YAMAHA TW200 2002 Repair Manual

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PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
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2
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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
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PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU01304
Rear 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 brake adjusting
nut and brake rod from the
brake cam lever.
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4 5
1. Adjusting nut
2. Brake rod
3. Axle nut
4. Cotter pin
5. Chain adjusting plate
2. Remove the axle nut cotter pin
and loosen the axle nut.
3. Elevate the rear wheel by plac-
ing a suitable stand under the
engine.
4. Remove the axle nut.
5. Push the wheel forward and
remove the drive chain.
6. Pull out the axle and remove
the rear wheel assembly by
pulling it backwards.EAU01308
Rear wheel installation
1. Install the wheel assembly and
insert the axle from the left-
hand side. Be sure that the
chain adjusting plates are
installed with the punched side
outward and the slot in the
brake shoe plate is fit over the
stopper on the swingarm.
2. Install and adjust the drive
chain. (See page 6-22 for
details about adjusting the
drive chain slack.)
3. Install the axle nut and let the
motorcycle down.
4. Tighten the axle nut to the
specified torque and install the
axle nut cotter pin.
Tightening torque:
Axle nut:
90 Nm (9.0 m0kg)
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EW000110
w
Always use a new cotter pin on
the axle nut.
5. Insert the brake rod into the
brake cam lever and install the
brake pedal free play adjusting
nut.
6. Adjust the rear brake pedal
free play. (See page 6-19.)
EW000103
w
Check the operation of the brake
light after adjusting the rear brake.
EAU01008Troubleshooting
Although Yamaha motorcycles
receive a rigid inspection before
shipment from the factory, trouble
may occur during operation.
Any problem in the fuel, compres-
sion, or ignition systems can cause
poor starting and loss of power.
The troubleshooting chart
describes a quick, easy procedure
for making checks.
If your motorcycle requires any
repair, bring it to a Yamaha dealer.
The skilled technicians at a
Yamaha dealership have the tools,
experience, and know-how to
properly service your motorcycle.
Use only genuine Yamaha parts on
your motorcycle. Imitation parts
may look like Yamaha parts, but
they are often inferior.
Consequently, they have a shorter
service life and can lead to expen-
sive repair bills.
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EAU01260
Troubleshooting chartEW000125
w
Never check the fuel system while smoking or in the vicinity of an open flame.
1. Fuel
2. Compression
3. Ignition
4. Battery
Use electric starter.
Remove spark
There is compression.
Go to ignition check.
No compression.
Ask a Yamaha dealer to inspect.
Wet
DryWipe clean with dry cloth and correct
Open the throttle half-way and start
Ask a Yamaha dealer to inspect.
Check if there is fuel
Enough fuel
No fuelGo to compression check.
Supply fuel.
in the fuel tank
electrode. plugs and check
Engine doesn’t start, go to battery
check. the engine. spark plug gap or replace spark plugs.
Engine turns over
Engine turns overBattery good.
Check fluid, recharge,
quickly.
slowly. check connections.Engine doesn’t start, ask aYamaha dealer to inspect.
Engine doesn’t start, go to compression check.
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7-1
EAU01010
CLEANING AND STORAGE
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EAU01301A. CLEANING
Frequent, thorough cleaning of
your motorcycle will not only
enhance its appearance but will
improve its
general performance and extend
the useful life of many compo-
nents.
ECA00002
cC
8Improper cleaning can damage
the cowlings, panels and other
plastic parts. Use only a soft,
clean cloth or sponge with
mild detergent and water to
clean plastic.
8Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abra-
sive cleaning products, solvent
or thinner, fuel (gasoline), rust
removers or inhibitors, brake
fluid, antifreeze or electrolyte.
EC000111
cC
Excessive hose pressure may
cause water seepage and deterio-
ration of wheel bearings, front
fork, brakes, transmission seals
and electrical parts.
Many expensive repair bills have
resulted from improper high pres-
sure detergent applications such
as those available in coin-operated
car washers.
4. After riding on salted roads,
wash the motorcycle with cold
water immediately. Do not use
warm water as it increases the
chemical reaction of the salt.
5. Once the majority of the dirt
has been hosed off, wash all
surfaces with warm water and
mild, detergent-type soap. An
old toothbrush or bottle brush
is handy for hard-to-get-at
places. 1. Before cleaning the motorcy-
cle:
a. Block off the end of the
exhaust pipe to prevent water
entry; a plastic bag and strong
rubber band may be used.
b. Make sure the spark plug and
all filler caps are properly
installed.
2. If the engine case is excessive-
ly greasy, apply degreaser
with a paint brush. Do not
apply degreaser to the chain,
sprockets or wheel axles.
