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EAU10100 Welcome to the Yamaha world of motorcycling! As the owner of the TW200EW, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual.
TABLE OF CONTENTS SAFETY INFORMATION ....1-1 PRE-OPERATION CHECKS ....4-1 Spoke wheels ....... 6-16 Location of important labels .....1-5 Pre-operation check list ....4-2 Adjusting the clutch lever free play ..........6-16 DESCRIPTION ........2-1 OPERATION AND IMPORTANT Adjusting the brake lever free Left view ...........2-1 RIDING POINTS........
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TABLE OF CONTENTS Battery ...........6-27 Replacing the fuse ......6-30 Replacing the headlight bulb ..6-30 Replacing the tail/brake light bulb ..........6-32 Replacing a turn signal light bulb ..........6-33 Supporting the motorcycle .....6-33 Front wheel ........6-34 Rear wheel ........6-35 Troubleshooting ......6-37 Troubleshooting chart ....6-38 MOTORCYCLE CARE AND STORAGE ...........7-1 Care ..........7-1...
SAFETY INFORMATION EAU10311 TIONS. motorist’s blind spot. Many accidents involve inexperi- MOTORCYCLES SINGLE Safe riding enced operators. In fact, many op- TRACK VEHICLES. THEIR SAFE Always make pre-operation erators who have been involved in USE AND OPERATION ARE DEPEN- checks. Careful checks may help accidents do not even have a cur- DENT UPON THE USE OF PROPER prevent an accident.
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Modifications made to this motorcycle juries. The use of a safety helmet is the not approved by Yamaha, or the re- When loading within this weight limit, single most critical factor in the preven-...
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SAFETY INFORMATION Cargo accessory weight stallation and use of non-Yamaha the motorcycle due to aerody- should be kept as low and close to accessories. Use extreme caution namic effects. Wind may at- the motorcycle as possible. Make when selecting and installing any ac-...
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SAFETY INFORMATION refueling. a flammable source (e.g., a ker- Take care not to spill any gaso- osene heater, or near an open line on the engine or exhaust flame), otherwise it could catch system when refueling. fire. Never refuel while smoking or in When transporting the motorcycle the vicinity of an open flame.
SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
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SAFETY INFORMATION Before you operate this vehicle, read the owner’s manual. Prima di usare il veicolo, leggete il manuale di istruzioni. Lire le manuel du propri étaire avant d ’utiliser ce v éhicule. Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren. Antes de conducir este vehículo, lea el Manual del Propietario.
INSTRUMENT AND CONTROL FUNCTIONS EAU10460 EAU10710 To unlock the steering Main switch/steering lock LOCK Insert the key and turn it to “OFF”. The steering is locked, and all electrical EWA10070 systems are off. The key can be re- WARNING moved. Never turn the key to “LOCK”...
INSTRUMENT AND CONTROL FUNCTIONS EAU10980 EAU11080 EAU11630 Indicator lights Speedometer unit High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched 1. Speedometer 1. Turn signal indicator light “ ” 2.
INSTRUMENT AND CONTROL FUNCTIONS EAU12346 Right EAU12500 Handlebar switches Horn switch “ ” Press this switch to sound the horn. Left EAU12660 Engine stop switch “ ” Set this switch to “ ” before starting the engine. Set this switch to “ ”...
INSTRUMENT AND CONTROL FUNCTIONS EAU12820 EAU12870 EAU12890 Clutch lever Shift pedal Brake lever 1. Clutch lever 1. Shift pedal 1. Brake lever The clutch lever is located at the left The shift pedal is located on the left The brake lever is located at the right handlebar grip.
INSTRUMENT AND CONTROL FUNCTIONS EAU12941 EAU32280 NOTE: Brake pedal Fuel tank cap The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. EWA10120 WARNING Make sure that the fuel tank cap is...
WARNING Do not overfill the fuel tank, oth- With the lever in this position, fuel will Your Yamaha engine has been de- erwise it may overflow when the not flow. Always return the lever to this signed to use regular unleaded gaso- fuel warms up and expands.
