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Yamaha AG200F Owner'S Manual Download Page 52

6-16

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

3

4

5

6

7

8

9

b

a

1

2

3

EAU00699*

Front brake lever free play
adjustment

The front brake lever free play
should be adjusted to 10 ~ 20 mm
(0.39 ~ 0.79 in).

1. Loosen the locknut at the

brake lever.

2. Turn the adjusting bolt at the

brake lever in direction 

a

to

increase free play or in direc-
tion 

b

to decrease free play.

3. Tighten the locknut at the

brake lever .

1.

Adjusting bolt

2.

Locknut

3.

Free play

If the specified free play cannot be
obtained, proceed with the follow-
ing steps.

4. Loosen the locknut at the

brake lever.

5. Turn the adjusting bolt at the

brake lever in direction 

a

to

loosen the cable.

6. Loosen the locknut at the

brake hub.

7. Turn the adjusting nut at the

brake hub in direction 

a

to

increase free play or in direc-
tion 

b

to decrease free play.

8. Tighten the locknut at the

brake hub and the brake lever.

a

b

1

2

4. Loosen the locknut at the

clutch lever.

5. Turn the adjusting bolt at the

clutch lever in direction 

a

to

loosen the cable.

6. Loosen the locknut at the

crankcase side.

7. Turn the adjusting nut at the

crankcase in direction 

a

to

increase free play or in direc-
tion 

b

to decrease free play.

8. Tighten the locknut at the

crankcase and the clutch lever.

1.

Adjusting nut

2.

Lock nut

a

b

1

2

1.

Adjusting nut

2.

Locknut

 3GX-9-33 (E)  12/10/07 11:17 AM  Page 50

ProCarManuals.com

Summary of Contents for AG200F

Page 1: ...3GX 28199 33 AG200F X OWNER S MANUAL ProCarManuals com ...

Page 2: ...1 2 3 4 5 6 7 8 9 ProCarManuals com ...

Page 3: ...g racing machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic mainte nance of this motorcycle If you have any questions about the operation or maintenance of your motorcycle please consult a Yamaha dealer 3GX 9 33 E 12 10 07 11 17 AM Page 1 ProCarManual...

Page 4: ...cycle A NOTE provides key information to make procedures easier or clearer Q w cC NOTE NOTE 8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold 8 Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product information available at the time o...

Page 5: ...ACTURED FOR OFF ROAD USE ONLY IT IS ILLEGAL TO OPERATE THIS MOTORCYCLE ON ANY PUBLIC STREET ROAD OR HIGHWAY SUCH USE IS PROHIBITED BY LAW THIS MOTORCYCLE COMPLIES WITH ALMOST ALL STATE OFF HIGHWAY NOISE LEVEL AND SPARK ARRESTER LAWS AND REGULATIONS PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERATING THIS MOTORCYCLE 3GX 9 33 E 12 10 07 11 17 AM Page 3 ProCarManuals com ...

Page 6: ...aha Motor Co Ltd 1st Edition November 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EAU00008 3GX 9 33 E 12 10 07 11 17 AM Page 4 ProCarManuals com ...

Page 7: ... 3 5 Fuel tank cap 3 5 Fuel 3 6 Fuel cock 3 7 Starter choke For 6 V model 3 8 Starter choke 1 For 12 V model 3 8 Kick starter 3 8 Seat 3 9 Rear shock absorber adjustment 3 9 Front and rear carriers 3 10 Auxiliary DC terminal For 12 V model 3 11 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting and warming up a cold engine For 6 V model 5 1 Sta...

Page 8: ...shift pedal lubrication 6 21 Brake and clutch lever lubrication 6 22 Sidestand lubrication 6 22 Rear suspension lubrication 6 22 Front fork inspection 6 23 Steering inspection 6 23 Wheel bearings 6 24 Battery For 6 V model 6 24 Battery For 12 V model 6 26 Fuse replacement For 6 V model 6 27 Fuse replacement For 12 V model 6 28 Replacing the headlight bulb 6 29 Tail light bulb replacement 6 30 Turn...

Page 9: ...1 SPECIFICATIONS For 12 V model 8 4 How to use the conversion table 8 7 CONSUMER INFORMATION 9 1 Identification numbers record 9 1 Key identification number 9 1 Vehicle identification number 9 2 Model label 9 2 8 9 3GX 9 33 E 12 10 07 11 17 AM Page 7 ProCarManuals com ...

