PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories. See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual. OWNER’S MANUAL TW200P(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001·5–0.
EAU03438
FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 1 EAU00002 INTRODUCTION 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. 1 2 This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 2 EAU00003 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: 1 The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Q 2 3 w 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.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 3 IMPORTANT MANUAL INFORMATION w EW000000 PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 4 1 2 3 AFFIX DEALER LABEL HERE 4 5 6 7 8 9 EAU04247 TW200P(C) OWNER’S MANUAL ©2001 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2001 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.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 5 EAU00009 TABLE OF CONTENTS 1 SAFETY INFORMATION ....................................1-1 Safe riding ........................................................1-1 Protective apparel ............................................1-3 Modifications ....................................................1-3 Loading and accessories .................................1-3 Gasoline and exhaust gas ...............................1-5 Location of important labels ...............
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 6 TABLE OF CONTENTS 1 2 3 4 5 6 7 8 9 General maintenance and lubrication chart..............................................6-4 Removing and installing the cowling and panels ........................................6-7 Checking the spark plug ..................................6-9 Canister (for California only) ..........................6-11 Engine oil and oil filter element ......................6-11 Cleaning the air filter element and check hose ............
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 7 TABLE OF CONTENTS 7 MOTORCYCLE CARE AND STORAGE...........................................................7-1 Care .................................................................7-1 Storage ............................................................7-4 1 8 SPECIFICATIONS ..............................................8-1 2 9 CONSUMER INFORMATION .............................9-1 Identification numbers ......................................
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 8 EAU00017 Q SAFETY INFORMATION 1 2 3 4 5 6 7 8 9 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: 1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. 2.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 9 Q SAFETY INFORMATION 4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. a. Make sure that you are qualified and that you only lend your motorcycle to other qualified operators. b. Know your skills and limits. Staying within your limits may help you to avoid an accident. c.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 10 Q SAFETY INFORMATION Protective apparel 1 2 3 4 5 6 7 8 The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. 1. Always wear an approved helmet. 2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard. 3.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 11 Q SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 180 kg (397 lb) TW200/179kg (395 lb) TW200C. When loading within this weight limit, keep the following in mind: 1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 12 Q SAFETY INFORMATION 1 2 3 4 5 6 7 8 9 a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 13 Q SAFETY INFORMATION a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. c. Do not park the motorcycle near a flammable source (e.g., a kerosene heater, or near an open flame), otherwise it could catch fire. 4.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 14 Q SAFETY INFORMATION EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 15 Q SAFETY INFORMATION 6 1 q q WARNING WARNING 1 Improper loading can cause loss of control. Read owner’s manual for proper loading. BEFORE YOU OPERATE THIS VEHICLE, READ THE OWNER’S MANUAL AND ALL LABELS. ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET, eye protection, and protective clothing. 3JJ-28446-A0 2 3MX-2118K-A0 3 7 2 q WARNING CAUTION This unit contains high pressure nitrogen gas. Mishandling can cause explosion.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 16 EAU00026 DESCRIPTION Left view 1 2 3 4 1 2 3 4 5 6 7 8 8 7 9 1. 2. 3. 4. 