3. Rinse the dirt and degreaser
off with a garden hose. Use
only enough pressure to do
the job.
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CLEANING AND STORAGE
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96. Rinse the motorcycle off
immediately with clean water
and dry all surfaces with a
chamois, clean towel, or soft
absorbent cloth.
7. Dry the chain and lubricate it
to prevent rust.
8. Clean the seat with a vinyl
upholstery cleaner to keep the
cover pliable and glossy.
9. Automotive-type wax may be
applied to all painted and
chrome-plated surfaces. Avoid
combination cleaner-waxes.
Many contain abrasives which
may mar the paint or protec-
tive finish. When finished, start
the engine and let it idle for
several minutes.
EAU01107B. STORAGE
Long term storage (60 days or
more) of your motorcycle will
require some preventive proce-
dures to guard against deteriora-
tion. After thoroughly cleaning the
motorcycle, prepare for storage as
follows:
1. Fill the fuel tank with fuel and
add fuel stabilizer (if available).
2. Remove the spark plug, pour
about one tablespoon of SAE
10W30 or 20W40 motor oil in
the spark plug hole and rein-
stall the spark plug. Turn the
engine over several times
(ground spark plug lead) to
coat the cylinder wall with oil.
EW000127
w
When using the starter motor to
crank the engine, remove the
spark plug wires, and ground them
to prevent sparking.
3. Thoroughly clean and lubricate
the drive chain. (For details,
see “Drive chain lubrication”
on page 6-23.)
4. Lubricate all control cables.
5. Block up the frame to raise
both wheels off the ground.
6. Tie a plastic bag over the
exhaust pipe outlet to prevent
moisture from entering.
7. If storing in a humid or salt-air
atmosphere, coat all exposed
metal surfaces with a light film
of oil. Do not apply oil to any
rubber parts or the seat cover.
8. Remove the battery and
charge it. Store it in a dry place
and recharge it once a month.
Do not store the battery in an
excessively warm or cold place
(less than 0°C or more than
30°C.
NOTE:
Make any necessary repairs before
storing the motorcycle.
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8-1
EAU01038
SPECIFICATIONS
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Specifications
Model TW200E
Dimensions:
Overall length 2,090 mm
Overall width 815 mm
Overall height 1,115 mm
Seat height 790 mm
Wheel base 1,325 mm
Ground clearance 250 mm
Minimum turning radius 1,900 mm
Basic weight (With oil and full
fuel tank):126 kg
Engine:
Engine type Air-cooled 4-stroke, SOHC,
gasoline
Cylinder arrangement Forward inclined
single cylinder
Displacement 196 cm
3
Bore ×Stroke 67.0 ×55.7 mm
Compression ratio 9.5:1
Starting system Electric and kick starter
Lubrication system Wet sumpEngine oil:
Type:
Classification API Service “SE”, “SF” type
or equivalent
(e.g. “SF-SE”, “SF-SE-CC”,
“SF-SE-SD” etc.)
Capacity:
Periodic oil change 1.0 L
With oil filter replacement 1.1 L
Total amount 1.3 L
Air filter:Wet type element
Fuel:
Type Regular gasoline
Fuel tank capacity 7.0 L
Reserve amount 1.7 L
Carburetor:
Type / quantity Y29P-5C / 1
Manufacturer TEIKEI
–10° 0° 10° 20° 30° 40°
SAE 10W/30
SAE 10W/40
SAE 20W/40
SAE 20W/50C
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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.
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SPECIFICATIONS
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Wheels:
Type:
Front Spoke wheel
Rear Spoke wheel
Size:
Front 18 ×2.50
Rear 14M/C ×MT4.50
Brakes:
Front:
Type Drum brake
Operation Right hand operation
Rear:
Type Drum brake
Operation Right foot operation
Suspension:
Front Telescopic fork
Rear Swingarm
(Monocross suspension)
Shock absorber:
Front Coil spring / oil damper
Rear Coil-gas spring / oil damper
Wheel travel:
Front 160 mm
Rear 150 mmElectrical:
Ignition system: C.D.I.
Charging system:
Type A.C. magneto
Standard output 12V 11A / 5,000 rpm
Battery:
Type GM7CZ-3D
Voltage, capacity 12V 7 AH
Headlight typeHalogen bulb
Bulb voltage, wattage ×quantity:
Headlight 12V 35W / 35W ×1
Stop / tail light 12V 27W / 8W ×1
Front flasher light 12V 27W / 8W ×2
Rear flasher light 12V 27W ×2
Meter light 12V 3.4W ×1
Neutral indicator light 12V 3.4W ×1
High beam indicator light 12V 3.4W ×1
Turn indicator light 12V 3.4W ×1
Fuse:
Main 15A
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