YFS200P SUPPLEMENTARY SERVICE MANUAL LIT-11616-15-05 3JM-28197-11
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFS200P. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual. YFS200U SERVICE MANUAL: 2XJ-28197-10 YFS200A SUPPLEMENTARY SERVICE MANUAL: 3JM-28197-10 YFS200P SUPPLEMENTARY SERVICE MANUAL 2001 by Yamaha Motor Corporation, U.S.A. First Edition, May 2001 All rights reserved.
EB001000 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.
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 symbol. (For the chapter “Periodic inspection and adjustment” the 3rd title appears.) 3rd title 3: This is a final title.
1 EB003000 2 GEN INFO ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the top right of each page and indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical 9 Troubleshooting ENG 5 6 CARB DRIV 7 8 CHAS – ELEC + 0 Illustrated symbols 0 to F are used to identify the specifications appearing in the text.
CONTENTS GENERAL INFORMATION............................................................................... 1 MACHINE IDENTIFICATION .................................................................... 1 MODEL LABEL ..................................................................................... 1 SPECIFICATIONS ............................................................................................ 2 GENERAL SPECIFICATIONS ..................................................................
MACHINE IDENTIFICATION GEN INFO GENERAL INFORMATION MACHINE IDENTIFICATION MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code number Spark plug: Type/manufacturer Spark plug gap Tire: Type Size: Front Rear Electrical: Ignition system Generator system Headlight type Headlight bulb type Bulb wattage × quantity: Headlight Tail/brake light Indicator light “OIL LEVEL” YFS200P 5KJ7 (USA) BR8ES/NGK 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) Tubeless AT21 × 7 – 10 DUNLOP KT851A CHENG SHIN C873N AT21 × 10 – 8 DUNLOP KT895A CHENG SHIN C874N C.D.I. C.D.I.
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Model YFS200P Piston: Piston size “D” Measuring point “H” Piston off-set Piston-to-cylinder clearance D Oversize 1st 2nd Piston ring: Sectional sketch Top ring 65.940 ~ 66.000 mm (2.596 ~ 2.598 in) 10 mm (0.39 in) 0 mm (0 in) H 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 (0.110 in) B T 2nd ring Keystone B = 1.2 mm (0.047 in) T = 2.
MAINTENANCE SPECIFICATIONS 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 Valve seat size Starter jet Float height Fuel level Engine idling speed SPEC YFS200P Yamalube 2 or air cooled 2-stroke engine oil (M.J.) (M.A.J.) (J.N.) (N.J.) (C.A.) (P.O.) (P.J.) (B.P.1.) (V.S.) (G.S.) (F.H.) (F.L.) 2XJ01 #230 ø0.7 5J22-2 P-6 (#345) 2.0 0.6 #32.5 0.8 × 3.75 ø2.8 #45 20.5 ~ 21.5 mm (0.81 ~ 0.85 in) 0.5 ~ 1.5 mm (0.
MAINTENANCE SPECIFICATIONS SPEC CHASSIS Model Rear suspension: Shock absorber travel Spring free length Spring rate Stroke YFS200P 80 mm (3.15 in) 248 mm (9.76 in) 44.1 N/mm (4.50 kg/mm, 252.0 lb/in) 83.4 N/mm (8.50 kg/mm, 476.0 lb/in) 0 ~ 58.0 mm (0 ~ 2.28 in) 58.0 ~ 105.0 mm (2.28 ~ 4.13 in) No. K1 K2 K1 K2 Optional spring Brake lever: Brake lever free play Clutch lever: Clutch lever free play 3 ~ 5 mm (0.12 ~ 0.20 in) at lever pivot 2 ~ 3 mm (0.08 ~ 0.
CABLE ROUTING SPEC CABLE ROUTING 1 Clutch cable 2 Parking brake cable 3 Front brake cable 4 Throttle switch lead 5 Front brake light switch 6 Band 7 Throttle cable 8 Handlebar switch lead (left) 9 Voltage regulator lead 0 Front brake light switch lead A Oil indicator light lead B Main switch lead C Headlight lead D Control unit E CDI unit F Ground lead G Voltage regulator –6– È The throttle cable should be routed behind the clutch cable, and on the left side of the guide.
