Yamaha TW200M 1999 Owner'S Manual Download Page 47

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6-7

PERIODIC MAINTENANCE AND MINOR REPAIR

Panel A

EAU00494

Panel A

To remove

Pull outward on the areas shown.

To install

Place the panel in its original posi-
tion.

EAU01833

Spark plug

Removal

1. Remove the spark plug cap.
2. Use the spark plug wrench in

the tool kit to remove the spark
plug as shown.

Spark plug wrench

Panel B

Screw (

EAU01345

Panel B

To remove

Remove the screws and pull out-
ward on the areas shown.

To install

Place the panel in the original posi-
tion and install the screws.

3XT-9-29-6 (AUS) 4/12/0 5:33 AM Page 7

ProCarManuals.com

Summary of Contents for TW200M 1999

Page 1: ...3XT 28199 29 OWNER S MANUAL TW200M 3XT 9 29 hyousi AUS 4 12 0 5 14 AM Page 1 2 1 Magenta plate ProCarManuals com ...

Page 2: ...siro page 4 6 0 3 58 AM Page 1 ProCarManuals com ...

Page 3: ...acing machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic mainte nance of this motorcycle If you have any questions about the operation or maintenance of your motorcycle please consult a Yamaha dealer 3XT 9 29 0 1 2 AUS 4 12 0 5 31 AM Page 1 ProCarManu...

Page 4: ... 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 product inform...

Page 5: ...IMPORTANT MANUAL INFORMATION 1 2 3 4 5 6 7 8 9 EW000002 w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE 3XT 9 29 0 1 2 AUS 4 12 0 5 31 AM Page 3 ProCarManuals com ...

Page 6: ...a Motor Co Ltd 1st Edition July 1999 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EAU00008 3XT 9 29 0 1 2 AUS 4 12 0 5 31 AM Page 4 ProCarManuals com ...

Page 7: ...3 5 Rear brake pedal 3 5 Fuel tank cap 3 5 Fuel 3 6 Fuel cock 3 7 Starter choke 1 3 8 Kick starter 3 8 Steering lock 3 9 Seat 3 9 Helmet holder 3 10 Rear shock absorber 3 10 Rear carrier 3 11 Sidestand 3 11 Sidestand clutch switch operation check 3 12 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...

Page 8: ...ve chain lubrication 6 23 Cable inspection and lubrication 6 24 Throttle cable and grip lubrication 6 24 Brake and shift pedal lubrication 6 24 Brake and clutch lever lubrication 6 25 Sidestand lubrication 6 25 Rear suspension lubrication 6 25 Front fork inspection 6 26 Steering inspection 6 26 Wheel bearings 6 27 Battery 6 27 Fuse replacement 6 29 Headlight bulb replacement 6 30 Turn signal light...

Page 9: ...MER INFORMATION 9 1 Identification number records 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 Noise regulation For Australia 9 2 3XT 9 29 0 1 2 AUS 4 12 0 5 31 AM Page 7 ProCarManuals com ...

Page 10: ...ARY 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 auto mobile driver who did not see the...

Page 11: ...urn due to EXCESSIVE SPEED or under cornering insufficient lean angle for the speed a Always obey the speed limits and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure other motorists see you 6 The operator s and passenger s posture are important for proper control a The operator should keep both hands on the handlebars an...

Page 12: ...They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions Modification Modifications made to the motorcycle not approved by Yamaha or the removal of original equipment may render your motorcycle unsafe for use and may cause severe personal injury Modifications may also make your motorcycle ...

Page 13: ...ncluding such cargo as sleeping bags duffle bags or tents can create unstable handling or slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories which may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories You should u...

Page 14: ...ol ability Therefore such accessories are not recommended 2 Caution must be used if adding electrical accessories If these 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 off the engine when refueling b Take care n...

