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- Page 1 2002 YFA1 3FA-AE1 SUPPLEMENTARY SERVICE MANUAL...
- Page 3 Service Manual together with the following manual. YFA1W SERVICE MANUAL: 3FA-ME1 YFA1(P) 2002 SUPPLEMENTARY SERVICE MANUAL 2001 by Yamaha Motor Co., Ltd. First Edition, May 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.
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Page 4: Important Information
EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. -
Page 5: How To Use This Manual
HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1: This is a chapter with its symbol on the upper right of each page. 2nd title 2: This title appears on the upper of each page on the left of the chapter sym- bol. - Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the SPEC top right of each page and indicate the subject INFO of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Drive train 7 Chassis 8 Electrical...
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Page 7: Table Of Contents
CONTENTS GENERAL INFORMATION ................1 MACHINE IDENTIFICATION ..............1 MODEL LABEL ..................1 SPECIFICATIONS ....................2 GENERAL SPECIFICATIONS ..............2 MAINTENANCE SPECIFICATIONS ............3 ENGINE ....................3 CHASSIS ....................5 ELECTRICAL ..................6 CABLE ROUTING ..................8 PERIODIC CHECKS AND ADJUSTMENTS ..........14 INTRODUCTION ..................14 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ......14 CHASSIS ....................15 ADJUSTING THE FRONT BRAKE .............15 CHASSIS ......................16 STEERING SYSTEM ................16... -
Page 9: General Information
MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts. – 1 –... -
Page 10: Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model YFA1 (P) 2002 Model code number 3FAY (CDN, Europe and Oceania) Engine: Engine type Air-cooled 4-stroke, SOHC Cylinder arrangement Forward-inclined single cylinder Displacement 124 cm Bore × stroke 49 × 66 mm (1.93 × 2.60 in) Compression ratio 9.0 : 1 Compression pressure... -
Page 11: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model YFA1 (P) 2002 Cylinder: Bore size 48.99 ~ 49.03 mm (1.9287 ~ 1.9303 in)<49.15 mm (1.935 in)> Measuring point “ ” 45 mm (1.77 in) Camshaft: Drive method Chain drive (left) Cam dimensions Intake “A”... - Page 12 SPEC MAINTENANCE SPECIFICATIONS Model YFA1 (P) 2002 Inside diameter (valve guide) Intake 5.000 ~ 5.012 mm (0.197 in) Exhaust 5.000 ~ 5.012 mm (0.197 in) Stem-to-guide clearance Intake 0.010 ~ 0.037 mm (0.004 ~ 0.0014 in) Exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) Stem runout limit 0.01 mm (0.0004 in) Valve seat width...
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Page 13: Chassis
SPEC MAINTENANCE SPECIFICATIONS Model YFA1 (P) 2002 Side clearance Top ring 0.03 ~ 0.07 mm (0.0012 ~ 0.0027 in) Second ring 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) Carburetor: I.D. mark 3FA02 Main jet (M.J.) #82.5 Main air jet (M.A.J.) ø1.3 Jet needle... -
Page 14: Electrical
5 ~ 8 mm (0.20 ~ 0.31 in) At lever pivot. ELECTRICAL Model YFA1 (P) 2002 C.D.I.: Magneto model/manufacturer F3FA/YAMAHA 248 ~ 372 Ω at 20 °C (68 °F) Pickup coil resistance (lead color) (White–Red) C.D.I. unit model/manufacturer 3FA/YAMAHA Ignition coil:... -
Page 15
8.0 A Withstand voltage 200 V Electric starting system: Type Constant mesh Starter motor Model/manufacturer 3FA1/YAMAHA Output 0.4 kW 0.019 ~ 0.023 Ω at 20 °C (68 °F) Armature coil resistance Overall length (brush) 10.0 mm (0.39 in)
<3.5 mm (0.14 in>... -
Page 16: Cable Routing
SPEC CABLE ROUTING CABLE ROUTING 1 Throttle cable 2 Band 3 Breather hose 4 Rear brake switch lead 5 Rear brake cable 6 Front brake cable 7 Front brake switch lead – 8 –... - Page 17 SPEC CABLE ROUTING 1 Front brake cable È Pass leads in front of the brake cable and con- 2 Band nect them inside the headlight body. 3 Rear brake cable É Pass the inlet and outlet hoses between the 4 Rear brake switch lead brake cables.
