Yamaha TW200N Service Manual
  1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Motorcycle
  5. TW200N
  6. Service manual
Yamaha TW200N Service Manual

Yamaha TW200N Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

TW200N
TW200NC
SUPPLEMENTARY
SERVICEMANUAL
LIT-11616-14-43
2YG-28197-11

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the TW200N and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Yamaha TW200N

Summary of Contents for Yamaha TW200N

  • Page 1 TW200N TW200NC SUPPLEMENTARY SERVICEMANUAL LIT-11616-14-43 2YG-28197-11...
  • Page 2 TW200T/TC ’87 SERVICE MANUAL: LIT-11616-05-93 (2JX-28197-10) TW200EU/EUC ’88 SUPPLEMENTARY SERVICE MANUAL: LIT-11616-06-26 (2YG-28197-10) TW200N/TW200NC SUPPLEMENTARY SERVICE MANUAL © 2000 by Yamaha Motor Corporation, U.S.A. First edition, November 2000 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

  • Page 3: Important Manual Information

    If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

  • Page 4: How To Use This Manual

    EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
  • Page 5 EAS00008 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetion 6 Chassis 7 Electrical system CHAS CARB 8 Troubleshooting...

  • Page 6: Table Of Contents

    CONTENTS GENERAL INFORMATION................1 MOTORCYCLE IDENTIFICATION ............1 VEHICLE IDENTIFICATION NUMBER ..........1 MODEL CODE ..................1 SPECIFICATIONS .................... 2 GENERAL SPECIFICATIONS ..............2 MAINTENANCE SPECIFICATIONS ............4 ENGINE ....................4 TIGHTENING TORQUESS ..............6 CHASSIS ....................7 TIGHTENING TORQUESS ..............8 ELECTRICAL ..................
  • Page 7 CHASSIS ......................40 FRONT WHEEL AND BRAKE DISC ............40 REMOVING THE FRONT WHEEL ............ 42 CHECKING THE BRAKE DISC ............42 INSTALLING THE FRONT WHEEL ........... 44 FRONT BRAKE ..................46 FRONT BRAKE PADS ............... 46 REPLACING THE FRONT BRAKE PADS ......... 47 FRONT BRAKE MASTER CYLINDER ..........

  • Page 8: General Information

    MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL CODE The model code label 1 is affixed to the frame.

  • Page 9: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model TW200EN/TW200ENC Model code number: TW200EN: 5FY8 TW200ENC: 5FY9 Dimensions: Overall length 2,090 mm (82.3 in) Overall width 820 mm (32.3 in) Overall height 1,120 mm (44.1 in) Seat height 790 mm (31.1 in) Wheelbase 1,325 mm (52.2 in) Minimum ground clearance...
  • Page 10 SPEC GENERAL SPECIFICATIONS Model TW200EN/TW200ENC Basic weight: With oil and full fuel tank 126 kg (278 lb)/(TW200EN), 127 kg (280 lb) (TW200ENC) Maximum load* 157 kg (346 lb)/(TW200EN), 156 kg (344 lb) (TW200ENC) Cold tire pressure: Front Rear Up to 80 kg (176 lb) load* 125 kPa 125 kPa (1.25 kg/cm...

  • Page 11: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model TW200EN/TW200ENC Camshaft: Drive method Chain drive (left) Cam cap inside diameter 25.000 ~ 25.021 mm (0.984 ~ 0.985 in) Camshaft outside diameter 24.96 ~ 24.98 mm (0.983 ~ 0.984 in) Shaft-to-cap clearance 0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in) Cam dimensions: Intake: “A”...
  • Page 12 SPEC MAINTENANCE SPECIFICATIONS Model TW200EN/TW200ENC Carburetor: ID mark TW200EN: 5FY10 TW200ENC: 5FY00 Main jet (M.J.) TW200EN: #126 TW200ENC: #128 Main air jet (M.A.J.) Jet needle-clip/position (J.N) TW200EN: 5B21-1/1 TW200ENC: 5B21-1/3 Main nozzle (M.N.) 2.600 Pilot jet (P.J.) Pilot air jet (P.A.J.) TW200EN: 0.95 TW200ENC: 1.0...

