engine YAMAHA TW200 2002 Owner's Manual

6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9i. Fill the engine with oil. Install
the oil filler cap and tighten.
EC000066
cC
8Do not put in any chemical
additives. Engine oil also lubri-
cates the clutch and additives
could cause clutch slippage.
8Be sure no foreign material
enters the crankcase.
Recommended oil:
See page 8-1
Oil quantity:
Total amount:
1.3 L
Periodic oil change:
1.0 L
With oil filter replacement:
1.1 LTightening torque:
Drain plug:
10 Nm (1.0 m0kg)
Filter cover screw:
10 Nm (1.0 m0kg)
Drain bolt (filter cover):
10 Nm (1.0 m0kg)j. Start the engine and warm up
for a few minutes. While
warming up, check for oil leak-
age. If oil leakage is found,
stop the engine immediately
and check for the cause.
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 40

6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EAU01094Air filter
The air filter should be cleaned at
the specified intervals. It should be
cleaned more frequently if you are
riding in unusually wet or dusty
areas.
1. Remove panel B. (See page 6-7
for panel removal and installa-
tion procedures.)
2. Remove the air filter case fit-
ting screws and the air filter
case cover.
1
1. Air filter
3. Remove the air filter from its
case and clean it with solvent.
After cleaning, remove the
remaining solvent by squeez-
ing the air filter.
4. Apply the recommended oil to
the entire surface of the filter
and squeeze out the excess oil.
It should be wet but not drip-
ping.
1
1. Screw (×4)
Recommended oil:
Same as engine oil
5. Install the air filter in its case.
6. Install panel B.
EC000085
cC
8Make sure the air filter is prop-
erly seated in the filter case.
8The engine should never be
run without the air filter
installed. Excessive piston
and/or cylinder wear may
result.
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 41

6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EAU00629Carburetor adjustment
The carburetor is a vital part of the
engine and requires very sophisti-
cated adjustment. Most adjust-
ments should be left to a Yamaha
dealer who has the professional
knowledge and experience to do
so. However, the following may be
serviced by the owner as part of
routine maintenance.
EC000094
cC
The carburetor was set at the
Yamaha factory after many tests. If
the settings are changed, poor
engine performance and damage
may result.
EAU01168Idle speed adjustment
NOTE:
A diagnostic tachometer must be
used for this procedure.
1. Attach the tachometer. Start
the engine and warm it up for
a few minutes at approximate-
ly 1,000 to 2,000 r/min.
Occasionally rev the engine to
4,000 to 5,000 r/min. The
engine is warm when it quickly
responds to the throttle.
b
a1
1. Throttle stop screw
2. Set the idle to the specified
engine speed by adjusting the
throttle stop screw. Turn the
screw in direction ato
increase engine speed and in
direction bto decrease engine
speed.
NOTE:
If the specified idle speed cannot
be obtained by performing the
above adjustment, consult a
Yamaha dealer.
Standard idle speed:
1,350 ~ 1,450 r/min
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 42

6-14
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EAU00635
Throttle cable free play
inspection
There should be a free play of 2 ~ 5
mm at the throttle grip. If the free
play is incorrect, ask a Yamaha
dealer to make this adjustment.
EAU00636Cam chain adjustment
The cam chain becomes loose with
use, resulting in improper valve
timing and engine noise. To pre-
vent this, the cam chain tensioner
must be adjusted regularly. This
adjustment, however, should be
left to a professional Yamaha ser-
vice technician.
EAU00637
Valve clearance adjustment
The correct valve clearance
changes with use, resulting in
improper fuel/air supply or engine
noise. To prevent this, the valve
clearance must be adjusted regu-
larly. This adjustment however,
should be left to a professional
Yamaha service technician.
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 43

6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9 To check the chain slack the motor-
cycle must be held straight up with
both wheels on the ground and
without rider. Check the slack at
the position shown in the illustra-
tion. Normal slack is approximately
30 ~ 40 mm. If the slack exceeds 40
mm, adjust.
EAU01302
Drive chain slack adjustment
1. Loosen the rear brake adjust-
ing nut.
2. Remove the cotter pin from
the axle nut.
3. Loosen the axle nut.
4. Turn both left and right chain
adjusting plates the same
amount. Make sure that they
are in the same position for
proper wheel alignment.
1
2
3 4
1. Adjusting nut
2. Axle nut
3. Cotter pin
4. Chain adjusting plate
EC000096
cC
Too little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits.
5. After adjusting, be sure to
tighten the axle nut to the
specified torque.
Tightening torque:
Axle nut:
90 Nm (9.0 m0kg)
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 51

