Yamaha AG200FEE 2014, Owner'S Manual

Page 1: ...q Read this manual carefully before operating this vehicle OWNER S MANUAL AG200FEE 53C 28199 23 U53C23E0_Hyoshi indd 1 2014 01 23 15 07 38...

Page 2: ...Q Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold EAU46091 U53C23E0_Hyoshi indd 2 2014 01 23 15 07 38...

Page 3: ...rouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha...

Page 4: ...alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could r...

Page 5: ...200FEE OWNER S MANUAL 2014 by Yamaha Motor Co Ltd 1st edition January 2014 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly pro...

Page 6: ...iodic maintenance chart for the emission control system 7 3 General maintenance and lubrication chart 7 4 Removing and installing panels 7 7 Checking the spark plug 7 8 Engine oil and oil filter eleme...

Page 7: ...ing a turn signal light bulb 7 30 Supporting the motorcycle 7 31 Front wheel 7 32 Rear wheel 7 34 Troubleshooting 7 36 Troubleshooting chart 7 37 MOTORCYCLE CARE AND STORAGE 8 1 Matte color caution 8...

Page 8: ...d all of the labels on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or c...

Page 9: ...manuale di istruzioni Lire le manuel du propri taire avant d utiliser ce v hicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este veh culo lea el Manual del...

Page 10: ...le properly increases the possibility of an accident or equipment damage See page 5 1 for a list of pre operation checks This motorcycle is designed for off road use only therefore it is il legal to o...

Page 11: ...ntribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loos...

Page 12: ...us injury or death You are responsible for injuries related to changes in the vehicle Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never ins...

Page 13: ...there are no fuel leaks Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to pre vent movement Shift the transmission in gear for models with a manual tran...

Page 14: ...ESCRIPTION EAU10411 Left view 1 3 4 5 6 7 2 1 Headlight page 7 29 2 Fuel tank cap page 4 5 3 Fuel cock page 4 6 4 Main fuse page 7 28 5 Owner s tool kit page 7 2 6 Air filter element page 7 12 7 Shift...

Page 15: ...1 3 1 Rear carrier page 4 10 2 Shock absorber assembly spring preload adjusting ring page 4 9 3 Front carrier page 4 10 4 Engine oil filter element page 7 9 5 Brake pedal page 4 4 6 Kickstarter page...

Page 16: ...4 5 6 7 8 9 1 Clutch lever page 4 3 2 Left handlebar switches page 4 2 3 Speedometer unit page 4 2 4 Auxiliary DC jack page 4 13 5 Starter choke knob page 4 7 6 Right handlebar switches page 4 2 7 Bra...

Page 17: ...tarted The key cannot be removed EAU45752 OFF All electrical systems are off The key can be removed WARNING EWA10073 Never turn the key to OFF while the vehicle is moving otherwise the electrical syst...

Page 18: ...tch Set this switch to for the high beam and to for the low beam EAU12461 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leas...

Page 19: ...r See page 6 1 for start ing instructions prior to starting the en gine EAU35001 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the h...

Page 20: ...of the 5 speed con stant mesh transmission equipped on this motorcycle EAU12892 Brake lever The brake lever is located on the right side of the handlebar To apply the front brake pull the lever toward...

Page 21: ...refuel while smoking or while in the vi cinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank Stop fil...

Page 22: ...octane number of 91 or higher If knocking or pinging oc curs use a gasoline of a different brand or premium unleaded fuel Use of un leaded fuel will extend spark plug life and reduce maintenance cost...

Page 23: ...the tank at the first oppor tunity Be sure to set the lever back to ON after refueling EAU13601 Starter choke knob Starting a cold engine requires a richer air fuel mixture which is supplied by the s...

Page 24: ...ed in any gear if the clutch is disengaged However shifting the transmission into the neutral position before starting is recommended EAU13962 Seat To remove the seat Remove the bolts and then pull th...

Page 25: ...rber Use the special wrench includ ed in the owner s tool kit to make the adjustment 3 Install the seat WARNING EWA10222 This shock absorber assembly con tains highly pressurized nitrogen gas Read and...

Page 26: ...limits of 2 kg 4 lb for the front carrier and 10 kg 22 lb for the rear carrier EAU48861 Sidestands The sidestands are located on the left and right side of the frame Raise a sid estand or lower it wi...