  • Page 13: Tightening Torquess

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUESS Tightening Thread torque Parts to be tightened Part name Q’ty Remarks size Nm m·kg ft·lb Cam sprocket cover Bolt Tappet cover Bolt Timing chain tensioner Bolt Oil filter cover Bolt Muffler protector Screw Crankcase Bolt Crankcase cover (left) Bolt Crankcase cover (right)

  • Page 14: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Model TW200EN/TW200ENC Steering system: Steering bearing type Angular ball Drive chain: Type/manufacturer 428HG (I)/DAIDO Number of links 121 links + joint Chain free play 35 ~ 60 mm (1.38 ~ 2.36 in) Front brake: Brake type Single-disc brake Disc outside diameter ×...

  • Page 15: Tightening Torquess

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUESS Tightening torque Parts to be tightened Thread size Remarks m·kg ft·lb M6 × 1.0 Throttle cable and carburetor M12 × 1.25 Pivot shaft and frame M10 × 1.25 Rear shock absorber and frame M5 × 0.8 Drive chain case and swingarm M8 ×...

  • Page 16: Electrical

    MAINTENANCE SPECIFICATIONS ELECTRICAL Model TW200EN/TW200ENC C.D.I.: Magneto model/manufacturer F5BT/YAMAHA 656 ~ 984 Ω at 20 °C (68 °F) (R–W) Pickup coil resistance (color) 624 ~ 936 Ω at 20 °C (68 °F) (Br–G) Source coil resistance (color) C.D.I. unit-model/manufacturer 5LB/YAMAHA...

  • Page 17: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Throttle cable 9 Indicator lights lead È Fasten the brake hose with a 2 Front brake light switch lead 0 Speedometer cable plastic locking tie to the 3 Right handlebar switch lead A Meter light lead brake hose grommet.
  • Page 18 SPEC CABLE ROUTING 1 Clutch cable È Fasten the resonator hose with a plastic band between the resonator 2 Left handlebar switch lead hose protectors so that the fastener does not squeeze the hose. 3 Clutch switch lead É Pass the canister hose through the guide of the frame. (for California) 4 Resonator hose Ê...
  • Page 19 SPEC CABLE ROUTING 1 Sidestand switch lead È Fasten the AC magneto leads with a plastic locking tie to the frame at 2 Crankcase breather hose the section where the frame starts to curve. 3 Battery negative terminal É Fasten the carburetor air vent hose, carburetor overflow hose, and 4 Carburetor air vent hose neutral switch lead with a plastic clip.
  • Page 20 SPEC CABLE ROUTING 1 Ignition coil È Fasten the wire harness, right handlebar switch lead, front brake light 2 Throttle cable switch lead, clutch switch lead, main switch lead, and throttle cable 3 Horn lead with a plastic band. 4 Canister hose (for California) É...
  • Page 21 SPEC CABLE ROUTING Ì Fasten the wire harness, right handlebar switch lead, front brake light switch lead, clutch switch lead, main switch lead, resonator hose, ignition coil lead, ground lead, and horn lead with a plastic band. Í Fasten the canister hose with a plastic band. (for California) Î...
  • Page 22 SPEC CABLE ROUTING 1 Diode È Fasten the wire harness with a plastic locking tie at the section just before the 2 Battery positive lead leads split. 3 Starter relay É Pass the battery breather hose inside the battery positive lead. 4 Starter motor lead Ê...
  • Page 23 SPEC CABLE ROUTING 1 Clutch switch lead B Left handlebar switch lead Ê Fasten the left handlebar switch 2 Clutch cable lead and clutch switch lead with 3 Brake hose È Fasten right handlebar a plastic band. 4 Throttle cable switch lead and front brake light 5 Front brake light switch lead switch lead with a plastic band.
  • Page 24 SPEC CABLE ROUTING 1 Battery positive lead È Fasten the wire harness and rear turn signal light lead (right) 2 Rear turn signal light lead (right) with a plastic locking tie at the section behind the hook. 3 Tail/brake light lead É...

