2012

SUPPLEMENTARY
SERVICE MANUAL

AG200F/FE(B)

3GX-28197-E4
 FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for
the AG200F/FE(B) 2012. For complete service information procedures it is necessary to use this
Supplementary Service manual together with the following manual.

AG200F 1997 SERVICE MANUAL: 3GX-AE1

AG200F 2003 SUPPLEMENTARY SERVICE MANUAL: 3GX-AE2
AG200F/FE 2008 SUPPLEMENTARY SERVICE MANUAL: 3GX-28197-E3

EAS00000

AG200F/FE(B) 2012
SUPPLEMENTARY
SERVICE MANUAL
©2011 by Yamaha Motor Co., Ltd.
First edition, October, 2011
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
 IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic
in one manual. 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 knowl-
edge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in
regard to performance and emissions. Proper service with the correct tools is necessary to ensure
that the vehicle will operate as designed. If there is any question about a service procedure, it is
imperative that you contact a Yamaha dealer for any service information changes that apply to this
model. This policy is intended to provide the customer with the most satisfaction from his vehicle
and to conform to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha
dealers and will appear in future editions of this manual where applicable.

TIP
9 This Service Manual contains information regarding periodic maintenance to the emission con-
trol system. Please read this material carefully.
9 Designs and specifications are subject to change without notice.

IMPORTANT MANUAL INFORMATION

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

This is the safety alert symbol. It is used to alert you to potential per-
sonal injury hazards. Obey all safety messages that follow this sym-
bol to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided,

WARNING
could result in death or serious injury.

NOTICE A NOTICE indicates special precautions that must be taken to avoid

damage to the vehicle or other property.

TIP A TIP provides key information to make procedures easier or clearer.

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic.
Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check
procedures are laid out with the individual steps in sequential order.

1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.

2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)
appears.

3 Sub-section titles appear in smaller print than the section title.

4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.

5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates
a disassembly step.

6 Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.

8 Jobs requiring more information (such as special tools and technical data) are described
sequentially.
2 1 3

8
5

6 6

7
 EAS00009
1 2
SYMBOLS
GEN The following symbols are not relevant to
SPEC
INFO every vehicle.
Symbols 1 to 8 indicate the subject of each
3 4 chapter.
CHK 1 General information
ENG
ADJ 2 Specifications
3 Periodic checks and adjustments
5 6 4 Engine
5 Carburetor(s)
CARB CHAS 6 Chassis
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
q w w Special tool
e Tightening torque
r Wear limit, clearance
t Engine speed
y Electrical data
e r

t y

Symbols u to f in the exploded diagrams

u i o p
indicate the types of lubricants and lubrication
points.
E G M BF
u Engine oil
i Gear oil
a s d f
o Molybdenum-disulfide oil
B LS M S p Brake fluid
a Wheel-bearing grease
s Lithium-soap-based grease
g h d Molybdenum-disulfide grease
f Silicone grease
Symbols g and h in the exploded diagrams
indicate the following.
g Apply locking agent (LOCTITE®)
h Replace the part
 CONTENTS
SPECIFICATIONS ………………………………………………………………… 1
GENERAL SPECIFICATIONS … …………………………………………… 1
ENGINE SPECIFICATIONS … ……………………………………………… 1
ELECTRICAL SPECIFICATIONS …………………………………………… 1
TIGHTENING TORQUES … ………………………………………………… 2
ENGINE … ………………………………………………………………… 2
CHASSIS …………………………………………………………………… 2
CABLE ROUTING … ………………………………………………………… 3

PERIODIC CHECKS AND ADJUSTMENTS … ……………………………… 10

PERIODIC MAINTENANCE … ……………………………………………… 10
INTRODUCTION … ……………………………………………………… 10
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM … ………………………………………………… 10
GENERAL MAINTENANCE AND LUBRICATION CHART …………… 11
ADJUSTING THE THROTTLE CABLE … ……………………………… 13

CARBURETOR …………………………………………………………………… 15
CARBURETOR ……………………………………………………………… 15

AG200F/FE(B) 2012 WIRING DIAGRAM

GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS/
ELECTRICAL SPECIFICATIONS SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Model AG200F/FE(B)
Model code AG200F: 53C9 (ZAF)(GTM)(CIV)
53CC (PER)
AG200FE: 53C8 (ZAF)(GTM)(CIV)
53CB (PER)
AG200FEB: 53CA (AUS)