Page 15: ...torcycle could catch fire 4 When transporting the motorcycle in another vehicle be sure it is kept upright and that the fuel cock s is turned to ON or RES for vacuum type OFF for manual type If it 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 in your eyes see your doctor immediately...

Page 16: ...Y INFORMATION 1 2 3 4 5 6 7 8 9 EAU02977 Location of the important labels Please read the following labels carefully before operating this motorcycle 1 2 3XT 9 29 0 1 2 AUS 4 12 0 5 31 AM Page 14 ProCarManuals com ...

Page 17: ...ARNING Before you operate this vehicle read the owner s manual English 3HP 21568 00 4AA 22259 40 1 8 Q SAFETY INFORMATION 1 2 3 4 5 6 7 8 9 1 2 3XT 9 29 0 1 2 AUS 4 12 0 5 31 AM Page 15 ProCarManuals com ...

Page 18: ...ge 6 30 2 Fuel cock page 3 7 3 Starter choke 1 page 3 8 4 Air filter page 6 12 5 Battery page 6 27 6 Helmet holder page 3 10 7 Rear carrier page 3 11 8 Shift pedal page 3 4 1 2 3 4 5 6 7 8 Left view 3XT 9 29 0 1 2 AUS 4 12 0 5 31 AM Page 16 ProCarManuals com ...

Page 19: ...ESCRIPTION 1 2 3 4 5 6 7 8 9 9 Fuse page 6 29 10 Kick starter page 3 8 11 Rear brake pedal page 3 5 6 19 12 Tool kit page 6 1 9 10 11 12 Right view 3XT 9 29 0 1 2 AUS 4 12 0 5 31 AM Page 17 ProCarManuals com ...

Page 20: ... page 3 3 15 Speedometer page 3 2 16 Right handlebar switches page 3 3 17 Front brake lever page 3 5 6 18 18 Throttle grip page 6 14 6 24 19 Fuel tank cap page 3 5 20 Main switch page 3 1 13 14 15 16 17 18 19 20 Controls Instruments 3XT 9 29 0 1 2 AUS 4 12 0 5 31 AM Page 18 ProCarManuals com ...

Page 21: ...ctrical circuits are switched off The key can be removed in this position EAU00043 LOCK The steering is locked in this posi tion and all electrical circuits are switched off The key can be removed in this position To lock the steering turn the han dlebars all the way to the left or right With the key at OFF push it into the main switch and release it turn it counterclockwise to LOCK and remove it ...

Page 22: ...al indicator light N EAU00063 High beam indicator light This indicator comes on when the headlight high beam is used 1 2 3 4 EAU00095 Speedometer The speedometer shows riding speed This speedometer is equipped with an odometer and trip odometer The trip odometer can be reset to 0 with the reset knob Use the trip odometer to estimate how far you can ride on a tank of fuel This information will enab...

Page 23: ...l push the switch in after it has returned to the center position 1 Dimmer switch 2 Turn signal switch 3 Horn switch EAU00129 Horn switch Press the switch to sound the horn 1 2 EAU00137 Engine stop switch ENGINE STOP The engine stop switch is a safety device for use in an emergency such as when the motorcycle over turns or if trouble occurs in the throttle system Turn the switch to RUN to start th...

Page 24: ...s engage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth clutch operation Refer to the engine starting procedures for a descrip tion of the ignition circuit cut off system 1 Clutch lever 1 N 5 4 3 2 1 EAU00157 Shift pedal This motorcycle is equipped with a constant mesh 5 speed transmis sion The shift pedal is located on the l...

Page 25: ...ke pedal The rear brake pedal is on the right side of the motorcycle Press down on the brake pedal to apply the rear brake EAU00177 Fuel tank cap To open Insert the key and turn it 1 4 turn counterclockwise Turn the cap 1 3 turn counterclockwise and remove it from the tank To close Put the cap in the filler neck and turn it 1 3 turn clockwise Lock the cap by turning the key 1 4 turn clockwise and ...

