Yamaha TW200E manual

5FY -28199-E1 TW200E PRINTED ON RECYCLED P APER Y AMAHA MOT OR CO. , L TD. PRINTED IN JAP AN 2003.6–0.1 × 1 ! (E) OWNER’S MANUAL 5FY-9-E1_hyoushi 6/4/03 9:28 AM Page 1[...]

INTRODUCTION EAU10100 Welcome to the Yamaha world of motorcycling! As the owner of the TW200E, you are benefiting from Yamaha’s vast experience and newest technology regarding the de- sign and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as t[...]

IMPORTANT MANUAL INFORMATION EAU10150 Particularly important information is distinguished in this manual by the following notations: NO TE: ● 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 qu[...]

IMPORTANT MANUAL INFORMATION EAU10200 TW200E O WNER’S MANU AL ©2003 by Y amaha Motor Co., Ltd. 1st edition, J une 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Y amaha Motor Co., Ltd. is expressl y prohibited. Printed in Japan.[...]

TABLE OF CONTENTS SAFETY INFORMATION ............. 1-1 DESCRIPTION ............................. 2-1 Left view ..................................... 2-1 Right view ................................... 2-2 Controls and instruments ........... 2-3 INSTRUMENT AND CONTROL FUNCTIONS ................................ 3-1 Main switch/steering lock .........[...]

TABLE OF CONTENTS Checking and lubricating the brake and shift pedals ........... 6-24 Checking and lubricating the brake and clutch levers ......... 6-24 Checking and lubricating the sidestand ............................... 6-25 Lubricating the rear suspension ............................ 6-25 Checking the front fork ............ 6-25 Checking th[...]

1-1 1 SAFETY INFORMATION EAU10310 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPEN- DENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERA- TOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE- MENTS BEFORE RIDING THIS MO- TORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUC- TIONS FROM [...]

SAFETY INFORMATION 1-2 1 dercornering (insufficient lean an- gle for the speed). ● Always obey the speed limit and never travel faster than warrant- ed by road and traffic conditions. ● Always signal before turning or changing lanes. Make sure that other motorists can see you. ● The posture of the operator and passenger is important for prope[...]

SAFETY INFORMATION 1-3 1 not exceed the maximum load limit of 180 kg (397 lb). When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbal- an[...]

SAFETY INFORMATION 1-4 1 motorcycle’s electrical system an electric failure could result, which could cause a dangerous loss of lights or engine power. Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMA- BLE: ● Always turn the engine off when refueling. ● Take care not to spill any gaso- line on the engine or exhaust system when refueling[...]

2-1 1 2 3 4 5 6 7 8 9 DESCRIPTION EAU10410 Left view 1 2 3 4 5 7 6 1. Fuel coc k (page 3-6) 2. Helmet holder (page 3-9) 3. Luggage str ap holder (page 3-10) 4. Driv e chain slack adjusting plate 5. Air filter element (page 6-10) 6. Starter (choke) knob (page 3-7) 7. Shift pedal (page 3-4)[...]

DESCRIPTION 2-2 2 3 4 5 6 7 8 9 EAU10420 Right view 12 65 4 3 7 8 9 1. Carrier 2. Battery (page 6-27) 3. Kic kstar ter (page 3-8) 4. Engine oil filter element (page 6-7) 5. Engine oil le v el check windo w (page 6-7) 6. Br ake pedal (page 3-5) 7. Owner’ s tool kit (page 6-1) 8. Fuse (page 6-29) 9. Luggage str ap holder (page 3-10)[...]

