Yamaha TW200P manual

PRINTED IN JAPAN 2001 · 5 – 0.7 × 1(E) ! OWNER ’ S MANUAL 5FY-28199-14 LIT-11626-15-17 PRINTED ON RECYCLED PAPER See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual. PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories. Y AMAHA MOTOR CO. , L TD. TW200P(C)[...]

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EAU00002 INTRODUCTION 1 2 3 4 5 6 7 8 9 Congratulations on your purchase of the Yamaha TW200/TW200C. 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. This [...]

EAU00003 IMPORT ANT MANUAL INFORMA TION 1 2 3 4 5 6 7 8 9 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander[...]

IMPORT ANT MANUAL INFORMA TION 1 2 3 4 5 6 7 8 9 EW000000 w 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 BEE[...]

1 2 3 4 5 6 7 8 9 TW200P(C) OWNER’S MANUAL ©2001 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2001 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. P/N LIT-11626-15-17 EAU04247 AFFIX DEALER LABEL HERE 5FY-9-14 (TW200, US[...]

EAU00009 T ABLE OF CONTENTS 1 2 3 4 5 6 7 8 9 1 5 SAFETY INFORMATION ....................................1-1 Safe riding ........................................................1-1 Protective apparel ............................................1-3 Modifications ....................................................1-3 Loading and accessories ........[...]

General maintenance and lubrication chart ..............................................6-4 Removing and installing the cowling and panels ........................................6-7 Checking the spark plug ..................................6-9 Canister (for California only) ..........................6-11 Engine oil and oil filter element .........[...]

T ABLE OF CONTENTS 1 2 3 4 5 6 7 8 9 MOTORCYCLE CARE AND STORAGE...........................................................7-1 Care .................................................................7-1 Storage ............................................................7-4 SPECIFICATIONS ..............................................8-1 CONSUMER INF[...]

1-1 EAU00017 Q SAFETY INFORMA TION 1 2 3 4 5 6 7 8 9 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. OBTAIN THOROUGH INSTRU[...]

1-2 Q SAFETY INFORMA TION 1 2 3 4 5 6 7 8 9 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. b. Know your skills and limits. Staying [...]

1-3 Q SAFETY INFORMA TION 1 2 3 4 5 6 7 8 9 Protective apparel The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. 1. Always wear an approved helmet. 2. Wear a face shield or goggles. Wind in your unprotec[...]

1-4 Q SAFETY INFORMA TION 1 2 3 4 5 6 7 8 9 Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 180 kg (397 lb) TW200/179kg (395 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 motorcyc[...]

1-5 Q SAFETY INFORMA TION 1 2 3 4 5 6 7 8 9 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. Bulky or large accessor[...]

1-6 Q SAFETY INFORMA TION 1 2 3 4 5 6 7 8 9 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. Do not park the motorcycle near a flammable source (e.g., a [...]

1-7 Q SAFETY INFORMA TION 1 2 3 4 5 6 7 8 9 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle. 1 23 4 7 8 56 5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 14[...]

1-8 Q SAFETY INFORMA TION 1 2 3 4 5 6 7 8 9 q WARNING Improper loading can cause loss of control. Read owner ’ s manual for proper loading. 3JJ-28446-A0 WARNING q 8 8 This unit contains high pressure nitrogen gas. Mishandling can cause explosion. Read owner's manual for instructions. Do not incinerate, puncture or open. 4AA-22259-80 TIRE INF[...]

2-1 EAU00026 DESCRIPTION 1 2 3 4 5 6 7 8 9 1. Fuel tank cap (page 3-5) 2. Fuel cock (page 3-7) 3. Helmet holder (page 3-9) 4. Luggage strap holders (page 3-10) 5. Drive chain adjusting plate (page 6-28) 6. Air filter element (page 6-14) 7. Starter (choke) knob (page 3-8) 8. Shift pedal (page 3-4) 12 3 4 5 6 8 7 Left view 5FY-9-14 (TW200, USA) 5/11/[...]

