fuel YAMAHA TW200 2004 Owners Manual

TABLE OF CONTENTS
SAFETY INFORMATION ............. 1-1
DESCRIPTION ............................. 2-1
Left view ..................................... 2-1
Right view................................... 2-2
Controls and instruments ........... 2-3
INSTRUMENT AND CONTROL
FUNCTIONS ................................ 3-1
Main switch/steering lock .......... 3-1
Indicator lights ........................... 3-2
Speedometer unit ...................... 3-2
Handlebar switches ................... 3-3
Clutch lever ............................... 3-4
Shift pedal ................................. 3-4
Brake lever ................................ 3-4
Brake pedal ............................... 3-5
Fuel tank cap ............................. 3-5
Fuel ........................................... 3-6
Fuel cock ................................... 3-6
Starter (choke) knob “
1
” .......... 3-7
Kickstarter ................................. 3-8
Seat ........................................... 3-8
Helmet holder ............................ 3-9
Shock absorber ......................... 3-9
Carrier ....................................... 3-9
Luggage strap holders ............ 3-10
Sidestand ................................ 3-10Ignition circuit cut-off system ... 3-11
PRE-OPERATION CHECKS ........ 4-1
Pre-operation check list ............ 4-2
OPERATION AND IMPORTANT
RIDING POINTS .......................... 5-1
Starting a cold engine ............... 5-1
Starting a warm engine ............. 5-2
Shifting ...................................... 5-2
Tips for reducing fuel
consumption ............................ 5-3
Engine break-in ......................... 5-3
Parking ...................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR ........................... 6-1
Owner’s tool kit ......................... 6-1
Periodic maintenance and
lubrication chart ....................... 6-2
Removing and installing the
cowling and panels ................. 6-5
Checking the spark plug ........... 6-6
Engine oil and oil filter
element ................................... 6-7
Cleaning the air filter element
and check hose ..................... 6-10
Adjusting the carburetor .......... 6-12Adjusting the engine idling
speed .................................... 6-12
Adjusting the throttle cable free
play ....................................... 6-13
Adjusting the valve
clearance .............................. 6-13
Tires ........................................ 6-13
Spoke wheels .......................... 6-16
Adjusting the clutch lever free
play ....................................... 6-16
Adjusting the brake lever free
play ....................................... 6-17
Adjusting the brake pedal
position and free play ............ 6-18
Adjusting the rear brake light
switch .................................... 6-19
Checking the front brake pads
and rear brake shoes ............ 6-19
Checking the brake fluid
level ....................................... 6-20
Changing the brake fluid ......... 6-21
Drive chain slack ..................... 6-21
Lubricating the drive chain ...... 6-23
Checking and lubricating the
cables .................................... 6-23
Checking and lubricating the
throttle grip and cable ........... 6-24

SAFETY INFORMATION
1-4
1
motorcycle’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas

GASOLINE IS HIGHLY FLAMMA-
BLE:

Always turn the engine off when
refueling.

Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.

Never refuel while smoking or in
the vicinity of an open flame.

Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has ad-
equate ventilation.

Always turn the engine off before
leaving the motorcycle unattended
and remove the key from the main
switch. When parking the motorcy-cle, note the following:

The engine and exhaust system
may be hot, therefore, park the
motorcycle in a place where pe-
destrians or children are not like-
ly to touch these hot areas.

Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.

Do not park the motorcycle near
a flammable source (e.g., a ker-
osene heater, or near an open
flame), otherwise it could catch
fire.

When transporting the motorcycle
in another vehicle, make sure that
it is kept upright and that the fuel
cock(s) are turned to “ON” or
“RES” (for vacuum type)/“OFF”
(for manual type). If the motorcycle
should lean over, gasoline may
leak out of the carburetor or fuel
tank.

If you should swallow any gaso-
line, inhale a lot of gasoline vapor,
or allow gasoline to get into youreyes, see your doctor immediate-
ly. If any gasoline spills on your
skin or clothing, immediately wash
the affected area with soap and
water and change your clothes.

2-1
1
2
3
4
5
6
7
8
9

DESCRIPTION
EAU10410
Left view
1
2
3
4 5 76

1. Fuel cock (page 3-6)
2. Helmet holder (page 3-9)
3. Luggage strap holder (page 3-10)
4. Drive chain slack adjusting plate
5. Air filter element (page 6-10)
6. Starter (choke) knob (page 3-7)
7. Shift pedal (page 3-4)

DESCRIPTION
2-3
1
2
3
4
5
6
7
8
9

EAU10430
Controls and instruments
12 3 4
567
8
9

1. Clutch lever (page 3-4)
2. Left handlebar switches (page 3-3)
3. Speedometer unit (page 3-2)
4. Main switch/steering lock (page 3-1)
5. Indicator lights (page 3-2)
6. Right handlebar switches (page 3-3)
7. Brake lever (page 3-4)
8. Throttle grip (page 6-13)9. Fuel tank cap (page 3-5)

