oil YAMAHA TW200 2003 User Guide

6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00772
Cable inspection and
lubrication
EW000112
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Damage to the outer housing of
cables may lead to internal rusting
and interfere with the cable move-
ment. Replace damaged cables as
soon as possible to prevent unsafe
conditions.
Lubricate the cables and cable
ends. If a cable does not operate
smoothly, ask a Yamaha dealer to
replace it.
Recommended lubricant:
Same as engine oil
EAU00773
Throttle cable and grip
lubrication
The throttle twist grip assembly
should be greased at the time that
the cable is lubricated, since the
grip must be removed to get at the
end of the throttle cable. After
removing the screws, hold the end
of the cable up in the air and put in
several drops of lubricant. With the
throttle grip disassembled, coat the
metal surface of the grip assembly
with a suitable all-purpose grease.
EAU00776
Brake and shift pedal
lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Same as engine oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00778
Brake and clutch lever
lubrication
Lubricate the pivoting parts.
EAU00785
Sidestand lubrication
Lubricate the sidestand pivoting
point and metal-to-metal contact
surfaces. Check that the sidestand
moves up and down smoothly.
EW000113
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If the sidestand does not move
smoothly, consult a Yamaha deal-
er.
Recommended lubricant:
Same as engine oil
Recommended lubricant:
Same as engine oil
EAU00791
Rear suspension lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Lithium soap base grease
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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00793Front fork inspection
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Securely support the motorcycle
so there is no danger of it falling
over.
1. Visual check
Check for scratches or damage
on the inner tube and exces-
sive oil leakage from the front
fork.2. Operation check
Place the motorcycle on a level
place.
a. Hold the motorcycle in an
upright position and apply the
front brake.
b. Push down hard on the han-
dlebars several times and
check if the fork rebounds
smoothly.
EC000098
cC
If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer.
EAU00794Steering inspection
Periodically inspect the condition
of the steering. Worn out or loose
steering bearings may be danger-
ous. Place a stand under the
engine to raise the front wheel off
the ground. Hold the lower end of
the front forks and try to move
them forward and backward. If any
free play can be felt, ask a Yamaha
dealer to inspect and adjust the
steering. Inspection is easier if the
front wheel is removed.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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EW000116
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Battery electrolyte is poisonous
and dangerous, causing severe
burns, etc. It contains sulfuric acid.
Avoid contact with skin, eyes or
clothing.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities
of water or milk. Follow with milk
of magnesia, beaten egg, or veg-
etable oil. Call a physician immedi-
ately.
EYES: Flush with water for 15 min-
utes and get prompt medical
attention. Batteries produce explo-
sive gases. Keep sparks, flame, cig-
arettes etc., away. Ventilate when
charging or using in an enclosed
space. Always shield your eyes
when working near batteries.
KEEP OUT OF REACH OF CHIL-
DREN.
EW000117
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Take care not to spill battery fluid
on the chain.
Battery fluid may weaken the
chain causing shorter chain life
and possibly result in an accident
Battery storage
1. When the motorcycle will not
be used for a month or longer,
remove the battery, fully
charge it and store it in a cool,
dry place. Completely recharge
the battery before reinstalla-
tion.
2. If the battery will be stored for
longer than two months, check
the specific gravity of the fluid
at least once a month and fully
recharge the battery when it is
too low. Replenishing the battery fluid
A poorly maintained battery will
corrode and discharge quickly. The
battery fluid should be checked at
least once a month. The level
should be between the minimum
level and maximum level marks.
Use only distilled water if refilling
is necessary.
EC000100
cC
Normal tap water contains miner-
als which are harmful to a battery;
therefore, refill only with distilled
water.
1
2
1. Maximum level mark
2. Minimum level mark
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PERIODIC MAINTENANCE AND MINOR REPAIR
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1
3. Remove the connector and the
bulb holder cover.
4. Turn the bulb holder counter-
clockwise to remove it and
remove the defective bulb.
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Keep flammable products and your
hands away from a bulb while it is
on, as it is hot. Do not touch a bulb
until it cools down.
5. Put a new bulb into position
and secure it in place with the
bulb holder.
1. Bulb holder cover
EAU01191
Headlight bulb replacement
This motorcycle is equipped with a
quartz bulb headlight. If the head-
light bulb burns out, replace it as
follows:
1. Remove cowling A. (See page
6-6 for cowling removal and
installation procedures.)
2. Remove the headlight unit.
1
EC000105
cC
Avoid touching the glass part of a
bulb. Keep it free from oil; other-
wise, the transparency of the
glass, life of the bulb, and lumi-
nous flux will be adversely affect-
ed. If oil gets on a bulb, thoroughly
clean it with a cloth moistened
with alcohol or lacquer thinner.
6. Install the bulb holder cover,
connector and headlight unit.
