brake YAMAHA TW200 2004 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU24360
Front wheel
EAU24580
To remove the front wheel
WARNING

EWA10820

It is advisable to have a Yamaha
dealer service the wheel.

Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Disconnect the speedometer ca-
ble from the front wheel.
2. Loosen the axle nut.
3. Lift the front wheel off the ground
according to the procedure onpage 6-33.
4. Remove the axle nut, pull the
wheel axle out, and then remove
the wheel.
CAUTION:

ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU24981
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.
2. Lift the wheel up between the fork
legs.
NOTE:

Make sure that there is enough space
between the brake pads before insert-
ing the brake disc and that the slot in
the speedometer gear unit fits over the
retainer on the fork leg.3. Insert the wheel axle, and then in-
stall the axle nut.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the axle nut to the speci-
fied torque.
6. Connect the speedometer cable.
1. Speedometer cable
2. Axle nut
1
2

1. Retainer
2. Speedometer cable
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
2 1

PERIODIC MAINTENANCE AND MINOR REPAIR
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9

EAU25080
Rear wheel
EAU25420
To remove the rear wheel
WARNING

EWA10820

It is advisable to have a Yamaha
dealer service the wheel.

Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Loosen the axle nut.
2. Remove the brake pedal free playadjusting nut, and then disconnect
the brake rod from the brake cam-
shaft lever.
3. Turn the drive chain adjusting
plate on each side of the swingarm
fully in direction (a).
4. Lift the rear wheel off the ground
according to the procedure on
page 6-33.
5. Remove the axle nut, and then pull
the wheel axle out.
6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:

The drive chain does not need to be
disassembled in order to remove and
install the wheel.
7. Remove the wheel.
EAU25761
To install the rear wheel
1. Insert the wheel axle from the
left-hand side.
NOTE:

Make sure that the drive chain adjust-
ing plates are installed with thepunched sides facing to the outside
and that the slot in the brake shoe plate
fits over the retainer on the swingarm.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-21.)
3. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
4. Tighten the axle nut to the speci-
fied torque.
1. Axle nut
2. Brake pedal free play adjusting nut
3. Brake rod
4. Brake camshaft lever
5. Drive chain slack adjusting plate
5
2
1
3
4
(a)

1. Retainer
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
1

PERIODIC MAINTENANCE AND MINOR REPAIR
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5. Install the brake rod onto the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.
6. Adjust the brake pedal free play.
(See page 6-18.)
WARNING

EWA10660
After adjusting the brake pedal free
play, check the operation of the
brake light.
EAU25850
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.

MOTORCYCLE CARE AND STORAGE
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9

EAU26000
Care
While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a motor-
cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your mo-
torcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and abrush, but never apply such prod-
ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
CAUTION:

ECA10770

Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.

Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.

Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths orsponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.

Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.

For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave

MOTORCYCLE CARE AND STORAGE
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9any marks. If the windshield is
scratched, use a quality plastic
polishing compound after

washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:

Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the motorcycle with cold wa-ter and a mild detergent, after the
engine has cooled down.
CAUTION:

ECA10790
Do not use warm water since it in-
creases the corrosive action of the
salt.
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stain-
less-steel parts, including the ex-
haust system. (Even the thermally
induced discoloring of stain-
less-steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
WARNING

EWA10930

Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent.

Before operating the motorcy-
cle test its braking performance
and cornering behavior.
CAUTION:

ECA10800

Apply spray oil and wax spar-

SPECIFICATIONS
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3rd:
29/22 (1.318)
4th:
26/25 (1.040)
5th:
23/28 (0.821)
Chassis:
Frame type:
Diamond
Caster angle:
26.0 °
Trail:
95.0 mm (3.74 in)
Front tire:
Type:
With tube
Size:
130/80-18M/C 66P
Manufacturer/model:
BRIDGESTONE/TW31
Rear tire:
Type:
With tube
Size:
180/80-14M/C 78P
Manufacturer/model:
BRIDGESTONE/TW34
Loading:
Maximum load:
180 kg (397 lb)
(Total weight of rider, passenger, cargo
and accessories)
Tire air pressure (measured on cold
tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
125 kPa (18 psi) (1.25 kgf/cm
2

)
Rear:
125 kPa (18 psi) (1.25 kgf/cm
2

)
Loading condition:
90–180 kg (198–397 lb)
Front:
150 kPa (22 psi) (1.50 kgf/cm
2

)
Rear:
175 kPa (25 psi) (1.75 kgf/cm
2

)
Off-road riding:
Front:
125 kPa (18 psi) (1.25 kgf/cm
2

)
Rear:
125 kPa (18 psi) (1.25 kgf/cm
2

)
Front wheel:
Wheel type:
Spoke wheel
Rim size:
18x2.50
Rear wheel:
Wheel type:
Spoke wheel
Rim size:
14M/C x MT4.50
Front brake:
Type:
Single disc brake Operation:
Right hand operation
Recommended fluid:
Dot 4
Rear brake:
Type:
Drum brake
Operation:
Right foot operation
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
160.0 mm (6.30 in)
Rear suspension:
Type:
Swingarm (monocross)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
150.0 mm (5.91 in)
Electrical system:
Ignition system:
C.D.I.
Charging system:
A.C. magneto
Battery:
Model:
GM7CZ-3D
Voltage, capacity:
12 V, 7.0 Ah

SPECIFICATIONS
8-3
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89 Headlight:

Bulb type:
Halogen bulb
Bulb voltage, wattage x quantity:
Headlight:
12 V, 60 W/55.0 W
×
1
Tail/brake light:
12 V, 8 W/27.0 W
×
1
Front turn signal/position light:
12 V, 27 W/8.0 W
×
2
Rear turn signal light:
12 V, 27.0 W
×
2
Meter lighting:
12 V, 3.4 W
×
1
Neutral indicator light:
12 V, 3.4 W
×
1
High beam indicator light:
12 V, 3.4 W
×
1
Turn signal indicator light:
12 V, 3.4 W
×
1

Fuse:
Fuse:
20.0 A