6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EAU00772
Cable inspection and
lubrication
EW000112
w
Damage to the outer housing of
cables may lead to internal rusting
and interfere with the cable move-
ment. Replace damaged cables as
soon as possible to prevent unsafe
conditions.
Lubricate the cables and cable
ends. If a cable does not operate
smoothly, ask a Yamaha dealer to
replace it.
Recommended lubricant:
Same as engine oil
EAU00773
Throttle cable and grip
lubrication
The throttle twist grip assembly
should be greased at the time that
the cable is lubricated, since the
grip must be removed to get at the
end of the throttle cable. After
removing the screws, hold the end
of the cable up in the air and put in
several drops of lubricant. With the
throttle grip disassembled, coat the
metal surface of the grip assembly
with a suitable all-purpose grease.
EAU00776
Brake and shift pedal
lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Same as engine oil
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 53

6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EAU00778
Brake and clutch lever
lubrication
Lubricate the pivoting parts.
EAU00785
Sidestand lubrication
Lubricate the sidestand pivoting
point and metal-to-metal contact
surfaces. Check that the sidestand
moves up and down smoothly.
EW000113
w
If the sidestand does not move
smoothly, consult a Yamaha deal-
er.
Recommended lubricant:
Same as engine oil
Recommended lubricant:
Same as engine oil
EAU00791
Rear suspension lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Lithium soap base grease
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 54

6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EAU00793Front fork inspection
EW000115
w
Securely support the motorcycle
so there is no danger of it falling
over.
1. Visual check
Check for scratches or damage
on the inner tube and exces-
sive oil leakage from the front
fork.2. Operation check
Place the motorcycle on a level
place.
a. Hold the motorcycle in an
upright position and apply the
front brake.
b. Push down hard on the han-
dlebars several times and
check if the fork rebounds
smoothly.
EC000098
cC
If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer.
EAU00794Steering inspection
Periodically inspect the condition
of the steering. Worn out or loose
steering bearings may be danger-
ous. Place a stand under the
engine to raise the front wheel off
the ground. Hold the lower end of
the front forks and try to move
them forward and backward. If any
free play can be felt, ask a Yamaha
dealer to inspect and adjust the
steering. Inspection is easier if the
front wheel is removed.
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 55

6-31
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EAU00862
Supporting the motorcycle
Since the Yamaha TW200E has no
centerstand, follow these precau-
tions when removing the front and
rear wheel or performing other
maintenance requiring the motor-
cycle to stand upright.
Front wheel service:
To stabilize the rear of the motor-
cycle, either use a motorcycle
stand or place a motorcycle jack
under the frame in front of the rear
wheel to prevent it from moving
from side to side. Then use a
motorcycle stand to elevate the
front wheel off of the ground.
Rear wheel service:
Use a motorcycle stand or motor-
cycle jack to elevate the motorcycle
so the rear wheel is off the ground.
Alternatively, two jacks can be
placed under the frame or
swingarm.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.
3
2
41
EAU00908
Front wheel removalEW000122
w
8It is advisable to have a
Yamaha dealer service the
wheel.
8Securely support the motorcy-
cle so there is no danger of it
falling over.
1. Remove the clip holding the
speedometer cable in the
speedometer gear housing.
Then remove the speedometer
cable by pulling it outward.
1. Speedometer cable
2. Axle nut
3. Cotter pin
4. Clip
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 60

6-32
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9 2. Loosen the brake cable free
play adjusting nuts. Remove
the brake cable from the han-
dlebar lever holder and then
from the front wheel hub.
3. Remove the cotter pin and
loosen the axle nut.
4. Elevate the front wheel by
placing a suitable stand under
the engine.
5. Remove the axle nut and
wheel axle.3. Make sure the axle nut is prop-
erly torqued, and a new cotter
pin is installed.
EW000124
w
Always use a new cotter pin.
4. Adjust the free play in the
brake lever. Axle holder nut torque:
90 Nm (9.0 m0kg)EAU00927
Front wheel installation
When installing the front wheel,
reverse the removal procedure.
Pay attention to the following
points:
1. Make sure the wheel hub and
the brake shoe plate assembly
are installed with the projec-
tions meshed into the slots.
2. Make sure the slot in the brake
shoe plate fits over the stopper
on the front fork outer tube.
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 61