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2002 YFA1 3FA-AE1 SUPPLEMENTARY SERVICE MANUAL...
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Service Manual together with the following manual. YFA1W SERVICE MANUAL: 3FA-ME1 YFA1(P) 2002 SUPPLEMENTARY SERVICE MANUAL 2001 by Yamaha Motor Co., Ltd. First Edition, May 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
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.
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.
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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 Drive train 7 Chassis 8 Electrical...
MACHINE IDENTIFICATION 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. – 1 –...
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YFA1 (P) 2002 Model code number 3FAY (CDN, Europe and Oceania) Engine: Engine type Air-cooled 4-stroke, SOHC Cylinder arrangement Forward-inclined single cylinder Displacement 124 cm Bore × stroke 49 × 66 mm (1.93 × 2.60 in) Compression ratio 9.0 : 1 Compression pressure...
SPEC MAINTENANCE SPECIFICATIONS Model YFA1 (P) 2002 Side clearance Top ring 0.03 ~ 0.07 mm (0.0012 ~ 0.0027 in) Second ring 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) Carburetor: I.D. mark 3FA02 Main jet (M.J.) #82.5 Main air jet (M.A.J.) ø1.3 Jet needle...
5 ~ 8 mm (0.20 ~ 0.31 in) At lever pivot. ELECTRICAL Model YFA1 (P) 2002 C.D.I.: Magneto model/manufacturer F3FA/YAMAHA 248 ~ 372 Ω at 20 °C (68 °F) Pickup coil resistance (lead color) (White–Red) C.D.I. unit model/manufacturer 3FA/YAMAHA Ignition coil:...
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8.0 A Withstand voltage 200 V Electric starting system: Type Constant mesh Starter motor Model/manufacturer 3FA1/YAMAHA Output 0.4 kW 0.019 ~ 0.023 Ω at 20 °C (68 °F) Armature coil resistance Overall length (brush) 10.0 mm (0.39 in) <Limit> <3.5 mm (0.14 in>...
SPEC CABLE ROUTING CABLE ROUTING 1 Throttle cable 2 Band 3 Breather hose 4 Rear brake switch lead 5 Rear brake cable 6 Front brake cable 7 Front brake switch lead – 8 –...
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SPEC CABLE ROUTING 1 Front brake cable È Pass leads in front of the brake cable and con- 2 Band nect them inside the headlight body. 3 Rear brake cable É Pass the inlet and outlet hoses between the 4 Rear brake switch lead brake cables.
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SPEC CABLE ROUTING 1 Throttle cable È Fasten the wire harness, starting motor lead and 2 Rectifier/regulator transmission case breather hose to the frame with 3 Starting motor a plastic band. 4 CDI magneto lead 5 Clamp 6 Ignition coil –...
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SPEC CABLE ROUTING 1 Taillight C Battery negative lead 2 Reverse relay D Reverse switch lead 3 Starting circuit cut-off relay 4 Fuse holder È Hold the clamp and ground lead to the crank- 5 Starter relay case with a screw. 6 Wire harness É...
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SPEC CABLE ROUTING 1 Inlet hose È Pass the breather hose through the hole of han- 2 Outlet hose dlebar cover and then between the steering col- 3 Fuel hose umn and fuel tank. 4 Breather hose (crankcase) É Pass the overflow hose left side of the engine 5 Overflow hose stay.
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SPEC CABLE ROUTING 1 CDI unit C Reverse relay 2 Band 3 Starter cable È Pass the breather hose between the throttle 4 Wire harness cable and starter cable. 5 Breather hose (transmission case) 6 Ignition coil 7 Battery positive lead 8 Battery negative lead 9 Breather hose (crankcase) 0 Throttle cable...
Fittings and Fasteners* • Correct if necessary. • Check specific gravity. Battery* • Check breather hose for proper operation. • Correct if necessary. It is recommended that these items be serviced by a Yamaha dealer. ** Lithium-soap-based grease – 14 –...
ADJUSTING THE FRONT BRAKE CHASSIS ADJUSTING THE FRONT BRAKE 1.Check: Front brake lever free play a Out of specification → Adjust. Front brake lever free play: 5 ~ 8 mm (0.20 ~ 0.3 in) at lever pivot 2.Adjust: Front brake lever free play *********************************************** Loosen the locknut 1.
– ELEC CHECKING THE SWITCH 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.
– ELEC SIGNAL SYSTEM CHECKING THE SIGNAL SYSTEM 1.If the tail/brake light fails to come on: 1.Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continu- ity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.Brake light switches Refer to “CHECKING THE SWITCH”.