Yamaha YFS200R 2002 Service Manual
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Yamaha YFS200R 2002 Service Manual

Yamaha YFS200R 2002 Service Manual

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YFS200R
2XJ-AE3
SUPPLEMENTARY
SERVICE MANUAL

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  • Page 1 YFS200R 2XJ-AE3 SUPPLEMENTARY SERVICE MANUAL...
  • Page 3 YFS200A(’90) SUPPLEMENTARY SERVICE MANUAL: 2XJ-AE1 YFS200(P) 2002 SUPPLEMENTARY SERVICE MANUAL: 2XJ-AE2 YFS200R SUPPLEMENTARY SERVICE MANUAL ©2002 by Yamaha Motor Co., Ltd. First edition, July 2002 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
  • Page 4 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.
  • Page 5 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.
  • Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the SPEC top right of each page and indicate the subject INFO of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Chassis 7 Electrical 8 Troubleshooting...

  • Page 7: Table Of Contents

    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...
  • Page 8 TROUBLESHOOTING ..................64 STARTING FAILURE/HARD STARTING ..........64 ELECTRICAL SYSTEM ..............64 FAULTY BRAKE ..................64 POOR BRAKING EFFECT ..............64 YFS200R WIRING DIAGRAM...

  • Page 9: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YFS200R Model code: 5VM1: (Oceania) 5VM2: (CDN and Europe) Basic weight: With oil and full fuel tank 155 kg (342 lb) Chassis: Frame type Steel tube Caster angle 9° Camber angle 1° Kingpin angle 13°...

  • Page 10: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model YFS200R Piston: Piston size “D” 65.960 ~ 65.985 mm (2.596 ~ 2.597 in) Measuring point “H” 10 mm (0.39 in) Piston off-set 0 mm (0 in) Piston-to-cylinder clearance 0.035 ~ 0.040 mm (0.0014 ~ 0.0016 in) <Limit>...

  • Page 11: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model YFS200R Front suspension: Shock absorber travel 90 mm (3.54 in) Spring free length 226.6 mm (8.93 in) Spring rate 29.4 N/mm (2.94 kg/mm, 164.6 lb/in) 34.3 N/mm (3.43 kg/mm, 192.1 lb/in) Stroke 0 ~ 46.7 mm (0 ~ 1.84 in) 46.7 ~ 112.2 mm (1.84 ~ 4.42 in) Optional spring Front disc brake:...

  • Page 12: Electrical

    MAINTENANCE SPECIFICATIONS ELECTRICAL Model YFS200R C.D.I.: Magneto model/manufacturer F2XJ/YAMAHA 16 ~ 24 Ω at 20 °C (68 °F)/White/Red – Black Pickup coil resistance/color 192 ~ 288 Ω at 20 °C (68 °F)/Green/White – Charging coil resistance/color Black/Red C.D.I. unit model/manufacturer 5VM/YAMAHA –...

  • Page 13: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Parking brake switch lead B C.D.I. unit lead È Route each lead through the 2 Clutch cable C C.D.I. unit cable guide and in front of the 3 Parking brake cable D Voltage regulator clutch cable and parking brake 4 Oil indicator light lead E Ground lead...
  • Page 14 SPEC CABLE ROUTING 1 Front brake hose È Pass the crankcase ventilation hose between 2 Throttle cable the parking brake cable and clutch cable, and 3 Clutch cable then fasten it with a band. 4 Parking brake cable 5 Crankcase ventilation hose 6 Front brake pipe 7 Handlebar cover È...
  • Page 15 SPEC CABLE ROUTING 1 Clutch cable È Route the clutch cable and parking brake cable 2 Parking brake cable in front of the fender stay. 3 Throttle cable É 30 ~ 40 mm (1.18 ~ 1.57 in) 4 Fuel breather hose 5 Crankcase ventilation hose 6 Wire harness 7 Front brake hose...
  • Page 16 SPEC CABLE ROUTING 1 Wire harness È To install the wire harness, align the positioning 2 Crankcase ventilation hose tape with the wire holder. 3 Fuel hose É The leads should be clamped on the inward half 4 Wire holder of the frame pipe.
  • Page 17 SPEC CABLE ROUTING 1 Front brake hose C Throttle cable 2 Parking brake cable D Ignition coil lead 3 Spark plug lead E Ignition coil 4 Crankcase ventilation hose F Ground lead 5 Rear brake light switch G Rear brake light switch lead 6 Band 7 Tail/brake light lead È...
  • Page 18 SPEC CABLE ROUTING 1 Oil hose È Route the parking brake cable in front of the 2 Crankcase ventilation hose fender stay. 3 Clutch cable 4 Parking brake cable 5 Cable guide – 10 –...
  • Page 19 SPEC CABLE ROUTING 1 Rear brake hose 2 Parking brake cable 3 Rear brake light switch – 11 –...

