Yamaha YFM200N 1983-1986 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Yamaha Model: YFM200N Model Nickname: Moto-4 Production Years Covered: 1983, 1984, 1985, 1986 Codes Manual Product Code: Likely internal, not provided Vehicle Chassis Codes: YFM200N (specific VIN prefixes may vary by region) 👋 Introduction Market Position Vehicle Segment: Sport ATV / All-Terrain Vehicle Target Demographic: Recreational riders, utility users, entry-level ATV enthusiasts. Competitive Analysis Key Competitors Era: Early to mid-1980s sport ATVs from manufacturers like Honda (e.g., TRX200), Kawasaki (e.g., KLT200), Suzuki (e.g., ALT250), and possibly early Yamaha models like the YFM250R. Key Features Engine Configuration: Single-cylinder, air-cooled, two-stroke (common for this era, though 200cc can sometimes be 4-stroke, YFM200N is typically 2-stroke) or four-stroke. Transmission Type: Typically a 5-speed manual transmission with an automatic clutch or a semi-automatic transmission. Drivetrain Configuration: Shaft drive or chain drive, likely RWD for the YFM200N. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Manual Scope: Complete Factory Official Service Manual Intended Audience: Yamaha Technicians, Professional Mechanics, DIY Enthusiasts Page Count Estimated Page Count: Hundreds of pages (actual count not specified, but indicative of comprehensive content) Language Language: English (Assumed for North American market product description) Format Download Format: PDF Download Printability: Printable in its entirety 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage of engine disassembly, assembly, inspection, adjustment, and troubleshooting. Fuel System: Carburetor tuning, fuel pump operation, fuel line maintenance. Electrical System: Wiring diagrams, ignition system diagnosis and repair, lighting, charging system (stator, regulator/rectifier), battery maintenance. Drivetrain: Chain drive maintenance, sprocket inspection and replacement, gearbox operation and overhaul. Suspension: Front fork servicing, rear shock absorber inspection and replacement, linkage lubrication. Brakes: Drum brake inspection, adjustment, and component replacement (front and rear). Chassis And Body: Frame inspection, body panel removal and installation, seat, handlebars, fenders. Wheels And Tires: Tire pressure checks, wheel bearing inspection, rim maintenance. Procedures Included Maintenance Procedures: Oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement, valve clearance checks. Diagnostic Procedures: Troubleshooting guides for common performance issues, starting problems, electrical faults. Repair Procedures: Step-by-step instructions for engine rebuilds, carburetor overhauls, brake system repairs, electrical component replacement. Adjustment Procedures: Carburetor idle and mixture adjustments, brake cable tension, clutch lever free play. Technical Depth Depth Of Information: Comprehensive factory-level detail, suitable for complete mechanical overhauls and advanced diagnostics. Special Tools: Likely lists required special Yamaha tools for specific procedures (e.g., flywheel puller, bearing drivers). Torque Specifications: Detailed torque values for critical fasteners throughout the vehicle. Clearances And Tolerances: Precise specifications for engine component clearances (e.g., piston ring gap, valve stem clearance). 📊 Manual Specifications File Format File Type: PDF Searchability: Presumed to be searchable text within the PDF for quick information retrieval. Print Quality Print Resolution: High resolution suitable for clear printing of text and diagrams. Binding Type Binding Style: N/A (Digital PDF download) Paper Type Paper Quality: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, 4-stroke, SOHC Displacement: 195 cc Bore X Stroke: 66.0 mm x 57.0 mm Compression Ratio: 9.7:1 Carburetor Model: Mikuni VM26SS (example, specific variant may differ) Performance Horsepower: Approximately 15-18 HP (estimated, actual figures vary by tuning and year) Torque: Approximately 12-14 lb-ft (estimated) Fuel System Fuel Type: Unleaded gasoline Fuel Tank Capacity: Approximately 2.6 US gallons (9.8 L) Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) Cooling System Cooling Method: Air cooling 🔧 Transmission Standard Transmission Type: 5-speed manual with automatic clutch Optional Optional Transmission: N/A (Typically single transmission option for this model) Features Drive System: Shaft drive (RWD) Final Drive: Bevel gear (shaft drive) 📐 Dimensions Exterior Overall Length: Approximately 71.5 inches (1815 mm) Overall Width: Approximately 40.0 inches (1015 mm) Overall Height: Approximately 43.1 inches (1095 mm) Weights Dry Weight: Approximately 357 lbs (162 kg) Curb Weight: Not explicitly provided, but typically around 380-400 lbs with fluids. Ground Clearance: Approximately 6.3 inches (160 mm) Wheels And Tires Front Tire Size: AT22 x 8-10 (common for the era) Rear Tire Size: AT22 x 10-10 (common for the era) Front Wheel Type: Steel, 10-inch diameter Rear Wheel Type: Steel, 10-inch diameter 🛡️ Safety Features Ratings Atv Safety Standards: Adheres to industry standards for ATVs of its time; modern safety features not applicable. Active Features Braking System: Front and rear drum brakes. Throttle Limiter: Likely equipped with a throttle limiter screw for beginner control. Passive Features Lighting: Single halogen headlight, dual taillight/stoplight. Operator Control: Handlebar controls with clutch lever, throttle, and brake levers. 💡 Technology Features Infotainment Infotainment Systems: N/A (This is a 1980s utility/recreational ATV with no electronic infotainment systems). Driver Assistance Driver Assistance Features: N/A (No electronic driver assistance features). Connectivity Connectivity Options: N/A (No electronic connectivity features). 🔧 Maintenance Service Intervals Engine Oil Change: Every 600 miles or 6 months (typical for the era). Air Filter Cleaning: Every 600 miles or annually, depending on operating conditions. Spark...