CABLE ROUTING 1 Front brake cable 2 Clutch cable 3 Main switch lead 4 Fuel breather hose 5 Band 6 Wire harness 7 Crankcase ventilation hose SPEC È Route the clutch cable in front of the fender stay. É Route the front brake cable through the cable guide, behind the front shock absorber, and above the tie rod.
CABLE ROUTING 1 Wire harness 2 Crankcase ventilation hose 3 Fuel hose 4 Wire holder 5 Rear brake light switch 6 Band 7 Clamp 8 Oil hose 9 Carburetor overflow hose 0 Flywheel magneto lead SPEC È For installing the wire harness, align the positioning tape with the wire holder. É The leads should be clamped on the inward half of the frame pipe. Ê Clamp the oil hose and rear brake light switch lead with the plastic clamp.
CABLE ROUTING 1 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 8 Oil level gauge lead 9 Oil hose 0 Wire harness A Clamp B Throttle switch lead SPEC C Throttle cable D Clutch cable E Ignition coil lead F Ignition coil G Ground lead È Place the slack of the spark plug lead toward the left side of the frame.
CABLE ROUTING 1 Rear brake light switch 2 Oil hose 3 Crankcase ventilation hose 4 Parking brake cable 5 Cable guide 6 Rear brake cable SPEC È Route the parking brake cable in front of the fender stay.
INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION INTERVALS EB300000 CHK ADJ PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. 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.
ADJUSTING THE REAR BRAKE LIGHT SWITCH CHK ADJ CHASSIS ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: 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: ● Rear brake light operation timing Incorrect → Adjust. 2.
CHECKING THE SWITCH ELEC – + 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: ● Set the pocket tester to “0” before starting the test. ● The pocket tester should be set to the “Ω × 1” range when testing the switch for continuity. ● Turn the switch on and off a few times when checking it.
Br Y – 14 – B G B Y Br 2 1 Y B Y/R B L Y L B/W Br E OFF LO HI C (BLACK) (BLACK) B F Y/R L Br B B/W B B B Y L L Y/R B G G D Y Y B/R B/R Y/R W/R W/R RUN OFF B B/W B B/W B 3 OFF ON A O B/W B O B 0 9 B G G Br 5 4 Y/B (GRAY) B B B Y/B (GRAY) Y/B 8 B/W B 6 B 7 Y/B B B Y/B B B (BLACK) (BLACK) Y/B Y/B B/W Y/B Y/B B/W 1 CDI magneto 2 Voltage regulator 9 Oil indicator light 0 Oil level gauge E Tail/brake light F Rear brake light
SIGNAL SYSTEM ELEC CHECKING THE SIGNAL SYSTEM 1.If the tail/brake light fails to come on: NO CONTINUITY 1.Bulb and bulb socket ● Check the bulb and bulb socket for continuity. Replace the bulb and/or bulb socket. CONTINUITY NO CONTINUITY 2.Brake light switches Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the brake switch. 3.Voltage ● ● Connect the tachometer to the spark plug lead. Connect the pocket tester (DC 20V) to the bulb socket connector.
SIGNAL SYSTEM ELEC * 4.Lighting coil resistance ● ● Disconnect the CDI magneto leads (Yellow/Red and Black). Connect the pocket tester (Ω × 1) to the lighting coil leads. Tester (+) lead → Yellow/Red lead 1 Tester (–) lead → Black lead 2 OUT OF SPECIFICATION ● Measure the lighting coil resistance. Lighting coil resistance: 0.16 ~ 0.24 Ω at 20 °C (68 °F) Replace the stator assembly. MEETS SPECIFICATION POOR CONNECTION 5.Wiring connections ● Check the connections of the entire lighting system.
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
Br Y B G B Y Br 2 1 Y B L Y/R B B B Y L B/W Br E OFF LO HI C (BLACK) (BLACK) B F Y/R L Br B B/W B Y Y/R G Y L L B G D Y B/R B/R Y/R W/R W/R YFS200P WIRING DIAGRAM RUN OFF B B/W B B/W B 3 OFF ON A O B/W B O B 0 9 B G Br 4 5 Y/B (GRAY) B B B B B Y/B B/R........ Black/Red B/W ....... Black/White W/R....... White/Red Y/B ........ Yellow/Black Y/R........