Page 26: ... or it may overflow when the fuel heats up later and expands EAU00185 cC Always wipe off spilled fuel imme diately with a dry and clean soft cloth Fuel may deteriorate painted surfaces or plastic parts 1 Filler tube 2 Fuel level NOTE The tank cap cannot be reinstalled unless it is unlocked The key must remain in the cap until the cap is properly installed and locked onto the fuel tank EW000023 w B...

Page 27: ...ill not flow Always return the lever to this position when the engine is not running RES ON FUEL OFF 1 1 Arrow mark Recommended fuel Regular gasoline For Australia Unleaded fuel only Fuel tank capacity Total 7 0 L Reserve 1 0 L ON FUEL RES OFF 1 ON 1 Arrow mark ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position OFF ON 3XT 9 29 3 4 ...

Page 28: ...to this position Fill the tank at the first opportunity Be sure to set the fuel cock back to ON after refueling OFF ON FUEL RES 1 RES 1 Arrow mark RES EAU00212 Kick starter Rotate the kick starter away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and forcefully to start the engine This model has a primary coupled kick starter so the engine ...

Page 29: ...ert the key and turn it 1 8 turn counterclockwise Then push the key in while turning the handlebars slightly to the left and turn the key 1 8 turn clockwise Check that the steering is locked remove the key and close the lock cover To unlock the steering Insert the key push it in and turn it 1 8 turn counterclockwise so that it moves out Then release and remove the key 1 Steering lock 3XT 9 29 3 4 ...

Page 30: ...ive gas pressure 8 Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance 8 Take your shock absorber to a Yamaha dealer for any service 1 2 EAU00260 Helmet holder To open the helmet holder insert the key in the lock and turn it as shown To lock the helmet holder replace the holder in its original position EW000030 w Never ride with a helmet in the h...

Page 31: ...retracting the sidestand Please check carefully the operating instructions listed below and if there is any indication of a malfunction return the motor cycle to a Yamaha dealer immedi ately for repair 1 1 Rear carrier EAU00320 Rear carrier EW000032 w Do not exceed the load limit of 3 kg EAU00330 Sidestand This model is equipped with an ignition circuit cut off system The motorcycle must not be ri...

Page 32: ...K EAU00331 Sidestand clutch switch operation check Check the operation of the side stand switch and clutch switch against the information below TURN THE MAIN SWITCH TO ON AND THE ENGINE STOP SWITCH TO RUN TRANSMISSION IS IN GEAR AND SIDESTAND IS UP PULL IN CLUTCH LEVER AND PUSH THE START SWITCH ENGINE WILL START CLUTCH SWITCH IS OK 3XT 9 29 3 4 5 AUS 4 12 0 5 19 AM Page 12 ProCarManuals com ...

Page 33: ...nd free play 3 4 6 18 9 Adjust if necessary 9 Check for smooth operation Throttle grip and housing 9 Lubricate 6 14 6 24 9 Adjust throttle cable free play if necessary Engine oil 9 Check oil level 6 9 6 11 9 Fill with oil if necessary Drive chain 9 Check chain slack and condition 6 21 6 23 9 Adjust if necessary Wheels and tires 9 Check tire pressure wear damage and spoke tightness 6 15 6 17 9 Tigh...

Page 34: ... time involved w If any item in the PRE OPERATION CHECKS is not working properly have it inspected and repaired before oper ating the motorcycle ITEM CHECKS PAGE Fuel tank 9 Check fuel level 3 5 3 7 9 Fill with fuel if necessary Lights signals and 9 Check for proper operation 6 30 6 31 switches Battery 9 Check fluid level 6 27 6 29 9 Fill with distilled water if necessary 3XT 9 29 3 4 5 AUS 4 12 0...

Page 35: ...Before starting out always be sure the sidestand is up Failure to retract the sidestand completely can result in a seri ous accident when you try to turn a corner EAU00411 Starting and warming up a cold engine NOTE This motorcycle is equipped with a starting and an ignition circuit cut off switch The engine can be started only under one of the following condi tions 8 The transmission is in neutral...