DESCRIPTION 2-3 1 2 3 4 5 6 7 8 9 EAU10430 Controls and instruments 12 3 4 5 67 8 9 1. Clutch le v er (page 3-4) 2. Left handlebar s witches (page 3-3) 3. Speedometer unit (page 3-2) 4. Main s witch/steering lock (page 3-1) 5. Indicator lights (page 3-2) 6. Right handlebar s witches (page 3-3) 7. Br ake le v er (page 3-4) 8. Throttle g rip (page 6-[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-1 2 3 4 5 6 7 8 9 EAU10460 Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU10510 ON All electrical systems are supplied with power, and the headlight, meter light- ing, taillight and [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-2 1 2 3 4 5 6 7 8 9 EAU10980 Indicator lights EAU11020 Turn signal indicator light “” This indicator light flashes when the turn signal switch is pushed to the left or right. EAU11060 Neutral indicator light “” This indicator light comes on when the transmission is in the neutral position. EAU11080 High be[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-3 2 3 4 5 6 7 8 9 EAU12341 Handlebar switches Left Right EAU12400 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam. EAU12460 Turn signal switch “ / ” To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-4 1 2 3 4 5 6 7 8 9 EAU12820 Clutch lever The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handle- bar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation. The clutch lever is equ[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-5 2 3 4 5 6 7 8 9 EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. EAU32280 Fuel tank cap To remove the fuel tank cap 1. Insert the key into the lock and turn it 1/3 turn counterclockwise. 2. Turn the fuel tank cap 1/3 turn counter[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-6 1 2 3 4 5 6 7 8 9 EAU13210 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. W ARNING EWA10880 ● Do not overfill the fuel tank, oth- erwise it may overflow when the fuel warms up and expands. ● Avoid spilling fuel on the hot en- gine. CAUT[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-7 2 3 4 5 6 7 8 9 ON With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first oppor- tunity. Be sure to set the lever back to “[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-8 1 2 3 4 5 6 7 8 9 EAU13660 Kickstarter If the engine fails to start by pushing the start switch, try to start it by using the kickstarter. To start the engine, fold out the kickstarter lever, move it down light- ly with your foot until the gears engage, and then push it down smoothly but forcefully. This model i[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-9 2 3 4 5 6 7 8 9 EAU14280 Helmet holder To open the helmet holder, insert the key into the lock, and then turn the key as shown. To lock the helmet holder, place it in the original position, and then remove the key. W ARNING EWA10160 Never ride with a helmet attached to the helmet holder, since the helmet may hit[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-10 1 2 3 4 5 6 7 8 9 EAU15170 Luggage strap holders There are four luggage strap holders below the carrier. EAU15300 Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright. NO TE: The built-in sidestand switch is part of th[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-11 2 3 4 5 6 7 8 9 EAU15311 Ignition circuit cut-off system The ignition circuit cut-off system (com- prising the sidestand switch, clutch switch and neutral switch) has the fol- lowing functions. ● It prevents starting when the trans- mission is in gear and the side- stand is up, but the clutch lever is not pul[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-12 1 2 3 4 5 6 7 8 9 With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. T ur n the ke y on. 4. Shift the transmission into the neutral position. 5. Push the star t switch. Does the engine start? With the engine still running: 6. Move the sidestand up .[...]

PRE-OPERATION CHECKS 4-1 2 3 4 5 6 7 8 9 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 consequ[...]

PRE-OPERATION CHECKS 4-2 1 2 3 4 5 6 7 8 9 EAU15601 Pre-operation check list ITEM CHECKS P A GE Fuel ● Check fuel le v el in fuel tank. ● Refuel if necessary . ● Check fuel line f or leakage. 3-6 Engine oil ● Check oil le v el in engine. ● If necessary , add recommended oil to specified level. ● Check v ehicle f or oil leakage. 6-7 Fro[...]

PRE-OPERATION CHECKS 4-3 2 3 4 5 6 7 8 9 Drive chain ● Check chain slac k. ● Adjust if necessary . ● Check chain condition. ● Lubricate if necessar y . 6-21, 6-23 Wheels and tires ● Check f or damage. ● Check tire condition and tread depth. ● Check air pressure . ● Correct if necessary . 6-13, 6-16 Brake and shift pedals ● Make su[...]

OPERATION AND IMPORTANT RIDING POINTS 5-1 1 2 3 4 5 6 7 8 9 EAU15950 W ARNING EWA10270 ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer re- garding any control or function that you do not thoroughly un- derstand. ● Never start the engine or oper- ate it in a closed area for any [...]

OPERATION AND IMPORTANT RIDING POINTS 5-2 2 3 4 5 6 7 8 9 CAUTION: ECA11040 For maximum engine life, never ac- celerate hard when the engine is cold! 7. When the engine is warm, turn the starter (choke) off. NO TE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off. EAU16640 Starting a warm engine Follo[...]

OPERATION AND IMPORTANT RIDING POINTS 5-3 1 2 3 4 5 6 7 8 9 CAUTION: ECA10260 ● Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long dis- tances. The transmission is properly lubricated only when the engine is running. Inade- quate lubrication may dam[...]

