Monthly Archives: July 2015

Owner/Operation manuals

I know, I know! These manuals can be downloaded from the Yamaha Australia site. It’s not the easiest thing to use though and is not the easiest thing to find either. So I thought what the hay, lets put them where all the other AG200 info is in the universe! Not only that, but it will be an interesting discussion on what was different in the manuals and therefore it may give you a hint on the changes Yamaha made to the bikes as well.

1983 AG200L – This is the bike that started it all folks. The first AG2001984_mc_ag200_m_mc2968 that came to Australia. There is some debate over the year of  ’83 or ’84 as the year of release. Yamaha used to introduce their new model range here a few months before Xmas. For example the “L” YZ motocross models were the ’84 year range but were actually released a month or two before the new year. My guess is the AG200 was the same, a few would of showed up here in late ’83 but most of them got off the boats in ’84. I haven’t seen a ’83 complied AG200 yet but I bet they are out there, or what’s left of them anyway!

1989 AG200W – So what happened between ’83 and ’89? Not much! Change 1989_mc_ag200_m_mc4131of colour was about it by the looks of it. This colour was probably the least liked of the AG200 range. The beige looked daggy real fast and made the seat look pink which was less than manly to the farmers involved at the time!

The manuals pretty much confirm the story as far as changes go. The ’89 manual is two pages longer than the older manual and there is a bit of info at the front making it quite clear that it is illegal to use the bike on public roads…say goodbye to the compliance plate of the old bike. In fact, on page 62 of the ’83 manual it states that the noise output is designed to meet ADR39 which is missing from the ’89 manual so Yamaha defiantly let ADR go on this model.

Starting to move into the nanny-state thinking here where there are more warnings about safety both for maintenance and riding. The fuel cock inspection and cleaning section is missing from the newer (p.33, ’83) bike manual which signifies Yamaha changing this part of the bike. The newer bike had no removable bowl under the fuel tap to catch rubbish.

I notice in the specifications section they take out the 30deg climbing ability in the new manual. Bit subjective was it Yamaha?! The engine is now a 3GX2 not a 3GX…wonder if anything was actually changed? The specifications format is changed around a bit but most of the info is still there and the newer manual has added a wiring diagram at the end. Nice touch.

1990 AG200A – The manual is an extra four pages long, 76 up from 72. Most of it is more brain-dead safety info in the first ten pages or so. Litigation must of been catching up with Yamaha! Not much else to report here except that the ’90 model is a better scan so download this one if your bike is around this era. Engine change in specs. to 3GX3.

1991 AG200B – First impressions are ‘meh’, same amount of pages, must be the same manual? Not so! All the safety rubbish is gone from the front. Cool…oh wait…its after the contents pages now! And they have added a ‘location of warning labels’ diagram…sigh!

This manual has the front fork oil change procedure removed from it so my guess is this is the year Yamaha removed the oil drain screw from the front forks. Strangely, the front headlight adjustment procedure has been removed as well. Engine specs. change again to 3GX4.

1992 AG200D – Same number of pages here again. Front cover is tarted up a bit. On page 41 (of the PDF doc) they have made a few additions to step 2c and 2g of the oil change procedure. Looks like the earlier manual forgot to tell people to put the filter back in! A few pages later they have actually added a tightening torque for the oil pressure check bolt –  7Nm which sounds a bit tight to me. I’d say they have added this because people are breaking them off.

On page 58 they are telling us to now lubricate brake lever pivot points with oil rather than grease. Why? I would always prefer grease than oil, particularly on an AG bike where oil will just get washed out after the first wet ride. The specs. section is all the same again except we have an upgrade to engine type 3GX5.

1993 AG200E – New manual is one page less. They have removed a page of safety label descriptions from the bike! Nothing else I can see except for the engine upgrade in the spec. section to a  3GX6.

1994 AG200F – Not much going on here. Page 46 gives us a change of info about the spark plug. They cut a heap of technical info out and add a little bit about how to install a spark plug with out a torque wrench. Nice work Yamaha. Once again we get an engine spec upgrade to 3GX7…keep rolling those big upgrades out guys!

1996 AG200FH – You get the feeling something is going to happen now! 1996_mc_ag200_m_mc5750-1They skipped a year and the manual has grown to 83 pages. Time for a colour update too, check it out! This is my preferred scheme of all the AG200s and the picture doesn’t do it justice.  Back to the manual…they dropped the imperial measurements from all the specifications throughout, which was a move forward. The description at the front of the manual has been simplified from 22 items to 15. I guess most people don’t need to know where the front fender, the tail-light and fuel tank is!