Weight
With oil and fuel AG200F: 126 kg (278 lb)
AG200FE(B): 128 kg (282 lb)

ENGINE SPECIFICATIONS
Item Standard
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 (2.64 × 2.19 in)
Compression ratio 9.50 : 1
Standard compression pressure 900 kPa (9.0 kg/cm2, 128.0 psi) at 1000 r/min
(at sea level)
Starting system AG200F: Kickstarter
AG200FE(B): Electric and kickstarter

ELECTRICAL SPECIFICATIONS
Item Standard
Voltage
System voltage 12 V

Ignition system
Ignition system DC CDI
Advancer type Digital
Ignition timing (B.T.D.C.) 9.0°/1300 r/min

Battery
Model YTZ7S
Voltage, capacity 12 V, 6.0 Ah
Specific gravity 1.31
Manufacturer GS YUASA
Ten hour rate amperage 0.6 A

–1–
 TIGHTENING TORQUES SPEC
TIGHTENING TORQUES
ENGINE

Thread Tightening torque

Part to be tightened Part name Q’ty Remarks
size Nm m•kg ft•lb

Air filter case and frame Bolt M6 2 7 0.7 5.1

Throttle cable locknut (carburetor side) Nut M6 2 4 0.4 2.9

CHASSIS

Thread Tightening torque

Part to be tightened Part name Q’ty Remarks
size Nm m•kg ft•lb

Throttle cable locknut (handlebar side) Nut M6 2 2.8 0.28 2.0

–2–
 CABLE ROUTING SPEC
EAS00035

CABLE ROUTING
1 Clutch cable A Clamp the throttle cable, D Clamp the handlebar switch
2 Cable guide clutch cable, and handlebar lead and clutch switch lead.
3 Front brake cable switch lead. Cut off the excess E Clamp the front turn signal
4 Throttle cable end of the plastic locking tie to light lead (right) at the right
5 Starter (choke) cable 5–7 mm (0.20–0.28 in). end hole in the handle crown.
6 Front brake switch lead B Pass the throttle cable behind Cut off the excess end of the
7 Clutch switch lead the main switch. plastic locking tie to 5–7 mm
8 Clamp C Clamp the handlebar switch (0.20–0.28 in).
9 Throttle cable housing lead and front brake switch
lead.

–3–
 CABLE ROUTING SPEC
F From the left, front turn sig- I Pass the starter (choke) cable L Apply lithium-soap-based
nal light lead (right), handle- to the inside of the front turn grease to the installation area
bar switch lead (right), main signal light lead, front brake of the throttle cable and throt-
switch lead, auxiliary DC ter- switch lead, and clutch switch tle grip assembly.
minal lead, speedometer lead, lead. M Install the protrusion in the
and front turn signal light lead J Decelerator side. handle side hole.
(left). K Apply lithium-soap-based N Accelerator side.
G Insert the front fork breather grease to the inside of the
hose into the hole under the throttle grip assembly.
headlight body.
H To the headlight.

–4–
 CABLE ROUTING SPEC
1 Decompression cable w Protector d Fuse box (kickstarter model)
2 High-tension cord e Battery positive lead f Rectifier/regulator
3 Ignition coil r Rear carrier
4 Ignition coil lead t Plastic locking tie
(primary side) y Clamp
5 Starting motor lead u Rear turn signal light lead
6 Breather hose (right)
7 Magneto lead i Rear turn signal light lead (left)
8 Over flow hose o Clamp
9 Protector p Clamp
0 Clamp (plastic locking tie) a Clamp
q Clamp s Wire harness

–5–
 CABLE ROUTING SPEC
A Tighten with the ignition coil D Align the end of the protector
and earth lead. as shown in the illustration.
B Place the hole with slit in the E Assemble the protector and
protector on the side cover clamp (plastic locking tie) as
installation rivet (kickstarter shown in the illustration.
model). F Insert it to the end so that it is
C Place the end of the clamp securely fitted.
(plastic locking tie) between G Cut off the excess end of the
the decompression cable and plastic locking tie to 5–7 mm
the frame, pointing inward. (0.20–0.28 in), and then point
the end inward.

