Yamaha TW200E Owner's Manual
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Yamaha TW200E Owner's Manual

2003
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OWNER'S MANUAL
TW200E
5FY-28199-E1

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  • Page 1 OWNER’S MANUAL TW200E 5FY-28199-E1...
  • Page 2 Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TW200E. The owner’s manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury.

  • Page 3: Important Manual Information

    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.
  • Page 4 IMPORTANT MANUAL INFORMATION EAU10200 TW200E OWNER’S MANUAL ©2003 by Yamaha Motor Co., Ltd. 1st edition, June 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION .....1-1 Ignition circuit cut-off system ...3-11 Adjusting the engine idling speed ........6-12 DESCRIPTION ......2-1 PRE-OPERATION CHECKS ..4-1 Adjusting the throttle cable free Left view ........2-1 Pre-operation check list ....4-2 play ........6-13 Right view........2-2 Adjusting the valve Controls and instruments ...2-3 OPERATION AND IMPORTANT...
  • Page 6 TABLE OF CONTENTS Checking and lubricating the Storage ........7-3 brake and shift pedals ...6-24 Checking and lubricating the SPECIFICATIONS ....... 8-1 brake and clutch levers ..6-24 Checking and lubricating the CONSUMER INFORMATION ..9-1 sidestand .......6-25 Identification numbers ....9-1 Lubricating the rear suspension ......6-25 Checking the front fork ....6-25...

  • Page 7: Safety Information

    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.
  • Page 8 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.
  • Page 9 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...
  • Page 10 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.

  • Page 11: Description

    DESCRIPTION EAU10410 Left view 1. Fuel cock (page 3-6) 2. Helmet holder (page 3-9) 3. Luggage strap holder (page 3-10) 4. Drive chain slack adjusting plate 5. Air filter element (page 6-10) 6. Starter (choke) knob (page 3-7) 7. Shift pedal (page 3-4)

  • Page 12: Right View

    DESCRIPTION EAU10420 Right view 1. Carrier 9. Luggage strap holder (page 3-10) 2. Battery (page 6-27) 3. Kickstarter (page 3-8) 4. Engine oil filter element (page 6-7) 5. Engine oil level check window (page 6-7) 6. Brake pedal (page 3-5) 7.

  • Page 13: Controls And Instruments

    DESCRIPTION EAU10430 Controls and instruments 1. Clutch lever (page 3-4) 9. Fuel tank cap (page 3-5) 2. Left handlebar switches (page 3-3) 3. Speedometer unit (page 3-2) 4. Main switch/steering lock (page 3-1) 5. Indicator lights (page 3-2) 6. Right handlebar switches (page 3-3) 7.

  • Page 14: Instrument And Control Functions

    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”...

  • Page 15: Indicator Lights

    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.

  • Page 16: Handlebar Switches

    INSTRUMENT AND CONTROL FUNCTIONS EAU12341 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 “ ”...

  • Page 17: Clutch Lever

    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.

  • Page 18: Brake Pedal

    INSTRUMENT AND CONTROL FUNCTIONS EAU12941 EAU32280 unless the key is in the lock. In addition, Brake pedal Fuel tank cap the key cannot be removed if the cap is not properly installed and locked. EWA10120 WARNING Make sure that the fuel tank cap is properly closed and locked before riding.

  • Page 19: Fuel

    INSTRUMENT AND CONTROL FUNCTIONS EAU13210 fuel may deteriorate painted surfac- EAU13560 Fuel Fuel cock es or plastic parts. The fuel cock supplies fuel from the EAU13241 tank to the carburetor while filtering it al- Recommended fuel: Regular unleaded gasoline The fuel cock has three positions: only Fuel tank capacity: 7.0 L (1.85 US gal)

  • Page 20: Starter (Choke) Knob "1

    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.

  • Page 21: Kickstarter

    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- (×2) If the engine fails to start by pushing the tion, and then tighten the bolts.

  • Page 22: Helmet Holder

    Always have a Yamaha dealer service the shock absorber.

  • Page 23: Luggage Strap Holders

    EAU15170 EAU15300 regularly as described below and Luggage strap holders Sidestand have a Yamaha dealer repair it if it The sidestand is located on the left side does not function properly. (×2) of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright.

  • Page 24: Ignition Circuit Cut-Off System

    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...
  • Page 25 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.

  • Page 26: Pre-Operation Checks

    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.

