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EAU00000 INTRODUCTION Congratulations on your purchase of the Yamaha TW200. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
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If there is any question concerning this manual, please consult your Yamaha dealer.
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IMPORTANT MANUAL INFORMATION EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
EAU00009 TABLE OF CONTENTS SAFETY INFORMATION ........1-1 Starter (choke) “1” .........3-8 Safe riding ............1-1 Kick starter ............3-8 Protective apparel ..........1-3 Steering lock.............3-9 Modification............1-3 Seat ..............3-9 Loading and accessories .........1-3 Helmet holder..........3-10 Gasoline and exhaust gas .......1-5 Rear shock absorber ........3-10 Location of the important labels.....1-7 Rear carrier .............3-11 Sidestand ............3-11...
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TABLE OF CONTENTS Cowling and panel removal and Brake and shift pedal lubrication ....6-24 installation ............6-6 Brake and clutch lever lubrication ....6-25 Cowling A ............6-6 Sidestand lubrication........6-25 Panel A ..............6-7 Rear suspension lubrication......6-25 Panel B ..............6-7 Front fork inspection........6-26 Spark plug............6-7 Steering inspection ........6-26 Engine oil ............6-9 Wheel bearings ..........6-27...
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CONSUMER INFORMATION ......9-1 Identification number records......9-1 Key identification number .......9-1 Vehicle identification number ......9-1 Model label ............9-2 Noise regulation (For Australia)......9-2...
EAU00017 Q SAFETY INFORMATION TWO-WHEELED MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPER- ATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING. HE OR SHE SHOULD: 1.
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Q SAFETY INFORMATION 4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. a. Make sure you are qualified. Also, only lend your motorcycle to experienced operators. b.
6. A passenger should also observe the above precautions. Modification Modifications made to the motorcycle not approved by Yamaha, or the removal of original equipment, may render your motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use.
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Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories which may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. You should use extreme caution when selecting and installing any accessories.
Q SAFETY INFORMATION a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum.
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Q SAFETY INFORMATION a. The engine and exhaust system may be hot. Park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. b. Do not park the motorcycle on a slope or soft ground; the motorcycle may fall over. c.
EAU00027 INSTRUMENT AND CONTROL FUNCTIONS To lock the steering, turn the han- dlebars all the way to the left or right. With the key at “OFF”, push it into the main switch and release it, turn it counterclockwise to “LOCK” and remove it. To release the lock, turn the key to “OFF”.
INSTRUMENT AND CONTROL FUNCTIONS EAU00063 High beam indicator light “&” 1 2 3 This indicator comes on when the headlight high beam is used. 1. Turn indicator light “5” 1. Speedometer 2. High beam indicator light 2. Odometer “&” 3. Trip meter 3.
INSTRUMENT AND CONTROL FUNCTIONS 1. Engine stop switch “ENGINE STOP” 1. Clutch lever 1. Shift pedal 2. Start switch “START” N. Neutral EAU00152 EAU00141 EAU00157 Clutch lever Shift pedal Start switch “START” The clutch lever is located on the starter motor cranks This motorcycle is equipped with a...
INSTRUMENT AND CONTROL FUNCTIONS 1. Front brake lever 1. Rear brake pedal 1. Unlock 2. Open EAU00158 EAU00162 EAU00177 Front brake lever Rear brake pedal Fuel tank cap The front brake lever is located on The rear brake pedal is on the right To open the right handlebar.
INSTRUMENT AND CONTROL FUNCTIONS EAU00185 NOTE: The tank cap cannot be reinstalled Always wipe off spilled fuel imme- unless it is unlocked. The key must diately with a dry and clean soft remain in the cap until the cap is cloth.
INSTRUMENT AND CONTROL FUNCTIONS EAU00192 Recommended fuel: Regular gasoline For Australia: Unleaded fuel only FUEL FUEL Fuel tank capacity: Total: 7.0 L Reserve: 1. Arrow mark 1. Arrow mark 1.0 L EAU01121 Fuel cock With the lever in this position, fuel The fuel cock supplies fuel from flows to the carburetor.
INSTRUMENT AND CONTROL FUNCTIONS FUEL 1. Arrow mark 1. Starter (choke) “1” 1. Kick starter EAU02976 EAU00212 Starter (choke) “1” Kick starter This indicates reserve. If you run Starting a cold engine requires a Rotate the kick starter away from out of fuel while riding, move the richer air-fuel mixture.
INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering Insert the key, push it in and turn it 1/8 turn counterclockwise so that it moves out. Then, release and remove the key. 1. Steering lock 1. Bolt (×2) EAU02934 EAU01092 Steering lock Seat To lock the steering To remove the seat, remove the...
