YAMAHA TW200E Manuals

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Yamaha TW200E Service Manual

Yamaha TW200E Service Manual (276 pages)

274 Pgs + 2 flo

Brand: Yamaha | Category: Motorcycle | Size: 47.88 MB

Table of Contents

Table of Contents
8
Chapter 1 General Information

15
- Motorcycle Identification
  15
  - Vehicle Identification Number
    15
  - Engine Serial Number
    15
- Important Information
  16
  - PREPARATION for REMOVAL and Disassembly
    16
  - All Replacement Parts
    17
  - Gaskets, Oil Seals, and O-Rings
    17
  - Lock Washers/Plates and Cotter Pins
    17
  - Bearings and Oil Seals
    17
  - Circlips
    18
- Special Tools
  18
  - For Tune-Up
    18
  - For Engine Service
    19
  - For Chassis Service
    21
  - For Electrical Components
    22
Chapter 2 Specifications

23
- GENERAL Specifications
  23
- Maintenance Specifications
  26
  - Engine
    26
  - Chassis
    33
  - Electrical
    36
- General Torque Specifications
  38
- Definition of Units
  38
- Lubrication Points and Type of Lubricants
  39
  - Engine
    39
  - Chassis
    40
- Lubrication Diagrams
  41
- Cable Routing
  43
Chapter 3 Periodic Inspection and Adjustment

47
- Introduction
  47
- Periodic Maintenance/Lubrication Intervals
  47
- Engine
  49
  - Valve Clearance Adjustment
    49
  - Cam Chain Adjustment
    51
  - Idle Speed Adjustment
    52
  - Throttle Cable Free Play Adjustment
    53
  - Spark Plug Inspection
    54
  - Ignition Timing Check
    55
  - Compression Pressure Measurement
    56
  - Engine Oil Level Inspection
    57
  - Engine Oil Replacement
    58
  - Clutch Adjustment
    61
  - Air Filter Cleaning
    63
  - Carburetor Joint Inspection
    64
  - Fuel Line Inspection
    65
  - Crankcase Ventilation Hose Inspection
    65
  - Exhaust System Inspection
    65
- Chassis
  65
  - Front Brake Adjustment
    65
  - Rear Brake Adjustment
    66
  - Brake Shoe Inspection
    67
  - Brake Light Switch Adjustment
    67
  - Drive Chain Slack Adjustment
    67
  - DRIVE CHAIN Lubrication
    68
  - Steering Head Adjustment
    69
  - Front Fork Oil Replacement
    70
  - Tire Inspection
    72
  - Wheel Inspection
    73
  - Spoke Inspection and Tightening
    73
  - CABLE INSPECTION and Lubrication
    74
- Electrical
  75
  - Battery Inspection
    75
  - Fuse Inspection
    77
  - Headlight Beam Adjustment
    78
  - Headlight Bulb Replacement
    79
Chapter 4 Engine Overhaul

81
- Engine Removal
  81
  - Fuel Tank
    81
  - Exhaust Pipe and Engine Guard
    81
  - Crankcase Cover (Left)
    82
  - Drive Sprocket
    82
  - Carburetor
    83
  - Wiring and Cables
    83
  - Engine Removal
    83
- Disassembly
  85
  - Cylinder Head
    85
  - Cylinder
    86
  - Piston
    87
  - Clutch
    111
  - Oil Pump
    112
  - Oil Pump
    113
  - Primary Drive
    113
  - Transmission and Shifter
    113
  - Kick Starter
    114
  - Crankshaft
    115
  - Starter Drive
    115
  - Balancer Drive Gear and Balancer Gear
    116
  - Bearing and Oil Seal
    117
  - Crankcase
    117
- Engine Assembly and Adjustment
  120
  - Balancer and Crankshaft
    124
  - Transmission and Shifter
    124
  - Crankcase (Left)
    125
  - Col MAGNETO
    127
  - Shift Shaft
    129
  - Kick Axle
    132
  - Primary Drive Gear and Balancer Gear
    133
  - Oil Pump
    134
  - Starter Motor
    134
  - Clutch
    135
  - Piston
    140
  - Cylinder Head
    142
  - Remounting Engine
    146
Chapter 5 Carburetion

