YAMAHA TW200 2002 Workshop Manual

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EAU00744Drive chain slack check
NOTE:
Spin the wheel several times and
find the tightest position of the
chain. Check and/or adjust the
chain slack while it’s in this tightest
position.
EAU00719
Checking the brake shoes
A wear indicator is provided on
each brake. This indicator allows
inspection of shoe wear without
disassembling the brake. Apply the
brake and inspect the position of
the indicator. If the indicator reach-
es to the wear limit line, ask a
Yamaha dealer to replace the
shoes.
1
2
1. Wear indicator
2. Wear limit
FRONT
21
1. Wear indicator
2. Wear limit
REAR
a
a. 30 ~ 40 mm
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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)
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1
6. Insert a new cotter pin into the
axle nut and bend the end of
the cotter pin as shown in the
illustration. If the notch in the
nut and cotter pin hole do not
match, tighten the nut slightly
to align them.
EW000110
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Always use a new cotter pin on
the axle nut.
1. Cotter pin
7. Adjust the free play in the
brake pedal.
EW000103
w
Check the operation of the brake
light after adjusting the rear brake.
EAU01106Drive chain lubrication
The chain consists of many parts
which work with each other. If the
chain is not maintained properly, it
will wear out quickly. Therefore,
the chain must be serviced regular-
ly. This service is especially neces-
sary when riding in dusty areas.
1. The drive chain should be
lubricated every 500 km. First,
remove all dirt and mud from
the chain with a brush or cloth.
Then, spray any of the many
brands of spray-type chain
lubricant between both rows
of side plates and on all center
rollers.
2. To clean the chain thoroughly,
remove it from the motorcycle,
dip it in solvent, and clean out
as much dirt as possible. Then,
take the chain out of the sol-
vent to dry it, and immediately
lubricate it to prevent it from
rusting.
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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
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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
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EAU00793Front fork inspection
EW000115
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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.
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EAU01144Wheel bearings
If there is play in the front or rear
wheel hub or if the wheel does not
turn smoothly, have a Yamaha
dealer inspect the wheel bearings.
EW000115
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Securely support the motorcycle
so there is no danger of it falling
over.
EAU01071
Battery
Check the level of the battery elec-
trolyte and make sure that the ter-
minals are tight.
Fill with distilled water if the elec-
trolyte level is low.
EC000099
cC
When inspecting the battery, be
sure the breather hose is routed
correctly. If the breather hose is
positioned in such a way as to
cause battery electrolyte or gas to
exit onto the frame, structural and
cosmetic damage to the motorcy-
cle can occur.
1
2
1. Battery
2. Battery breather hose
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EW000116
w
Battery electrolyte is poisonous
and dangerous, causing severe
burns, etc. It contains sulfuric acid.
Avoid contact with skin, eyes or
clothing.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities
of water or milk. Follow with milk
of magnesia, beaten egg, or veg-
etable oil. Call a physician immedi-
ately.
EYES: Flush with water for 15 min-
utes and get prompt medical
attention. Batteries produce explo-
sive gases. Keep sparks, flame, cig-
arettes etc., away. Ventilate when
charging or using in an enclosed
space. Always shield your eyes
when working near batteries.
KEEP OUT OF REACH OF CHIL-
DREN.
EW000117
w
Take care not to spill battery fluid
on the chain.
Battery fluid may weaken the
chain causing shorter chain life
and possibly result in an accident
Battery storage
1. When the motorcycle will not
be used for a month or longer,
remove the battery, fully
charge it and store it in a cool,
dry place. Completely recharge
the battery before reinstalla-
tion.
2. If the battery will be stored for
longer than two months, check
the specific gravity of the fluid
at least once a month and fully
recharge the battery when it is
too low. Replenishing the battery fluid
A poorly maintained battery will
corrode and discharge quickly. The
battery fluid should be checked at
least once a month. The level
should be between the minimum
level and maximum level marks.
Use only distilled water if refilling
is necessary.
EC000100
cC
Normal tap water contains miner-
als which are harmful to a battery;
therefore, refill only with distilled
water.
1
2
1. Maximum level mark
2. Minimum level mark
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93. Always make sure the connec-
tions are correct when putting
the battery back in the motor-
cycle. Make sure the breather
hose is properly connected
and is not damaged or
obstructed.
EC000103
cC
Do not use fuses of higher amper-
age rating than those recommend-
ed. Substitution of a fuse of
improper rating can cause exten-
sive electrical system damage and
possibly a fire.
EAU01307Fuse replacement
The fuse is located behind panel A.
(See page 6-7 for panel removal
and installation procedures.)
If the fuse is blown, turn off the
main switch and the switch of the
circuit in question. Install a new
fuse of proper amperage. Turn on
the switches and see if the electri-
cal device operates. If the fuse
immediately blows again, consult a
Yamaha dealer.
1
1. Fuse
Specified fuse: 15A
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3. Remove the connector and the
bulb holder cover.
4. Turn the bulb holder counter-
clockwise to remove it and
remove the defective bulb.
EW000119
w
Keep flammable products and your
hands away from a bulb while it is
on, as it is hot. Do not touch a bulb
until it cools down.
5. Put a new bulb into position
and secure it in place with the
bulb holder.
1. Bulb holder cover
EAU01191
Headlight bulb replacement
This motorcycle is equipped with a
quartz bulb headlight. If the head-
light bulb burns out, replace it as
follows:
1. Remove cowling A. (See page
6-6 for cowling removal and
installation procedures.)
2. Remove the headlight unit.
1
EC000105
cC
Avoid touching the glass part of a
bulb. Keep it free from oil; other-
wise, the transparency of the
glass, life of the bulb, and lumi-
nous flux will be adversely affect-
ed. If oil gets on a bulb, thoroughly
clean it with a cloth moistened
with alcohol or lacquer thinner.
6. Install the bulb holder cover,
connector and headlight unit.
7. Install the cowling.
8. If the headlight beam adjust-
ment is necessary, ask a
Yamaha dealer to make that
adjustment.
1. Bulb holder
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