The helmet may hit cylinder in any way. Cylinder objects, causing loss of control damage will result in poor and possibly an accident. damping performance. 8 Take your shock absorber to a Yamaha dealer for any service. 3-10...
Please check carefully EW000032 the operating instructions listed below and if there is any indication Do not exceed the load limit of of a malfunction, return the motor- 3 kg. cycle to a Yamaha dealer immedi- ately for repair. 3-11...
EW000045 TURN THE MAIN SWITCH TO “ON” AND THE ENGINE STOP SWITCH TO If improper operation is noted, “RUN”. consult a Yamaha dealer immedi- ately. TRANSMISSION IS IN GEAR AND SIDESTAND IS UP. PULL IN CLUTCH LEVER AND PUSH THE START SWITCH.
EAU01114 PRE-OPERATION CHECKS Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual inspection, you check the following points before each ride.
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PRE-OPERATION CHECKS ITEM CHECKS PAGE 9 Check fuel level. Fuel tank 3-5 ~ 3-7 9 Fill with fuel if necessary. Lights, signals and 9 Check for proper operation. 6-30 ~ 6-31 switches 9 Check fluid level. Battery 6-27 ~ 6-29 9 Fill with distilled water if necessary.
This motorcycle is equipped with a their functions. Consult starting and an ignition circuit cut- Yamaha dealer regarding any off switch. control or function that you do The engine can be started only not thoroughly understand. under one of the following condi-...
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OPERATION AND IMPORTANT RIDING POINTS TURN THE MAIN SWITCH TO “ON” AND THE ENGINE STOP SWITCH TO “RUN” IF TRANSMISSION IS IN NEUTRAL IF TRANSMISSION IS IN GEAR AND AND SIDESTAND IS DOWN, SIDESTAND IS UP, PUSH START SWITCH OR PULL IN CLUTCH LEVER AND PUSH START KICK THE KICK STARTER.
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If the light does not come on, ask a Yamaha dealer to NOTE: inspect it. For maximum engine life, always warm up the engine before starting off.
OPERATION AND IMPORTANT RIDING POINTS EAU01258 EC000048 Starting a warm engine The starter (choke) is not required 8 Do not coast for long periods when the engine is warm. with the engine off, and do EC000046 not tow the motorcycle a long distance.
OPERATION AND IMPORTANT RIDING POINTS EAU00424 EAU00436 EAU00446 Tips for reducing fuel Engine break-in 0 ~ 150 km consumption There is never a more important Avoid operation above 1/3 throttle. Your motorcycle’s fuel consump- period in the life of your motorcy- Stop the engine and let it cool for 5 tion depends to a large extent on cle than the period between zero...
Avoid prolonged full-throttle oper- ation. Vary speed occasionally. EC000049 FUEL If any engine trouble should occur during the break-in period, consult a Yamaha dealer immediately. 1. Arrow mark EAU00457 Parking When parking the motorcycle, stop the engine and remove the ignition key.
If you are not familiar with motor- motorcycle in the safest and most cycle service, this work should be efficient condition possible. Safety done by a Yamaha dealer. is an obligation of the motorcycle owner. The maintenance and lubri- cation schedule chart should be...
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Yamaha dealer for service. EW000063 Modifications to this motorcycle not approved by Yamaha may cause loss of performance, and render it unsafe for use. Consult a Yamaha dealer before attempting any changes.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00473 PERIODIC MAINTENANCE AND LUBRICATION Every Every 6,000 km 12,000 km INITIAL ITEM CHECKS AND MAINTENANCE JOBS (1,000 km) 6 months 12 months (Whichever (Whichever comes first) comes first) 9 Check fuel hoses for cracks or damage. √...
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PERIODIC MAINTENANCE AND MINOR REPAIR Every Every 6,000 km 12,000 km INITIAL ITEM CHECKS AND MAINTENANCE JOBS (1,000 km) 6 months 12 months (Whichever (Whichever comes first) comes first) 9 Check bearing for looseness or damage. √ √ 12 * Wheel bearings 9 Replace if necessary.
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√ 9 Clean or replace if necessary. 25 * Engine oil strainer Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. EAU00479 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cowling A 1. Panel B 1. Screw 2. Panel A EAU01145 EAU01139 Cowling A Cowling and panel removal To remove and installation Remove the cowling screw and The cowlings and panels illustrated pull outward on the areas shown. need to be removed to perform some maintenance...
