2002 Yamaha ATV YFA1(P),YFMA1W Service Manual

EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page. 3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa- nied by corresponding illustrations. EXPLODED DIAGRAMS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs. 2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6. The meanings of the symbol marks are given on the next page. 4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart. - www.instant-manuals.com -

EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 8 are printed on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Chassis 7 Electrical 8 Troubleshooting Illustrated symbols 9 to E are used to identify the specifications appearing in the text. 9 Filling fluid 0 Lubricant A Special tool B Torque C Wear limit, clearance D Engine speed E Ω, V, A Illustrated symbols F to L in the exploded diagrams indicate the types of lubricants and lubrication points. F Apply engine oil G Apply gear oil H Apply molybdenum disulfide oil I Apply wheel bearing grease J Apply lightweight lithium soap base grease K Apply molybdenum disulfide grease L Apply silicon grease Illustrated symbols M to N in the exploded diagrams indicate where to apply a locking agent M and when to install a new part N. M Apply the locking agent (LOCTITE ® ) N Replace 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I M N GEN INFO SPEC CHK ADJ ENG CARB CHAS – + ELEC TRBL SHTG T R . . E G M B LS M S J K L LT New - www.instant-manuals.com -

CONTENTS SPECIFICATIONS ............................................................................................1 GENERAL SPECIFICATIONS ..................................................................1 MAINTENANCE SPECIFICATIONS .........................................................2 ENGINE ................................................................................................2 CHASSIS ..............................................................................................2 ELECTRICAL ........................................................................................3 CABLE ROUTING .....................................................................................4 PERIODIC CHECKS AND ADJUSTMENTS ..................................................17 SEAT, CARRIERS AND FENDERS ........................................................17 SEAT, FRONT CARRIER, FRONT BUMPER AND CENTER COVER ....17 FRONT GRILL ASSEMBLY AND FRONT FENDER ..........................19 REAR CARRIER AND REAR FENDER ..............................................20 ELECTRICAL ..........................................................................................22 ADJUSTING THE HEADLIGHT BEAMS ............................................22 REPLACING A HEADLIGHT BULB ....................................................22 ELECTRICAL .................................................................................................24 IGNITION SYSTEM .................................................................................24 CIRCUIT DIAGRAM ............................................................................24 CHARGING SYSTEM .............................................................................25 CIRCUIT DIAGRAM ............................................................................25 LIGHTING SYSTEM ................................................................................26 CIRCUIT DIAGRAM ............................................................................26 TROUBLESHOOTING ........................................................................27 SIGNAL SYSTEM ...................................................................................29 CIRCUIT DIAGRAM ............................................................................29 YFM125S WIRING DIAGRAM - www.instant-manuals.com -

– 1 – SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model YFM125S Model code number 1C51 Dimensions Overall length 1,710 mm (67.3 in) Overall width 990 mm (39.0 in) Overall height 980 mm (38.6 in) Seat height 705 mm (27.8 in) Wheelbase 1,080 mm (42.5 in) Minimum ground clearance 145 mm (5.7 in) Basic weight Wet (with oil and a full fuel tank) 152 kg (335 lb) Dry (without oil and fuel) 144 kg (317 lb) Maximum load (except vehicle) 100 kg (220 lb) Fuel Type Unleaded gasoline only Fuel tank capacity 7.6 L (1.67 Imp gal, 2.01 US gal) Reserve amount 1.3 L (0.28 Imp gal, 0.34 US gal) Spark plug Type/manufacturer CR7HS/NGK Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Electrical Ignition system DC C.D.I. Generator system A.C. magneto generator Battery capacity 12V 12Ah Battery type 12N12C-4A-2 Headlight type Bulb type Headlight bulb type Krypton Bulb wattage (quantity) Headlight 12 V 30 W/30 W (2 pc.) Tail/brake light 12 V 5 W/21 W (1 pc.) Neutral indicator light 12 V 1.7 W (1 pc.) Reverse indicator light 12 V 1.7 W (1 pc.) GENERAL SPECIFICATIONS - www.instant-manuals.com -