7. Install the cowling.
8. If the headlight beam adjust-
ment is necessary, ask a
Yamaha dealer to make that
adjustment.
1. Bulb holder
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7-2
CLEANING AND STORAGE
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96. Rinse the motorcycle off
immediately with clean water
and dry all surfaces with a
chamois, clean towel, or soft
absorbent cloth.
7. Dry the chain and lubricate it
to prevent rust.
8. Clean the seat with a vinyl
upholstery cleaner to keep the
cover pliable and glossy.
9. Automotive-type wax may be
applied to all painted and
chrome-plated surfaces. Avoid
combination cleaner-waxes.
Many contain abrasives which
may mar the paint or protec-
tive finish. When finished, start
the engine and let it idle for
several minutes.
EAU01107B. STORAGE
Long term storage (60 days or
more) of your motorcycle will
require some preventive proce-
dures to guard against deteriora-
tion. After thoroughly cleaning the
motorcycle, prepare for storage as
follows:
1. Fill the fuel tank with fuel and
add fuel stabilizer (if available).
2. Remove the spark plug, pour
about one tablespoon of SAE
10W30 or 20W40 motor oil in
the spark plug hole and rein-
stall the spark plug. Turn the
engine over several times
(ground spark plug lead) to
coat the cylinder wall with oil.
EW000127
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When using the starter motor to
crank the engine, remove the
spark plug wires, and ground them
to prevent sparking.
3. Thoroughly clean and lubricate
the drive chain. (For details,
see “Drive chain lubrication”
on page 6-23.)
4. Lubricate all control cables.
5. Block up the frame to raise
both wheels off the ground.
6. Tie a plastic bag over the
exhaust pipe outlet to prevent
moisture from entering.
7. If storing in a humid or salt-air
atmosphere, coat all exposed
metal surfaces with a light film
of oil. Do not apply oil to any
rubber parts or the seat cover.
8. Remove the battery and
charge it. Store it in a dry place
and recharge it once a month.
Do not store the battery in an
excessively warm or cold place
(less than 0°C or more than
30°C.
NOTE:
Make any necessary repairs before
storing the motorcycle.
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8-1
EAU01038
SPECIFICATIONS
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Specifications
Model TW200E
Dimensions:
Overall length 2,090 mm
Overall width 815 mm
Overall height 1,115 mm
Seat height 790 mm
Wheel base 1,325 mm
Ground clearance 250 mm
Minimum turning radius 1,900 mm
Basic weight (With oil and full
fuel tank):126 kg
Engine:
Engine type Air-cooled 4-stroke, SOHC,
gasoline
Cylinder arrangement Forward inclined
single cylinder
Displacement 196 cm
3
Bore ×Stroke 67.0 ×55.7 mm
Compression ratio 9.5:1
Starting system Electric and kick starter
Lubrication system Wet sumpEngine oil:
Type:
Classification API Service “SE”, “SF” type
or equivalent
(e.g. “SF-SE”, “SF-SE-CC”,
“SF-SE-SD” etc.)
Capacity:
Periodic oil change 1.0 L
With oil filter replacement 1.1 L
Total amount 1.3 L
Air filter:Wet type element
Fuel:
Type Regular gasoline
Fuel tank capacity 7.0 L
Reserve amount 1.7 L
Carburetor:
Type / quantity Y29P-5C / 1
Manufacturer TEIKEI
–10° 0° 10° 20° 30° 40°
SAE 10W/30
SAE 10W/40
SAE 20W/40
SAE 20W/50C
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8-3
SPECIFICATIONS
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Wheels:
Type:
Front Spoke wheel
Rear Spoke wheel
Size:
Front 18 ×2.50
Rear 14M/C ×MT4.50
Brakes:
Front:
Type Drum brake
Operation Right hand operation
Rear:
Type Drum brake
Operation Right foot operation
Suspension:
Front Telescopic fork
Rear Swingarm
(Monocross suspension)
Shock absorber:
Front Coil spring / oil damper
Rear Coil-gas spring / oil damper
Wheel travel:
Front 160 mm
Rear 150 mmElectrical:
Ignition system: C.D.I.
Charging system:
Type A.C. magneto
Standard output 12V 11A / 5,000 rpm
Battery:
Type GM7CZ-3D
Voltage, capacity 12V 7 AH
Headlight typeHalogen bulb
Bulb voltage, wattage ×quantity:
Headlight 12V 35W / 35W ×1
Stop / tail light 12V 27W / 8W ×1
Front flasher light 12V 27W / 8W ×2
Rear flasher light 12V 27W ×2
Meter light 12V 3.4W ×1
Neutral indicator light 12V 3.4W ×1
High beam indicator light 12V 3.4W ×1
Turn indicator light 12V 3.4W ×1
Fuse:
Main 15A
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