AG200 service information

Maintaining and repairing motorcycles is just as enjoyable for me as riding them…I find it relaxing and satisfying when you know a job is done right. But maintenance and repairs can be frustrating, detrimental to your machine or even dangerous to yourself if you don’t have the required tools and service information. Good tools and service info are two must haves for any work on any bike in my opinion. So I have posted all the relevant data for the AG200 so you can access it to help you out on your AG journey. I will add more info as it becomes available and anyone who thinks I’m short on something just let me know.

1997 3GX – link to the first PDF format manual that I have found. It’s a scan but still very helpful.

3GX ’03 update – link to the updates for ’03.

3GX ’08 update – link to the ’08 updates.

These are manuals related to the Australian models but the rest of the world should be pretty close. They are also not as comprehensive as one might think but I will try and cover some of the discrepancies as time goes on.

Cheers

AGman

27 thoughts on “AG200 service information

  1. Thanks AGman, very informative. I just purchased an 86 AG200, very cheap, very rough and are looking for some engine side covers. Can you tell me what the cable operated mechanism near the kickstart assembly did/does.
    Best regards

    1. Hi Andy
      Thanks for the comments.
      You got an early one huh?! Good luck with the restoration.
      The assembly near the kick start lever is the automatic decompresser that goes up to the exhaust rocker cover on the head, via a cable. I dont know why they put it on because they aren’t hard to start without it and they left it off on the later models even the ones without electric start.
      Cheers
      Jim

  2. You sir are a bloody legend. The manuals are gonna be exceedingly helpful. I got a 85 model that was left on the side of the road for pick up in hard garbage. (a victorian thing) I asked the guy throwing it if I might partake and he was happy for me to take it. I tried it on the side of the road and it started…….so home to the trailer and been tinkering with it ever since.

    I’m afraid it won’t really look like an old AG by the time I’m done……but she’ll have a new life with me and the young fella.

    1. Thanks for the comments Sean.
      Yes the manuals can be helpful especially when your flying blind on a bike you haven’t worked on before. Enjoy your AG!
      Cheers
      AGman

  3. Hey man, thanks for taking the time to make time for research on a tough ass bike. I bought one a few weeks ago, mid 80’s model. Runs fine but needs some tender lovin’ care before I can hope to get it registered. For now, I’m trying to connect the headlights and speedometer, wires all messed up. I hope there’s something in the manuals to help me through. First time attempting to restore anything. Lets see how it goes.
    Cheers
    Uzair

    1. Hi Uzair

      Thanks for the comments. Good luck with the resto, you have chosen a good bike to do your first one – nice and simple. Having said this, an old timer once told me if you can restore anything used by a farmer you can restore anything! I think he was right! Check the service manual (download from my earlier post) for a wiring diagram for the headlight. Good luck and drop us a line if you need any help.

      Cheers
      AGman

        1. Hi Uzair
          As far as electrical properties go, the light will work fine. Not sure how you go about mounting it though. Shouldn’t be too hard, but its hard to say without looking at it. Wont be a problem if your handy with the tools.
          Cheers
          AGman

  4. Hello AG Man,

    Love your site, very helpful. However i am having trouble tracking down a kick start return spring for my 87′ AG 200. Any ideas? Part Number? or another model which uses the same spring?

    Thank you!

    Lachlan.

    1. Hi Lachlan
      Thanks for the comments.
      There are a few models that may work like the TW and the XT200, but they are rarer than any AG! Plenty of trashed AGs around…find a small country Yamaha dealer, they will probably have a wrecker hanging around.
      Cheers
      AGman

      1. Thanks for the info! I ended up sourcing a brand new spring for a TW from an eBay seller in Greece of all places for $25 delivered, should come in the mail this week.

        I’m in the process tidying up my little 87′ AG which is actually running like a dream (aside from having to manually pick the kick start off the floor every time i want to start it).

        Also the clutch is a little sticky after changing up gears, so when the RH case is off I’ll give it a new set of plates, is it likely they clutch springs will need changing too? the only reason i ask is that the only full clutch kit (springs included) i can find is from the UK where as i can get a plates only kit from closer to home for a fair bit less.

        Thanks again.