Page 10: ... PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER S MANU AL AND OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed for off road use only It is illegal for this motorcycle to be operated on any public street road or highway Off road use on public lands may be ille gal Please...

Page 11: ...or drugs Protective apparel The majority of fatalities from motorcycle accidents are the result of head injuries The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries 1 Always wear an approved helmet 2 Wear a face shield or goggles Wind on your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard 3 Th...

Page 12: ... must personally be responsible for the proper selection installation and use of non Yamaha accessories You should use extreme caution when selecting and installing any accessories Keep in mind these guidelines for mounting accessories in addition to those provided under LOADING 1 Never install accessories or carry cargo that would impair the performance of your motor cycle Carefully inspect the a...

Page 13: ...GASOLINE IS HIGHLY FLAMMABLE a Always turn off the engine when refueling b Take care not to spill any gasoline on the engine or exhaust system when refueling c Never refuel while smoking or in the vicinity of an open flame 2 Never start the engine or let it run for any length of time in a closed area The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time ...

Page 14: ...ne may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get in your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash it off with soap and water and change your clothes 1 5 Q SAFETY INFORMATION 1 2 3 4 5 6 7 8 9 3GX 9 33 E 12 10 07 11 17 AM Page 12 ProCarManuals com ...

Page 15: ...l veicolo leggete il manuale di istruzioni Lire le manuel du propriétaire avant d utiliser ce véhicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehículo lea el Manual del Propietario 4AA 22259 40 follows FRONT REAR 3GX 21668 00 Cold tire normal pressure should be set as 125 kPa 1 25 kgf cm2 18 psi 150 kPa 1 50 kgf cm2 22 psi 2 3 3GX 9 33 E 12 10 07 ...

Page 16: ... 7 8 9 2 1 1 Headlight page 6 29 6 30 2 Fuel cock page 3 7 3 Fuse For 12 V model page 6 28 4 Tool kit page 6 1 5 Air filter page 6 10 6 Shift pedal page 3 4 1 2 3 4 5 6 Left view 3GX 9 33 E 12 10 07 11 17 AM Page 14 ProCarManuals com ...

Page 17: ... 7 Rear shock absorber spring preload adjuster page 3 9 8 Rear brake pedal page 3 5 9 Kick starter page 3 8 10 Battery page 6 24 6 27 11 Fuse page 6 27 6 28 7 8 9 10 11 Right view 3GX 9 33 E 12 10 07 11 17 AM Page 15 ProCarManuals com ...

Page 18: ... page 3 1 16 Auxiliary DC terminal For 12 V model page 3 11 17 Starter choke 1 For 12 V model page 3 8 18 Right handlebar switches page 3 2 3 4 19 Front brake lever page 3 5 6 16 20 Throttle grip page 6 21 21 Main switch page 3 1 22 Fuel tank cap page 3 5 12 13 15 16 17 18 19 20 21 22 14 Controls Instruments 3GX 9 33 E 12 10 07 11 17 AM Page 16 ProCarManuals com ...

Page 19: ...circuits are switched off The key can be removed in this position EAU00027 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 1 EAU00056 Indicator light EAU00062 Neutral indicator light NEUTRAL This indicator comes on when the transmission is in neutral 1 Neutral indicator light NEUTRAL 1 2 EAU00098 Speedometer The speedometer shows riding speed This speedometer is equipped with an odometer 1 Spee...

Page 20: ... position switch The center position is off Turn to L to turn on the left flasher and to R for the right flasher Be sure to turn the switch off after completing a turn EAU00130 Horn switch HORN Press the switch to sound the horn EAU00137 Engine stop switch ENGINE STOP The engine stop switch is a safety device for use in an emergency such as when the motorcycle over turns or if trouble occurs in th...

Page 21: ... push the switch to 4 Once the switch is released it will return to the center position To cancel the signal push the switch in after it has returned to the center position EAU00129 Horn switch Press the switch to sound the horn EAU00138 Engine stop switch The engine stop switch is a safety device for use in an emergency such as when the motorcycle over turns or if trouble occurs in the throttle s...

