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Welcome to the Yamaha world of motorcycling! As the owner of the TW200E, you are benefiting from Yamaha’s vast experience and newest technology regarding the de- sign and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
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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 ....... 6-15 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 Replacing the fuse ......6-29 Replacing the headlight bulb ..6-30 Replacing the tail/brake light bulb ..........6-32 Replacing a turn signal light bulb ..........6-32 Supporting the motorcycle .....6-33 Front wheel ........6-34 Rear wheel ........6-35 Troubleshooting ......6-36 Troubleshooting chart ....6-37 MOTORCYCLE CARE AND STORAGE ...........7-1 Care ..........7-1...
SAFETY INFORMATION EAU10310 SARY BY MECHANICAL CONDI- Ride where other motorists can MOTORCYCLES SINGLE TIONS. see you. Avoid riding in another TRACK VEHICLES. THEIR SAFE Safe riding motorist’s blind spot. USE AND OPERATION ARE DEPEN- Always make pre-operation Many accidents involve inexperi- DENT UPON THE USE OF PROPER checks.
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Modifications made to this motorcycle never travel faster than warrant- single most critical factor in the preven- not approved by Yamaha, or the re- ed by road and traffic conditions. tion or reduction of head injuries. moval of original equipment, may ren- Always signal before turning or Always wear an approved helmet.
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If accessories 180 kg (397 lb). When loading within this motorcycle. Since Yamaha cannot are added to the handlebar or this weight limit, keep the following in test all other accessories that may be...
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SAFETY INFORMATION motorcycle’s electrical system an cle, note the following: eyes, see your doctor immediate- electric failure could result, which The engine and exhaust system ly. If any gasoline spills on your could cause a dangerous loss of may be hot, therefore, park the skin or clothing, immediately wash lights or engine power.
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 EAU12343 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...
EWA10880 WARNING With the lever in this position, fuel will Your Yamaha engine has been de- Do not overfill the fuel tank, oth- not flow. Always return the lever to this signed to use regular unleaded gaso- erwise it may overflow when the position when the engine is not running.
INSTRUMENT AND CONTROL FUNCTIONS fuel while riding, move the lever to this EAU13600 Starter (choke) knob “ ” position. Fill the tank at the first oppor- tunity. Be sure to set the lever back to “ON” after refueling! FUEL 1. Arrow mark positioned over “ON” 1.
INSTRUMENT AND CONTROL FUNCTIONS EAU13660 EAU13970 Kickstarter Seat To remove the seat 1. Remove the bolts, and then pull the seat off. 1. Projection 2. Seat holder 1. Kickstarter 2. Place the seat in the original posi- (×2) If the engine fails to start by pushing the tion, and then tighten the bolts.
EAU15300 this system regularly as described Luggage strap holders Sidestand below and have a Yamaha dealer re- The sidestand is located on the left side pair it if it does not function proper- (×2) of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright.
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 6-23...
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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 EAU16640 EAU16671 ECA11040 Starting a warm engine Shifting CAUTION: Follow the same procedure as for start- For maximum engine life, never ac- ing a cold engine with the exception celerate hard when the engine is that the starter (choke) is not required cold! when the engine is warm.
OPERATION AND IMPORTANT RIDING POINTS EAU16800 EAU16841 ECA10260 Tips reducing fuel Engine break-in CAUTION: consumption There is never a more important period Even with the transmission in in the life of your engine than the period Fuel consumption depends largely on the neutral position, do not 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.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17240 EAU17340 a Yamaha dealer perform it for you. Owner’s tool kit Safety is an obligation of the owner. Pe- EWA10350 riodic inspection, adjustment and lubri- WARNING cation will keep your vehicle in the Modifications...
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 Front and rear brake √ √ √ √ √ √ 25 * Check operation. switches √ √ √ √ √ Moving parts and cables Lubricate.
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 Panel A maintenance jobs described in this...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU19602 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. Instead, have a Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) Yamaha dealer check the vehicle. 2. Clean the surface of the spark plug 2. Check the spark plug for electrode gasket and its mating surface, and...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU19792 3. Remove the engine oil filler cap NOTE: Engine filter and drain bolt to drain the oil from The engine oil should be between the element the crankcase. minimum and maximum level marks. The engine oil level should be checked before each ride.