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel A 1. Panel B 1. Spark plug wrench 2. Screw (×2) EAU00494 EAU01833 EAU01345 Panel A Spark plug Panel B To remove Removal To remove Pull outward on the areas shown. 1. Remove the spark plug cap. Remove the screws and pull out- 2.
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Instead, take and, if necessary, adjust the the motorcycle to a Yamaha deal- 4. Install the spark plug cap. gap to specification. er. You should periodically remove and inspect the spark plug because...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00517 Engine oil Oil level measurement 1. Place the motorcycle on a level place and hold it in an upright position. Warm up the engine for several minutes. NOTE: Be sure the motorcycle is posi- 1.
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PERIODIC MAINTENANCE AND MINOR REPAIR 1. Drain plug 1. Drain plug 1. Filter cover screw (×2) 2. O-ring 2. Drain bolt 3. Remove the drain plug and 3. Compression spring 4. Remove the filter cover screws 4. Oil strainer drain bolt. and the oil filter cover.
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PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Recommended oil: Drain plug: See page 8-1. 43 Nm (4.3 m0kg) Total amount: Filter cover screw: 1.3 L 7 Nm (0.7 m0kg) Periodic oil change: Drain bolt (filter cover): 1.0 L 10 Nm (1.0 m0kg) With oil filter replacement: 1.1 L 9.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (×4) 1. Air filter 2. Air filter case cover 3. Remove the air filter from its 5. Install the air filter in its case. EAU01094 Air filter case and clean it with solvent. 6.
Most adjust- increase engine speed and in ments should be left to a Yamaha direction b to decrease engine dealer who has the professional speed. knowledge and experience to do so. However, the following may be...
To prevent this, the valve must be adjusted regularly. This clearance must be adjusted regu- adjustment, however, should be larly. This adjustment however, left to a professional Yamaha ser- should be left to a professional vice technician. Yamaha service technician. a. Free play...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00668 EW000087 Maximum load* 180 kg Tires Cold tire pressure Front Rear To ensure maximum performance, Proper loading of your motorcycle 125 kPa 125 kPa Up to 90 kg (1.25 kgf/cm , (1.25 kgf/cm long service, and safe operation, is important for several character- 1.25 bar) 1.25 bar)
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After extensive tests, the tires BRIDGESTONE 130/80-18 66P TW31 mentioned below have been REAR approved by Yamaha Motor Co., Manufacturer Size Type Ltd. for this model. No guarantee BRIDGESTONE 180/80-14M/C 78P TW34 for handling characteristics can be Minimum tire tread...
8 Always inspect the wheels have a Yamaha dealer replace before a ride. Check for cracks, the tire immediately. Brakes, bends warpage tires, and related wheel parts wheel.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Locknut 1. Clutch cable 1. Adjusting bolt 2. Adjusting bolt 2. Adjusting nut 2. Locknut 3. Free play 3. Locknut 3. Free play EAU00694 EAU00699 If the specified free play cannot be Clutch lever free play Front brake lever free play obtained, proceed with the follow- adjustment...
4. Loosen the locknut at the brake lever. EW000104 5. Turn the adjusting bolt at the brake lever in direction a to It is advisable to have a Yamaha loosen the cable. dealer make this adjustment. 6. Loosen the locknut at the brake hub.
8 If it is impossible to make Turn the adjusting nut in direction proper adjustment, consult a b to make the brake light come on Yamaha dealer. later. 6-20...
A wear indicator is provided on cator reaches to the wear limit line, without rider. each brake. This indicator allows ask a Yamaha dealer to replace the inspection of shoe wear without shoes. disassembling the brake. 6-21...
PERIODIC MAINTENANCE AND MINOR REPAIR EC000096 Too little chain slack will overload the engine and other vital parts. Keep the slack within the specified limits. 5. After adjusting, be sure to tighten the axle nut to the a. Chain slack 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU01106 7. Adjust the free play in the Drive chain lubrication brake pedal. (See page 6-19.) The chain consists of many parts which work with each other. If the EW000103 chain is not maintained properly, it will wear out quickly.
Lubricate the cables and cable with a suitable all-purpose grease. ends. If a cable does not operate smoothly, ask a Yamaha dealer to replace it. Recommended lubricant: Engine oil 6-24...
Recommended lubricant: moves up and down smoothly. Engine oil Recommended lubricant: Engine oil EW000113 EAU00791 Rear suspension lubrication Lubricate the pivoting parts. If the sidestand does not move smoothly, consult a Yamaha deal- Recommended lubricant: Lithium soap base grease 6-25...
If any Check for scratches or damage on free play can be felt, ask a Yamaha the inner tube and excessive oil dealer to inspect and adjust the leakage from the front fork.
