Yamaha TW200T1 Owner'S Manual Download Page 55 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-20

2

3

4

5

6

7

8

9

the use of items which have not

been approved by Yamaha.

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 clutch le-
ver free play and, if necessary, adjust it
as follows.

1. Loosen the locknut at the clutch le-

ver.

2. To increase the clutch lever free

play, turn the adjusting bolt in di-
rection (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).

NOTE:

If the specified clutch lever free play
could be obtained as described above,
tighten the locknut and skip the rest of
the procedure, otherwise proceed as

follows.

3. Fully turn the adjusting bolt at the

clutch lever in direction (a) to loos-
en the clutch cable.

4. Loosen the locknut at the crank-

case.

5. To increase the clutch lever free

play, turn the adjusting nut in direc-
tion (a). To decrease the clutch le-

1. Locknut (clutch lever)
2. Adjusting bolt
3. Clutch lever free play

1

2

3

(a)

(b)

1. Locknut (crankcase)
2. Adjusting nut

(b)

(a)

2 1

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Summary of Contents for TW200T1

Page 1: ...R S MANUAL PRINTED IN JAPAN 2002 5 0 6 1 E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2004 6 0 8 1 E LIT 11626 18 27 5FY 28199 17 TW200T1C TW200T1 5FY 9 17_hyoushi 5 7 04 8 24 AM Page 1 ...

Page 2: ...5FY 9 17_hyoushi2 3 4 9 04 2 40 PM Page 1 ...

Page 3: ...ic maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle 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 reducing the performance or economy of operation of the motorcyc...

Page 4: ...OTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTORCY CLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABI...

Page 5: ...AL 2004 by Yamaha Motor Corporation U S A 1st edition April 2004 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 18 27 AFFIX DEALER LABEL HERE ...

Page 6: ...ral maintenance and lubrication chart 6 4 Removing and installing the cowling and panels 6 8 Checking the spark plug 6 9 Canister for California only 6 11 Engine oil and oil filter element 6 11 Cleaning the air filter element and check hose 6 14 Cleaning the spark arrester 6 15 Adjusting the carburetor 6 16 Adjusting the throttle cable free play 6 16 Adjusting the valve clearance 6 17 Tires 6 17 S...

Page 7: ...ht bulb 6 37 Supporting the motorcycle 6 37 Front wheel 6 38 Rear wheel 6 39 Troubleshooting 6 41 Troubleshooting chart 6 42 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED...

Page 8: ...ts Many accidents have been caused by an automobile driver who 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 ap proaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to oc cur Ride where ...

Page 9: ...ment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing 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 exhaust system during or after operation They become very hot and can cause ...

Page 10: ...the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance 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 control operation or ob s...

Page 11: ...main switch When parking the motorcy cle note the following The engine and exhaust system may be hot therefore 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 the motorcycle near a flammable source e g a ker osene heater or near an open flame otherwise ...

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 4 7 8 5 6 ...

Page 13: ...G 8 8 This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 4AA 22259 80 1 3 CALIFORNIA ONLY 4 5 6 7 8 WARNING Improper loading can cause loss of control Read owner s manual for proper loading 3JJ 28446 A1 CAUTION Read owner s manual before servicing battery Electrolyte will damage metal parts or paint ...

Page 14: ...ft view 1 2 3 4 5 6 8 7 1 Fuel tank cap page 3 5 2 Fuel cock page 3 7 3 Helmet holder page 3 9 4 Luggage strap holder page 3 10 5 Drive chain slack adjusting plate 6 Air filter element page 6 14 7 Starter choke knob page 3 8 8 Shift pedal page 3 4 ...

Page 15: ...420 Right view 1 2 6 5 4 3 7 8 1 Carrier page 3 9 2 Battery page 6 31 3 Engine oil level check window page 6 11 4 Brake pedal page 3 5 5 Owner s tool kit page 6 1 6 Fuse page 6 34 7 Luggage strap holder page 3 10 8 Spark arrester page 6 15 ...

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 7 Brake lever page 3 4 8 Throttle grip page 6 16 9 Fuel tank cap page 3 5 ...

Page 17: ... on 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 key can be re moved To lock the steering Turn the handlebars all the way to the left or right 1 Push the key in from the OFF po sition release it and then turn it to LOCK 2 Remove the key To unlock...

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 distance traveled The tripmeter shows the distance traveled since it was last set to zero with the reset knob The tripmeter can be used to estimate the distance that can be traveled with a full tank of fu...

