maintenance YAMAHA TW200 2005 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2005, Model line: TW200, Model: YAMAHA TW200 2005Pages: 80, PDF Size: 2.6 MB
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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
Page 7 of 80
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-
Page 33 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
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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
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EAU17710
Periodic maintenance and lubrication chart
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
From 30,000 km, repeat the maintenance intervals starting from 6,000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1,000 km)
ANNUAL
CHECK
1 6 12 18 24
1*
Fuel line
Check fuel hoses for cracks or damage.
√
√
√
√
√
2
Spark plug
Check condition.
Clean and regap.
√
√
Replace.
√
√
3*
Valves
Check valve clearance.
Adjust.
√
√
√
√
4
Air filter element
Clean.
√
√
Replace.
√
√
5*
Battery
Check electrolyte level and specific gravity.
Make sure that the breather hose is properly routed.
√
√
√
√
√
6
Clutch
Check operation.
Adjust.
√
√
√
√
√
7*
Front brake
Check operation, fluid level and vehicle for fluid leak-
age. (See NOTE following this chart.)
√
√
√
√
√
√
Replace brake pads. Whenever worn to the limit
8*
Rear brake
Check operation and adjust brake pedal free play.
√
√
√
√
√
√
Replace brake shoes. Whenever worn to the limit
9*
Brake hose
Check for cracks or damage.
√
√
√
√
√
Replace. (See NOTE following this chart.) Every 4 years
Page 35 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
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2
3
4
5
6
7
8
9
10
*
Wheels
Check runout, spoke tightness and for damage.
Tighten spokes if necessary.
√
√
√
√
11
*
Tires
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
√
√
√
√
√
12
*
Wheel bearings
Check bearing for looseness or damage.
√
√
√
√
13
*
Swingarm
Check operation and for excessive play.
√
√
√
√
Lubricate with lithium-soap-based grease. Every 24,000 km
14
Drive chain
Check chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.Every 500 km and after washing the motorcycle or
riding in the rain
15
*
Steering bearings
Check bearing play and steering for roughness.
√
√
√
√
√
Lubricate with lithium-soap-based grease. Every 24,000 km
16
*
Chassis fasteners
Make sure that all nuts, bolts and screws are properly
tightened.
√
√
√
√
√
17
Sidestand
Check operation.
Lubricate.
√
√
√
√
√
18
*
Sidestand switch
Check operation.
√
√
√
√
√
√
19
*
Front fork
Check operation and for oil leakage.
√
√
√
√
20
*
Shock absorber assem-
bly
Check operation and shock absorber for oil leakage.
√
√
√
√
21
*
Carburetor
Check starter (choke) operation.
Adjust engine idling speed.
√
√
√
√
√
√
22
Engine oil
Change.
Check oil level and vehicle for oil leakage.
√
√
√
√
√
√
23
Engine oil filter element
Clean.
√
√
√
24
*
Engine oil strainer
Clean.
√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1,000 km)
ANNUAL
CHECK
1 6 12 18 24
Page 36 of 80
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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
Page 37 of 80
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8
9
EAU18720
Removing and installing the
cowling and panels
The cowling and panels shown above
need to be removed to perform some ofthe maintenance jobs described in this
chapter. Refer to this section each time
the cowling or a panel needs to be re-
moved and installed.
EAU18810
Cowling A
To remove the cowling
Remove the screw, and then pull the
cowling off as shown.
To install the cowlingPlace the cowling in the original posi-
tion, and then install the screw.
EAU32451
Panel A
To remove the panel
Remove the screws, and then pull the
panel out at the area shown.To install the panel
Place the panel in the original position,
and then install the screws.
Panel B
To remove the panelPull the panel off as shown.
1. Cowling A
2. Panel A
1. Panel B
12
1
1. Screw
1
1. Panel A
2. Screw
2(×2)
1
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To install the panel
Place the panel in the original position.
EAU19601
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
NOTE:
If the spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the vehicle.
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
1. Panel B
1
1. Spark plug cap
1
1. Spark plug wrench
1
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necessary.
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from thespark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
4. Install the spark plug cap.
EAU19792
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment cleaned at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-right side of the Specified spark plug:
NGK/DR8EA
DENSO/X24ESR-U
1. Spark plug gap
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
1
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf,
12.5 ft·lbf)
Page 40 of 80
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crankcase.
NOTE:
The engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
To change the engine oil (with or
without oil filter element cleaning)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engineto collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
CAUTION:
ECA11000
When removing the engine oil drain
bolt, the O-ring, compression
spring, and oil strainer will fall out.
Take care not to lose these parts.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
2
3 1
1. Engine oil filler cap
1
1. Engine oil drain bolt
1