INSTRUMENT AND CONTROL FUNCTIONS This indicates reserve. If you run out of EAU13600 Starter (choke) knob “ ” fuel 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”...
INSTRUMENT AND CONTROL FUNCTIONS EAU13660 EAU13970 Kickstarter Seat To remove the seat Remove the bolts, and then pull the seat off. 1. Projection 2. Seat holder 1. Kickstarter 2. Place the seat in the original posi- If the engine fails to start by pushing the tion, and then tighten the bolts.
Never ride with a helmet attached to will result in poor damping per- the helmet holder, since the helmet formance. may hit objects, causing loss of con- Always have a Yamaha dealer trol and possibly an accident. service the shock absorber.
Yamaha’s ignition circuit cut-off system has been designed to assist the operator in fulfilling the respon- sibility of raising the sidestand be- fore starting off. Therefore, check this system regularly as described below and have a Yamaha dealer re- 3-10...
Periodically check the operation of the ignition circuit cut-off system according to the following procedure. EWA10250 WARNING If a malfunction is noted, have a Yamaha dealer check the system be- fore riding. 3-11...
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5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.
PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
Adjust if necessary. Make sure that operation is smooth. Check cable free play. Throttle grip 6-13, 6-24 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. Make sure that operation is smooth. Control cables 6-24...
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Instruments, lights, signals Check operation. — and switches Correct if necessary. Check operation of ignition circuit cut-off system. Sidestand switch 3-10 If system is defective, have Yamaha dealer check vehicle. Check fluid level. Battery 6-27 Fill with distilled water if necessary.
OPERATION AND IMPORTANT RIDING POINTS EAU15950 EAU16530 should be on, otherwise have a Starting a cold engine Yamaha dealer check the electrical cir- EWA10270 In order for the ignition circuit cut-off cuit. WARNING system to enable starting, one of the 4.
OPERATION AND IMPORTANT RIDING POINTS starter (choke) off. EAU16640 EAU16671 Starting a warm engine Shifting NOTE: Follow the same procedure as for start- The engine is warm when it responds ing a cold engine with the exception normally to the throttle with the starter that the starter (choke) is not required (choke) turned off.
OPERATION AND IMPORTANT RIDING POINTS the neutral position, do not EAU16800 EAU16841 Tips for reducing fuel Engine break-in coast for long periods of time consumption There is never a more important period with the engine off, and do not in the life of your engine than the period tow the motorcycle for long dis- Fuel consumption depends largely on between 0 and 1600 km (1000 mi).
Yamaha dealer check the vehi- ans or children are not likely to cle. touch them. Do not park on a slope or on soft ground, otherwise the vehicle may overturn.
Yamaha dealer certain maintenance work correctly. do it for you. NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you.
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in- stead. From 30000 km, repeat the maintenance intervals starting from 6000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km)
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PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Check runout, spoke tightness and for damage. √ √ √ √ 10 * Wheels Tighten spokes if necessary. Check tread depth and for damage. Replace if necessary.
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PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK √ √ √ √ √ Moving parts and cables Lubricate. Check operation and free play. Throttle grip housing √ √ √ √ √ 27 * Adjust the throttle cable free play if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU18721 To install the cowling Removing and installing the Place the cowling in the original posi- cowling and panels tion, and then install the screw. The cowling and panels shown need to be removed to perform some of the EAU32451 maintenance jobs described in this Panel A...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU19603 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.
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Do not attempt to diagnose such problems yourself. In- Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) stead, have a Yamaha dealer check the vehicle. 2. Clean the surface of the spark plug 2. Check the spark plug for electrode...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU19792 to collect the used oil. NOTE: Engine oil and oil filter 3. Remove the engine oil filler cap The engine oil should be between the element and drain bolt to drain the oil from minimum and maximum level marks.
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PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil drain bolt 1. O-ring 1. Oil filter element cover 2. Compression spring 2. Bolt ECA11000 3. Oil strainer 3. Oil filter element drain bolt CAUTION: 5. Remove the oil filter element cover When removing the engine oil drain NOTE: by removing the bolts.