2-2 DESCRIPTION 1 2 3 4 5 6 7 8 9 9. Carrier (page 3-9) 10. Battery (page 6-34) 11. Engine oil level check window (page 6-11) 12. Brake pedal (page 3-5, 6-23) 13. Owner ’ s tool kit (page 6-1) 14. Fuse (page 6-37) 15. Luggage strap holders (page 3-10) 16. Spark arrester (page 6-16) 9 10 14 13 12 11 15 16 Right view 5FY-9-14 (TW200, USA) 5/11/01 8[...]

2-3 DESCRIPTION 1 2 3 4 5 6 7 8 9 1. Clutch lever (page 3-4, 6-22) 2. Left handlebar switches (page 3-2) 3. Speedometer unit (page 3-2) 4. Main switch/steering lock (page 3-1) 5. Indicator lights (page 3-2) 6. Right handlebar switches (page 3-3) 7. Brake lever (page 3-4, 6-23) 8. Throttle grip (page 6-18) 9. Fuel tank cap (page 3-5) 12 3 4 5 67 8 9[...]

3-1 EAU00027 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 EAU00029 Main switch/steering lock The main switch/steering lock con- trols the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU00032 ON All electrical systems are supplied with power, and the headlight, meter lighting, tai[...]

3-2 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 EAU00095 Speedometer unit The speedometer unit is equipped with a speedometer, an odometer and a tripmeter. The speedometer shows riding speed. The odometer shows the total distance traveled. The tripmeter shows the distance traveled since it was last set to zero with the reset knob. The tripme[...]

3-3 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 EAU00129 Horn switch “ * ” Press this switch to sound the horn. EAU00143 Start switch “ , ” Push this switch to crank the engine with the starter. EC000005 c C See page 5-1 for starting instruc- tions prior to starting the engine. 1 2 EAU03890 Engine stop switch “ # / $ ” Set this s[...]

3-4 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 EAU00157 Shift pedal The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 5-speed constant-mesh transmission equipped on this motorcycle. 1. Shift pedal N. Neutral EAU00152 Clutch lever The clutch lever is loca[...]

3-5 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 1. Brake pedal EAU00177 Fuel tank cap To remove the fuel tank cap 1. Insert the key into the lock and turn it 1/4 turn counterclockwise. 2. Turn the fuel tank cap[...]

3-6 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 1 2 EAU03753 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. EW000130 w 8 Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. 8 Avoid spilling fuel on the hot engine. 1. Filler tube [...]

3-7 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 EAU03050 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: OFF With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running. 1. Arrow mark positioned o[...]

3-8 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 EAU04038 Starter (choke) knob “ 1 ” Starting a cold engine requires a rich- er air-fuel mixture, which is supplied by the starter (choke). Move the knob in direction a to turn on the starter (choke). Move the knob in direction b to turn off the starter (choke). 1. Starter (choke) knob “ 1[...]

3-9 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 EAU00260 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. EW000030 w Never ride with a helmet attached to the helmet holder, since the hel- met may hit ob[...]

3-10 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 EAU01493 Luggage strap holders There are four luggage strap holders below the carrier. 1. Luggage strap holder ( × 4) 1 1 EAU00330 Sidestand The sidestand is located on the left side of the frame. Raise the side- stand or lower it with your foot while holding the motorcycle upright. NOTE: The[...]

3-11 INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 EAU03720 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. 8 It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. 8 I[...]

3-12 INSTRUMENT AND CONTROL FUNCTIONS 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 set to “ # ” . 3. Turn the key to “ ON ” . 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? The neutral switch may be defective. The [...]

4-1 EAU01114 PRE-OPERA TION CHECKS 1 2 3 4 5 6 7 8 9 The condition of a vehicle is the owner ’ s responsibility. Vital components can start to deteriorate quickly and unexpect- edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak- age or loss of tire air pressure could have seriou[...]

4-2 PRE-OPERA TION CHECKS 1 2 3 4 5 6 7 8 9 Throttle grip • Make sure that operation is smooth. • Check free play. • If necessary, have Yamaha dealer make adjustment or lubricate. 6-18 Control cables • Make sure that operation is smooth. • Lubricate if necessary. 6-30 Drive chain • Check chain slack. • Adjust if necessary. • Check c[...]

