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Yamaha · European two-stroke single (DKW, Jawa, CZ, MZ, Puch, Bultaco, Montesa, Ossa)

AG 100

Library entry covers 1979-2007

31 factory 41 guideline

Published source

Yamaha AG100F 2016 Owner's Manual B4A-28199-20 (Australia, English), periodic maintenance charts pp.7-3 to 7-6, TIPs pp.7-3 and 7-6

Factory owner's handbook. Covers AG100F; 2016 Australia owner's manual B4A-28199-20, English. Chart columns 1000/6000/12000/18000/24000 km (600/3500/7000/10500/14000 mi) plus annual check; from 30000 km (17500 mi) repeat the intervals starting from 6000 km (3500 mi); annual checks every year except if a distance-based maintenance is performed instead. Chart lists Autolube pump, transmission oil, brake shoes front and rear, drive chain.

Open the source

72 items for a 1987 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Two-stroke
Engine lubrication: Two-stroke premix (oil in fuel)
Oil filtration: None (no filter)
Valve gear: None (two-stroke porting)
Ignition: Magneto (incl. magdyno, flywheel magneto)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Drum (or band / stirrup)
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1987 Yamaha AG 100

On the road: every 150 mi

1 item

Check two-stroke oil tank / carry premix oil

Pre-ride / on the road

Guideline

Running a two-stroke out of oil seizes it. Injection bikes: check the tank. Premix: carry oil and a measure.

On the road: every 300 mi

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 300 mi

1 item

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Factory

Manual: Drive chain (check chain slack, alignment and condition; adjust and lubricate chain with a special O-ring chain lubricant thoroughly). Factory: Every 500 km (300 mi) and after washing the motorcycle, riding in the rain or riding in wet areas, printed as text; not a dealer item (p.7-5)

Every 1,000 mi or 1 month

1 item

Check battery electrolyte, top up with distilled water

Ignition and electrics

Guideline

Wet-cell batteries on old machines need regular topping up, more in hot weather.

Every 1,000 mi or 6 months

2 items

Adjust front drum brake

Brakes

Guideline
Adjust rear drum brake and rod / cable linkage

Brakes

Guideline

Every 2,000 mi or 12 months

1 item

Replace spark plugs (two-stroke)

Engine

Guideline

Every 3,000 mi or 12 months

7 items

Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Check / set ignition timing

Ignition and electrics

Guideline
Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Guideline
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline

Every 3,000 mi or 2 years

1 item

Decarbonize exhaust ports, pipes and baffles

Engine

Guideline

Two-strokes coke up the exhaust port and muffler baffles; power falls off gradually.

Every 3,500 mi or 12 months

17 items

Chassis fasteners (make sure all nuts, bolts and screws are properly tightened)

Engine

Factory

Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; annual check; dealer item (p.7-5)
Lights, signals and switches (check operation, adjust headlight beam)

Engine

Factory

Factory: Every column incl. 1000 km (600 mi) initial; annual check; dealer item (p.7-6)
Replace spark plugs

Engine

Factory

Manual: Spark plug (replace). Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; annual check; not a dealer item (p.7-3)
Carburetor (check starter (choke) operation, adjust engine idling speed)

Fuel and air

Factory

Factory: Every column incl. 1000 km (600 mi) initial; annual check; dealer item (p.7-3)
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle grip (check operation, check throttle grip free play and adjust if necessary, lubricate cable and grip housing). Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; annual check; dealer item (p.7-6)
Replace fuel lines

Fuel and air

Factory

Manual: Fuel line (check fuel hoses for cracks or damage). Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; annual check; dealer item (p.7-3)
Battery (check electrolyte level and specific gravity, make sure the breather hose is properly routed)

Ignition and electrics

Factory

Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; annual check; dealer item (p.7-4)
Clutch lever pivot shaft (lubricate with lithium-soap-based grease)

Primary and gearbox

Factory

Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; annual check; not a dealer item (p.7-5)
Transmission oil (check oil level)

Primary and gearbox

Factory

Factory: Every column incl. 1000 km (600 mi) initial; annual check; not a dealer item (p.7-5)
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Sidestands (check operation, lubricate). Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; annual check; not a dealer item (p.7-5)
Brake lever pivot shaft (lubricate with lithium-soap-based grease)

