel tank cap after removing the center cover to prevent dust mud etc from entering the fuel tank For installation reverse the removal pro cedure ...

Page 27: ...nt grill assembly and front fender Remove the parts in the order listed Seat center cover Refer to SEAT FRONT CARRIER FRONT BUMPER AND CENTER COVER 1 Main switch coupler 1 Disconnect 2 Headlight coupler 2 Disconnect 3 Air filter cover 1 4 Front grill assembly 1 5 Air duct outlet hose 1 Disconnect 6 Air duct inlet hose 1 Disconnect 7 Front fender 1 For installation reverse the removal pro cedure ...

Page 28: ...ier and rear fender Remove the parts in the order listed Seat center cover Refer to SEAT FRONT CARRIER FRONT BUMPER AND CENTER COVER Front grill assembly front fender Refer to FRONT GRILL ASSEMBLY AND FRONT FENDER 1 Tail brake light connector 3 Disconnect 2 Tail brake light 1 3 Rear carrier 1 4 Battery lead 2 Disconnect CAUTION First disconnect the negative lead then disconnect the positive lead ...

Page 29: ...17 ft Ib 3 4 4 4 9 8 2 5 1 4 7 6 Order Job Part Q ty Remarks 5 Battery 1 6 Carburetor joint clamp screw 1 Loosen 7 Crankcase breather hose 1 Disconnect 8 Air filter case 1 9 Rear fender 1 For installation reverse the removal pro cedure SEAT CARRIERS AND FENDERS ...

Page 30: ...NG THE HEADLIGHT BEAMS 1 Adjust headlight beam vertically a Turn the adjusting screw 1 in direction a or b Direction a Headlight beam is raised Direction b Headlight beam is lowered b 1 a EBS00124 REPLACING A HEADLIGHT BULB 1 Remove headlight unit cover 1 1 2 Remove headlight bulb holder cover 1 1 ...

Page 31: ... your hands away from the bulb while it is on since it will be hot Do not touch the bulb until it cools down 4 Install bulb CAUTION _ Avoid touching the glass part of the bulb Keep it free from oil otherwise the trans parency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moistened with alcohol or lac quer thinner...

Page 32: ...Sb R B Br R W B B R R R R B B G Y B G Y B Y G B Y G B Y G B R B L Br R W G Y B Br B Y L Y 1 2 3 5 6 8 7 0 A Br Sb F H G Y Br G L G W B G I K J È L M N N OFF ON O Br R GRAY 4 B C L L L D G W B B Br Y E 9 Sb L W Br R B G W B Br G L W W W W W W B R W W W BLACK Y Y G G B Br Br B P Br P P B B B Y B B G Br Br G L Sb Sb G L R W R W Br G L 1 A C magneto 3 Main switch 4 Fuse 5 Battery 9 C D I unit 0 Igniti...

Page 33: ...R B Br L R W W W W B R L R B R W Br W R BLACK R W BLACK R Br Br G Y Y B G Y Br B GRAY Y Br GRAY B B R W L W R W L W L W L W Sb R B Br R W B B R R R R B B Y G B R B L Br R W G Y B Br B Y 1 2 3 5 6 8 7 H G Y G K J È L M Br R GRAY 4 Br Y Sb L W Br R B W W W W W W B R W W W BLACK Y G 1 A C magneto 2 Rectifier regulator 4 Fuse 5 Battery ...

Page 34: ... 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 B B G Y B G Y B Y G B Y G B Y G B R B L Br R W G Y B Br B Y L Y 1 2 3 5 6 8 7 0 A Br Sb F H G Y Br G L G W B G I K J È L M N N OFF ON O Br R GRAY 4 B C L L L D G W B B Br Y E 9 Sb L W Br R B G W B Br G L W W W W W W B R W W W BLACK Y Y G G B Br Br B P Br P P B B B Y B B G Br Br G L Sb Sb G L R W R W Br G L 3 Main switch 4 Fuse ...

Page 35: ... Check the fuse for continuity Refer to CHECKING THE SWITCH Manual No 3FA AE1 Is the fuse OK Replace the fuse 2 Battery Check the condition of the battery Refer to BATTERY INSPECTION in chapter 3 Manual No 3FA ME1 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery 3 Main switch Check the main switch for continuity ...

Page 36: ...tem s wiring Refer to WIRING DIAGRAM Is the lighting system s wiring properly connected and without defects Check the condition of each of the lighting system s circuits Refer to LIGHTING SYSTEM in chapter 7 Manual No 3FA ME1 Properly connect or repair the lighting system s wiring ...

Page 37: ...L W B B L W L W Sb R B Br R W B B R R R R B B G Y B G Y B Y G B Y G B Y G B R B L Br R W G Y B Br B Y L Y 1 2 3 5 6 8 7 0 A Br Sb F H G Y Br G L G W B G I K J È L M N N OFF ON O Br R GRAY 4 B C L L L D G W B B Br Y E 9 Sb L W Br R B G W B Br G L W W W W W W B R W W W BLACK Y Y G G B Br Br B P Br P P B B B Y B B G Br Br G L Sb Sb G L R W R W Br G L 3 Main switch 4 Fuse 5 Battery G Brake lever switc...

Page 38: ...rminal as shown Positive tester probe pink 1 Negative tester probe ground Set the main switch to ON Push the horn switch Measure the voltage DC 12 V of pink at the horn terminal Is the voltage within specification The wiring circuit from the main switch to the horn connector is faulty and must be repaired 3 Horn Disconnect the black connector at the horn terminal Connect a jumper lead 1 to the hor...

Page 39: ......

Page 40: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 41: ...G G B Br Br B P Br P P B B B Y B B G Br Br G L Sb Sb G L R W R W Br G L 1 A C magneto 2 Rectifier regulator 3 Main switch 4 Fuse 5 Battery 6 Starter relay 7 Starter motor 8 Starting circuit cut off relay 9 C D I unit 0 Ignition coil A Spark plug B Reverse indicator light C Neutral indicator light D Neutral switch E Reverse switch F Reverse relay G Brake lever switch H Front brake light switch I Ta...

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