engine YAMAHA TW200 2002 Owners Manual

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TABLE OF CONTENTS
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3
4
5
6
7
8
9 GIVE SAFETY THE RIGHT OF WAY ..................1-1
DESCRIPTION .....................................................2-1
Left view............................................................2-1
Right view .........................................................2-2
Controls/Instruments .......................................2-3
INSTRUMENT AND CONTROL
FUNCTIONS ........................................................3-1
Main switch/Steering lock ...............................3-1
Indicator lights..................................................3-2
Speedometer ....................................................3-2
Handlebar switches..........................................3-3
Clutch lever .......................................................3-4
Shift pedal.........................................................3-4
Front brake lever ..............................................3-5
Rear brake pedal ..............................................3-5
Fuel tank cap.....................................................3-5
Fuel ....................................................................3-6
Fuel cock ...........................................................3-7
Starter (choke) “1” .........................................3-8
Kick starter ........................................................3-8
Seat ...................................................................3-9
Helmet holder ...................................................3-9
Rear shock absorber ......................................3-10
Rear carrier .....................................................3-10Sidestand ........................................................3-10
Sidestand/clutch switch operation check .....3-11
PRE-OPERATION CHECKS.................................4-1
Pre-operation check list ...................................4-1
OPERATION AND IMPORTANT RIDING
POINTS................................................................5-1
Starting and warming up a cold engine.........5-1
Starting a warm engine ...................................5-4
Shifting..............................................................5-4
Engine break-in ................................................5-5
Parking ..............................................................5-6
PERIODIC MAINTENANCE AND MINOR
REPAIR ................................................................6-1
Tool kit ..............................................................6-1
Periodic maintenance and lubrication............6-3
Cowling and panel removal and
installation ........................................................6-6
Cowling A .........................................................6-6
Panel A ..............................................................6-7
Panel B ..............................................................6-7
Spark plug inspection ......................................6-7
Engine oil ..........................................................6-8
Air filter ...........................................................6-12
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3-1
LOCKOFFON
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Main switch/Steering lock
The main switch controls the igni-
tion and lighting systems. Its oper-
ation is described below.
EAU00032
ON:
All electrical circuits are switched
on, and the headlight, meter light,
taillight and front position lights
come on. The engine can be start-
ed. The key cannot be removed in
this position.
EAU00038
OFF:
All electrical circuits are switched
off. The key can be removed in this
position.
EAU00042
LOCK:
The steering is locked in this posi-
tion and all electrical circuits are
switched off.
The key can be removed in this
position.
To lock the steering, turn the han-
dlebars all the way to the left. With
the key at “OFF”, push it into the
main switch and release it, turn it
counterclockwise to “LOCK” and
remove it.
To release the lock, turn the key to
“OFF”.
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Never turn the key to “OFF” or
“LOCK” when the motorcycle is
moving. The electrical circuits will
be switched off which may result
in loss of control or an accident. Be
sure the motorcycle is stopped
before turning the key to “OFF” or
“LOCK”.
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INSTRUMENT AND CONTROL FUNCTIONS
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3-3
INSTRUMENT AND CONTROL FUNCTIONS
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23
EAU00118Handlebar switches
EAU00122Dimmer switch “LIGHTS”
Turn the switch to “HI” for the high
beam and to “LO” for the low
beam.
EAU00128Turn signal switch “TURN”
This is a three-position switch. The
center position is off.
Turn to “L” to turn on the left
flasher, and to “R” for the right
flasher. Be sure to turn the switch
off after completing a turn.
1. Dimmer switch “LIGHTS”
2. Turn signal switch “TURN”
3. Horn switch “HORN”
EAU00130Horn switch “HORN”
Press the switch to sound the horn.1
2
EAU00137
Engine stop switch “ENGINE
STOP”
The engine stop switch is a safety
device for use in an emergency
such as when the motorcycle over-
turns or if trouble occurs in the
throttle system. Turn the switch to
“RUN” to start the engine. In case
of emergency, turn the switch to
“OFF” to stop the engine.
1. Engine stop switch “ENGINE STOP”
2. Start switch “START”
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3-4
EAU00141Start switch “START”
The starter motor cranks the
engine when pushing the start
switch.
EC000005
cC
See starting instructions prior to
starting the engine.
