5FY-9-17_hyoushi 5/7/04 8:24 AM Page 1 OWNER’S MANUAL TW200T1 TW200T1C YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN ! 2002·5–0.6×1(E) 2004.6–0.
5FY-9-17_hyoushi2&3 4/9/04 2:40 PM Page 1
INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha TW200/TW200C. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
IMPORTANT MANUAL INFORMATION EAU10130 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.
IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE TW200T1/TW200T1(C) OWNER’S MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan.
TABLE OF CONTENTS SAFETY INFORMATION ...................1-1 Location of important labels .............1-5 PRE-OPERATION CHECKS .............. 4-1 Pre-operation check list ................... 4-2 DESCRIPTION ...................................2-1 Left view ...........................................2-1 Right view .........................................2-2 Controls and instruments..................2-3 OPERATION AND IMPORTANT RIDING POINTS ..................................
TABLE OF CONTENTS Checking the front fork ..................6-30 Checking the steering ....................6-30 Checking the wheel bearings ........6-31 Battery ...........................................6-31 Replacing the fuse .........................6-34 Replacing the headlight bulb .........6-34 Replacing the tail/brake light bulb ............................................6-36 Replacing a turn signal light bulb ............................................6-37 Supporting the motorcycle .............
SAFETY INFORMATION EAU10310 1 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. THE WARNINGS ● OBSERVE AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
SAFETY INFORMATION dercornering (insufficient lean angle for the speed). Always obey the speed limit and never travel faster than warranted by road and traffic conditions. Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control. The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle.
SAFETY INFORMATION 1 not exceed the maximum load limit of 179 kg (395 lb) (CAL) 180 kg (397 lb) (U49). When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability. ● Shifting weights can create a sudden imbalance.
SAFETY INFORMATION motorcycle’s electrical system an electric failure could result, which could cause a dangerous loss of lights or engine power. Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: Always turn the engine off when refueling. Take care not to spill any gasoline on the engine or exhaust system when refueling. Never refuel while smoking or in the vicinity of an open flame. ● Never start the engine or let it run for any length of time in a closed area.
SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
SAFETY INFORMATION 1 6 WARNING WARNING BEFORE YOU OPERATE THIS VEHICLE, READ THE OWNER’S MANUAL AND ALL LABELS. ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET, eye protection, and protective clothing. Improper loading can cause loss of control. Read owner’s manual for proper loading. 3JJ—28446—A1 5GK-2118K-00 7 2 WARNING CAUTION This unit contains high pressure nitrogen gas. Mishandling can cause explosion. 8 Read owner's manual for instructions. 8 Do not incinerate, puncture or open.
DESCRIPTION EAU10410 Left view 3 1 2 4 1 2 3 4 5 6 7 87 8 9 1. Fuel tank cap (page 3-5) 2. Fuel cock (page 3-7) 3. Helmet holder (page 3-9) 4. Luggage strap holder (page 3-10) 5. Drive chain slack adjusting plate 6. Air filter element (page 6-14) 7. Starter (choke) knob (page 3-8) 8.
DESCRIPTION EAU10420 Right view 1 2 2 3 4 5 6 7 8 7 6 5 4 1. Carrier (page 3-9) 2. Battery (page 6-31) 3. Engine oil level check window (page 6-11) 4. Brake pedal (page 3-5) 5. Owner’s tool kit (page 6-1) 6. Fuse (page 6-34) 7. Luggage strap holder (page 3-10) 8.
DESCRIPTION EAU10430 Controls and instruments 1 1 2 3 4 5 6 2 3 4 5 9 6 7 8 9 1. Clutch lever (page 3-4) 2. Left handlebar switches (page 3-3) 3. Speedometer unit (page 3-2) 4. Main switch/steering lock (page 3-1) 5. Indicator lights (page 3-2) 6. Right handlebar switches (page 3-3) 7. Brake lever (page 3-4) 8. Throttle grip (page 6-16) 9.
INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock OFF EAU10710 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To lock the steering ON To unlock the steering Insert the key and turn it to “OFF”. EWA10070 WARNING Never turn the key to “LOCK” while the motorcycle is moving. 2 1 LOCK 2 3 4 The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below.