  • Page 27: Pre-Operation Check List

    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...
  • Page 28 Instruments, lights, signals Check operation. — and switches Correct if necessary. Check operation of ignition circuit cut-off system. Sidestand switch 3-11 If system is defective, have Yamaha dealer check vehicle. Check fluid level. Battery 6-27 Fill with distilled water if necessary.

  • Page 29: Operation And Important Riding Points

    The transmission is in the neutral Consult a Yamaha dealer re- 4. Turn the starter (choke) on and position. garding any control or function completely close the throttle. (See...

  • Page 30: Starting A Warm Engine

    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.

  • Page 31: Tips For Reducing Fuel

    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).

  • Page 32: Parking

    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.

  • Page 33: Periodic Maintenance And Minor Repair

    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...

  • Page 34: Periodic Maintenance And Lubrication Chart

    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. ODOMETER READING (× 1,000 km)
  • Page 35 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1,000 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.
  • Page 36 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Front and rear brake √ √ √ √ √ √ 25 * Check operation. switches √ √ √ √ √ Moving parts and cables Lubricate.

  • Page 37: Removing And Installing The Cowling And Panels

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU18720 the maintenance jobs described in this Removing and installing the chapter. Refer to this section each time cowling and panels the cowling or a panel needs to be re- moved and installed. (×2) EAU18810 Cowling A To remove the cowling Remove the screw, and then pull the...

  • Page 38: Checking The Spark Plug

    Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. 1. Spark plug cap 2. Check the spark plug for electrode 2. Remove the spark plug as shown,...

  • Page 39: Element

    PERIODIC MAINTENANCE AND MINOR REPAIR necessary. spark plug threads. EAU19792 Engine filter 3. Install the spark plug with the Specified spark plug: element spark plug wrench, and then tight- NGK/DR8EA The engine oil level should be checked en it to the specified torque. DENSO/X24ESR-U before each ride.
  • Page 40 PERIODIC MAINTENANCE AND MINOR REPAIR crankcase. to collect the used oil. 3. Remove the engine oil filler cap NOTE: and drain bolt to drain the oil from The engine oil should be between the minimum and maximum level marks. the crankcase. 1.
  • Page 41 PERIODIC MAINTENANCE AND MINOR REPAIR 7. Check the O-ring for damage and replace it if necessary. 8. Clean the oil filter element with sol- vent, and then install it. NOTE: Check the oil filter element for damage and replace it if necessary. (×2) 9.

  • Page 42: Cleaning The Air Filter Element And Check Hose

    PERIODIC MAINTENANCE AND MINOR REPAIR bolt, and then tighten the drain bolt er quality than specified. In EAU20830 Cleaning the air filter element to the specified torque. addition, do not use oils labeled and check hose “ENERGY CONSERVING II” or Tightening torque: The air filter element should be cleaned higher.
  • Page 43 PERIODIC MAINTENANCE AND MINOR REPAIR material, and then squeeze the ex- To clean the air filter check hose 1. Check the hose at the bottom of cess oil out. the air filter case for accumulated NOTE: dirt or water. The sponge material should be wet but not dripping.

  • Page 44: Adjusting The Carburetor

    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.

  • Page 45: Adjusting The Throttle Cable Free Play

    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.
  • Page 46 125 kPa (18 psi) (1.25 kgf/cm nail or glass fragments in it, or if the Maximum load*: sidewall is cracked, have a Yamaha 180 kg (397 lb) dealer replace the tire immediately. * Total weight of rider, passenger,...
  • Page 47 When a tire tread Yamaha Motor Co., Ltd. begins to show crosswise lines, have a Yamaha dealer replace the tire immediately. The replacement of all wheel- and brake-related parts, includ- ing the tires, should be left to a...

  • Page 48: Spoke Wheels

    5. Loosen the locknut at the crank- age before each ride. If any dam- case. age is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to 1. Locknut (clutch lever) the wheel.

  • Page 49: Adjusting The Brake Lever Free Play

    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 2. Adjusting bolt operating the motorcycle.

  • Page 50: Adjusting The Brake Pedal Position And Free Play

    WARNING 2. Adjusting bolt pedal free play and, if necessary, adjust 3. Brake pedal position It is advisable to have a Yamaha it as follows. dealer make these adjustments. 3. Tighten the locknut. To increase the brake pedal free play,...

  • Page 51: Adjusting The Rear Brake Light Switch

    If obtained as described, have a 1. Brake pad wear indicator groove necessary, adjust the brake light switch Yamaha dealer make this ad- Each front brake pad is provided with as follows. justment. wear indicator grooves, which allow...

  • Page 52: Checking The Brake Fluid Level

    Yamaha As the brake pads wear, it is nor- Observe these precautions: dealer replace the brake shoes as a...