149
- Carburetor
  149
  - Disassembly
    150
  - Inspection
    153
  - Assembly
    154
  - Installation
    156
  - Fuel Level Adjustment
    157
Chapter 6 Chassis

159
- Front Wheel
  159
  - Removal
    160
  - Inspection
    160
  - Installation
    163
- Rear Wheel
  165
  - Removal
    166
  - Inspection
    166
  - Installation
    167
- Front Fork
  169
  - Removal
    170
  - Disassembly
    171
  - Inspection
    172
  - Assembly
    173
  - Installation
    176
- Steering and Handlebar
  177
  - Removal
    178
  - Inspection
    179
  - Installation
    180
- Rear Shock Absorber and Swingarm
  183
  - Handling Notes
    184
  - Notes on Disposal
    184
  - Removal
    185
  - Disassembly
    187
  - Inspection
    187
  - Assembly
    189
  - Installation
    189
- Drive Chain and Sprockets
  191
  - Removal
    191
  - Inspection
    191
  - Installation
    192
Chapter 7 Electrical

196
- Tw200T/Tc Circuit Diagram
  196
- Electrical Components
  198
- Ignition System
  200
  - Circuit Diagram
    200
  - Troubleshooting
    202
- Electrical Starting Systeme
  210
  - Circuit Diagram
    210
  - Troubleshooting
    212
  - Starter Motor
    214
- Charging System
  222
  - Circuit Diagram
    222
  - Troubleshooting
    224
- Lighting System
  226
  - Circuit Diagram
    226
  - Troubleshooting
    228
- Signal Systeme
  230
  - Circuit Diagram
    230
  - Switches Test
    238
  - Troubleshooting
    239
- Starting Failure/Hard Starting
  239
Chapter 8

239
- Fuel System
  239
- Electrical System
  240
- Compression System
  241
- Poor Idle Speed Performance
  241
- Poor Medium and High Speed Performance
  242
- Faulty Gear Shifting
  243
  - Hard Shifting
    243
  - Ctiange PEDAL DOES NOT MOVE
    243
  - Jump-Out Gear
    243
- Clutch Slipping/Dragging
  244
  - Clutch Slipping
    244
  - Clutch Dragging
    244
- Improper Kicking
  245
  - Slipping
    245
  - Hard Kicking
    245
  - Kick Crank Not Returning
    245
- Faulty Brake
  246
  - Poor Braking Effect
    246
- Malfunction
  246
  - Oil Leakage
    246
- Instable Handling
  247
  - General Information
    257
  - Motorcycle Identification
    257
  - Vehicle Identification Number
    257
  - Engine Serial Number
    257
  - Specifications
    258
  - General Specifications
    258
  - Maintenance Specifications
    259
  - Electrical
    261
  - Tw200Eu/Euc Circuit Diagram
    261
  - Charging System
    263
  - Lighting System
    267

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Yamaha TW200E Service Manual

Yamaha TW200E Service Manual (277 pages)

