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

Yamaha TW200E Owner's Manual

1997
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OWNER'S MANUAL
TW200E
5FY-28199-E0

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  • Page 1 OWNER’S MANUAL TW200E 5FY-28199-E0...
  • Page 2 INTRODUCTION EAU00000 Congratulations on your purchase of the Yamaha TW200E. 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.

  • Page 3: Important Manual Information

    If there is any question concerning this manual, please consult your Yamaha dealer.
  • Page 4 IMPORTANT MANUAL INFORMATION EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
  • Page 5 EAU00008 TW200E OWNER’S MANUAL ©1997 by Yamaha Motor Co., Ltd. 1st Edition, November 1997 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...

  • Page 6: Table Of Contents

    EAU00009 TABLE OF CONTENTS GIVE SAFETY THE RIGHT OF WAY ....1-1 Sidestand ............3-10 Sidestand/clutch switch operation check..3-11 DESCRIPTION .............2-1 Left view............2-1 PRE-OPERATION CHECKS.........4-1 Right view ............2-2 Pre-operation check list ........4-1 Controls/Instruments ........2-3 OPERATION AND IMPORTANT RIDING INSTRUMENT AND CONTROL POINTS..............5-1 FUNCTIONS............3-1 Starting and warming up a cold engine..5-1 Main switch/Steering lock .......3-1...
  • Page 7 TABLE OF CONTENTS Carburetor adjustment ........6-13 Fuse replacement...........6-29 Idle speed adjustment ........6-13 Headlight bulb replacement......6-30 Throttle cable free play inspection ....6-14 Supporting the motorcycle ......6-31 Cam chain adjustment........6-14 Front wheel removal........6-31 Valve clearance adjustment ......6-14 Front wheel installation .........6-32 Tires..............6-15 Rear wheel removal ........6-33 Wheels ............6-17 Rear wheel installation ........6-33...
  • Page 8 EAU00021 Q GIVE SAFETY THE RIGHT OF WAY Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. Regular care and maintenance are essential for preserving your motorcycle’s value and operat- ing condition.

  • Page 9: Description

    EAU00026 DESCRIPTION Left view 2 3 4 5 1. Headlight (page 6-30) 6. Helmet holder (page 3-9) 2. Fuel cock (page 3-7) 7. Rear carrier (page 3-10) 3. Starter(choke) “1“ (page 3-8) 8. Shift pedal (page 3-4) 4. Air filter (page 6-12) 5.

  • Page 10: Right View

    DESCRIPTION Right view 9. Fuse (page 3-6) 10. Kick starter (page 3-8) 11. Rear brake pedal (page 3-5) 12. Tool kit (page 6-1)

  • Page 11: Controls/Instruments

    DESCRIPTION Controls/Instruments 13. Clutch lever (page 3-4, 6-18) 18. Throttle grip (page 6-14, 6-24) 14. Left handlebar switches (page 3-3) 19. Fuel tank cap (page 3-5) 15. Speedometer (page 3-2) 20. Main switch (page 3-1) 16. Right handlebar switches (page 3-3) 17.

  • Page 12: Instrument And Control Functions

    EAU00027 INSTRUMENT AND CONTROL FUNCTIONS EAU00038 EW000016 OFF: All electrical circuits are switched Never turn the key to “OFF” or off. The key can be removed in this “LOCK” when the motorcycle is position. moving. The electrical circuits will be switched off which may result EAU00042 in loss of control or an accident.

  • Page 13: Indicator Lights

    INSTRUMENT AND CONTROL FUNCTIONS EAU00064 High beam indicator light “HIGH 1 2 3 BEAM” This indicator comes on when the headlight high beam is used. 1. Turn indicator light “TURN” 1. Speedometer 2. High beam indicator light 2. Odometer “HIGH BEAM” EAU00098 Speedometer 3.

  • Page 14: Handlebar Switches

    INSTRUMENT AND CONTROL FUNCTIONS EAU00130 Horn switch “HORN” Press the switch to sound the horn. 1. Dimmer switch “LIGHTS” 1. Engine stop switch “ENGINE STOP” 2. Turn signal switch “TURN” 2. Start switch “START” 3. Horn switch “HORN” EAU00137 Engine stop switch “ENGINE...

