Yamaha TW200E W 2007 Owner'S Manual Download Page 84

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INDEX

Turn signal light bulb, replacing .............. 6-33
Turn signal switch ..................................... 3-3

Valve clearance ...................................... 6-13
Vehicle identification number .................... 9-1

Wheel bearings, checking....................... 6-27
Wheel (front) ........................................... 6-34
Wheel (rear) ............................................ 6-35
Wheels .................................................... 6-16

Summary of Contents for TW200E W 2007

Page 1: ...3XT 28199 2G TW200EW OWNER S MANUAL...

Page 2: ......

Page 3: ...manual thoroughly so as to enjoy all advantages of your TW200EW The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yours...

Page 4: ...torcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTO...

Page 5: ...U10200 TW200EW OWNER S MANUAL 2006 by Yamaha Motor Co Ltd 1st edition April 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is express...

Page 6: ...art 6 2 Removing and installing the cowling and panels 6 5 Checking the spark plug 6 6 Engine oil and oil filter element 6 8 Cleaning the air filter element and check hose 6 11 Adjusting the carbureto...

Page 7: ...32 Replacing a turn signal light bulb 6 33 Supporting the motorcycle 6 33 Front wheel 6 34 Rear wheel 6 35 Troubleshooting 6 37 Troubleshooting chart 6 38 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Sto...

Page 8: ...ho did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when a...

Page 9: ...ing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or...

Page 10: ...of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or c...

Page 11: ...ore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park t...

Page 12: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 1 2 3...

Page 13: ...he owner s manual 5PA 21568 00 Prima di usare il veicolo leggete il manuale di istruzioni Lire le manuel du propri taire avant d utiliser ce v hicule Lesen Sie die Bedienungsanleitung bevor Sie dieses...

Page 14: ...EAU10410 Left view 1 2 3 4 5 7 6 1 Fuel cock page 3 6 2 Helmet holder page 3 9 3 Luggage strap holder page 3 10 4 Drive chain slack adjusting plate 5 Air filter element page 6 11 6 Starter choke knob...

Page 15: ...6 5 4 3 7 8 9 1 Carrier page 3 9 2 Battery page 6 27 3 Kickstarter page 3 8 4 Engine oil filter element page 6 8 5 Engine oil level check window page 6 8 6 Brake pedal page 3 5 7 Owner s tool kit pag...

Page 16: ...4 5 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...

Page 17: ...n and the engine can be started The key cannot be removed EAU10660 OFF All electrical systems are off The key can be removed EAU10710 LOCK The steering is locked and all electrical systems are off The...

Page 18: ...headlight is switched on EAU11630 Speedometer unit The speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odometer shows the total dista...

Page 19: ...push the switch in after it has re turned to the center position EAU12500 Horn switch Press this switch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set...

Page 20: ...ver is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 11 EAU12870 Shift pedal The shift pedal is located on the left side of the engine and is used in c...

Page 21: ...counterclockwise and pull it off 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...

Page 22: ...on rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging oc curs use a gas...

Page 23: ...ill the tank at the first oppor tunity Be sure to set the lever back to ON after refueling EAU13600 Starter choke knob Starting a cold engine requires a richer air fuel mixture which is supplied by th...

Page 24: ...h a primary kickstarter allowing the en gine to be started in any gear if the clutch is disengaged However shifting the transmission into the neutral posi tion before starting is recommended EAU13970...

Page 25: ...nd understand the following information before handling the shock absorber The manufacturer cannot be held re sponsible for property damage or personal injury that may result from improper handling Do...

Page 26: ...down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not sta...

Page 27: ...r and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running...

Page 28: ...nd 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 system is OK The motorcycle can b...

Page 29: ...ressure could have serious consequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be m...

Page 30: ...ecessary Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 17 6 19 6 20 Rea...

Page 31: ...e and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 25 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 25 Chassis fastener...

Page 32: ...WA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 11 Never ride with the sidestand down 1 Turn the fuel cock...

Page 33: ...arter choke is not required when the engine is warm EAU16671 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear pos...

Page 34: ...he engine while shifting down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traffic ligh...

Page 35: ...ring the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17170 Parking When parking stop the engine remove the key from the main switch and then turn the fuel cock lever...

Page 36: ...HORT ENED WARNING EWA10320 If you are not familiar with mainte nance work have a Yamaha dealer do it for you EAU17340 Owner s tool kit The owner s tool kit is located behind panel B See page 6 5 The s...

Page 37: ...OMETER READING 1000 km ANNUAL CHECK 1 6 12 18 24 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plug Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Air filt...

Page 38: ...r riding in the rain 15 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 24000 km 16 Chassis fasteners Make sure that all nuts bolts and s...

Page 39: ...ponents of the brake master cylinder and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 26 Moving parts and cables Lubricate 27 Throttle grip hou...

Page 40: ...eeds to be re moved and installed EAU18810 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 an...

Page 41: ...ch 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 mainte nance and lubrication chart In...

Page 42: ...ug 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any...

Page 43: ...for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase NOTE The e...

Page 44: ...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 5 Remove the oil filter element cover by removing the bolts 6...

Page 45: ...TION ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a hig...

Page 46: ...filter element frame clean it with solvent and then squeeze the remaining solvent out 5 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the ex cess oil...