OPERATION AND IMPORTANT RIDING POINTS 5-4 2 3 4 5 6 7 8 9 CAUTION: ECA12711 ● After 1000 km (600 mi) of opera- tion, the engine oil must be changed, the oil filter element and the oil strainer cleaned. ● If any engine trouble should oc- cur during the engine break-in period, immediately have a Yamaha dealer check the vehi- cle. EAU17170 Parking[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-1 1 2 3 4 5 6 7 8 9 EAU17240 Safety is an obligation of the owner. Pe- riodic inspection, adjustment and lubri- cation will keep your vehicle in the safest and most efficient condition pos- sible. The most important points of in- spection, adjustment, and lubrication are explained on the following pages. The [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-2 2 3 4 5 6 7 8 9 EAU17710 Periodic maintenance and lubrication chart NO TE: ● 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[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-3 1 2 3 4 5 6 7 8 9 10 * Wheels ● Check runout, spoke tightness and f or damage . ● Tighten spokes if necessary . √ √ √ √ 11 * Tires ● Check tread depth and f or damage. ● Replace if necessary . ● Check air pressure . ● Correct if necessary . √ √ √ √ √ 12 * Wheel bearings ● Che[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-4 2 3 4 5 6 7 8 9 EAU18660 NO TE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake service ● Regularly check and, if necessary, correct the brake fluid level. ● Every two years replace the internal components of the brake master cylinder[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-5 1 2 3 4 5 6 7 8 9 EAU18720 Removing and installing the cowling and panels The cowling and panels shown above need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the cowling or a panel needs to be re- moved and installed. EAU18810 Cowling A To[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-6 2 3 4 5 6 7 8 9 To install the panel Place the panel in the original position. EAU19601 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 accordan[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-7 1 2 3 4 5 6 7 8 9 necessary. To install the spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if nec- essary, adjust the gap to specifica- tion. 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install t[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-8 2 3 4 5 6 7 8 9 crankcase. NO TE: The engine oil should be between the minimum and maximum level marks. 4. If the engine oil is below the mini- mum level mark, add sufficient oil of the recommended type to raise it to the correct level. To change the engine oil (with or without oil filter element cleaning) [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-9 1 2 3 4 5 6 7 8 9 NO TE: Skip steps 4–9 if the oil filter element is not being cleaned. 4. Remove the oil filter element drain bolt to drain the oil from the oil filter element. 5. Remove the oil filter element cover by removing the bolts. 6. Remove the oil filter element and O-rings. 7. Check the O-ring [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-10 2 3 4 5 6 7 8 9 bolt, and then tighten the drain bolt to the specified torque. 12. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap. CAUTION: ECA11620 ● In order to prevent clutch slip- page (since the engine oil also lubricates the clutch), do not m[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-11 1 2 3 4 5 6 7 8 9 4. Remove the sponge material from the air filter element frame, clean it with solvent, and then squeeze the remaining solvent out. 5. Apply oil of the recommended type to the entire surface of the sponge material, and then squeeze the ex- cess oil out. NO TE: The sponge material should b[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-12 2 3 4 5 6 7 8 9 EAU21280 Adjusting the carburetor The carburetor is an important part of the engine and requires very sophisti- cated adjustment. Therefore, most car- buretor adjustments should be left to a Yamaha dealer, who has the neces- sary professional knowledge and expe- rience. The adjustment descr[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-13 1 2 3 4 5 6 7 8 9 EAU21380 Adjusting the throttle cable free play The throttle cable free play should mea- sure at the throttle grip. Periodically check the throttle cable free play and, if necessary, have a Yamaha dealer ad- just it. EAU21400 Adjusting the valve clearance The valve clearance changes with [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-14 2 3 4 5 6 7 8 9 W ARNING EWA10530 Proper loading of your motorcycle is important for several characteristics of your motorcycle; such as han- dling, braking, performance and safety. Do not carry loosely packed items that can shift. Securely pack your heaviest items close to the cen- ter of the motorcycle, [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-15 1 2 3 4 5 6 7 8 9 with the local regulations. Tire information This motorcycle is equipped with tube tires. W ARNING EWA10460 ● The front and rear tires should be of the same make and de- sign, otherwise the handling characteristics of the vehicle cannot be guaranteed. ● After extensive tests, only the[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-16 2 3 4 5 6 7 8 9 EAU21940 Spoke wheels To maximize the performance, durabil- ity, and safe operation of your motorcy- cle, note the following points regarding the specified wheels. ● The wheel rims should be checked for cracks, bends or warpage, and the spokes for looseness or dam- age before each ride. I[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-17 1 2 3 4 5 6 7 8 9 7. Tighten the locknut at the clutch le- ver and the crankcase. EAU22091 Adjusting the brake lever free play The brake lever free play should mea- sure 5.0–8.0 mm (0.20–0.31 in) as shown. Periodically check the brake le- ver free play and, if necessary, adjust it as follows. 