Brakes

Factory

Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; annual check; not a dealer item (p.7-5)
Brake pedal pivot shaft (lubricate with lithium-soap-based grease)

Brakes

Factory

Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; annual check; not a dealer item (p.7-5)
Check brake pads and discs

Brakes

Factory

Manual: Front brake (check operation and adjust brake lever free play; replace brake shoes). Factory: Every column incl. 1000 km (600 mi) initial; annual check; brake shoes replaced whenever worn to the limit, printed as text; dealer item (p.7-4)
Front and rear brake switches (check operation)

Brakes

Factory

Factory: Every column incl. 1000 km (600 mi) initial; annual check; dealer item (p.7-5)
Rear brake (check operation and adjust brake pedal free play; replace brake shoes)

Brakes

Factory

Factory: Every column incl. 1000 km (600 mi) initial; annual check; brake shoes replaced whenever worn to the limit, printed as text; dealer item (p.7-4)
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tires (check tread depth and for damage, replace if necessary, check and correct air pressure). Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; annual check; dealer item (p.7-4)
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Moving parts and cables (lubricate). Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; annual check; not a dealer item (p.7-5)

Every 3,500 mi

8 items

Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter element (clean, replace if necessary). Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; no annual check; not a dealer item. TIP: more frequent service in unusually wet or dusty areas (p.7-4, 7-6)
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch (check operation, adjust). Factory: Every column incl. 1000 km (600 mi) initial; no annual check; not a dealer item (p.7-4)
Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearings (check bearing play and steering for roughness). Factory: Every column incl. 1000 km (600 mi) initial; no annual check; dealer item (p.7-5)
Front fork (check operation and for oil leakage)

Front end

Factory

Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; no annual check; no fork oil change interval printed; dealer item (p.7-5)
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Shock absorber assemblies (check operation and shock absorbers for oil leakage). Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; no annual check; dealer item (p.7-5)
Swingarm (check operation and for excessive play)

Rear suspension and frame

Factory

Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; no annual check; dealer item (p.7-4)
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings (check bearings for looseness or damage). Factory: Marked 6000-24000 km (3500-14000 mi); not at 1000 km initial; no annual check; dealer item (p.7-4)
Wheels (check runout, spoke tightness and for damage, tighten spokes if necessary)

Wheels and tires

Factory

Factory: Every column incl. 1000 km (600 mi) initial; no annual check; dealer item (p.7-4)

Every 4,000 mi or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 6,000 mi or 12 months

4 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 6,000 mi or 2 years

2 items

Lubricate and check automatic advance unit

Ignition and electrics

Guideline
Magneto: clean slip ring and pickup brush, check HT lead

Ignition and electrics

Guideline

Every 7,000 mi or 12 months

1 item

Autolube pump (check operation, bleed if necessary)

Engine

Factory

Factory: Marked at 1000, 12000 and 24000 km (600/7000/14000 mi); annual check; dealer item (p.7-5)

Every 7,000 mi

1 item

Replace fuel filter

Fuel and air

Factory

Manual: Fuel cock filter (check condition, replace if necessary). Factory: Marked at 12000 and 24000 km (7000/14000 mi); no annual check; dealer item (p.7-3)

Every 10,000 mi or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 12,000 mi or 2 years

1 item

Replace air filter element

Fuel and air

Guideline

Every 12,000 mi or 3 years

1 item

Replace points and condenser

Ignition and electrics

Guideline

Every 14,000 mi

3 items

Change gearbox oil

Primary and gearbox

Factory

Manual: Transmission oil (change). Factory: Marked at 1000 km (600 mi) initial and 24000 km (14000 mi); no annual check; not a dealer item (p.7-5)
Repack / replace steering head bearings

Front end

Factory

Manual: Steering bearings (lubricate with lithium-soap-based grease). Factory: Every 24000 km (14000 mi), printed as text; dealer item (p.7-5)
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Swingarm (lubricate with lithium-soap-based grease). Factory: Every 24000 km (14000 mi), printed as text; dealer item (p.7-4)

Every 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

1 item

Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 25,000 mi or 10 years

1 item

Magneto overhaul / re-magnetize, replace capacitor

Ignition and electrics

Guideline

Weak spark when hot is the classic symptom. Old capacitors fail with age, not miles.

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

2 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.