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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 TW200P

Page 1: ...WNER 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 Accessor...

Page 2: ......

Page 3: ......

Page 4: ...EAU03438...

Page 5: ...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 comp...

Page 6: ...e 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 a...

Page 7: ...OT 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 IN...

Page 8: ...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 1...

Page 9: ...ver 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 cir...

Page 10: ...d 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...

Page 11: ...ION 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 S...

Page 12: ...ECESSARY 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 f...

Page 13: ...eering 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 tion...

Page 14: ...r 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 Modification...

Page 15: ...nt 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...

Page 16: ...ntrol 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 ele...

Page 17: ...t 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 m...

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 3...

Page 19: ...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...

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...

Page 21: ...ge 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...

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 23: ...gine 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...

Page 24: ...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 si...

Page 25: ...tarter 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 eng...

Page 26: ...age 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 e...

Page 27: ...ockwise 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...

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 ping...

Page 29: ...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 ou...

Page 30: ...ection 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...

Page 31: ...g 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 a...

Page 32: ...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...

Page 33: ...nd 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...

Page 34: ...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 1...

Page 35: ...GE 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...

Page 36: ...ake 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...

Page 37: ...h 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 i...

Page 38: ...ract 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 su...

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 li...

Page 40: ...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...

Page 41: ...to 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 e...

Page 42: ...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...

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 slop...

Page 44: ...E 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...

Page 45: ...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...

Page 46: ...nce 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 h...

Page 47: ...ement 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...

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 lub...

Page 49: ...ice 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 r...

Page 50: ...e 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 cowli...

Page 51: ...emove 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 re...

Page 52: ...ld 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 re...

Page 53: ...rrect 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 R...

Page 54: ...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 uprig...

Page 55: ...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...

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 t...

Page 57: ...il 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...

Page 58: ...ment 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 re...

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...

Page 60: ...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 carbu...

Page 61: ...d 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...

Page 62: ...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...

Page 63: ...orcy 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 Whe...

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 t...

Page 65: ...lutch 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 clu...

Page 66: ...re 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 deale...

Page 67: ...n 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 necessar...

Page 68: ...o 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...

Page 69: ...sassemble 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...

Page 70: ...ay 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 g...

Page 71: ...ear 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 D...

Page 72: ...e 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 c...

Page 73: ...ntrol 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 Y...

Page 74: ...g 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 lubrica...

Page 75: ...ng 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 lubri...

Page 76: ...t 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 ste...

Page 77: ...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 Nega...

Page 78: ...ery 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...

Page 79: ...e 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 batter...

Page 80: ...rcycle 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 headl...

Page 81: ...ay 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 to...

Page 82: ...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...

Page 83: ...rcycle 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 t...

Page 84: ...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...

Page 85: ...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 co...

Page 86: ...or 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 tak...

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 repla...

Page 88: ...ell 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...

Page 89: ...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 the...

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 brake...

Page 91: ...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 t...

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 c...

Page 93: ...tric 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 modifi...

Page 94: ...tem 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 Constan...

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 for...

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...

Page 97: ...U01042 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 n...

Page 98: ...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...

Page 99: ...pen 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 yo...

Page 100: ...y 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...

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: ...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...

Page 103: ...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...

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: ...WNER 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 Accessor...

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