Yamaha YFS200R 2002, Service Manual

Page: 7 / 75

CONTENTS
SPECIFICATIONS ............................................................................................1
GENERAL SPECIFICATIONS ..................................................................1
MAINTENANCE SPECIFICATIONS .........................................................2
ENGINE ................................................................................................2
CHASSIS ..............................................................................................3
ELECTRICAL ........................................................................................4
CABLE ROUTING .....................................................................................5
PERIODIC CHECKS AND ADJUSTMENTS ..................................................12
INTRODUCTION .....................................................................................12
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ......................12
CHASSIS .................................................................................................14
ADJUSTING THE PARKING BRAKE .................................................14
ADJUSTING THE REAR BRAKE .......................................................15
CHECKING THE BRAKE FLUID LEVEL ............................................16
CHECKING THE BRAKE PADS .........................................................16
CHECKING THE BRAKE HOSES ......................................................17
BLEEDING THE HYDRAULIC BRAKE SYSTEM ...............................18
ELECTRICAL ..........................................................................................20
ADJUSTING THE HEADLIGHT BEAM ...............................................20
REPLACING THE HEADLIGHT BULB ...............................................20
CHASSIS ........................................................................................................23
FRONT AND REAR BRAKES .................................................................23
REPLACING THE BRAKE PADS .......................................................25
DISASSEMBLING THE BRAKE CALIPERS .......................................30
DISASSEMBLING THE BRAKE MASTER CYLINDER ......................33
CHECKING THE BRAKE CALIPER
AND BRAKE MASTER CYLINDER ....................................................36
ASSEMBLING THE BRAKE CALIPER ...............................................40
ASSEMBLING THE MASTER CYLINDER .........................................46
STEERING SYSTEM ..............................................................................51
FRONT SHOCK ABSORBERS AND FRONT ARMS .............................52
REAR SHOCK ABSORBER AND SWINGARM ......................................53
ELECTRICAL .................................................................................................54
IGNITION SYSTEM .................................................................................54
CIRCUIT DIAGRAM ............................................................................54
TROUBLESHOOTING ........................................................................55
LIGHTING SYSTEM ................................................................................60
CIRCUIT DIAGRAM ............................................................................60
TROUBLESHOOTING ........................................................................61
LIGHTING SYSTEM CHECK ..............................................................62