2003

AG200F 3GX-AE2

SUPPLEMENTARY
SERVICE MANUAL
 FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
AG200F 2003. For complete service information procedures it is necessary to use this Supplementary
Service Manual together with the following manual.

AG200F ’97 SERVICE MANUAL: 3GX-AE1

EAS00000

AG200F 2003
SUPPLEMENTARY
SERVICE MANUAL
©2002 by Yamaha Motor Co., Ltd.
First Edition, March 2002
All rights reserved.
Any reprinting or unauthorized use with-
out the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS00003

NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of 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.
NOTE:
Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!

w Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person checking or repairing the motorcycle.

cC A CAUTION indicates special precautions that must be taken to avoid damage to

the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

 EAS00009
1 2
SYMBOLS
GEN The following symbols are not relevant to every
SPEC
INFO vehicle.
Symbols 1 to 8 indicate the subject of each
3 4 chapter.
CHK 1 General information
ENG
ADJ 2
3
Specifications
Periodic checks and adjustments
5 6 4 Engine
5 Carburetor(s)
6 Chassis
CARB CHAS 7 Electrical system
8 Troubleshooting
7 8

TRBL
ELEC SHTG
9 0 Symbols 9 to y indicate the following.

9 Serviceable with engine mounted

0 Filling fluid
q Lubricant
w Special tool
q w
e Tightening torque
r Wear limit, clearance
t Engine speed
y Electrical data

e r

t y

Symbols u to s in the exploded diagrams indi-

u i o cate the types of lubricants and lubrication
points.

u Engine oil
i Gear oil
p a s o Molybdenum-disulfide oil
p Wheel-bearing grease
a Lithium-soap-based grease
s Molybdenum-disulfide grease

d f Symbols d to f in the exploded diagrams indi-

cate the following.
LT New
d Apply locking agent (LOCTITE®)
f Replace the part
 CONTENTS
SPECIFICATIONS...................................................................................................1
GENERAL SPECIFICATIONS ..........................................................................1
MAINTENANCE SPECIFICATIONS .................................................................2
CHASSIS .....................................................................................................2
ELECTRICAL...............................................................................................2
TIGHTENING TORQUES ..................................................................................3
ENGINE .......................................................................................................3
CABLE ROUTING.............................................................................................4

PERIODIC CHECKS AND ADJUSTMENTS...........................................................8

INTRODUCTION ...............................................................................................8
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS.......................8

ELECTRICAL ........................................................................................................10
IGNITION SYSTEM .........................................................................................10
CIRCUIT DIAGRAM ..................................................................................10
TROUBLESHOOTING ..............................................................................11

AG200F 2002 WIRING DIAGRAM

 GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model AG200F
Model code: 3GXF
Engine:
Engine type Air-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 0.196 L (196 cm3)
Bore × stroke 67.0 × 55.7 mm
Compression ratio 9.5 : 1
Compression pressure (STD) 900 kPa (9.0 kg/cm2, 130.5 psi) at 1,000 r/min
Starting system Electric and kick starter
Lubrication system: Wet sump
Chassis:
Frame type Diamond
Caster angle 27.42°
Trail 87 mm
Tire:
Type With tube
Size front 80/100-21 51M
rear 4.10-18 59M
Manufacturer front IRC
rear IRC
Type front VE-32
rear FARM SPECIAL - Z2
Tire pressure (cold tire):
Maximum load-except motorcycle 112 kg
Loading condition A * 0~112 kg
(off road riding)
front 120 kPa (1.2 kgf/cm2, 17.4 psi)
rear 150 kPa (1.5 kgf/cm2, 21.8 psi)
Electrical:
Ignition system DC-CDI
Generator system AC magneto
Battery type GT6B-3
Battery capacity 12V 6 Ah
*Load is the total weight of cargo, rider, passenger, and accessories.

