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Yamaha TW200 Owner's Manual

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OWNER'S MANUAL
TW200N(C)
LIT-11626-14-43
5FY-28199-13

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Summary of Contents for Yamaha TW200

  • Page 1 OWNER’S MANUAL TW200N(C) LIT-11626-14-43 5FY-28199-13...
  • Page 2 EAU03438...
  • Page 3 The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met these standards without reduc- ing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.

  • Page 4: Important Manual Information

    8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. 8 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 5 IMPORTANT MANUAL INFORMATION EW000000 PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADE- QUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
  • Page 6 AFFIX DEALER LABEL HERE EAU03336 TW200N(C) OWNER’S MANUAL ©2000 by Yamaha Motor Corporation, U.S.A. 1st Edition, August 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan.

  • Page 7: Table Of Contents

    EAU00009 TABLE OF CONTENTS SAFETY INFORMATION ........1-1 Seat..............3-8 Safe riding ............1-1 Helmet holder...........3-9 Protective apparel ..........1-3 Shock absorber ..........3-9 Modifications ............1-3 Carrier ..............3-9 Loading and accessories .........1-3 Luggage strap holders ........3-10 Gasoline and exhaust gas .......1-5 Sidestand ............3-10 Location of important labels ......1-7 Ignition circuit cut-off system......3-11 DESCRIPTION............2-1 PRE-OPERATION CHECKS ......4-1...
  • Page 8 TABLE OF CONTENTS General maintenance and Drive chain slack ..........6-28 lubrication chart..........6-4 Lubricating the drive chain ......6-29 Removing and installing the Checking and lubricating the cowling and panels ........6-7 cables............6-30 Checking the spark plug ........6-9 Checking and lubricating the throttle grip Canister (for California only) ......6-11 and cable .............6-31 Engine oil and oil filter element ......6-11...
  • Page 9 Storage ............7-4 SPECIFICATIONS ..........8-1 CONSUMER INFORMATION ......9-1 Identification numbers ........9-1 Key identification number.........9-1 Vehicle identification number ......9-1 Model label............9-2 Reporting safety defects ........9-3 Motorcycle noise regulation ......9-4 Maintenance record .........9-5 Street and enduro motorcycle limited warranty ..........9-7 Yamaha extended service .......9-9...

  • Page 10: Safety Information

    EAU00017 Q SAFETY INFORMATION MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPER- TISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE- MENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: 1.
  • Page 11 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 that you are qualified and that you only lend your motorcycle to other qualified oper- ators.

  • Page 12: Protective Apparel

    6. Passengers should also observe the precautions mentioned above. Modifications Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use.
  • Page 13 Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 157 kg (346 lb) TW200/156 kg (344 lb) TW200C. When loading within this weight limit, keep the following in mind: 1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible.

  • Page 14: Gasoline And Exhaust Gas

    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. b.
  • Page 15 Q SAFETY INFORMATION a. The engine and exhaust system may be hot, therefore, 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, otherwise it may fall over. c.

  • Page 16: Location Of Important Labels

    Q SAFETY INFORMATION EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle.
  • Page 17 Q SAFETY INFORMATION q WARNING WARNING Improper loading can cause loss of control. BEFORE YOU OPERATE THIS VEHICLE, READ Read owner’s manual for proper loading. THE OWNER’S MANUAL AND ALL LABELS. 3JJ-28446-A0 ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET, eye protection, and protective clothing. 3MX-2118K-A0 WARNING CAUTION...

  • Page 18: Description

    EAU00026 DESCRIPTION Left view 1. Fuel tank cap (page 3-5) 6. Air filter element (page 6-14) 2. Fuel cock (page 3-7) 7. Starter (choke) knob (page 3-8) 3. Helmet holder (page 3-9) 8. Shift pedal (page 3-4) 4. Luggage strap holders (page 3-10) 5.

  • Page 19: Right View

    DESCRIPTION Right view 14 13 12 11 9. Carrier (page 3-9) 14. Fuse (page 6-37) 10. Battery (page 6-34) 15. Luggage strap holders (page 3-10) 11. Engine oil level check window (page 6-11) 16. Spark arrester (page 6-16) 12. Brake pedal (page 3-5, 6-23) 13.

