Yamaha TW200C Owner'S Manual Download Page 74

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6-31

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU03370

Checking and lubricating the
brake and shift pedals

The operation of the brake and shift
pedals should be checked before
each ride, and the pedal pivots
should be lubricated if necessary.

Recommended lubricant:

Lithium-soap-based grease
(all-purpose grease)

EAU03164

Checking and lubricating the
brake and clutch levers

The operation of the brake and clutch
levers should be checked before
each ride, and the lever pivots should
be lubricated if necessary.

Recommended lubricant:

Lithium-soap-based grease
(all-purpose grease)

EAU04034

Checking and lubricating the
throttle grip and cable

The operation of the throttle grip
should be checked before each ride.
In addition, the cable should be lubri-
cated or replaced at the intervals
specified in the periodic maintenance
chart.

5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 70

Summary of Contents for TW200C

Page 1: ...OWNER S MANUAL 5FY 28199 14 LIT 11626 15 17 PRINTED ON RECYCLED PAPER See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories YAMAHA MOTOR CO LTD TW200P C ...

Page 2: ......

Page 3: ......

Page 4: ...EAU03438 ...

Page 5: ...e of this motorcycle If you have any questions concerning the operation or maintenance of your motorcy cle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reduc ing the performance or economy of operation of the motorcycle To maint...

Page 6: ...be taken to avoid damage to the motorcycle A NOTE provides key information to make procedures easier or clearer Q w cC NOTE NOTE 8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold 8 Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current produc...

Page 7: ...NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADE QUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPEC TIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 3 ...

Page 8: ...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 P N LIT 11626 15 17 EAU04247 AFFIX DEALER LABEL HERE 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 4 ...

Page 9: ...ever 3 4 Brake pedal 3 5 Fuel tank cap 3 5 Fuel 3 6 Fuel cock 3 7 Starter choke knob 3 8 Seat 3 8 Helmet holder 3 9 Shock absorber 3 9 Carrier 3 9 Luggage strap holders 3 10 Sidestand 3 10 Ignition circuit cut off system 3 11 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting and warming up a cold engine 5 1 Starting a warm engine 5 3 Shifting ...

Page 10: ...nd rear brake shoes 6 25 Checking the brake fluid level 6 26 Changing the brake fluid 6 27 Drive chain slack 6 28 Lubricating the drive chain 6 29 Checking and lubricating the cables 6 30 Checking and lubricating the throttle grip and cable 6 31 Checking and lubricating the brake and shift pedals 6 31 Checking and lubricating the brake and clutch levers 6 31 Checking and lubricating the sidestand ...

Page 11: ...TION 9 1 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 6 Street and enduro motorcycle limited warranty 9 8 Yamaha extended service 9 10 8 9 7 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 7 ...

Page 12: ...NECESSARY BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not se...

Page 13: ...veering wide on a turn due to EXCESSIVE SPEED or undercornering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic condi tions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep bo...

Page 14: ...er operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 Passengers should also observe the precautions mentioned above Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may als...

Page 15: ...ont fender These items including such cargo as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of non Yamaha...

Page 16: ...ontrol ability therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn the engine off when refueling b Take care...

Page 17: ...it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock s are turned to ON or RES for vacuum type OFF for manual type If the motor cycle should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your d...

Page 18: ... INFORMATION 1 2 3 4 5 6 7 8 9 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle 1 2 3 4 7 8 5 6 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 14 ...

Page 19: ...a 1 25 kgf cm2 18 psi REAR 175 kPa 1 75 kgf cm2 25 psi 8 90kg 198 lbs maximum load 1 2 4 5 6 7 8 q 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 3MX 2118K A0 CAUTION Read owner s manual before servicing battery Electrolyte will damage metal parts or paint If electrolyte spills wash are...

Page 20: ... Fuel cock page 3 7 3 Helmet holder page 3 9 4 Luggage strap holders page 3 10 5 Drive chain adjusting plate page 6 28 6 Air filter element page 6 14 7 Starter choke knob page 3 8 8 Shift pedal page 3 4 1 2 3 4 5 6 8 7 Left view 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 16 ...

Page 21: ...age 6 34 11 Engine oil level check window page 6 11 12 Brake pedal page 3 5 6 23 13 Owner s tool kit page 6 1 14 Fuse page 6 37 15 Luggage strap holders page 3 10 16 Spark arrester page 6 16 9 10 14 13 12 11 15 16 Right view 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 17 ...