  • Page 15: Clutch Lever

    INSTRUMENT AND CONTROL FUNCTIONS EAU00141 Start switch “START” starter motor cranks engine when pushing the start switch. EC000005 See starting instructions prior to starting the engine. N. Neutral 1. Shift pedal EAU00152 Clutch lever EAU00157 Shift pedal The clutch lever is located on the This motorcycle is equipped with a left handlebar, and the ignition cir- constant-mesh 5-speed transmis-...

  • Page 16: Front Brake Lever

    INSTRUMENT AND CONTROL FUNCTIONS 1. Unlock 2. Open EAU00158 EAU00162 Front brake lever Rear brake pedal EAU00177 Fuel tank cap The front brake lever is located on The rear brake pedal is on the right TO OPEN: the right handlebar. Pull it toward side of the motorcycle.

  • Page 17: Fuel

    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.

  • Page 18: Fuel Cock

    INSTRUMENT AND CONTROL FUNCTIONS EAU00187 Recommended fuel: Regular gasoline Fuel tank capacity: Total: FUEL 7.0 L FUEL Reserve: 1.7 L 1. Arrow mark 1. Arrow mark EAU01121 ON: With the fuel cock in this Fuel cock position, fuel flows to the car- The fuel cock supplies fuel from buretor.

  • Page 19: Starter(Choke) "1

    INSTRUMENT AND CONTROL FUNCTIONS FUEL 1. Starter (choke) “1” 1. Kick starter 1. Arrow mark EAU00210 EAU00212 RES: This indicates reserve. If you Starter(choke) “1” Kick starter run out of fuel while riding, Starting a cold engine requires a Rotate the kick starter away from set the fuel cock to this posi- richer air-fuel mixture.

  • Page 20: Seat

    INSTRUMENT AND CONTROL FUNCTIONS 1. Bolt (×2) 1. Open 2. Helmet holder EAU01092 To install the seat, insert the pro- Seat EAU00260 Helmet holder jection on the front of the seat into To remove the seat, remove the To open the helmet holder, insert the holder and push down on the bolts.

  • Page 21: Rear Shock Absorber

    3. Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance. 4. Take your shock absorber to a Yamaha dealer for any service. 3-10...

  • Page 22: Sidestand/Clutch Switch Operation Check

    PULL IN CLUTCH LEVER AND of a malfunction, return the motor- PUSH THE START SWITCH. cycle to a Yamaha dealer immedi- ately for repair. ENGINE WILL START. CLUTCH SWITCH IS OK. 3-11...

  • Page 23: Pre-Operation Checks

    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.
  • Page 24 PRE-OPERATION CHECKS ITEM CHECKS PAGE 9 Check fuel level. Fuel tank 3-5 ~ 3-6 9 Fill with fuel if necessary. Lights, signals and 9 Check for proper operation. 6-30 switches 9 Check fluid level. Battery 6-27 ~ 6-29 9 Fill with distilled water if necessary. NOTE: Pre-operation checks should be made each time the motorcycle is used.

  • Page 25: Operation And Important Riding Points

    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 1. The engine can be started only not thoroughly understand. under the following condi- 2.
  • Page 26 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.
  • Page 27 If the light does not motor, kick the kick starter to start come on, ask a Yamaha dealer to the engine. inspect it. 6. After starting the engine, move 4.

  • Page 28: Starting A Warm Engine

    OPERATION AND IMPORTANT RIDING POINTS EAU01258 EC000048 Starting a warm engine The starter (choke) is not required 1. Do not coast for long periods when the engine is warm. with the engine off, and do not tow the motorcycle a long EC000046 distance.

  • Page 29: Engine Break-In

    Yamaha dealer immediately. first 1,000 km. The various parts in 2. 150 ~ 500 km: the engine wear and polish them-...

  • Page 30: Parking

    OPERATION AND IMPORTANT RIDING POINTS EAU00457 Parking When parking the motorcycle, stop the engine and remove the ignition key. Turn the fuel cock to “OFF” whenever stopping the engine. EW000058 The exhaust system is hot. Park the motorcycle in a place where pedestrians or children are not likely to touch the motorcycle.

  • Page 31: Periodic Maintenance And Minor Repair

    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...
  • Page 32 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.

  • Page 33: Periodic Maintenance And Lubrication

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU00473 PERIODIC MAINTENANCE AND LUBRICATION 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. √...
  • Page 34 PERIODIC MAINTENANCE AND MINOR REPAIR 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.
  • Page 35 √ 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.

  • Page 36: Cowling And Panel Removal And Installation

    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cowling A 1. Panel B 1. Screw 2. Panel A EAU01344 Cowling A EAU01139 Cowling and panel removal To remove: and installation Remove the screw. The cowlings and panels illustrated need to be removed to perform To install: some maintenance...