  • Page 20: Controls And Instruments

    DESCRIPTION Controls and instruments 1. Clutch lever (page 3-4, 6-22) 6. Right handlebar switches (page 3-3) 2. Left handlebar switches (page 3-2) 7. Brake lever (page 3-4, 6-23) 3. Speedometer unit (page 3-2) 8. Throttle grip (page 6-18, 6-31) 4. Main switch/steering lock (page 3-1) 9.

  • Page 21: Instrument And Control Functions

    EAU00027 INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering Insert the key and turn it to “OFF”. EW000017 Never turn the key to “LOCK” while the motorcycle is moving. LOCK a. Push. b. Release. EAU00029 c. Turn. Main switch/steering lock EAU00043 The main switch/steering lock con- LOCK...

  • Page 22: Indicator Lights

    INSTRUMENT AND CONTROL FUNCTIONS 1. Turn signal indicator light “5” 1. Speedometer 1. Dimmer switch 2. High beam indicator light “&” 2. Odometer 2. Turn signal switch 3. Neutral indicator light “N” 3. Tripmeter 3. Horn switch “*” 4. Reset knob EAU00056 EAU00118 Indicator lights...
  • Page 23 INSTRUMENT AND CONTROL FUNCTIONS EAU00129 EAU00143 Horn switch “*” Start switch “,” Press this switch to sound the horn. Push this switch to crank the engine with the starter. EC000005 See page 5-1 for starting instruc- tions prior to starting the engine. 1.

  • Page 24: Clutch Lever

    INSTRUMENT AND CONTROL FUNCTIONS 1. Clutch lever 1. Shift pedal 1. Brake lever N. Neutral EAU00152 EAU00158 EAU00157 Clutch lever Brake lever Shift pedal The clutch lever is located at the left The brake lever is located at the right The shift pedal is located on the left handlebar grip.

  • Page 25: Brake Pedal

    INSTRUMENT AND CONTROL FUNCTIONS To install the fuel tank cap 1. Insert the fuel tank cap into the tank opening with the key insert- ed in the lock, and then turn the cap 1/3 turn clockwise. 2. Turn the key 1/4 turn clockwise, and then remove it.

  • Page 26: Fuel

    INSTRUMENT AND CONTROL FUNCTIONS EAU00185 Your Yamaha engine has been designed to use regular unleaded Immediately wipe off spilled fuel gasoline with a pump octane number with a clean, dry, soft cloth, since [(R+M)/2] of 86 or higher, or a...

  • Page 27: Fuel Cock

    INSTRUMENT AND CONTROL FUNCTIONS OFF: Closed position ON: Normal position RES: Reserve position FUEL FUEL FUEL 1. Arrow mark positioned over “OFF” 1. Arrow mark positioned over “ON” 1. Arrow mark positioned over “RES” EAU03050 Fuel cock With the lever in this position, fuel This indicates reserve.

  • Page 28: Starter (Choke) Knob

    INSTRUMENT AND CONTROL FUNCTIONS 1. Starter (choke) knob “1” 1. Bolt (×2) 1. Projection 2. Seat holder EAU03032 EAU01092 To install the seat Starter (choke) knob “1” Seat 1. Insert the projection on the front Starting a cold engine requires a rich- of the seat into the seat holder er air-fuel mixture, which is supplied To remove the seat...

  • Page 29: Helmet Holder

    8 Always have a Yamaha dealer service the shock absorber.

  • Page 30: Luggage Strap Holders

    There are four luggage strap holders fulfilling the responsibility of rais- off system.) below the carrier. ing the sidestand before starting off. Therefore, check this system regularly as described below and have a Yamaha dealer repair it if it does not function properly. 3-10...

  • Page 31: Ignition Circuit Cut-Off System

    Periodically check the operation of the ignition circuit cut-off system according to the following procedure. EW000045 If a malfunction is noted, have a Yamaha dealer check the system before riding. 3-11...
  • Page 32 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 33: Pre-Operation Checks

    • If necessary, add recommended oil to specified level. 6-11–6-14 • Check vehicle for oil leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check lever free play. Front brake • Adjust if necessary.
  • Page 34 • Make sure that operation is smooth. • Lubricate throttle grip, housing and cables if necessary. Throttle grip 6-18, 6-31 • Check free play. • If necessary, have Yamaha dealer make adjustment. • Make sure that operation is smooth. Control cables 6-30 • Lubricate if necessary.
  • Page 35 ITEM CHECKS PAGE ep19a0y • Check operation of ignition circuit cut-off system. 3-10 Sidestand switch • If system is defective, have Yamaha dealer check vehicle. ep20a0y • Check fluid level. 6-34–6-37 Battery • Fill with distilled water if necessary. NOTE: Pre-operation checks should be made each time the motorcycle is used.

