This Workshop Service Manual provides comprehensive documentation for the 1983-1986 YTM200 (Tri-Moto, Yamahauler), YTM225 (Tri-Moto), and YFM200 (Moto-4) All-Terrain Vehicles. These models represent a significant era in ATV development, offering robust engineering and reliable performance for both recreational and utility purposes. The manual covers a range of engine displacements, from approximately 196cc to 222cc, featuring air-cooled, 4-stroke, SOHC gasoline engines, and manual transmissions with wet multi-plate clutches. Key features include models like the YTM200EK, YTM225DXK, YTM200L, YTM225DXL, YFM200N-S, YTM200N, YTM225DXN, and YFM200DXS, reflecting a pioneering role in the burgeoning ATV market of the mid-1980s.
This English-language manual is designed to be an indispensable resource for owners, mechanics, and technicians. It details all major systems, including the engine, clutch, transmission, fuel system, electrical system, suspension, steering, and brakes. The manual covers routine maintenance, lubrication, tune-up procedures, and in-depth repair instructions, from basic adjustments to complete engine and transmission rebuilds. Troubleshooting guidance and diagnostic procedures are thoroughly explained, enabling users to effectively maintain and repair their ATVs, ensuring longevity and optimal performance. The comprehensive scope of this Workshop Service Manual is essential for preserving the operational integrity and value of these vintage off-road vehicles.
This service manual covers service and repair of ATV Yamaha YTM200, YTM225 and YFM200.
Models Covered:
1983 Yamaha YTM200EK Yamahauler
1983 Yamaha YTM225DXK Tri-Moto
1984 Yamaha YTM200L Tri-Moto
1984 Yamaha YTM225DXL Tri-Moto
1985 Yamaha YFM200N-S Moto-4
1985 Yamaha YTM200N Tri-Moto
1985 Yamaha YTM225DXN Tri-Moto
1986 Yamaha YFM200DXS Moto-4
Manual Contents:
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, caution and warnings / Safety first / Service hints / Torque specifications / Fasteners / Lubricants / Parts replacement / Basic hand tools / Test equipment / Mechanic's tips
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Engine starting / Engine performance / Engine noises / Engine lubrication / Clutch / Transmission / Carburetor / Charging system / Electrical starting system / Electrical problems / Ignition system / Excessive vibration / Front suspension and steering / Brake problems
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / Service intervals / Tires and wheels / Battery / Periodic lubrication / Engine oil and filter change / Front fork oil change / Final drive oil change / Steering head bearing lubrication / Knuckle and steering shaft lubrication / Periodic maintenance / Drive chain adjustment / Brake adjustment / Clutch adjustment / Decompression lever adjustment / Air cleaner service / Fuel shut off valve and filter service / Steering inspection and steering head adjustment / Suspension adjustment / Tune-up / Torque cylinder head bolts / Valve clearance adjustment / Camshaft chain adjustment / Engine compression check / Ignition timing / Idle speed adjustment / Specifications
CHAPTER FOUR / ENGINE
Engine principles / Engine cooling / Servicing engine in frame / Engine / Cylinder head / Camshaft/rocker arms / Camshaft chain / Cam chain tensioner (automatic type) / Cam chain tensioner (adjustable type) / Valves and valve components / Cylinder / Piston and piston pin / Piston rings / Oil pumps / Crankcase and crankshaft / Alternator rotor, starter clutch assembly and gears / Recoil starter / Middle gear case / Middle/reverse gear case / Break-in / Specifications
CHAPTER FIVE / CLUTCH AND TRANSMISSION
Clutch / Clutch lever and external shift mechanism / Drive sprocket (YTM200K, L, N) / Transmission / Specifications
CHAPTER SIX / FUEL AND EXHAUST SYSTEMS
Air cleaner / Carburetor operation / Carburetor service / Carburetor adjustments / Throttle cable / Fuel tank / Fuel shutoff valve / Exhaust system / Specifications
CHAPTER SEVEN / ELECTRICAL SYSTEM
Charging system (shaft drive models) / Charging system (chain drive models) / Alternator / Ignition system (fully transistorized) / Ignition unit / Ignition coil / Pickup coil / Spark plugs / Starting system / Lighting system / Switches / Fuse / Specifications
CHAPTER EIGHT / FRONT SUSPENSION AND STEERING (YTM200 AND YTM225)
Front wheel / Front hub / Handlebar / Steering head / Front forks / Tires / Specifications
CHAPTER NINE / FRONT SUSPENSION AND STEERING (YFM200)
Front wheel / Front hubs / Steering / Steering shaft / Handlebar / Front shock absorbers (YFM200DXS) / Specifications
CHAPTER TEN / REAR SUSPENSION AND FINAL DRIVE
Rear wheel / Rear axle (chain drive) / Rear axle (drive shaft) / Drive chain (YTM200K, L, and N) / Driven sprocket (chain drive) / Tire changing and tire repairs / Rear shock absorber (YTM225 and YFM200DXS) / Swing arm (YTM225 and YFM200DXS) / Final drive unit and drive shaft / Rear axle bearing holder / Specifications
CHAPTER ELEVEN / BRAKES
Front drum brake / Rear disc brake / Brake cables / Specifications
INDEX
WIRING DIAGRAMS
This service manual covers service and repair of ATV Yamaha YTM200, YTM225 and YFM200.