4-3 PRE-OPERA TION CHECKS 1 2 3 4 5 6 7 8 9 NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved. EWA00033 w If any item in the Pre-operation check list is not working properly, have it inspected a[...]

5-1 EAU00372 OPERA TION AND IMPORT ANT RIDING POINTS 1 2 3 4 5 6 7 8 9 EAU00373 w 8 Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or func- tion that you do not thorough- ly understand. 8 Never start the engine or oper- ate it in a closed area for any length of[...]

5-2 OPERA TION AND IMPORT ANT RIDING POINTS 1 2 3 4 5 6 7 8 9 1. Turn the fuel cock lever to “ ON ” . 2. Turn the key to “ ON ” and make sure that the engine stop switch is set to “ # ” . 3. Shift the transmission into the neutral position. NOTE: When the transmission is in the neu- tral position, the neutral indicator light should be o[...]

5-3 OPERA TION AND IMPORT ANT RIDING POINTS 1 2 3 4 5 6 7 8 9 EAU01258 Starting a warm engine Follow the same procedure as for starting a cold engine with the excep- tion that the starter (choke) is not required when the engine is warm. EC000048 c C 8 Even with the transmission in the neutral position, do not coast for long periods of time with the[...]

5-4 OPERA TION AND IMPORT ANT RIDING POINTS 1 2 3 4 5 6 7 8 9 EAU02974 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below. EAU02988 To start out and accelerate 1. Pull the clutch lever to disengage the clutch. 2. Shift the transmission into first gear. The neutral indicator light [...]

5-5 OPERA TION AND IMPORT ANT RIDING POINTS 1 2 3 4 5 6 7 8 9 EAU01128 Engine break-in There is never a more important peri- od in the life of your engine than the period between 0 and 1,600 km (1,000 mi). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the fir[...]

5-6 OPERA TION AND IMPORT ANT RIDING POINTS 1 2 3 4 5 6 7 8 9 EAU00457 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “ OFF ” . EW000058 w 8 Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them. 8 Do[...]

6-1 EAU00462 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU01790 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condi- tion possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the follow[...]

6-2 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 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 w Modifications not approved by Yamaha may cause loss of perfor- mance and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any c[...]

6-3 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU00471 Periodic maintenance chart for the emission control system * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. ** California type only. INITIAL ODOMETER READINGS NO. ITEM ROUTINE 600 mi 4,000 mi 7,000 mi 10,000 mi 13,000[...]

6-4 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU00472 General maintenance and lubrication chart INITIAL ODOMETER READINGS NO. ITEM ROUTINE TYPE 600 mi 4,000 mi 7,000 mi 10,000 mi 13,000 mi (1,000 km) or (6,000 km) or (11,000 km) or (16,000 km) or (21,000 km) or 1 month 6 month 12 month 18 month 24 month 1 Engine oil 9 Warm-up engine[...]

6-5 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 INITIAL ODOMETER READINGS NO. ITEM ROUTINE TYPE 600 mi 4,000 mi 7,000 mi 10,000 mi 13,000 mi (1,000 km) or (6,000 km) or (11,000 km) or (16,000 km) or (21,000 km) or 1 month 6 month 12 month 18 month 24 month Control and 9 Apply chain lube Yamaha chain and 7 meter cable throughly. cable l[...]

6-6 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU03906 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 disassembl[...]

6-7 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU03516 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 removed and installed. 1. Panel B 1. Cowling [...]

6-8 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU01492 Panel A To remove the panel Remove the screws, and then pull the panel out at the area shown. 1. Panel A 2. Screw ( × 2) 2 1 To install the panel Place the panel in the original posi- tion, and then install the screws. EAU00494 Panel B To remove the panel Pull the panel off as s[...]

6-9 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 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. In a[...]

To check the spark plug 1. Check that the porcelain insula- tor around the center electrode of the spark plug is a medium-to- light tan (the ideal color when the motorcycle is ridden normally). NOTE: If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have [...]

