AG200 Repair Manual

[morosz]

Good People,

Is there a repair manual in existence for a Yamaha AG200 farmbike? I could sure use one. To make a long story short, I have become very attached to the AG200 I learned to ride on. It lives in Lesotho in southern Africa and I visit it sometimes. Some annoying folks crashed it a few times and now it needs my attention to get better. I replaced the cracked piston and put new rings on, but alas I don't think I have the timing quite right. It has other issues too, and a manual would be useful. I'm posting here because you are the only folks I've found online who even know what an AG200 is, since we dont have any in the USA. Thanks in advance for your help,

mso

[MSTRS]

Can't find a PDF manual online anywhere??

[morosz]

I've looked around quite a bit. Havent come up with anything. Theres no Clymer or Hanes manual...

[MSTRS]

Hmmmmm. I have a mate with an AG200. I will see what he can do to help

[cheese]

Fuck me you have a still runnign AG?

Anyway what is the issue, is it missign farting away? or running like a bag oh shite?

[morosz]

Well it runs, just not well. The carbs are pristine, the spark is good, and the compression is good. But it bogs down seriously and has no power. I think the spark is late, and I want to check to make sure the timing is correct. Since I took apart the engine block to replace the cracked piston, its possible that I didnt position the timing sprocket exactly right upon reassembly. So at this point, I need a manual to go through the timing.

[cheese]

try removing the mag cover and slowly adjusting the timing. it maybe only slightly out. They are pretty good oly bikes the AG's I had a AG100 as my first bike.

[Gixxer 4 ever]

Hi Morosz. I have several going AG 200 and a few in bits. The timing is all keyed and there are timing marks. If you want I can get an old motor and take some pics for you. The problem areas with these bikes are the CDI and the mounting block for the carburettor to the back of the cylinder head. They leak air after a while. They look ok but they are a problem. After they are a few years old they need to be replaced. How was it running before the crash? Remember you have removed this piece to do the work and it may have damaged the material it is made of.
I have never seen a manual but if you want me to ask our local shop I will do so.
Do you want some pics for timing? Is yours a 12 or 6 volt? I might have a 6 volt CDI here. The newer ones are 12 volt.

We still buy them new here in NZ and Australia.

[Gixxer 4 ever]

try removing the mag cover and slowly adjusting the timing. it maybe only slightly out. They are pretty good oly bikes the AG's I had a AG100 as my first bike.
The 200 is keyed and I am sure you can not udjust it. The only problem is when you put the cam chain on. You can be a tooth out.

[Gixxer 4 ever]

Another tip for you. Don't purchase a new timing chain. Weld a 10 mm extension on the end of the factory adjuster and reinstall. I have run these bikes for years on the so called stuffed chains. Never had to replace one yet. Good luck but send more info if I can help.

[Gixxer 4 ever]

Pics from one of my old engines. You will note this is from the dump and has been outside. However they are just about the same bikes from the first made till now. Main change was the 6 to 12 volt thing.
Note the timing mark on the sprocket to the cam. Note the casting in the head above it. Line them up.
Note the mark on the crank case for the bottom end and the punch mark on the sprocket for the chain. Line them up.
If you have a one piece cam chain, and most of them are, you have to put the top sprocket in the chain and then on the shaft. Check it doesn't end up one tooth out. When assembled turn one full revolution by hand to check valve clearances. Put the chain adjuster in or the chain will jump on the sprocket. Leave the spark plug out.They will break or bend valves if timing is too far out..

[Gixxer 4 ever]

Symptoms of the CDI problem as I experienced it. The bike will start and run. However when you take off it will die away and back fire and fart around. Will keep running but ruff. Then it will stop. Can start it again but again it will not go for long. I replace the carb and plug etc but the problem would not go away. I replaced the CDI and it was fine from then on. Cost me $240.00 NZ at the time. If it is a 12 volt bike and you want to see if the spare I have would fit let me know. I could send pics of the plugs and things and you could see if it was worth sending it to you. I do not want anything for it but the P/P will cost you.
I will run it in my good bike first to check it. Anyway good luck.

[IronicCapers]

http://www.manuals.co.nz/?page=shop/browse&category_id=570&CLSN_728=1139564063728e6832a6de09e823e1af


Dont know if youll find it here but i went lookn and i think its a good chance that you mite find it here

[morosz]

I appreciate the help you guys are giving me. I may be a tooth off on the timing (I did align the marks and it looks like the cylinder is at TDC when it should be, but I didnt check the valve clearance). The air leak sounds like a possibility, the carbs are kinda too far in for the air intake hose to grab onto them well. I wont get a chance to tinker with it again for a while, but if anyone comes up with a manual please let me know. Thanks again,

mso

[NordieBoy]

I'll get my brother to have a look for a manual (bike mechanic).
Anyway aren't AG's meant to be fixable with a sledgehammer, fencing wire and baling twine?