  • Page 20: Periodic Checks And Adjustments

    Throttle, control cable* • Lubricate. Outside nuts and bolts • Tighten if necessary. Frame • Clean and Inspect. Lighting • Inspect. * It is recommended that these items be serviced by a Yamaha dealer. ** Lithium-soap-based grease – 12 –...
  • Page 21 PERIODIC MAINTENANCE/LUBRICATION INTERVALS NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement: 1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add fluid as required. 2.On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.

  • Page 22: Chassis

    ADJUSTING THE PARKING BRAKE CHASSIS ADJUSTING THE PARKING BRAKE 1.Check: Parking brake cable length a Out of specification → Adjust. Parking brake cable length: 64 ~ 68 mm (2.52 ~ 2.68 in) 2.Adjust: Parking brake cable ***************************************************** Adjustment steps: Loosen the locknut 1. Turn the adjuster 2 fully clockwise.

  • Page 23: Adjusting The Rear Brake

    ADJUSTING THE REAR BRAKE ADJUSTING THE REAR BRAKE 1.Check: Rear brake pedal position a Out of specification → Adjust. Brake pedal position: 0 ~ 10 mm (0 ~ 0.39 in) 1 Brake pedal 2 Footrest 2.Adjust: Brake pedal position ***************************************************** Adjustment steps: Loosen the locknut 1.

  • Page 24: Checking The Brake Fluid Level

    CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE BRAKE PADS CHECKING THE BRAKE FLUID LEVEL 1.Place the machine on a level surface. NOTE: When checking the brake fluid level, make sure that the top of the brake fluid reservoir top is horizontal. È...

  • Page 25: Checking The Brake Hoses

    CHECKING THE BRAKE PADS/ CHECKING THE BRAKE HOSES È 3.Check: Brake pad Wear indicator grooves 1 almost contact the brake disc → Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES”. Wear limit: 1.0 mm (0.04 in) È...

  • Page 26: Bleeding The Hydraulic Brake System

    CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM 4.Install: Front panel Refer to “REPLACING THE HEADLIGHT BULB”. BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system if: The system has been disassembled. A brake hose or brake pipe have been loosened or removed.
  • Page 27 BLEEDING THE HYDRAULIC BRAKE SYSTEM j. Tighten the bleed screw. Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • lb) NOTE: If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared.

  • Page 28: Electrical

    ADJUSTING THE HEADLIGHT BEAM/ REPLACING THE HEADLIGHT BULB ELECTRICAL ADJUSTING THE HEADLIGHT BEAM 1.Adjust: Headlight beam (vertical) Turn the adjusting screw 1 in or out. Headlight beam is Turning in raised. Headlight beam is Turning out lowered. REPLACING THE HEADLIGHT BULB 1.Remove: Screws 1 Front panel 2...
  • Page 29 REPLACING THE HEADLIGHT BULB 4.Remove: Headlight beam adjusting screw 1 Washer Spring Screws 2 Headlight unit assembly 5.Remove: Headlight bulb holder cover Headlight bulb holder 1 Turn the headlight bulb holder counterclock- wise. Headlight bulb WARNING Keep flammable products or your hands away from the bulb while it is on, since it will be hot.
  • Page 30 REPLACING THE HEADLIGHT BULB 8.Install: Headlight unit assembly Screws Spring Washer Headlight adjusting screw Headlight assembly 9.Connect: Headlight connectors 10.Install: Front panel 11.Adjust: Headlight beam (vertical) Refer to “ADJUSTING THE HEADLIGHT BEAM”. – 22 –...