  • Page 25: Periodic Checks And Adjustments

    √ sion control sys- • Replace if necessary. tem** *: Since these items require special tools, data and technical skills, have a Yamaha dealer perform the ser- vice. **: California type only. NOTE: From 16,000 mi (26,000 km) or 30 months, repeat the maintenance intervals starting from 4,000 mi (6,000 km) or 6 months.

  • Page 26: General Maintenance And Lubrication Chart

    √ √ 2 * Oil filter/strainer – • Replace oil filter and strainer if dam- aged. • Wet type filter must Yamaha foam air fil- √ √ √ √ √ 3 * Air filter be washed and ter oil or other quality damped with oil.
  • Page 27 – saly. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the ser- vice. NOTE: 1. The air filter element needs more frequent service if you are riding in unusually wet or dusty areas.

  • Page 28: Engine

    ADJUSTING THE THROTTLE CABLE FREE PLAY ENGINE ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted properly. 1. Measure: • throttle cable free play a Out of specification → Adjust. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0.12 ~ 0.20 in)

  • Page 29: Cleaning The Spark Arrester

    ADJUSTING THE THROTTLE CABLE FREE PLAY/ CLEANING THE SPARK ARRESTER Handlebar side a. Slide back the rubber cover 3. b. Loosen the locknut 4. c. Turn the adjusting nut 5 in direction c or d until the specified throttle cable free play is obtained.

  • Page 30: Chassis

    ADJUSTING THE FRONT BRAKE CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: • brake lever free play a Out of specification → Adjust. Brake lever free play (at the end of the brake lever) 2 ~ 5 mm (0.08 ~ 0.20 in) 2.

  • Page 31: Checking The Brake Fluid Level

    CHECKING THE BRAKE FLUID LEVEL CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure that the motorcycle is upright. 2. Check: • brake fluid level Below the minimum level mark a →...

  • Page 32: Checking The Brake Pads

    CHECKING THE BRAKE PADS/ CHECKING THE BRAKE HOSE CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • front brake pad Wear indicator groove 1 almost disap- peared → Replace the brake pads as a set. Refer “REPLACING FRONT...

  • Page 33: Bleeding The Hydraulic Brake System

    BLEEDING THE HYDRAULIC BRAKE SYSTEM BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system when- ever: • the brake system was disassembled, • a brake hose was loosened, disconnected or replaced, • the brake fluid level is very low, •...
  • Page 34 BLEEDING THE HYDRAULIC BRAKE SYSTEM h. Tighten the bleed screw and then release the brake lever. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. Bleed screw 6 Nm (0.6 m ·...

  • Page 35: Engine

    CYLINDER HEAD ENGINE CYLINDER HEAD Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Carburetor Refer to “CARBURETOR”. Fuel tank Exhaust pipe Resonator hose Disconnect. Carburetor joint Timing chain tensioner cap bolt Refer to “INSTALLING THE TIMING Timing chain tensioner CHAIN TENSIONER”.

  • Page 36: Checking The Timing Chain Tensioner

    CYLINDER HEAD CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage/rough movement → Replace. a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. NOTE: While pressing the timing chain tensioner rod, wind it clockwise with a thin screwdriver 1 until it stops.

  • Page 37: Ac Magneto

    AC MAGNETO AC MAGNETO STATOR COIL ASSEMBLY AND PICKUP COIL 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the stator coil assembly Remove the parts in the order listed. and pickup coil Engine oil Drain.

  • Page 38: Ac Magneto

    AC MAGNETO AC MAGNETO Order Job/Part Q’ty Remarks Removing the AC magneto Remove the parts in the order listed. AC magneto Starter idle gear shaft/collar Starter idle gear Woodruff key Starter wheel gear Washer Roller Spring cap Spring Starter clutch For installation, reverse the removal procedure.

  • Page 39: Carburetion

    CARB CARBURETOR CARBURETION CARBURETOR Order Job/Part Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Seat Side cover Fuel tank Throttle cable Clamp (carburetor joint) Clamp (ail filter joint) Carburetor assembly For installation, reverse the removal procedure. –...
  • Page 40 CARB CARBURETOR Order Job/Part Q’ty Remarks Disassembling the carburetor Remove the parts in the order listed. NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. Starter plunger Vacuum chamber cover/spring Jet needle holder...
  • Page 41 CARB CARBURETOR Order Job/Part Q’ty Remarks Float chamber/gasket Refer to “ASSEMBLING THE CARBU- Float pin RETOR”. Float Needle valve Valve seat set Main jet Pilot jet Main jet nozzle For assembly, reverse the disassembly procedure. – 34 –...