5. Fuel tank cap Fuel cock Helmet holder Luggage strap holders Drive chain adjusting plate 6 (page 3-5) (page 3-7) (page 3-9) (page 3-10) (page 6-28) 5 6. Air filter element 7. Starter (choke) knob 8.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 17 DESCRIPTION 9 Right view 10 1 2 3 4 5 6 7 8 16 9. 10. 11. 12. 13. 15 Carrier Battery Engine oil level check window Brake pedal Owner’s tool kit 14 13 12 11 (page 3-9) 14. Fuse (page 6-34) 15. Luggage strap holders (page 6-11) 16.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 18 DESCRIPTION Controls and instruments 1 1 2 3 4 5 6 7 8 2 3 4 5 9 6 7 8 9 1. 2. 3. 4. 5. Clutch lever Left handlebar switches Speedometer unit Main switch/steering lock Indicator lights (page 3-4, 6-22) (page 3-2) (page 3-2) (page 3-1) (page 3-2) 2-3 6. 7. 8. 9.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 19 EAU00027 INSTRUMENT AND CONTROL FUNCTIONS OFF ON a b To unlock the steering Insert the key and turn it to “OFF”. c w EW000017 Never turn the key to “LOCK” while the motorcycle is moving. LOCK 1 2 3 EAU00029 Main switch/steering lock a. Push. b. Release. c. Turn. 4 EAU00043 The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 20 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 1 2 1 1 2 4 2 3 3 4 5 3 1. Turn signal indicator light “5” 2. High beam indicator light “&” 3. Neutral indicator light “N” EAU00056 Indicator lights 7 8 9 Speedometer Odometer Tripmeter Reset knob 1. Dimmer switch 2. Turn signal switch 3. Horn switch “*” EAU00118 EAU00095 EAU00057 6 1. 2. 3. 4.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 21 INSTRUMENT AND CONTROL FUNCTIONS EAU00129 EAU00143 Horn switch “*” Press this switch to sound the horn. Start switch “,” Push this switch to crank the engine with the starter. 1 cC 2 EC000005 See page 5-1 for starting instructions prior to starting the engine. 1. Engine stop switch 2. Start switch “,” 1 2 3 4 EAU03890 Engine stop switch “#/$” Set this switch to “#” before starting the engine.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 22 INSTRUMENT AND CONTROL FUNCTIONS 1 1 1 5 4 3 2 N 1 2 3 4 1 1. Clutch lever EAU00152 5 6 7 8 9 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.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 23 INSTRUMENT AND CONTROL FUNCTIONS To install the fuel tank cap 1. Insert the fuel tank cap into the tank opening with the key inserted in the lock, and then turn the cap 1/3 turn clockwise. 2. Turn the key 1/4 turn clockwise, and then remove it. a b 1 1 1. Brake pedal EAU00162 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 2 3 1. Fuel tank cap a. Unlock. b. Turn.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 24 INSTRUMENT AND CONTROL FUNCTIONS 1 Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. 2 1 EAU00185 cC 2 3 EAU04194 4 1. Filler tube 2. Fuel level 5 Fuel EAU03753 6 7 8 9 Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 25 INSTRUMENT AND CONTROL FUNCTIONS OFF: Closed position ON: Normal position RES: Reserve position RES RES RES 1 RES OFF OFF ON FUEL ON 1 1 ON 1. Arrow mark positioned over “OFF” EAU03050 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: 2 OFF FUEL ON FUEL 1 1. Arrow mark positioned over “ON” 1.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 26 INSTRUMENT AND CONTROL FUNCTIONS 2 1 2 1 1 b a 1 3 4 1. Starter (choke) knob “1” 1. Bolt (×2) EAU04038 5 6 7 8 Starter (choke) knob “1” 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). EAU01092 Seat To remove the seat Remove the bolts, and then pull the seat off. 1.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 27 INSTRUMENT AND CONTROL FUNCTIONS EAU01343 1 Shock absorber EAU00315 w 1 1. Helmet holder EAU00260 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. w EW000030 Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 28 INSTRUMENT AND CONTROL FUNCTIONS EAU00330 1 1 2 w The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the motorcycle upright. The motorcycle must not be ridden with the sidestand down, or if the sidestand cannot be properly moved up (or does not stay up), otherwise the sidestand could contact the ground and distract the operator, resulting in a possible loss of control.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 29 INSTRUMENT AND CONTROL FUNCTIONS EAU03720 Ignition circuit cut-off system 1 The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. 8 It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. 8 It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 30 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 YES 8 NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. NO The sidestand switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. NO The clutch switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 31 EAU01114 PRE-OPERATION CHECKS 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.