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PERIODIC MAINTENANCE AND MINOR REPAIR 7. Check the O-ring for damage and 13. Start the engine, and then let it idle Tightening torque: replace it if necessary. for several minutes while checking Engine oil drain bolt: 8. Clean the oil filter element with sol- it for oil leakage.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU20831 3. Pull the air filter element out. to the entire surface of the sponge Cleaning the air filter element 4. Remove the sponge material from material, and then squeeze the ex- and check hose the air filter element frame, clean it cess oil out.
Therefore, most car- checked and, if necessary, adjusted as buretor adjustments should be left to a follows at the intervals specified in the Yamaha dealer, who has the neces- periodic maintenance and lubrication sary professional knowledge and expe- chart.
The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. 1. Throttle stop screw Engine idling speed: 1350–1550 r/min...
(minimum tread depth), if the tire has a Check the condition and pressure of nail or glass fragments in it, or if the your tires. NEVER OVERLOAD sidewall is cracked, have a Yamaha YOUR MOTORCYCLE. Make sure 6-14...
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When a tire tread tires. begins to show crosswise lines, EWA10460 WARNING have a Yamaha dealer replace the tire immediately. The front and rear tires should The replacement of all wheel- be of the same make and de-...
3. Fully turn the adjusting bolt at the age before each ride. If any dam- clutch lever in direction (a) to loos- age is found, have a Yamaha en the clutch cable. dealer replace the wheel. Do not 4. Loosen the locknut at the crank- attempt even the smallest repair to case.
A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. If there is air in the hy- draulic system, have a Yamaha dealer bleed the system before 1. Locknut operating the motorcycle. Air in 2.
EWA10670 2. Adjusting bolt WARNING direction (a). To decrease the brake 3. Brake pedal position It is advisable to have a Yamaha pedal free play, turn the adjusting nut in 3. Tighten the locknut. dealer make these adjustments. direction (b).
If proper adjustment cannot be on just before braking takes effect. If obtained as described, have a necessary, adjust the brake light switch Yamaha dealer make this ad- 1. Brake pad wear indicator groove justment. as follows. Each front brake pad is provided with...
EAU32343 Checking the front brake fluid peared, have a Yamaha dealer replace level the brake pads as a set. Insufficient brake fluid may allow air to enter the brake system, possibly caus-...
EAU22720 Changing the brake fluid handlebars. Have a Yamaha dealer change the Use only the recommended quality brake fluid at the intervals specified in brake fluid, otherwise the rubber the NOTE after the periodic mainte- seals may deteriorate, causing nance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. EAU22771 To check the drive chain slack 1. Place the motorcycle on the side- stand. NOTE: 1. Drive chain slack 1.
NOTE: brake light. For a thorough cleaning, have a Yamaha 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...
If a cable is damaged maintenance chart. or does not move smoothly, have a Yamaha dealer check or replace it. Recommended lubricant: Engine oil The operation of the brake and shift...
Recommended lubricant: EWA10730 Lithium-soap-based grease (all-pur- WARNING Recommended lubricant: pose grease) If the sidestand does not move up Lithium-soap-based grease and down smoothly, have a Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-pur- pose grease) 6-25...
Check the inner tubes for scratches, fork does not operate smoothly, Securely support the vehicle so that damage and excessive oil leakage. have a Yamaha dealer check or re- there is no danger of it falling over. pair it. To check the operation 2.
Yamaha dealer check tervals specified in the periodic mainte- the wheel bearings. nance and lubrication chart.
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PERIODIC MAINTENANCE AND MINOR REPAIR of water. INTERNAL: Drink large quan- tities of water or milk and im- mediately call a physician. EYES: Flush with water for 15 minutes and seek prompt medical attention. Batteries produce explosive hy- drogen gas. Therefore, keep sparks, flames, cigarettes, etc., 1.
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PERIODIC MAINTENANCE AND MINOR REPAIR tive (-) terminal. ages. 11. Install the seat. To store the battery 1. If the vehicle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. 2.
2. Remove the headlight unit by re- 4. If the fuse immediately blows 2. Remove the blown fuse, and then moving the bolts. again, have a Yamaha dealer install a new fuse of the specified check the electrical system. amperage.
