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PERIODIC MAINTENANCE AND MINOR REPAIR

6-34

EAU24360

Front wheel

EAU24580

To remove the front 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. Disconnect the 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 6-33.

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. 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.

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.

1. Speedometer cable
2. Axle nut

1. Speedometer gear unit

1. Retainer
2. Speedometer cable

ProCarManuals.com

Содержание TW200ET

Страница 1: ...3XT 28199 2E TW200ET PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2004 6 0 1 1 E OWNER S MANUAL 3XT 9 2E_hyoushi 5 7 04 8 22 AM Page 1 ProCarManuals com ...

Страница 2: ...US_hyoushi2 3 4 30 03 3 06 PM Page 1 ProCarManuals com ...

Страница 3: ... thoroughly so as to enjoy all advantages of your TW200E The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact...

Страница 4: ...epancies between your motorcycle 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 MOTORCYCLE The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the motorcy...

Страница 5: ...W200ET OWNER S MANUAL 2004 by Yamaha Motor Co Ltd 1st edition April 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ProCarManuals com ...

Страница 6: ...g 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 10 Adjusting the carburetor 6 12 Adjusting the engine idling speed 6 12 Adjusting the throttle cable free play 6 13 Adjusting the valve clearance 6 13 Tires 6 13 Spoke wheels 6 15 Adjusting the clutch lever free play 6 16 Adjusting the brake...

Страница 7: ...a turn signal light bulb 6 32 Supporting the motorcycle 6 33 Front wheel 6 34 Rear wheel 6 35 Troubleshooting 6 36 Troubleshooting chart 6 37 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 ProCarManuals com ...

Страница 8: ...ccidents 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 other mot...

Страница 9: ...ision 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 burns Alw...

Страница 10: ...ines 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 scure lights or refle...

Страница 11: ...ch 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 it could ...

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 ProCarManuals com ...

Страница 13: ... s manual 5PA 21568 00 Prima di usare il veicolo leggete il manuale di istruzioni Lire le manuel du propriétaire avant d utiliser ce véhicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehículo lea el Manual del Propietario 3 ProCarManuals com ...

Страница 14: ...0 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 10 6 Starter choke knob page 3 7 7 Shift pedal page 3 4 ProCarManuals com ...

Страница 15: ... 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 page 6 1 8 Fuse page 6 29 9 Luggage strap holder page 3 10 ProCarManuals com ...

Страница 16: ...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 13 9 Fuel tank cap page 3 5 ProCarManuals com ...

Страница 17: ...he 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 the stee...

Страница 18: ...t 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 fuel This i...

Страница 19: ... 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 starter CA...

Страница 20: ...quipped 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 grip To ...

Страница 21: ...lockwise 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 WARNING EW...

Страница 22: ... 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 gasoline of a different brand or premium unleaded fuel Use of un leaded fuel will extend spark plug life and reduce maintenance costs EAU13560 Fuel cock The fuel cock supplies fuel from the tank to the carbureto...

Страница 23: ...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 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 1 Arrow mark positioned over ON 1 Arrow mark positioned over RES ON FUEL RE...

Страница 24: ...y 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 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 tio...

Страница 25: ...rstand 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 dam...

Страница 26: ...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 in fulfi...

Страница 27: ...e 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 If a mal...

Страница 28: ...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 may be d...

Страница 29: ...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 Pre opera...

Страница 30: ... 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 Rear brake Check operation Check pedal free play Adjust if necessary 6 17 6 19 Clutch Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 6 16 Throttle grip Make sure that oper...

Страница 31: ...utch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 24 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 25 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 ignition...

Страница 32: ...e 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 the transmission into the neu tral position NOTE When...

Страница 33: ... 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 engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration NOTE To shift the transmission into the neu tral position press the shift pedal down ...

Страница 34: ...on Do not rev the 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 lights or at railroad crossings EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you ...

Страница 35: ... 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 to OFF WARNING EWA10310 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise t...

Страница 36: ...D 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 service information included in this manual 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 su...

Страница 37: ...EADING 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 filter element Clean Replace 5 Battery Check electrolyte level and specific gravity Make sure that the breather hose is properly routed 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level an...

Страница 38: ... motorcycle or 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 screws are properly tightened 17 Sidestand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Shock absorber assem bly Check...

Страница 39: ...der and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 25 Front and rear brake switches Check operation 26 Moving parts and cables Lubricate 27 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 28 Lights signals and switches Check operati...

Страница 40: ...e 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 install the ...

Страница 41: ...sy 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 includ ed in ...

Страница 42: ...he 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 good estim...

Страница 43: ...t 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 between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil with or without oil filter el...

Страница 44: ... oil filter element for damage and replace it if necessary 9 Install the oil filter element cover by installing the bolts and the drain bolt then tightening them to the specified torques NOTE Make sure that the O rings are properly seated 10 Clean the oil strainer with solvent and then check it for damage and replace it if necessary 11 Install the oil strainer compression spring O ring and engine ...

Страница 45: ...the cause 14 Turn the engine off and then check the oil level and correct it if necessary EAU20831 Cleaning the air filter element and check hose The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas In addition the air filter check hose mu...

Страница 46: ...he air filter case CAUTION ECA10480 Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 8 Install the air filter case cover by in stalling the screws 9 Install the panel To clean the air filter check hose 1 Check the hose a...