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 32 PRE-OPERATION CHECKS ITEM 3 • Make sure that operation is smooth. • Check free play. • If necessary, have Yamaha dealer make adjustment or lubricate. 6-18 Control cables • Make sure that operation is smooth. • Lubricate if necessary. 6-30 Drive chain • • • • Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. 6-28–6-30 Wheels and tires • • • • Check for damage. Check tire condition and tread depth.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 33 PRE-OPERATION CHECKS ITEM CHECKS Sidestand switch • Check operation of ignition circuit cut-off system. • If system is defective, have Yamaha dealer check vehicle. Battery • Check fluid level. • Fill with distilled water if necessary. PAGE 3-10 1 6-34–6-36 2 NOTE: Pre-operation checks should be made each time the motorcycle is used.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 34 EAU00372 OPERATION AND IMPORTANT RIDING POINTS w 1 2 3 4 5 6 7 8 9 EAU00373 8 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. 8 Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 35 OPERATION AND IMPORTANT RIDING POINTS 4. Turn the starter (choke) on and completely close the throttle. (See page 3-8 for starter (choke) operation.) 5. Start the engine by pushing the start switch. RES OFF ON ON FUEL 1 1. Arrow mark positioned over “ON” 1. Turn the fuel cock lever to “ON”. 2. Turn the key to “ON” and make sure that the engine stop switch is set to “#”. 3. Shift the transmission into the neutral position.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 36 OPERATION AND IMPORTANT RIDING POINTS EAU01258 cC Starting a warm engine 1 2 Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. 5 4 3 2 N 1 1 3 4 1. Shift pedal N. Neutral position 5 Shifting EAU00423 6 7 Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 37 OPERATION AND IMPORTANT RIDING POINTS EAU02988 EAU00427 To start out and accelerate 1. Pull the clutch lever to disengage the clutch. 2. Shift the transmission into first gear. The neutral indicator light should go out. 3. Open the throttle gradually, and at the same time, release the clutch lever slowly. 4. At the recommended shift points shown in the table on page 5-4, close the throttle, and at the same time, quickly pull the clutch lever in. 5.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 38 OPERATION AND IMPORTANT RIDING POINTS EAU01128 Engine break-in 1 2 3 4 5 6 7 There is never a more important period in the life of your engine than the period between 0 and 1,600 km (1,000 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 1,600 km (1,000 mi). The various parts in the engine wear and polish themselves to the correct operating clearances.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 39 OPERATION AND IMPORTANT RIDING POINTS RES 1 OFF ON 2 FUEL 1 3 1. Arrow mark positioned over “OFF” 4 EAU00457 Parking 5 When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”. w 6 EW000058 7 8 Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 40 EAU00462 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01790 6 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.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 41 PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. w 1 2 EW000063 3 Modifications not approved by Yamaha may cause loss of performance and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 42 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00471 Periodic maintenance chart for the emission control system 1 2 NO.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 43 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00472 General maintenance and lubrication chart NO. 1 ITEM Engine oil 2 * Oil filter/Strainer 3 * Air filter 4 * Brake system 5 * Clutch 6 Drive chain ROUTINE 9 Warm-up engine before draining. 9 Clean filter element and oil strainer. 9 Replace oil filter and strainer if damaged. 9 Wet type filter must be washed and damped with oil. 9 Adjust free play. 9 Check fluid leakage.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 44 PERIODIC MAINTENANCE AND MINOR REPAIR NO. ITEM ROUTINE 7 Control and meter cable 9 Apply chain lube throughly. 8 * Rear arm pivot shaft 9 Apply until new grease shows. 9 Brake/Clutch lever pivot shaft 9 Apply chain lube lightly. 10 Brake pedal and shift pedal shaft 1 2 3 4 5 11 * Sidestand pivots 6 12 * Front fork 7 13 * Steering bearings 8 14 * Wheel bearings 9 15 Battery 16 * Sidestand switch 9 Lubricate. 9 Apply chain lube lightly.