        Lachlan

        1. Hi Lachlan
          I have the photos for clutch replacement done, just need to do the writeup! Is probably a few posts away. I always replace the plates and springs as a set but most people don’t and still get away with it! Check out the specs in the manual and measure your springs if you want a definitive answer. I always do them because I think the clutch is borderline in the bike, especially if you up the gearing. My guess with the age of your bike that the springs will be under spec. They aren’t that expensive from Yamaha either. The manual tells you how to adjust the clutch via the lock-nut in the center of the unit. If the clutch is sticking, it may just need a tweek, when it slips is when you need to do the plates and springs.
          Keep us updated.
          Cheers
          AGman

  5. Hi there,
    I am having trouble getting my Ag to start. I have 12volts going into the starter solenoid but only 7volts going out the other side to the starter motor. I have brought a new solenoid and that does exactly the same. Any ideas why this might be and how to fix it?? Thanks Matt

    1. Hi Matt
      At what point are you measuring the 7 Volts? If its down at the starter motor then you are losing it in the cable. Check the connections at both ends, particularly the one at the starter end, it is right in the flow of crud from the front wheel and can suffer due to this. Also check the ground cable from the battery, check the battery end and the eyelet that connects onto the engine case bolt near the oil fill plug.
      Let me know if this helps…
      Cheers
      agman

      1. I measured 12volts on one side of the solenoid then when pressing the start button the solenoid clicks and there is only 7volts on the other side of the solenoid. both the new and old solenoids do this. Im guessing it has something to do with the other small 3 wires going into the top of the solenoid but I’m unsure what they do? one must come from the starter button?

        1. Hi Matt
          Simple ohms law if want to look it up. You have a high resistance somewhere in the high current path of the starter circuit. Somewhere between the battery and the starter you have a high resistance that drops the circuit by 5V when solenoid switches the battery into the circuit. It could be before the solenoid, after the solenoid or the earth cable as I have mentioned. Inspect and clean all these connectors even if they look OK. The solenoid is the first thing I would of suspected, then I would be looking at all the high current cabling related to it now.
          Good luck, keep us updated…
          Cheers
          AGman

    1. Hi Jan
      Have been getting copyright spiders giving my site a lot of attention lately and thought I would cool it for a while. Keep checking back here and the forum and I’ll get them up again soon.
      Cheers
      AGman

  6. Hi there AG Man, I have a 3gx motor that i am going to give a new life in an offroad go-kart for my grandson, I am wondering if there is a list of engine numbers – year of manufacture out there as I don’t have the rest of the bike.
    I am looking for a carbi and cylinder mount and CDI module and maybe a harness to attach the module to the engine.
    The engine number is 3GX-072286.
    Any help is most appreciated.
    Graham
    Also I have registered on the Forum but have not received a confirmation yet.
    Many thanx
    Graham

    1. Hi Graham
      Is your bike electric start or kick only? Try Parts listings for parts listings, the older listing is for pre-electric leg, the newer listing is for electric leg. There are few changes for all the years for these different models. If there were any parts updates, your Yamaha dealer should have the newer part listed in his listings.
      I will check out the forum…seems to be an issue, lots of people signing up but not getting the confirmation email.
      Cheers
      AGman

  7. I bought an AG200, 2004 model in very excellent condition from a company. The motorcycle was thoroughly serviced by the dealers prior to selling it. However the motorcycle has a hard start. You have to kick it several times before starting. However when i was getting it from the company it used to start with just one kick. The only change is that after purchase i immediately replaced a broken cable – one that moves when you are kicking (it runs from close to the kicking pedal to the upper side close to the tank where it connects to some round metal plate). Please assist what the problem could be. Is it this cable that has changed the behaviour of the motorcycle.

    1. Hi Timothy
      The cable is for the auto decompresser, it opens the exhaust valve slightly to reduce compression so the bike is easier to start. My guess is that it is adjusted incorrectly and it is holding the exhaust valve open too much making it harder to start. You need to get this cable adjusted correctly or remove it completely until you do because it may be holding the exhaust valve open all the time which will damage the engine. Unfortunately, I have no information on this procedure so I cant help you out there but a mechanic in your area should be able to help you out. If not, just remove the cable, it will be fine with out it.
      Cheers
      AGman

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