Page 22: ...ver provided to keep the clutch in the disengaged position Pull the clutch lever then push down the lock lever The clutch lever will stay in the disen gaged position To release the lock simply pull the clutch lever 1 Clutch lock lever 2 Clutch lever 3 4 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 1 N 5 4 3 2 1 EAU00157 Shift pedal This motorcycle is equipped with a constant mesh 5 speed tra...

Page 23: ...handlebar to apply the front brake 1 Front brake lever 1 Rear brake pedal 1 Fuel tank cap EAU00162 Rear brake pedal The rear brake pedal is on the right side of the motorcycle Press down on the brake pedal to apply the rear brake EAU00179 Fuel tank cap Remove the fuel tank cap by turn ing it counterclockwise 3GX 9 33 E 12 10 07 11 17 AM Page 21 ProCarManuals com ...

Page 24: ...the fuel tank above the bot tom of the filler tube or it may overflow when the fuel heats up later and expands EAU00185 cC Always wipe off spilled fuel imme diately with a dry and clean soft cloth Fuel may deteriorate painted surfaces or plastic parts 1 2 1 Filler tube 2 Fuel level EAU00192 Recommended fuel Regular unleaded gasoline only Fuel tank capacity Total 10 0 L 2 64 US gal 2 20 Imp gal Res...

Page 25: ...the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES ON FUEL OFF 1 1 Arrow mark OFF ON RES This indicates reserve If you run out of fuel while riding move the lever to this position Fill the tank at the first opportunity Be sure to set the fuel cock back to ON after refuel...

Page 26: ...rcefully to start the engine This model has a primary coupled kick starter so the engine can be started in any gear if the clutch is disengaged However shifting to neutral before starting is recom mended 1 Starter choke 1 Kickstarter 3 8 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 b a 1 EAU00210 Starter choke 1 For 12 V model Starting a cold engine requires a richer air fuel mixture A separ...

Page 27: ...ake sure that the seat is securely fitted 5 4 3 2 1 b a 1 2 1 Special wrench 2 Position indicator EAU00295 Rear shock absorber adjustment This shock absorber is equipped with a spring preload adjusting ring Adjust spring preload as fol lows Turn the adjusting ring in direction a to increase spring preload and in direction b to decrease spring preload Make sure that the appropriate notch in the adj...

Page 28: ...the shock absorber to an open flame or other high heat source This may cause the unit to explode due to excessive gas pressure 8 Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance 8 Take your shock absorber to a Yamaha dealer for any service EAU01644 Front and rear carriers EWA00009 w Do not exceed the loading limit Front carrier 2 kg 4 lb Rear ...

Page 29: ...re used in excess of the above capacity or if acces sories are used with the engine not running the battery will lose its charge and engine starting may become difficult How to use the Auxiliary DC termi nal 1 Start the engine See page 5 2 2 Remove the dust cap from the receptacle 3 Insert the accessory plug into the receptacle and secure it with the screw on cap 4 When the accessory terminal is n...

Page 30: ...free play 3 4 6 15 6 16 9 Adjust if necessary 9 Check for smooth operation Throttle grip and housing 9 Lubricate 6 12 6 13 6 21 9 Adjust throttle cable free play if necessary Engine oil 9 Check oil level 6 8 6 10 9 Fill with oil if necessary Drive chain 9 Check chain slack and condition 6 19 6 20 9 Adjust if necessary Wheels and tires 9 Check tire pressure wear damage and spoke tightness 6 13 6 15...

Page 31: ...ches NOTE Pre operation checks should be made each time the motorcycle is used Such an inspection can be accom plished in a very short time and the added safety it assures is more than worth the time involved w If any item in the Pre Operation Check is not working properly have it inspected and repaired before operating the motorcycle 3GX 9 33 E 12 10 07 11 17 AM Page 29 ProCarManuals com ...

Page 32: ...00406 Starting and warming up a cold engine For 6 V model 1 Turn the fuel cock to ON 2 Turn the main switch to ON and the engine stop switch to RUN 3 Shift transmission into neutral NOTE When the transmission is in neu tral the neutral indicator light should be on If the light does not come on ask a Yamaha dealer to inspect it 4 Turn on the starter choke and completely close the throttle grip 5 Ki...