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PERIODIC MAINTENANCE AND MINOR REPAIR bolt, O-ring, compression 7. Check the O-ring for damage and spring, and oil strainer will fall out. replace it if necessary. Take care not to lose these parts. 8. Clean the oil filter element with sol- vent, and then install it.
PERIODIC MAINTENANCE AND MINOR REPAIR to the specified torque. higher. EAU20831 Cleaning the air filter element Make sure that no foreign mate- Tightening torque: and check hose rial enters the crankcase. Engine oil drain bolt: The air filter element should be cleaned 43 Nm (4.3 m·kgf, 31 ft·lbf) 13.
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PERIODIC MAINTENANCE AND MINOR REPAIR 4. Remove the sponge material from material, and then squeeze the ex- To clean the air filter check hose 1. Check the hose at the bottom of the air filter element frame, clean it cess oil out. the air filter case for accumulated with solvent, and then squeeze the NOTE:...
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.
To prevent this cle, note the following points regarding from occurring, the valve clearance the specified tires. must be adjusted by a Yamaha dealer Tire air pressure The tire air pressure should be checked at the intervals specified in the periodic and, if necessary, adjusted before each maintenance and lubrication chart.
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PERIODIC MAINTENANCE AND MINOR REPAIR YOUR MOTORCYCLE. Make sure sidewall is cracked, have a Yamaha Tire air pressure (measured on cold the total weight of the cargo, rider, dealer replace the tire immediately. tires): passenger, and accessories (fairing, 0–90 kg (0–198 lb) :...
BRIDGESTONE/TW34 the spokes for looseness or dam- age before each ride. If any dam- EWA10560 age is found, have a Yamaha WARNING dealer replace the wheel. Do not It is dangerous to ride with a attempt even the smallest repair to worn-out tire.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22041 ver free play, turn the adjusting nut NOTE: Adjusting the clutch lever free in direction (b). If the specified clutch lever free play play 6. Tighten the locknut at the clutch le- could be obtained as described above, ver and the crankcase.
The brake lever free play should mea- ish the braking performance, It is advisable to have a Yamaha sure 5.0–8.0 mm (0.20–0.31 in) as which may result in loss of con- dealer make these adjustments.
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If proper adjustment cannot be direction (b). EWA11230 obtained as described, have a WARNING Yamaha dealer make this ad- After adjusting the brake pedal posi- justment. tion, the brake pedal free play must After adjusting the brake pedal be adjusted.
EAU22380 indicator grooves have almost disap- Adjusting the rear brake light Checking the front brake pads peared, have a Yamaha dealer replace switch and rear brake shoes the brake pads as a set. The front brake pads and the rear brake...
PERIODIC MAINTENANCE AND MINOR REPAIR brake shoes as a set. EAU32343 make sure that the top of the mas- Checking the front brake fluid ter cylinder is level by turning the level handlebars. Insufficient brake fluid may allow air to Use only the recommended quality enter the brake system, possibly caus- brake fluid, otherwise the rubber...
EAU22760 Changing the brake fluid Drive chain slack brake fluid level goes down sud- Have a Yamaha dealer change the The drive chain slack should be denly, have a Yamaha dealer brake fluid at the intervals specified in checked before each ride and adjusted check the cause.
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PERIODIC MAINTENANCE AND MINOR REPAIR ECA10570 CAUTION: Improper drive chain slack will over- load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits.
Service the drive chain as ed if necessary. If a cable is damaged follows. or does not move smoothly, have a ECA10581 Yamaha dealer check or replace it. CAUTION: Recommended lubricant: The drive chain must be lubricated Engine oil after washing the motorcycle and riding in the rain.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23110 EAU23131 EAU23140 Checking and lubricating the Checking and lubricating the Checking and lubricating the throttle grip and cable brake and shift pedals brake and clutch levers The operation of the throttle grip should be checked before each ride. In addi- tion, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart.