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 45 PERIODIC MAINTENANCE AND MINOR REPAIR EAU03906 NOTE: From 16,000 mi (26,000 km) or 30 months, repeat the maintenance intervals starting from 4,000 mi (6,000 km) or 6 months. EAU03057 NOTE: 8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 8 Hydraulic brake system 9 When disassembling the master cylinder or caliper cylinder, always replace the brake fluid.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 46 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 1 1 2 1 3 4 1. Cowling A 2. Panel A 1. Panel B 1. Screw EAU01145 EAU03516 5 6 7 8 Cowling A To remove the cowling Remove the screw, and then pull the cowling off as shown. Removing and installing the cowling and panels The cowling and panels shown above need to be removed to perform some of the maintenance jobs described in this chapter.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 47 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 1 2 1 1. Panel A 2. Screw (×2) 3 1. Panel B EAU01492 Panel A To remove the panel Remove the screws, and then pull the panel out at the area shown. To install the panel Place the panel in the original position, and then install the screws. 4 EAU00494 Panel B To remove the panel Pull the panel off as shown.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 48 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01833 Checking the spark plug 1 2 3 4 5 To install the panel Place the panel in the original position. 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.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 49 PERIODIC MAINTENANCE AND MINOR REPAIR To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-tolight tan (the ideal color when the motorcycle 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 motorcycle. 2.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 50 PERIODIC MAINTENANCE AND MINOR REPAIR EAU03936 Engine oil and oil filter element 1 1 2 2 4 5 1. 2. 3. 4. 3 Rollover valve Carburetor Canister Vent hose EAU01796 Canister (for California only) 6 7 8 9 2 3 The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element cleaned at the intervals specified in the periodic maintenance and lubrication chart.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 51 PERIODIC MAINTENANCE AND MINOR REPAIR 3 1 1 1 2 2 1 1. Engine oil filler cap 1. Engine oil drain bolt To change the engine oil (with or without oil filter element cleaning) 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase. 3 1. O-ring 2. Spring 3.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 52 PERIODIC MAINTENANCE AND MINOR REPAIR 9. Install the oil filter element cover by installing the bolts and the drain bolt, then tightening them to the specified torques. 1 1 2 2 3 4 5 6 7 8 9 1 2 2 3 1. Oil filter element cover 2. Bolt (×2) 3. Oil filter element drain bolt 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.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 53 PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Engine oil drain bolt: 43 Nm (4.3 m·kgf, 31 ft·lb) 12. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap. Recommended engine oil: See page 8-1. Oil quantity: Without oil filter element removal: 1.0 L (0.9 Imp qt, 1.1 US qt) With oil filter element removal: 1.1 L (1.0 Imp qt, 1.2 US qt) Total amount (dry engine): 1.3 L (1.1 Imp qt, 1.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 54 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 2 2 2 3 4 5 6 7 1. Air filter case cover 2. Screw (×4) 2. Remove the air filter case cover by removing the screws. 1 2 1. Sponge material 2. Air filter element frame 3. Pull the air filter element out. 4. Remove the sponge material from the air filter element frame, clean it with solvent, and then squeeze the remaining solvent out. 5.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 55 PERIODIC MAINTENANCE AND MINOR REPAIR cC EC000082* 8 Make sure that the air filter element is properly seated in the air filter case. 8 The engine should never be operated without the air filter element installed, otherwise the piston and/or cylinder may become excessively worn. 8. Install the air filter case cover by installing the screws. 9. Install the panel.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 56 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01752 Adjusting the carburetor 1 1 2 1 3 4 5 6 7 8 9 2 1. Muffler 2. Screw 1. Remove the tailpipe by removing the screw, and then pulling it out of the muffler. 2 1. Tailpipe 2. Spark arrester 2. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe. 3. Insert the tailpipe into the muffler, and then install and tighten the screw.