Page 36: ... WILL START RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDEN IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP PULL IN CLUTCH LEVER AND PUSH START SWITCH OR KICK THE KICK STARTER ENGINE WILL START TURN THE MAIN SWITCH TO ON AND THE ENGINE STOP SWITCH TO RUN 3XT 9 29 3 4 5 AUS 4 12 0 5 19 AM Page 16 ProCarManuals com ...

Page 37: ... the start switch wait a few sec onds then try again Each attempt should be as short as possible to preserve the battery Do not crank the engine more than 10 seconds on any one attempt If the engine does not start with the starter motor kick the kick starter to start the engine 6 After starting the engine move the starter to the halfway posi tion NOTE For maximum engine life always warm up the eng...

Page 38: ...not tow the motorcycle a long distance Even with gears in neutral the transmission is only properly lubricated when the engine is running Inadequate lubrication may damage the transmission 8 Always use the clutch when changing gears The engine transmission and driveline are not designed to withstand the shock of forced shifting and can be damaged by shifting without using the clutch 1 N 5 4 3 2 1 ...

Page 39: ...we ask that you carefully read the fol lowing material Because the engine is brand new you must not put an excessive load on it for the first 1 000 km The various parts in the engine wear and polish them selves to the correct operating clearances During this period pro longed full throttle operation or any condition which might result in excessive heating of the engine must be avoided EAU00446 0 1...

Page 40: ...y EAU00457 Parking When parking the motorcycle stop the engine and remove the ignition key Turn the fuel cock to OFF whenever stopping the engine EW000058 w The exhaust system is hot Park the motorcycle in a place where pedestrians or children are not likely to touch the motorcycle Do not park the motorcycle on a slope or soft ground the motorcycle may overturn RES ON FUEL OFF 1 1 Arrow mark 3XT 9...

Page 41: ...NT The most important points of motorcycle inspection adjustment and lubri cation are explained in the follow ing pages EW000060 w If you are not familiar with motor cycle service this work should be done by a Yamaha dealer 1 EAU01175 Tool kit The tool kit is located behind panel A See page 6 7 for panel removal and installation procedures The tools provided in the owner s tool kit are to assist y...

Page 42: ...ring a service opera tion take your motorcycle to a Yamaha dealer for service EW000063 w Modifications to this motorcycle not approved by Yamaha may cause loss of performance and render it unsafe for use Consult a Yamaha dealer before attempting any changes 3XT 9 29 6 AUS 4 12 0 5 33 AM Page 2 ProCarManuals com ...

Page 43: ...eck electrolyte level and specific gravity 6 Battery 9 Correct or recharge if necessary 9 Make sure that the breather hose is properly routed 7 Clutch 9 Check operation 9 Adjust or replace cable 8 Front brake 9 Check operation 9 Adjust brake lever freeplay and replace brake shoes if necessary 9 Rear brake 9 Check operation 9 Adjust brake pedal freeplay and replace brake shoes if necessary 10 Wheel...

Page 44: ...g bearings 9 Correct accordingly 9 Lubricate with lithium soap base grease every 24 000 km or 24 months whichever comes first 16 Chassis fasteners 9 Make sure that all nuts bolts and screws are properly tightened 9 Tighten if necessary 17 Sidestand 9 Check operation 9 Lubricate and repair if necessary 18 Sidestand switch 9 Check operation 9 Replace if necessary 19 Front fork 9 Check operation and ...

Page 45: ...t or dusty areas Every Every 6 000 km 12 000 km No ITEM CHECKS AND MAINTENANCE JOBS INITIAL or or 1 000 km 6 months 12 months Whichever Whichever comes first comes first 9 Check oil level and vehicle for oil leakage 23 Engine oil 9 Correct if necessary 9 Change Warm engine before draining 24 Engine oil filter element 9 Clean or replace if necessary 25 Engine oil strainer 9 Clean or replace if nece...

