maintenance YAMAHA TW200 2002 User Guide

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PERIODIC MAINTENANCE AND MINOR REPAIR
6 break down and erode. If electrode
erosion becomes excessive, or if
carbon and other deposits are
excessive, you should replace the
spark plug with the specified plug.
Before installing the spark plug,
measure the electrode gap with a
wire thickness gauge; adjust the
gap to specification as necessary.
When installing the plug, always
clean the gasket surface and use a
new gasket. Wipe off any grime
from the threads and tighten the
spark plug to the specified torque.Specified spark plug:
DR8EA (NGK) or
X24ESR-U (DENSO)Spark plug gap:
0.6 ~ 0.7 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 m0kg)
NOTE:
If a torque wrench is not available
when you are installing a spark
plug, a good estimate of the cor-
rect torque is 1/4 to 1/2 turn past
finger tight. Have the spark plug
tightened to the specified torque as
soon as possible.EAU00517Engine oil
1. Oil level measurement
a. Place the motorcycle on a level
place and hold it in an upright
position. Warm up the engine
for several minutes.
NOTE:
Be sure the motorcycle is posi-
tioned straight up when checking
the oil level. A slight tilt toward the
side can result in false readings.
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1
2. Engine oil replacement
a. Warm up the engine for a few
minutes.
b. Stop the engine. Place an oil
pan under the engine and
remove the oil filler cap.
1. Oil filler cap
2
3 1
b. With the engine stopped,
check the oil level through the
level window located at the
lower part of the right side
crankcase cover.
NOTE:
Wait a few minutes until the oil
level settles before checking.
c. The oil level should be
between the maximum and
minimum marks. If the level is
low, add sufficient oil to raise
it to the proper level.
1. Level window
2. Maximum level mark
3. Minimum level mark
1
c. Remove the drain plug and
drain bolt.
1. Drain plug
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1 2 3
4
EC000070
cC
When removing the oil drain plug,
the O-ring, compression spring,
and oil strainer will fall out. Take
care not to lose these parts.
NOTE:
The oil filter cover is secured by
two screws and a drain bolt.
Remove the drain bolt to drain the
filter cavity.
1. Drain plug
2. O-ring
3. Compression spring
4. Oil strainer
1
2
d. Remove the filter cover screws
and the oil filter cover.
e. Remove the oil filter element
and O-ring.
f. Clean the oil filter and strainer
with solvent. Replace if neces-
sary.
g. Check the O-rings. If damaged,
replace.
h. Install the drain plug, filter
cover, screws and drain bolt.
Tighten the drain plug to the
specified tightening torque.
1. Filter cover screw (×2)
2. Drain bolt
21
NOTE:
Make sure the O-ring is seated
properly.
EC000071
cC
Before reinstalling the oil drain
plug, do not forget to install the O-
ring, compression spring, and oil
strainer in position.
1. Oil filter
2. O-ring (×2)
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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.
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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.
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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
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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.
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EW000087
w
Proper loading of your motorcycle
is important for several character-
istics of your motorcycle; such as
handling, braking, performance
and safety. Do not carry loosely
packed items that can shift.
Securely pack your heaviest items
close to the center of the motorcy-
cle, and distribute the weight
evenly from side to side. Check the
condition and pressure of your
tires. NEVER OVERLOAD YOUR
MOTORCYCLE. Make sure the
total weight of the cargo, rider,
passenger, and accessories (fair-
ing, saddlebags, etc. if approved
for this model) does not exceed
the maximum load of the motorcy-
cle. Operation of an overloaded
motorcycle could cause tire dam-
age, an accident, or even injury.
* Load is the total weight of cargo, rider, passen-
ger, and accessories.
Maximum load* 157 kg
Cold tire pressure: Front Rear
125 kPa 150 kPa
Up to 90 kg (1.25 kgf/cm
2, (1.50 kgf/cm2,1.25 bar) 1.50 bar)
90 kg load ~150 kPa 175 kPa
Maximum load*(1.50 kgf/cm
2, (1.75 kgf/cm2,1.50 bar) 1.75 bar)
Off-road riding125 kPa 125 kPa
(1.25 kgf/cm
2, (1.25 kgf/cm2,1.25 bar) 1.25 bar)
High-speed riding150 kPa 175 kPa
(1.50 kgf/cm
2, (1.75 kgf/cm2,
1.50 bar) 1.75 bar)
EAU00668Tires
To ensure maximum performance,
long service, and safe operation,
note the following:
1. Tire air pressure
Always check and adjust the
tire pressure before operating
the motorcycle.
EW000082
w
Tire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire infla-
tion pressure must be adjusted
according to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if
approved for this model), and vehi-
cle speed.
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Manufacturer Size Type
BRIDGESTONE 130/80-18 66P TW31
Manufacturer Size Type
BRIDGESTONE
180/80-14M/C 78PTW32
REAR:
Minimum tire tread
depth : 1.0 mm
(front and rear)
FRONT:
1
2
2. Tire inspection
Always check the tires before
operating the motorcycle. If
center tread depth reaches the
limit as shown, if the tire has a
nail or glass fragments in it, or
if the side wall is cracked, con-
tact a Yamaha dealer immedi-
ately and have the tire
replaced.
1. Tread depth
2. Side wall
NOTE:
These limits may be different by
regulation from country to country.
If so, conform to the limits speci-
fied by the regulations of your own
country.
EW000078
w
After extensive tests, the tires
mentioned below have been
approved by Yamaha Motor Co.,
Ltd. for this model. No guarantee
for handling characteristics can be
given if tire combinations other
than what is approved are used on
this motorcycle. The front and rear
tires should be of the same manu-
facture and design.
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EAU00685Wheels
To ensure maximum performance,
long service, and safe operation,
note the following:
1. Always inspect the wheels
before a ride. Check for cracks,
bends or warpage of the
wheel. Be sure the spokes are
tight and undamaged. If any
abnormal condition exists in a
wheel, consult a Yamaha deal-
er. Do not attempt even small
repairs to the wheel. If a wheel
is deformed or cracked, it must
be replaced.
2. Tires and wheels should be
balanced whenever either one
is changed or replaced. Failure
to have a wheel balanced can
result in poor performance,
adverse handling characteris-
tics, and shortened tire life.3. Ride at moderate speeds after
changing a tire since the tire
surface must first be broken in
for it to develop its optimal
characteristics.
EAU00680
w
1. It is dangerous to ride with a
worn-out tire. When a tire
tread begins to show lines,
have a Yamaha dealer replace
the tire immediately. Brakes,
tires, and related wheel parts
replacement should also be
left to a Yamaha dealer.
2. Patching a punctured tube is
not recommended. If it is
absolutely necessary to do so,
use great care and replace the
tube as soon as possible with
a good quality replacement.
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