- Page 18 SPEC CABLE ROUTING 1 Throttle cable È Fasten the wire harness, starting motor lead and 2 Rectifier/regulator transmission case breather hose to the frame with 3 Starting motor a plastic band. 4 CDI magneto lead 5 Clamp 6 Ignition coil –...
- Page 19 SPEC CABLE ROUTING 1 Taillight C Battery negative lead 2 Reverse relay D Reverse switch lead 3 Starting circuit cut-off relay 4 Fuse holder È Hold the clamp and ground lead to the crank- 5 Starter relay case with a screw. 6 Wire harness É...
- Page 20 SPEC CABLE ROUTING 1 Inlet hose È Pass the breather hose through the hole of han- 2 Outlet hose dlebar cover and then between the steering col- 3 Fuel hose umn and fuel tank. 4 Breather hose (crankcase) É Pass the overflow hose left side of the engine 5 Overflow hose stay.
- Page 21 SPEC CABLE ROUTING 1 CDI unit C Reverse relay 2 Band 3 Starter cable È Pass the breather hose between the throttle 4 Wire harness cable and starter cable. 5 Breather hose (transmission case) 6 Ignition coil 7 Battery positive lead 8 Battery negative lead 9 Breather hose (crankcase) 0 Throttle cable...
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Page 22: Periodic Checks And Adjustments
Fittings and Fasteners* • Correct if necessary. • Check specific gravity. Battery* • Check breather hose for proper operation. • Correct if necessary. It is recommended that these items be serviced by a Yamaha dealer. ** Lithium-soap-based grease – 14 –... -
Page 23: Chassis
ADJUSTING THE FRONT BRAKE CHASSIS ADJUSTING THE FRONT BRAKE 1.Check: Front brake lever free play a Out of specification → Adjust. Front brake lever free play: 5 ~ 8 mm (0.20 ~ 0.3 in) at lever pivot 2.Adjust: Front brake lever free play *********************************************** Loosen the locknut 1. -
Page 24: Chassis
CHAS STEERING SYSTEM CHASSIS STEERING SYSTEM 1 Handlebar holder (upper) 7 Steering bracket 2 Handlebar holder (lower) 8 Oil seal 3 Steering column 9 Steering bracket 4 Cable joint 0 Steering knuckle 5 Cable joint bracket A Tie-rod 6 Collar –... -
Page 25: Electrical
– ELEC CHECKING THE SWITCH ELECTRICAL CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester: P/N. YU-03112, 90890-03112 NOTE: Set the pocket tester to “0” before starting the test. -
Page 26: Signal System
– ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM – 18 –... -
Page 27: Checking The Signal System
– ELEC SIGNAL SYSTEM CHECKING THE SIGNAL SYSTEM 1.If the tail/brake light fails to come on: 1.Bulb and bulb socket NO CONTINUITY Check the bulb and bulb socket for continu- ity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.Brake light switches Refer to “CHECKING THE SWITCH”. -
Page 29: Yfa1(P) 2002 Wiring Diagram
YFA1(P) 2002 WIRING DIAGRAM 1 AC magneto 2 Rectifier/regulator 3 Main switch W/R W/L W/L W/R R/B B O G/Y 4 Fuse W/R W/L G/W 5 Battery 6 Starter relay 7 Starter motor 8 Starting circuit cut-off relay 9 CDI unit 0 Ignition coil A Spark plug B Neutral indicator light...