–1–
 MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
CHASSIS
Item Standard Limit
Rear suspension:
Shock absorber stroke 82 mm •••
Spring free length 279 mm 276 mm
Fitting length 265 mm •••
Spring rate (K1) 44.3 N/mm (4.52 kg/mm) •••
(K2) 70.8N/mm (7.22 kg/mm) •••
Stroke (K1) 0 ~ 42 mm •••
(K2) 42 ~ 82 mm •••
Drive chain:
Type/manufacturer 428HG/DAIDO •••
No. of links 122 •••
Chain free play 30~45 mm •••

ELECTRICAL

Item Standard Limit

CDI:
CDI magneto model/manufacturer 3GX/YAMAHA •••
Pickup coil resistance/color 656~984 Ω at 20°C/ •••
Red — White
Ignition coil:
Model/manufacturer 2JN/YAMAHA •••
Minimum spark gap 6 mm •••
Primary winding resistance 0.24~0.36 Ω at 20°C •••
Secondary winding resistance 5.68~8.52 kΩ at 20°C •••
Charging system:
Type CDI magneto •••
Model/manufacturer F5MP/YAMAHA •••
Standard output 14 V, 175W @5,000 r/min •••
Stator coil resistance/color 0.56~0.84 Ω at 20°C/ •••
White — White •••
Rectifier/regulator:
Model/manufacturer SH629A-12/SHINDENGEN •••
Type (regulator) Semi conductor - short circuit type •••
No load regulated voltage 14.1~14.9 V •••
Capacity (rectifier) 10 A •••
Withstand voltage 200 V •••

–2–
 MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Electric starter system:
Type Constant mesh type
Starter motor:
Model/manufacturer 4JG/YAMAHA •••
Output 0.4 kW •••
Armature coil resistance 0.0126~0.0154 Ω at 20°C •••
Brush overall length 10 mm 3.5 mm
Brash spring pressure 5.52~8.28 N (563~844g) •••
Starter relay:
Model/manufacturer MS5F-431/JIDECO •••
Amperage rating 180 A •••
Coil winding resistance 4.18~4.62 Ω at 20°C •••
Flasher relay:
Type Full transistor type •••
Model/manufacturer FE218BH/DENSO •••
Flasher frequency 75~95 cycle/min •••

TIGHTENING TORQUES
ENGINE
Tightening
Thread torque
Part to be tightened Part name Q’ty Remarks
size
Nm m•kg
Carburetor joint and carburetor Bolt M6 2 12 1.2

–3–
 CABLE ROUTING SPEC
EAS00035

CABLE ROUTING
1 Clutch cable å Pass the throttle cable behind pler, speedometer lead and
2 Cable guide the main switch. front turn signal light lead (left).
3 Front brake cable ∫ Clamp the handlebar switch ´ Insert the front fork breather
4 Throttle cable lead and the front brake switch hose into the headlight body
5 Front brake switch lead lead. under hole.
6 Clutch switch lead ç Clamp the handlebar switch ƒ To the headlight.
7 Clamp lead and the clutch lead.
∂ From the left, front turn signal
light lead (right), handlebar
switch lead (right), main switch
lead, auxiliary DC terminal cou-

2 3
1
4
å

ç ∂
∫
5
6

–4–
 CABLE ROUTING SPEC
1 High-tension cord å Tighten with the ignition coil and ƒ Clamp the battery positive lead
2 Ignition coil the earth lead. (bypass from the and wireharness.
3 Ignition coil lead (primary side) wireharness) © Insert the fuse holder into the
4 Starting motor lead ∫ Clamp the wireharness and the guard flap projection.
5 Breather hose starting motor lead behind the
6 Magneto lead air cleaner duct.
7 Over flow hose ç To the regulator earth lead.
8 Rectifier/regulator lead ∂ Black coupler. (to the regulator
9 Brake switch lead coupler)
0 Battery positive lead ´ White coupler. (to the starter
q Starter relay lead relay)
w Wireharness
e Battery negative lead

2
1

A
3

4
5
6
7 0
ƒ
w
ç ∂
0
8 9
∫ ©

9
4
e
´ q

–5–
 CABLE ROUTING SPEC
1 Starter (choke) cable å Clamp the throttle cable, starter ∂ Clamp the wireharness, CDI
2 Handlebar switch lead (choke) cable and handlebar unit lead, magneto (pickup coil)
3 Throttle cable switch lead (left). lead and starting motor lead.
4 Starter circuit cut-off relay ∫ Clamp the wireharness, CDI ´ Align the location tape with the
5 CDI unit unit lead, magneto (pickup coil) seat pillar tube.
6 CDI unit lead lead, magneto (charge, neutral) ƒ Clamp the magneto (pickup
7 Starting motor lead lead and throttle cable coupler coil) lead, magneto (charge,
8 Magneto lead (charge, neutral) with front and rear by the band. neutral) lead and starting motor
9 Magneto lead (pickup coil) ç Clamp the wireharness, CDI lead.
0 Cable guide unit lead, magneto (pickup coil)
lead, magneto (charge, neutral)
lead and throttle cable coupler
with front and rear by the band.