Early to mid-1980s sport ATVs from manufacturers like Honda (e.g., TRX200), Kawasaki (e.g., KLT200), Suzuki (e.g., ALT250), and possibly early Yamaha models like the YFM250R.
Key Features
Engine Configuration:
Single-cylinder, air-cooled, two-stroke (common for this era, though 200cc can sometimes be 4-stroke, YFM200N is typically 2-stroke) or four-stroke.
Transmission Type:
Typically a 5-speed manual transmission with an automatic clutch or a semi-automatic transmission.
Drivetrain Configuration:
Shaft drive or chain drive, likely RWD for the YFM200N.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Manual Scope:
Complete Factory Official Service Manual
Intended Audience:
Yamaha Technicians, Professional Mechanics, DIY Enthusiasts
Page Count
Estimated Page Count:
Hundreds of pages (actual count not specified, but indicative of comprehensive content)
Language
Language:
English (Assumed for North American market product description)
Format
Download Format:
PDF Download
Printability:
Printable in its entirety
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive coverage of engine disassembly, assembly, inspection, adjustment, and troubleshooting.
Fuel System:
Carburetor tuning, fuel pump operation, fuel line maintenance.
Electrical System:
Wiring diagrams, ignition system diagnosis and repair, lighting, charging system (stator, regulator/rectifier), battery maintenance.
Drivetrain:
Chain drive maintenance, sprocket inspection and replacement, gearbox operation and overhaul.
Suspension:
Front fork servicing, rear shock absorber inspection and replacement, linkage lubrication.
Brakes:
Drum brake inspection, adjustment, and component replacement (front and rear).
Chassis And Body:
Frame inspection, body panel removal and installation, seat, handlebars, fenders.
Wheels And Tires:
Tire pressure checks, wheel bearing inspection, rim maintenance.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement, valve clearance checks.
Diagnostic Procedures:
Troubleshooting guides for common performance issues, starting problems, electrical faults.
Repair Procedures:
Step-by-step instructions for engine rebuilds, carburetor overhauls, brake system repairs, electrical component replacement.
Adjustment Procedures:
Carburetor idle and mixture adjustments, brake cable tension, clutch lever free play.
Technical Depth
Depth Of Information:
Comprehensive factory-level detail, suitable for complete mechanical overhauls and advanced diagnostics.
Special Tools:
Likely lists required special Yamaha tools for specific procedures (e.g., flywheel puller, bearing drivers).
Torque Specifications:
Detailed torque values for critical fasteners throughout the vehicle.
Clearances And Tolerances:
Precise specifications for engine component clearances (e.g., piston ring gap, valve stem clearance).
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Presumed to be searchable text within the PDF for quick information retrieval.
Print Quality
Print Resolution:
High resolution suitable for clear printing of text and diagrams.