  • Page 42: Disassembling The Carburetor

    CARB CARBURETOR DISASSEMBLING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. CHECKING THE CARBURETOR 1. Check: • carburetor body •...
  • Page 43 CARB CARBURETOR 6. Check: • needle valve 1 • needle valve seat 2 Damage/obstruction/wear → Replace the needle valve, needle valve seat and O-ring as a set. 7. Check: • O-ring 3 Damage/wear → Replace the needle valve, needle valve seat and O-ring as a set. 8.

  • Page 44: Assembling The Carburetor

    CARB CARBURETOR 12.Check: • casting enricher 1 Cracks/tears → Replace. • casting enricher cover 2 • casting enricher spring 3 Cracks/damage → Replace. 13.Check: • fuel hoses Cracks/damage/wear → Replace. Obstruction → Clean. Blow out the hoses with compressed air. 14.Check: •...

  • Page 45: Installing The Carburetor

    CARB CARBURETOR 2. Measure: • float height a Out of specification → Adjust. Float height (F.H.): 10 ~ 11 mm (0.39 ~ 0.43 in) a. Hold the carburetor in an upside down posi- tion. b. Measure the distance from the front mating surface of the float chamber (gasket removed) to the top of the float.

  • Page 46: Measuring And Adjusting The Fuel Level

    CARB CARBURETOR MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: • fuel level a Out of specification → Adjust. Fuel level (above the line on the float chamber mating surface) 0.5 ~ 1.5 mm (0.02 ~ 0.06 in) a. Stand the motorcycle on a level surface. b.

  • Page 47: Chassis

    CHAS FRONT WHEEL AND BRAKE DISC CHASSIS FRONT WHEEL AND BRAKE DISC 90 Nm (9.0 m kg, 65 ft • • 13 Nm (1.3 m kg, 9.4 ft • • Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed.
  • Page 48 CHAS FRONT WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal Wheel bearing (left and right) Spacer For assembly, reverse the disassembly procedure. – 41 –...

  • Page 49: Removing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 50 CHAS FRONT WHEEL AND BRAKE DISC 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc. Max. brake disc deflection 0.15 mm (0.006 in) a. Place the motorcycle on a suitable stand so that the wheel is elevated.

  • Page 51: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc.
  • Page 52 CHAS FRONT WHEEL AND BRAKE DISC 5. Tighten: • wheel axle nut 1 90 Nm (9.0 m · kg, 65 ft · lb) CAUTION: Before tightening the wheel axle nut, push down hard on the handlebars several times and check if the front fork rebounds smoothly.

  • Page 53: Front Brake

    CHAS FRONT BRAKE FRONT BRAKE FRONT BRAKE PADS 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Retaining bolt (lower) Brake caliper Brake pad Brake pad spring For installation, reverse the removal procedure.

  • Page 54: Replacing The Front Brake Pads

    CHAS FRONT BRAKE CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 55 CHAS FRONT BRAKE 2. Remove: • brake pads 1 • brake pad springs 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.8 mm (0.03 in) 4.
  • Page 56 CHAS FRONT BRAKE 5. Install: • retaining bolt (lower) 27 Nm (2.7 m · kg, 19 ft · lb) 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level.

  • Page 57: Front Brake Master Cylinder

    CHAS FRONT BRAKE FRONT BRAKE MASTER CYLINDER 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain.
  • Page 58 CHAS FRONT BRAKE Order Job/Part Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order listed. ter cylinder Brake master cylinder reservoir dia- phragm Dust boot Circlip Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure.

  • Page 59: Disassembling The Front Brake Master Cylinder

    CHAS FRONT BRAKE DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect • front brake light switch 2. Remove: • union bolt 1 • copper washers 2 •...

