Yamaha TW200Z Owner'S Manual Download Page 6

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TABLE OF CONTENTS

LOCATION OF IMPORTANT
LABELS

............................................. 1-1

SAFETY INFORMATION

.................. 2-1

DESCRIPTION

.................................. 3-1

Left view .......................................... 3-1
Right view ........................................ 3-2
Controls and instruments................. 3-3

INSTRUMENT AND CONTROL
FUNCTIONS

....................................... 4-1

” .............. 4-8

Seat ................................................ 4-8
Helmet holder  ................................. 4-9
Shock absorber assembly  .............. 4-9
Carrier ........................................... 4-10
Luggage strap holders .................. 4-10
Sidestand ...................................... 4-10
Ignition circuit cut-off system  ........ 4-11

FOR YOUR SAFETY –
PRE-OPERATION CHECKS

............. 5-1

OPERATION AND IMPORTANT
RIDING POINTS

................................. 6-1

Starting and warming up a cold

engine ......................................... 6-1

Starting a warm engine  ..................  6-2
Shifting ...........................................  6-2
Engine break-in  ..............................  6-4
Parking ...........................................  6-4

PERIODIC MAINTENANCE AND
ADJUSTMENT

................................... 7-1

Owner’s tool kit ............................... 7-2
Periodic maintenance chart for

the emission control system ....... 7-3

General maintenance and

lubrication chart .......................... 7-4

Removing and installing the

cowling and panels ..................... 7-8

Checking the spark plug .................  7-9
Canister (for California only)  ........  7-11
Engine oil and oil filter element  ....  7-11
Cleaning the air filter element

and check hose ......................... 7-14

Cleaning the spark arrester .......... 7-15
Carburetor .................................... 7-16
Checking the engine idling

speed ........................................ 7-16

Checking the throttle cable

free play .................................... 7-16

Valve clearance  ...........................  7-17
Tires .............................................  7-17
Spoke wheels  ..............................  7-19
Adjusting the clutch lever free

play ........................................... 7-19

Adjusting the brake lever free

play ........................................... 7-20

Adjusting the brake pedal

position and free play ............... 7-21

Adjusting the rear brake light

switch ........................................ 7-22

Checking the front brake pads

and rear brake shoes ............... 7-22

Checking the brake fluid level  ......  7-23
Changing the brake fluid  ..............  7-24
Drive chain slack ..........................  7-24
Cleaning and lubricating the

drive chain ................................ 7-25

Checking and lubricating the

cables ....................................... 7-26

Checking and lubricating the

throttle grip and cable ............... 7-26

Checking and lubricating the

brake and clutch levers ............. 7-26

Checking and lubricating the

brake pedal ............................... 7-27

Checking and lubricating the

sidestand .................................. 7-27

Lubricating the rear suspension ... 7-28

Summary of Contents for TW200Z

Page 1: ...10D 28199 13 TW200ZC OWNER S MANUAL Read this manual carefully before operating this vehicle LIT 11626 23 38 TW200Z ...

Page 2: ...EAU10042 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold Q ...

Page 3: ...tion of the motorcycle To maintain these high standards it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most cur rent product information available at the time of printing th...

Page 4: ...personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE ...

Page 5: ...WNER S MANUAL 2009 by Yamaha Motor Corporation U S A 1st edition April 2009 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 23 38 ...

Page 6: ...eral maintenance and lubrication chart 7 4 Removing and installing the cowling and panels 7 8 Checking the spark plug 7 9 Canister for California only 7 11 Engine oil and oil filter element 7 11 Cleaning the air filter element and check hose 7 14 Cleaning the spark arrester 7 15 Carburetor 7 16 Checking the engine idling speed 7 16 Checking the throttle cable free play 7 16 Valve clearance 7 17 Ti...

Page 7: ...pporting the motorcycle 7 35 Front wheel 7 36 Rear wheel 7 37 Troubleshooting 7 38 Troubleshooting chart 7 40 MOTORCYCLE CARE AND STORAGE 8 1 Matte color caution 8 1 Care 8 1 Storage 8 3 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 Reporting safety defects 10 3 Motorcycle noise regulation 10 4 Maintenance record 10 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTO...

Page 8: ... the labels on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 3 6 7 4 5 ...

Page 9: ...ol Read owner s manual for proper loading 3JJ 28446 A1 2 California only 3 WARNING 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 6 10D 21668 00 Cold tire normal pressure should be set as follows Up to 90 kg 198 Ibs load FRONT 125 kPa 1 25 kgf cm2 18 psi REAR 125 kPa 1 25 kgf cm2 18 ...

Page 10: ...LOCATION OF IMPORTANT LABELS 1 3 1 2 3 4 5 6 7 8 9 1 ...