–6–
 CABLE ROUTING SPEC
1 Starter (choke) cable w Rectifier/regulator lead D Clamp the wire harness, mag-
2 Clutch cable e Brake switch lead neto lead (pickup coil), and
3 Throttle cable r Battery positive lead magneto lead (charge, neu-
4 Handlebar switch lead t Starter relay lead tral) so that the wire harness
5 Starter circuit cut-off relay y Starting motor lead is the farthest left side.
6 CDI unit Clamp them at the both side
7 Starting motor lead A Clamp the throttle cable, start- of the couplers and point the
8 Magneto lead er (choke) cable, and handle- end of the plastic locking tie
(charge, neutral) bar switch lead (left). inward.
9 Magneto lead (pickup coil) B 30 mm (1.18 in).
0 Cable guide C Clamp the throttle cable and
q Clamp starter (choke) cable.

–7–
 CABLE ROUTING SPEC
E Clamp the wire harness and G Clamp the magneto (pickup H Clamp the wire harness, and
starting motor lead (electric coil) lead, magneto (charge, starter (choke) cable on the
and kickstarter model). neutral) lead, and starting center of the engine mount
Clamp the wire harness (kick- motor lead. Point the end of stay. Point the end of the plas-
starter model). the plastic locking tie inward tic locking tie inward.
F Align the location tape with (electric and kickstarter model). I Clamp the wire harness and
the seat pillar tube. Clamp the magneto (pickup starter (choke) cable. Point
coil) lead, and magneto the end of the plastic locking
(charge, neutral) lead. Point tie inward.
the end of the plastic locking J Clamp the handlebar switch
tie inward (kickstarter model). lead and clutch cable.

–8–
 CABLE ROUTING SPEC
K Pass the throttle cable, han- O To the regulator earth lead.
dlebar switch lead, and clutch P Connect the black coupler (to
cable (under side) through the the regulator coupler).
cable guide. Q Connect the white coupler (to
L Pass the starter (choke) cable the starter relay).
outside the cable guide. R Clamp the wire harness and
M Electric and kickstarter model. starting motor lead.
N Clamp the regulator earth Point the end of the plastic
lead and regulator lead. Point locking tie inward.
the end of the plastic locking S Kickstarter model.
tie inward.

–9–
 CHK
PERIODIC MAINTENANCE ADJ
PERIODIC CHECKS AND ADJUSTMENTS
EAS20450

PERIODIC MAINTENANCE
EAS20460

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjust-
ments. 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.

EAU46920

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

TIP
9 The annual checks must be performed every year, except if a kilometer-based mainte-
nance, or for the UK, a mileage-based maintenance, is performed instead.
9 From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi).
9 Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.

ODOMETER READING
ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB 1000 km 6000 km 12000 km 18000 km 24000 km CHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)

1 * Fuel line 9 Check fuel hoses for cracks or damage. √ √ √ √ √

9 Check condition.
√ √
2 Spark plug 9 Clean and regap.
9 Replace. √ √
9 Check valve clearance.
3 * Valves √ √ √ √
9 Adjust.
9 Check starter (choke) operation.
4 * Carburetor √ √ √ √ √ √
9 Adjust engine idling speed.

–10–
 CHK
PERIODIC MAINTENANCE ADJ
EAU17717

GENERAL MAINTENANCE AND LUBRICATION CHART

TIP
9 The annual checks must be performed every year, except if a kilometer-based mainte-
nance, or for the UK, a mileage-based maintenance, is performed instead.
• From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi).
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.