Models Covered:
1983 Yamaha YTM200EK Yamahauler
1983 Yamaha YTM225DXK Tri-Moto
1984 Yamaha YTM200L Tri-Moto
1984 Yamaha YTM225DXL Tri-Moto
1985 Yamaha YFM200N-S Moto-4
1985 Yamaha YTM200N Tri-Moto
1985 Yamaha YTM225DXN Tri-Moto
1986 Yamaha YFM200DXS Moto-4
Manual Contents:
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, caution and warnings / Safety first / Service hints / Torque specifications / Fasteners / Lubricants / Parts replacement / Basic hand tools / Test equipment / Mechanic's tips
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Engine starting / Engine performance / Engine noises / Engine lubrication / Clutch / Transmission / Carburetor / Charging system / Electrical starting system / Electrical problems / Ignition system / Excessive vibration / Front suspension and steering / Brake problems
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / Service intervals / Tires and wheels / Battery / Periodic lubrication / Engine oil and filter change / Front fork oil change / Final drive oil change / Steering head bearing lubrication / Knuckle and steering shaft lubrication / Periodic maintenance / Drive chain adjustment / Brake adjustment / Clutch adjustment / Decompression lever adjustment / Air cleaner service / Fuel shut off valve and filter service / Steering inspection and steering head adjustment / Suspension adjustment / Tune-up / Torque cylinder head bolts / Valve clearance adjustment / Camshaft chain adjustment / Engine compression check / Ignition timing / Idle speed adjustment / Specifications
CHAPTER FOUR / ENGINE
Engine principles / Engine cooling / Servicing engine in frame / Engine / Cylinder head / Camshaft/rocker arms / Camshaft chain / Cam chain tensioner (automatic type) / Cam chain tensioner (adjustable type) / Valves and valve components / Cylinder / Piston and piston pin / Piston rings / Oil pumps / Crankcase and crankshaft / Alternator rotor, starter clutch assembly and gears / Recoil starter / Middle gear case / Middle/reverse gear case / Break-in / Specifications
CHAPTER FIVE / CLUTCH AND TRANSMISSION
Clutch / Clutch lever and external shift mechanism / Drive sprocket (YTM200K, L, N) / Transmission / Specifications
CHAPTER SIX / FUEL AND EXHAUST SYSTEMS
Air cleaner / Carburetor operation / Carburetor service / Carburetor adjustments / Throttle cable / Fuel tank / Fuel shutoff valve / Exhaust system / Specifications
CHAPTER SEVEN / ELECTRICAL SYSTEM
Charging system (shaft drive models) / Charging system (chain drive models) / Alternator / Ignition system (fully transistorized) / Ignition unit / Ignition coil / Pickup coil / Spark plugs / Starting system / Lighting system / Switches / Fuse / Specifications
CHAPTER EIGHT / FRONT SUSPENSION AND STEERING (YTM200 AND YTM225)
Front wheel / Front hub / Handlebar / Steering head / Front forks / Tires / Specifications
CHAPTER NINE / FRONT SUSPENSION AND STEERING (YFM200)
Front wheel / Front hubs / Steering / Steering shaft / Handlebar / Front shock absorbers (YFM200DXS) / Specifications
CHAPTER TEN / REAR SUSPENSION AND FINAL DRIVE
Rear wheel / Rear axle (chain drive) / Rear axle (drive shaft) / Drive chain (YTM200K, L, and N) / Driven sprocket (chain drive) / Tire changing and tire repairs / Rear shock absorber (YTM225 and YFM200DXS) / Swing arm (YTM225 and YFM200DXS) / Final drive unit and drive shaft / Rear axle bearing holder / Specifications
CHAPTER ELEVEN / BRAKES
Front drum brake / Rear disc brake / Brake cables / Specifications
INDEX
WIRING DIAGRAMS