Brand: Yamaha | Category: Motorcycle | Size: 46.95 MB

Table of Contents

Illustrated Symbols
6
Index
7
Contents
8
General Information
15
Motorcycle Identification
15
Vehicle Identification Number
15
Engine Serial Number
15
Important Information
16
Preparation for Removal and Disassembly
16
All Replacement Parts
17
Gaskets, Oil Seals, and O-Rings
17
Lock Washers/Plates and Cotter Pins
17
Bearings and Oil Seals
17
Special Tools
18
Circlips
18
For Tune-Ups
18
For Engine Service
19
For Chassis Service
21
For Electrical Components
22
General Specifications
23
Maintenance Specifications
26
Tightening Torque
31
General Torque Specifications
38
Definition of Units
38
Lubrication Points and Type of Lubricants
39
Lubrication Diagrams
41
Cable Routing
43
Periodic Inspection and Adjustment
47
Periodic Maintenance/Lubrication Intervals
47
Engine
49
Valve Clearance Adjustment
49
Cam Chain Adjustment
51
Idle Speed Adjustment
52
Throttle Cable Free Play Adjustment
53
Spark Plug Inspection
54
Ignition Timing Check
55
Compression Pressure Measurement
56
Engine Oil Level Inspection
57
Engine Oil Replacement Without Oil Filter Change
58
Engine Oil Replacement with Oil Filter Change
59
Drain Plug
60
Recommended Engine Oil
60
Clutch Adjustment
61
Free Play Adjustment
61
Mechanism Adjustment
61
Air Filter Cleaning
63
Carburetor Joint Inspection
64
Fuel Line Inspection
65
Crankcase Ventilation Hose Inspection
65
Exhaust System Inspection
65
Chassis Front Brake Adjustment
65
Rear Brake Adjustment
66
Brake Shoe Inspection
67
Brake Light Switch Adjustment
67
Drive Chain Slack Adjustment
67
Drive Chain Lubrication
68
Steering Head Adjustment
69
Front Fork Oil Replacement
70
Tire Inspection
72
Recommended Tire
72
Wheel Inspection
73
Spoke Inspection and Tightening
73
Cable Inspection and Lubrication
74
Recommended Lubricant
74
Electrical
75
Battery Inspection
75
Fuse Inspection
77
Headlight Beam Adjustment
78
Headlight Bulb Replacement
78
Engine Overhaul
81
Engine Removal
81
Exhaust Pipe and Engine Guard
81
Crankcase Cover (Left)
82
Drive Sprocket
82
Carburetor
83
Wiring and Cables
83
Disassembly
85
Cylinder Head
85
Cylinder
86
Piston
87
Clutch
88
Starter Motor
89
Oil Pump
90
Primary Drive Gear and Balancer Gear
90
Kick Axle
91
Shift Shaft
92
CDI Magneto
93
Cam Chain and Cam Chain Guide (Intake)
94
Crankcase (Left)
94
Shifter and Transmission
95
Balancer and Crankshaft
96
Valve, Rocker Arm and Camshaft
96
Inspection and Repair
99
Valve and Valve Guide
100
Valve Seat
102
Valve Seat Refacing Steps
103
Valve Spring
105
Camshaft
106
Rocker Arm and Rocker Arm Shaft
106
Cam Chain and Cam Sprocket
107
Cam Chain Guide
108
Cylinder and Piston
108
Piston-To-Cylinder Clearance Measurement
108
Piston-To-Cylinder Clearance
109
Piston Ring
110
Piston Pin
111
Primary Drive
113
Transmission and Shifter
113
Kick Starter
114
Crankshaft
115
Starter Drive
115
Balancer Drive Gear and Balancer Gear
116
Bearing and Oil Seal
117
Crankcase
117
Engine Assembly and Adjustment
118
Crankshaft, Balancer and Crankcase
121
Transmission
122
Shifter
123
Cam Chain and Cam Chain Guide
128
Shift Shaft and Kick Axle
130
Primary Drive Gear, Balancer Gear and Oil Pump
131
Piston and Cylinder
139
Remounting Engine
146
Carburetion
149
Carburetor Specifications
149
Carburetor Removal
150
Carburetor Disassembly
150
Carburetor Inspection
153
Carburetor Assembly
154
Carburetor Installation
156
Fuel Level Adjustment
157
Chassis
159
Front Wheel
159
Front Wheel Removal
160
Front Wheel Inspection
160
Front Wheel Installation
163
Rear Wheel
165
Rear Wheel Removal
166
Rear Wheel Inspection
166
Rear Wheel Installation
167
Front Fork
169
Front Fork Removal
170
Front Fork Disassembly
171
Front Fork Inspection
172
Front Fork Assembly
173
Front Fork Installation
176
Steering and Handlebar
177
Steering and Handlebar Removal
178
Steering and Handlebar Inspection
179
Steering and Handlebar Installation
180
Rear Shock Absorber and Swingarm
183
Rear Shock Absorber and Swingarm Handling Notes
184
Rear Shock Absorber and Swingarm Notes on Disposal
184
Rear Shock Absorber Removal
185
Swingarm Removal
186
Rear Shock Absorber and Swingarm Disassembly
187
Rear Shock Absorber and Swingarm Inspection
187
Side Clearance Adjustment Steps
187
Rear Shock Absorber and Swingarm Assembly
189
Swingarm Installation
189
Rear Shock Absorber Installation
190
Drive Chain and Sprockets Removal
191
Drive Chain and Sprockets Inspection
191
Drive Chain and Sprockets Installation
192
TW200T/TC Circuit Diagram
196
Electrical Components
198
Ignition System Circuit Diagram
200
Ignition System Troubleshooting
202
Electrical Starting System Circuit Diagram
210
Electrical Starting System Troubleshooting
212
Electrical Starting System Starting Circuit Operation
215
Electrical Starting System Starter Motor
216
Charging System Circuit Diagram
222
Charging System Troubleshooting
224
Lighting System Circuit Diagram
226
Lighting System Troubleshooting
228
Signal System Circuit Diagram
230
Signal System Troubleshooting
232
Signal System Switches Test
238
Troubleshooting
239
Starting Failure/Hard Starting
239
Poor Idle Speed Performance
241
Poor Medium and High Speed Performance
242
Faulty Gear Shifting
243
Clutch Slipping/Dragging
244
Improper Kicking
245
Faulty Brake
246
Front Fork Oil Leakage and Front Fork Malfunction
246
Instable Handling
247
Faulty Signal and Lighting System
248
TW200EU/EUC Circuit Diagram
261
TW200EU/TW200EUC Wiring Diagram
274
TW200T/TC Wiring Diagram
275

