2XJ-AE2
Contents
1. YAMAHA 2007 2XJ AE2 SUPPLEMENTARY MANUAL FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFS200 P 2002 For complete information on service procedures it is necessary 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 rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd Is expressly prohibited 28001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics It is not possible to include all the knowledge of a mechanic in one manual so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use Yamaha Motor Company Ltd is continually striving to improve all its models Modifications 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 NOTE2. front of the cables 8 D Front brake cable 2 Clutch cable 3 Main switch lead 4 Fuel breather hose 5 Band 6 Wire harness 7 Crankcase ventilation hose CABLE ROUTING SPEC y Route the clutch cable in front of the fender stay Route the front brake cable through the cable guide behind the front shock absorber and above the tie rod CABLE ROUTING SPEC y CD Wire harness For installing the wire harness align the posi 2 Crankcase ventilation hose tioning tape with the wire holder 9 Fuel hose The leads should be clamped on the inward half 4 Wire holder of the frame pipe 5 Rear brake light switch Clamp the oil hose and rear brake light switch 6 Band lead with the plastic clamp Clamp Oil hose 9 Carburetor overflow hose Flywheel magneto lead D Front brake cable 2 Parking brake cable 3 Spark plug lead 4 Crankcase ventilation hose 5 Rear brake light switch 6 Band 7 Tail brake light lead Oil level gauge lead 9 Oil hose Wire harness 4 Clamp 2 Throttle switch lead 1 Val Ll CABLE ROUTING SPEC y 43 Throttle cable Clutch cable 5 Ignition coil lead Ignition coil 2 Ground lead Place the slack of the spark plug lead toward the left side of the frame CABLE ROUTING SPEC y D Rear brake light switch Route the parking brake cable in front of the 2 Oil
3. 10044 YOUMS 1461 6 6 QD 1461 IO q2 D SIGNAL SYSTEM CIRCUIT DIAGRAM EB806000 14 SIGNAL SYSTEM ELEC CHECKING THE SIGNAL SYSTEM 1 If the tail brake light fails to come on NO CONTINUITY 1 Bulb and bulb socket e m the bulb and bulb socket for continu 1 Replace the bulb and or bulb socket emm 2 Brake light switches Refer to CHECKING THE SWITCH 1 4 CONTINUITY Replace the brake switch e Connect the tachometer to the spark plug lead e Connect the pocket tester DC 20V to the bulb socket connector 3 Voltage Tester lead Yellow terminal 1 Tester lead Black terminal e otart the engine and accelerate to about 5 000 r min Do not run the engine in neutral above MEETS SPECIFICATION 6 000 r min for more than 1 or 2 seconds l Lighting voltage 13 5 14 1 V at 5 000 r min The lighting circuit is not faulty OUT OF SPECIFICATION X 15 SIGNAL SYSTEM ELEC 4 Lighting coil resistance e Disconnect the CDI magneto leads Yel low Red and Black e Connect the pocket tester x 1 to the lighting coil leads OUT OF SPECIFICATION e Measure the lighting coil resistance 1111 Lighting coil resistance 0 16 0 24 Q at 20 68 F Replace the stator assembly MEETS SPECIFICATI
4. Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations AN The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must be taken to avoid dam age to the machine NOTE A NOTE provides key information to make procedures easier or clearer HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects See Illustrated symbols 1st title 1 This is a chapter with its symbol on the upper right of each page 2nd title 2 This title appears on the upper of each page on the left of the chapter sym bol For the chapter Periodic inspection and adjustment the 3rd title appears ard title 3 This is a final title MANUAL FORMAT All of the procedures in this manual are organized in a sequential step by step format The informa tion has been compiled to provide the mechanic with an easy to read handy reference that contains comprehensive explanations of all disassembly repair assembly and inspections A set of particularly important procedure 2 is placed between a line of asterisks dure