3 å
2
4
1
5
6
µ
0¬

∫
˚ ç

© ∂

˙ ´
ˆ 9
8 7 ƒ

–6–
 CABLE ROUTING SPEC
© Pass the wireharness to the far- ˚ Pass the starter (choke) cable
thest left side. and handlebar switch lead
˙ Clamp the wireharness, CDI through the outside of the cable
unit lead, magneto lead, throttle guide.
cable, and starter (choke) cable ¬ Pass the throttle cable and
on the center of the engine clutch cable (under side) into
mount stay. the cable guide .
ˆ Clamp the wireharness. µ Pass the starter (choke) cable
∆ Clamp the handlebar switch in front of the throttle cable and
lead and clutch cable. clutch cable.

3 å
2
4
1
5
6
µ
0¬

∫
˚ ç

© ∂

˙ ´
ˆ 9
8 7 ƒ

–7–
 INTRODUCTION/ CHK
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ADJ
EAS00036

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer
service life and reduce the need for costly overhaul work. 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.
EAS00037

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

ODOMETER READING (× 1,000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24 CHECK
1 * Fuel line • Check fuel hoses for cracks or damage. √ √ √ √ √
• Check condition.
√ √
2 Spark plug • Clean and regap.
• Replace. √ √
• Check valve clearance.
3 * Valves √ √ √ √
• Adjust.
• Clean. √ √
4 Air filter element
• Replace. √ √
• Check operation.
5 Clutch √ √ √ √ √
• Adjust.
• Check operation and adjust brake lever free play. √ √ √ √ √ √
6 * Front brake
• Replace brake shoes. Whenever worn to the limit
• Check operation and adjust brake pedal free play. √ √ √ √ √ √
7 * Rear brake
• Replace brake shoes. Whenever worn to the limit
• Check runout, spoke tightness and for damage.
8 * Wheels √ √ √ √
• Tighten spokes if necessary.
• Check tread depth and for damage.
• Replace if necessary.
9 * Tires √ √ √ √ √
• Check air pressure.
• Correct if necessary.
10 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √
• Check operation and for excessive play. √ √ √ √
11 * Swingarm
• Lubricate with lithium-soap-based grease. Every 24,000 km
• Check chain slack.
Every 500 km and after washing
12 Drive chain • Make sure that the rear wheel is properly aligned.
the motorcycle or riding in the rain
• Clean and lubricate.
• Check bearing play and steering for roughness. √ √ √ √ √
13 * Steering bearings
• Lubricate with lithium-soap-based grease. Every 24,000 km
• Make sure that all nuts, bolts and screws are properly
14 * Chassis fasteners √ √ √ √ √
tightened.
• Check operation.
15 Sidestand √ √ √ √ √
• Lubricate.
16 * Front fork • Check operation and for oil leakage. √ √ √ √
Shock absorber
17 * • Check operation and shock absorber for oil leakage. √ √ √ √
assembly
• Check starter (choke) operation.
18 * Carburetor √ √ √ √ √ √
• Adjust engine idling speed.
• Change.
19 Engine oil √ √ √ √ √ √
• Check oil level and vehicle for oil leakage.
Engine oil filter
20 • Clean. √ √ √
element

*: It is recommended that these items be serviced by a Yamaha dealer.

–8–
 CHK
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ADJ
ODOMETER READING (× 1,000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24 CHECK
21 * Engine oil strainer • Clean. √
Front and rear brake
22 * • Check operation. √ √ √ √ √ √
switches
Moving parts and
23 • Lubricate. √ √ √ √ √
cables
• Check operation and free play.
Throttle grip housing
24 * • Adjust the throttle cable free play if necessary. √ √ √ √ √
and cable
• Lubricate the throttle grip housing and cable.
Lights, signals and • Check operation.
25 * √ √ √ √ √ √
switches • Adjust headlight beam.

*: It is recommended that these items be serviced by a Yamaha dealer.

NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

–9–
 t
r
e
w
0
7
6
5
3
1
EAS00734

Br B Or
W/R W/L L/Y

Battery

CDI unit
(B)

Spark plug
Ignition coil
W/L W/R R W

Main switch
1
Sb

CDI magneto
W/R W/R PU+
W/L W/L PU- e
W W W W L/Y STOP
W W Br +V

Positive wire lead

Rectifier regulator
IGN Or Or

Negative wire lead

Engine stop switch

GND
r
CIRCUIT DIAGRAM

W W W
B
2
IGNITION SYSTEM

B
R L/Y L/Y t
W W W R 0 q w
B/W B B B/W OFF FREE RUN R/W R/W L/Y B
Br R R Br ON PUSH OFF L/W B L/Y R/W
W W (R) (R)
R W 3
(B) Br
B R/W B

5 R R R
4
B R
B B 6 R
R/W L/W

20A
8R
L/W
B B

B B B R/W
B Sb

7 i
B Br

– 10 –
9 Br Br B
Br
B B
s L/W
a p B/Y
P Br d
ELECTRICAL

Br/W
Br Br B
B/Y
Y B

P o
Br/W Y
B
R B
P Br L Br/W B
(G)
h j l
OFF OFF B
k HIGH L

10A
f ON ON LOW NL
NR
R

Br Br/W Y Dg
P
IGNITION SYSTEM

P L B G Ch

Y G Ch Dg
Dg Y Br/W Br
P Ch G B L P
Y G Ch Ch Dg Dg Y L
B

g
ELEC

B c x z
b v ;
B B B B B B B
 IGNITION SYSTEM ELEC
EAS00736 EAS00739

TROUBLESHOOTING 2. Battery
The ignition system fails to operate (no 9Check the condition of the battery.
spark or intermittent spark). Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3.
Check:
Minimum open-circuit voltage
1. Main fuse
12.8 V or more at 20 °C (68 °F)
2. Battery
3. Spark plug 9Is the battery OK?
4. Ignition spark gap
5. Spark plug cap resistance YES NO
6. Ignition coil resistance
7. Main switch 9Clean the battery 9Recharge or
8. Engine stop switch terminals. replace the bat-
9. Pickup coil resistance tery.
10.Wiring connections (of the entire ignition sys- EAS00740

tem)
3. Spark plug
NOTE: 9Check the condition of the spark plug.
9Before troubleshooting, remove the following 9Check the spark plug type.
part(s): 9Measure the spark plug gap.
1.Headlight unit Refer to “CHECKING THE SPARK PLUG” in
2.Seat chapter 3.
3.Fuel tank Standard spark plug
9Troubleshoot with the following special tool(s). D8EA (NGK)
X24ES-U (DENSO)
Spark plug gap
Ignition checker: 0.6 ~ 0.7 mm
90890-06754
9Is the spark plug in good condition, is it of
Pocket tester:
the correct type, and is its gap within specifi-
90890-03112
cation?
EAS00738

1. Main fuse YES NO

9Check the main fuse for continuity. Re-gap or replace

Refer to “CHECKING THE FUSES” in chap- the spark plug.
ter 3.
9Is the main fuse OK?

YES NO

Replace the fuse (s).

– 11 –
 IGNITION SYSTEM ELEC
EAS00743
Spark plug cap resistance
4. Ignition spark gap 10 kΩ at 20°C (68°F)
The following procedure applies to all of the 9Is the spark plug cap OK?
spark plug.
9Disconnect the spark plug cap from the
YES NO
spark plug.
9Connect the ignition checker 1 as shown. Replace the spark
2 Spark plug cap plug cap.
9Set the main switch to “ON”.
EAS00746
9Measure the ignition spark gap a.
9Crank the engine by pushing the starter 6. Ignition coil resistance
switch or kicking the kick starter and gradu- 9Disconnect the ignition coil connectors from
ally increase the spark gap until a misfire the ignition coil terminals.
occurs. 9Connect the pocket tester (Ω x 1) to the igni-
tion coil as shown.
Positive tester probe → orange 1
Negative tester probe → ground 2

a 1 2
1

Minimum ignition spark

6 mm
9Is there a spark and is the spark gap within
specification? 9 Measure the primary coil resistance.

