Yamaha AG200F X 2008 Owner's manual
OWNER’S MANUAL
AG200F(X)
3GX-28199-33
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INTRODUCTION
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Congratulations on your purchase of the Yamaha AG200F(X). This model is the result of
Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing
machines. It represents the high degree of craftsmanship and reliability that have made
Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you have any questions about the operation or maintenance of
your motorcycle, please consult a Yamaha dealer.
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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
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NOTE:
NOTE:
8 This manual should be considered a permanent part of this motorcycle and should
8 Yamaha continually seeks advancements in product design and quality. Therefore,
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
remain with it even if the motorcycle is subsequently sold.
while this manual contains the most current product information available at the time
of printing, there may be minor discrepancies between your motorcycle and this manual. If there is any question concerning this manual, please consult your Yamaha dealer.
*Product and specifications are subject to change without notice.
IMPORTANT MANUAL INFORMATION
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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
MOTORCYCLE.
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THIS MOTORCYCLE IS DESIGNED AND MANUFACTURED FOR OFF-ROAD USE ONLY. IT IS
ILLEGAL TO OPERATE THIS MOTORCYCLE ON ANY PUBLIC STREET, ROAD OR HIGHWAY.
SUCH USE IS PROHIBITED BY LAW. THIS MOTORCYCLE COMPLIES WITH ALMOST ALL
STATE OFF-HIGHWAY NOISE LEVEL AND SPARK ARRESTER LAWS AND REGULATIONS.
PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERATING
THIS MOTORCYCLE.
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AG200F(X)
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OWNER’S MANUAL
©2007 by Yamaha Motor Co., Ltd.
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1st Edition, November 2007
All rights reserved. Any reprinting or
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unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
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TABLE OF CONTENTS
SAFETY INFORMATION ....................................1-1
1
Safe riding ........................................................1-1
Protective apparel ............................................1-2
Modification......................................................1-3
Loading and accessories .................................1-3
Gasoline and exhaust gas ...............................1-4
Location of the important labels.....................1-6
DESCRIPTION .....................................................2-1
2
Left view............................................................2-1
Right view.........................................................2-2
Controls/Instruments .......................................2-3
INSTRUMENT AND CONTROL
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FUNCTIONS........................................................3-1
Main switch ......................................................3-1
Indicator lights..................................................3-1
Speedometer....................................................3-1
Handlebar switches (For 6 V model) ..............3-2
Handlebar switches (For 12 V model) ............3-3
Clutch lever.......................................................3-4
Shift pedal.........................................................3-4
Front brake lever ..............................................3-5
Rear brake pedal ..............................................3-5
Fuel tank cap.....................................................3-5
Fuel....................................................................3-6
Fuel cock ...........................................................3-7
Starter (choke) (For 6 V model).......................3-8
Starter (choke) “1” (For 12 V model)............3-8
Kick starter........................................................3-8
Seat ...................................................................3-9
Rear shock absorber adjustment....................3-9
Front and rear carriers...................................3-10
Auxiliary DC terminal (For 12 V model) .......3-11
PRE-OPERATION CHECKS.................................4-1
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Pre-operation check list ...................................4-1
OPERATION AND IMPORTANT RIDING
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POINTS................................................................5-1
Starting and warming up a cold engine
(For 6 V model).................................................5-1
Starting and warming up a cold engine
(For 12 V model)...............................................5-2
Starting a warm engine...................................5-3
Shifting..............................................................5-3
Tips for reducing fuel consumption ...............5-4
Engine break-in ................................................5-4
Parking ..............................................................5-5
PERIODIC MAINTENANCE AND MINOR
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REPAIR ................................................................6-1
Tool kit ..............................................................6-1
Periodic maintenance and lubrication............6-3
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TABLE OF CONTENTS
Panel removal and installation .......................6-6
Panel A and B ...................................................6-6
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Spark plug inspection......................................6-7
Engine oil..........................................................6-8
Air filter ...........................................................6-10