Page 33: ...mum engine life always warm up the engine before starting off Never accelerate hard with a cold engine 7 After warming up the engine turn off the starter choke completely NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EAU01689 Starting and warming up a cold engine For 12 V model NOTE This motorcycle is equipped with a clutch switch which control...

Page 34: ...e clutch when changing gears The engine transmission and driveline are not designed to withstand the shock of forced shifting and can be damaged by shifting without using the clutch OPERATION AND IMPORTANT RIDING POINTS 1 2 3 4 5 6 7 8 9 EAU00423 Shifting The transmission lets you control the amount of power you have available at a given speed for start ing accelerating climbing hills etc The use ...

Page 35: ... Do not operate it at one set throttle position 150 500 km 93 300 mi Avoid prolonged operation above 1 2 throttle Rev the motorcycle freely through the gears but do not use full throttle at any time 500 1 000 km 300 600 mi Avoid cruising speeds in excess of 3 4 throttle 1 000 km 600 mi and beyond Avoid prolonged full throttle oper ation Vary speeds occasionally EAU00424 Tips for reducing fuel cons...

Page 36: ... the motorcycle in a place where pedestrians or children are not likely to touch the motorcycle Do not park the motorcycle on a slope or soft ground the motorcy cle may overturn EC000059 cC 8 After 1 000 km 600 mi of operation be sure to replace the engine oil and oil filter and clean the oil strainer 8 If any engine trouble should occur during the break in peri od consult a Yamaha dealer immediat...

Page 37: ...EDULE TO SHORTER INTERVALS TO MATCH THE ENVIRONMENT The most important points of motorcycle inspection adjustment and lubri cation are explained in the follow ing pages EW000060 w If you are not familiar with motor cycle service this work should be done by a Yamaha dealer 1 EAU00469 Tool kit The service information included in this manual is intended to provide you the owner with the necessary inf...

Page 38: ...for service EW000063 w Modifications to this motorcycle not approved by Yamaha may cause loss of performance and render it unsafe for use Consult a Yamaha dealer before attempting any changes 6 2 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 8 9 1 1 Tool kit 3GX 9 33 E 12 10 07 11 17 AM Page 36 ProCarManuals com ...

Page 39: ...f necessary 4 Air filter 9 Clean or replace if necessary 5 Clutch 9 Check operation 9 Adjust or replace cable 6 Front brake 9 Check operation 9 Adjust brake lever freeplay and replace brake shoes if necessary 7 Rear brake 9 Check operation 9 Adjust brake pedal freeplay and replace brake shoes if necessary 8 Wheels 9 Check balance runout spoke tightness and for damage 9 Tighten spokes and rebalance...

Page 40: ...oughness 13 Steering bearings 9 Correct accordingly 9 Lubricate with lithium soap grease every 24 000 km 14 000 mi or 24 months whichever comes first 14 Chassis fasteners 9 Make sure that all nuts bolts and screws are properly tightened 9 Tighten if necessary 15 Sidestands 9 Check operation 9 Lubricate and repair if necessary 16 Front fork 9 Check operation and for oil leakage 9 Correct accordingl...

Page 41: ... needs more frequent service if you are riding in unusually wet or dusty areas EVERY 6 000 km 12 000 km No ITEM CHECKS AND MAINTENANCE JOBS Initial 3 500 mi or 7 000 mi or 1 000 km 6 months 12 months 600 mi Whichever Whichever comes first comes first 20 Engine oil filter element 9 Replace 21 Engine oil strainer 9 Clean or replace if necessary 3GX 9 33 E 12 10 07 11 17 AM Page 39 ProCarManuals com ...

Page 42: ...e removed to perform some of the maintenance described in this chapter Refer to this section each time a panel has to be removed or rein stalled 1 Panel A 1 Panel B EAU00494 Panel A and B To remove Pull outward on the areas shown To install Place the panel in its original posi tion 3GX 9 33 E 12 10 07 11 17 AM Page 40 ProCarManuals com ...

Page 43: ...he condition of the engine The ideal color on the white insulator around the center electrode is a medium to light tan color for a motorcycle that is being ridden normally Do not attempt to diagnose any prob lems yourself Instead take the motorcycle to a Yamaha dealer The spark plug should be periodi cally removed and inspected because heat and deposits will cause the spark plug to slowly break do...