Page 22: ... 2 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 6 23 8 Throttle grip page 6 18 9 Fuel tank cap page 3 5 1 2 3 4 5 6 7 8 9 Controls and instruments 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 18 ...

Page 23: ...ngine can be started The key cannot be removed EAU00038 OFF All electrical systems are off The key can be removed EAU00043 LOCK The steering is locked and all electri cal systems are off The key can be removed To lock the steering 1 Turn the handlebars all the way to the left or right 2 Push the key in from the OFF position release it and then turn it to LOCK 3 Remove the key a Push b Release c Tu...

Page 24: ...9 Turn signal switch 4 6 To signal a right hand turn push this switch to 6 To signal a left hand turn push this switch to 4 When released the switch returns to the center position To cancel the turn signal lights push the switch in after it has returned to the center position 1 Dimmer switch 2 Turn signal switch 3 Horn switch 4 2 3 1 1 2 3 EAU00056 Indicator lights EAU00057 Turn signal indicator l...

Page 25: ...starter EC000005 cC See page 5 1 for starting instruc tions prior to starting the engine 1 2 EAU03890 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emer gency such as when the motorcycle overturns or when the throttle cable is stuck 1 Engine stop switch 2 Start switch 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 21 ...

Page 26: ...gage the clutch pull the lever toward the han dlebar 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 igni tion circuit cut off system See page 3 11 for an explanation of the ignition circuit cut off system 1 Clutch lever EAU00158 Brake lever The brak...

Page 27: ...lockwise and pull it off 1 Fuel tank cap a Unlock b Turn To install the fuel tank cap 1 Insert the fuel tank cap into the tank opening with the key insert ed in the lock and then turn the cap 1 3 turn clockwise 2 Turn the key 1 4 turn clockwise and then remove it NOTE The fuel tank cap cannot be installed unless the key is in the lock In addi tion the key cannot be removed if the cap is not proper...

Page 28: ... exhaust system etc Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premium unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gasohol co...

Page 29: ...d over OFF ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position 1 Arrow mark positioned over ON RES This indicates reserve If you run out of 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 1 Arrow mark positioned over RES RES ON FUEL OFF 1 OF...

Page 30: ...rection b to turn off the starter choke 1 Starter choke knob 1 a b 1 EAU01092 Seat To remove the seat Remove the bolts and then pull the seat off 1 Bolt 2 To install the seat 1 Insert the projection on the front of the seat into the seat holder as shown 2 Place the seat in the original position and then tighten the bolts NOTE Make sure that the seat is properly secured before riding 1 Projection 2...

Page 31: ...ng informa tion before handling the shock absorber The manufacturer can not be held responsible for proper ty damage or personal injury that may result from improper han dling 8 Do not tamper with or attempt to open the gas cylinder 8 Do not subject the shock absorber to an open flame or other high heat sources other wise it may explode due to excessive gas pressure 8 Do not deform or damage the g...

Page 32: ...s See further down for an explanation of the ignition circuit cut off system EW000044 w 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 con tact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist t...

Page 33: ...and 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 8 It cuts the running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure EW000045 w If a malfunction is no...

Page 34: ...7 Keep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcy...

Page 35: ...AGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 3 6 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 11 6 14 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check fluid level in reservoir If necessary add re...

Page 36: ...rake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 31 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 31 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 31 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary In...

Page 37: ...th the time involved EWA00033 w If any item in the Pre operation check list is not working properly have it inspected and repaired before operat ing the motorcycle Sidestand switch Check operation of ignition circuit cut off system If system is defective have Yamaha dealer check vehicle 3 10 Battery Check fluid level Fill with distilled water if necessary 6 34 6 36 ITEM CHECKS PAGE 5FY 9 14 TW200 ...

Page 38: ...tract the opera tor resulting in a possible loss of control EAU00376 cC 8 Make sure not to store person al items near the air cleaner intake otherwise air intake will be blocked and performance will suffer 8 Make sure not to put anything near the battery and its termi nals otherwise electrical fail ure and acid corrosion may result EAU01751 Starting and warming up a cold engine In order for the ig...