Page 46: ...e of the maintenance described in this chapter Refer to this section each time a cowling or panel has to be removed or reinstalled 1 Panel B 1 2 1 Cowling A 2 Panel A 1 1 Screw EAU01145 Cowling A To remove Remove the cowling screw and pull outward on the areas shown To install Place in the original position and install the screw 3XT 9 29 6 AUS 4 12 0 5 33 AM Page 6 ProCarManuals com ...

Page 47: ...AU01833 Spark plug Removal 1 Remove the spark plug cap 2 Use the spark plug wrench in the tool kit to remove the spark plug as shown 1 Spark plug wrench 1 2 1 Panel B 2 Screw 2 EAU01345 Panel B To remove Remove the screws and pull out ward on the areas shown To install Place the panel in the original posi tion and install the screws 3XT 9 29 6 AUS 4 12 0 5 33 AM Page 7 ProCarManuals com ...

Page 48: ...on becomes excessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug 1 Spark plug gap Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification 2 Clean the gasket surface Wipe off any grime from the threads 3 Install the spark plug and tight en it to the specified torque NOTE If a to...

Page 49: ...Warm up the engine for a few minutes 2 Stop the engine Place an oil pan under the engine and remove the oil filler cap 1 Oil filler cap 2 3 1 2 With the engine stopped check the oil level through the level window located at the lower part of the right side crankcase cover NOTE Wait a few minutes until the oil level settles before checking 3 The oil level should be between the maximum and minimum m...

Page 50: ...Remove the drain bolt to drain the filter cavity 1 Drain plug 2 O ring 3 Compression spring 4 Oil strainer 1 3 2 4 Remove the filter cover screws and the oil filter cover 5 Remove the oil filter element and O ring 6 Clean the oil filter and strainer with solvent Replace if neces sary 7 Check the O rings If damaged replace 8 Install the drain plug filter cover screws and drain bolt Tighten the drai...

Page 51: ...ives Engine oil also lubri cates the clutch and additives could cause clutch slippage 8 Be sure no foreign material enters the crankcase 10 Start the engine and warm up for a few minutes While warming up check for oil leak age If oil leakage is found stop the engine immediately and check for the cause Recommended oil See page 8 1 Total amount 1 3 L Periodic oil change 1 0 L With oil filter replace...

Page 52: ... from its case and clean it with solvent After cleaning remove the remaining solvent by squeez ing the air filter 4 Apply the recommended oil to the entire surface of the filter and squeeze out the excess oil It should be wet but not drip ping 1 2 1 Screw 4 2 Air filter case cover Recommended oil Same as engine oil 5 Install the air filter in its case 6 Install panel B EC000085 cC 8 Make sure the ...

Page 53: ... 1 EAU01168 Idle speed adjustment NOTE A diagnostic tachometer must be used for this procedure 1 Attach the tachometer Start the engine and warm it up for a few minutes at approximate ly 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 1 Throttle stop screw 2 Set the idle to the specified engine speed by adjusting ...

Page 54: ...lve timing and engine noise To pre vent this the cam chain tensioner must be adjusted regularly This adjustment however should be left to a professional Yamaha ser vice technician EAU00637 Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regu larly This adjustment howev...

Page 55: ...ir temperature Tire infla tion pressure must be adjusted according to total weight of cargo rider passenger and accessories fairing saddlebags etc if approved for this model and vehi cle speed EW000087 w Proper loading of your motorcycle is important for several character istics of your motorcycle such as handling braking performance and safety Do not carry loosely packed items that can shift Secu...

Page 56: ...ave been approved by Yamaha Motor Co Ltd for this model No guarantee for handling characteristics can be given if tire combinations other than what is approved are used on this motorcycle The front and rear tires should be of the same manu facture and design Manufacturer Size Type BRIDGESTONE 130 80 18 66P TW31 Manufacturer Size Type BRIDGESTONE 180 80 14M C 78P TW34 REAR Minimum tire tread depth ...

