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PERIODIC MAINTENANCE AND MINOR REPAIR

 

6-35

 

1

2

3

4

5

6

7

8

9

 

2. Lift the wheel up between the fork

legs.

NOTE:

 

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 the

 

retainer on the fork leg.

3. Insert the wheel axle, and then in-

stall the axle nut.

4. Lower the front wheel so that it is

on the ground.

5. Tighten the axle nut to the speci-

fied torque.

6. Connect the speedometer cable.

 

EAU25080

 

Rear wheel 

 

EAU25420

 

To remove the rear wheel

WARNING

 

EWA10820

 

 

It is advisable to have a Yamaha
dealer service the 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-
shaft lever.

3. Turn the drive chain adjusting

plate on each side of the swingarm
fully in direction (a).

 

1. Retainer
2. Speedometer cable

2

1

 

Tightening torque:

 

Axle nut:

90 Nm (9.0 m·kgf, 65 ft·lbf)

Содержание TW200E W 2007

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

Страница 2: ......

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

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

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

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

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

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

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

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

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

Страница 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...

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

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

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

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

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

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

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

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

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

Страница 28: ...nd down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can b...

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

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

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

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

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

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

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

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

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

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

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

Страница 40: ...eeds to be re moved and installed EAU18810 Cowling A To remove the cowling Remove the screw and then pull the cowling off as shown To install the cowling Place the cowling in the original posi tion an...

Страница 41: ...ch is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accordance with the periodic mainte nance and lubrication chart In...

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

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

Страница 44: ...4 9 if the oil filter element is not being cleaned 4 Remove the oil filter element drain bolt to drain the oil from the oil filter element 5 Remove the oil filter element cover by removing the bolts 6...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 66: ...it with the bulb holder CAUTION ECA10660 Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb lif...

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

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

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

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

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

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

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

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

Страница 75: ...bsorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stain less steel parts including the ex haust system Eve...

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

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

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

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

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

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

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

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

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

Страница 85: ......

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

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