– 2 – SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE CHASSIS Tightening torques Model YFM125S Carburetor I.D. mark 5VJ2 10 Main jet (M.J) # 77.5 Main air jet (M.A.J) ø 1.3 Jet needle (J.N) 4HPY46-1 Needle jet (N.J) O-1M Cutaway (C.A) 2.5 Pilot air jet (P.A.J) # 130 Pilot outlet (P.O) ø 0.7 Pilot jet (P.J) # 12.5 Bypass 1 (B.P.1) 1.1 Valve seat size (V.S) 1.8 Starter jet (G.S) # 45 Fuel level (F.L) 3.5 ~ 4.5 mm (0.14 ~ 0.18 in) With special tool Engine idling speed 1,650 ~ 1,750 r/min Intake vacuum 26.7 kPa (200 mmHg, 7.88 inHg) Part to be tightened Thread size Tightening torque Remarks Nm m · kg ft · lb Footrest board and footrest bracket M5 7 0.7 5.1 Footrest and footrest bracket M6 10 1.0 7.2 Front fender and frame M6 7 0.7 5.1 Front carrier and front grill M6 7 0.7 5.1 Fuel tank M6 10 1.0 7.2 - www.instant-manuals.com -

– 3 – SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model YFM125S C.D.I. Magneto model/manufacturer F1C5/YAMAHA Pickup coil resistance 248 ~ 372 Ω at 20 °C (68 °F) (lead color) (white-red) C.D.I. unit model/manufacturer 3FA/YAMAHA Charging system Type A.C. magneto generator Magneto model/manufacturer F1C5/YAMAHA Charging coil resistance 0.8 ~ 1.2 Ω at 20 °C (68 °F) (lead color) (white-white) Charging current (Minimum) 6.2 A at 1,500 r/min (Maximum) 13 A at 5,000 r/min Standard output 14 V 150 W at 5,000 r/min Rectifier/regulator Model/manufacturer SH640E-11/SHINDENGEN Regulator type Semi conductor short circuit type No load regulated voltage (DC) 14.0 ~ 15.0 V Rectifier capacity 14.0 A Withstand voltage 200 V Electric starting system Type Constant mesh Starter motor Model/manufacturer 3FA/YAMAHA Output 0.4 kW Armature coil resistance 0.019 ~ 0.023 Ω at 20 °C (68 °F) Overall length (brush) 10.0 mm (0.39 in) <Limit> <3.5 mm (0.14 in)> Brush spring pressure 552 ~ 828 g Commutator diameter 22.0 mm (0.87 in) <Wear limit> <21.0 mm (0.83 in)> Mica undercut 1.5 mm (0.06 in) Starter relay Model/manufacturer MS5E-661/JIDECO Amperage rating 100 A Coil resistance 4.18 ~ 4.62 Ω at 20 °C (68 °F) Starting circuit cut off relay Model/manufacturer ACA12115-1/MATSUSHITA Coil resistance 72 ~ 88 Ω at 20 °C (68 °F) Diode No Circuit breaker Type Fuse Amperage for individual circuit Main 15 A - www.instant-manuals.com -

– 4 – SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake switch lead 2 Rear brake cable 3 Front brake cable 4 Front brake switch lead 5 Throttle cable 6 Fuel tank breather hose 7 Headlight lead (left) 8 Headlight lead (right) 9 Neutral/reverse indicator light lead 0 Main switch lead A Coupler cover B Steering shaft OFF RUN ENG.STOP LO HI 0FF LIGHTS 1 4 2 3 É 8 7 B A Ë Ê Ì 9 0 6 5 È - www.instant-manuals.com -

– 5 – SPEC CABLE ROUTING È Fasten the front brake switch lead with two plastic bands. É Fasten the rear brake switch lead and handlebar switch lead with two plastic bands. Ê Do not pull the wire harness after fastening it. Ë When installing the front fender, do not pinch the coupler cover. Ì Pass the leads and wire harness through the guides on the front fender as shown. OFF RUN ENG.STOP LO HI 0FF LIGHTS 1 4 2 3 É 8 7 B A Ë Ê Ì 9 0 6 5 È - www.instant-manuals.com -

– 6 – SPEC CABLE ROUTING 1 Front brake cable 2 Throttle cable 3 Rear brake cable 4 Rear brake switch lead 5 Handlebar switch lead 6 Wire harness 7 Front brake switch lead È Pass the front brake cable and rear brake cable through the cable guide. É Route the rear brake cable to the inside of the front fender bracket. Ê Pass the air duct inlet and outlet hoses between the brake cables. Ë Cross the front brake cables behind the steering shaft. Route the right front brake cable in front of the left front brake cable. 1 2 3 4 7 5 È É Ê Í Ë Ì 6 - www.instant-manuals.com -

– 7 – SPEC CABLE ROUTING Ì Put the cover on the couplers, and then fasten a plastic band around the middle of the cover. Í Route the rear brake switch lead and the handlebar switch lead behind the throttle cable and the rear brake cable. 1 2 3 4 7 5 È É Ê Í Ë Ì 6 - www.instant-manuals.com -

2002 Yamaha ATV YFA1(P),YFMA1W Service Manual

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