  • Page 36: Operation And Important Riding Points

    Consult Yamaha dealer be blocked and performance 8 The transmission is in the neutral regarding any control or func- will suffer.
  • Page 37 ECA00055 should be on, otherwise have a Yamaha dealer check the electrical For maximum engine life, always circuit. warm the engine up before starting off. Never accelerate hard when the engine is cold!

  • Page 38: Starting A Warm Engine

    OPERATION AND IMPORTANT RIDING POINTS EAU01258 EC000048 Starting a warm engine Follow the same procedure as for 8 Even with the transmission in starting a cold engine with the excep- the neutral position, do not tion that the starter (choke) is not coast for long periods of time required when the engine is warm.

  • Page 39: Recommended Shift Points

    OPERATION AND IMPORTANT RIDING POINTS EAU02988 EAU00427 EAU02974 Recommended shift points To start out and accelerate To decelerate 1. Pull the clutch lever to disengage 1. Apply both the front and the rear The recommended shift points during the clutch. brakes to slow the motorcycle.

  • Page 40: Engine Break-In

    1/2 throttle. during the engine break-in period, 8 Rev the engine freely through overheating must be avoided. immediately have a Yamaha dealer the gears, but do not use full check the vehicle. throttle at any time. 500–1,000 km (300–600 mi) Avoid prolonged operation above 3/4 throttle.

  • Page 41: Parking

    OPERATION AND IMPORTANT RIDING POINTS FUEL 1. Arrow mark positioned over “OFF” EAU00457 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”. EW000058 8 Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely...

  • Page 42: Periodic Maintenance And Minor Repair

    GROUPED SEPARATELY. THESE ventive maintenance minor Yamaha dealer do it for you. SERVICES REQUIRE SPECIALIZED repairs. However, additional tools DATA, KNOWLEDGE, AND EQUIP- such as a torque wrench may be nec- MENT. YAMAHA DEALERS ARE...
  • Page 43 PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you. EW000063 Modifications not approved by Yamaha may cause loss of perfor- mance and render the vehicle unsafe for use.

  • Page 44: Periodic Maintenance Chart For The Emission Control System

    9 Replace if necessary. system** * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. ** 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...

  • Page 45: General Maintenance And Lubrication Chart

    √ √ √ 2 * Oil filter/Strainer — 9 Replace oil filter and strainer if damaged. 9 Wet type filter must Yamaha foam air filter √ √ √ √ √ 3 * Air filter be washed and oil or othe quality air filter damped with oil.
  • Page 46 9 Correct if necessary. 9 Check and clean or √ √ √ √ √ 16 * Sidestand switch — replace if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
  • Page 47 PERIODIC MAINTENANCE AND MINOR REPAIR 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. EAU03057 NOTE: 8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 8 Hydraulic brake system 9 When disassembling the master cylinder or caliper cylinder, always replace the brake fluid.

  • Page 48: Removing And Installing The Cowling And Panels

    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cowling A 1. Panel B 1. Screw 2. Panel A EAU01145 EAU03516 Cowling A Removing and installing the To remove the cowling cowling and panels Remove the screw, and then pull the The cowling and panels shown above cowling off as shown.
  • Page 49 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel A 1. Panel B 2. Screw (×2) EAU00494 To install the panel EAU01492 Panel B Place the panel in the original posi- Panel A To remove the panel tion, and then install the screws. To remove the panel Pull the panel off as shown.

  • Page 50: Checking The Spark Plug

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU01833 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart.

  • Page 51: To Check/Install Spark Plug

    Instead, However, the spark plug should be 1. Measure the spark plug gap with have a Yamaha dealer check the tightened to the specified torque as a wire thickness gauge and, if motorcycle. soon as possible. necessary, adjust the gap to specification.