  • Page 31: Chassis

    CHAS FRONT AND REAR BRAKES CHASSIS FRONT AND REAR BRAKES 1 Brake master cylinder 6 Union bolt D Brake caliper body K Brake disc guard (inner) 7 Brake hose E Brake pad shim L Bearing reservoir cap 2 Brake master cylinder 8 Brake hose holder F Brake pad M Spacer...
  • Page 32 CHAS FRONT AND REAR BRAKES 1 Retaining bolt B O-ring M Adjusting bolt W Brake fluid reservoir 2 Lock washer C Washer N Union bolt hose 3 Brake caliper body D Spring (parking brake) O Copper washer X Brake fluid reservoir 4 Bleed screw E Adjuster nut P Brake hose...

  • Page 33: Replacing The Brake Pads

    CHAS FRONT AND REAR BRAKES CAUTION: Disc brake components rarely require dis- assembly. DO NOT: Disassemble components unless it is absolutely necessary. Use solvents on internal brake compo- nents. Reuse brake fluid for cleaning. Use fresh brake fluid only. Allow brake fluid to come in contact with your eyes as this may cause eye injury.
  • Page 34 CHAS FRONT AND REAR BRAKES 3.Remove: Brake pads 1 (with pad shim 2) Pad spring 3 4.Measure: Brake pad wear limit a Out of specification → Replace the brake pads as a set. Wear limit a: 1.0 mm (0.04 in) NOTE: When pad replacement is required, also replace the pad spring and shim.
  • Page 35 CHAS FRONT AND REAR BRAKES 6.Install: Retaining bolts Front brake caliper Retaining bolt: 18 Nm (1.8 m • kg, 13 ft • lb) Bolt (front brake caliper): 28 Nm (2.8 m • kg, 20 ft • lb) 7.Install: Front wheel Refer to “FRONT WHEEL AND FRONT BRAKE”...
  • Page 36 CHAS FRONT AND REAR BRAKES 4.Remove: Brake pads 1 (with pad shim 2) Pad spring 3 5.Measure: Brake pad wear limit a Out of specification → Replace the brake pads as a set. Wear limit: 1.0 mm (0.04 in) NOTE: When pad replacement is required, also replace the pad spring and shims.
  • Page 37 CHAS FRONT AND REAR BRAKES 7.Install: Lock washer Retaining bolts NOTE: Bend the lock washer tab along a flat side of the nut. WARNING Always use a new lock washer. Retaining bolt: 18 Nm (1.8 m • kg, 13 ft • lb) 8.Install: Rear brake caliper Bolt (rear brake caliper):...

  • Page 38: Disassembling The Brake Calipers

    CHAS FRONT AND REAR BRAKES DISASSEMBLING THE BRAKE CALIPERS NOTE: Before disassembling the front brake caliper or rear brake caliper, drain the brake fluid of the brake hoses, brake pipe, master cylinder, brake caliper, and brake fluid reservoir. Front brake caliper 1.Remove: Front wheel Refer to “FRONT WHEEL AND FRONT...
  • Page 39 CHAS FRONT AND REAR BRAKES 6.Remove: Piston 1 Piston seals 2 Bleed screw 3 ***************************************************** Removal steps: Place a rag between the brake caliper and brake caliper body. Blow compressed air into the hose joint opening a to force out the caliper piston from the caliper body.
  • Page 40 CHAS FRONT AND REAR BRAKES 5.Remove: Adjusting bolt 1 Locknut 2 Parking brake lever 3 Spring 4 6.Remove: Parking brake assembly 1 Gasket 7.Remove: Cover 1 Spring 2 Adjuster nut 3 Parking brake cam 4 8.Remove: Caliper body 1 Caliper bracket 2 NOTE: Before removing the caliper body from the bracket, remove the dust boot from the guide...

