service YAMAHA TW200 2004 Owners Manual

1-1
1
SAFETY INFORMATION
EAU10310
MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE
USE AND OPERATION ARE DEPEN-
DENT UPON THE USE OF PROPER
RIDING TECHNIQUES AS WELL AS
THE EXPERTISE OF THE OPERA-
TOR. EVERY OPERATOR SHOULD
KNOW THE FOLLOWING REQUIRE-
MENTS BEFORE RIDING THIS MO-
TORCYCLE.
HE OR SHE SHOULD:

OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.

OBSERVE THE WARNINGS
AND MAINTENANCE REQUIRE-
MENTS IN THE OWNER’S MAN-
UAL.

OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.

OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECES-SARY BY MECHANICAL CONDI-
TIONS.
Safe riding

Always make pre-operation
checks. Careful checks may help
prevent an accident.

This motorcycle is designed to car-
ry the operator and a passenger.

The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.

Therefore:

Wear a brightly colored jacket.

Use extra caution when ap-
proaching and passing through
intersections, since intersec-
tions are the most likely places
for motorcycle accidents to oc-
cur.

Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.

Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent motorcycle license.

Make sure that you are qualified
and that you only lend your mo-
torcycle to other qualified opera-
tors.

Know your skills and limits.
Staying within your limits may
help you to avoid an accident.

We recommend that you prac-
tice riding your motorcycle
where there is no traffic until you
have become thoroughly famil-
iar with the motorcycle and all of
its controls.

Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
erator is veering wide on a turn
due to EXCESSIVE SPEED or un-

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

EAU14280
Helmet holder
To open the helmet holder, insert the
key into the lock, and then turn the key
as shown.
To lock the helmet holder, place it in the
original position, and then remove the
key.
WARNING

EWA10160
Never ride with a helmet attached to
the helmet holder, since the helmet
may hit objects, causing loss of con-
trol and possibly an accident.
EAU15090
Shock absorber
WARNING

EWA10220
This shock absorber contains highly
pressurized nitrogen gas. For prop-
er handling, read and understand
the following information before
handling the shock absorber. The
manufacturer cannot be held re-
sponsible for property damage or
personal injury that may result from
improper handling.

Do not tamper with or attempt to
open the gas cylinder.

Do not subject the shock ab-
sorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.

Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping per-
formance.

Always have a Yamaha dealer
service the shock absorber.
EAU15110
Carrier
WARNING

EWA10170

Do not exceed the load limit of
3 kg (7 lb) for the carrier.

Do not exceed the maximum
load of 180 kg (397 lb) for the ve-
hicle.
1. Helmet holder
1

1. Carrier
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
1
2
3
4
5
6
7
8
9

EAU17240
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING

EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
EAU17340
Owner’s tool kit
The owner’s tool kit is located behind
panel B. (See page 6-5.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
WARNING

EWA10350
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es.
1. Owner’s tool kit
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
2
3
4
5
67
8
9

EAU18660
NOTE:


The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.

Replace the brake hoses every four years and if cracked or damaged.
25

*
Front and rear brake
switches

Check operation.
√

√

√

√

√

√


26

Moving parts and cables

Lubricate.
√

√

√

√

√


27

*
Throttle grip housing
and cable

Check operation and free play.

Adjust the throttle cable free play if necessary.

Lubricate the throttle grip housing and cable.
√

√

√

√

√


28

*
Lights, signals and
switches

Check operation.

Adjust headlight beam.
√

√

√

√

√

√

NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1,000 km)
ANNUAL
CHECK
1 6 12 18 24

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
1
2
3
4
5
6
7
8
9

EAU23010
Lubricating the drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the General maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
CAUTION:

ECA10580
The drive chain must be lubricated
after washing the motorcycle or
riding in the rain.
1. Remove all dirt and mud from the
drive chain with a brush or cloth.
NOTE:

For a thorough cleaning, have a Yama-
ha dealer remove the drive chain and
soak it in solvent.
2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on both sides
and on the middle of the chain,
making sure that all side plates
and rollers have been sufficientlyoiled.
EAU23100
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING

EWA10720
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.
Recommended lubricant:
Engine oil

PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
1
2
3
4
5
6
7
8
9
CAUTION:

ECA10680
Do not overtighten the screws, oth-
erwise the lens may break.
EAU24350
Supporting the motorcycle
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
a jack either under each side of theframe in front of the rear wheel or under
each side of the swingarm.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
2
3
4
5
67
8
9

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
6-35
1
2
3
4
5
6
7
8
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
6-36
2
3
4
5
67
8
9
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.

SPECIFICATIONS
8-1
2
3
4
5
6
7
89

EAU26332
Dimensions:
Overall length:
2090 mm (82.3 in)
Overall width:
820 mm (32.3 in)
Overall height:
1120 mm (44.1 in)
Seat height:
790 mm (31.1 in)
Wheelbase:
1325 mm (52.2 in)
Ground clearance:
265 mm (10.43 in)
Minimum turning radius:
1900 mm (74.8 in)
Weight:
With oil and fuel:
126.0 kg (278 lb)
Engine:
Engine type:
Air cooled 4-stroke, SOHC
Cylinder arrangement:
Forward inclined single cylinder
Displacement:
196.0 cm
3

(11.96 cu.in)
Bore
×
stroke:
67.0
×
55.7 mm (2.64
×
2.19 in)
Compression ratio:
9.50 :1
Starting system:
Electric and kick starter
Lubrication system:
Wet sump

Engine oil:
Type:
YAMALUBE 4, SAE10W30 or SAE20W40
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Without oil filter element removal:
1.00 L (1.06 US qt) (0.88 Imp.qt)
With oil filter element removal:
1.10 L (1.16 US qt) (0.97 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
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)
Carburetor:
Manufacturer:
TEIKEI
Type x quantity:
MV28 x 1
Spark plug(s):
Manufacturer/model:
NGK/DR8EA
Manufacturer/model:
DENSO/X24ESR-U
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Wet, multiple-disc
Transmission:
Primary reduction system:
Spur gear
Primary reduction ratio:
73/22 (3.318)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
50/14 (3.571)
Transmission type:
Constant mesh 5-speed
Operation:
Left foot operation
Gear ratio:
1st:
34/12 (2.833)
2nd:
34/19 (1.789)
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40