  • Page 37: Panel A

    Do not attempt to diagnose any problems yourself. Instead, take the motorcycle to a Yamaha dealer. You should period- ically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly...

  • Page 38: Engine Oil

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU00517 break down and erode. If electrode NOTE: Engine oil erosion becomes excessive, or if If a torque wrench is not available 1. Oil level measurement carbon and other deposits are when you are installing a spark a.
  • Page 39 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Level window 1. Oil filler cap 1. Drain plug 2. Maximum level mark 2. Engine oil replacement c. Remove the drain plug and 3. Minimum level mark a. Warm up the engine for a few drain bolt.
  • Page 40 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Drain plug 1. Filter cover screw (×2) 1. Oil filter 2. O-ring 2. Drain bolt 2. O-ring (×2) 3. Compression spring d. Remove the filter cover screws NOTE: 4. Oil strainer and the oil filter cover. Make sure the O-ring is seated EC000070 e.
  • Page 41 PERIODIC MAINTENANCE AND MINOR REPAIR j. Start the engine and warm up Tightening torque: Recommended oil: minutes. While Drain plug: See page 8-1 warming up, check for oil leak- 10 Nm (1.0 m0kg) Oil quantity: age. If oil leakage is found, Filter cover screw: Total amount: stop the engine immediately...

  • Page 42: Air Filter

    PERIODIC MAINTENANCE AND MINOR REPAIR 5. Install the air filter in its case. 6. Install panel B. EC000085 8 Make sure the air filter is prop- erly seated in the filter case. 8 The engine should never be without filter 1.

  • Page 43: Carburetor Adjustment

    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...

  • Page 44: Throttle Cable Free Play Inspection

    If the free improper fuel/air supply or engine vent this, the cam chain tensioner play is incorrect, ask a Yamaha noise. To prevent this, the valve must be adjusted regularly. This dealer to make this adjustment.

  • Page 45: Tires

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU00668 EW000087 Maximum load* 157 kg Tires Cold tire pressure: Front Rear To ensure maximum performance, Proper loading of your motorcycle 125 kPa 150 kPa long service, and safe operation, Up to 90 kg (1.25 kgf/cm , (1.50 kgf/cm is important for several character- 1.25 bar)
  • Page 46 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 TW32 for handling characteristics can be Minimum tire tread...

  • Page 47: Wheels

    1. 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.

  • Page 48: Clutch Lever Free Play Adjustment

    PERIODIC MAINTENANCE AND MINOR REPAIR 2 1 3 1. Locknut 1. Adjusting nut 1. Locknut 2. Adjusting bolt 2. Locknut 2. Adjusting bolt 3. Free play 3. Free play If the specified free play cannot be EAU00694 EAU00699 obtained, proceed with the follow- Clutch lever free play Front brake lever free play ing steps.

  • Page 49: Rear Brake Pedal Height And Free Play Adjustment

    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.

  • Page 50: Brake Light Switch Adjustment

    2. Free play EAU00713 Brake light switch proper adjustment, consult a The rear brake pedal free play Yamaha dealer. adjustment should be adjusted to 20 ~ 30 mm at the brake pedal end. The rear brake light switch is acti-...

  • Page 51: Checking The Brake Shoes

    Apply the chain slack while it’s in this tightest brake and inspect the position of position. the indicator. If the indicator reach- es to the wear limit line, ask a Yamaha dealer to replace the shoes. 6-21...

  • Page 52: Drive Chain Slack Adjustment

    PERIODIC MAINTENANCE AND MINOR REPAIR EC000096 To check the chain slack the motor- cycle must be held straight up with Too little chain slack will overload both wheels on the ground and the engine and other vital parts. without rider. Check the slack at Keep the slack within the specified the position shown in the illustra- limits.

  • Page 53: Drive Chain Lubrication

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU01106 7. Adjust the free play in the Drive chain lubrication brake pedal. The chain consists of many parts EW000103 which work with each other. If the chain is not maintained properly, it Check the operation of the brake will wear out quickly.

  • Page 54: Cable Inspection And Lubrication

    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: Same as engine oil 6-24...

  • Page 55: Brake And Clutch Lever Lubrication

    Recommended lubricant: surfaces. Check that the sidestand Recommended lubricant: Lithium soap base grease moves up and down smoothly. Same as engine oil Recommended lubricant: Same as engine oil EW000113 If the sidestand does not move smoothly, consult a Yamaha deal- 6-25...