INSTRUMENT AND CONTROL FUNCTIONS EAU10980 Indicator lights 1 2 EAU11080 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. 3 1 2 EAU11630 Speedometer unit 1 4 2 3 3 4 5 1. Turn signal indicator light “ 2. High beam indicator light “ 3. Neutral indicator light “ 1. Speedometer 2. Odometer 3. Tripmeter 4.
INSTRUMENT AND CONTROL FUNCTIONS EAU12343 Handlebar switches Right EAU12500 Horn switch “ ” Press this switch to sound the horn. Left 1 EAU12660 Engine stop switch “ / ” Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck. 1 2 2 3 1. Engine stop switch “ 2. Start switch “ 1. Dimmer switch “ / 2. Turn signal switch “ 3.
INSTRUMENT AND CONTROL FUNCTIONS EAU12820 Clutch lever EAU12870 Shift pedal EAU12890 Brake lever 1 1 1 5 4 3 2 N 1 2 3 1 4 5 6 7 8 9 1. Clutch lever The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation. The clutch lever is equipped with a clutch switch, which is part of the ignition circuit cut-off system.
INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal EAU32280 NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. Fuel tank cap 2 1 1 1. Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 1. Fuel tank cap 2. Unlock. To remove the fuel tank cap 1. Insert the key into the lock and turn it 1/3 turn counterclockwise. 2.
INSTRUMENT AND CONTROL FUNCTIONS EAU13210 Fuel 1 1 EAU13300 2 2 3 4 5 6 Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 7.0 L (1.85 US gal) (1.54 Imp.gal) Fuel reserve amount: 1.7 L (0.45 US gal) (0.37 Imp.gal) ECA11400 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. EWA10880 7 ● 8 9 fuel may deteriorate painted surfaces or plastic parts.
INSTRUMENT AND CONTROL FUNCTIONS EAU13560 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: OFF ON fuel while riding, move the lever to this position. Fill the tank at the first opportunity. Be sure to set the lever back to “ON” after refueling! RES OFF ON FUEL 2 1 ON 3 RES 1. Arrow mark positioned over “ON” OFF ON FUEL 1 With the lever in this position, fuel flows to the carburetor.
INSTRUMENT AND CONTROL FUNCTIONS EAU13600 Starter (choke) knob “ ” EAU13970 Seat To remove the seat 1. Remove the bolts, and then pull the seat off. 1 2 1 1 2 (b) (a) 3 4 5 6 7 1. Projection 2. Seat holder 1. Starter (choke) knob “ ” Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke). Move the knob in direction (a) to turn on the starter (choke). Move the knob in direction (b) to turn off the starter (choke). 1(×2) 1.
INSTRUMENT AND CONTROL FUNCTIONS EAU14281 Helmet holder EAU15090 Shock absorber EAU15110 Carrier EWA10220 1 1. Helmet holder To open the helmet holder, insert the key into the lock, and then turn the key as shown. To lock the helmet holder, place it in the original position, and then remove the key. EWA10160 WARNING Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident.
INSTRUMENT AND CONTROL FUNCTIONS EAU15170 Luggage strap holders 1(×2) 1 2 3 4 5 6 7 8 9 1(×2) 1. Luggage strap holder There are four luggage strap holders below the carrier. EAU15300 Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright. NOTE: The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations.
INSTRUMENT AND CONTROL FUNCTIONS EAU15311 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. ● It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down.
INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES NOTE: This check is most reliable if performed with a warmed-up engine. NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.
PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
PRE-OPERATION CHECKS EAU15602 Pre-operation check list ITEM CHECKS ● 1 Fuel ● ● 2 ● Engine oil ● ● ● 3 ● ● 4 ● Front brake ● ● 5 ● ● ● 6 ● Rear brake ● ● 7 ● Clutch 8 ● ● ● ● 9 Throttle grip Control cables ● ● ● ● Check fuel level in fuel tank. Refuel if necessary. Check fuel line for leakage. Check oil level in engine. If necessary, add recommended oil to specified level. Check vehicle for oil leakage. Check operation.
PRE-OPERATION CHECKS ITEM CHECKS ● Drive chain ● ● ● ● Wheels and tires ● ● ● Brake and shift pedals Brake and clutch levers Sidestand Chassis fasteners Instruments, lights, signals and switches Sidestand switch Battery ● ● ● ● ● ● ● ● ● ● ● ● ● ● Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. Make sure that operation is smooth.
OPERATION AND IMPORTANT RIDING POINTS ● 1 2 3 ● 4 5 6 7 8 9 ● EAU15950 EAU32290 EWA10270 Starting and warming up a cold engine WARNING Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time.