YAMAHA TW200E Owner's Manual

YAMAHA TW200E Owner's Manual (80 pages)

2003

Brand: YAMAHA | Category: Motorcycle | Size: 2.86 MB

Table of Contents

Important Manual Information
3
Table of Contents
5
Safety Information
7
Description
11
Left View
11
Right View
12
Controls and Instruments
13
Instrument and Control Functions
14
Main Switch/Steering Lock
14
Speedometer Unit
15
Indicator Lights
15
Handlebar Switches
16
Clutch Lever
17
Shift Pedal
17
Brake Lever
17
Brake Pedal
18
Fuel Tank Cap
18
Fuel
19
Fuel Cock
19
Starter (Choke) Knob "1
20
Seat
21
Kickstarter
21
Shock Absorber
22
Carrier
22
Helmet Holder
22
Luggage Strap Holders
23
Sidestand
23
Ignition Circuit Cut-Off System
24
Pre-Operation Checks
26
Pre-Operation Check List
27
Operation and Important Riding Points
29
Starting a Cold Engine
29
Shifting
30
Starting a Warm Engine
30
Tips for Reducing Fuel
31
Consumption
31
Engine Break-In
31
Parking
32
Periodic Maintenance and Minor Repair
33
Owner's Tool Kit
33
Periodic Maintenance and Lubrication Chart
34
Removing and Installing the Cowling and Panels
37
Checking the Spark Plug
38
Element
39
Cleaning the Air Filter Element and Check Hose
42
Adjusting the Carburetor
44
Adjusting the Engine Idling Speed
44
Adjusting the Throttle Cable Free Play
45
Adjusting the Valve Clearance
45
Tires
45
Spoke Wheels
48
Adjusting the Clutch Lever Free Play
48
Adjusting the Brake Lever Free Play
49
Adjusting the Brake Pedal Position and Free Play
50
Adjusting the Rear Brake Light Switch
51
Checking the Front Brake Pads and Rear Brake Shoes
51
Checking the Brake Fluid Level
52
Changing the Brake Fluid
53
Drive Chain Slack
53
Lubricating the Drive Chain
55
Checking and Lubricating the Cables
55
Checking and Lubricating the Brake and Shift Pedals
56
Checking and Lubricating the Brake and Clutch Levers
56
Checking and Lubricating the Throttle Grip and Cable
56
Checking the Front Fork
57
Lubricating the Rear
57
Suspension
57
Checking and Lubricating the Sidestand
57
Checking the Steering
58
Checking the Wheel Bearings
59
Battery
59
Replacing the Fuse
61
Replacing the Headlight Bulb
62
Replacing the Tail/Brake Light Bulb
64
Replacing a Turn Signal Light Bulb
64
Supporting the Motorcycle
65
Front Wheel
66
Rear Wheel
67
Troubleshooting
68
Troubleshooting Chart
69
Motorcycle Care and Storage
70
Care
70
Storage
72
Specifications
74
Consumer Information
77
Identification Numbers
77

