YAMAHA TW200 2003 Owners Manual

PRINTED IN JAPAN
2000·12– 0.1×2(E)
!5FY-28199-E0
OWNER’S MANUAL
TW200E
PRINTED ON RECYCLED PAPER
YAMAHA MOTOR CO., LTD.

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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IMPORTANT MANUAL INFORMATION
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Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
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NOTE:
NOTE:
8This manual should be considered a permanent part of this motorcycle and should
remain with it even if the motorcycle is subsequently sold.
8Yamaha continually seeks advancements in product design and quality. Therefore,
while this manual contains the most current product information available at the time
of printing, there may be minor discrepancies between your motorcycle and this manu-
al. If there is any question concerning this manual, please consult your Yamaha dealer.
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IMPORTANT MANUAL INFORMATION
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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
MOTORCYCLE.
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9TW200E
OWNER’S MANUAL
©1997 by Yamaha Motor Co., Ltd.
1st Edition, November 1997
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
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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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Carburetor adjustment ..................................6-13
Idle speed adjustment ...................................6-13
Throttle cable free play inspection ...............6-14
Cam chain adjustment ...................................6-14
Valve clearance adjustment ..........................6-14
Tires.................................................................6-15
Wheels ............................................................6-17
Clutch lever free play adjustment .................6-18
Front brake lever free play adjustment ........6-18
Rear brake pedal height and free play
adjustment ......................................................6-19
Brake light switch adjustment.......................6-20
Checking the brake shoes..............................6-21
Drive chain slack check ..................................6-21
Drive chain slack adjustment ........................6-22
Drive chain lubrication...................................6-23
Cable inspection and lubrication ..................6-24
Throttle cable and grip lubrication ...............6-24
Brake and shift pedal lubrication ..................6-24
Brake and clutch lever lubrication ................6-25
Sidestand lubrication .....................................6-25
Rear suspension lubrication..........................6-25
Front fork inspection ......................................6-26
Steering inspection ........................................6-26
Wheel bearings ..............................................6-27
Battery .............................................................6-27Fuse replacement ...........................................6-29
Headlight bulb replacement ..........................6-30
Supporting the motorcycle ...........................6-31
Front wheel removal ......................................6-31
Front wheel installation .................................6-32
Rear wheel removal .......................................6-33
Rear wheel installation ..................................6-33
Troubleshooting .............................................6-34
Troubleshooting chart ...................................6-35
CLEANING AND STORAGE ...............................7-1
Cleaning ............................................................7-1
Storage..............................................................7-2
SPECIFICATIONS................................................8-1
How to use the conversion table ....................8-4
CONSUMER INFORMATION .............................9-1
Identification numbers record.........................9-1
Key identification number ...............................9-1
Vehicle identification number .........................9-1
Model label .......................................................9-2
TABLE OF CONTENTS
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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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DESCRIPTION
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2-1
1. Headlight (page 6-30)
2. Fuel cock (page 3-7)
3. Starter(choke) “1“ (page 3-8)
4. Air filter (page 6-12)
5. Battery (page 6-27)6. Helmet holder (page 3-9)
7. Rear carrier (page 3-10)
8. Shift pedal (page 3-4)
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Left view
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DESCRIPTION
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2-2
9. Fuse (page 3-6)
10. Kick starter (page 3-8)
11. Rear brake pedal (page 3-5)
12. Tool kit (page 6-1)
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Right view
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