1. Loosen[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-18 2 3 4 5 6 7 8 9 EAU22191 Adjusting the brake pedal position and free play W ARNING EWA10670 It is advisable to have a Yamaha dealer make these adjustments. Brake pedal position The top of the brake pedal should be positioned approximately 15.0 mm (0.59 in) below the top of the footrest. Periodically check [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-19 1 2 3 4 5 6 7 8 9 W ARNING EWA10680 ● After adjusting the drive chain slack or removing and installing the rear wheel, always check the brake pedal free play. ● If proper adjustment cannot be obtained as described, have a Yamaha dealer make this ad- justment. ● After adjusting the brake pedal free pl[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-20 2 3 4 5 6 7 8 9 peared, have a Yamaha dealer replace the brake pads as a set. EAU22540 Rear brake shoes The rear brake is provided with a wear indicator, which allows you to check the brake shoe wear without having to dis- assemble the brake. To check the brake shoe wear, check the position of the wear ind[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-21 1 2 3 4 5 6 7 8 9 brake fluid level goes down sud- denly, have a Yamaha dealer check the cause. EAU22720 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic mainte- nance and lubrication chart. In addition, have the oil seals of the[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-22 2 3 4 5 6 7 8 9 4. If the drive chain slack is incorrect, adjust it as follows. EAU22830 To adjust the drive chain slack 1. Loosen the brake pedal free play adjusting nut. 2. Loosen the axle nut. 3. To tighten the drive chain, turn the adjusting plate on each side of the swingarm in direction (a). To loos-[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-23 1 2 3 4 5 6 7 8 9 EAU23010 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the General maintenance and lubrica- tion chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows. CAUTION:[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-24 2 3 4 5 6 7 8 9 EAU23110 Checking and lubricating the throttle grip and cable 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. EAU23131 Checking and lubricating the [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-25 1 2 3 4 5 6 7 8 9 EAU23200 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride, and the sidestand pivot and metal-to-metal contact surfaces should be lubricated if necessary. W ARNING EWA10730 If the sidestand does not move up and down smoothly, have a Y[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-26 2 3 4 5 6 7 8 9 CAUTION: ECA10590 If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or re- pair it. EAU23280 Checking the steering Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as fol- lows at the inte[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-27 1 2 3 4 5 6 7 8 9 EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica- tion chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. E[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-28 2 3 4 5 6 7 8 9 6. If the electrolyte is at or below the minimum level mark, add distilled water to raise the electrolyte to the maximum level mark. W ARNING EWA10760 ● Electrolyte is poisonous and dangerous since it contains sul- furic acid, which causes severe burns. Avoid any contact with skin, eyes o[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-29 1 2 3 4 5 6 7 8 9 battery lead to the battery’s posi- tive (+) terminal. 10. Connect and tighten the negative battery lead to the battery’s nega- tive (–) terminal. 11. Install the seat. To store the battery 1. If the vehicle will not be used for more than one month, remove the battery, fully charge [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-30 2 3 4 5 6 7 8 9 CAUTION: ECA10640 Do not use a fuse of a higher amper- age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blow[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-31 1 2 3 4 5 6 7 8 9 W ARNING EWA10790 Headlight bulbs get very hot. There- fore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. 5. Place a new bulb into position, and then secure it with the bulb holder. CAUTION: ECA10660 Do not touch the glass par[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-32 2 3 4 5 6 7 8 9 EAU24131 Replacing the tail/brake light bulb 1. Remove the tail/brake light lens by removing the screws. 2. Remove the defective bulb by pushing it in and turning it counter- clockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clock- wise until it stops. 4. Install[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-33 1 2 3 4 5 6 7 8 9 CAUTION: ECA10680 Do not overtighten the screws, oth- erwise the lens may break. EAU24350 Supporting the motorcycle Since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-34 2 3 4 5 6 7 8 9 EAU24360 Front wheel EAU24580 To remove the front wheel W ARNING EWA10820 ● It is advisable to have a Yamaha dealer service the wheel. ● Securely support the motorcy- cle so that there is no danger of it falling over. 1. Disconnect the speedometer ca- ble from the front wheel. 2. Loosen[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-35 1 2 3 4 5 6 7 8 9 EAU25080 Rear wheel EAU25420 To remove the rear wheel W ARNING EWA10820 ● It is advisable to have a Yamaha dealer service the wheel. ● Securely support the motorcy- cle so that there is no danger of it falling over. 1. Loosen the axle nut. 2. Remove the brake pedal free play adjusting[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-36 2 3 4 5 6 7 8 9 5. Install the brake rod onto the brake camshaft lever, and then install the brake pedal free play adjusting nut onto the brake rod. 6. Adjust the brake pedal free play. (See page 6-18.) W ARNING EWA10660 After adjusting the brake pedal free play, check the operation of the brake light. EAU[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-37 1 2 3 4 5 6 7 8 9 EAU25962 Troubleshooting chart W ARNING EWA10840 Keep away open flames and do not smoke while checking or working on the fuel system. Check the fuel level in the fuel tank. 1. Fuel There is enough fuel. There is no fuel. Check the compression. Supply fuel. The engine does not start. Check[...]