Страница 47: ...21340 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart The engine should be warm before making this adjustment NOTE The engine is warm when it quickly responds to the throttle A diagnostic tachometer is needed to make this adjustment 1 Attach the tachometer to ...

Страница 48: ...amaha dealer at the intervals specified in the periodic maintenance and lubrication chart EAU21571 Tires To maximize the performance durabil ity and safe operation of your motorcy cle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and ...

Страница 49: ...se lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer replace the tire immediately NOTE The tire tread depth limits may differ from country to country Always comply with the local regulations Tire information This motorcycle is equipped with tube tires WARNING EWA10460 The front and rear tires should be of the same make and ...

Страница 50: ...motorcy cle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tir...

Страница 51: ...ction 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 ...

Страница 52: ...t or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will dimin ish the braking performance which may result in loss of con trol and an accident EAU22192 Adjusting the brake pedal position and free play WARNING EWA1067...

Страница 53: ...if necessary adjust it as follows To increase the brake pedal free play turn the adjusting nut at the brake rod in direction a To decrease the brake pedal free play turn the adjusting nut in direction b WARNING EWA10680 After adjusting the drive chain slack or removing and installing the rear wheel always check the brake pedal free play If proper adjustment cannot be obtained as described have a Y...

Страница 54: ...e and lubrication chart EAU22430 Front brake pads Each front brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a ...

Страница 55: ...d 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 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the ...

Страница 56: ... leaking Oil seals Replace every two years Brake hose Replace every four years EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary EAU22770 To check the drive chain slack 1 Place the motorcycle on a level surface and hold it in an upright po sition NOTE When checking and adjusting the drive chain slack the motorcycle should be positioned st...

Страница 57: ... both adjusting plates are in the same position for proper wheel alignment CAUTION ECA10570 Improper drive chain slack will over load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage To prevent this from occurring keep the drive chain slack within the specified limits 4 Tighten the axle nut to the speci fied torque 5 Adjust the brake pedal free p...

Страница 58: ...n and soak it in solvent 2 Spray Yamaha Chain and Cable Lube or a high quality spray type drive chain lubricant on both sides and on the middle of the chain making sure that all side plates and rollers have been sufficiently oiled EAU23100 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and c...

Страница 59: ...and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary EAU23140 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Li...

Страница 60: ... EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place ...

Страница 61: ...peration of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play...

Страница 62: ...hould 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 positive battery lead and the battery breather hose from the battery 4 Unhook the battery band and then pull the battery out of the battery compartm...

Страница 63: ... 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 enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN CAUTION ECA10610 Use only distilled water as tap water con...

Страница 64: ...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 good condition and not obstructed CAUTION ECA10600 If the breather hose is positioned in such a way that the frame is ex posed to electrolyte or gas expelled from the battery the frame could...

Страница 65: ...ows 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 Remove cowling A See page 6 5 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 ...

Страница 66: ...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 coupler 7 Install the headlight unit by install ing the bolts 8 Install the cowling...

Страница 67: ...the lens by installing the screws CAUTION ECA10680 Do not overtighten the screws oth erwise the lens may break EAU24210 Replacing a turn signal light bulb 1 Remove the turn signal lens by re moving 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 i...

Страница 68: ...rting 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 der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Rais...

Страница 69: ... 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 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 NOTE Make sure that there is enough space between the brake pads before insert ing the brake disc and that the slo...

Страница 70: ...ake 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 6 33 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 NOTE The drive chain does not need to be disassembled in order to remove and in...

Страница 71: ...lay See page 6 17 WARNING EWA10660 After adjusting the brake pedal free play check the operation of the brake light EAU25850 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 troubles...

Страница 72: ...ssion 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 the thrott...

Страница 73: ...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 mild detergen...

Страница 74: ...n 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 of stain ...

Страница 75: ... 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 fuel stabiliz...

Страница 76: ...r 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 store the ...

Страница 77: ...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 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...

Страница 78: ...dition 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 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 suspension Type Telescopic fork Spring sh...

Страница 79: ...W 1 Tail brake light 12 V 5 0 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 indicator light 12 V 3 4 W 1 Turn signal indicator light 12 V 3 4 W 1 Fuse Fuse 20 0 A ProCarManuals com ...

Страница 80: ...RMATION 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 identify...

Страница 81: ...E 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 any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and The use of the vehicle after...

Страница 82: ...b 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 identification number 9 1 Kickstarter 3 8 L Labels location of 1 5 Luggage strap holders 3 10 M Main switch steering lock 3 1 Model label 9 2 N Neutral indicator light 3 2 Noise regulation for Australia 9 2 P Parking 5 4 Part ...

Страница 83: ...gnal light bulb replacing 6 32 Turn signal switch 3 3 V Valve clearance adjusting 6 13 Vehicle identification number 9 1 W Wheel bearings checking 6 27 Wheel front 6 34 Wheel rear 6 35 Wheels 6 15 ProCarManuals com ...

Страница 84: ...ProCarManuals com ...

Страница 85: ...US_hyoushi2 3 4 30 03 3 06 PM Page 1 ProCarManuals com ...

Страница 86: ...3XT 28199 2E TW200ET PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2004 6 0 1 1 E OWNER S MANUAL 3XT 9 2E_hyoushi 5 7 04 8 22 AM Page 1 ProCarManuals com ...

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