Lithium-soap-based grease If the sidestand does not move up several times to check if the front and down smoothly, have a Yamaha fork compresses and rebounds dealer check or repair it. smoothly. Recommended lubricant:...
EWA10750 WARNING fork does not operate smoothly, Securely support the vehicle so that have a Yamaha dealer check or re- there is no danger of it falling over. pair it. 2. Hold the lower ends of the front fork legs and try to move them for- ward and backward.
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 lowing FIRST AID. compartment, and then hook the EXTERNAL: Flush with plenty battery band onto the holder. 8. Connect the breather hose to the of water. battery and make sure that it is INTERNAL: Drink large quan- properly routed.
PERIODIC MAINTENANCE AND MINOR REPAIR 9. Connect and tighten the positive EAU23501 ECA10600 Replacing the fuse CAUTION: battery lead to the battery’s posi- The fuse holder is located behind panel If the breather hose is positioned in tive (+) terminal. B.
1. Headlight coupler devices operate. 2. Headlight bulb cover 4. If the fuse immediately blows 4. Remove the headlight bulb holder again, have a Yamaha dealer by turning it counterclockwise, and check the electrical system. then remove the defective bulb. (×2) 1.
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8. Install the cowling. 1. Headlight bulb holder 9. Have a Yamaha dealer adjust the EWA10790 headlight beam if necessary. WARNING Headlight bulbs get very hot. There- fore, keep flammable products away 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24131 EAU24210 Replacing the tail/brake light Replacing a turn signal light bulb bulb 1. Remove the tail/brake light lens by 1. Remove the turn signal lens by re- removing the screws. moving the screws. (×2) 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24350 frame in front of the rear wheel or under ECA10680 Supporting the motorcycle CAUTION: each side of the swingarm. Since this model is not equipped with a Do not overtighten the screws, oth- centerstand, follow these precautions erwise the lens may break.
WARNING ECA11070 ing the brake disc and that the slot in CAUTION: It is advisable to have a Yamaha the speedometer gear unit fits over the Do not apply the brake after the dealer service the wheel. retainer on the fork leg.
EAU25420 To remove the rear wheel 6. Connect the speedometer cable. EWA10820 WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcy- cle so that there is no danger of 1. Axle nut 2. Brake pedal free play adjusting nut it falling over.
6. Adjust the brake pedal free play. self. However, should your motorcycle (See page 6-17.) require any repair, take it to a Yamaha EWA10660 dealer, whose skilled technicians have WARNING the necessary tools, experience, and...
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 EAU26000 brush, but never apply such prod- sponges which have been in Care ucts onto seals, gaskets, sprock- contact with strong or abrasive While the open design of a motorcycle ets, the drive chain and wheel cleaning products, solvent or reveals the attractiveness of the tech- axles.
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MOTORCYCLE CARE AND STORAGE any marks. If the windshield is ter and a mild detergent, after the tection spray metal, scratched, use a quality plastic engine has cooled down. including chrome- and nickel-plat- polishing compound after ed, surfaces. ECA10790 CAUTION: washing.
NOTE: tect the cylinder, piston rings, etc. wet, will allow water and humid- Consult a Yamaha dealer for advice on from corrosion. ity to seep in and cause rust. what products to use.
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MOTORCYCLE CARE AND STORAGE from the spark plug, and then place and charge it once a month. install the spark plug and the Do not store the battery in an ex- spark plug cap. cessively cold or warm place EWA10950 [less than 0 °C (30 °F) or more WARNING than 30 °C (90 °F)].
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.
The use of the vehicle after such spare parts from a Yamaha dealer. device or element of design has 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 ..........6-10 Pre-operation check list......4-2 Front fork, checking .........6-25 Fuel............3-6 Battery............. 6-27 Fuel cock ...........3-6 Rear brake light switch, adjusting....
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INDEX Turn signal light bulb, replacing ....6-32 Turn signal switch ........3-3 Valve clearance, adjusting.......6-13 Vehicle identification number.....9-1 Wheel bearings, checking .......6-27 Wheel (front) ..........6-34 Wheel (rear)..........6-35 Wheels.............6-15...
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YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.6–0.1×1 !