OPERATION AND IMPORTANT RIDING POINTS off. Never accelerate hard when the engine is cold! 7. When the engine is warm, turn the starter (choke) off. NOTE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off. To avoid the possibility of excessive exhaust emissions, never leave the starter (choke) on longer than necessary. The time necessary for starter (choke) use depends upon the ambient temperature.
OPERATION AND IMPORTANT RIDING POINTS ECA10260 1 2 3 4 5 6 7 8 9 CAUTION: ● Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.
OPERATION AND IMPORTANT RIDING POINTS EAU16841 Engine break-in There is never a more important period in the life of your engine than the period between 0 and 1600 km (1000 mi). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1600 km (1000 mi). The various parts in the engine wear and polish themselves to the correct operating clearances.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 1 2 3 4 5 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages. Maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified (if applicable).
PERIODIC MAINTENANCE AND MINOR REPAIR a Yamaha dealer perform it for you. EWA10340 WARNING Modifications not approved by Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17580 Periodic maintenance chart for the emission control system INITIAL 1 No. ITEM ROUTINE 2 ● 1 * Fuel line 3 ● ● ● 4 2 Spark plug 3 Spark arrester ● 5 6 7 4 * Valve clearance 5 * Idle speed ● ● ● ● 8 9 6 * Exhaust system Evaporative emis7 * sion control system (For California only) ● ● ● ● Check fuel hoses for cracks or damage. Replace if necessary. Check condition. Adjust gap and clean.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU32161 General maintenance and lubrication chart INITIAL No. ITEM 1 * Air filter element ROUTINE ● ● ● 2 * Battery 3 * Clutch ● ● ● 4 * Front brake ● ● 5 * Rear brake 6 * Brake hose ● ● ● ● 7 * Wheels ● ● 8 * Tires ● ● ● Clean with solvent. Replace if necessary. Check specific gravity and breather hose for proper operation. Check operation. Adjust or replace cable. Check operation, fluid level, and for fluid leakage. Replace brake pads if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 1 ● 2 9 * Wheel bearings ● ● 3 10 * Swingarm pivot bushes ● 4 ● 5 11 Drive chain 6 7 ● ● 12 * Steering bearings ● 8 ● 13 * Chassis fasteners 9 ● 14 Brake and clutch lever pivot shafts ● Check bearings for smooth operation. Replace if necessary. Check bush assemblies for looseness. Apply lithium-soap-based grease until new grease shows. Check chain slack/alignment and condition.
PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. 15 ITEM Brake and shift pedal pivot shafts ROUTINE ● ● 16 Sidestand pivot 17 * Sidestand switch ● ● ● 18 * Front fork ● 19 * 20 21 22 23 * Shock absorber assembly Engine oil Engine oil filter element Engine oil strainer Control and meter cables ● ● ● Apply lithium-soap-based grease (all-purpose grease) lightly. Check operation. Apply lithium-soap-based grease (all-purpose grease) lightly. Check operation and replace if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 1 ● 2 Throttle grip housing and cable 24 * 3 ● ● 600 mi (1000 km) or 1 month Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable.
PERIODIC MAINTENANCE AND MINOR REPAIR To install the cowling Place the cowling in the original position, and then install the screw. EAU18721 Removing and installing the cowling and panels 1 The cowling and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the cowling or a panel needs to be removed and installed. 2 1 EAU32451 Panel A To remove the panel Remove the screws, and then pull the panel out at the area shown.