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 57 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00637 Adjusting the valve clearance a a. Free play EAU00635 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.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 58 PERIODIC MAINTENANCE AND MINOR REPAIR Tire air pressure (measured on cold tires) Load* Front Rear 1 125 kPa 125 kPa Up to 90 kg (198 lbs) (1.25 kgf/cm2, (1.25 kgf/cm2, 18 psi) 18 psi) 2 90 kg (198 lbs)– maximum 150 kPa 175 kPa (1.50 kgf/cm2, (1.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 59 PERIODIC MAINTENANCE AND MINOR REPAIR w EW000079 8 Have a Yamaha dealer replace excessively worn tires. Besides being illegal, operating the motorcycle with excessively worn tires decreases riding stability and can lead to loss of control. 8 The replacement of all wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 60 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00685 Spoke wheels 1 2 3 4 5 6 7 8 9 To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels. 8 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. Do not attempt even the smallest repair to the wheel.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 61 PERIODIC MAINTENANCE AND MINOR REPAIR 3. If the specified clutch lever free play could be obtained as described above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows. 4. Fully turn the adjusting bolt at the clutch lever in direction a to loosen the clutch cable. 1 a c b 2 1. Locknut (clutch lever) 2. Adjusting bolt c. Free play a 1 b 2 2 1 1. Locknut (crankcase) 2. Adjusting nut 5.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 62 PERIODIC MAINTENANCE AND MINOR REPAIR c 1 2 1 b 2 a 3 4 5 6 7 8 9 1. Locknut 2. Adjusting bolt c. Free play EAU00696 Adjusting the brake lever free play The brake lever free play should measure 2–5 mm (0.08–0.20 in) as shown. Periodically check the brake lever free play and, if necessary, adjust it as follows. 1. Loosen the locknut at the brake lever. 2. To increase the brake lever free play, turn the adjusting bolt in direction a.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 63 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Loosen the locknut at the brake pedal. 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. 3. Tighten the locknut. w a 1 b 2 a 3 EWA00044 After adjusting the brake pedal position, the brake pedal free play must be adjusted. 1 a. Brake pedal free play 1.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 64 PERIODIC MAINTENANCE AND MINOR REPAIR w 1 2 3 4 5 6 7 8 9 EW000106 8 After adjusting the drive chain slack or removing and installing the rear wheel, always check the brake pedal free play. 8 If proper adjustment cannot be obtained as described, have a Yamaha dealer make this adjustment. 8 After adjusting the brake pedal free play, check the operation of the brake light.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 65 PERIODIC MAINTENANCE AND MINOR REPAIR FRONT REAR 1 1 2 1 2 1 3 1. Wear indicator groove (×3) EAU03938 Front brake pads Each front brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 66 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 8 9 Observe these precautions: 8 When checking the fluid level, make sure that the top of the brake fluid reservoir is level. 8 Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4 8 Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 67 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00744 1 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. 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. 1 a 2 2 b a 3 3 a. Drive chain slack 2.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 68 PERIODIC MAINTENANCE AND MINOR REPAIR 1 NOTE: Make sure that both adjusting plates are in the same position for proper wheel alignment. 2 cC 3 4 5 6 7 8 9 EW000103 w EAU00767 Lubricating the drive chain After adjusting the brake pedal free play, check the operation of the brake light. EC000096 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.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 69 PERIODIC MAINTENANCE AND MINOR REPAIR 2. Spray Yamaha Chain and Cable Lube or a high-quality spray-type drive chain lubricant on both sides and on the middle of the chain, making sure that all side plates and rollers have been sufficiently oiled. w EW000111 Damage to the outer housing of cables may result in internal rusting and cause interference with cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 70 PERIODIC MAINTENANCE AND MINOR REPAIR EAU04034 Checking and lubricating the throttle grip and cable 1 2 3 The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 71 PERIODIC MAINTENANCE AND MINOR REPAIR EAU02939 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1 1 2 3 To check the condition 1.