Page 27: ...ct the operator re sulting in a possible loss of control EAU53131 Starting circuit cut off system The starting circuit cut off system com prising the clutch switch and the neutral switch prevents star...

Page 28: ...ng correctly The motorcycle should not be ridden until checked by a Yamaha dealer 5 Turn the engine off 6 Shift the transmission into gear 7 Keep the clutch lever pulled 8 Push the start switch or pus...

Page 29: ...the ON position and should only be used when the engine is running Refer to the following chart for correct usage Amperage chart To use the auxiliary DC jack 1 Turn the key to OFF 2 Remove the dust ca...

Page 30: ...ler Before using this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 5 Engine oil Check oil level in engine If...

Page 31: ...Shift pedal Make sure that operation is smooth Correct if necessary 7 20 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 7 24 Brake and clutch levers Make s...

Page 32: ...ift the transmission into the neu tral position The neutral indicator light should come on If not ask a Yamaha dealer to check the elec trical circuit 4 Turn the starter choke on and completely close...

Page 33: ...ransmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel NOTICE ECA10261 Even with the transmission in the neutral position do not coast for...

Page 34: ...0 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the e...

Page 35: ...r to OFF WARNING EWA10312 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on...

Page 36: ...15123 Turn off the engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks o...

Page 37: ...s provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perfo...

Page 38: ...risk should be performed by a Yamaha dealer as they require special tools data and technical skills EAU46921 Periodic maintenance chart for the emission control system NO ITEM CHECK OR MAINTENANCE JOB...

Page 39: ...heck operation and adjust brake pedal free play Replace brake shoes Whenever worn to the limit 5 Wheels Check runout spoke tightness and for damage Tighten spokes if necessary 6 Tires Check tread dept...

Page 40: ...se 14 Clutch lever pivot shaft Lubricate with lithium soap based grease 15 Sidestands Check operation Lubricate 16 Front fork Check operation and for oil leakage 17 Shock absorber assembly Check opera...

Page 41: ...usty areas 23 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 24 Lights signals and switches Check operation Adjust headlight beam...

Page 42: ...oved to perform some of the maintenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed EAU19303 Panels A and B To remove a panel Pull the pane...

Page 43: ...d the center electrode of the spark plug is a medium to light tan the ideal color when the vehicle is ridden normally TIP If the spark plug shows a distinctly dif ferent color the engine could be oper...

Page 44: ...t in an upright posi tion A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and...

Page 45: ...4 Remove the oil filter element drain bolt to drain the oil from the oil filter element 5 Remove the oil filter element cover by removing the bolts 6 Remove the oil filter element and O rings 1 Engin...

Page 46: ...ter the engine and exhaust sys tem have cooled down NOTICE ECA11621 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oi...

Page 47: ...er case 4 Remove the sponge material from the air filter element frame 5 Clean the sponge material with solvent and then squeeze the re maining solvent out 6 Apply oil of the recommended type to the e...

Page 48: ...intenance NOTICE ECA10551 The carburetor has been set and ex tensively tested at the Yamaha fac tory Changing these settings without sufficient technical knowl edge may result in poor perfor mance of...

Page 49: ...r edge of the throttle grip Periodi cally check the throttle grip free play and if necessary have a Yamaha dealer adjust it EAU21402 Valve clearance The valve clearance changes with use resulting in i...

Page 50: ...ssories approved for this model WARNING EWA10512 Never overload your vehicle Opera tion of an overloaded vehicle could cause an accident Tire inspection The tires must be checked before each ride If t...

Page 51: ...oderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal characteristics EAU21944 Spoke wheels WARNING EWA10611 The wheels on this model are no...

Page 52: ...e specified clutch lever free play could be obtained as described above skip steps 4 7 4 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 5 Loosen the lockn...

Page 53: ...fied brake lever free play could be obtained as described above skip steps 4 7 4 Fully turn the adjusting bolt at the brake lever in direction a to loos en the brake cable 5 Loosen the locknut at the...

Page 54: ...sting bolt in direction a To lower the brake pedal turn the adjusting bolt in di rection b 3 Tighten the locknut WARNING EWA11232 After adjusting the brake pedal height the brake pedal free play must...