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 this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the s...

Page 20: ...ever 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 com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorcycle EAU12890 Brake lever The brake lever is located at the right handlebar...

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 1 3 turn clockwise and then remove it NOTE The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked W...

Page 22: ... the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line 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 premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso ho...

Page 23: ...n the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while riding move the lever to this position Fill the tank at the first oppor tunity Be sure to set the lever back to ON after refueling 1 Arrow mark positioned over OFF RES ON FUEL OFF 1 1 Arrow mark pos...

Page 24: ...Move the knob in direction b to turn off the starter choke EAU13970 Seat To remove the seat 1 Remove the bolts and then pull the seat off 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 posi tion and then tighten the bolts NOTE Make sure that the seat is properly se cured before riding 1 Starter choke knob 1 a b 1 ...

Page 25: ...d 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 not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage t...

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 stay up otherwise the sidestand could contact 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 the operator...

Page 27: ...ar 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 engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10250...

Page 28: ...and 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 be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch...

Page 29: ...pressure 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 made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the ...

Page 30: ...necessary 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 21 6 23 6 24 Rear brake Check operation Check pedal free play Adjust if necessary 6 22 6 23 Clutch Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 6 20 Throttle grip Make sure ...

Page 31: ...ke and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 29 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 29 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of...

Page 32: ...ral position The transmission is in gear with the clutch lever pulled and the sid estand up WARNING EWA10290 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 lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set to 3 Shift trans...

Page 33: ...nd temperatures below 10 C 50 F re quire about 35 seconds with the starter choke turned on then about 2 5 min utes with the starter choke in the half way position EAU16640 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm EAU16671 Shifting Shifting gears lets you control the amount of en...

Page 34: ... in 5 Shift the transmission into second gear Make sure not to shift the transmission into the neutral posi tion 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 recommended shift points EAU16700 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift ...

Page 35: ... 0 600 mi Avoid prolonged operation above 1 3 throttle 1000 1600 km 600 1000 mi Avoid prolonged operation above 1 2 throttle 1600 km 1000 mi and beyond The vehicle can now be operated nor mally CAUTION ECA12711 After 1000 km 600 mi of opera tion the engine oil must be changed the oil filter element and the oil strainer cleaned If any engine trouble should oc cur during the engine break in period i...

Page 36: ...ESPECIALLY IMPORTANT ARE THE MAINTE NANCE SERVICES RELATED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE...

Page 37: ...3 4 5 6 7 8 9 a Yamaha dealer perform it for you WARNING EWA10340 Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes ...

Page 38: ... 24 months 16000 mi 26000 km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check condition Adjust gap and clean Replace at 7000 mi 11000 km or 12 months and thereaf ter every 6000 mi 10000 km or 12 months Replace Replace 3 Spark arrester Clean 4 Valve clearance Check and adjust valve clear ance when engine is cold 5 Idle speed Check and adjust eng...

Page 39: ...nt Replace if necessary 2 Battery Check specific gravity and breather hose for proper oper ation 3 Clutch Check operation Adjust or replace cable 4 Front brake Check operation fluid level and for fluid leakage Replace brake pads if neces sary 5 Rear brake Check operation Adjust cable and replace brake shoes if necessary 6 Brake hose Check for cracks or damage Replace Every 4 years 7 Wheels Check r...

Page 40: ...and after washing the motorcycle or riding in the rain 12 Steering bearings Check bearing assembly for looseness Moderately repack with lith ium soap based grease every 10000 mi 16000 km or 18 months Repack 13 Chassis fasteners Check all chassis fitting and fasteners Correct if necessary 14 Brake and clutch lever pivot shafts Apply lithium soap based grease all purpose grease lightly No ITEM ROUTI...

Page 41: ...or oil leakage Replace if necessary 19 Shock absorber assembly Check operation and for oil leakage Replace if necessary 20 Engine oil Change warm engine before draining 21 Engine oil filter ele ment Clean 22 Engine oil strainer Clean 23 Control and meter cables Apply Yamaha chain and cable lube or engine oil 10W 30 thor oughly No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 400...

Page 42: ...or caliper cylinder always replace the brake fluid Check the brake fluid level regularly and fill as required Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years Replace the brake hoses every four years or if cracked or damaged 24 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricat...