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 72 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00794 Checking the steering 1 2 3 4 8 To check the operation 1. Place the motorcycle on a level surface and hold it in an upright position. 2. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly. 9 cC 5 6 7 Worn or loose steering bearings may cause danger.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 73 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01144 EAU03806 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.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 74 PERIODIC MAINTENANCE AND MINOR REPAIR EW000116 w 1 1 2 2 3 4 5 1. Maximum level mark 2. Minimum level mark 5. Place the battery on a level surface, and then check the electrolyte level in the battery. 6 7 8 9 NOTE: The electrolyte should be between the minimum and maximum level marks. 6. If the electrolyte is at or below the minimum level mark, add distilled water to raise the electrolyte to the maximum level mark.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 75 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 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. If the motorcycle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. 2.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 76 PERIODIC MAINTENANCE AND MINOR REPAIR EC000103 cC 2 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. 1 2 3 4 1 1. Fuse 2. Spare fuse EAU01307 5 6 7 8 9 Replacing the fuse The fuse holder is located behind panel B. (See page 6-8 for panel removal and installation procedures.) If the fuse is blown, replace it as follows. 1.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 77 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 a 2 1 2 3 1. Headlight coupler 2. Headlight bulb cover 3. Disconnect the headlight coupler, and then remove the headlight bulb cover. 1. Headlight bulb holder a. Do not touch this area. 4. Remove the headlight bulb holder by turning it counterclockwise, and then remove the defective bulb. EW000119 w Headlight bulbs get very hot.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 78 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 3 1 2 2 3 4 5 6 7 8 9 6. Install the bulb cover, and then connect the coupler. 7. Install the headlight unit by installing the bolts. 8. Install the cowling. 9. Have a Yamaha dealer adjust the headlight beam if necessary. 1. Screw 2. Bulb 3. Lens 1. Screw (×2) EAU01623 EAU03497 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. 2.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 79 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 Supporting the motorcycle 1 1. Bulb 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. Install the lens by installing the screws. cC EC000108 Do not overtighten the screws, otherwise the lens may break.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 80 PERIODIC MAINTENANCE AND MINOR REPAIR 3. Lift the front wheel off the ground according to the procedure on page 6-40. 4. Remove the axle nut, pull the wheel axle out, and then remove the wheel. 1 1 2 2 4 1. Speedometer cable 2. Axle nut 5 Front wheel EAU03517 6 7 8 9 Do not apply the brake after the wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 81 PERIODIC MAINTENANCE AND MINOR REPAIR 3. Insert the wheel axle, and then install the axle nut. 4. Lower the front wheel so that it is on the ground. 5. Tighten the axle nut to the specified torque. Tightening torque: Axle nut: 90 Nm (9.0 m·kgf, 65 ft·lb) 6. Connect the speedometer cable. 2 3 4 5 a 1 1. 2. 3. 4. 5.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 82 PERIODIC MAINTENANCE AND MINOR REPAIR 3. Install the axle nut, and then lower the rear wheel so that it is on the ground. 4. Tighten the axle nut to the specified torque. 1 2 3 4 Tightening torque: Axle nut: 90 Nm (9.0 m·kgf, 65 ft·lb) 1 1. Retainer EAU03520 5 To install the rear wheel 1. Insert the wheel axle from the left-hand side.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 83 PERIODIC MAINTENANCE AND MINOR REPAIR EAU03473 Troubleshooting chart EW000125 w 1 Keep away open flames and do not smoke while checking or working on the fuel system. 2 1. Fuel Check the fuel level in the fuel tank. There is enough fuel. Check the compression. There is no fuel. Supply fuel. 3 The engine does not start. Check the compression. 2. Compression There is compression. Check the ignition. There is no compression.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 84 EAU03521 MOTORCYCLE CARE AND STORAGE Care 1 2 3 4 5 6 7 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.