Yamaha Ytm 200 Ern Ek El Repair Manual Improved
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Yamaha Ytm 200 Ern Ek El Repair Manual Improved
INTRODUCTION:
This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if follovved, vvill ensure more reliable vehicle operation and a longer service life. The need for costly overhaul vvork vvill be greatly reduced. This information applies to vehicles already in service and to new vehicles that are being prepared for sale. All service technicians should be familiar vvith this entire chapter.
MAINTENANCE INTERVALS CHARTS:
The follovving charts should be considered strictly as a guide to general maintenance and lubrication intervals. You must take into consideration that vveather, terrain, geographical location, and a variety of individual uses. This time schedule should be altered to match individual ovvner’s requirements. For example, if the machine is continually operated in an area of high humidity, then all parts must be lubricated much more frequently that shovvn on the chart to avoid damage caused by vvater to metal parts.
TABLE OF CONTENTS:
Yamaha Ytm 200 Ern Ek El Repair Manual Improved
INDEX................................................... 1 YTM 225 DRS Supplementary Service Manual................ 2 CONTENTS............................................ 3 SPECIAL TOOLS................................... 4 FRONT FORK...................................... 5 SPECIFICATIONS.................................. 12 CABLE ROUTING................................... 25 YTM 225 DRN Supplementary Service Manual................ 30 CONTENTS............................................ 30 SPECIAL TOOLS....................................... 31 MIDDLE GEAR SERVICE................................. 33 DRIVE SHAFT......................................... 55 ELECTRICAL.......................................... 60 YTM225DRN CIRCUIT DIAGRAM....................... 61 ELECTRICAL COMPONENTS 1......................... 63 ELECTRICAL COMPONENTS 2......................... 64 ELECTRIC STARTING SYSTEM........................ 65 TROUBLESHOOTING CHART....................... 67 STARTING CIRCUIT CUT-OFF SYSTEM............. 69 CHARGING SYSTEM................................. 74 TROUBLESHOOTING CHART....................... 76 IGNITION SYSTEM................................. 80 TROUBLESHOOTING CHART....................... 82 TROUBLESHOOTING CHART (2)................... 85 LIGHTING SYSTEM................................. 88 TROUBLESHOOTING CHART....................... 90 SIGNAL SYSTEM................................... 91 TROUBLESHOOTING CHART....................... 93 SVVITCHES................................... 94 APPENDICES.......................................... 95 SPECIFICATIONS.................................. 95 CABLE ROUTING...................................107 VVIRING DIAGRAM.................................111 YTM 200 ERN Supplementary Service Manual................112 SPECIAL TOOLS.......................................112 NEW SERVICE.........................................113 REVERSE SYSTEM..................................113 MIDDLE GEAR.....................................114 DAMPER CAM......................................125 ELECTRICAL COMPONENTS...........................127 APPENDICES..........................................128 SPECIFICATIONS......................................128 1. GENERAL SPECIFICATIONS.......................128 II. MAINTENANCE SPECIFICATIONS..................130 GENERAL TORQUE SPECIFICATIONS...................140 DEFINITION OF UNITS.............................140 ELECTRICAL..........................................141 CIRCUIT DIAGRAM.................................141 VVIRING DIAGRAM.................................142 YTM 225 DXK Supplementary Service Manual................ 0 SPECIAL TOOLS.......................................144 MAINTENANCE AND LUBRICATION CHART...................145 PERIODIC MAINTENANCE............................145 LUBRICATION INTERVALS...........................145 NEW SERVICE.........................................146 ENGINE..........................................146 MIDDLE GEAR SERVICE.............................147 CHASSIS.........................................150 FRONT FORK..................................150 REAR SHOCK ABSORBER.........................154 SVVINGARM...................................157 FINAL GEAR..................................163 DRIVE SHAFT.................................172 SPECIFICATIOIMS.....................................173 I. GENERAL SPECIFICATIONS.......................173 II. MAINTENANCE SPECIFICATIONS..................175 GENERAL TOROUE SPECIFICATIONS...................184 CONVERSION TABLES...............................185 EXPLODED DIAGRAMS...................................186 LUBRICATION DIAGRAMS................................201 CABLE ROUTING.......................................204 YTM225DXK VVIRING DIAGRAM...........................206 YTM 200 EK Service Manual...............................207 CHAPTER 1.GENERAL INFORMATION.......................208 MACHINE IDENTIFICATION..........................209 SPECIAL TOOLS...................................210 CHAPTER 2.PERIODIC INSPECTIONS ANDADJUSTMENT........215 INTRODUCTION....................................216 MAINTENANCE INTERVALS CHARTS....................216 PERIODIC MAINTENANCE........................216 LUBRICATION INTERVALS.......................217 ENGINE..........................................218 CHASSIS.........................................224 ELECTRICAL......................................232 CHAPTER 3.ENGINE OVERHAUL...........................234 ENGINE REMOVAL..................................236 ENGINE DISASSEMBLY..............................240 INSPECTION AND REPAIR...........................248 ENGINE ASSEMBLY ANDADJUSTMENT...................268 MIDDLE GEAR SERVICE.............................289 CHAPTER 4.CARBURETION...............................295 CHAPTER 5.CHASSIS...............................301 FRONT WHEEL.....................................303 REAR VVHEEL.....................................305 FRONT FORK......................................311 STEERING HEAD...................................316 CABLES AND FITTINGS.............................318 SHAFT DRIVE.....................................319 CARBURETOR......................................296 AIR CLEANER AND CRANKCASE VENTILATION SYSTEM....300 CHAPTER 5.CHASSIS...................................301 FRONT WHEEL.....................................303 REAR VVHEEL.....................................305 FRONT FORK......................................311 STEERING HEAD...................................316 CABLES AND FITTINGS.............................318 SHAFT DRIVE.....................................319 DRIVE SHAFT (COUPLING GEAR).....................327 CHAPTER 6.ELECTRICAL................................328 YTM200EK CIRCUIT DIAGRAM........................329 ELECTRIC STARTING SYSTEM........................330 STARTING CIRCUITOPERATION.......................331 STARTER MOTOR...................................332 STARTER RELAY...................................333 STARTING CIRCUITCUT-OFF RELAY...................334 CHARGING SYSTEM.................................336 FLYWHEEL MAGNETO AND RECTIFIER..................337 IGNITION SYSTEM.................................339 LIGHTING SYSTEM.................................343 CHAPTER 7. APPENDICES...............................350
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