Page 43: ...eds 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 and then install the screw EAU32451 Panel A To remove the panel Remove the screws and then pull the panel out at the area shown To install the panel Place the panel in the original position and then inst...

Page 44: ...hich 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 addition the condition of the spark plug can re veal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench inc...

Page 45: ...easure 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 grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque NOTE If a torque wrench is not available when installing a spark plug a go...

Page 46: ...ion NOTE Make sure that the vehicle 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 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 engine oil should be betwe...

Page 47: ...e these parts NOTE Skip steps 4 9 if the oil filter element is not being cleaned 4 Remove the oil filter element drain bolt to drain the oil from the oil filter element 5 Remove the oil filter element cover by removing the bolts 6 Remove the oil filter element and O rings 1 Engine oil filler cap 1 Engine oil drain bolt 1 1 1 O ring 2 Compression spring 3 Oil strainer 3 2 1 1 Oil filter element cov...

Page 48: ...AUTION 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 higher quality than specified In addition do not use oils la beled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 13 Start the engine and then let it idle for s...

Page 49: ...lean 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 out NOTE The sponge material should be wet but not dripping 6 Pull the sponge material over the air filter element frame 7 Insert the element into the air filter case CAUTION ECA10480 Make sure that the air filter ele ment...

Page 50: ...ntenance and lubrication chart WARNING EWA10980 Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system NOTE Make sure to select a well ventilated area free of combustible materials to clean the spark arrester 1 Remove the tailpipe by removing the screw and then pulling it out of the muffler 2 Tap the tailpipe lightly and the...

Page 51: ...the engine and its emission control sys tem which requires very sophisticated adjustment Therefore carburetor ad justments should be left to Yamaha dealer who has the necessary profes sional knowledge and experience EAU21380 Adjusting the throttle cable free play The throttle cable free play should mea sure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free pla...

Page 52: ...en the temperature of the tires equals the ambient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10530 Proper loading of your motorcycle is important for several characteris tics of your motorcycle such as handling braking performance and safety Do not ca...

Page 53: ...This motorcycle is equipped with tube tires WARNING EWA10460 The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the vehicle cannot be guaranteed After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Ltd WARNING EWA10560 It is dangerous to ride with a worn out tire When a tire tread begins to sh...

Page 54: ... a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU22011 Accessories and replacement parts WARNING EWA10621 This vehicle is not designed to pull a trailer or to be attached to a sidecar The accessories or replacement parts you choose for your vehicle should be designed specifically ...

Page 55: ...g bolt in di rection a To decrease the clutch lever free play turn the adjusting bolt in direction b NOTE If the specified clutch lever free play could be obtained as described above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 3 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 4 Loosen the locknut at the crank case...

Page 56: ...turn the adjusting 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 free play and make sure that the brake is working properly 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 hy drau...

Page 57: ...the 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 play must be adjusted Brake pedal free play The brake pedal free play should mea sure 20 0 30 0 mm 0 79 1 18 in as shown Periodically check the brake pedal free play and if necessary adjust it as fol...

Page 58: ...djusting 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 in direction b EAU22380 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic main ten...

Page 59: ...e wear indicator 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 possibly caus ing it to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake...

Page 60: ...ay result in vapor 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 However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU22720 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals ...

Page 61: ...ate the tight est portion of the drive chain and then measure the drive 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 To tighten the drive chain turn the adjusting plate on each side of the swingarm in direction a To loos en the drive chain turn the ...

Page 62: ...in must be cleaned and 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 follows CAUTION ECA10581 The drive chain must be lubricated after washing the motorcycle and riding in the rain 1 Remove all dirt and mud from the drive chain with a brush or cloth ...

Page 63: ...able movement Replace damaged ca bles as soon as possible to prevent unsafe conditions EAU23110 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift pedals The...

Page 64: ...he 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 EAU23250 Lubricating the rear suspension The pivoting points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant...

Page 65: ... 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 check or re pair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the ...

Page 66: ...361 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 tervals specified in the periodic mainte nance and lubrication chart To check the electrolyte level 1 Remove the seat See page 3 8 2 Disconnect the negative battery lead from the battery 3 Disconnect the...

Page 67: ... administer the fol lowing FIRST AID EXTERNAL Flush with plenty 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 drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclo...

Page 68: ... it in a cool dry place 2 If the battery will be stored for 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 installation make sure that the battery leads are properly con nected to the battery terminals and that the breather hose is properly routed in go...