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YAMAHA TW200E Owner's Manual

YAMAHA TW200E Owner's Manual (74 pages)

1997

Brand: YAMAHA | Category: Motorcycle | Size: 1.65 MB

Table of Contents

Important Manual Information
3
Table of Contents
6
2 Description

9
- Left View
  9
- Right View
  10
- Controls/Instruments
  11
3 Instrument and Control Functions

12
- Main Switch/Steering Lock
  12
- Indicator Lights
  13
- Speedometer
  13
- Handlebar Switches
  14
- Clutch Lever
  15
- Shift Pedal
  15
- Front Brake Lever
  16
- Rear Brake Pedal
  16
- Fuel Tank Cap
  16
- Fuel
  17
- Fuel Cock
  18
- Starter(Choke) "1
  19
- Kick Starter
  19
- Seat
  20
- Helmet Holder
  20
- Rear Shock Absorber
  21
- Rear Carrier
  21
- Sidestand
  21
- Sidestand/Clutch Switch Operation Check
  22
4 Pre-Operation Checks

23
- Pre-Operation Check List
  23
5 Operation and Important Riding Points

25
- Starting and Warming up a Cold Engine
  25
- Starting a Warm Engine
  28
- Shifting
  28
- Engine Break-In
  29
- Parking
  30
6 Periodic Maintenance and Minor Repair

31
- Tool Kit
  31
- Periodic Maintenance and Lubrication
  33
- Cowling and Panel Removal and Installation
  36
- Cowling a
  36
- Panel a
  37
- Panel B
  37
- Spark Plug Inspection
  37
- Engine Oil
  38
- Air Filter
  42
- Carburetor Adjustment
  43
- Idle Speed Adjustment
  43
- Throttle Cable Free Play Inspection
  44
- Cam Chain Adjustment
  44
- Valve Clearance Adjustment
  44
- Tires
  45
- Wheels
  47
- Clutch Lever Free Play Adjustment
  48
- Front Brake Lever Free Play Adjustment
  48
- Rear Brake Pedal Height and Free Play Adjustment
  49
- Brake Light Switch Adjustment
  50
- Checking the Brake Shoes
  51
- Drive Chain Slack Check
  51
- Drive Chain Slack Adjustment
  52
- Drive Chain Lubrication
  53
- Cable Inspection and Lubrication
  54
- Throttle Cable and Grip Lubrication
  54
- Brake and Shift Pedal Lubrication
  54
- Brake and Clutch Lever Lubrication
  55
- Sidestand Lubrication
  55
- Rear Suspension Lubrication
  55
- Front Fork Inspection
  56
- Steering Inspection
  56
- Wheel Bearings
  57
- Battery
  57
  - Fuse Replacement
    59
  - Headlight Bulb Replacement
    60
  - Supporting the Motorcycle
    61
  - Front Wheel Removal
    61
  - Front Wheel Installation
    62
  - Rear Wheel Removal
    63
  - Rear Wheel Installation
    63
  - Troubleshooting
    64
  - Troubleshooting Chart
    65
7 Cleaning and Storage

66
- Cleaning
  66
- Storage
  67
8 Specifications

68
- How to Use the Conversion Table
  71
9 Consumer Information

72
- Identification Numbers Record
  72
- Key Identification Number
  72
- Vehicle Identification Number
  72
- Model Label
  73

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