Page 11: ... 3 4 5 6 7 8 9 1 Read owner s manual before servicing battery Electrolyte will damage metal parts or paint If electrolyte spills wash area with fresh water immediately Be sure to connect breather hose after installing battery 10D 2815N 00 ...

Page 12: ...er The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents 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 you ar...

Page 13: ...ive 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 Always wear protective clothing that covers your legs ankles and feet The engine or exhaust sys tem become very hot during or af ter operation and can cause burns A passenger should also observe the above precau...

Page 14: ...ake sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load and check the con dition and pressure of your tires Never attach any large or heavy items to the handlebar front fork or front fender These items including such cargo as sleeping bags duffel bags or tents can ...

Page 15: ...amic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross winds These ac cessories may also cause instability when ...

Page 16: ...ew 1 2 3 4 5 6 8 7 1 Fuel tank cap page 4 5 2 Fuel cock page 4 7 3 Helmet holder page 4 9 4 Luggage strap holder page 4 10 5 Drive chain slack adjusting plate page 7 24 6 Air filter element page 7 14 7 Starter choke knob page 4 8 8 Shift pedal page 4 4 ...

Page 17: ...20 Right view 1 2 6 5 4 3 7 8 1 Carrier page 4 10 2 Battery page 7 30 3 Engine oil level check window page 7 11 4 Brake pedal page 4 5 5 Owner s tool kit page 7 2 6 Fuse page 7 32 7 Luggage strap holder page 4 10 8 Spark arrester page 7 15 ...

Page 18: ... 4 5 6 7 8 9 1 Clutch lever page 4 4 2 Left handlebar switches page 4 3 3 Speedometer unit page 4 2 4 Main switch steering lock page 4 1 5 Indicator lights page 4 2 6 Right handlebar switches page 4 3 7 Brake lever page 4 4 8 Throttle grip page 7 16 9 Fuel tank cap page 4 5 ...

Page 19: ...oved EAU10661 OFF All electrical systems are off The key can be removed WARNING EWA10061 Never turn the key to OFF or LOCK while the vehicle is moving Otherwise the electrical systems will be switched off which may result in loss of control or an accident EAU10711 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all t...

Page 20: ... 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 21: ...l lights 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 EAU12711 Start switch Push this switch to crank the engine wi...

Page 22: ...ever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 4 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 23: ...ise 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 TIP 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 WARNING EWA10121...

Page 24: ...since fuel may deteri orate painted surfaces or plastic parts ECA10071 4 Be sure to securely close the fuel tank cap WARNING EWA15151 Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gaso line by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi ately If gasoline spills on...

Page 25: ...ha because it can cause damage to the fuel system or vehicle performance problems EAU13561 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it al so The fuel cock has three positions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not running ON With the lever in this position fuel flows to the ...

Page 26: ...0 Starter choke knob Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the knob in direction a to turn on the starter choke Move the knob in direction b to turn off the starter choke EAU13970 Seat To remove the seat 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 holde...

Page 27: ...WA10161 EAU46021 Shock absorber assembly WARNING EWA10221 This shock absorber assembly con tains highly pressurized nitrogen gas Read and understand the fol lowing information before handling the shock absorber assembly Do not tamper with or attempt to open the cylinder assembly Do not subject the shock ab sorber assembly to an open flame or other high heat source This may cause the unit to ex plo...

Page 28: ...ch is part of the ignition circuit cut off system which cuts the ignition in certain situations See page 4 11 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 p...

Page 29: ...ing when the trans mission is in gear 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 f...

Page 30: ...ll 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 The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked b...

Page 31: ...ore using this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 6 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 11 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if ne...

Page 32: ... Make sure that operation is smooth Correct if necessary Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 7 27 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 7 26 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 7 27 Chassis fasteners Make sure that all nuts bolts and screws ...

Page 33: ...ould come on If not ask a Yamaha dealer to check the electrical circuit 4 Turn the starter choke on and completely close the throttle See page 4 8 5 Start the engine by pushing the start switch If the engine fails to start release the start switch wait a few sec onds and then try again Each starting attempt should be as short as possible to preserve the bat tery Do not crank the engine more than 1...

Page 34: ...is not required when the engine is warm EAU16671 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration TIP To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE ECA102...

Page 35: ...o 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 TIP When shifting gears in normal operat ing conditions use the recommended shift points EAU16700 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift...

Page 36: ...ter 1000 km 600 mi of operation the engine oil must be changed the oil filter element and the oil strainer cleaned If any engine trouble should occur during the engine break in period immedi ately have a Yamaha dealer check the vehicle ECA12712 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 EAU17171 Parking...

Page 37: ...e unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 1 for more in formation about carbon monox ide EAU17302 Emission controls not only function to ensure cleane...

Page 38: ...al and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 1 Owner s tool kit 1 ...