INSTRUMENT AND CONTROL FUNCTIONS
3-2
1
2
3
4
5
6
7
8
9

EAU10980
Indicator lights
EAU11020
Turn signal indicator light “”
This indicator light flashes when the
turn signal switch is pushed to the left or
right.
EAU11060
Neutral indicator light “”
This indicator light comes on when the
transmission is in the neutral position.
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11630
Speedometer unit
The speedometer unit is equipped with
a speedometer, an odometer and a
tripmeter. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeter
shows the distance traveled since it
was last set to zero with the reset knob.
The tripmeter can be used to estimate
the distance that can be traveled with a
full tank of fuel. This information will en-
able you to plan future fuel stops.
1. Turn signal indicator light “ ”
2. High beam indicator light “ ”
3. Neutral indicator light “ ”
3
12

1. Speedometer
2. Odometer
3. Tripmeter
4. Reset knob
4
23 1

INSTRUMENT AND CONTROL FUNCTIONS
3-5
2
34
5
6
7
8
9

EAU12941
Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
EAU32280
Fuel tank cap
To remove the fuel tank cap
1. Insert the key into the lock and turn
it 1/3 turn counterclockwise.
2. Turn the fuel tank cap 1/3 turn
counterclockwise and pull it off.
To install the fuel tank cap
1. Insert the fuel tank cap into the
tank opening with the key inserted
in the lock, and then turn the cap 1/
3 turn clockwise.
2. Turn the key 1/3 turn clockwise,
and then remove it.
NOTE:

The fuel tank cap cannot be installedunless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly installed and locked.
WARNING

EWA10120
Make sure that the fuel tank cap is
properly closed and locked before
riding.
1. Brake pedal
1

1. Fuel tank cap
2. Unlock.
1
2

INSTRUMENT AND CONTROL FUNCTIONS
3-6
1
2
3
4
5
6
7
8
9

EAU13210
Fuel
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
WARNING

EWA10880

Do not overfill the fuel tank, oth-
erwise it may overflow when the
fuel warms up and expands.

Avoid spilling fuel on the hot en-
gine.
CAUTION:

ECA10070
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, sincefuel may deteriorate painted surfac-
es or plastic parts.
EAU13241EAU13560
Fuel cock
The fuel cock supplies fuel from the
tank to the carburetor while filtering it al-
so.
The fuel cock has three positions:
OFF
With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.
1. Fuel tank filler tube
2. Fuel level
1
2

Recommended fuel:
Regular unleaded gasoline
only
Fuel tank capacity:
7.0 L (1.85 US gal)
(1.54 Imp.gal)
Fuel reserve amount:
1.7 L (0.45 US gal)
(0.37 Imp.gal)
1. Arrow mark positioned over “OFF”
RES
ONFUEL
OFF
1

INSTRUMENT AND CONTROL FUNCTIONS
3-7
2
34
5
6
7
8
9 ON
With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
RES
This indicates reserve. If you run out offuel while riding, move the lever to this
position. Fill the tank at the first oppor-
tunity. Be sure to set the lever back to
“ON” after refueling!

EAU13600
Starter (choke) knob “”
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the knob in direction (a) to turn on
the starter (choke).
Move the knob in direction (b) to turn off
the starter (choke).
1. Arrow mark positioned over “ON”
1. Arrow mark positioned over “RES”
ON
FUEL
RES
OFF
1
ON
OFF
ONFUEL RES
1
RES

1. Starter (choke) knob “”
1(a) (b)

PRE-OPERATION CHECKS
4-2
1
2
3
4
5
6
7
8
9

EAU15601
Pre-operation check list
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.3-6
Engine oil

Check oil level in engine.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.6-7
Front brake

Check operation.

If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check lever free play.

Adjust if necessary.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.6-17, 6-19, 6-20
Rear brake

Check operation.

Check pedal free play.

Adjust if necessary.6-18, 6-19
Clutch

Check operation.

Lubricate cable if necessary.

Check lever free play.

Adjust if necessary.6-16
Throttle grip

Make sure that operation is smooth.

Check cable free play.

If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-13, 6-24
Control cables

Make sure that operation is smooth.

Lubricate if necessary.6-23

OPERATION AND IMPORTANT RIDING POINTS
5-1
1
2
3
4
5
6
7
8
9

EAU15950
WARNING

EWA10270

Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.

Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.

Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU16530
Starting a cold engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.

The transmission is in gear with
the clutch lever pulled and the sid-
estand up.
WARNING

EWA10290

Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-11.

Never ride with the sidestand
down.
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
3. Shift the transmission into the neu-
tral position.
NOTE:

When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a Yama-
ha dealer check the electrical circuit.
4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-7.)
5. Start the engine by pushing the
start switch or by pushing the kick-
starter lever down.
NOTE:

If the engine fails to start by pushing the
start switch, release the switch, wait a
few seconds, and then try again. Each
starting attempt should be as short as
possible to preserve the battery. Do not
crank the engine more than 10 seconds
on any one attempt. If the engine does
not start with the starter motor, try using
the kickstarter.
6. After starting the engine, move the
starter (choke) back halfway.