PERIODIC MAINTENANCE AND MINOR REPAIR To install the panel Place the panel in the original position. 1 2 3 4 Panel B To remove the panel Pull the panel off as shown. EAU19602 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR necessary. Specified spark plug: NGK/DR8EA DENSO/X24ESR-U 1 1. Spark plug wrench To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-to-light tan (the ideal color when the vehicle is ridden normally). NOTE: If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. 2.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU19671 Canister (for California only) 1 1 2 2 3 4 5 6 7 8 9 3 4 1. Rollover valve 2. Carburetor 3. Canister 4. Vent hose This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere. ● Check each hose connection. ● Check each hose and canister for cracks or damage. Replace if damaged. ● Make sure the vent hose is not blocked. Clean it if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase. bolt, the O-ring, compression spring, and oil strainer will fall out. Take care not to lose these parts. 3 1 1 2 2(×2) 1 3 2 1. Engine oil filler cap 1. O-ring 2. Compression spring 3. Oil strainer NOTE: Skip steps 4–9 if the oil filter element is not being cleaned. 4. Remove the oil filter element drain bolt to drain the oil from the oil filter element. 1 6 8 2 9 1.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 8 9 7. Check the O-ring for damage and replace it if necessary. 8. Clean the oil filter element with solvent, and then install it. NOTE: Check the oil filter element for damage and replace it if necessary. 9. Install the oil filter element cover by installing the bolts and the drain bolt, then tightening them to the specified torques. Tightening torques: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil filter element drain bolt: 10 Nm (1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU20820 Cleaning the air filter element and check hose The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. In addition, the air filter check hose must be frequently checked and cleaned if necessary. To clean the air filter element 1. Remove panel A. (See page 6-8.) 2.
PERIODIC MAINTENANCE AND MINOR REPAIR To clean the air filter check hose 1. Check the hose at the bottom of the air filter case for accumulated dirt or water. 1 EAU21233 Cleaning the spark arrester The spark arrester should be cleaned at the intervals specified in the Periodic maintenance and lubrication chart. EWA10980 2 ● 3 1 4 5 6 7 8 1. Air filter check hose 2. If dirt or water is visible, remove the hose, clean it, and then install it.
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Insert the tailpipe into the muffler, and then install and tighten the screw. NOTE: Make sure to align the screw holes when inserting the tailpipe. EAU21250 Adjusting the carburetor The carburetor is an important part of the engine and its emission control system, which requires very sophisticated adjustment. Therefore, carburetor adjustments should be left to Yamaha dealer, who has the necessary professional knowledge and experience.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU21400 1 2 3 EAU21571 Adjusting the valve clearance Tires The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires.
PERIODIC MAINTENANCE AND MINOR REPAIR to side. Check the condition and pressure of your tires. NEVER OVERLOAD YOUR MOTORCYCLE. Make sure the total weight of the cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if approved for this model) does not exceed the maximum load of the motorcycle. Operation of an overloaded motorcycle could cause tire damage, an accident, or even injury. Tire inspection ride.
PERIODIC MAINTENANCE AND MINOR REPAIR very carefully and replace it as soon as possible with a high-quality product. 1 2 3 4 5 6 7 8 9 EAU21940 Spoke wheels To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels. ● The wheel rims should be checked for cracks, bends or warpage, and the spokes for looseness or damage before each ride. If any damage is found, have a Yamaha dealer replace the wheel.
PERIODIC MAINTENANCE AND MINOR REPAIR the use of items which have not been approved by Yamaha. EAU22041 Adjusting the clutch lever free play 1 (a) 3 (b) 2 1. Locknut (clutch lever) 2. Adjusting bolt 3. Clutch lever free play The clutch lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows. 1. Loosen the locknut at the clutch lever. 2.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 ver free play, turn the adjusting nut in direction (b). 6. Tighten the locknut at the clutch lever and the crankcase. EAU22092 Adjusting the brake lever free play EWA10630 ● 3 1 2 2 3. Tighten the locknut. (b) ● 3 (a) 4 5 6 7 8 9 1. Locknut 2. Adjusting bolt 3. Brake lever free play The brake lever free play should measure 5.0–8.0 mm (0.20–0.31 in) as shown. Periodically check the brake lever free play and, if necessary, adjust it as follows. 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22192 Adjusting the brake pedal position and free play 2. To raise the brake pedal, turn the adjusting bolt in direction (a). To lower the brake pedal, turn the adjusting bolt in direction (b). pedal free play and, if necessary, adjust it as follows. 2 3 1 1 (a) 1 1. Brake pedal position EWA10670 WARNING It is advisable to have a Yamaha dealer make these adjustments. Brake pedal position The top of the brake pedal should be positioned approximately 15.
