1985-1988 Yamaha YFM200 Moto-4 Service Manual (P/N LIT-11616-05-40)
Yamaha Models Covered & Key Technical Specifications
Models: Yamaha YFM200 Moto-4
Sub-models / Variants: YFM200N, YFM200DXS, YFM200DXT, YFM200U
Trade Names: Moto-4
Model Years: 1985–1988
Serial Numbers: YFM200N...JY452H00*FC000101, YFM200N...52H-000101
Technical Data:
- Engine displacement: 196.3 cm³
- Engine type: 4-stroke, single-cylinder
- Transmission: 5-speed forward, 1-speed reverse
- Valve clearance (intake, cold): 0.05–0.09 mm
- Valve clearance (exhaust, cold): 0.11–0.15 mm
- Compression pressure (standard): 883 kPa (9 kg/cm², 128 psi)
- Spark plug (standard): D7EA (NGK) or X22ES-U (NIPPONDENSO)
- Engine oil capacity (total): 1.8 L
- Engine idle speed: 1,400 ± 50 r/min
Yamaha Manual Features & Content Preview
- Covers 1985–1988 Yamaha YFM200 Moto-4 models, including YFM200N, DXS, DXT, and U variants
- Original OEM publication P/N LIT-11616-YF-20 (first edition, April 1984)
- Features comprehensive engine overhaul exploded-view diagrams, transmission gear lash settings, and electrical system schematics
- Serves as the foundational service reference for the initial release of the shaft-drive Moto-4 series
Technical Structure and Content
This 1985–1988 Yamaha YFM200 Moto-4 service manual provides the complete technical foundation for maintaining the 196.3 cc engine and chassis systems. It defines standard practices for periodic inspections, engine removal, and detailed overhaul sequences for the secondary and primary clutch, balancer assembly, and gear-drive reverse system. Before diving into any teardown, always review the manufacturer safety protocols outlined in the first chapter to prevent injury or equipment damage. You will also find extensive sections documenting chassis maintenance. These cover front and rear brake adjustments, steering system inspections, and exact tire maintenance parameters for the 22x8-10 and 22x11-8 sizing requirements. Having these factory sequences on hand cuts down diagnostic time and keeps workshop operations efficient.
Specification Highlights
This document acts as an official workshop manual for Yamaha ATV maintenance, detailing the necessary tolerances for wear-limit assessments and performance verification. For instance, cylinder head warpage limits are specified at 0.03 mm in the inspection data. You can easily reference the middle gear lash standard, which is documented at 0.1 to 0.2 mm for radial clearance calibration. Final-stage torque for the clutch-boss securing nut is firmly listed at 50 Nm (36 ft-lb). Routine maintenance specs are equally precise. Engine oil capacity during periodic changes is rated at 1.5 liters using 20W40 SE grade lubricant, while the standardized gap for spark plug electrode spacing is set at 0.6 to 0.7 mm.
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