ESP YAMAHA TW200 2002 Owners Manual

3-10
1
EAU01343Rear shock absorberEAU00315
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This shock absorber contains high-
ly pressurized nitrogen gas. Read
and understand the following
information before handling the
shock absorber. The manufacturer
cannot be held responsible for
property damage or personal
injury that may result from
improper handling.
1. Do not tamper with or
attempt to open the cylinder
assembly.
2. Do not subject the shock
absorber to an open flame or
other high heat source. This
may cause the unit to explode
due to excessive gas pressure.
3. Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.
4. Take your shock absorber to a
Yamaha dealer for any service.
1. Rear carrier
EAU00320Rear carrier
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Do not exceed the load limit of 3
kg.
EAU00330Sidestand
This model is equipped with an
ignition circuit cut-off system. The
motorcycle must not be ridden
when the sidestand is down. The
sidestand is located on the left side
of the frame. (Refer to page 5-1 for
an explanation of this system.)
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
6
7
8
9
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3-11
EW000044
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This motorcycle must not be oper-
ated with the sidestand in the
down position. If the stand is not
properly retracted, it could contact
the ground and distract the opera-
tor, resulting in a possible loss of
control. Yamaha has designed into
this motorcycle a lockout system
to assist the operator in fulfilling
the responsibility of retracting the
sidestand. Please check carefully
the operating instructions listed
below and if there is any indication
of a malfunction, return the motor-
cycle to a Yamaha dealer immedi-
ately for repair.
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
6
7
8
9
EAU00331
Sidestand/clutch switch
operation check
Check the operation of the side-
stand switch and clutch switch
against the information below.
TURN THE MAIN SWITCH TO “ON”
AND THE ENGINE STOP SWITCH TO
“RUN”.
TRANSMISSION IS IN GEAR AND
SIDESTAND IS UP.
PULL IN CLUTCH LEVER AND
PUSH THE START SWITCH.
ENGINE WILL START.
CLUTCH SWITCH IS OK.
EW000045
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If improper operation is noted,
consult a Yamaha dealer immedi-
ately.
SIDESTAND IS DOWN.
ENGINE WILL STALL.
SIDESTAND SWITCH IS OK.
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4-1
EAU01114
PRE-OPERATION CHECKS
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6
7
8
9Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to
deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements).
Any damage, fluid leak or loss of tire pressure could have serious consequences. Therefore, it is very important
that, in addition to a thorough visual inspection, you check the following points before each ride.
EAU00340PRE-OPERATION CHECK LIST
ITEM CHECKS PAGE
Brakes9Check operation, condition and free play.
3-5, 6-18 ~ 6-21
9Adjust if necessary.
Clutch9Check operation and free play.
3-4, 6-18
9Adjust if necessary.
9Check for smooth operation.
Throttle grip and housing9Lubricate.6-14, 6-24
9Adjust throttle cable free play if necessary.
Engine oil9Check oil level.
6-8 ~ 6-11
9Fill with oil if necessary.
Drive chain9Check chain slack and condition.
6-21 ~ 6-23
9Adjust if necessary.
Wheels and tires9Check tire pressure, wear, damage and spoke tightness.
6-15 ~ 6-17
9Tighten spokes if necessary.
Brake and shift pedal shafts9Check for smooth operation.
6-24
9Lubricate if necessary.
Brake and clutch lever pivots9Check for smooth operation.
6-25
9Lubricate if necessary.
Sidestand pivot9Check for smooth operation.
6-25
9Lubricate if necessary.
Chassis fasteners9Make sure that all nuts, bolts, and screws are properly tightened.
—
9Tighten if necessary.
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5-3
OPERATION AND IMPORTANT RIDING POINTS
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7
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91. Turn the fuel cock to “ON”.
2. Turn the main switch to ON”
and the engine stop switch to
“RUN”.
3. Shift transmission into neutral.
NOTE:
When the transmission is in neu-
tral, the neutral indicator light
should be on. If the light does not
come on, ask a Yamaha dealer to
inspect it.
4. Turn on the starter and com-
pletely close the throttle grip.
5. Start the engine by pushing
the start switch or by kicking
the kick starter.
NOTE:
If the engine fails to start, release
the start switch, wait a few sec-
onds, then try again. Each attempt
should be as short as possible to
preserve the battery. Do not crank
the engine more than 10 seconds
on any one attempt. If the engine
does not start with the starter
motor, kick the kick starter to start
the engine.
6. After starting the engine, move
the starter to the halfway posi-
tion.
NOTE:
For maximum engine life, always
warm up the engine before starting
off. Never accelerate hard with a
cold engine.
7. After warming up the engine,
turn off the starter completely.
NOTE:
The engine is warm when it
responds normally to the throttle
with the starter turned off.
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6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
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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
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6-23
PERIODIC MAINTENANCE AND MINOR REPAIR
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9
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.
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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.
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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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7-2
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.
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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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