PERIODIC MAINTENANCE AND MINOR REPAIR (a) 1 EAU22270 EAU22380 Adjusting the rear brake light switch Checking the front brake pads and rear brake shoes (b) 1 2 1 3 (a) 1. Brake pedal free play adjusting nut 4 5 ● ● 8 ● 9 EAU22430 Front brake pads EWA10680 6 7 2 (b) The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set. shoes as a set. EAU32343 Checking the front brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 ● 2 3 make sure that the top of the master cylinder is level by turning the handlebars. Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. ually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause. Recommended brake fluid: DOT 4 4 ● 5 6 ● 7 8 ● 9 ● Refill with the same type of brake fluid.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 1 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. (a) 2 EAU22770 To check the drive chain slack 1. Place the motorcycle on a level surface and hold it in an upright position. NOTE: When checking and adjusting the drive chain slack, the motorcycle should be positioned straight up and there should be no weight on it. 2. Shift the transmission into the neutral position. 3.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23012 ECA10570 3 CAUTION: Improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits. 4 4. Tighten the axle nut to the specified torque.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23090 EAU23110 EAU23131 Checking and lubricating the cables Checking and lubricating the throttle grip and cable Checking and lubricating the brake and shift pedals The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 EAU23200 Checking and lubricating the brake and clutch levers Checking and lubricating the sidestand EAU23250 Lubricating suspension the rear 1 2 1(×2) 3 4 5 6 7 8 9 The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23271 EAU23280 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the condition Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 1 2 3 EAU23361 Checking the wheel bearings Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. A poorly maintained battery will corrode and discharge quickly.
PERIODIC MAINTENANCE AND MINOR REPAIR 4 ● 1 5 1 lowing FIRST AID. EXTERNAL: Flush with plenty of water. INTERNAL: Drink large quantities of water or milk and immediately call a physician. EYES: Flush with water for 15 minutes and seek prompt medical attention. Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space. KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 battery band onto the holder. 8. Connect the breather hose to the battery and make sure that it is properly routed. 2 1 3 4 5 1. Battery breather hose 6 1 7 2 8 9 1. Battery 2. Battery breather hose 9. Connect and tighten the positive battery lead to the battery’s positive (+) terminal. 10. Connect and tighten the negative battery lead to the battery’s negative (-) terminal. 11. Install the seat. To store the battery 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23501 Replacing the fuse The fuse holder is located behind panel B. (See page 6-8.) If the fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off all electrical circuits. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. 2 EAU23811 ECA10640 CAUTION: Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. 3.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 fected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. 1 2 1 2 1 3 4 5 6 7 8 9 1. Headlight coupler 2. Headlight bulb cover 4. Remove the headlight bulb holder by turning it counterclockwise, and then remove the defective bulb. 1. Headlight bulb holder EWA10790 WARNING Headlight bulbs get very hot.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24131 Replacing the tail/brake light bulb 1 1. Remove the tail/brake light lens by removing the screws. 2 1(×2) 3 8. Install the cowling. 9. Have a Yamaha dealer adjust the headlight beam if necessary. 1. Tail/brake light bulb 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws. 1. Screw 2. Remove the defective bulb by pushing it in and turning it counterclockwise.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24201 Replacing a turn signal light bulb 1 1. Remove the turn signal light lens by removing the screw. ECA11190 CAUTION: Do not overtighten the screw, otherwise the lens may break. 1 2 3 3 2 4 5 6 7 8 9 1. Screw 2. Bulb 3. Turn signal light lens 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4.
PERIODIC MAINTENANCE AND MINOR REPAIR frame in front of the rear wheel or under each side of the swingarm. EAU24360 Front wheel EAU24580 To remove the front wheel EWA10820 ● ● WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so that there is no danger of it falling over. 1. Disconnect the speedometer cable from the front wheel. 2. Loosen the axle nut. 1 according to the procedure on page 6-37. 4.
PERIODIC MAINTENANCE AND MINOR REPAIR 2. Lift the wheel up between the fork legs. 1 2 NOTE: Make sure that there is enough space between the brake pads before inserting the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg. EAU25080 Tightening torque: Axle nut: 90 Nm (9.0 m·kgf, 65 ft·lbf) 6. Connect the speedometer cable. 1 2 WARNING It is advisable to have a Yamaha dealer service the wheel.
PERIODIC MAINTENANCE AND MINOR REPAIR 7. Remove the wheel. 2 3 4 EAU25761 To install the rear wheel 1. Insert the wheel axle from the left-hand side. 5 (a) 1 1. Axle nut 2. Brake pedal free play adjusting nut 3. Brake rod 4. Brake camshaft lever 5. Drive chain slack adjusting plate NOTE: Make sure that the drive chain adjusting plates are installed with the punched sides facing to the outside and that the slot in the brake shoe plate fits over the retainer on the swingarm. 4.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU25850 Troubleshooting 1 2 3 4 5 6 7 8 9 Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU25962 Troubleshooting chart EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel Check the fuel level in the fuel tank. There is enough fuel. Check the compression. There is no fuel. Supply fuel. 2 The engine does not start. Check the compression. 3 4 2. Compression There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle.