  • Page 56: Front Fork Inspection

    1. Visual check them forward and backward. If any Check for scratches or damage free play can be felt, ask a Yamaha on the inner tube and exces- dealer to inspect and adjust the sive oil leakage from the front steering.

  • Page 57: Wheel Bearings

    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.
  • Page 58 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. burns, etc. It contains sulfuric acid. Battery fluid may weaken the Avoid contact with skin, eyes or chain causing shorter chain life clothing.

  • Page 59: Fuse Replacement

    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...

  • Page 60: Headlight Bulb Replacement

    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 adjustment. 6-30...

  • Page 61: Supporting The Motorcycle

    EAU00862 Check that the motorcycle is in a Supporting the motorcycle stable and level position before Since the Yamaha TW200E has no starting any maintenance. A strong centerstand, follow these precau- wooden box can be placed under tions when removing the front and the engine for added stability.

  • Page 62: Front Wheel Installation

    PERIODIC MAINTENANCE AND MINOR REPAIR 2. Loosen the brake cable free 3. Make sure the axle nut is prop- play adjusting nuts. Remove erly torqued, and a new cotter the brake cable from the han- pin is installed. dlebar lever holder and then EW000124 from the front wheel hub.

  • Page 63: Rear Wheel Removal

    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.

  • Page 64: Troubleshooting

    (See page 6-19.) for making checks. EW000103 If your motorcycle requires any repair, bring it to a Yamaha dealer. Check the operation of the brake skilled technicians light after adjusting the rear brake.

  • Page 65: Troubleshooting Chart

    2. Compression There is compression. Go to ignition check. Use electric starter. No compression. Ask a Yamaha dealer to inspect. 3. Ignition Wipe clean with dry cloth and correct Open the throttle half-way and start Remove spark spark plug gap or replace spark plugs.

  • Page 66: Cleaning And Storage

    EAU01010 CLEANING AND STORAGE EAU01301 EC000111 1. Before cleaning the motorcy- A. CLEANING cle: Frequent, thorough cleaning of Excessive hose pressure a. Block off the end of the your motorcycle will not only cause water seepage and deterio- exhaust pipe to prevent water enhance its appearance but will ration of wheel bearings, front entry;...

  • Page 67: Storage

    CLEANING AND STORAGE EAU01107 6. Rinse motorcycle 3. Thoroughly clean and lubricate B. STORAGE immediately with clean water the drive chain. (For details, Long term storage (60 days or and dry all surfaces with a see “Drive chain lubrication” more) of your motorcycle will chamois, clean towel, or soft on page 6-23.) require some preventive proce-...

  • Page 68: Specifications

    EAU01038 SPECIFICATIONS Specifications Model TW200E Engine oil: –10° 0° 10° 20° 30° 40° Dimensions: Type: Overall length 2,090 mm SAE 10W/30 Overall width 815 mm SAE 10W/40 Overall height 1,115 mm SAE 20W/40 Seat height 790 mm SAE 20W/50 Wheel base...
  • Page 69 EAU01038 SPECIFICATIONS Spark plug: Tire: Type With tube Type / Manufacturer D8EA / NGK or X24ES-U / DENSO Size: Spark plug gap 0.6 ~ 0.7 mm Front 130/80-18 66P Clutch type: Wet, multiple-disc Rear 180/80-14M/C 78P Transmission: Manufacturer / model: Primary reduction system Spur gear Front...
  • Page 70 SPECIFICATIONS Wheels: Electrical: Type: Ignition system: C.D.I. Front Spoke wheel Charging system: Rear Spoke wheel Type A.C. magneto Size: Standard output 12V 11A / 5,000 rpm 18 × 2.50 Front Battery: 14M/C × MT4.50 Rear Type GM7CZ-3D Brakes: Voltage, capacity 12V 7 AH Front: Headlight type...

  • Page 71: How To Use The Conversion Table

    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 •...

  • Page 72: Consumer Information

    Yamaha dealer or for reference in case the vehicle is stolen. 1. Key identification number 1. Vehicle identification number 1. KEY IDENTIFICATION...

  • Page 73: Model Label

    The model label is affixed to the frame under the seat. (See page 3- 9 for seat removal procedures.) Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer.
  • Page 74 YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN PRINTED ON RECYCLED PAPER 2000·12–0.1×2(E)

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