Page 47: ...or has been set and ex tensively tested at the Yamaha fac tory Changing these settings without sufficient technical knowl edge may result in poor perfor mance of or damage to the engine EAU21340 Adjus...

Page 48: ...the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21401 Valve clearance The valve clearance changes with use resulting in improper...

Page 49: ...ift Securely pack your heaviest items close to the cen ter of the motorcycle and distribute the weight evenly from side to side Check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTOR...

Page 50: ...y Yamaha Motor Co Ltd WARNING EWA10560 It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement o...

Page 51: ...en in for it to develop its optimal characteris tics EAU22041 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 0 15 0 mm 0 39 0 59 in as shown Periodically check the...

Page 52: ...sting screw in di rection a To decrease the brake lever free play turn the adjusting screw in direction b 3 Tighten the locknut WARNING EWA10630 After adjusting the brake lever free play check the fre...

Page 53: ...he adjusting bolt in direction a To lower the brake pedal turn the ad justing bolt in direction b 3 Tighten the locknut WARNING EWA11230 After adjusting the brake pedal posi tion the brake pedal free...

Page 54: ...usting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut...

Page 55: ...reaches the wear limit line have a Yamaha dealer replace the brake shoes as a set EAU32343 Checking the front brake fluid level Insufficient brake fluid may allow air to enter the brake system possibl...

Page 56: ...lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down How...

Page 57: ...rive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows EAU22830 To adjust the drive chain slack 1 Loosen the brake pedal free play adjusting nut 2 Loosen the axle nut 3...

Page 58: ...lubricated at the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as fol...

Page 59: ...n and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle grip and cable The operation of the thr...

Page 60: ...e sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10730 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EAU...

Page 61: ...on the handlebars several times to check if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer che...

Page 62: ...61 Battery A poorly maintained battery will corrode and discharge quickly The electrolyte level battery lead connections and breather hose routing should be checked before each ride and at the in terv...

Page 63: ...lenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy...

Page 64: ...or more than two months check the specif ic gravity of the electrolyte at least once a month and fully charge the battery whenever necessary 3 Fully charge the battery before in stallation 4 After ins...

Page 65: ...void causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If the fuse immediately blows agai...

Page 66: ...it with the bulb holder CAUTION ECA10660 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 lif...

Page 67: ...lb 1 Remove the tail brake light lens by removing the screws 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn...

Page 68: ...ront and rear wheel or performing other maintenance requiring the motorcycle to stand up right Check that the motorcycle is in a stable and level position before starting any maintenance A strong wood...

Page 69: ...peedometer ca ble from the front wheel 2 Loosen the axle nut 3 Lift the front wheel off the ground according to the procedure on page 6 33 4 Remove the axle nut pull the wheel axle out and then remove...

Page 70: ...ighten the axle nut to the speci fied torque 6 Connect the speedometer cable EAU25080 Rear wheel EAU25420 To remove the rear wheel WARNING EWA10820 It is advisable to have a Yamaha dealer service the...

Page 71: ...d that the slot in the brake shoe plate fits over the retainer on the swingarm 2 Install the drive chain onto the rear sprocket and then adjust the drive chain slack See page 6 22 3 Install the axle n...

Page 72: ...and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Y...

Page 73: ...compression There is no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wet Dry Wipe off with a dry cloth and correct t...

Page 74: ...ducts are used on hard to remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor...

Page 75: ...bsorbing 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 stain less steel parts including the ex haust system Eve...

Page 76: ...s equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosening the drain bolt this will prevent fuel deposits from building up...

Page 77: ...re and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cov...

Page 78: ...her Engine oil quantity Without oil filter element removal 1 00 L 1 06 US qt 0 88 Imp qt With oil filter element removal 1 10 L 1 16 US qt 0 97 Imp qt Air filter Air filter element Wet element Fuel Re...

Page 79: ...ading condition 90 180 kg 198 397 lb Front 150 kPa 22 psi 1 50 kgf cm2 Rear 175 kPa 25 psi 1 75 kgf cm2 Front wheel Wheel type Spoke wheel Rim size 18x2 50 Rear wheel Wheel type Spoke wheel Rim size 1...

Page 80: ...W 55 0 W 1 Tail brake light 12 V 5 0 W 21 0 W 1 Front turn signal light 12 V 21 0 W 2 Rear turn signal light 12 V 21 0 W 2 Meter lighting 12 V 3 4 W 1 Neutral indicator light 12 V 3 4 W 1 High beam in...

Page 81: ...EL INFORMATION EAU26390 Key identification number The key identification number is stamped into the key Record this num ber in the space provided and use it for reference when ordering a new key EAU26...

Page 82: ...WITH NOISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of an...

Page 83: ...3 Headlight bulb replacing 6 30 Helmet holder 3 9 High beam indicator light 3 2 Horn switch 3 3 I Identification numbers 9 1 Ignition circuit cut off system 3 11 Indicator lights 3 2 K Key identificat...

Page 84: ...INDEX Turn signal light bulb replacing 6 33 Turn signal switch 3 3 V Valve clearance 6 13 Vehicle identification number 9 1 W Wheel bearings checking 6 27 Wheel front 6 34 Wheel rear 6 35 Wheels 6 16...

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Page 86: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 6 0 1 1 E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 6 0 1 1 E...

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