service YAMAHA TW200 2002 Owners Manual

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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
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EW000060
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If you are not familiar with motor-
cycle service, this work should be
done by a Yamaha dealer.
EAU00464
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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*: 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.√√
25
*
Engine oil strainer9Clean or replace if necessary.√√
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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
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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.
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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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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.
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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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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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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
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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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