  • Page 52: Canister (For California Only)

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU03936 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element cleaned at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 53 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil filler cap 1. Engine oil drain bolt 1. O-ring 2. Spring To change the engine oil (with or 3. Oil strainer without oil filter element cleaning) EC000070 1. Start the engine, warm it up for several minutes, and then turn it When removing the engine oil off.
  • Page 54 PERIODIC MAINTENANCE AND MINOR REPAIR 9. Install the oil filter element cover by installing the bolts and the drain bolt, then tightening them to the specified torques. Tightening torques: Oil filter element cover bolt: 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil filter element drain bolt: 1.

  • Page 55: Cleaning The Air Filter Element And Check Hose

    PERIODIC MAINTENANCE AND MINOR REPAIR EC000072 EAU03789* Tightening torque: Cleaning the air filter Engine oil drain bolt: element and check hose 8 In order to prevent clutch slip- 43 Nm (4.3 m·kg, 31 ft·lb) The air filter element should be page (since the engine oil also cleaned at the intervals specified in lubricates the clutch), do not...
  • Page 56 The sponge material should be wet but not dripping. Recommended oil: Yamaha foam air filter oil or other quality air filter oil 6. Pull the sponge material over the air filter element frame. 7. Insert the element into the air fil- ter case.

  • Page 57: Cleaning The Spark Arrester

    PERIODIC MAINTENANCE AND MINOR REPAIR EC000082 EAU01549 Cleaning the spark arrester 8 Make sure that the air filter ele- The spark arrester should be cleaned at the intervals specified in the ment is properly seated in the Periodic maintenance and lubrication air filter case.

  • Page 58: Adjusting The Carburetor

    The carburetor is an important part of the engine and its emission control system, which requires very sophisti- cated adjustment. Therefore, carbu- retor adjustments should be left to Yamaha dealer, who has the neces- sary professional knowledge and experience. 1. Muffler 1. Tailpipe 2.

  • Page 59: Adjusting The Throttle Cable Free Play

    To prevent regarding the specified tires. this from occurring, the valve clear- ance must be adjusted by a Yamaha Tire air pressure dealer at the intervals specified in the The tire air pressure should be...
  • Page 60 25 psi) 25 psi) packed items that shift. 157 kg (346 lb) TW200 Securely pack your heaviest items Maximum load* 156 kg (344 lb) TW200C 1. Side wall close to the center of the motorcy- 2. Wear indicator * Total weight of rider, passenger, cargo and cle, and distribute the weight even- a.
  • Page 61 PERIODIC MAINTENANCE AND MINOR REPAIR Tire information EW000079 EAU00680 This motorcycle is equipped with tube 8 Have a Yamaha dealer replace 8 It is dangerous to ride with a tires. excessively worn tires. worn-out tire. When a tire EW000078 Besides being illegal, operat-...

  • Page 62: Spoke Wheels

    PERIODIC MAINTENANCE AND MINOR REPAIR manufactured by other companies, EAU00685 EAU00691 Spoke wheels Accessories and replace- Yamaha cannot be held liable for ment parts To maximize the performance, dura- any consequences caused by the bility, and safe operation of your EW000098...

  • Page 63: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE AND MINOR REPAIR 3. If the specified clutch lever free play could obtained described above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows. 4. Fully turn the adjusting bolt at the clutch lever in direction a to loosen the clutch cable.

  • Page 64: Adjusting The Brake Lever Free Play

    2–5 mm (0.08–0.20 in) as braking performance, It is advisable to have a Yamaha shown. Periodically check the brake which may result in loss of dealer make these adjustments. lever free play and, if necessary, control and an accident.
  • Page 65 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Loosen the locknut at the brake pedal. 2. To raise the brake pedal, turn the adjusting bolt in direction a. To lower the brake pedal, turn the adjusting bolt in direction b. 3. Tighten the locknut. EWA00044 a.

  • Page 66: Adjusting The Rear Brake Light Switch

    8 If proper adjustment cannot be chart. obtained as described, have a 1. Brake light switch Yamaha dealer make this 2. Adjusting nut adjustment. EAU00713 8 After adjusting the brake pedal...

  • Page 67: Checking The Brake Fluid Level

    If the brake level is low, be line, have a Yamaha dealer replace sure to check the brake pads for the brake shoes as a set.