Page 39: ...24 months 16000 mi 26000km 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 thereafter every 6000 mi 10000 km or 12 months Replace Replace 3 Spark arrester Clean 4 Valve clearance Check and adjust valve clearance when engine is cold 5 Idle speed Check and adjust engine ...

Page 40: ... Battery Check specific gravity and breather hose for proper operation 3 Clutch Check operation Adjust or replace cable 4 Front brake Check operation fluid level and for fluid leakage Adjust brake lever free play and replace brake pads if necessary 5 Rear brake Check operation Adjust brake pedal free play and replace brake shoes if necessary 6 Brake hose Check for cracks or damage Replace Every 4 ...

Page 41: ...rain 12 Steering bearings Check bearing assemblies for looseness Moderately repack with lithium 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 lever pivot shaft Apply silicone grease lightly 15 Brake pedal pivot shaft Apply lithium soap based grease lightly 16 Clutch lever pivot shaft Apply li...

Page 42: ...nge warm engine before draining 22 Engine oil filter element Clean 23 Engine oil strainer Clean 24 Front and rear brake switches Check operation 25 Control and meter cables Apply Yamaha chain and cable lube or engine oil thoroughly 26 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 27 Light...

Page 43: ...ore frequent service if you are riding in unusually wet or dusty areas Hydraulic brake system When disassembling the master cylinder 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 o...

Page 44: ...eeds to be re moved and installed EAU18810 Cowling A To remove the cowling Remove the screw and then pull the cowling off as shown To install the cowling Place the cowling in the original posi tion 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 ins...

Page 45: ...ch is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accordance with the periodic mainte nance and lubrication chart In 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 inclu...

Page 46: ...ug 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any 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 TIP If a torque wrench is not available when installing a spark plug...

Page 47: ...light 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 TIP The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark ad...

Page 48: ...er 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 cover 2 Bolt 3 Oil filter element drain bolt 1 Oil f...

Page 49: ...ter the engine and exhaust sys tem have cooled down NOTICE 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 high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the cran...

Page 50: ... clean it with solvent and then squeeze the remaining solvent out 5 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the ex cess oil out TIP 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 NOTICE Make sure that the air filter element is proper...

Page 51: ...WA10980 Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system 1 Remove the tailpipe by removing the screw and then pulling it out of the muffler 2 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark ar rester portion of the tailpipe and in side of the tailpipe housing 3 Insert the...

Page 52: ...as the necessary profes sional knowledge and experience EAU44734 Checking the engine idling speed Check the engine idling speed and if necessary have it corrected by a Yamaha dealer EAU21382 Checking 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 play and if neces sary have a Yamaha d...

Page 53: ... with im proper tire pressure may cause se vere injury or death from loss of control The tire air pressure must be checked and adjusted on cold tires i e when 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 EWA10...

Page 54: ...fter extensive tests only the tires list ed below have been approved for this model by Yamaha Motor Co Ltd WARNING EWA10561 It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary pr...

Page 55: ...or it to develop its optimal characteris tics EAU22043 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 Slide the rubber cover back at the clutch lever 2 Loosen the locknut 3 To increase the clutch lever free play turn the adjusting bolt in di rec...

Page 56: ...n the brake lever free play adjusting screw in direction a To decrease the brake lever free play turn the adjusting screw in direc tion 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...

Page 57: ...he adjusting bolt in direction a To lower the brake pedal turn the ad justing bolt in direction b 3 Tighten the locknut WARNING EWA11230 After adjusting the brake pedal posi tion the brake pedal free 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 foll...

Page 58: ...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 tenance and ...

Page 59: ...ke system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the mas ter cylinder is level by turning the handlebars Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refi...

Page 60: ...e chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22773 To check the drive chain slack 1 Place the motorcycle on the side stand TIP When checking and adjusting the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neu tral position 3 Move the rear wheel by pushing the motorcycle to locate the tight est ...

Page 61: ...0660 After adjusting the brake pedal free play check the operation of the brake light EAU23013 Cleaning and lubricating the drive chain The drive chain 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 NOTICE ECA10581 The driv...

Page 62: ...cause interfer ence with cable movement Replace damaged cables as soon as possi ble to prevent unsafe condi tions EWA10711 EAU23111 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 at the intervals specified in the periodic maintenance chart EAU23142 Checking and lubricating the br...

Page 63: ...ked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10731 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible loss of control Recommended lubricants Brake lever Silicone grease Clutch le...

Page 64: ... To check the condition Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 2 While applying the front brake push down hard on the handlebars several times to check if the front for...

Page 65: ...or more information WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specif...

Page 66: ...ry compartment 5 Place the battery on a level sur face and then check the electro lyte level in the battery TIP The electrolyte should be between the minimum and maximum level marks 6 If the electrolyte is at or below the minimum level mark add distilled water to raise the electrolyte to the maximum level mark NOTICE Use only distilled water as tap water contains minerals that are harmful to the b...