Page 39: ... possible to pre serve the battery Do not crank the engine more than 10 seconds on any one attempt 6 After starting the engine move the starter choke knob back halfway ECA00055 cC For maximum engine life always warm the engine up before starting 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 t...

Page 40: ...s running Inadequate lubrication may damage the transmission 8 Always use the clutch while changing gears to avoid dam aging the engine transmis sion and drive train which are not designed to withstand the shock of forced shifting 1 N 5 4 3 2 1 EAU00423 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions ...

Page 41: ...nto the neutral position 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear NOTE Always shift gears at the recommend ed shift points EAU00427 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift the transmission into first gear when the motorcycle reach es 20 km h 12 5 mi h If the ...

Page 42: ...g this period pro longed full throttle operation or any condition that might result in engine overheating must be avoided EAU01500 0 1 000 km 0 600 mi Avoid prolonged operation above 1 3 throttle 1 000 1 600 km 600 1 000 mi Avoid prolonged operation above 1 2 throttle EC000057 cC After 1 000 km 600 mi of opera tion the engine oil must be changed the oil filter cartridge ele ment replaced and the o...

Page 43: ... turn the fuel cock lever to OFF EW000058 w 8 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them 8 Do not park on a slope or on soft ground otherwise the motorcycle may overturn 1 Arrow mark positioned over OFF RES ON FUEL OFF 1 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 39 ...

Page 44: ...CE ESPECIALLY IMPOR TANT ARE THE MAINTENANCE SERVICES RELATED TO EMIS SIONS CONTROL THESE CON TROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PER FORMANCE IN THE FOLLOWING PERIODIC MAINTENANCE CHARTS THE SERVICES RELAT ED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALER...

Page 45: ...r experi ence required for a particular job have a Yamaha dealer perform it for you EW000063 w Modifications not approved by Yamaha may cause loss of perfor mance 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 41 ...

Page 46: ...ance when engine is cold 9 Check condition 9 Adjust gap and clean 2 Spark plug 9 Replace at 11 000 km or 12 months Replace Replace and thereafter every 10 000 km or 12 months 3 Fuel line 9 Check fuel hose for crack or damage 9 Replace if necessary 9 Check for leakage 4 Exhaust system 9 Retighten if necessary 9 Replace gaskets if necessary 5 Spark arrester 9 Clean 6 Idle speed 9 Check and adjust en...

Page 47: ...lement 2 Oil filter Strainer and oil strainer 9 Replace oil filter and strainer if damaged 9 Wet type filter must Yamaha foam air filter 3 Air filter be washed and oil or othe quality air filter damped with oil oil 9 Adjust free play 9 Check fluid leakage Front see NOTE page 6 6 4 Brake system 9 Correct if necessary 9 Replace pads if necessary Front 9 Replace shoes if necessary Rear 5 Clutch 9 Adj...

Page 48: ... Lithium soap based 10 shift pedal shaft 9 Apply chain lube grease all purpose lightly grease 9 Check operation and Lithium soap based 11 Sidestand pivots lubricate grease all purpose 9 Apply chain lube lightly grease 12 Front fork 9 Check operation and leakage 9 Check bearings 13 Steering bearings assembly for looseness Medium weight wheel Repack 9 Moderately repack every bearing grease 10 000 mi...

Page 49: ...vice 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 Check the brake fluid level regularly and fill as required 9 Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years 9 Replace the brake hoses every four years or if cracked or damage...

Page 50: ...ce jobs described in this chapter Refer to this section each time the cowling or a panel needs to be removed and installed 1 Panel B 1 Cowling A 2 Panel A 1 2 1 1 EAU01145 Cowling A To remove the cowling Remove the screw and then pull the cowling off as shown To install the cowling Place the cowling in the original posi tion and then install the screw 1 Screw 5FY 9 14 TW200 USA 5 11 01 8 31 AM Pag...

Page 51: ...Remove the screws and then pull the panel out at the area shown 1 Panel A 2 Screw 2 2 1 To install the panel Place the panel in the original posi tion and then install the screws EAU00494 Panel B To remove the panel Pull the panel off as shown 1 Panel B 1 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 47 ...

Page 52: ...uld be removed and checked in accordance with the periodic maintenance and lubrication chart In addition the condition of the spark plug can reveal the condition of the engine 1 Spark plug wrench To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit 1 To install the panel Place the panel in the original pos...