Page 57: ...eplaced Failure to have a wheel balanced can result in poor performance adverse handling characteris tics and shortened tire life EAU00680 w 8 It is dangerous to ride with a worn out tire When a tire tread begins to show lines have a Yamaha dealer replace the tire immediately Brakes tires and related wheel parts replacement should also be left to a Yamaha dealer 8 Patching a punctured tube is not ...

Page 58: ...ing bolt at the clutch lever in direction a to loosen the cable 6 Loosen the locknut at the crankcase side 7 Turn the adjusting nut at the crankcase in direction a to increase free play or in direc tion b to decrease free play 8 Tighten the locknut at the crankcase and the clutch lever a b 2 3 1 1 Clutch cable 2 Adjusting nut 3 Locknut b a 2 1 3 EAU00699 Front brake lever free play adjustment The ...

Page 59: ...the brake hub and the brake lever 1 Adjusting nut 2 Locknut 3 4 2 1 a b EAU00707 Rear brake pedal height and free play adjustment EW000104 w It is advisable to have a Yamaha dealer make this adjustment Pedal height The brake pedal should be posi tioned so that its top end is approximately 15 mm below the top of the footrest 1 Loosen the locknut 1 Locknut 2 Adjusting bolt 3 Footrest 4 Pedal height ...

Page 60: ...the brake light come on later 1 Brake light switch 2 Adjusting nut Turn the adjusting nut on the brake rod in direction a to increase free play or in direction b to decrease free play EW000106 w 8 Brake pedal free play should be checked whenever the chain is adjusted or the rear wheel is removed and then reinstalled 8 Check the operation of the brake light after adjusting the rear brake 8 If it is...

Page 61: ...indicator If the indi cator reaches to the wear limit line ask a Yamaha dealer to replace the shoes 2 1 1 Wear indicator 2 Wear limit EAU00744 Drive chain slack check NOTE Spin the wheel several times and find the tightest position of the chain Check and or adjust the chain slack while it s in this tightest position To check the chain slack the motor cycle must be held straight up with both wheels...

Page 62: ...plates the same amount Make sure that they are in the same position for proper wheel alignment To tighten the chain turn in direc tion a To loosen the chain turn in direction b 1 2 3 4 b a 1 Rear brake pedal free play adjusting nut 2 Axle nut 3 Cotter pin 4 Chain adjusting plate EC000096 cC Too little chain slack will overload the engine and other vital parts Keep the slack within the specified li...

Page 63: ...parts which work with each other If the chain is not maintained properly it will wear out quickly Therefore the chain must be serviced regular ly This service is especially neces sary when riding in dusty areas 1 The drive chain should be lubricated every 500 km First remove all dirt and mud from the chain with a brush or cloth Then spray any of the many brands of spray type chain lubricant betwee...

Page 64: ...d lubricant Engine oil EAU00773 Throttle cable and grip lubrication The throttle twist grip assembly should be greased at the time that the cable is lubricated since the grip must be removed to get at the end of the throttle cable After removing the screws hold the end of the cable up in the air and put in several drops of lubricant With the throttle grip disassembled coat the metal surface of the...

Page 65: ...int and metal to metal contact surfaces Check that the sidestand moves up and down smoothly EW000113 w If the sidestand does not move smoothly consult a Yamaha deal er EAU00791 Rear suspension lubrication Lubricate the pivoting parts Recommended lubricant Lithium soap base grease Recommended lubricant Engine oil Recommended lubricant Engine oil 3XT 9 29 6 AUS 4 12 0 5 33 AM Page 25 ProCarManuals c...