Page 67: ...d to the battery s posi tive terminal 10 Connect and tighten the negative battery lead to the battery s nega tive terminal 11 Install the seat To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place NOTICE When removing the battery be sure the key is turned to OFF then discon nect the negative lead befo...

Page 68: ... fol lows 1 Turn the key to OFF and turn off all electrical circuits 2 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive dam age to the electrical system and possibly a fire EWA15131 3 Turn the key to ON and turn on the electrical circuits to check if the devices operate 4 If...

Page 69: ...sely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner 1 Remove cowling A See page 7 8 2 Remove the headlight unit by re moving the bolts 3 Disconnect the headlight coupler and then remove the headlight bulb cover 4 Remove the headlight bulb holder by turning it counterclockwise and then remove the burnt out bulb 5 Place...

Page 70: ...adlight beam if necessary EAU24133 Replacing the tail brake light bulb 1 Remove the tail brake light lens by removing the screws 2 Remove the burnt out 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 NOTICE Do not over tighten the screws otherwise the lens ma...

Page 71: ...forming 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 is not available by placing a jack un...

Page 72: ...the brake disc otherwise the brake pads will be forced shut ECA11071 EAU24981 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jections mesh with the slots 2 Lift the wheel up between the fork legs TIP Make sure that there is enough space between the brake pads before insert ing the brake disc and that the slot in the speedometer gear unit fits over...

Page 73: ...om the brake cam shaft lever 3 Turn the drive chain adjusting plate on each side of the swingarm fully in direction a 4 Lift the rear wheel off the ground according to the procedure on page 7 35 5 Remove the axle nut and then pull the wheel axle out 6 Push the wheel forward and then remove the drive chain from the rear sprocket TIP The drive chain does not need to be disassembled in order to remov...

Page 74: ...lay check the operation of the brake light EAU25851 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vi...

Page 75: ...PERIODIC MAINTENANCE AND ADJUSTMENT 7 39 2 3 4 5 6 7 8 9 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage ...

Page 76: ...ition 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 the throttle halfway and operate the electric starter...

Page 77: ...ore cleaning 1 Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug cap are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the d...

Page 78: ...h warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are ...

Page 79: ... or wax to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAU261...

Page 80: ...ARNING To prevent dam age or injury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10951 e Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug cap 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 7 Check and if necessary correct the tire ...

Page 81: ...JASO stan dard MA Engine oil quantity Without oil filter element removal 1 00 L 1 06 US qt 0 88 Imp qt With oil filter element removal 1 10 L 1 16 US qt 0 97 Imp qt Air filter Air filter element Wet element Fuel 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 Type quantity MV28 x 1 Spark plug s ...

Page 82: ...ing condition 90 179 kg 198 395 lb CAL 90 180 kg 198 397 lb U49 Front 150 kPa 1 50 kgf cm2 22 psi Rear 175 kPa 1 75 kgf cm2 25 psi 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 suspe...

Page 83: ...W 1 Tail brake light 12 V 8 0 W 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 84: ... LABEL 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 TIP The vehicle identification number is used t...

Page 85: ... will be needed when ordering spare parts from a Yamaha dealer EAU48060 Vehicle Emission Control Information label The Vehicle Emission Control Informa tion label is affixed at the location in the illustration This label shows specifica tions related to exhaust emissions as required by federal law state law and Environment Canada 1 Model label 1 1 Vehicle Emission Control Information label 1 ...

Page 86: ...aints 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 call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or wri...

Page 87: ...ign 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 syst...

Page 88: ...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 19000 mi 3100...

Page 89: ...CONSUMER INFORMATION 10 6 2 3 4 5 6 7 8 9 10 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 90: ...hine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each s...

Page 91: ...f sale and upon your request at any later date Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcycle dealer for the policy to remain effective CUSTOMER SE...

Page 92: ...n t 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 replaceme...

Page 93: ...ing 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 94: ...33 Helmet holder 4 9 High beam indicator light 4 2 Horn switch 4 3 I Identification numbers 10 1 Ignition circuit cut off system 4 11 Indicator lights 4 2 K Key identification number 10 1 L Labels location 1 1 Luggage strap holders 4 10 M Main switch steering lock 4 1 Maintenance and lubrication periodic 7 4 Maintenance emission control system 7 3 Maintenance record 10 5 Matte color caution 8 1 Mo...

Page 95: ...rn signal switch 4 3 V Valve clearance 7 17 Vehicle Emission Control Information label 10 2 Vehicle identification number 10 1 W Warranty extended 10 9 Warranty limited 10 7 Wheel bearings checking 7 29 Wheel front 7 36 Wheel rear 7 37 Wheels 7 19 ...

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Page 98: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2009 05 0 8 1 E ...

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Yamaha TW200Z, Owner'S Manual

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