5. TE Replace if necessary Rear brake pads eee e Replace if necessary Clutch Inspect free play and operation e Replace if necessary Drive chain Lubricate check free play and alignment e Replace if necessary SINE coan guaraana e Check wear and replace if necessary rollers Steering system e Inspect free play clean and lubricate Front and rear suspension Inspect and lubricate Inspect air pressure wheel runout and tire wear Tire wheels Inspect bearings e Replace bearings if necessary tis recommended that these items be serviced by a Yamaha dealer Lithium soap based grease Throttle control cable neck routing and connection e Lubricate we 4o ADJUSTING THE REAR BRAKE LIGHT SWITCH ADJ CHASSIS ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE nmm The rear brake light switch is operated by movement of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check e Rear brake light operation timing Incorrect Adjust 2 Adjust e Rear brake light operation timing kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk e Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut in direction until the rear brake light comes on at the proper time Direction Brake light comes on sooner D
6. plug Type manufacturer BR8ES NGK Spark plug gap 0 7 0 8 mm 0 028 0 031 in Tire Type Tubeless Size Front AT21x7 10 DUNLOP KT851A CHENG SHIN C873N Hear 21 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 x quantity Headlight 12 V 45 W 45 W x 1 Tail brake light 12 V 5 W 21 W x 1 Indicator light OIL LEVEL 12V 3 4 W x 1 MAINTENANCE SPECIFICATIONS SPEC y MAINTENANCE SPECIFICATIONS ENGINE Model Piston Piston size D Measuring point H Piston off set Piston to cylinder clearance Limit Oversize 1st 2nd Piston ring sectional sketch Top ring Th 2nd ring cp End gap Installed Top ring 2nd ring Side clearance Top ring 2nd ring Crankshaft Crank width A lt Runout limit C Big end side clearance D Big end radial clearance E Small end free play F Clutch Friction plate thickness quantity Wear limit Clutch plate thickness quantity Warp limit Clutch spring free length quantity Clutch spring minimum length Clutch housing radial clearance Clutch release method Push rod bending limit YFS200 P 2002 65 940 66 000 mm 2 596 2 598 in 10 mm 0 39 in 0 in 0 035 0 040 mm 0 0014 0 0016 in 0 100 mm 0 0039 in 66 25 mm 2 608 in 66 50 mm 2 618 in Keystone B 1 2 mm 0 047 in T 2 8 mm 0 1
7. 10 in Keystone B 1 2 mm 0 047 in T 2 8 mm 0 110 in 0 20 0 40 mm 0 008 0 016 in 0 20 0 40 mm 0 008 0 016 in 0 03 0 05 mm 0 0012 0 0020 in 0 03 0 05 mm 0 0012 0 0020 in 57 90 57 95 mm 2 280 2 281 in 0 03 mm 0 0012 in 0 2 0 7 mm 0 008 0 028 in 0 021 0 035 mm 0 0008 0 0014 in 0 8 1 0 mm 0 031 0 039 in 2 92 3 08 mm 0 115 0 121 in 7 pcs 2 8 mm 0 110 in 1 05 1 35 mm 0 041 0 053 in 6 pcs 0 05 mm 0 002 in 34 5 mm 1 36 in 5 pcs 30 0 mm 1 18 in 0 015 0 049 mm 0 0006 0 0019 in Inner push cam push 0 15 mm 0 006 in MAINTENANCE SPECIFICATIONS SPEC y Model Air filter oil grade Carburetor I D mark Main jet Main air jet Jet needle clip position Needle jet Cutaway Pilot outlet Pilot jet Bypass 1 Pilot air screw Valve seat size Starter jet Float height Fuel level Engine idling speed YFS200 P 2002 Yamalube 2 or air cooled 2 stroke engine oil 2XJ01 230 20 7 5J22 2 P 6 345 2 0 0 6 1132 5 0 8 x 3 75 1 and 1 2 turns out 92 8 45 20 5 21 5 0 81 0 85 0 5 1 5 mm 0 02 0 06 in 1 450 1 550 r min MAINTENANCE SPECIFICATIONS SPEC y CHASSIS YFS200 P 2002 Rear suspension Shock absorber travel 80 mm 3 15 in Spring free length 248 mm 9 76 in Spring rate 44 1 N mm 4 50 kg mm 252 0 Ib in 83 4 N mm 8 50 kg mm 476 0 Ib in Stroke 0 58 0 mm 0 2 2