Page 55: ...smooth have a Yamaha dealer check the vehicle EAU22274 Brake light switches The brake light which is activated by the brake pedal and brake lever should come on just before braking takes ef fect If n...

Page 56: ...ke shoe has worn to the point that the wear indicator reaches the wear limit line have a Yamaha dealer replace the brake shoes as a set EAU22762 Drive chain slack The drive chain slack should be check...

Page 57: ...in direction b and then push the rear wheel forward NOTICE Improper drive chain slack will overload the en gine as well as other vital parts of the motorcycle and can lead to chain slippage or breaka...

Page 58: ...or riding in wet areas 1 Remove all dirt and mud from the drive chain with a brush or cloth TIP For a thorough cleaning have a Yamaha dealer remove the drive chain and soak it in solvent 2 Spray Yamah...

Page 59: ...etely protect the cable from water entry Therefore use care not to pour water directly onto the cover or cable when washing the vehicle If the cable or cover becomes dirty wipe clean with a moist clot...

Page 60: ...ealer at the intervals specified in the periodic maintenance and lubrication chart EAU51951 Checking the front fork The condition and operation of the front fork must be checked as follows at the inte...

Page 61: ...ne to raise the front wheel off the ground See page 7 31 for more information WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10752 2 Hold the lower en...

Page 62: ...d pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN NOTICE ECA10621 Never attempt to remove the battery cell seals as this...

Page 63: ...can cause permanent battery damage EAU23562 Replacing the fuses The main fuse is located behind panel A See page 7 7 The auxiliary DC jack fuse is located behind panel B See page 7 7 If a fuse is blow...

Page 64: ...cing the headlight bulb If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by re moving the bolt 2 Disconnect the headlight lead con nectors and then remove the headligh...

Page 65: ...unter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws NOTICE Do not over tighten the screws otherwise th...

Page 66: ...level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a moto...

Page 67: ...he locknut at the brake shoe plate and the brake lever free play adjusting nut 3 Slide the rubber cover back 4 Loosen the locknut at the brake le ver and then fully turn the brake lever free play adju...

Page 68: ...e that the slot in the brake shoe plate fits over the retainer on the fork leg 3 Insert the wheel axle from the right hand side and then install the axle nut 4 Lower the front wheel so that it is on t...

Page 69: ...e by re moving the brake torque rod cotter pin the nut and the bolt 2 Remove the brake pedal free play adjusting nut and then disconnect the brake rod from the brake cam shaft lever 3 Loosen the axle...

Page 70: ...rake rod onto the brake camshaft lever and then install the brake pedal free play adjusting nut onto the brake rod 4 Connect the brake torque rod to the brake shoe plate by installing the brake torque...

Page 71: ...ever should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine...

Page 72: ...e Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha deal...

Page 73: ...cleaning 1 Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug...

Page 74: ...a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a...

Page 75: ...d plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Wa...

Page 76: ...er This will coat the cylinder wall with oil WARNING To prevent dam age or injury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10952 e Remove the spark...

Page 77: ...stan dard MA Engine oil quantity Without oil filter element removal 1 00 L 1 06 US qt 0 88 Imp qt With oil filter element removal 1 10 L 1 16 US qt 0 97 Imp qt Air filter Air filter element Wet elemen...

Page 78: ...Right hand operation Rear brake Type Drum brake Operation Right foot operation Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 200 mm 7 9 in Rear s...

Page 79: ...TIFICATION NUMBER ENGINE SERIAL NUMBER MODEL LABEL INFORMATION EAU26401 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the...

Page 80: ...OISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any devi...

Page 81: ...entification numbers 10 1 Indicator light 4 1 K Kickstarter 4 8 L Labels location 1 1 Light switch 4 3 M Main switch 4 1 Maintenance and lubrication periodic 7 4 Maintenance emission control system 7...

Page 82: ...INDEX 11 2 1 2 3 4 5 6 7 8 9 10 11 12 W Wheel bearings checking 7 26 Wheel front 7 32 Wheel rear 7 34 Wheels 7 16 U53C23E0 book 2...

Page 83: ...U53C23E0_Hyoshi indd 3 2014 01 23 15 07 38...

Page 84: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2014 01 0 4 1 E U53C23E0_Hyoshi indd 4 2014 01 23 15 07 39...