Page 53: ...orrect torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 4 Install the spark plug cap 6 10 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 8 9 Specified spark plug DR8EA NGK or X24ESR U DENSO a a Spark plug gap To install the spark plug 1 Measure the spark plug gap with a wire thickness gauge and if necessary adjust ...

Page 54: ...e oil filter element cleaned at the intervals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE Make sure that the motorcycle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several ...

Page 55: ...e 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 1 Engine oil filler cap 1 Engine oil drain bolt 1 1 EC000070 cC When removing the engine oil drain bolt the O ring spring and oil strainer will fall out Take care not to lose these parts 1 O ring 2 Spring 3 Oil strainer 3 2 1 5FY 9 14 TW200 USA 5 11 01 8 31 AM...

Page 56: ... by removing the bolts 6 Remove the oil filter element and O rings 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 dam age and replace it if necessary 1 Oil filter element 2 O ring 2 1 2 2 NOTE Skip steps 4 9 if the oil filter element is not being cleaned 4 Remove the oil filter element ...

Page 57: ...oil drain bolt 43 Nm 4 3 m kgf 31 ft lb EC000072 cC 8 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives with the oil or use oils of a higher grade than CD In addition do not use oils labeled ENERGY CONSERV ING II or higher 8 Make sure that no foreign material enters the crankcase 13 Start the engine and then let it idle for sever...

Page 58: ...ement frame 7 Insert the element into the air fil ter case 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 1 Sponge material 2 Air filter element frame Recommended oil Yamaha foam air filter oil or other quality air filter oil 1 2 1 2 2 1 Air filter case cover 2 Screw 4 2 Remove the ai...

Page 59: ... 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 EAU01549 Cleaning the spark arrester The spark arrester should be cleaned at the intervals specified in the Periodic maintenance and lubrication chart EWA00007 w 8 Always let the exhaust system cool prior to touching exh...

Page 60: ...w holes when inserting the tailpipe 1 Tailpipe 2 Spark arrester 1 2 1 Remove the tailpipe by removing the screw and then pulling it out of the muffler 1 Muffler 2 Screw 1 2 EAU01752 Adjusting the carburetor The carburetor is an important part of the engine and its emission control system which requires very sophisti cated adjustment Therefore carbu retor adjustments should be left to Yamaha dealer...

Page 61: ...ed by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EAU03790 Tires To maximize the performance dura bility and safe operation of your motorcycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride EW000082 w 8 The tire air pressure must be checked ...

Page 62: ...r cycle could cause tire damage an accident or even injury 1 2 a 1 Side wall 2 Wear indicator a Tread depth Tire inspection The tires must be checked before each ride If the tire shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer replace the tire imme diately NOTE The tire tread depth limits may differ from c...

Page 63: ...torcy cle cannot be guaranteed 8 After extensive tests only the tires listed below have been approved for this model by Yamaha Motor Co Ltd EAU00680 w 8 It is dangerous to ride with a worn out tire When a tire tread begins to show cross wise lines have a Yamaha dealer replace the tire immedi ately 8 The replacement of all wheel and brake related parts including the tires should be left to a Yamaha...

Page 64: ... face must first be broken in for it to develop its optimal charac teristics EAU00691 Accessories and replace ment parts EW000098 w This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replacement parts you choose for your motorcycle should be designed specifically for this model and they must be securely mounted to maintain the inherent stability of ...

Page 65: ...clutch lever free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch lever 2 To increase the clutch lever free play turn the adjusting bolt in direction a To decrease the clutch lever free play turn the adjusting bolt in direction b 1 Locknut clutch lever 2 Adjusting bolt c Free play c 1 2 a b 5 Loosen the locknut at the crankcase 6 To increase the clutch lever free play...

Page 66: ...ure that the brake is working properly 8 A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will diminish the braking performance which may result in loss of control and an accident c 2 1 b a EAU00707 Adjusting t...

Page 67: ...on the brake pedal free play must be adjusted a Brake pedal free play The brake pedal free play should measure 20 30 mm 0 8 1 22 in as shown Periodically check the brake pedal free play and if necessary adjust it as follows a Brake pedal free play To increase the brake pedal free play turn the adjusting nut at the brake rod in direction a To decrease the brake pedal free play turn the adjusting nu...