Page 44: ...vel mark 3 Minimum level mark 1 Drain plug Engine oil replacement 1 Warm up the engine for a few minutes 2 Stop the engine Place an oil pan under the engine and remove the oil filler cap 1 1 Oil filler cap 2 With the engine stopped check the oil level through the level window located at the lower part of the right side crankcase cover NOTE Wait a few minutes until the oil level settles before chec...

Page 45: ... filter cover 5 Remove the oil filter element and O ring 6 Clean the oil filter and strainer with solvent Replace if neces sary 7 Check the O rings If damaged replace 8 Install the drain plug filter cover screws and drain bolt Tighten the drain plug to the specified tightening torque NOTE Make sure the O ring is seated properly EC000071 cC Before reinstalling the oil drain plug do not forget to in...

Page 46: ... 1 Periodic oil change 1 0 L 1 06 US qt 0 88 Imp qt With oil filter replacement 1 1 L 1 16 US qt 0 97 Imp qt 1 1 Screw 5 EAU01094 Air filter The air filter should be cleaned at the specified intervals It should be cleaned more frequently if you are riding in unusually wet or dusty areas 1 Remove panel B See page 6 6 for panel removal and installa tion procedures 2 Remove the air filter case fit ti...

Page 47: ...n without the air filter installed Excessive piston and or cylinder wear may result EAU00629 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisti cated adjustment Most adjust ments should be left to a Yamaha dealer who has the professional knowledge and experience to do so However the following may be serviced by the owner as part of routine maintenance EC0...

Page 48: ...peed by adjusting the throttle stop screw Turn the screw in direction a to increase engine speed and in direction b to decrease engine speed NOTE If the specified idle speed cannot be obtained by performing the above adjustment consult a Yamaha dealer EAU00634 Throttle cable free play adjustment NOTE Before checking the throttle cable free play the engine idling speed should be adjusted Adjust the...

Page 49: ...y and in direction b to decrease free play 3 Tighten the locknut EAU01645 Tires To ensure maximum performance long service and safe operation note the following Tire air pressure Always check and adjust the tire pressure before operating the motorcycle EW000091 w Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature Free play 3 5...

Page 50: ... tread begins to show lines have a Yamaha dealer replace the tire immediately Brakes tires and related wheel parts replacement should also be left to a Yamaha dealer 8 Patching a punctured tube is not recommended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement Manufacturer Size Type IRC 3 00 19 49M FARM SPECIAL Z2 Manuf...

Page 51: ...eel is deformed or cracked it must be replaced 8 Tires and wheels should be balanced whenever either one is changed or replaced Failure to have a wheel balanced can result in poor performance adverse handling characteris tics and shortened tire life b a 3 1 2 EAU00694 Clutch lever free play adjustment The clutch lever free play should be adjusted to 10 15 mm 0 39 0 59 in 1 Loosen the locknut at th...

Page 52: ...urn the adjusting bolt at the brake lever in direction a to loosen the cable 6 Loosen the locknut at the brake hub 7 Turn the adjusting nut at the brake hub in direction a to increase free play or in direc tion b to decrease free play 8 Tighten the locknut at the brake hub and the brake lever a b 1 2 4 Loosen the locknut at the clutch lever 5 Turn the adjusting bolt at the clutch lever in directio...

Page 53: ...e this adjustment Pedal height The brake pedal should be posi tioned so that its top end is approximately 10 mm 0 39 in below the top of the footrest 1 Loosen the locknut 1 Adjusting bolt for pedal height 2 Locknut 3 Pedal height 4 Free play a 2 1 b Free play The rear brake pedal free play should be adjusted to 20 30 mm 0 79 1 18 in at the brake pedal end Turn the adjusting nut on the brake rod in...

Page 54: ... later 1 Brake light switch 2 Adjusting nut EW000106 w 8 Brake pedal free play should be checked whenever the chain is adjusted or the rear wheel is removed and then reinstalled 8 Check the operation of the brake light after adjusting the rear brake 8 If it is impossible to make proper adjustment consult a Yamaha dealer EAU00719 Checking the brake shoes A wear indicator is provided on each brake T...

Page 55: ... held straight up with both wheels on the ground and without rider Check the slack at the position shown in the illustra tion If the drive chain slack is incorrect adjust it as follows a a Chain slack EAU01274 Drive chain slack adjustment 1 Loosen the rear brake pedal free play adjusting nut 2 Loosen the axle nut and sprocket shaft nut 3 2 1 1 Axle nut 2 Sprocket shaft nut 3 Chain adjusting plate ...