ODOMETER READING
ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1000 km 6000 km 12000 km 18000 km 24000 km CHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
9 Clean.
1 Air filter element √ √ √ √
9 Replace if necessary.
9 Check operation.
2 Clutch √ √ √ √ √
9 Adjust.
9 Check operation and adjust brake lever
√ √ √ √ √ √
3 * Front brake free play.
9 Replace brake shoes. Whenever worn to the limit
9 Check operation and adjust brake pedal
√ √ √ √ √ √
4 * Rear brake free play.
9 Replace brake shoes. Whenever worn to the limit
9 Check runout, spoke tightness and for
5 * Wheels damage. √ √ √ √ √
9 Tighten spokes if necessary.
9 Check tread depth and for damage.
9 Replace if necessary.
6 * Tires √ √ √ √ √
9 Check air pressure.
9 Correct if necessary.
9 Check bearing for looseness or
7 * Wheel bearings √ √ √ √
damage.
9 Check operation and for excessive play. √ √ √ √
8 * Swingarm 9 Lubricate with lithium-soap-based
Every 24000 km (14000 mi)
grease.
9 Check chain slack, alignment and
condition. Every 500 km (300 mi) and after washing the motorcycle,
9 Drive chain
9 Adjust and thoroughly lubricate chain riding in the rain or riding in wet areas
with engine oil.
9 Check bearing play and steering for
√ √ √ √ √
roughness.
10 * Steering bearings
9 Lubricate with lithium-soap-based
Every 24000 km (14000 mi)
grease.
9 Make sure that all nuts, bolts and
11 * Chassis fasteners √ √ √ √ √
screws are properly tightened.
Brake lever pivot 9 Lubricate with lithium-soap-based
12 √ √ √ √ √
shaft grease.
Brake pedal pivot 9 Lubricate with lithium-soap-based
13 √ √ √ √ √
shaft grease.
Clutch lever pivot 9 Lubricate with lithium-soap-based
14 √ √ √ √ √
shaft grease.
9 Check operation.
15 Sidestands √ √ √ √ √
9 Lubricate.
16 * Front fork 9 Check operation and for oil leakage. √ √ √ √
Shock absorber 9 Check operation and shock absorber
17 * √ √ √ √
assembly for oil leakage.
9 Change.
18 Engine oil 9 Check oil level and vehicle for oil √ √ √ √ √ √
leakage.

–11–
 CHK
PERIODIC MAINTENANCE ADJ
ODOMETER READING
ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1000 km 6000 km 12000 km 18000 km 24000 km CHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
Engine oil filter
19 9 Clean. √ √ √
element
20 * Engine oil strainer 9 Clean. √
Front and rear
21 * 9 Check operation. √ √ √ √ √ √
brake switches
Moving parts and
22 9 Lubricate. √ √ √ √ √
cables
9 Check operation.
9 Check throttle grip free play, and adjust
23 * Throttle grip √ √ √ √ √
if necessary.
9 Lubricate cable and grip housing.
Lights, signals 9 Check operation.
24 * √ √ √ √ √ √
and switches 9 Adjust headlight beam.

EAU18690

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

–12–
 CHK
PERIODIC MAINTENANCE ADJ
ADJUSTING THE THROTTLE CABLE
1. Check:
9 Throttle cable
Damage/deterioration → Replace.
9 Throttle cable installation
Incorrect → Reinstall the throttle cable.
Refer to “HANDLEBAR” on 3GX-AE1 in
chapter 6.

2. Check:
9 Throttle grip movement
Rough movement → Lubricate or replace
the defective part(s).

Recommended lubricant
Suitable cable lubricant

TIP
With the engine stopped, turn the throttle
grip slowly and release it. Make sure that the
throttle grip turns smoothly and returns prop-
erly when released.
Repeat this check with the handlebar turned
all the way to the left and right.

3. Check:
9 Throttle grip free play a
Out of specification → Adjust.

Throttle grip free play

3.0–5.0 mm (0.12–0.20 in)

–13–
 CHK
PERIODIC MAINTENANCE ADJ
4. Adjust:
9 Throttle grip free play
b 3
2 TIP
1
Prior to adjusting the throttle grip free play,
the engine idling speed should be adjusted.
a
qqqqqqqqqqqqqqqqqqqqqqqqqqq
Handlebar side
a. Slide back the rubber cover 1.
b. Loosen the locknut 2.
c. Turn the adjusting nut 3 in direction a or
b until the specified throttle grip free play
is obtained.

Direction a
Throttle grip free play is increased.
Direction b
Throttle grip free play is decreased.
d. Tighten the locknut.
2.8 Nm (0.28 m·kg, 2.0 ft·lb)

e. Slide the rubber cover to its original po-

sition.
TIP
Make sure that the adjusting nut is covered
completely by the rubber cover.

WARNING
After adjusting the throttle grip free play,
start the engine and turn the handlebar to
the right or left to ensure that this does
not cause the engine idling speed to
change.