Interesting on p. 18 of the new manual that they drop the section telling you where the engine number is and tell you about the model label up on the head stem. On the previous page they want you to record the key ID, the VIN and the number on this model label rather than the engine number.

There are quite a few additions to the Periodic Maintenance section. A bit of butt covering at the start (in upper case I might add) with an addition about how maintenance can change depending on individual conditions etc. There is two additions to check in the Periodic Maintenance section; the kick stand and battery.

Here I was eagerly anticipating the introduction of the 3GX8 engine and they dumped it from the engine specs.! They dropped the minimum turning radius too. And the last big addition to report is the conversion table added to the last page.

There was a lot of little changes to this manual but most were irrelevant like extra cautions and stuff like that – lawyer changes!

1998 AG200FK – So this is the big one. Electric start! The manual is pretty 1997_mc_ag200f_m_mc6052much brand new so I wont go into the changes page by page. Its still a crappy old scan though! I will just look at the interesting specs. and other things. Now you might think that the picture at left is the same bike as in the last description but if you have a close look you will see the starter motor at the front of the engine and the larger front wheel and brake drum.

1999_mc_ag200_m_mc6619I do know that ’98 was not the first electric start bike though. I do think it was the first of the blue AG200s but the grey, electric start AG200 came along in ’86 – ’87. I had one so I know they came earlier than the blue bikes.

So what was new? The choke moved from the lower clutch side bar to up next to the ignition key. They still show the old choke in the manual under Controls/Instruments description. The switchgear is all new (they stuffed up the diagram), Electric start (no starter motor in the right or left view under description), 12V electrics with auxiliary plug up on the bars near the choke. Larger headlight, 21″ front wheel and larger front brake.

Because of all the changes there were a lot of new numbers in the specification section at the rear of the manual. Length was up to 2160mm from 2135mm, height was 1155mm, up from 1110mm. Seat height is up 10mm to 830mm, ground clearance up 10mm to 255mm, and weight up to 127kg from 121kg. Other changes occurred to caster angle and trail, obviously a 21″ front rim and an updated 12v electrical system capable of delivering reasonable current for a bike that may have accessories.

A few service things were new too. For the first time Yamaha recommended a 20w50 oil if you had temperatures to suit. I also noted that in the maintenance schedule that washing the oil filter was not even mentioned, you’re expected to replace it. And for the first time that I can remember, they tell us it’s OK to use the grease nipples on the swing-arm pivot!

2002 AG200FR – Here’s one for out Latin America friends! This manual is a biggie, 184 pages. Why so big? because there are two manuals, the first is English the second is Spanish. The English version has all the pictorial bugs mentioned in the ’89 manual fixed and it all seems good.

There is an added page for battery maintenance, the AG200 never had the best charging system and Yamaha are covering themselves again. There are two or three new pages going into more depth on changing globes, both headlight, tail-light and indicator. I find it funny that we are supposed to go back to grease for the stand pivots again! Finally there is an added piece in the specifications section warning against using car engine oils in the AG200’s wet clutch system.

2008 AG200FX(6v & 12V) – The AG200 was introduced around the same time as the first Apple Macintosh computer. So 24 years after the release of the system that revolutionised the the field of desktop publishing, Yamaha (or was it Yamaha Australia?) manages to get an AG200 manual out that is in a native digital format and not some dodgy scan! Way to go Yamaha!

We are back to 90 pages and it is soooo much better than this 1999_mc_ag200_m_mc6759other stuff that Yamaha Australia posts up for us to download. I couldn’t believe it when I saw all the imperial measurements. Yep they’re back! Its interesting because this manual also covers the 6v, non electric start model as well as the 12v version. They revived the old bike right down to the crusty old choke lever under the clutch side controls!

So all those spec. differences mentioned for the ’98 model  are all in this one! All in an easy to read, neat format. Nice.

2010 AG200FZ – Lucky last! This manual was a lot bigger than previous downloads and it shows. The quality is excellent.

First time for a very long time that Yamaha changed the introduction. Check out page 25, it the first time I’ve seen Yamaha mention the dual stands! Spark plug torque has gone up 1/2 a Nm to 18! Also a first…a decent index. Yamaha went out with a bang!

That’s it folks, that’s all Yamaha Australia have supplied anyway. I know there was an slightly updated model released in 2014, but Yamaha Australia haven’t posted up the user manual for that yet. When/if they do, I’ll post it up. If anyone out there can help me out with a link then I will get it up on here ASAP.

Cheers

AGman