8. 5 623 Apply the locking agent LOCTITE 0 Replace CONTENTS GENERAL INFORMATION epa tures teen Ln x s EORR Cu ud rape da 1 MACHINE IDENTIFICATION iaoiit Prts d Cos oit lt 1 MODEL AMAN DA En RE 1 SPECIFICA TIONS isis pice 2 GENERAL FON 2 MAINTENANCE SPECIFICATIONS 3 Eit cH TREES 3 Silo CTS 5 ELECTRICA ee EN 5 Qe ID Cc c 6 PERIODIC CHECKS AND 11 INTRODUCTIO N Er 11 PERIODIC MAINTENANCE LUBRICATION INTERVALS 11 Sig co 12 ADJUSTING THE REAR BRAKE LIGHT SWITCH 12 ELECTRICAL _ _____ 13 CHECKING TEE SWTO 13 CHECKING THE SWITO 13 CHECKING A SWITCH SHOWN IN THE MANUAL 13 SIGNALS Yo TEM LIU 14 DIAGRAM 14 CHECKING THE SIGNAL SYSTEM rnt iacta 15 YFS200 P 2002 WIRING DIAGRAM MACHINE IDENTIFICATION lt GENERAL INFORMATION MACHINE IDENTIFICATION MODEL LABEL The model label is affixed to the frame This information will be needed to order spare parts GENERAL SPECIFICATIONS SPEC y SPECIFICATIONS GENERAL SPECIFICATIONS Model code number 5KJ8 CDN Europe veil Spark
9. 8 in 58 0 105 0 mm 2 28 4 13 in Optional spring No Brake lever Clutch lever 2 3 0 08 0 12 in at lever pivot Tightening torque Tightening torque raue Parts to be tightened Thread size Remarks i Front arm lower and upper and frame M10 x 1 25 Steering knuckle and ball joint front lower arm M10 x 1 25 Steering knuckle and ball joint front upper arm M10 x 1 25 Footrest M10 x 1 25 Rear bumper M8 x 1 25 ELECTRICAL YFS200 P 2002 Ignition coil Model manufacturer 2JN YAMAHA Minimum spark gap 6 mm 0 24 in Primary coil resistance 0 18 0 28 Q at 20 C 68 F Secondary coil resistance 6 32 9 48 KQ at 20 C 68 F Spark plug cap Type Resin type Resistance 5 CABLE ROUTING SPEC y CABLE ROUTING D Clutch cable 2 Main switch lead 2 Parking brake cable 3 Headlight lead 3 Front brake cable Control unit 4 Throttle switch lead 5 CDI unit 5 Front brake light switch Ground lead 6 Band 07 Voltage regulator 7 Throttle cable Handlebar switch lead left 9 Voltage regulator lead Front brake light switch lead 42 Oil indicator light lead iu WS gt The throttle cable should be routed behind the clutch cable and on the left side of the guide Route all leads behind the cables and through the cable guide Route all leads toward the CDI unit side D The ground and voltage regula tor leads should be routed in
10. ON POOR CONNECTION 5 Wiring connections 71 e Check the connections of the entire lighting System Refer to CIRCUIT DIAGRAM Properly connect the lighting system CORRECT Replace the voltage regulator 16 YFS200 P 2002 WIRING DIAGRAM D CDI magneto 2 Voltage regulator CDi unit l5 4 Ignition coil 5 Spark plug 6 Control unit Throttle switch Carburetor switch 9 Oil indicator light Oil level gauge 0 Main switch 2 Engine stop switch 3 Lights switch gt Headlight 1 5 Tail brake light Rear brake light switch 7 Front brake light switch 9 B 1 GRAY GRAY BLACK BLACK Gly ith A A 06 BLACK BLACK E u 4 4 COLOR CODE B Black B HR Black Red B Brown B W Black White G Green W R White Red Blue Yellow Black Orange Yellow Red Yellow
11. gauge 2 on the cylinder head Esa Joint drive chain Measure the warpage ss Clip drive chain 8 if the warpage is out of specification re NC surface the cylinder head Place 400 600 grit wet sandpaper the surface plate and resurface the head using a figure eight sanding pattern NOTE Rotate the head several times to avoid re moving too much material from one side 55922900920200000950920989000209990900029 TRBL SHTG ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter D General information 2 Specifications 3 Periodic checks and adjustments 2 Engine 5 Carburetion 6 Drive train 7 Chassis Electrical 9 Troubleshooting Illustrated symbols 49 to 46 are used to identify the specifications appearing in the text Filling fluid 17 Lubricant 2 Special tool 43 Torque Wear limit clearance 5 Engine speed Q Illustrated symbols 7 to in the exploded diagrams indicate the types of lubricants and lubrication points 7 Apply engine oil Apply gear oil Apply molybdenum disulfide oil 09 Apply wheel bearing grease 2 Apply lightweight lithium soap base grease 02 Apply molybdenum disulfide grease 03 Apply silicon grease Illustrated symbols 4 to the exploded diagrams indicate where to apply a locking agent 62 and when to install a new part 0