Page 56: ...adjusting the rear brake Tightening torque Axle nut 85 Nm 8 5 m0kgf 61 5 ft0kgf Sprocket shaft nut 85 Nm 8 5 m0kgf 61 5 ft0kgf EAU01106 Drive chain lubrication The chain consists of many parts which work with each other If the chain is not maintained properly it will wear out quickly Therefore the chain must be serviced regular ly This service is especially neces sary when riding in dusty areas 1 ...

Page 57: ... cable and grip lubrication The throttle twist grip assembly should be greased at the time that the cable is lubricated since the grip must be removed to get at the end of the throttle cable After removing the screws hold the end of the cable up in the air and put in several drops of lubricant With the throttle grip disassembled coat the metal surface of the grip assembly with a suitable all purpo...

Page 58: ...h sidestand pivoting point and metal to metal contact surfaces Check that each side stand moves up and down smoothly EW000113 w If the sidestand does not move smoothly consult a Yamaha deal er Recommended lubricant Lithium soap based grease EAU00791 Rear suspension lubrication Lubricate the pivoting parts 1 1 Grease nipple Recommended lubricant Lithium soap based grease 3GX 9 33 E 12 10 07 11 17 A...

Page 59: ... dlebars several times and check if the fork rebounds smoothly EC000098 cC If any damage or unsmooth move ment is found with the front fork consult a Yamaha dealer EAU00794 Steering inspection Periodically inspect the condition of the steering Worn out or loose steering bearings may be danger ous Place a stand under the engine to raise the front wheel off the ground Hold the lower end of the front...

Page 60: ...earings EAU01071 Battery For 6 V model Check the level of the battery elec trolyte and make sure that the ter minals are tight Fill with distilled water if the elec trolyte level is low EC000099 cC When inspecting the battery be sure the breather hose is routed correctly If the breather hose is positioned in such a way as to cause battery electrolyte or gas to exit onto the frame structural and co...

Page 61: ... an enclosed space Always shield your eyes when working near batteries KEEP OUT OF REACH OF CHIL DREN Replenishing the battery fluid A poorly maintained battery will corrode and discharge quickly The battery fluid should be checked at least once a month The level should be between the minimum level and maximum level marks Use only distilled water if refilling is necessary 2 3 1 1 Battery 2 Maximum...

Page 62: ...cle Make sure the breather hose is properly connected and is not damaged or obstructed PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 8 9 EAU00800 Battery For 12 V model This motorcycle is equipped with a sealed type battery Therefore it is not necessary to check the elec trolyte or fill the battery with dis tilled water 8 If the battery seems to have discharged consult a Yamaha dealer 8 If t...

Page 63: ...move the battery fully charge it and store it in a cool dry place EC000102 cC 8 Completely recharge the bat tery before storing Storing a discharged battery can cause permanent battery damage 8 Use a battery charger designed for a sealed type MF battery Using a conven tional battery charger will cause battery damage If you do not have a sealed type bat tery charger contact your Yamaha dealer 8 Alw...

Page 64: ...n consult a Yamaha dealer 1 2 1 Auxiliary DC terminal fuse 2 Spare fuse EC000103 cC Do not use fuses of higher amper age rating than those recommend ed Substitution of a fuse of improper rating can cause exten sive electrical system damage and possibly a fire Specified fuse 10A EC000103 cC Do not use fuses of higher amper age rating than those recommend ed Substitution of a fuse of improper rating...

Page 65: ...ight bulb burns out replace the bulb as follows 1 Remove the screw holding the headlight unit 1 1 Screw 1 1 Screw For 6 V model For 12 V model 2 Disconnect the headlight leads and remove the bulb holder cover 1 2 1 Leads 3 2 Bulb holder cover For 12 V model 3GX 9 33 E 12 10 07 11 17 AM Page 63 ProCarManuals com ...

Page 66: ...lammable products and your hands away from a bulb while it is on as it is hot Do not touch a bulb until it cools down 5 Put a new bulb into position and secure it in place with the bulb holder 1 1 Bulb holder 1 2 1 Bulb holder cover For 12 V model 2 Bulb holder For 12 V model For 6 V model 1 2 3 EAU01623 Tail light bulb replacement 1 Remove the screws and the lense 2 Remove the defective bulb by p...