Page 68: ...To make the brake light come on later turn the adjusting nut in direc tion b 1 Brake light switch 2 Adjusting nut EW000106 w 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 ope...

Page 69: ...isassemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear limit line have a Yamaha dealer replace the brake shoes as a set 1 Wear indicator 2 Wear limit line 1 FRONT 2 1 REAR EAU03776 Checking the brake fluid level Insufficient brake fluid may allow air to enter ...

Page 70: ...may result in vapor lock 8 Brake fluid may deteriorate paint ed surfaces or plastic parts Always clean up spilled fluid immediately 8 As the brake pads wear it is nor mal for the brake fluid level to gradually go down However if the brake fluid level goes down suddenly have a Yamaha dealer check the cause Recommended brake fluid DOT 4 EAU03985 Changing the brake fluid Have a Yamaha dealer change t...

Page 71: ...rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown 4 If the drive chain slack is incor rect adjust it as follows a Drive chain slack 35 60 mm 1 38 2 36 in EAU03765 To adjust the drive chain slack 1 Loosen the brake pedal free play adjusting nut 2 Loosen the axle nut 3 To tighten the drive chain turn the adjusting ...

Page 72: ...ce dures EW000103 w After adjusting the brake pedal free play check the operation of the brake light Tightening torque Axle nut 90 Nm 9 0 m kgf 65 ft lb EAU00767 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the General maintenance and lubri cation chart otherwise it will quickly wear out especially when riding in dusty or wet areas Servic...

Page 73: ...ontrol 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 EW000111 w Damage to the outer housing of cables may result in internal rust ing and cause interference with cable movement Replace dam aged cables as soon as possibl...

Page 74: ...ng and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lubricated if necessary Recommended lubricant Lithium soap based grease all purpose grease EAU04034 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addition the cab...

Page 75: ...ing the rear suspension The pivoting points of the rear sus pension must be lubricated at the intervals specified in the periodic maintenance and lubrication chart 1 Grease nipple 2 1 Recommended lubricant Lithium soap based grease all purpose grease EAU02939 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the peri odic...

Page 76: ...at there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them forward and backward If any free play can be felt have a Yamaha dealer check or repair the steering 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 handle bars several times to check if ...

Page 77: ...e level battery lead connections and breather hose routing should be checked before each ride and at the intervals specified in the periodic maintenance and lubrication chart 4 1 2 3 5 1 Battery 2 Negative lead black 3 Positive lead red 4 Battery breather hose 5 Band To check the electrolyte level 1 Remove the seat See page 3 8 for seat removal and installation procedures 2 Disconnect the negative...

Page 78: ...tery and provide sufficient ventilation when charging it in an enclosed space 8 KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN 1 Battery breather hose 1 EC000100 cC Use only distilled water as tap water contains minerals that are harmful to the battery 7 Place the battery in the battery compartment and then hook the battery band onto the holder 8 Connect the breather hose to the battery...

Page 79: ...ce 2 If the battery will be stored for more than two months check the specific gravity of the electrolyte at least once a month and fully charge the battery whenever necessary 3 Fully charge the battery before installation 4 After installation make sure that the battery leads are properly connected to the battery termi nals and that the breather hose is properly routed in good condi tion and not o...

Page 80: ...orcycle is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove cowling A See page 6 7 for cowling removal and installation procedures 2 Remove the headlight unit by removing the bolts 1 Bolt 2 1 Specified fuse 20A EAU01307 Replacing the fuse The fuse holder is located behind panel B See page 6 8 for panel removal and installation procedures If the f...

Page 81: ...way from a lit headlight bulb and do not touch the bulb until it has cooled down 5 Place a new bulb into position and then secure it with the bulb holder 1 Headlight bulb holder 1 EC000105 cC Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off ...

Page 82: ...e a Yamaha dealer adjust the headlight beam if necessary EAU03497 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pushing it in and turning it coun terclockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw ECA00065 cC Do not overtighten...

Page 83: ...orcycle to stand upright Check that the motor cycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcy cle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack under the frame in front of the rear wheel 2...

Page 84: ...t the projections mesh with the slots 2 Lift the wheel up between the fork legs 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 1 Retainer 2 Speedometer cable 2 1 1 2 EAU03517 Front wheel To remove the front wheel EW000122 w 8 It is advisable to have a Yamaha deale...