Binding Type
Binding Style:
N/A (Digital PDF download)
Paper Type
Paper Quality:
N/A (Digital PDF download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 4-stroke, SOHC
Displacement:
195 cc
Bore X Stroke:
66.0 mm x 57.0 mm
Compression Ratio:
9.7:1
Carburetor Model:
Mikuni VM26SS (example, specific variant may differ)
Performance
Horsepower:
Approximately 15-18 HP (estimated, actual figures vary by tuning and year)
Torque:
Approximately 12-14 lb-ft (estimated)
Fuel System
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approximately 2.6 US gallons (9.8 L)
Ignition System
Ignition Type:
CDI (Capacitor Discharge Ignition)
Cooling System
Cooling Method:
Air cooling
🔧 Transmission
Standard
Transmission Type:
5-speed manual with automatic clutch
Optional
Optional Transmission:
N/A (Typically single transmission option for this model)
Features
Drive System:
Shaft drive (RWD)
Final Drive:
Bevel gear (shaft drive)
📐 Dimensions
Exterior
Overall Length:
Approximately 71.5 inches (1815 mm)
Overall Width:
Approximately 40.0 inches (1015 mm)
Overall Height:
Approximately 43.1 inches (1095 mm)
Weights
Dry Weight:
Approximately 357 lbs (162 kg)
Curb Weight:
Not explicitly provided, but typically around 380-400 lbs with fluids.
Ground Clearance:
Approximately 6.3 inches (160 mm)
Wheels And Tires
Front Tire Size:
AT22 x 8-10 (common for the era)
Rear Tire Size:
AT22 x 10-10 (common for the era)
Front Wheel Type:
Steel, 10-inch diameter
Rear Wheel Type:
Steel, 10-inch diameter
🛡️ Safety Features
Ratings
Atv Safety Standards:
Adheres to industry standards for ATVs of its time; modern safety features not applicable.
Active Features
Braking System:
Front and rear drum brakes.
Throttle Limiter:
Likely equipped with a throttle limiter screw for beginner control.
Passive Features
Lighting:
Single halogen headlight, dual taillight/stoplight.
Operator Control:
Handlebar controls with clutch lever, throttle, and brake levers.
💡 Technology Features
Infotainment
Infotainment Systems:
N/A (This is a 1980s utility/recreational ATV with no electronic infotainment systems).
Driver Assistance
Driver Assistance Features:
N/A (No electronic driver assistance features).
Connectivity
Connectivity Options:
N/A (No electronic connectivity features).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 600 miles or 6 months (typical for the era).
Air Filter Cleaning:
Every 600 miles or annually, depending on operating conditions.
Spark Plug Replacement:
Every 1,800 miles or 18 months (typical).
Valve Clearance Check:
Every 1,800 miles or 18 months (typical).
Chain Lubrication Adjustment:
Every 300 miles or monthly, and adjust as needed.
Fluid Specifications
Engine Oil Type:
Yamalube 4 (or equivalent API SE, SF, SG service classification, SAE 10W-40 or 20W-40 recommended depending on temperature).
Engine Oil Capacity:
Approximately 1.8 L (1.9 US qt) for oil change, 2.1 L (2.2 US qt) for oil filter change.
Gear Oil Type:
Yamalube Hypoid Gear Oil (or equivalent SAE 80W-90 API GL-4).
Gear Oil Capacity:
Approximately 100 ml (0.1 US qt) for final drive.
Known Issues
Common Wear Items:
Chain and sprockets, brake shoes, wheel bearings, swingarm bushings, carburetor jets due to fuel degradation, CDI unit (can be prone to failure with age).
Engine Performance Degradation:
Carbon buildup in exhaust and piston rings, carburetor jet clogging, weak ignition spark.
Yamaha has a long and successful history in ATV manufacturing, starting with the groundbreaking 'Three Wheelers' and transitioning to popular 'Four Wheelers' like the Moto-4 and later Warrior and Raptor models.
Model Evolution
Moto-4 Lineage:
The YFM200N Moto-4 was part of Yamaha's early entry into the 4-wheel ATV market, establishing a platform for more performance-oriented and utility-focused models that followed.
Predecessors And Successors:
Evolved from Yamaha's 3-wheelers and paved the way for the YFM225, YFM250, and the sportier YFM250R.
Production
Manufacturing Location:
Likely manufactured in Japan or at Yamaha's overseas facilities at the time.
Market Impact:
Contributed to Yamaha's growing market share in the emerging ATV segment, offering a balance of utility and recreational capability.
🏆 Awards & Recognition
Recognitions
Industry Awards:
Specific awards for the YFM200N are unlikely to be widely documented, but it was a significant model in Yamaha's ATV lineup during its production years.
Ratings
Consumer Ratings:
Generally considered a reliable and capable utility ATV for its class and era.
Certifications
Safety Certifications:
Met all relevant safety certifications for ATVs in its production markets.
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