Page 67: ...fective bulb by pushing it inward and turning it counterclockwise 3 Install a new bulb by pushing it inward and turning it clock wise 4 Install the lense and tighten the screw For 6 V model 1 2 3 1 Lense 2 Bulb 3 Holder EAU01731 Turn signal light bulb replacement For 12 V model 1 Remove the lense by pushing down lightly and pulling it out ward 2 Push the bulb inward and turn it counterclockwise to...

Page 68: ...e jack under the frame in front of the rear wheel to prevent it from moving from side to side Then use a motorcycle stand to elevate the front wheel off of the ground Rear wheel service Use a motorcycle stand or motor cycle jack to elevate the motorcycle so the rear wheel is off the ground Alternatively two jacks can be placed under the frame or swingarm 1 2 EAU00908 Front wheel removal EW000122 w...

Page 69: ...7 Front wheel installation 1 Install the brake shoe plate assembly into the wheel hub Make sure the projections are meshed into the slots 2 Lift up the wheel between the front fork legs 3 Install the wheel axle and the axle nut make sure the slot in the brake shoe plate fits over the stopper on the front fork outer tube 4 Let the motorcycle down 5 Install the brake cable at the handlebar lever hol...

Page 70: ...Remove the cotter pin nut and the brake torque rod bolt from the brake shoe plate 1 Brake torque rod 2 Brake torque rod nut and bolt 3 Brake torque rod cotter pin 4 Brake camshaft lever 5 Rear brake pedal free play adjusting nut 6 Brake rod 1 2 Remove the brake free play adjusting nut and brake rod from the brake cam lever 3 Loosen the wheel axle nut 4 Elevate the rear wheel by plac ing a suitable...

Page 71: ...orque rod nut 19 Nm 1 9 m0kgf 13 7 ft0lbf Axle nut 85 Nm 8 5 m0kgf 61 5 ft0lbf EAU01008 Troubleshooting Although Yamaha motorcycles receive a rigid inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compres sion or ignition systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making chec...

Page 72: ... ignition check No compression Ask a Yamaha dealer to inspect Wet Dry Wipe clean with dry cloth and correct Open throttle half way and start Ask a Yamaha dealer to inspect Check if there is fuel Enough fuel No fuel Go to compression check Supply fuel in the fuel tank electrodes plug and check Engine doesn t start ask a Yamaha dealer to inspect the engine spark gap or replace spark plug Engine does...

Page 73: ...ry cloth and Ask a Yamaha dealer to inspect Check if there is fuel Enough fuel No fuel Go to compression check Supply fuel in the fuel tank Remove spark electrodes plug and check Open throttle half way and start the Engine doesn t start go to battery check engine correct spark gap or replace spark plug Engine turns over Engine turns over Battery good Check connections quickly slowly or recharge En...

Page 74: ...ler outlet with a plastic bag 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug cap are tightly installed 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such products onto seals gaskets sprockets the drive chain and wheel axles Always rinse the dirt and degreaser of...

Page 75: ...indshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning compounds for plas tic may leave scratches on the windshield Test the product on a small hidden part of the windshield to make sure they do not leave any marks If the windshield is scratched use a quality plastic polishing com pound after washing Cleaning After normal use Remove dirt with wa...

Page 76: ...el parts including the exhaust system Even the thermally induced discoloring of stainless steel exhaust sys tems can be removed through polishing 4 To prevent corrosion it is rec ommended to apply a corro sion protection spray on all even chrome and nickel plat ed metal surfaces 5 Use spray oil as a universal cleaner to remove any remain ing dirt 6 Touch up minor paint damage caused by stones etc ...

Page 77: ...oring your motorcycle for several months 1 Follow all the instructions in the Care section of this chapter 2 Drain the carburetor float chamber by loosening the drain bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 3 Only for motorcycles equipped with a fuel cock which has an OFF position Turn the fuel cock to OFF 4 Fill up the fuel tank and add fuel ...

Page 78: ...Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 7 Check and if necessary cor rect the tire air pressure then raise the motorcycle so that both of its wheels are off the ground Alternatively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover up the muffler outlet with a p...