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PERIODIC MAINTENANCE AND MINOR REPAIR and fingerprints on the headlight bulb using a cloth moistened with al- cohol or thinner. 1. Headlight coupler 1. Headlight bulb holder 2. Headlight bulb cover EWA10790 WARNING 4. Remove the headlight bulb holder by turning it counterclockwise, and Headlight bulbs get very hot.
PERIODIC MAINTENANCE AND MINOR REPAIR 8. Install the cowling. EAU24131 Replacing the tail/brake light 9. Have a Yamaha dealer adjust the bulb headlight beam if necessary. 1. Remove the tail/brake light lens by removing the screws. 1. Tail/brake light bulb 3.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24210 EAU24350 ECA10680 Replacing a turn signal light Supporting the motorcycle CAUTION: bulb Since this model is not equipped with a Do not overtighten the screws, oth- centerstand, follow these precautions 1. Remove the turn signal lens by re- erwise the lens may break.
To remove the front wheel the wheel. EWA10820 ECA11070 WARNING CAUTION: It is advisable to have a Yamaha Do not apply the brake after the dealer service the wheel. wheel has been removed together Securely support the motorcy- with the brake disc, otherwise the cle so that there is no danger of brake pads will be forced shut.
EWA10820 ing the brake disc and that the slot in WARNING the speedometer gear unit fits over the It is advisable to have a Yamaha retainer on the fork leg. dealer service the wheel. Securely support the motorcy- cle so that there is no danger of it falling over.
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PERIODIC MAINTENANCE AND MINOR REPAIR EAU25761 fied torque. To install the rear wheel 1. Insert the wheel axle from the Tightening torque: Axle nut: left-hand side. 90 Nm (9.0 m·kgf, 65 ft·lbf) NOTE: Make sure that the drive chain adjust- 5.
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.
Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.
MOTORCYCLE CARE AND STORAGE EAU26001 ucts onto seals, gaskets, sprock- cleaning products, solvent or Care ets, the drive chain and wheel thinner, fuel (gasoline), rust re- While the open design of a motorcycle axles. Always rinse the dirt and de- movers or inhibitors, brake flu- reveals the attractiveness of the tech- greaser off with water.
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MOTORCYCLE CARE AND STORAGE After normal use salt. 7. Wax all painted surfaces. Remove dirt with warm water, a mild 8. Let the motorcycle dry completely 2. Apply a corrosion protection spray detergent, and a soft, clean sponge, before storing or covering it. on all metal, including chrome- and and then rinse thoroughly with clean EWA11130...
EAU26150 “OFF”. Storage NOTE: 3. Drain the carburetor float chamber Consult a Yamaha dealer for advice on by loosening the drain bolt; this will what products to use. Short-term prevent fuel deposits from building Always store your motorcycle in a cool, up.
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MOTORCYCLE CARE AND STORAGE install the spark plug and the than 0 °C (30 °F) or more than spark plug cap. 30 °C (90 °F)]. For more informa- EWA10950 tion on storing the battery, see WARNING page 6-27. To prevent damage or injury from NOTE: sparking, make sure to ground the Make any necessary repairs before...
Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1.
This in- The use of the vehicle after such formation will be needed when ordering device or element of design has spare parts from a Yamaha dealer. been removed or rendered inoper- ative by any person.
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INDEX Engine, starting a warm......5-2 Part locations ..........2-1 Engine stop switch ........3-3 Periodic maintenance and lubrication Air filter element and check hose, chart ............6-2 cleaning ..........6-11 Pre-operation check list......4-2 Front fork, checking......... 6-26 Fuel ............3-6 Battery .............6-27 Fuel cock ...........
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INDEX Turn signal light bulb, replacing ....6-33 Turn signal switch ........3-3 Valve clearance ........6-13 Vehicle identification number ....9-1 Wheel bearings, checking....... 6-27 Wheel (front) ........... 6-34 Wheel (rear) ..........6-35 Wheels ............ 6-16...
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YAMAHA MOTOR CO., LTD. YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED ON RECYCLED PAPER PRINTED IN JAPAN PRINTED IN JAPAN 2006.6–0.1×1 ! 2006.6–0.1×1 !
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