Page 85: ...e axle nut 1 Axle nut 2 Brake pedal free play adjusting nut 3 Brake rod 4 Brake camshaft lever 5 Drive chain adjusting plate 5 a 2 1 3 4 2 Remove the brake pedal free play adjusting nut and then dis connect the brake rod from the brake camshaft lever 3 Turn the drive chain adjusting plate on each side of the swingarm fully in direction a 4 Lift the rear wheel off the ground according to the proced...

Page 86: ...oor starting and loss of power The following troubleshooting chart represents a quick and easy proce dure for checking these vital systems yourself However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may lo...

Page 87: ... no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plug and check electrodes 3 Ignition Wet Dry Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Open the throttle halfway and ope...

Page 88: ...well as all electrical cou plers and connectors including the spark plug cap are tightly installed 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such products onto seals gaskets sprockets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 cC 8 Avoid using strong acidic wheel c...

Page 89: ...s not leave 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 bottle brush 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 minu...

Page 90: ... up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry complete ly before storing or covering it EWA00001 w 8 Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or acetone and wash the tires with warm water and a mild detergent 8 Before operating the motorcy cle...

Page 91: ...n bolt this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to protect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the...

Page 92: ... little every month in order to pre vent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an excessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more information on storin...

Page 93: ...ctric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher cC Be sure to use motor oils that do not contain anti friction modifiers Passenger car motor oils often labeled ENERGY CONSERVING contain anti friction additives which will cause clutch and or starter clutch slippage resulting in reduced component life and poor engine...

Page 94: ...stem Spur gear Primary reduction ratio 73 22 3 318 Secondary reduction system Chain drive Secondary reduction ratio 3 571 Number of drive chain sprocket teeth rear front 50 14 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 833 2nd 1 789 3rd 1 318 4th 1 040 5th 0 821 Chassis Frame type Diamond Caster angle 25 8 Trail 95 mm 3 74 in Tires Front Type With tube Size 130 80...

Page 95: ... Size 2 50 18 Rear Type Spoke wheel Size 14M C MT4 50 Brakes Front Type Single disc brake Operation Right hand Fluid DOT 4 Rear Type Drum brake Operation Right foot Suspension Front Type Telescopic fork Rear Type Swingarm Monocross suspension Spring shock absorber Front Coil spring oil damper Rear Coil spring gas oil damper Wheel travel Front 160 mm 6 3 in Rear 150 mm 5 9 in Electrical Ignition sy...

Page 96: ... 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 4 W 1 Fuse 20 A 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 92 ...

Page 97: ...AU01042 Key identification number The key identification number is stamped into the key Record this number in the space pro vided and use it for reference when ordering a new key 1 Key identification number EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number ...

Page 98: ...7 Model label The model label is affixed to the loca tion shown Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label 1 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 94 ...

Page 99: ...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 However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Depar...

Page 100: ...ny 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 after such device or element of design has been removed or rendered inoperative by any per son AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification re...

Page 101: ...9 5 CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 97 ...

Page 102: ...e 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 Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1 000 km or 1 month 4 000 mi 6 000 km or 6 months 7 000 mi 11 000 km or 12 months 10 000 mi 16 000 km or 18 months 13 000 mi 21 000 km or 24 months 5...

Page 103: ...i 31 000 km or 36 months 22 000 mi 36 000 km or 42 months 25 000 mi 41 000 km or 48 months 28 000 mi 46 000 km or 54 months 31 000 mi 51 000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 99 ...

Page 104: ...9 8 CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 EAU02918 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 100 ...

Page 105: ...9 9 CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 5FY 9 14 TW200 USA 5 11 01 8 31 AM Page 101 ...

Page 106: ...9 10 CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 EAU01063 5FY 9 14 TW200 USA 5 11 01 8 32 AM Page 102 ...

Page 107: ...9 11 CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 5FY 9 14 TW200 USA 5 11 01 8 32 AM Page 103 ...

Page 108: ...5FY 9 14 TW200 USA 5 11 01 8 32 AM Page 104 ...

Page 109: ...OWNER S MANUAL 5FY 28199 14 LIT 11626 15 17 PRINTED ON RECYCLED PAPER See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories YAMAHA MOTOR CO LTD TW200P C ...

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