6-11 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 3. Wait a few minutes until the oil settles, and then check the oil level through the check window located at the bottom-right side of the crankcase. NOTE: The engine oil should be between the minimum and maximum level marks. 4. If the engine oil is below the min- imum level mark, add su[...]

6-12 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 To change the engine oil (with or without oil filter element cleaning) 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap and drain bolt to drain the oil from the cra[...]

6-13 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 9. Install the oil filter element cover by installing the bolts and the drain bolt, then tightening them to the specified torques. NOTE: Make sure that the O-rings are prop- erly seated. 10. Clean the oil strainer with sol- vent, and then check it for dam- age and replace it if necessary[...]

6-14 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU04211 Cleaning the air filter element and check hose The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrica- tion chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. In addi- tion, [...]

6-15 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 5. Apply oil of the recommended type to the entire surface of the sponge material, and then squeeze the excess oil out. NOTE: The sponge material should be wet but not dripping. 6. Pull the sponge material over the air filter element frame. 7. Insert the element into the air fil- ter cas[...]

6-16 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 To clean the air filter check hose 1. Check the hose at the bottom of the air filter case for accumulated dirt or water. 2. If dirt or water is visible, remove the hose, clean it, and then install it. 1. Air filter check hose 1 EC000082* c C 8 Make sure that the air filter ele- ment is p[...]

6-17 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 2. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe. 3. Insert the tailpipe into the muf- fler, and then install and tighten the screw. NOTE: Make sure to align the screw holes when inserting the tailpipe. 1[...]

6-18 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU00635 Adjusting the throttle cable free play The throttle cable free play should measure 2 – 5 mm (0.08 – 0.20 in) at the throttle grip. Periodically check the throttle cable free play and, if necessary, have a Yamaha dealer adjust it. a. Free play a EAU00637 Adjusting the valve c[...]

6-19 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EW000087 w Proper loading of your motorcycle is important for several character- istics of your motorcycle; such as handling, braking, performance and safety. Do not carry loosely packed items that can shift. Securely pack your heaviest items close to the center of the motorcy- cle, and [...]

6-20 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EW000079 w 8 Have a Yamaha dealer replace excessively worn tires. Besides being illegal, operat- ing the motorcycle with exces- sively worn tires decreases riding stability and can lead to loss of control. 8 The replacement of all wheel- and brake-related parts, including the tires, shou[...]

6-21 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU00685 Spoke wheels To maximize the performance, dura- bility, and safe operation of your motorcycle, note the following points regarding the specified wheels. 8 The wheel rims should be checked for cracks, bends or warpage, and the spokes for looseness or damage before each ride. If a[...]

6-22 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 3. If the specified clutch lever free play could be obtained as 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. EAU00694 Adjusting the cl[...]

6-23 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU00696 Adjusting the brake lever free play The brake lever free play should measure 2 – 5 mm (0.08 – 0.20 in) as shown. Periodically check the brake lever free play and, if necessary, adjust it as follows. 1. Loosen the locknut at the brake lever. 2. To increase the brake lever fre[...]

6-24 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 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 w After adjusting the brake pedal position, the brake pedal free play must b[...]

6-25 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 1 2 a b EAU00713 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal, is prop- erly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. Turn the adjusting nut[...]

6-26 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU03938 Front brake pads Each front brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that the wear i[...]

6-27 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 Observe these precautions: 8 When checking the fluid level, make sure that the top of the brake fluid reservoir is level. 8 Use only the recommended qual- ity brake fluid, otherwise the rub- ber seals may deteriorate, caus- ing leakage and poor braking performance. 8 Refill with the same[...]

6-28 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 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. NOTE: When checking and adjusting the drive chain slack, the moto[...]

6-29 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 NOTE: Make sure that both adjusting plates are in the same position for proper wheel alignment. EC000096 c C Improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep[...]

6-30 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 2. Spray Yamaha Chain and Cable Lube or a high-quality spray-type drive chain lubricant on both sides and on the middle of the chain, making sure that all side plates and rollers have been suf- ficiently oiled. EAU03297* Checking and lubricating the cables The operation of all control ca[...]

