torque YAMAHA TW200 2002 Owners Manual

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EAU00462
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.
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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6-8
PERIODIC MAINTENANCE AND MINOR REPAIR
6 break down and erode. If electrode
erosion becomes excessive, or if
carbon and other deposits are
excessive, you should replace the
spark plug with the specified plug.
Before installing the spark plug,
measure the electrode gap with a
wire thickness gauge; adjust the
gap to specification as necessary.
When installing the plug, always
clean the gasket surface and use a
new gasket. Wipe off any grime
from the threads and tighten the
spark plug to the specified torque.Specified spark plug:
DR8EA (NGK) or
X24ESR-U (DENSO)Spark plug gap:
0.6 ~ 0.7 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 m0kg)
NOTE:
If a torque wrench is not available
when you are installing a spark
plug, a good estimate of the cor-
rect torque is 1/4 to 1/2 turn past
finger tight. Have the spark plug
tightened to the specified torque as
soon as possible.EAU00517Engine oil
1. Oil level measurement
a. Place the motorcycle on a level
place and hold it in an upright
position. Warm up the engine
for several minutes.
NOTE:
Be sure the motorcycle is posi-
tioned straight up when checking
the oil level. A slight tilt toward the
side can result in false readings.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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EC000070
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When removing the oil drain plug,
the O-ring, compression spring,
and oil strainer will fall out. Take
care not to lose these parts.
NOTE:
The oil filter cover is secured by
two screws and a drain bolt.
Remove the drain bolt to drain the
filter cavity.
1. Drain plug
2. O-ring
3. Compression spring
4. Oil strainer
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d. Remove the filter cover screws
and the oil filter cover.
e. Remove the oil filter element
and O-ring.
f. Clean the oil filter and strainer
with solvent. Replace if neces-
sary.
g. Check the O-rings. If damaged,
replace.
h. Install the drain plug, filter
cover, screws and drain bolt.
Tighten the drain plug to the
specified tightening torque.
1. Filter cover screw (×2)
2. Drain bolt
21
NOTE:
Make sure the O-ring is seated
properly.
EC000071
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Before reinstalling the oil drain
plug, do not forget to install the O-
ring, compression spring, and oil
strainer in position.
1. Oil filter
2. O-ring (×2)
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9i. Fill the engine with oil. Install
the oil filler cap and tighten.
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8Do not put in any chemical
additives. Engine oil also lubri-
cates the clutch and additives
could cause clutch slippage.
8Be sure no foreign material
enters the crankcase.
Recommended oil:
See page 8-1
Oil quantity:
Total amount:
1.3 L
Periodic oil change:
1.0 L
With oil filter replacement:
1.1 LTightening torque:
Drain plug:
10 Nm (1.0 m0kg)
Filter cover screw:
10 Nm (1.0 m0kg)
Drain bolt (filter cover):
10 Nm (1.0 m0kg)j. Start the engine and warm up
for a few minutes. While
warming up, check for oil leak-
age. If oil leakage is found,
stop the engine immediately
and check for the cause.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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9 To check the chain slack the motor-
cycle must be held straight up with
both wheels on the ground and
without rider. Check the slack at
the position shown in the illustra-
tion. Normal slack is approximately
30 ~ 40 mm. If the slack exceeds 40
mm, adjust.
EAU01302
Drive chain slack adjustment
1. Loosen the rear brake adjust-
ing nut.
2. Remove the cotter pin from
the axle nut.
3. Loosen the axle nut.
4. Turn both left and right chain
adjusting plates the same
amount. Make sure that they
are in the same position for
proper wheel alignment.
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1. Adjusting nut
2. Axle nut
3. Cotter pin
4. Chain adjusting plate
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Too little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits.
5. After adjusting, be sure to
tighten the axle nut to the
specified torque.
Tightening torque:
Axle nut:
90 Nm (9.0 m0kg)
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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.
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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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Rear 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 brake adjusting
nut and brake rod from the
brake cam lever.
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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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SPECIFICATIONS
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HOW TO USE THE CONVERSION TABLE
All specification data in this manual are listed in SI
and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.
Ex.
METRIC MULTIPLIER IMPERIAL
** mm×0.03937 = ** in
2 mm×0.03937 = 0.08 inMETRIC TO IMPERIAL
Metric unit Multiplier Imperial unit
m•kg 7.233 ft.lb
Torquem•kg 86.794 in•lb
cm•kg 0.0723 ft•lb
cm•kg 0.8679 in•lb
Weightkg 2.205 lb
g 0.03527 oz
Speed km/hr 0.6214 mph
km 0.6214 mi
m 3.281 ft
Distance m 1.094 yd
cm 0.3937 in
mm 0.03937 in
cc (cm3) 0.03527 oz (IMP liq.)
Volume/ cc (cm3) 0.06102 cu•in
Capacity lt (liter) 0.8799 qt (IMP liq.)
lt (liter) 0.2199 gal (IMP liq.)
kg/mm 55.997 lb/in
Misc. kg/cm
214.2234 psi (lb/in2)Centigrade(°C)9/5 + 32Fahrenheit(°F)
CONVERSION TABLE
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