YES NO Primary coil resistance

0.24 ~ 0.36 Ω at 20°C (68°F)
The ignition system 9Connect the pocket tester (Ω x 1k) to the
is OK. ignition coil as shown.
EAS00744
Positive tester probe → spark plug lead 1
5. Spark plug cap resistance Negative tester probe → spark plug lead 2
9Remove the spark plug cap from the spark
plug lead. 2
9Connect the pocket tester (“Ω x 1k” range) to
the spark plug cap as shown.
9Measure the spark plug cap resistance.
1

– 12 –
 IGNITION SYSTEM ELEC

9Measure the secondary coil resistance. 9Measure the pickup coil resistance.

Secondary coil resistance Pickup coil resistance

5.68 ~ 8.52 kΩ at 20°C (68°F) 656 ~ 984 Ω at 20°C (68°F)
(between red and white)
9Is the ignition coil OK?
9Is the pickup coil OK?
YES NO
YES NO
Replace the ignition
coil. Replace the pick up
EAS00749 coil.
EAS00754
7. Main switch
10. Wiring
9Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”. 9Check the entire ignition system’s wiring.
9Is the main switch OK? Refer to “CIRCUIT DIAGRAM”.
9Is the ignition system’s wiring properly con-
YES NO nected and without defects?

Replace the main YES NO

switch.
EAS00750 Replace the CDI Properly connect or
unit. repair the ignition
8. Engine stop switch
system’s wiring.
9Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
9Is the engine stop switch switch OK?

YES NO

Replace the right

handlebar switch.
EAS00748

9. Pickup coil resistance

9Disconnect the pickup coil coupler from the
wire harness.
9Connect the pocket tester (Ω x 100) to the
pickup coil terminal as shown.

1
2

Positive tester probe → red 1

Negative tester probe → white 2

– 13 –
 YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
AG200F 2002 WIRING DIAGRAM
1 CDI magneto
2 Neutral switch
Br B Or
3 Rectifier regulator
W/R W/L L/Y 4 Fuse (20A)
(B)
5 Positive wire lead
6 Battery
W/L W/R R W 7 Negative wire lead
Sb 8 Starter relay
W/R W/R PU+
W/L W/L PU-
9 Starting motor
W W W W L/Y STOP 0 Main switch
W W Br +V
IGN Or Or q Start switch
GND w Engine stop switch
W W W
B
e CDI unit
r Ignition coil
B
R L/Y L/Y t Spark plug
y Meter light
W W W R
u Neutral indicator light
B/W B B B/W OFF FREE RUN R/W R/W L/Y B i Neutral relay
R Br ON PUSH OFF L/Y
Br R L/W B R/W
o Clutch switch
(R) (R)
W W
R W
p Rear brake switch
(B) Br
a Front brake switch
B R/W B
s Flasher relay
L d Horn
R R R
f Fuse (auxiliary DC terminal)
B
R R
R g Auxiliary DC terminal socket
B B 20A R/W L/W Br
Sb
h Horn switch
L/W j Lights switch
B B
Br Sb
k Dimmer switch
B L/W l Turn signal switch
B
B B
B
R/W Sb (B) ; Tail/Brake light
B z Rear turn signal light (right)
Sb Br
L B
x Front turn signal light (right)
B Br
(B) c Rear turn signal light (left)
v Front turn signal light (left)
Br Br B b Headlight
Br
B B B/Y L/W
L/W Sb Br
B/Y
COLOR CODE
P Br
Br/W
B...................Black
Br Br B Br .................Brown
B/Y
Y B Ch ................Chocolate
P
Dg ................Dark green
Br/W Y G ..................Green
B
R B B/Y L ...................Blue
P Br L Br/W B B O ..................Orange
(G)
Sb.................Sky blue
P...................Pink
10A OFF OFF HIGH L B
ON ON LOW NL
R ..................Red
NR Y...................Yellow
R W..................White
P
Br Br/W Y Dg B/W ..............Black/White
P L B G Ch
B/Y ...............Black/Yellow
Y G Ch Dg Br/W .............Brown/White
Dg Y Br/W Br
Ch G B L P
L/W...............Blue/White
P
Y G Ch Ch Dg Dg Y L L/Y................Blue/Yellow
B R/W ..............Red/White
W/L...............White/Blue
W/R ..............White/Red

MARK EXPLANATION
R,Br,Br/W, COLOR CORD
CONNECTING WITH GND.WIRE B B B B B B B
GND.