Page 66: ... dlebars several times and check if the fork rebounds smoothly EC000098 cC If any damage or unsmooth move ment is found with the front fork consult a Yamaha dealer EAU00794 Steering inspection Periodically inspect the condition of the steering Worn out or loose steering bearings may be danger ous Place a stand under the engine to raise the front wheel off the ground Hold the lower end of the front...

Page 67: ...1071 Battery Check the level of the battery elec trolyte and make sure that the ter minals are tight Fill with distilled water if the elec trolyte level is low EC000099 cC When inspecting the battery be sure the breather hose is routed correctly If the breather hose is positioned in such a way as to cause battery electrolyte or gas to exit onto the frame structural and cosmetic damage to the motor...

Page 68: ... discharge quickly The battery fluid should be checked at least once a month The level should be between the minimum level and maximum level marks Use only distilled water if refilling is necessary EC000100 cC Normal tap water contains miner als which are harmful to a battery therefore refill only with distilled water 1 2 1 Maximum level mark 2 Minimum level mark EW000117 w Take care not to spill ...

Page 69: ...nstallation procedures If the fuse is blown turn off the main switch and the switch of the circuit in question Install a new fuse of proper amperage Turn on the switches and see if the electri cal device operates If the fuse immediately blows again consult a Yamaha dealer 1 1 Fuse EC000103 cC Do not use fuses of higher amper age rating than those recommend ed Substitution of a fuse of improper rat...

Page 70: ...tz bulb headlight If the head light bulb burns out replace it as follows 1 Remove cowling A See page 6 6 for cowling removal and installation procedures 2 Remove the bolts and the headlight unit 1 EC000105 cC Avoid touching the glass part of a bulb Keep it free from oil other wise the transparency of the glass life of the bulb and lumi nous flux will be adversely affect ed If oil gets on a bulb th...

Page 71: ... wise 4 Install the lens and tighten the screw EAU01623 Taillight bulb replacement 1 Remove the screws and the lense 1 2 3 1 1 1 Screw 2 1 Bulb 1 Screw 2 2 Lense 3 Bulb 2 Remove the defective bulb by pushing it inward and turning it counterclockwise 3 Install a new bulb by pushing it inward and turning it clock wise 4 Install the lense and tighten the screws EC000108 cC Do not over tighten the scr...

Page 72: ...ly two jacks can be placed under the frame or swingarm EAU01579 Supporting the motorcycle Since the Yamaha TW200 has no centerstand follow these precau tions when removing the front and rear wheel or performing other maintenance requiring the motor cycle to stand upright Check that the motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed un...

Page 73: ... wheel hub Make sure the projections are meshed into the slots 2 Lift up the wheel between the front fork legs 3 Install the wheel axle and the axle nut make sure the slot in the brake shoe plate fits over the stopper on the front fork outer tube 4 Let the motorcycle down 5 Install the brake cable at the handlebar lever holder and at the front wheel hub 6 Install the speedometer cable and the clip...

Page 74: ...in the brake shoe plate is fit over the stopper on the swingarm 2 Install and adjust the drive chain See page 6 22 for details about adjusting the drive chain slack 3 Install the axle nut and let the motorcycle down 4 Tighten the axle nut to the specified torque and install the axle nut cotter pin Tightening torque Axle nut 90 Nm 9 0 m0kg EAU01505 Rear wheel removal EW000122 w 8 It is advisable to...

Page 75: ...y trouble may occur during operation Any problem in the fuel compres sion or ignition systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your motorcycle requires any repair bring it to a Yamaha dealer The skilled technicians at a Yamaha dealership have the tools experience and know how to properly service your motorcycl...

Page 76: ...ith dry cloth and Open throttle half way and start Ask a Yamaha dealer to inspect Engine turns over Engine turns over Battery good Check fluid recharge Use the electric starter Check if there is fuel Enough fuel No fuel Go to compression check Supply fuel in the fuel tank electrodes plug and check quickly slowly check connections Engine doesn t start go to battery check the engine correct spark ga...

Page 77: ...nnectors 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 After normal use Remove dirt with warm water a neutral detergent and a soft clean spon...