  • Page 53: Changing The Brake Fluid

    EAU22760 Changing the brake fluid Drive chain slack denly, have a Yamaha dealer Have a Yamaha dealer change the The drive chain slack should be check the cause. brake fluid at the intervals specified in checked before each ride and adjusted the NOTE after the periodic mainte- if necessary.
  • Page 54 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.

  • Page 55: Lubricating The Drive Chain

    Service the drive chain as ed if necessary. If a cable is damaged follows. or does not move smoothly, have a ECA10580 Yamaha dealer check or replace it. CAUTION: Recommended lubricant: The drive chain must be lubricated Engine oil after washing the motorcycle or riding in the rain.

  • Page 56: Checking And Lubricating The Throttle Grip And Cable

    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.

  • Page 57: Checking And Lubricating The Sidestand

    If the sidestand does not move up Lithium-soap-based grease 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:...

  • Page 58: Checking The Steering

    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.

  • Page 59: Checking The Wheel Bearings

    Yamaha dealer check tervals specified in the periodic mainte- the wheel bearings. nance and lubrication chart.
  • Page 60 PERIODIC MAINTENANCE AND MINOR REPAIR lowing FIRST AID. battery band onto the holder. EXTERNAL: Flush with plenty 8. Connect the breather hose to the of water. battery and make sure that it is INTERNAL: Drink large quan- properly routed. tities of water or milk and im- mediately call a physician.

  • Page 61: Replacing The Fuse

    PERIODIC MAINTENANCE AND MINOR REPAIR battery lead to the battery’s posi- such a way that the frame is ex- EAU23500 Replacing the fuse tive (+) terminal. posed to electrolyte or gas expelled 10. Connect and tighten the negative from the battery, the frame could battery lead to the battery’s nega- suffer structural and external dam- tive (–) terminal.

  • Page 62: Replacing The Headlight Bulb

    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.
  • Page 63 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.

  • Page 64: Replacing The Tail/Brake Light Bulb

    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.

  • Page 65: Supporting The Motorcycle

    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.

  • Page 66: Front Wheel

    To remove the front wheel the wheel. EWA10820 WARNING ECA11070 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.

  • Page 67: Rear Wheel

    EWA10820 WARNING plate on each side of the swingarm fully in direction (a). It is advisable to have a Yamaha 4. Lift the rear wheel off the ground dealer service the wheel. according to the procedure on Securely support the motorcy- page 6-33.

  • Page 68: Troubleshooting

    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.

  • Page 69: Troubleshooting Chart

    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.

  • Page 70: Motorcycle Care And Storage

    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.
  • Page 71 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.

  • Page 72: Storage

    5. Perform the following steps to pro- ing it with a tarp, while it is still NOTE: tect the cylinder, piston rings, etc. Consult a Yamaha dealer for advice on wet, will allow water and humid- from corrosion. what products to use.
  • Page 73 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]).

  • Page 74: Specifications

    SPECIFICATIONS EAU26332 Engine oil: Carburetor: Dimensions: Type: Manufacturer: Overall length: YAMALUBE 4, SAE10W30 or SAE20W40 TEIKEI 2090 mm (82.3 in) Type x quantity: -20 -10 10 20 30 40 50 ˚C Overall width: MV28 x 1 820 mm (32.3 in) Spark plug(s): SAE 10W-30 Overall height:...
  • Page 75 SPECIFICATIONS 3rd: Tire air pressure (measured on cold Operation: 29/22 (1.318) Right hand operation tires): 4th: Recommended fluid: Loading condition: 26/25 (1.040) Dot 4 0–90 kg (0–198 lb) 5th: Rear brake: Front: 23/28 (0.821) Type: 125 kPa (18 psi) (1.25 kgf/cm Chassis: Drum brake Rear:...
  • Page 76 SPECIFICATIONS Headlight: Bulb type: Halogen bulb Bulb voltage, wattage x quantity: Headlight: 12 V, 60 W/55.0 W × 1 Tail/brake light: 12 V, 8 W/27.0 W × 1 Front turn signal/position light: 12 V, 27 W/8.0 W × 2 Rear turn signal light: 12 V, 27.0 W ×...

  • Page 77: Consumer Information

    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.
  • Page 78 EAU26460 Model label 1. Model label The model label is affixed to the loca- tion shown. Record the information on this label in the space provided. This in- formation will be needed when ordering spare parts from a Yamaha dealer.
  • Page 80 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.6–0.1×1 !

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