Carburetor adjustment ..................................6-11
Idle speed adjustment ...................................6-12
Throttle cable free play adjustment..............6-12
Valve clearance adjustment ..........................6-13
Tires.................................................................6-13
Wheels ............................................................6-15
Clutch lever free play adjustment.................6-15
Front brake lever free play adjustment ........6-16
Rear brake pedal height and free play
adjustment......................................................6-17
Brake light switch adjustment.......................6-18
Checking the brake shoes..............................6-18
Drive chain slack check..................................6-19
Drive chain slack adjustment ........................6-19
Drive chain lubrication...................................6-20
Cable inspection and lubrication ..................6-21
Throttle cable and grip lubrication ...............6-21
Brake and shift pedal lubrication..................6-21
Brake and clutch lever lubrication ................6-22
Sidestand lubrication.....................................6-22
Rear suspension lubrication..........................6-22
Front fork inspection......................................6-23
Steering inspection........................................6-23
Wheel bearings ..............................................6-24
Battery (For 6 V model)..................................6-24
Battery (For 12 V model)................................6-26
Fuse replacement (For 6 V model)................6-27
Fuse replacement (For 12 V model)..............6-28
Replacing the headlight bulb ........................6-29
Tail light bulb replacement ...........................6-30
Turn signal light bulb replacement
(For 6 V model)...............................................6-31
Turn signal light bulb replacement
(For 12 V model).............................................6-31
Supporting the motorcycle ...........................6-32
Front wheel removal......................................6-32
Front wheel installation.................................6-33
Rear wheel removal.......................................6-34
Rear wheel installation ..................................6-35
Troubleshooting.............................................6-35
Troubleshooting chart (For 6 V model) ........6-36
Troubleshooting chart (For 12 V model) ......6-37
MOTORCYCLE CARE AND STORAGE ..............7-1
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Matte color caution..........................................7-1
Care ...................................................................7-1
Storage..............................................................7-4
SPECIFICATIONS (For 6 V model) ....................8-1
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SPECIFICATIONS (For 12 V model) ..................8-4
How to use the conversion table ....................8-7
CONSUMER INFORMATION .............................9-1
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Identification numbers record.........................9-1
Key identification number...............................9-1
Vehicle identification number.........................9-2
Model label.......................................................9-2
TABLE OF CONTENTS
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Q SAFETY INFORMATION
TWO-WHEELED MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE
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EXPERTISE OF THE OPERATOR.
EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING.
HE OR SHE SHOULD:
1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS
OF MOTORCYCLE OPERATION.
2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.
Safe riding
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1. Always make pre-operation checks. Careful checks may help prevent an accident.
2. This motorcycle is designed for off-road use only. It is illegal for this motorcycle to be
operated on any public street, road, or highway. Off-road use on public lands may be illegal. Please check local regulations before riding.
3. This motorcycle is designed to carry the operator only. No passengers.
4. Many accidents involve inexperienced operators.
a. Know your skills and limits. Staying within your limits may help you to avoid an accident.
b. Only lend your motorcycle to experienced operators.
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5. Many motorcycle accidents have been caused by motorcycle operator errors. A typical
error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). Never travel faster than warranted by conditions.
6. Ride cautiously in unfamiliar areas. You may encounter hidden obstacles which could
cause an accident.
7. The operator’s posture is important for proper control. The operator should keep both
hands on the handlebars and both feet on the operator footrests during operation to maintain control of the motorcycle.
8. Never ride under the influence of alcohol or drugs.
Protective apparel
The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a
safety helmet is the single most critical factor in the prevention or reduction of head injuries.
1. Always wear an approved helmet.
2. Wear a face shield or goggles. Wind on your unprotected eyes could contribute to an
impairment of vision which could delay seeing a hazard.
3. The use of heavy boots, jacket, trousers, gloves, etc. is effective in preventing or reducing
abrasions or lacerations.
4. Never wear loose fitting clothing. It could catch on the control levers, footrests, or wheels
and cause injury or accident.
5. Never touch the engine or exhaust system during or after operation. They become very hot
and can cause burns. Always wear protective clothing that covers your legs, ankles, and
feet.
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Modification
Modifications made to the motorcycle not approved by Yamaha, or the removal of original
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equipment, may render your motorcycle unsafe for use and may cause severe personal injury.