MOTORCYCLE CARE AND STORAGE 7-1 2 3 4 5 6 7 8 9 EAU26000 Care While the open design of a motorcycle reveals the attractiveness of the tech- nology, it also makes it more vulnera- ble. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go un- noticed on a car, however, it detracts from the overall appea[...]

MOTORCYCLE CARE AND STORAGE 7-2 1 2 3 4 5 6 7 8 9 any marks. If the windshield is scratched, use a quality plastic polishing compound after washing. After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn d[...]

MOTORCYCLE CARE AND STORAGE 7-3 2 3 4 5 6 7 8 9 ingly and make sure to wipe off any excess. ● Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product. ● Avoid using abrasive polishing compounds as they will wear away the paint. NO TE: Consult a Yamaha dealer for advice on what products to use. EAU2615[...]

MOTORCYCLE CARE AND STORAGE 7-4 1 2 3 4 5 6 7 8 9 from the spark plug, and then install the spark plug and the spark plug cap. W ARNING EWA10950 To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. 6. Lubricate all control cables and the pivoting points of all levers and pedals as w[...]

SPECIFICATIONS 8-1 2 3 4 5 6 7 8 9 EAU26332 Dimensions: Overall length: 2090 mm (82.3 in) Overall width: 820 mm (32.3 in) Overall height: 1120 mm (44.1 in) Seat height: 790 mm (31.1 in) Wheelbase: 1325 mm (52.2 in) Ground clearance: 265 mm (10.43 in) Minimum turning radius: 1900 mm (74.8 in) Weight: With oil and fuel: 126.0 kg (278 lb) Engine: Engi[...]

SPECIFICATIONS 8-2 1 2 3 4 5 6 7 8 9 3rd: 29/22 (1.318) 4th: 26/25 (1.040) 5th: 23/28 (0.821) Chassis: Frame type: Diamond Caster angle: 26.0 ° Trail: 95.0 mm (3.74 in) Front tire: Type: With tube Size: 130/80-18M/C 66P Manufacturer/model: BRIDGESTONE/TW31 Rear tire: Type: With tube Size: 180/80-14M/C 78P Manufacturer/model: BRIDGESTONE/TW34 Loadi[...]

SPECIFICATIONS 8-3 2 3 4 5 6 7 8 9 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 × 2 Meter lighting: 12 V, 3.4 W × 1 Neutral indicator light: 12 V, 3.4 W × 1[...]

CONSUMER INFORMATION 9-1 1 2 3 4 5 6 7 8 9 EAU26351 Identification numbers 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: VEHICLE[...]

CONSUMER INFORMATION 9-2 2 3 4 5 6 7 8 9 EAU26460 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. 1. Model label 1[...]

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5FY -28199-E1 TW200E PRINTED ON RECYCLED P APER Y AMAHA MOT OR CO. , L TD. PRINTED IN JAP AN 2003.6–0.1 × 1 ! (E) OWNER’S MANUAL 5FY-9-E1_hyoushi 6/4/03 9:28 AM Page 1[...]