  • Page 41: Disassembling The Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES 9.Remove: Piston 1 Piston seals 2 O-ring 3 Bleed screw 4 ***************************************************** Removal steps: Blow compressed air into the hose joint opening a to force out the caliper piston from the caliper body. Remove the piston seals. WARNING Never attempt to pry out the piston.
  • Page 42 CHAS FRONT AND REAR BRAKES 2.Remove: Brake lever 1 Union bolt 2 Copper washers Brake hose 3 NOTE: Hold a container under the master cylinder and under the brake hose end to collect the remaining brake fluid. 3.Remove: Brake master cylinder reservoir cap 1 Brake master cylinder reservoir diaphragm Brake master cylinder 2 4.Remove:...
  • Page 43 CHAS FRONT AND REAR BRAKES 3.Remove: Brake master cylinder 1 4.Remove: Brake master cylinder kit 1 5.Remove: Brake fluid reservoir 1 (from frame) 6.Remove: Brake fluid reservoir cap 1 Brake fluid reservoir diaphragm holder 2 Brake fluid reservoir diaphragm 3 –...

  • Page 44: Checking The Brake Caliper And Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES CHECKING THE BRAKE CALIPER AND BRAKE MASTER CYLINDER Recommended brake component replacement schedule: Brake pads As required Piston seal, dust seal Every two years Brake hoses Every two years Replace only when Brake fluid brakes are disassembled.
  • Page 45 CHAS FRONT AND REAR BRAKES È 2.Check: Caliper bracket 1 Cracks/damage → Replace. È Front É Rear É È 3.Check: Brake master cylinder 1 Wear/scratches → Replace the master cylin- der assembly. Brake master cylinder body 2 Cracks/damage → Replace. Oil delivery passage (brake master cylinder body) Blow out with compressed air.
  • Page 46 CHAS FRONT AND REAR BRAKES È 4.Check: Brake master cylinder kit 1 Scratches/wear/damage → Replace as a set. È Front É Rear É È É 5.Check: Brake master cylinder reservoir 1 Cracks/damage → Replace. Brake master cylinder reservoir diaphragm 2 Brake fluid reservoir 3 Brake fluid reservoir diaphragm 4 Brake fluid reservoir diaphragm holder 5...
  • Page 47 CHAS FRONT AND REAR BRAKES 7.Check: Parking brake assembly Cracks/wear/damage → Replace. È É 8.Check: Brake discs (front and rear) Galling/damage → Replace. È Front É Rear 9.Measure: Brake disc deflection Out of specification → Inspect wheel runout. If wheel runout is in good condition, replace the brake discs.