Modifications may also make your motorcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your motorcycle can adversely affect stability and handling if
the weight distribution of the motorcycle is changed. To avoid the possibility of an accident,
extreme caution should be used if adding cargo or accessories to your motorcycle. Use extra
care if riding a motorcycle which has added cargo or accessories.
Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since
Yamaha cannot test all other accessories which may be available, you must personally be
responsible for the proper selection, installation and use of non-Yamaha accessories. You
should use extreme caution when selecting and installing any accessories. Keep in mind these
guidelines for mounting accessories in addition to those provided under “LOADING”.
1. Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure it does not in any way
reduce ground clearance or cornering clearance, limit suspension travel, steering travel or
control operation, or obscure lights or reflectors.
a. Accessories fitted to the handlebar or the front fork area can create instability due to
improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a
minimum.
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b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aero-
dynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become
unstable in cross winds. These accessories may also cause instability when being passed
by or passing large vehicles.
c. Certain accessories can displace the operator from his or her normal riding position. This
improper position limits the freedom of movement of the operator and may limit control
ability. Therefore such accessories are not recommended.
2. Caution must be used if adding electrical accessories. If these accessories exceed the
capacity of the motorcycle’s electrical system, an electric failure could result, which could
cause a dangerous loss of lights or engine power.
Gasoline and exhaust gas
1. GASOLINE IS HIGHLY FLAMMABLE:
a. Always turn off the engine when refueling.
b. Take care not to spill any gasoline on the engine or exhaust system when refueling.
c. Never refuel while smoking or in the vicinity of an open flame.
2. Never start the engine or let it run for any length of time in a closed area. The exhaust
fumes are poisonous and may cause loss of consciousness and death within a short time.
Always operate your motorcycle in an area that has adequate ventilation.
3. Always turn off the engine before leaving the motorcycle unattended and remove the ignition key. When parking the motorcycle, note the following:
a. The engine and exhaust system may be hot. Park the motorcycle in a place where pedestri-
ans or children are not likely to touch these hot areas.
b. Do not park the motorcycle on a slope or soft ground; the motorcycle may fall over.
c. Do not park the motorcycle near a flammable source, e.g. a kerosene heater, or near an
open flame. The motorcycle could catch fire.
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Q SAFETY INFORMATION
4. When transporting the motorcycle in another vehicle, be sure it is kept upright and that the
fuel cock is turned to “ON” or “RES” (for vacuum type)/”OFF” (for manual type). If it
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should lean over, gasoline may leak out of the carburetor or fuel tank.
5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get
in your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing,
immediately wash it off with soap and water and change your clothes.
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Before you operate this vehicle, read the owner’s manual.
5PA-21568-00
Prima di usare il veicolo, leggete il manuale di istruzioni.
Lire le manuel du propri
étaire avant d
’utiliser ce v
éhicule.
Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.
Antes de conducir este vehículo, lea el Manual del Propietario.
4AA-22259-40
follows.
FRONT :
:REAR
3GX-21668-00
Cold tire normal pressure should be set as
125 kPa,{1.25 kgf/cm
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}, 18 psi
150 kPa,{1.50 kgf/cm2}, 22 psi
LOCATION OF THE IMPORTANT LABELS
Please read the following labels carefully before operating this motorcycle.
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DESCRIPTION
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Left view
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1. Headlight (page 6-29 ~ 6-30)
2. Fuel cock (page 3-7)
3. Fuse (For 12 V model) (page 6-28)
4. Tool kit (page 6-1)
5. Air filter (page 6-10)
6. Shift pedal (page 3-4)
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Right view
DESCRIPTION
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7. Rear shock absorber spring preload
adjuster (page 3-9)
8. Rear brake pedal (page 3-5)
9. Kick starter (page 3-8)
10. Battery (page 6-24 ~ 6-27)
11. Fuse (page 6-27 ~ 6-28)
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2-2
DESCRIPTION
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2021
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Controls/Instruments
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12. Clutch lever (page 3-4, 6-15 ~ 6-16)
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13. Left handlebar switches (page 3-2 ~ 3-4)
14. Starter (choke)
(For 6 V model) (page 3-8)
15. Speedometer (page 3-1)
16. Auxiliary DC terminal
(For 12 V model) (page 3-11)
17. Starter (choke) “1”
(For 12 V model) (page 3-8)
18. Right handlebar switches (page 3-2 ~ 3-4)
19. Front brake lever (page 3-5, 6-16)
20. Throttle grip (page 6-21)
21. Main switch (page 3-1)
22. Fuel tank cap (page 3-5)
2-3
ON
OFF
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INSTRUMENT AND CONTROL FUNCTIONS
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Main switch
The main switch controls the ignition and lighting systems. Its operation is described below.