12. hose fender stay Crankcase ventilation hose 4 Parking brake cable 5 Cable guide 6 Rear INTRODUCTION CHK 4o PERIODIC MAINTENANCE LUBRICATION INTERVALS ADJ Qi EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust ments These preventive maintenance procedures if followed will ensure more reliable vehicle operation and a longer service life The need for costly overhaul work will be greatly reduced This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale All service technicians should be familiar with this entire chapter EB30100 PERIODIC MAINTENANCE LUBRICATION INTERVALS Check condition Spark plug Adjust gap and clean Replace if necessary Clean Every 20 40 hours Replace if necessary More often in wet or dusty areas Check idle speed starter operation Adjust if necessary Crankcase breather system Check breather hose for cracks or damage Replace if necessary Check for leakage Exhaust system Retighten if necessary Replace gasket if necessary e Check fuel hose for cracks or damage e Replace if necessary Throttle operation Inspect and adjust free play if necessary 9d o Front brake operation Inspect and adjust free play if necessary E E Front brake shoes Mee bed
13. irection 6 light comes on eeu kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CHECKING THE SWITCH ELEC 2492 ELECTRICAL CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to check the terminals for continuity If the continuity is faulty at any point replace the switch Pocket tester P N YU 03112 90890 03112 NOTE _ _ e Set the pocket tester to 0 before starting the test e pocket tester should be set to the x 1 range when testing the switch for continuity e Turn the switch on and off a few times when checking it 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 OQ indicates the terminals with continuity The example chart shows that There is continuity between the Red and Brown leads when the switch is set to ON E 8 9 l LLI T A A LLI po T vove gt 6880 eap 4 ki UE t T 11 QU 4ov18 6l0v1g Avdo Gp dep T iz Y aN YOUMS 1461 exejq
14. preceded by e IMPORTANT FEATURES e Data and a special tool are framed in a box preceded by a relevant symbol 5 e An encircled numeral 6 indicates a part name and an encircled alphabetical letter data or an alignment mark 2 the others being indicated by an alphabetical letter in a box 8 e A condition of a faulty component will precede an arrow symbol 9 and the course of action will fol low it EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures with each proce 2 INSPECTION AND REPAIR ENG FRONTFORK K K Crankcase separating tool YU 01135 Scratches Bends Damage Replace ds WARNING WARNING 3 Do not attempt to straighten a bent inner fork tube as this may dangerously weaken 9143001 INSPECTION AND REPAIR CYLINDER HEAD 1 Eliminate Ist sea Carbon deposit Use rounded scraper NOTE Take to avoide damaging the spark plug threads D ot use sh instrument 7 Avoid scratching the aluminum 2 Measure Fork spring free length a 5 Cylinder head warpage CINE Out of specification Replace Out of specification Resurface un v Fork spring free length Warpeage limit 418 5 mm 16 5 in 0 02 mm 0 001 in Minimum free length 410 mm 16 1 in Warpage me ment and t ment step 4 Install Attach a straight edge 1 and thickne Drive chain 4 ss
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