6-31 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU03370 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) EAU03164 Checking and[...]

6-32 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU03165 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. EW000113 w If the sidestand does not move up and down smoothly, have a Yamaha[...]

6-33 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU00794 Checking the steering Worn or loose steering bearings may cause danger. Therefore, the opera- tion of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrica- tion chart. 1. Place a stand under the engine to raise the front whee[...]

6-34 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication 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. EA[...]

6-35 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EW000116 w 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 the following FIRST AID. 9 EXTERNAL: Flu[...]

6-36 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 1. Battery 2. Battery breather hose 1 2 9. Connect and tighten the positive battery lead to the battery ’ s posi- tive (+) terminal. 10. Connect and tighten the negative battery lead to the battery ’ s neg- ative ( – ) terminal. 11. Install the seat. To store the battery 1. If the [...]

6-37 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EC000103 c C Do not use a fuse of a higher amperage rating than recommend- ed 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[...]

6-38 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 3. Disconnect the headlight cou- pler, and then remove the head- light bulb cover. 1. Headlight coupler 2. Headlight bulb cover 1 2 4. Remove the headlight bulb hold- er by turning it counterclockwise, and then remove the defective bulb. EW000119 w Headlight bulbs get very hot. Therefore[...]

6-39 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU01623 Replacing the tail/brake light bulb 1. Remove the tail/brake light lens by removing the screws. 1. Screw ( × 2) 1 6. Install the bulb cover, and then connect the coupler. 7. Install the headlight unit by installing the bolts. 8. Install the cowling. 9. Have a Yamaha dealer adju[...]

6-40 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 2. Remove the defective bulb by pushing it in and turning it coun- terclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clock- wise until it stops. 4. Install the lens by installing the screws. EC000108 c C Do not overtighten the screws, otherwise the lens may[...]

6-41 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 3. Lift the front wheel off the ground according to the procedure on page 6-40. 4. Remove the axle nut, pull the wheel axle out, and then remove the wheel. ECA00048 c C Do not apply the brake after the wheel has been removed together with the brake disc, otherwise the brake pads will be [...]

6-42 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 3. Insert the wheel axle, and then install the axle nut. 4. Lower the front wheel so that it is on the ground. 5. Tighten the axle nut to the speci- fied torque. 6. Connect the speedometer cable. Tightening torque: Axle nut: 90 Nm (9.0 m · kgf, 65 ft · lb) EAU03519 Rear wheel To remove[...]

6-43 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 3. Install the axle nut, and then lower the rear wheel so that it is on the ground. 4. Tighten the axle nut to the speci- fied torque. 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 [...]

6-44 PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 EAU03473 T roubleshooting chart EW000125 w 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 the [...]

7-1 EAU03521 MOT ORCYCLE CARE AND ST ORAGE 1 2 3 4 5 6 7 8 9 Care While the open design of a motorcy- cle reveals the attractiveness of the technology, it also makes it more vul- nerable. Rust and corrosion can develop even if high-quality compo- nents are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall a[...]

7-2 MOT ORCYCLE CARE AND ST ORAGE 1 2 3 4 5 6 7 8 9 8 Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abra- sive cleaning products, sol- vent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or elec- trolyte. 8 Do not use hig[...]

7-3 MOT ORCYCLE CARE AND ST ORAGE 1 2 3 4 5 6 7 8 9 After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Immediately dry the drive chain and lubricate it to prevent it from rusting. 3. Use a chrome polish to shine chrome, aluminum and stainless- steel parts, including the exhaust system. (Even the thermally induced discolor[...]

MOT ORCYCLE CARE AND ST ORAGE 1 2 3 4 5 6 7 8 9 7-4 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, pro- tect it against dust with a porous cover. ECA00014 c C 8 Storing the motorcycle in a poorly ventilated room or cov- ering it with a tarp, while it is still wet, will allow water and humidity to seep in and[...]