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ON
Electrical circuits are switched on.
The engine can be started. The key
cannot be removed in this position.
OFF
All electrical circuits are switched
off. The key can be removed in this
position.
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1. Neutral indicator light “NEUTRAL”
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Indicator light
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Neutral indicator light “NEUTRAL”
This indicator comes on when the
transmission is in neutral.
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1. Speedometer
2. Odometer
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Speedometer
The speedometer shows riding
speed.
This speedometer is equipped with
an odometer.
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INSTRUMENT AND CONTROL FUNCTIONS
Lights switch “LIGHTS”
Turn the light switch to “ON” to
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1. Dimmer switch “LIGHTS”
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2. Light switch “LIGHTS”
3. Turn switch “TURN”
4. Horn switch “HORN”
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Handlebar switches
(For 6 V model)
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Dimmer switch “LIGHTS”
Turn the switch to “HI” for the high
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beam and to “LO” for the low
beam.
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turn on the headlight, taillight, and
meter lights.
Turn signal switch “TURN”
This is a three-position switch. The
center position is off.
Turn to “L” to turn on the left
flasher, and to “R” for the right
flasher. Be sure to turn the switch
off after completing a turn.
Horn switch “HORN”
Press the switch to sound the horn.
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1. Engine stop switch “ENGINE STOP”
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Engine stop switch “ENGINE
STOP”
The engine stop switch is a safety
device for use in an emergency
such as when the motorcycle overturns or if trouble occurs in the
throttle system. Turn the switch to
“RUN” to start the engine. In case
of emergency, turn the switch to
“OFF” to stop the engine.
3-2
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1. Lights switch “:”
2. Dimmer switch
3. Turn signal switch
4. Horn switch “*”
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Handlebar switches
(For 12 V model)
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Lights switch “:”
Turn the light switch to “:” to
turn on the headlight, taillight and
meter lights.
Dimmer switch
Turn the switch to “&” for the
high beam and to “%” for the low
beam.
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INSTRUMENT AND CONTROL FUNCTIONS
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Turn signal switch
To signal a right-hand turn, push
the switch to “6”. To signal a lefthand turn, push the switch to
“4”. Once the switch is released
it will return to the center position.
To cancel the signal, push the
switch in after it has returned to
the center position.
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Horn switch “*”
Press the switch to sound the horn.
1. Engine stop switch
2. Start switch “START”
Engine stop switch
The engine stop switch is a safety
device for use in an emergency
such as when the motorcycle overturns or if trouble occurs in the
throttle system. Turn the switch to
“#” to start the engine.
In case of emergency, turn the
switch to “$” to stop the engine.
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3-3
PUSH
2
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INSTRUMENT AND CONTROL FUNCTIONS
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1. Engine stop switch
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2. Start switch “START”
Start switch “START”
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The starter motor cranks the
engine when pushing the start
6
switch.
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See starting instructions prior to
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starting the engine.
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1. Clutch lock lever
2. Clutch lever
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Clutch lever
The clutch lever is located on the
left handlebar. Pull the clutch lever
to the handlebar to disengage the
clutch, and release the lever to
engage the clutch. The lever
should be pulled rapidly and
released slowly for smooth clutch
operation.
There is a lock lever provided to
keep the clutch in the disengaged
position. Pull the clutch lever, then
push down the lock lever. The
clutch lever will stay in the disengaged position. To release the lock,
simply pull the clutch lever.
3-4
1. Shift pedal
N. Neutral
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Shift pedal
This motorcycle is equipped with a
constant-mesh 5-speed transmission.
The shift pedal is located on the
left side of the engine and is used
in combination with the clutch
when shifting.