If there is play in the front or rear Securely support the motorcycle wheel hub or if the wheel does not so there is no danger of it falling turn smoothly, have a Yamaha over. dealer inspect the wheel bearings. 1. Battery 2.
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PERIODIC MAINTENANCE AND MINOR REPAIR EW000116 EW000117 Battery electrolyte is poisonous Take care not to spill battery fluid and dangerous, causing severe on the chain. Battery fluid may burns, etc. It contains sulfuric acid. weaken the chain causing shorter Avoid contact with skin, eyes or chain life and possibly result in an clothing.
Install a new fuse of proper amperage. Turn on the switches and see if the electri- cal device operates. If the fuse immediately blows again, consult a Yamaha dealer. 6-29 6-29...
6. Install the bulb holder cover, connector and headlight unit. 5. Put a new bulb into position 7. Install the cowling. and secure it in place with the 8. If the headlight beam adjust- bulb holder. ment necessary, Yamaha dealer to make that 6-30 adjustment.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (× 2) 1. Screw (× 2) 1. Bulb 2. Lense EAU01623 2. Remove the defective bulb by 3. Bulb Taillight bulb replacement pushing it inward and turning EAU01095 1. Remove the screws and the Turn signal light bulb it counterclockwise.
EAU01579 Rear wheel service Supporting the motorcycle Use a motorcycle stand or motor- Since the Yamaha TW200 has no cycle jack to elevate the motorcycle centerstand, follow these precau- so the rear wheel is off the ground. tions when removing the front and...
PERIODIC MAINTENANCE AND MINOR REPAIR 6. Install the speedometer cable and the clip. 7. Tighten the axle nut to the specified torque and install a new cotter pin. Tightening torque: Axle nut: 90 Nm (9.0 m0kg) 1. Brake cable free play adjusting nut 2.
EW000122 motorcycle down. 4. Tighten the axle nut to the 8 It is advisable to have a specified torque and install the Yamaha dealer service the axle nut cotter pin. wheel. 8 Securely support the motorcy- Tightening torque: cle so there is no danger of it Axle nut: falling over.
(See page 6-19.) for making checks. If your motorcycle requires any EW000103 repair, bring it to a Yamaha dealer. skilled technicians Check the operation of the brake Yamaha dealership have the tools, light after adjusting the rear brake.
2. Compression There is compression. Go to ignition check. Use the electric starter. No compression. Ask a Yamaha dealer to inspect. 3. Ignition Wipe clean with dry cloth and Open throttle half-way and start Wet. Remove spark correct spark gap or replace plug.
EAU01518 MOTORCYCLE CARE AND STORAGE Before cleaning Cleaning Care 1. Cover up the muffler outlet After normal use The exposure of its technology with a plastic bag. Remove dirt with warm water, a makes a motorcycle charming but 2. Make sure that all caps and neutral detergent and a soft clean also vulnerable.
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MOTORCYCLE CARE AND STORAGE 8 Improper cleaning can damage 8 Do high-pressure After riding in the rain, near the windshields, cowlings, panels washers or steam-jet cleaners sea or on salt-sprayed roads and other plastic parts. Use since they cause water seep- Since sea salt or salt sprayed on only a soft, clean cloth or age and deterioration in the...
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After cleaning 8. Let the motorcycle dry com- NOTE: 1. Dry the motorcycle with a pletely before storing it or cov- Consult Yamaha dealer chamois or an absorbing cloth. ering it. advice on what products to use. 2. Immediately drive...
MOTORCYCLE CARE AND STORAGE Long-term a. Remove the spark plug cap Storage Before storing your motorcycle for and spark plug. Short-term several months: b. Pour a teaspoonful of engine Always store your motorcycle in a 1. Follow all the instructions in oil into the spark plug bore.
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MOTORCYCLE CARE AND STORAGE 6. Lubricate all control cables and 9. Remove the battery and fully the pivoting points of all levers charge it. Store it in a cool, dry and pedals as well as of the place and recharge it once a sidestand/centerstand.
SPECIFICATIONS EAU01064 HOW TO USE THE CONVERSION TABLE CONVERSION TABLE All specification data in this manual are listed in SI METRIC TO IMPERIAL and METRIC UNITS. Metric unit Multiplier Imperial unit Use this table to convert METRIC unit data to m •...
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Yamaha dealer or for reference in case the vehicle is stolen. 1. Key identification number 1. Vehicle identification number EAU01042...
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Yamaha dealer. (b) The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
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PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN 2000·4–0.1×1(E)