clutch YAMAHA TW200 1998 User Guide

6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
EVERY
6,000 km 12,000 km
No. ITEM CHECKS AND MAINTENANCE JOBSInitial or or
(1,000 km) 6 months 12 months
(Whichever (Whichever
comes first) comes first)
1 * Fuel line 9Check fuel hoses for cracks or damage.
√√
9Replace if necessary.
2 Spark plug9Check condition.
√√√
9Clean, regap or replace if necessary.
3 * Valves9Check valve clearance.
√√√
9Adjust if necessary.
4 * Cam chain9Check chain tension.
√√√
9Adjust if necessary.
5 Air filter9Clean or replace if necessary.√√
9Check electrolyte level and specific gravity.
6 * Battery9Correct or recharge if necessary. √√
9Make sure that the breather hose is properly routed.
7 Clutch9Check operation.
√√√
9Adjust or replace cable.
8 * Front brake9Check operation.
√√√
9Adjust cable and replace brake shoes if necessary.
9 * Rear brake9Check operation.
√√√
9Adjust cable and replace brake shoes if necessary.
10 * Wheels9Check balance, runout, spoke tightness and for damage.
√√
9Tighten spokes and rebalance, replace if necessary.
9Check tread depth and for damage.
11 * Tires9Replace if necessary.
√√
9Check air pressure.
9Correct if necessary.
5FY-28199-EX (TW200) 4/16/02 5:38 PM Page 32

6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
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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-28199-EX (TW200) 4/16/02 5:38 PM Page 40

6-18
PERIODIC MAINTENANCE AND MINOR REPAIR
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a
b 3
12
EAU00694
Clutch lever free play
adjustment
The clutch lever free play should
be adjusted to 2 ~ 3 mm.
1. Loosen the locknut at the
clutch lever.
2. Turn the adjusting bolt at the
clutch lever in direction ato
increase free play or in direc-
tion bto decrease free play.
3. Tighten the locknut at the
clutch lever.
1. Locknut
2. Adjusting bolt
3. Free play
If the specified free play cannot be
obtained, proceed with the follow-
ing steps.
4. Loosen the locknut at the
clutch lever.
5. Turn the adjusting bolt at the
clutch lever in direction ato
loosen the cable.
6. Loosen the locknut at the
crankcase side.
7. Turn the adjusting nut at the
crankcase in direction ato
increase free play or in direc-
tion bto decrease free play.
8. Tighten the locknut at the
crankcase and the clutch lever.
b
a213
EAU00699
Front brake lever free play
adjustment
The front brake lever free play
should be adjusted to 2 ~ 4 mm.
1. Loosen the locknut at the
brake lever.
2. Turn the adjusting bolt at the
brake lever in direction ato
increase free play or in direc-
tion bto decrease free play.
3. Tighten the locknut at the
brake lever .
1. Locknut
2. Adjusting bolt
3. Free play
a
b
1
2
1. Adjusting nut
2. Locknut
5FY-28199-EX (TW200) 4/16/02 5:38 PM Page 47

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PERIODIC MAINTENANCE AND MINOR REPAIR
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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
5FY-28199-EX (TW200) 4/16/02 5:38 PM Page 54

8-2
EAU01038
SPECIFICATIONS
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Spark plug:
Type / Manufacturer D8EA / NGK or
X24ES-U / DENSO
Spark plug gap 0.6 ~ 0.7 mm
Clutch type:Wet, multiple-disc
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 3.318
Secondary reduction system Chain drive
Secondary reduction ratio 3.571
Number of sprocket teeth
(Rear/Front) 50/14
Transmission type Constant mesh 5-speed
Operation Left foot operation
Gear ratio 1st 2.833
2nd 1.789
3rd 1.318
4th 1.040
5th 0.821
Chassis:
Frame type Diamond
Caster angle 26.5°
Trail 94 mmTire:
Type With tube
Size:
Front 130/80-18 66P
Rear 180/80-14M/C 78P
Manufacturer / model:
Front BRIDGESTONE / TW31
Rear BRIDGESTONE / TW32
Maximum load* 157 kg
Air pressure (cold tire):
up to 80 kg load*
Front 125 kPa; 1.25 kgf/cm
2; 1.25 bar
Rear 125 kPa; 1.25 kgf/cm
2; 1.25 bar
80 kg load ~ Maximum
load*
Front 150 kPa; 1.50 kgf/cm
2; 1.50 bar
Rear 175 kPa; 1.75 kgf/cm
2; 1.75 bar
Off-road riding
Front 125 kPa; 1.25 kgf/cm
2; 1.25 bar
Rear 125 kPa; 1.25 kgf/cm
2; 1.25 bar
High-speed riding
Front 150 kPa; 1.50 kgf/cm
2; 1.50 bar
Rear 175 kPa; 1.75 kgf/cm
2; 1.75 bar
*Load is total weight of cargo, rider, passenger and accessories.
5FY-28199-EX (TW200) 4/16/02 5:38 PM Page 68