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 85 MOTORCYCLE CARE AND STORAGE 8 Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 86 MOTORCYCLE CARE AND STORAGE 1 2 3 4 5 6 7 8 9 After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Immediately dry the drive chain and lubricate it to prevent it from rusting. 3. Use a chrome polish to shine chrome, aluminum and stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.) 4.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 87 MOTORCYCLE CARE AND STORAGE Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. cC ECA00014 8 Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 88 MOTORCYCLE CARE AND STORAGE 1 2 3 4 5 6 7 8 9 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. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 89 EAU01038 SPECIFICATIONS Specifications Model Engine oil TW200(C) Type Dimensions Overall length Overall width Overall height 1,325 mm (52.2 in) YAMALUBE 4 (20W40) or SAE 20W40 –20° –10° 1,900 mm (74.8 in) Recommended engine oil classification 126 kg (278 lb) (TW200) 127 kg (280 lb) (TW200C) Cylinder arrangement Forward inclined single cylinder Displacement 196 cm3 Bore × Stroke 67.0 × 55.7 mm Compression ratio 9.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 90 SPECIFICATIONS 1 Fuel 1st 2.833 UNLEADED GASOLINE ONLY 2nd 1.789 Fuel tank capacity 7.0 L (1.5 Imp gal, 1.8 US gal) 3rd 1.318 Reserve amount 1.0 L (0.2 Imp gal, 0.3 US gal) 4th 1.040 5th 0.821 Type 2 3 4 Gear ratio Carburetor Manufacturer TEIKEI Model × quantity MV28 × 1 (TW200) MV28 1B × 1 (TW200C) Chassis Spark plug 5 Manufacturer/Type NGK/DR8EA DENSO/X24ESR-U 6 Gap 0.6–0.7 mm (0.02–0.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 91 SPECIFICATIONS Maximum load* Rear 180 kg (397 lb) (TW200) 179 kg (395 lb) (TW200C) 1 Type Drum brake Operation Right foot Air pressure (cold tire) up to 90 kg load* Front 125 kPa (1.25 kgf/cm , 18 psi) Suspension Rear 125 kPa (1.25 kgf/cm2, 18 psi) Front 2 90 kg load–Maximum load* Type Telescopic fork Type Swingarm (Monocross suspension) Rear Front 150 kPa (1.50 kgf/cm2, 22 psi) Rear 175 kPa (1.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 92 SPECIFICATIONS 1 Headlight bulb type Halogen bulb Bulb voltage, wattage × quantity 2 3 4 5 6 Headlight 12 V, 60/55 W × 1 Tail/brake light 12 V, 8/27 W × 1 Front turn signal light 12 V, 27/8 W × 2 Rear turn signal light 12 V, 27 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.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 93 EAU01039 CONSUMER INFORMATION EAU02944 Identification numbers 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. 1. KEY IDENTIFICATION NUMBER: 2. VEHICLE IDENTIFICATION NUMBER: 1 1 1 2 3 1. Key identification number 1.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 94 EAU01039 CONSUMER INFORMATION 1 1 2 3 4 1. Model label EAU03757 5 6 7 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.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 95 CONSUMER INFORMATION EAU01051 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.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 96 CONSUMER INFORMATION EAU01053 Motorcycle noise regulation 1 2 3 4 5 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 w
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 97 CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 9-5
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 98 CONSUMER INFORMATION EAU03052 Maintenance record 1 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.
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 99 CONSUMER INFORMATION Maintenance interval Date of service Servicing dealer name and address Mileage 16,000 mi (26,000 km) or 30 months Remarks 1 2 19,000 mi (31,000 km) or 36 months 3 22,000 mi (36,000 km) or 42 months 4 25,000 mi (41,000 km) or 48 months 5 28,000 mi (46,000 km) or 54 months 6 31,000 mi (51,000 km) or 60 months 7 8 9 9-7
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 100 CONSUMER INFORMATION EAU02918 1 2 3 4 5 6 7 8 9 9-8
5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 101 CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 9-9
5FY-9-14 (TW200, USA) 5/11/01 8:32 AM Page 102 CONSUMER INFORMATION EAU01063 1 2 3 4 5 6 7 8 9 9-10
5FY-9-14 (TW200, USA) 5/11/01 8:32 AM Page 103 CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 9-11
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PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories. See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual. OWNER’S MANUAL TW200P(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001·5–0.