  • Page 68: Changing The Brake Fluid

    Changing the brake fluid 8 When checking the fluid level, ed surfaces or plastic parts. Have a Yamaha dealer change the make sure that the top of the Always clean up spilled fluid brake fluid at the intervals specified in brake fluid reservoir is level.

  • Page 69: Drive Chain Slack

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU00744 Drive chain slack The drive chain slack should be checked before each ride and adjust- ed if necessary. To check the drive chain slack 1. Place the motorcycle on a level surface and hold it in an upright position.

  • Page 70: Lubricating The Drive Chain

    NOTE: Axle nut: For a thorough cleaning, have a 90 Nm (9.0 m·kg, 65 ft·lb) Yamaha dealer remove the drive chain and soak it in solvent. 5. Adjust the brake pedal free play. (See page 6-24 for brake pedal free...

  • Page 71: Checking And Lubricating The Cables

    PERIODIC MAINTENANCE AND MINOR REPAIR EW000111 2. Spray Yamaha Chain and Cable Lube or a high-quality spray-type Damage to the outer housing of drive chain lubricant on both cables may result in internal rust- sides and on the middle of the...

  • Page 72: Checking And Lubricating The Throttle Grip And Cable

    Recommended lubricant: and the cable should be lubricated or Throttle cable: replaced if necessary. Yamaha Chan and Cable Lube or engine oil NOTE: Throttle grip housing and grip: Since the throttle grip must be...

  • Page 73: Checking And Lubricating The Brake And Clutch Levers

    Recommended lubricant: Recommended lubricant: EW000113 Lithium-soap-based grease Lithium-soap-based grease If the sidestand does not move up (all-purpose grease) (all-purpose grease) down smoothly, have Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 6-32...

  • Page 74: Checking The Front Fork

    EC000098 If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it. 6-33...

  • Page 75: Checking The Wheel Bearings

    Yamaha intervals specified in the periodic dealer check the wheel bearings. maintenance and lubrication chart.
  • Page 76 PERIODIC MAINTENANCE AND MINOR REPAIR EW000116 8 Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any con- tact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer 1.
  • Page 77 PERIODIC MAINTENANCE AND MINOR REPAIR To store the battery 1. If the motorcycle will not be used more than month, remove the battery, fully charge it, and then place it in a cool, dry place. 2. If the battery will be stored for more than two months, check the specific gravity of the electrolyte 1.

  • Page 78: Replacing The Fuse

    EAU01307 Replacing the fuse 4. If the fuse immediately blows The fuse holder is located behind again, have a Yamaha dealer panel B. (See page 6-8 for panel check the electrical system. removal and installation procedures.) If the fuse is blown, replace it as fol- lows.

  • Page 79: Replacing The Headlight Bulb

    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Bolt (×2) 1. Headlight coupler 1. Headlight bulb holder 2. Headlight bulb cover EAU01158 4. Remove the headlight bulb hold- 3. Disconnect the headlight cou- Replacing the headlight bulb er by turning it counterclockwise, pler, and then remove the head- If the headlight bulb burns out, and then remove the defective...

  • Page 80: Replacing A Turn Signal Light Bulb

    1. Remove the turn signal light lens 8. Install the cowling. by removing the screw. 9. Have a Yamaha dealer adjust 2. Remove the defective bulb by the headlight beam if necessary. pushing it in and turning it coun- terclockwise.

  • Page 81: Replacing The Tail/Brake Light Bulb

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 Supporting the motorcycle Since this model is not equipped with a centerstand, follow these precau- tions when removing the front and rear wheel or performing other main- tenance requiring the motorcycle to stand upright. Check that the motor- cycle is in a stable and level position before starting any maintenance.

  • Page 82: Front Wheel

    To remove the front wheel EW000122 8 It is advisable to have a Yamaha dealer service the wheel. 8 Securely support the motorcy- cle so that there is no danger of it falling over.

  • Page 83: Rear Wheel

    2. Lift the wheel up between the To remove the rear wheel fork legs. EW000122 NOTE: 8 It is advisable to have a Make sure that there is enough Yamaha dealer service the space between brake pads wheel. before inserting the brake disc and...
  • Page 84 PERIODIC MAINTENANCE AND MINOR REPAIR 2. Remove the brake pedal free 3. Install the axle nut, and then play adjusting nut, and then dis- lower the rear wheel so that it is connect the brake rod from the on the ground. brake camshaft lever.