  • Page 48: Assembling The Brake Caliper

    CHAS FRONT AND REAR BRAKES ASSEMBLING THE BRAKE CALIPER WARNING All internal parts should be cleaned in new brake fluid only. Internal parts should be lubricated with brake fluid when installed. Recommended brake fluid: DOT 4 Replace the piston seals and dust seals whenever a caliper is disassembled.
  • Page 49 CHAS FRONT AND REAR BRAKES 3.Install: Brake caliper 1 (temporarily) Copper washer Brake hose 2 Union bolt Union bolt: 27 Nm (2.7 m • kg, 19 ft • lb) CAUTION: When installing the brake hose onto the brake caliper 1, make sure that the brake pipe contacts the projection a on the brake caliper.
  • Page 50 CHAS FRONT AND REAR BRAKES 6.Fill: Brake master cylinder reservoir tank Recommended brake fluid: DOT 4 CAUTION: Brake fluid may erode painted surfaces of plastic parts. Always clean up spilled fluid immediately. WARNING Use only the recommended brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
  • Page 51 CHAS FRONT AND REAR BRAKES Rear brake caliper 1.Install: Bleed screw 1 O-ring 2 Piston seals 3 Piston 4 WARNING Always use new O-ring and piston seals. 2.Install: Caliper bracket 1 Caliper body 2 Retaining bolt 3 NOTE: Apply the lithium-soap-based grease to the caliper guide shaft and retaining bolt.
  • Page 52 CHAS FRONT AND REAR BRAKES 5.Install: Parking brake lever 1 Spring 2 Locknut Adjusting bolt NOTE: Align the parking brake lever mark a with the adjuster nut corner b and position the parking brake lever as shown. Install the spring 2 with its hook ends facing down as shown.
  • Page 53 CHAS FRONT AND REAR BRAKES 8.Install: Pad spring Brake pads (with pad shim) Retaining bolts Rear brake caliper Refer to “REPLACING THE BRAKE PADS”. Retaining bolt: 18 Nm (1.8 m • kg, 13 ft • lb) Brake caliper bolt: 28 Nm (2.8 m • kg, 20 ft • lb) Rear wheel Refer to “REAR WHEEL AND REAR AXLE”...

  • Page 54: Assembling The Master Cylinder

    CHAS FRONT AND REAR BRAKES 11.Check: Brake fluid level Fluid level is below the “LOWER” level line → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”. ASSEMBLING THE MASTER CYLINDER WARNING All internal parts should be cleaned in new brake fluid only.
  • Page 55 CHAS FRONT AND REAR BRAKES 3.Install: Copper washers Brake hose 1 Union bolt 2 Union bolt: 27 Nm (2.7 m • kg, 19 ft • lb) Brake lever 3 NOTE: Tighten the union bolt, while holding the brake hose. Check that the brake hose does not contact other parts (throttle cables, wire harness, leads, etc.) when turning the handlebar left and right.
  • Page 56 CHAS FRONT AND REAR BRAKES Refill with the same type of brake fluid: mixing brake fluids may result in a harm- ful chemical reaction and lead to poor performance. Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the brake fluid and may result in vapor lock.
  • Page 57 CHAS FRONT AND REAR BRAKES 2.Install: Master cylinder kit 1 3.Install: Brake master cylinder 1 Brake master cylinder bolt: 20 Nm (2.0 m • kg, 14 ft • lb) 4.Install: Copper washers Brake hose 1 Union bolt 2 Union bolt: 30 Nm (3.0 m •...
  • Page 58 CHAS FRONT AND REAR BRAKES 6.Fill: Brake fluid reservoir Recommended brake fluid: DOT 4 CAUTION: Brake fluid may erode painted surfaces of plastic parts. Always clean up spilled fluid immediately. WARNING Use only the recommended brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 59: Steering System

    CHAS STEERING SYSTEM STEERING SYSTEM 1 Handlebar holder A Locknut 2 Bearing (lower) B Tie-rod 3 Oil seal C Steering knuckle 4 Bearing (upper) D Knuckle arm 5 Collar E Washer 6 Cable holder F Bushing 7 Lock washer G O-ring 8 Steering stem 9 Cotter pin 0 Tie-rod end...

  • Page 60: Front Shock Absorbers And Front Arms

    CHAS FRONT SHOCK ABSORBERS AND FRONT ARMS FRONT SHOCK ABSORBERS AND FRONT ARMS 1 Thrust cover 2 Bushing 3 Front arm (upper) 4 Inner collar 5 Knuckle arm 6 Steering knuckle 7 Shock absorber assembly 8 Front arm (lower) 9 Cotter pin –...

  • Page 61: Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 1 Rear shock absorber assembly A Inner collar 2 Bushing B Swingarm 3 Cotter pin C Protector guide 4 Swingarm pivot shaft D Thrust cover protector 5 Thrust cover E Chain guide 6 Plate washer F Under guard...