Page 79: ...tio 9 50 1 Starting system Kick starter Lubrication system Wet sump Engine oil Type SAE 10W 30 SAE 10W 40 SAE 15W 40 SAE 20W 40 or SAE 20W 50 Recommended engine oil grade API Service SE SF SG type or higher cC Be sure to use motor oils that do not contain anti friction modifiers Passenger car motor oils often labeled Energy Conserving contain anti friction additives which will cause clutch and or ...

Page 80: ...egular unleaded gasoline only Fuel tank capacity 10 0 L 2 64 US gal 2 20 Imp gal Reserve amount 2 0 L 0 53 US gal 0 44 Imp gal Carburetor Manufacturer MIKUNI Type quantity BS26 1 Spark plug Manufacturer model NGK D8EA DENSO X24ES U Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 74 20 3 700 Second...

Page 81: ...scopic fork Spring shock absorber type Coil spring oil damper Wheel travel 200 0 mm 7 87 in Rear suspension Type Swingarm Monocross Spring shock absorber type Coil spring gas oil damper Wheel travel 165 0 mm 6 50 in Electrical system Ignition system CDI Charging system Flywheel magneto Battery Model 6N4B 2A 3 Voltage capacity 6 V 4 5 Ah Headlight Bulb type Incandescence Bulb voltage wattage quanti...

Page 82: ...1 Starting system Electric starter and kickstarter Lubrication system Wet sump Engine oil Type SAE 10W 30 SAE 10W 40 SAE 15W 40 SAE 20W 40 or SAE 20W 50 Recommended engine oil grade API Service SE SF SG type or higher cC Be sure to use motor oils that do not contain anti friction modifiers Passenger car motor oils often labeled Energy Conserving contain anti friction additives which will cause clu...

Page 83: ...sion Primary reduction system Spur gear Primary reduction ratio 74 20 3 700 Secondary reduction system Chain drive Secondary reduction ratio 54 14 3 857 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio 1st 35 11 3 181 2nd 31 15 2 066 3rd 30 21 1 428 4th 25 26 0 961 5th 22 31 0 709 Chassis Frame type Diamond Caster angle 27 42 Trail 87 0 mm 3 43 in Front tire Type Wi...

Page 84: ...g shock absorber type Coil spring oil damper Wheel travel 200 0 mm 7 87 in Rear suspension Type Swingarm Monocross Spring shock absorber type Coil spring gas oil damper Wheel travel 165 0 mm 6 50 in Electrical system Ignition system DC CDI Charging system AC magneto Battery Model YTZ7S Voltage capacity 12 V 6 0 Ah Headlight Bulb type Incandescence Bulb voltage wattage quantity Headlight 12 V 45 W ...

Page 85: ...unit Multiplier Imperial unit m kg 7 233 ft lb Torque m kg 86 794 in lb cm kg 0 0723 ft lb cm kg 0 8679 in lb Weight kg 2 205 lb g 0 03527 oz Speed km hr 0 6214 mph km 0 6214 mi m 3 281 ft Distance m 1 094 yd cm 0 3937 in mm 0 03937 in cc cm3 0 03527 oz IMP liq Volume cc cm3 0 06102 cu in Capacity lt liter 0 8799 qt IMP liq lt liter 0 2199 gal IMP liq kg mm 55 997 lb in Misc kg cm2 14 2234 psi lb ...

Page 86: ... number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION 1 6 YAMAHA 1 Record this number in the space provided and use it for reference when obtaining a new key 1 Key identification number For 6 V model ...

Page 87: ...used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state 1 Vehicle identification number 1 EAU01049 Model label The model label is affixed to the location shown in the figure Record the information on this label in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label 3GX 9 33 E 1...

Page 88: ...1 2 3 4 5 6 7 8 9 3GX 9 33 E 12 10 07 11 17 AM Page 86 ProCarManuals com ...

Page 89: ...1 2 3 4 5 6 7 8 9 3GX 9 33 E 12 10 07 11 17 AM Page 87 ProCarManuals com ...

Page 90: ...1 2 3 4 5 6 7 8 9 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2007 12 0 9 1 E YAMAHA MOTOR CO LTD 3GX 9 33 E 12 10 07 11 17 AM Page 88 ProCarManuals com ...

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