  • Page 85: Troubleshooting

    Use only genuine Yamaha replace- ment parts. Imitation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills. 6-44...

  • Page 86: Troubleshooting Chart

    Remove the spark plug and check 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 87: Motorcycle Care And Storage

    EAU03521 MOTORCYCLE CARE AND STORAGE Care Before cleaning Cleaning 1. Cover the muffler outlet with a ECA00010 While the open design of a motorcy- plastic bag after the engine has cle reveals the attractiveness of the 8 Avoid using strong acidic cooled down.
  • Page 88 MOTORCYCLE CARE AND STORAGE 8 Do not use any harsh chemical 8 For motorcycles equipped After riding in the rain, near the sea products on plastic parts. Be with a windshield: Do not use or on salt-sprayed roads sure to avoid using cloths or strong cleaners hard...
  • Page 89 NOTE: 4. To prevent corrosion, it is recom- cle test its braking perfor- Consult a Yamaha dealer for advice mended to apply a corrosion pro- mance and cornering behav- tection spray on all metal, includ- on what products to use.

  • Page 90: Storage

    MOTORCYCLE CARE AND STORAGE Storage Long-term c. Install the spark plug cap onto Before storing your motorcycle for Short-term the spark plug, and then place several months: Always store your motorcycle in a the spark plug on the cylinder 1. Follow all the instructions in the cool, dry place and, if necessary, pro- head so that the electrodes “Care”...
  • Page 91 MOTORCYCLE CARE AND STORAGE 6. Lubricate all control cables and NOTE: the pivoting points of all levers Make any necessary repairs before and pedals as well as of the storing the motorcycle. sidestand/centerstand. 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels ground.

  • Page 92: Specifications

    API Service SE, SF, SG type Basic weight (with oil and full or higher fuel tank) 126 kg (278 lb) (TW200) 127 kg (280 lb) (TW200C) Engine Be sure to use motor oils that do not contain anti-friction Engine type Air-cooled 4-stroke, SOHC modifiers.
  • Page 93 Reserve amount 1.0 L (0.2 Imp gal, 0.3 US gal) 1.040 Carburetor 0.821 Manufacturer TEIKEI Chassis Model × quantity MV28 × 1 (TW200) Frame type Diamond MV28 1B × 1 (TW200C) Caster angle 25.8° Spark plug Trail 95 mm (3.74 in)
  • Page 94 SPECIFICATIONS Maximum load* 157 kg (346 lb) (TW200) Rear 156 kg (344 lb) (TW200C) Type Drum brake Air pressure (cold tire) Operation Right foot up to 90 kg load* Suspension Front 125 kPa (1.25 kg/cm , 18 psi) Front Rear 125 kPa (1.25 kg/cm...
  • Page 95 SPECIFICATIONS Headlight bulb type Halogen bulb Bulb voltage, wattage × quantity 12 V, 60/55 W × 1 Headlight 12 V, 8/27 W × 1 Tail/brake light 12 V, 27/8 W × 2 Front turn signal light 12 V, 27 W × 2 Rear turn signal light 12 V, 3.4 W ×...

  • Page 96: Consumer Information

    Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION 1. Key identification number 1.

  • Page 97: Model Label

    CONSUMER INFORMATION 1. Model label EAU03757 Model label The model label is affixed to the loca- tion shown. Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.

  • Page 98: Reporting Safety Defects

    If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should imme- diately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.

  • Page 99: Motorcycle Noise Regulation

    CONSUMER INFORMATION EAU01053 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any per- son.

  • Page 100: Maintenance Record

    CONSUMER INFORMATION EAU03052 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required.
  • Page 101 CONSUMER INFORMATION Maintenance Date of Servicing dealer Mileage Remarks interval service name and address 16,000 mi (26,000 km) or 30 months 19,000 mi (31,000 km) or 36 months 22,000 mi (36,000 km) or 42 months 25,000 mi (41,000 km) or 48 months 28,000 mi (46,000 km) or...
  • Page 102 CONSUMER INFORMATION EAU02918...
  • Page 103 CONSUMER INFORMATION...
  • Page 104 CONSUMER INFORMATION EAU01063...
  • Page 105 CONSUMER INFORMATION 9-10...
  • Page 106 PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories. See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual. YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000·11–1.6×1(E)

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