–14–
 CARBURETOR CARB

CARBURETOR
CARBURETOR

7 Nm (0.7 m•kg, 5.1 ft•lb)

4 Nm (0.4 m•kg, 2.9 ft•lb)

3

4
2

Order Job/Parts to remove Q’ty Remarks

Removing the carburetor Remove the parts in the order listed.
Side cover (left)
Refer to “SIDE COVER, SEAT AND FUEL
Seat
TANK” on 3GX-AE1 in chapter 3.
Fuel tank
Cover (air filter joint) TIP
Air filter case Remove the cover from the pin of the
frame and slide back the air filter case.

1 Throttle cable 1
2 Carburetor joint clamp screw 1 Loosen.
3 Air filter joint clamp screw 1 Loosen.
4 Starter (choke) cable 1
5 Carburetor assembly 1
For installation, reverse the removal
procedure.

–15–
 CARBURETOR CARB

–16–
WIRING DIAGRAM
AG200F/FE(B) 2012 COLOR CODE

1 CDI magneto % Rear turn signal light (left) B Black

2 Neutral switch ^ Front turn signal light (left) Br Brown
3 Rectifier/regulator & Joint 4 Ch Chocolate
4 Sub lead wire * Headlight Dg Dark green
5 Kickstarter model ( Joint 2 G Green
6 Electric and kickstarter model ) Joint 1 L Blue
7 Battery positive lead Q Joint 3 O Orange
8 Battery Sb Sky blue
9 Battery negative lead P Pink
0 Starter relay R Red
q Starting motor Y Yellow
w Main switch W White
e Joint 10 B/W Black/White
r Joint 8 B/Y Black/Yellow
t Joint 9 Br/W Brown/White
y Joint 7 L/W Blue/White
u Right handlebar switch L/Y Blue/Yellow
(electric and kickstarter model) R/W Red/White
i Start switch W/L White/Blue
o Engine stop switch W/R White/Red
p Right handlebar switch
(kickstarter model)
a CDI unit
s Ignition coil
d Spark plug
f Joint 5
g Meter light
h Neutral indicator light
j Neutral relay
k Clutch switch
l Rear brake switch
; Joint 6
z Front brake switch
x Flasher relay
c Horn
v Fuse (auxiliary DC terminal)
b Turn signal switch
n Dimmer switch
m Headlight switch
, Horn switch
. Auxiliary DC terminal socket
/ Tail/Brake light
! Joint 12
@ Joint 11
# Rear turn signal light (right)
$ Front turn signal light (right)
AG200F/FE(B) 2012
WIRING DIAGRAM

W/L W/R R W
Sb

Br B O
W/R W/R W/R W/L L/Y
PU+
W/L W/L PU-
(B)
W W W W B GND
W W Br +V
IGN O O

W W W L/Y L/Y L/Y STOP

B
R

B/W B B B/W L/Y L/Y

Br R R Br OFF
W W W R ON
(R) (R)

FREE RUN R/W R/W L/Y B RUN B B

W W R R R PUSH OFF L/W B L/Y R/W OFF
R W Br
(B) R
B R R
20A R/W L/W
R/W B
L/W
B
B

B B
B B B R/W
B Br

B L L
L
B L
Br
Br
Br Br Sb Sb Br
B L/W L B

R B B (B) (B)
Br
Sb
Br Sb
Br
B
R
20A
Br Br
Br
Br

R B Br B/Y L/W
L/W Sb Br
R B
B/Y
Br Br Br

B B/Y
10A P Br Br B
Br/W B B
Br Y B
(G)

Y B
P P Br L Br/W B

OFF OFF HIGH L

P ON ON LOW NL
NR Y
R
Br Br/W Y Dg
P L B G Ch
Y
B
Dg Y Br/W Br Y G Ch Dg
Ch G B L P

B
Ch Dg

Ch Ch Dg Dg Y L

B B

B B B
B B B

B B B

B B B B B B B B

B B
B
MARK EXPLANATION
R,Br,Br/W, COLOR CORD
GND.
AG200F/FE(B) 2012
WIRING DIAGRAM

PU+
PU-
(B)
GND
+V
IGN

STOP

OFF
ON
(R) (R)

FREE RUN RUN

PUSH OFF OFF

(B)
20A

(B) (B)

20A

10A

(G)

OFF OFF HIGH L

ON ON LOW NL
NR
R

MARK EXPLANATION
R,Br,Br/W, COLOR CORD
GND.