Page 69: ...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 again have a Yamaha dealer check the electrical system EAU23811 Replacing the headlight bulb This model is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Rem...

Page 70: ...e 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 life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner 6 Install the bulb cover and then connect the coupl...

Page 71: ...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 it clock wise until it stops 4 Install the lens by installing the screws CAUTION ECA10680 Do not overtighten the screws oth erwise the lens may break 1 Screw 1 2 1 Tail brake light bulb 1 ...

Page 72: ...oving the front 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 wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand ...

Page 73: ...speedometer 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 37 4 Remove the axle nut pull the wheel axle out and then remove the wheel CAUTION ECA11070 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU24981 To install the front wheel 1 Ins...

Page 74: ... 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 wheel Securely support the motorcy cle so that there is no danger of it falling over 1 Loosen the axle nut 2 Remove the brake pedal free play adjusting nut and then disconnect the brake rod from the brake cam s...

Page 75: ...nd 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 26 3 Install the axle nut and then lower the rear wheel so that it is on the ground 4 Tighten the axle nut to the speci fied torque 5 Install the brake rod onto the brake camshaft lever and then install the brake pedal fre...

Page 76: ...g 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 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 look like Yam...

Page 77: ...s 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 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 th...

Page 78: ... cleaners especially on spoked wheels If such products 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 rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mil...

Page 79: ...corrosion protection spray on all metal including chrome and nickel plated surfaces to prevent corrosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stain less steel parts including the ex haust system Even the thermally induced discoloring o...

Page 80: ...oring your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 For motorcycles 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 Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fue...

Page 81: ... tire air pressure 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 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 st...

Page 82: ... 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 Recommended fuel Unleaded gasoline only Fuel tank capacity 7 0 L 1 85 US gal 1 54 Imp gal Fuel reserve amount 1 7 L 0 45 US gal 0 37 Imp gal Carburetor Manufacturer TEIKEI Type x quantity MV28 x 1 Spark plug s Manufa...

Page 83: ... condition 90 179 kg 198 395 lb CAL 90 180 kg 198 397 lb U49 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 14M C x MT4 50 Front brake Type Single disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Drum brake Operation Right foot operation Front suspensi...

Page 84: ...5 0 W 1 Tail brake light 12 V 8 0 27 0 W 1 Front turn signal position light 12 V 27 W 8 0 W 2 Rear turn signal light 12 V 27 0 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 Fuse 20 0 A ...

Page 85: ...BEL 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 EAU26400 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 is used to ...

Page 86: ...5 6 7 8 9 EAU26460 Model label The model label is affixed to the loca tion shown Record the information on this label in the space provided This in formation will be needed when ordering spare parts from a Yamaha dealer 1 Model label 1 ...

Page 87: ...r complaints it may 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 writ...

Page 88: ...gn incorporated into any new ve hicle 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 person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following syste...

Page 89: ...arranty 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 1000 km or 1 month 4000 mi 6000 km or 6 months 7000 mi 11000 km or 12 months 10000 mi 16000 km or 18 months 13000 mi 21000 km or 24 months 16000 mi 26000 km or 30 months 1...

Page 90: ...NFORMATION 9 6 1 2 3 4 5 6 7 8 9 25000 mi 41000 km or 48 months 28000 mi 46000 km or 54 months 31000 mi 51000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks ...

Page 91: ...CONSUMER INFORMATION 9 7 2 3 4 5 6 7 8 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY ...

Page 92: ...CONSUMER INFORMATION 9 8 1 2 3 4 5 6 7 8 9 ...

Page 93: ... have to pay anything for covered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement ...

Page 94: ...ng you ll have strong factory backed protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 ...

Page 95: ...ndlebar switches 3 3 Headlight bulb replacing 6 34 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 identification number 9 1 L Labels location of 1 5 Luggage strap holders 3 10 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 M...

Page 96: ... Turn signal indicator light 3 2 Turn signal light bulb replacing 6 37 Turn signal switch 3 3 V Valve clearance adjusting 6 17 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 31 Wheel front 6 38 Wheel rear 6 39 Wheels 6 19 ...

Page 97: ...R S MANUAL PRINTED IN JAPAN 2002 5 0 6 1 E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2004 6 0 8 1 E LIT 11626 18 27 5FY 28199 17 TW200T1C TW200T1 5FY 9 17_hyoushi 5 7 04 8 24 AM Page 1 ...

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