7-5 MOT ORCYCLE CARE AND ST ORAGE 1 2 3 4 5 6 7 8 9 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little e[...]

8-1 EAU01038 SPECIFICA TIONS 1 2 3 4 5 6 7 8 9 Specifications Model TW200(C) 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) Ground clearance 265 mm (10.4 in) Minimum turning radius 1,900 mm (74.8 in) Basic weight (with oil and fu[...]

8-2 SPECIFICA TIONS 1 2 3 4 5 6 7 8 9 Fuel Type UNLEADED GASOLINE ONLY Fuel tank capacity 7.0 L (1.5 Imp gal, 1.8 US gal) Reserve amount 1.0 L (0.2 Imp gal, 0.3 US gal) Carburetor Manufacturer TEIKEI Model × quantity MV28 × 1 (TW200) MV28 1B × 1 (TW200C) Spark plug Manufacturer/Type NGK/DR8EA DENSO/X24ESR-U Gap 0.6 – 0.7 mm (0.02 – 0.03 in) [...]

8-3 SPECIFICA TIONS 1 2 3 4 5 6 7 8 9 Maximum load* 180 kg (397 lb) (TW200) 179 kg (395 lb) (TW200C) Air pressure (cold tire) up to 90 kg load* Front 125 kPa (1.25 kgf/cm 2 , 18 psi) Rear 125 kPa (1.25 kgf/cm 2 , 18 psi) 90 kg load – Maximum load* Front 150 kPa (1.50 kgf/cm 2 , 22 psi) Rear 175 kPa (1.75 kgf/cm 2 , 25 psi) *Total weight of rider,[...]

8-4 SPECIFICA TIONS 1 2 3 4 5 6 7 8 9 Headlight bulb type Halogen bulb Bulb voltage, wattage × quantity Headlight 12 V, 60/55 W × 1 Tail/brake light 12 V, 8/27 W × 1 Front turn signal light 12 V, 27/8 W × 2 Rear turn signal light 12 V, 27 W × 2 Meter lighting 12 V, 3.4 W × 1 Neutral indicator light 12 V, 3.4 W × 1 High beam indicator light 1[...]

9-1 EAU01039 CONSUMER INFORMA TION 1 2 3 4 5 6 7 8 9 EAU02944 Identification numbers 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 NUMBER: [...]

EAU01039 CONSUMER INFORMA TION 1 2 3 4 5 6 7 8 9 9-2 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. 1. Model label 1 5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 94[...]

9-3 CONSUMER INFORMA TION 1 2 3 4 5 6 7 8 9 EAU01051 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 s[...]

9-4 CONSUMER INFORMA TION 1 2 3 4 5 6 7 8 9 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 inc[...]

9-5 CONSUMER INFORMA TION 1 2 3 4 5 6 7 8 9 5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 97[...]

9-6 CONSUMER INFORMA TION 1 2 3 4 5 6 7 8 9 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[...]

9-7 CONSUMER INFORMA TION 1 2 3 4 5 6 7 8 9 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 54 months 31,000 mi (51,000 km) or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 5FY-9-14 [...]

9-8 CONSUMER INFORMA TION 1 2 3 4 5 6 7 8 9 EAU02918 5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 100[...]

9-9 CONSUMER INFORMA TION 1 2 3 4 5 6 7 8 9 5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 101[...]

9-10 CONSUMER INFORMA TION 1 2 3 4 5 6 7 8 9 EAU01063 5FY-9-14 (TW200, USA) 5/11/01 8:32 AM Page 102[...]

9-11 CONSUMER INFORMA TION 1 2 3 4 5 6 7 8 9 5FY-9-14 (TW200, USA) 5/11/01 8:32 AM Page 103[...]

5FY-9-14 (TW200, USA) 5/11/01 8:32 AM Page 104[...]

PRINTED IN JAPAN 2001 · 5 – 0.7 × 1(E) ! OWNER ’ S MANUAL 5FY-28199-14 LIT-11626-15-17 PRINTED ON RECYCLED PAPER See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual. PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories. Y AMAHA MOTOR CO. , L TD. TW200P(C)[...]