INSTRUMENT AND CONTROL FUNCTIONS
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2
3
4
5
6
7
8
9
EAU00152Clutch lever
The clutch lever is located on the
left handlebar, and the ignition cir-
cuit cut-off system is incorporated
in the clutch lever holder. Pull the
clutch lever to the handlebar to dis-
engage the clutch, and release the
lever to engage the clutch. The
lever should be pulled rapidly and
released slowly for smooth clutch
operation. (Refer to the engine
starting procedures for a descrip-
tion of the ignition circuit cut-off
system.)
1
N5
4
3
2
1
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Shift pedal
This motorcycle is equipped with a
constant-mesh 5-speed transmis-
sion.
The shift pedal is located on the
left side of the engine and is used
in combination with the clutch
when shifting.
N. Neutral
1. Shift pedal
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1
2
EAU01183Fuel
Make sure there is sufficient fuel in
the tank. Fill the fuel tank to the
bottom of the filler tube as shown
in the illustration.
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Do not overfill the fuel tank. Avoid
spilling fuel on the hot engine. Do
not fill the fuel tank above the bot-
tom of the filler tube or it may
overflow when the fuel heats up
later and expands.
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cC
Always wipe off spilled fuel imme-
diately with a dry and clean soft
cloth. Fuel may deteriorate painted
surfaces or plastic parts.
1. Filler tube
2. Fuel level
NOTE:
The tank cap cannot be reinstalled
unless it is unlocked. The key must
remain in the cap until the cap is
properly installed and locked onto
the fuel tank.
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Be sure the cap is properly
installed and locked in place
before riding the motorcycle.
3-6
INSTRUMENT AND CONTROL FUNCTIONS
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3
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3-7
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INSTRUMENT AND CONTROL FUNCTIONS
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9 Recommended fuel:
Regular gasoline
Fuel tank capacity:
Total:
7.0 L
Reserve:
1.7 L
ONFUEL
RES
OFF
1ON
1. Arrow mark
EAU01121Fuel cock
The fuel cock supplies fuel from
the tank to the carburetor while fil-
tering it also.
The fuel cock has three positions,
which should be set as shown in
the illustrations.
OFF: With the fuel cock in this
position, fuel will not flow.
Always set the fuel cock to
this position when the engine
is not running.ON: With the fuel cock in this
position, fuel flows to the car-
buretor. Set the fuel cock to
this position when starting
the engine and while riding.
RES
ONFUEL
OFF
1
1. Arrow mark
OFFON
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3-8
INSTRUMENT AND CONTROL FUNCTIONS
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9
ab
1
EAU00210Starter(choke) “1”
Starting a cold engine requires a
richer air-fuel mixture. A separate
starter circuit supplies this mixture.
Move in direction ato turn on the
starter(choke).
Move in direction bto turn off the
starter(choke).
1. Starter (choke) “1”
RES: This indicates reserve. If you
run out of fuel while riding,
set the fuel cock to this posi-
tion.
Fill the tank at the first oppor-
tunity. Be sure to set the fuel
cock back to “ON” after refu-
eling!
OFF
ONFUEL RES
1
RES
1. Arrow mark
RES
EAU00212Kick starter
Rotate the kick starter away from
the engine. Push the starter down
lightly with your foot until the
gears engage, then kick smoothly
and forcefully to start the engine.
This model has a primary-coupled
kick starter so the engine can be
started in any gear if the clutch is
disengaged. However, shifting to
neutral before starting is recom-
mended.
1
1. Kick starter
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3-11
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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
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3
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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.
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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
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PRE-OPERATION CHECKS
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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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1. Before riding this motorcycle,
become thoroughly familiar
with all operating controls and
their functions. Consult a
Yamaha dealer regarding any
control or function that you do
not thoroughly understand.
2. Never start your engine or let
it run for any length of time in
a closed area. The exhaust
fumes are poisonous and can
cause loss of consciousness
and death within a short time.
Always operate your motorcy-
cle in an area with adequate
ventilation.
3. Before starting out, always be
sure the sidestand is up.
Failure to retract the sidestand
completely can result in a seri-
ous accident when you try to
turn a corner.
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Starting and warming up a
cold engine
NOTE:
This motorcycle is equipped with a
starting and an ignition circuit cut-
off switch.
1. The engine can be started only
under the following condi-
tions:
a. The transmission is in neutral.
b. The sidestand is up, the trans-
mission is in gear, and the
clutch is disengaged.
2. The motorcycle must not be
ridden when the sidestand is
down.
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Before going through the follow-
ing steps, check the function of the
sidestand switch and clutch
switch. (Refer to page 3-11.)
5-1
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OPERATION AND IMPORTANT RIDING POINTS
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