  • Page 62: Electrical

    – ELEC IGNITION SYSTEM ELECTRICAL EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM – 54 –...

  • Page 63: Troubleshooting

    – ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): NOTE: When the parking brake is used, engine speed is limited to 2,300 r/min. Be sure the parking brake is released before moving the throttle lever. Otherwise, the engine will misfire, preventing normal operation.
  • Page 64 – ELEC IGNITION SYSTEM C0NTINUITY For CDN 2.Ignition spark gap Disconnect the plug cap from the spark plug. Connect the dynamic spark tester 1 as shown. 2 Spark plug cap 3 Spark plug Turn the main switch to “ON”. Check the ignition spark gap. Kickstart the engine, and increase the MEETS SPECIFICATION spark gap until a misfiring occurs.
  • Page 65 – ELEC IGNITION SYSTEM 3.Spark plug cap resistance Remove the spark plug cap. Connect the pocket tester (Ω × 1k) to the spark plug cap. OUT OF SPECIFICATION Measure the spark plug cap resistance. Spark plug cap resistance: 10 kΩ at 20 °C (68 °F) Replace the spark plug cap.
  • Page 66 – ELEC IGNITION SYSTEM C0NTINUITY 5.Engine stop switch INCORRECT Refer to “CHECKING THE SWITCH”. (Manual No.: 2XJ-AE2) CORRECT Replace the handlebar switch (left). 6.Parking brake switch INCORRECT Refer to “CHECKING THE SWITCH”. (Manual No.: 2XJ-AE2) CORRECT Replace the parking brake switch. 7.Throttle switch INCORRECT Refer to “CHECKING THE SWITCH”.
  • Page 67 – ELEC IGNITION SYSTEM C0NTINUITY 10.Pickup coil resistance Disconnect the C.D.I. magneto connectors from the wire harness. Connect the pocket tester (Ω × 1) to the pickup coil terminal. Tester (+) lead → White/Red lead 1 Tester (–) lead → Black lead 2 Measure the pickup coil resistance.

  • Page 68: Lighting System

    – ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 1 C.D.I. magneto 2 Voltage regulator C Light switch D Headlight E Tail/brake light – 60 –...

  • Page 69: Troubleshooting

    – ELEC LIGHTING SYSTEM EB805010 TROUBLESHOOTING IF THE HEADLIGHT, TAIL/BRAKE LIGHT FAIL TO COME ON: Procedure Check: 1.Lighting coil resistance 2.Light switch 3.Wiring connections (the entire lighting system) NOTE: Pocket tester: Remove the following parts before trouble- P/N. YU-03112, 90890-03112 shooting: 1)Seat 2)Fuel tank cover...

  • Page 70: Lighting System Check

    – ELEC LIGHTING SYSTEM C0NTINUITY EB805013 3.Wiring connection POOR CONNECTION Check the connections of the entire lighting system. Refer to “WIRING DIAGRAM”. Properly connect the lighting system. CORRECT Check the condition of each of the lighting system’s circuits. Refer to “LIGHTING SYSTEM CHECK”. EB805020 LIGHTING SYSTEM CHECK 1.If the headlight fails to come on:...
  • Page 71 – ELEC LIGHTING SYSTEM Turn the main switch to “ON”. OUT OF SPECIFICATION Kickstart the engine. Turn the light switch to “LO” or “HI”. Check the voltage (12 V) of the “Green” and “Yellow” leads on the bulb socket con- nector.
  • Page 72 TRBL STARTING FAILURE/HARD STARTING/ FAULTY BRAKE SHTG TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts.
  • Page 74 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 75 YFS200R WIRING DIAGRAM 1 C.D.I. magneto 2 Voltage regulator B B/W W/R 3 C.D.I. unit B/R Y/B G/Y G/W 4 Ignition coil (BLACK) 5 Spark plug 6 Parking brake switch 7 Throttle switch 8 Carburetor switch 9 Oil level warning light COIL 0 Oil level gauge STOP TORS GND...

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