  • Page 60: Assembling And Installing The Front Brake Mater Cylinder

    CHAS FRONT BRAKE ASSEMBLING AND INSTALLING THE FRONT BRAKE MATER CYLINDER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components. Recommended brake fluid DOT 4 1.
  • Page 61 CHAS FRONT BRAKE 3. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 62: Front Brake Caliper

    CHAS FRONT BRAKE FRONT BRAKE CALIPER 30 Nm (3.0 m kg, 22 ft • • 30 Nm (3.0 m kg, 22 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed.
  • Page 63 CHAS FRONT BRAKE Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. pers Retaining bolt Brake caliper bracket Brake pad Brake pad spring Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly procedure.

  • Page 64: Disassembling The Front Brake Caliper

    CHAS FRONT BRAKE DISASSEMBLING THE FRONT BRAKE CALIPER NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake sys- tem. 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.

  • Page 65: Checking The Front And Rear Brake Calipers

    CHAS FRONT BRAKE CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Every two years and whenever the Brake fluid brake is disassem- bled 1.

  • Page 66: Assembling And Installing The Front Brake Calipers

    CHAS FRONT BRAKE ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort.
  • Page 67 CHAS FRONT BRAKE 3. Remove: • retaining bolt (lower) 4. Install: • brake pad springs • brake pads • brake caliper 27 Nm (2.7 m · kg, 19 ft · lb) 5. Fill: • Brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT4...
  • Page 68 CHAS FRONT BRAKE 7. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”. 8. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system.

  • Page 69: Front Fork

    CHAS FRONT FORK FRONT FORK 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft • •...

  • Page 70: Steering Head

    CHAS STEERING HEAD STEERING HEAD 90 Nm (9.0 m kg, 65 ft • • 1st 38 Nm (3.8 m kg, 27 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • Order Job/Part Q’ty Remarks Removing the lower bracket Remove the parts in the order listed.
  • Page 71 CHAS STEERING HEAD 90 Nm (9.0 m kg, 65 ft • • 1st 38 Nm (3.8 m kg, 27 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • Order Job/Part Q’ty Remarks Bearing outer race Bearing outer rase For installation reverse the removal procedure.

  • Page 72: Installing The Bearing (Retainer Type)

    CHAS STEERING HEAD È INSTALLING THE BEARING (RETAINER TYPE) 1. Install: • Bearing (retainer type) NOTE: • When install the bearing (retainer type) make sure that the projections 1 on the surface of the bearing face upward. • Since there are differences in both the upper and lower bearings, the bearings can be É...

  • Page 73: Electrical

    – ELEC ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS 1 Wire harness A Rectifier/regulator 2 Main switch B Turn signal relay 3 Front brake light switch C Sidestand switch 4 Main fuse D Neutral switch 5 Starter relay E Pickup coil 6 Neutral relay F Stator coil assembly 7 Diode G Rear brake light switch...

  • Page 74: Switches

    – ELEC SWITCHES SWITCHES “∞” “0” CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. “Ω×1” CAUTION: Never insert the tester probes into the cou- pler terminal slots 1.

  • Page 75: Checking The Switches

    – ELEC CHECKING THE SWITCHES CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace the switch. Improperly connected → Properly connect. Incorrect continuity reading →...
  • Page 76 – ELEC CHECKING THE SWITCHES 1 Horn switch 2 Turn signal switch 3 Dimmer switch 4 Main switch 5 Clutch switch 6 Start switch 7 Engine stop switch 8 Front brake light switch 9 Rear brake light switch 0 Fuse A Neutral switch B Sidestand switch –...

  • Page 77: Ignition System

    – ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM – 70 –...

