maintenance YAMAHA TW200 2002 Owners Manual

INTRODUCTION
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Congratulations on your purchase of the Yamaha TW200E. This model is the result of
Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing
machines. It represents the high degree of craftsmanship and reliability that have made
Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic mainte-
nance of this motorcycle. If you have any questions about the operation or maintenance of
your motorcycle, please consult a Yamaha dealer.
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TABLE OF CONTENTS
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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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QGIVE SAFETY THE RIGHT OF WAY
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9 Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and
freedom. However, they also impose certain limits, which you must accept; even the best
motorcycle does not ignore the laws of physics.
Regular care and maintenance are essential for preserving your motorcycle’s value and operat-
ing condition. Moreover, what is true for the motorcycle is also true for the rider: good perfor-
mance depends on being in good shape. Riding under the influence of medication, drugs and
alcohol is, of course, out of the question. Motorcycle riders more than car drivers must always
be at their mental and physical best. Under the influence of even small amounts of alcohol,
there is a tendency to take dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and
passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant
synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting hel-
met. Optimum protective wear, however, should not encourage carelessness. Though full-cov-
erage helmets and suits, in particular, create an illusion of total safety and protection, motorcy-
clists will always be vulnerable. Riders who lack critical self-control run the risk of going too
fast and are apt to take chances. This is even more dangerous in wet weather. The good motor-
cyclist rides safely, predictably and defensively avoiding all dangers, including those caused by
others.
Enjoy your ride!
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PERIODIC MAINTENANCE AND MINOR REPAIR
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If you are not familiar with motor-
cycle service, this work should be
done by a Yamaha dealer.
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Periodic inspection, adjustment
and lubrication will keep your
motorcycle in the safest and most
efficient condition possible. Safety
is an obligation of the motorcycle
owner. The maintenance and lubri-
cation schedule chart should be
considered strictly as a guide to
general maintenance and lubrica-
tion intervals. YOU MUST TAKE
INTO CONSIDERATION THAT
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATIONS, AND A VARIETY
OF INDIVIDUAL USES ALL TEND
TO DEMAND THAT EACH OWNER
ALTER THIS TIME SCHEDULE TO
SHORTER INTERVALS TO MATCH
THE ENVIRONMENT. The most
important points of motorcycle
inspection, adjustment, and lubri-
cation are explained in the follow-
ing pages.1
EAU01175Tool kit
The tool kit is located behind panel
B. (See page 6-7 for panel removal
and installation procedures.)
The tools provided in the owner’s
tool kit are to assist you in the per-
formance of periodic maintenance.
However, some other tools such as
a torque wrench are also necessary
to perform the maintenance cor-
rectly.
The service information included in
this manual is intended to provide
you, the owner, with the necessary
information for completing some
of your own preventive mainte-
nance and minor repairs.
1. Tool kit
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NOTE:
If you do not have necessary tools
required during a service opera-
tion, take your motorcycle to a
Yamaha dealer for service.
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Modifications to this motorcycle
not approved by Yamaha may
cause loss of performance, and
render it unsafe for use. Consult a
Yamaha dealer before attempting
any changes.
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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.
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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)
12 * Wheel bearings9Check bearing for looseness or damage.
√√
9Replace if necessary.
9Check swingarm pivoting point for play.
13 * Swingarm9Correct if necessary. √√
9Lubricate with lithium soap base grease.
9Check chain slack.
14 Drive chain9
Adjust if necessary. Make sure that the rear wheel is properly aligned.Every 500 km and after washing
9Clean and lubricate.the motorcycle or riding in the rain
9Check bearing play and steering for roughness.
15 * Steering bearings9Correct accordingly.
√√
9Lubricate with lithium soap grease every 24,000 km or
24 months (whichever comes first).
16 * Chassis fasteners9
Make sure that all nuts, bolts and screws are properly tightened.√√9Tighten if necessary.
17 Sidestand9Check operation.
√√
9Lubricate and repair if necessary.
18 Sidestand switch9Check operation.
√√√
9Replace if necessary.
19 * Front fork9Check operation and for oil leakage.
√√
9Correct accordingly.
20 *Rear shock absorber 9Check operation and shock absorber for oil leakage.
√√
assembly9Replace shock absorber assembly if necessary.
Rear shock absorber9Check operation.
21 * assembly pivoting9Lubricate with lithium soap base grease every 24,000 km or√√
points24 months (whichever comes first).
22 * Carburetor9Check engine idling speed and starter operation.
√√√
9Adjust if necessary.
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*: Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.EAU00479
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
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)
9Check oil level and vehicle for oil leakage.
23 Engine oil9Correct if necessary.√√√
9Change. (Warm engine before draining.)
24Engine oil filter element9Clean or replace if necessary.√√
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Engine oil strainer9Clean or replace if necessary.√√
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Cowling and panel removal
and installation
The cowlings and panels illustrated
need to be removed to perform
some of the maintenance
described in this chapter.
Refer to this section each time a
cowling or panel has to be
removed or reinstalled.
1. Panel B
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1. Cowling A
2. Panel A
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1. Screw
EAU01344Cowling A
To remove:
Remove the screw.
To install:
Place in the original position and
install the screw.
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1. Panel A
EAU00494Panel A
To remove:
Pull outward on the areas shown.
To install:
Place the panel in its original posi-
tion.
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EAU00495Spark plug inspection
The spark plug is an important
engine component and is easy to
inspect. The condition of the spark
plug can indicate the condition of
the engine. The ideal color on the
white insulator around the center
electrode is a medium-to-light tan
color for a motorcycle that is being
ridden normally. Do not attempt to
diagnose any problems yourself.
Instead, take the motorcycle to a
Yamaha dealer. You should period-
ically remove and inspect the spark
plug because heat and deposits
will cause the spark plug to slowly
1. Spark plug gap
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1. Panel B
2. Screw (×2)
EAU01345Panel B
To remove:
Remove the screws and pull out-
ward on the areas shown.
To install:
Place the panel in the original posi-
tion and install the screws.
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