INSTRUMENT AND CONTROL FUNCTIONS
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1. Front brake lever 1. Rear brake pedal 1. Fuel tank cap
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Front brake lever
The front brake lever is located on
the right handlebar. Pull it toward
the handlebar to apply the front
brake.
Rear brake pedal
The rear brake pedal is on the right
side of the motorcycle. Press down
on the brake pedal to apply the
rear brake.
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Fuel tank cap
Remove the fuel tank cap by turning it counterclockwise.
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INSTRUMENT AND CONTROL FUNCTIONS
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1. Filler tube
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2. Fuel level
Fuel
5
Make sure there is sufficient fuel in
the tank. Fill the fuel tank to the
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bottom of the filler tube as shown
in the illustration.
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Do not overfill the fuel tank. Avoid
spilling fuel on the hot engine. Do
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not fill the fuel tank above the bottom of the filler tube or it may
overflow when the fuel heats up
later and expands.
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Always wipe off spilled fuel immediately with a dry and clean soft
cloth. Fuel may deteriorate painted
surfaces or plastic parts.
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Recommended fuel:
Regular unleaded gasoline
only
Fuel tank capacity:
Total:
10.0 L (2.64 US gal)
(2.20 Imp.gal)
Reserve:
2.0 L (0.53 US gal)
(0.44 Imp.gal)
3-6
INSTRUMENT AND CONTROL FUNCTIONS
ON
FUEL
RES
OFF
1
ON
RES
ON
FUEL
OFF
1
OFF
ON
FUEL
RES
1
RES
OFF ON
1. Arrow mark
Fuel cock
The fuel cock supplies fuel from
the tank to the carburetor while filtering it also.
The fuel cock has three positions:
OFF
With the lever in this position, fuel
will not flow. Always return the
lever to this position when the
engine is not running.
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1. Arrow mark
ON
With the lever in this position, fuel
flows to the carburetor. Normal
riding is done with the lever in this
position.
3-7
RES
1. Arrow mark
RES
This indicates reserve. If you run
out of fuel while riding, move the
lever to this position. Fill the tank
at the first opportunity. Be sure to
set the fuel cock back to “ON” after
refueling.
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a
b
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INSTRUMENT AND CONTROL FUNCTIONS
b
a
1
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1. Starter (choke) 1. Kickstarter
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Starter (choke)
(For 6 V model)
5
Starting a cold engine requires a
richer air-fuel mixture. A separate
6
starter circuit supplies this mixture.
Move in direction a to turn on the
7
starter (choke).
Move in direction b to turn off the
8
starter (choke).
1. Starter (choke) “1”
EAU00210*
Starter (choke) “1”
(For 12 V model)
Starting a cold engine requires a
richer air-fuel mixture. A separate
starter circuit supplies this mixture.
Move in direction a to turn on the
starter (choke).
Move in direction b to turn off the
starter (choke).
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3-8
1
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Kick starter
Rotate the kick starter away from
the engine. Push the starter down
lightly with your foot until the
gears engage, then kick smoothly
and forcefully to start the engine.
This model has a primary-coupled
kick starter so the engine can be
started in any gear if the clutch is
disengaged. However, shifting to
neutral before starting is recommended.
INSTRUMENT AND CONTROL FUNCTIONS
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5
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2
1
b
a
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2
1
2
3
1. Bolt (Left ×1, Right ×1)
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Seat
To remove
1. Remove panels A and B. (See
page 6-6 for panel removal
and installation procedures.)
2. Remove the seat bolts and lift
the seat upward.
To install
1. Insert the projections on the
front of the seat into the holders, then tighten the seat bolts.
2. Install the side panels.
NOTE:
Make sure that the seat is securely
fitted.
3-9
1. Special wrench
2. Position indicator
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Rear shock absorber adjustment
This shock absorber is equipped
with a spring preload adjusting
ring. Adjust spring preload as follows.
Turn the adjusting ring in direction
a to increase spring preload and
in direction b to decrease spring
preload.
Make sure that the appropriate
notch in the adjusting ring is
aligned with the position indicator
on the rear shock absorber.
Standard
Adjusting
Position
Hard
54 32 1
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