  • Page 78: Troubleshooting

    – ELEC IGNITION SYSTEM TROUBLESHOOTING 1. Spark plug The ignition system fails to operate (no The following procedure applies to all of the spark or intermittent spark). spark plug. • Check the condition of the spark plug. Check: • Check the spark plug type. 1.
  • Page 79 – ELEC IGNITION SYSTEM 2. Ignition spark gap 3. Spark plug cap resistance The following procedure applies to all of the The following procedure applies to all of the spark plug. spark plug cap. • Disconnect the spark plug cap from the •...
  • Page 80 – ELEC IGNITION SYSTEM 4. Ignition coil resistance 5. Pickup coil resistance • Disconnect the ignition coil connector from • Disconnect the pickup coil coupler from the the ignition coil terminal. wire harness. • Connect the pocket tester (Ω × 1) to the •...
  • Page 81 – ELEC IGNITION SYSTEM 6. Source coil resistance 8. Engine stop switch • Disconnect the source coil coupler from the • Check the engine stop switch for continuity. wire harness. Refer to “CHECKING THE SWITCHES” • Connect the pocket tester (Ω × 100) to the •...

  • Page 82: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM – 75 –...

  • Page 83: Starting Circuit Cut-Off System Operation

    – ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...

  • Page 84: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the battery fluid level, battery termi- nal and specific gravity. Check: Specific gravity 1. main fuse 1.280 at 20 °C (68 °F) 2. battery 3.
  • Page 85 – ELEC ELECTRIC STARTING SYSTEM 4. Neutral relay 5. Diode • Remove the neutral relay from the wire har- • Remove the diode from the wire harness. • Connect the pocket tester (Ω × 1) to the ness. • Connect the pocket tester (Ω × 1) and the diode terminals as shown.
  • Page 86 – ELEC ELECTRIC STARTING SYSTEM 6. Starter relay 8. Engine stop switch • Remove the starter relay from the wire har- • Check the engine stop switch for continuity. ness. Refer to “CHECKING THE SWITCHES”. • Connect the pocket tester (Ω × 1) and the •...
  • Page 87 – ELEC ELECTRIC STARTING SYSTEM 12.Start switch • Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the start switch OK? Replace right handlebar switch. EB803408 13.Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. •...

  • Page 88: Signaling System

    – ELEC SIGNALING SYSTEM SIGNALING SYSTEM CIRCUIT DIAGRAM – 81 –...

  • Page 89: Troubleshooting

    – ELEC SIGNALING SYSTEM TROUBLESHOOTING 2. Battery • Any of the following fail to light: turn • Check the battery fluid level, battery termi- signal light, brake light or an indicator nal and specific gravity. light. Specific gravity • The horn fails to sound. 1.280 at 20 °C (68 °F) Check: •...

  • Page 90: Checking The Signaling System

    – ELEC SIGNALING SYSTEM CHECKING THE SIGNALING SYSTEM 3. Horn 1. The horn fails to sound. • Disconnect the pink connector at the horn 1. Horn switch terminal. • Connect a jumper lead 1 to the horn termi- • Check the horn switch for continuity. nal and ground the jumper lead.
  • Page 91 – ELEC SIGNALING SYSTEM 2. A tail/brake light fails to come on. 3. Voltage 1. Tail/brake light bulb and socket • Connect the pocket tester (DC 20 V) to the tail/brake light connectors (wire harness • Check the tail/brake light bulb and socket side) as shown.
  • Page 92 – ELEC SIGNALING SYSTEM 2. Turn signal indicator light bulb and socket 4. Voltage • Check the turn signal indicator light bulb • Connect the pocket tester (DC 20 V) to the and socket for continuity. turn signal relay coupler (wire harness side) •...
  • Page 93 – ELEC SIGNALING SYSTEM 5. Voltage 6. Voltage • Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) turn signal light connectors or the meter as shown.
  • Page 94 – ELEC SIGNALING SYSTEM 4. The neutral indicator light fails to come on. 3. Voltage 1. Neutral indicator light bulb and socket • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) • Check the neutral indicator light bulb and as shown.
  • Page 95 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.

  • Page 96: Tw200En/Tw200Enc Wiring Diagram

    TW200EN/TW200ENC WIRING DIAGRAM 1 AC magneto 2 Neutral switch 3 Rectifier/regulator 4 Battery 5 Main fuse (GRAY) (GRAY) 6 Starter relay 7 Starter motor 8 Right handlebar switch 9 Start switch 0 Engine stop switch W W W A Main switch B Diode (BLACK) C Clutch switch...

This manual is also suitable for:

Tw200nc

Table of Contents

Save PDF