MOTORCYCLE CARE AND STORAGE EAU26000 Care 1 2 3 4 5 6 7 8 9 While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle.
MOTORCYCLE CARE AND STORAGE any marks. If the windshield is scratched, use a quality plastic polishing compound after washing. After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning.
MOTORCYCLE CARE AND STORAGE ● 1 2 3 4 5 6 7 8 9 ● ingly and make sure to wipe off any excess. Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product. Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: Consult a Yamaha dealer for advice on what products to use. EAU26150 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.
MOTORCYCLE CARE AND STORAGE from the spark plug, and then install the spark plug and the spark plug cap. EWA10950 WARNING To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/ centerstand. 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground.
SPECIFICATIONS 1 2 3 4 5 6 Overall length: 2090 mm (82.3 in) Overall width: 820 mm (32.3 in) Overall height: 1120 mm (44.1 in) Seat height: 790 mm (31.1 in) Wheelbase: 1325 mm (52.2 in) Ground clearance: 265 mm (10.43 in) Minimum turning radius: 1900 mm (74.8 in) Weight: With oil and fuel: 126.0 kg (278 lb) (U49) 127.0 kg (280 lb) (CAL) Engine: 7 8 9 Engine type: Air cooled 4-stroke, SOHC Cylinder arrangement: Forward-inclined single cylinder Displacement: 196.0 cm3 (11.96 cu.in) Bore × stroke: 67.
SPECIFICATIONS 3rd: 29/22 (1.318) 4th: 26/25 (1.040) 5th: 23/28 (0.821) Chassis: Frame type: Diamond Caster angle: 26.00 ° Trail: 95.0 mm (3.
SPECIFICATIONS Bulb voltage, wattage x quantity: 1 2 3 4 5 Headlight: 12 V, 60 W/55.0 W × 1 Tail/brake light: 12 V, 8.0/27.0 W × 1 Front turn signal/position light: 12 V, 27 W/8.0 W × 2 Rear turn signal light: 12 V, 27.0 W × 2 Meter lighting: 12 V, 3.4 W × 1 Neutral indicator light: 12 V, 3.4 W × 1 High beam indicator light: 12 V, 3.4 W × 1 Turn signal indicator light: 12 V, 3.4 W × 1 Fuse: 6 Fuse: 20.
CONSUMER INFORMATION EAU26351 Identification numbers EAU26390 Key identification number Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. KEY IDENTIFICATION NUMBER: 1 1 2 3 1.
CONSUMER INFORMATION EAU26460 Model label 1 2 1 3 4 5 6 1. Model label The model label is affixed to the location shown. Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
CONSUMER INFORMATION EAU26550 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
CONSUMER INFORMATION EAU26560 Motorcycle noise regulation 1 2 3 4 5 6 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle
CONSUMER INFORMATION EAU26611 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
CONSUMER INFORMATION Maintenance interval 1 2 3 Date of service Servicing dealer name and address Mileage 25000 mi (41000 km) or 48 months 28000 mi (46000 km) or 54 months 31000 mi (51000 km) or 60 months 4 5 6 7 8 9 9-6 Remarks
CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A.
CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 9-8
CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. 1 2 3 A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O.
INDEX A E Accessories and replacement parts ........6-19 Air filter element and check hose, cleaning .................................................6-14 Engine break-in ......................................... 5-4 Engine oil and oil filter element ............... 6-11 Engine, starting a warm............................. 5-2 Engine stop switch .................................... 3-3 B Battery .....................................................6-31 Brake and clutch levers, checking and lubricating .
INDEX Tires ........................................................ 6-17 Tool kit ...................................................... 6-1 Troubleshooting ...................................... 6-41 Troubleshooting chart ............................. 6-42 Turn signal indicator light .......................... 3-2 Turn signal light bulb, replacing .............. 6-37 Turn signal switch ..................................... 3-3 V Valve clearance, adjusting ......................
5FY-9-17_hyoushi 5/7/04 8:24 AM Page 1 OWNER’S MANUAL TW200T1 TW200T1C YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN ! 2002·5–0.6×1(E) 2004.6–0.