Page 78: ... use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning compounds for plas tic may leave scratches on the windshield Test the product on a small hidden part of the windshield to make sure they do not leave any marks If the windshield is scratched use a quality plastic polishing com pound after washing After riding in the rain near the sea or on salt sprayed road...

Page 79: ... 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry com pletely before storing it or cov ering it EWA00001 w Make sure that there is no oil or wax on the brakes and tires If nec essary clean the brake discs and linings with a regular brake disc cleaner or acetone and wash the tires with warm water and mild soap Then carefully test the motorcycle ...

Page 80: ...r motorcycles equipped with a fuel cock which has an OFF position Turn the fuel cock to OFF 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rust ing and the fuel from deterio rating 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 sp...

Page 81: ...rder to prevent the tires from becoming degraded in one spot 8 Cover up the muffler outlet with a plastic bag to prevent moisture from entering 9 Remove the battery and fully charge it Store it in a cool dry place and recharge it once a month Do not store the bat tery in an excessively cold or warm place less than 0 C or more than 30 C For more information see Battery stor age in the chapter PERIO...

Page 82: ...ystem Electric and kick 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 li...

Page 83: ...econdary reduction system Chain drive Secondary reduction ratio 45 14 3 214 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio 1st 2 833 2nd 1 789 3rd 1 318 4th 1 040 5th 0 821 Chassis Frame type Diamond Caster angle 26 3 Trail 94 mm Tires Type With tube Front Size 130 80 18 66P Manufacturer BRIDGESTONE TW31 model Rear Size 180 80 14M C 78P Manufacturer BRIDGESTONE TW...

Page 84: ...eration Right hand operation Rear Type Drum brake Operation Right foot operation Suspension Front Type Telescopic fork Rear Type Swingarm Monocross suspension Shock absorber Front Coil spring oil damper Rear Coil gas spring oil damper Wheel travel Front 160 mm Rear 150 mm Electrical Ignition system C D I Charging system Type C D I magneto Standard output 12 V 11A 5 000 r min Battery Type GM7CZ 3D ...

Page 85: ... light 12 V 21W 2 Rear flasher light 12 V 21W 2 Meter light 12 V 3 4W 1 Neutral indicator light 12 V 3 4W 1 High beam indicator light 12 V 3 4W 1 Turn indicator light 12 V 3 4W 1 Fuse Main 15A 3XT 9 29 7 8 9 AUS 4 12 0 5 34 AM Page 9 ProCarManuals com ...

Page 86: ...t Multiplier Imperial unit m kg 7 233 ft lb Torque m kg 86 794 in lb cm kg 0 0723 ft lb cm kg 0 8679 in lb Weight kg 2 205 lb g 0 03527 oz Speed km hr 0 6214 mph km 0 6214 mi m 3 281 ft Distance m 1 094 yd cm 0 3937 in mm 0 03937 in cc cm3 0 03527 oz IMP liq Volume cc cm3 0 06102 cu in Capacity lt liter 0 8799 qt IMP liq lt liter 0 2199 gal IMP liq kg mm 55 997 lb in Misc kg cm2 14 2234 psi lb in2...

Page 87: ...ey identification number 1 Vehicle identification number EAU01042 Key identification number The key identification number is stamped on the key Record this number in the space provided and use it for reference when obtaining a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space provided NOTE The veh...

Page 88: ... TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporat ed into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b The use of the vehicle after su...

Page 89: ...3XT 9 29 7 8 9 AUS 4 12 0 5 34 AM Page 13 ProCarManuals com ...

Page 90: ...PRINTED IN JAPAN 2000 4 0 1 1 E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 3XT 9 29 hyousi AUS 4 12 0 5 14 AM Page 1 1 1 Magenta plate ProCarManuals com ...

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Yamaha TW200M 1999, Owner'S Manual

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Summary of Contents for TW200M 1999

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