Yamaha TW200 User Manual

OWNER’S MANUAL

TW200

5FY-28199-EX

INTRODUCTION

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Congratulations on your purchase of the Yamaha TW200. This model is the result of Yamaha’s	1
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	2

these fields.

This manual will give you an understanding of the operation, inspection, and basic mainte-

nance of this motorcycle. If you have any questions about the operation or maintenance of

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your motorcycle, please consult a Yamaha dealer.

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IMPORTANT MANUAL INFORMATION

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Particularly important information is distinguished in this manual by the following notations:

QThe Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

wFailure to follow WARNING instructions could result in severe injury or death to the

motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.

cC	A CAUTION indicates special precautions that must be taken to avoid damage to
	the motorcycle.
NOTE:	A NOTE provides key information to make procedures easier or clearer.

NOTE:

88 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold.

98 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. If there is any question concerning this manual, please consult your Yamaha dealer.

		IMPORTANT MANUAL INFORMATION
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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS					1
MOTORCYCLE.
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TW200

OWNER’S MANUAL ©1997 by Yamaha Motor Co., Ltd.

1st Edition, November 1997

All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

Printed in Japan

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TABLE OF CONTENTS

1	GIVE SAFETY THE RIGHT OF WAY	..................1-1	........................................................Sidestand	3-10
			.....Sidestand/clutch switch operation check	3-11

	2	.....................................................DESCRIPTION	2-1
		Left view............................................................	2-1
		Right view.........................................................	2-2
		Controls/Instruments .......................................	2-3
		INSTRUMENT AND CONTROL
	3
		FUNCTIONS........................................................	3-1
		Main switch/Steering lock ...............................	3-1
		Indicator lights..................................................	3-2
		Speedometer....................................................	3-2
		Handlebar switches..........................................	3-3
		Clutch lever.......................................................	3-4
		Shift pedal.........................................................	3-4
		Front brake lever ..............................................	3-5
		Rear brake pedal ..............................................	3-5
		Fuel tank cap.....................................................	3-5
		Fuel....................................................................	3-6
		Fuel cock ...........................................................	3-7
		Starter (choke) “1”.........................................	3-8
		Kick starter........................................................	3-8
		Seat ...................................................................	3-9
		Helmet holder...................................................	3-9
		Rear shock absorber ......................................	3-10
		Rear carrier .....................................................	3-10

	4	.................................PRE-OPERATION CHECKS	4-1
		Pre-operation check list	4-1
		OPERATION AND IMPORTANT RIDING
	5
		POINTS................................................................	5-1
		Starting and warming up a cold engine.........	5-1
		Starting a warm engine ...................................	5-4
		Shifting..............................................................	5-4
		Engine break-in ................................................	5-5
		Parking ..............................................................	5-6
		PERIODIC MAINTENANCE AND MINOR
	6
		REPAIR ................................................................	6-1
		Tool kit ..............................................................	6-1
		Periodic maintenance and lubrication............	6-3
		Cowling and panel removal and
		installation ........................................................	6-6
		Cowling A .........................................................	6-6
		Panel A..............................................................	6-7
		Panel B ..............................................................	6-7
		Spark plug inspection ......................................	6-7
		Engine oil..........................................................	6-8
		Air filter ...........................................................	6-12

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TABLE OF CONTENTS

Carburetor adjustment ..................................	6-13
Idle speed adjustment ...................................	6-13
Throttle cable free play inspection ...............	6-14
Cam chain adjustment...................................	6-14
Valve clearance adjustment ..........................	6-14
Tires.................................................................	6-15
Wheels ............................................................	6-17
Clutch lever free play adjustment.................	6-18
Front brake lever free play adjustment ........	6-18
Rear brake pedal height and free play
adjustment......................................................	6-19
Brake light switch adjustment.......................	6-20
Checking the brake shoes..............................	6-21
Drive chain slack check..................................	6-21
Drive chain slack adjustment ........................	6-22
Drive chain lubrication...................................	6-23
Cable inspection and lubrication ..................	6-24
Throttle cable and grip lubrication ...............	6-24
Brake and shift pedal lubrication ..................	6-24
Brake and clutch lever lubrication ................	6-25
Sidestand lubrication.....................................	6-25
Rear suspension lubrication..........................	6-25
Front fork inspection......................................	6-26
Steering inspection........................................	6-26
Wheel bearings ..............................................	6-27
Battery.............................................................	6-27

		Fuse replacement...........................................	6-29
		Headlight bulb replacement..........................	6-30
		Supporting the motorcycle ...........................	6-31
		Front wheel removal......................................	6-31
		Front wheel installation .................................	6-32
		Rear wheel removal.......................................	6-33
		Rear wheel installation ..................................	6-33
		Troubleshooting.............................................	6-34
		Troubleshooting chart ...................................	6-35
		CLEANING AND STORAGE	7-1
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		Cleaning............................................................	7-1
		Storage..............................................................	7-2
		SPECIFICATIONS	8-1
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		How to use the conversion table ....................	8-4
		CONSUMER INFORMATION	9-1
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		Identification numbers record.........................	9-1
		Key identification number ...............................	9-1
		Vehicle identification number .........................	9-1
		Model label.......................................................	9-2

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Q GIVE SAFETY THE RIGHT OF WAY

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics.

Regular care and maintenance are essential for preserving your motorcycle’s value and operating condition. Moreover, what is true for the motorcycle is also true for the rider: good performance depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out of the question. Motorcycle riders more than car drivers must always be at their mental and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take dangerous risks.

Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum protective wear, however, should not encourage carelessness. Though full-cov- erage helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensively avoiding all dangers, including those caused by others.

Enjoy your ride!

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DESCRIPTION

Left view

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1.	Headlight (page 6-30)	6.	Helmet holder (page 3-9)
2.	Fuel cock (page 3-7)	7.	Rear carrier (page 3-10)
3.	Starter(choke) “1“ (page 3-8)	8.	Shift pedal (page 3-4)

4.Air filter (page 6-12)

5.Battery (page 6-27)

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DESCRIPTION

Right view

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9.Fuse (page 3-6)

10.Kick starter (page 3-8)

11.Rear brake pedal (page 3-5)

12.Tool kit (page 6-1)

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DESCRIPTION

Controls/Instruments

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

16.Right handlebar switches (page 3-3)

17.Front brake lever (page 3-5, 6-18)

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INSTRUMENT AND CONTROL FUNCTIONS

ON

OFF

LOCK

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Main switch/Steering lock

The main switch controls the ignition and lighting systems. Its operation is described below.

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ON:

All electrical circuits are switched on, and the headlight, meter light, taillight and front position lights come on. The engine can be started. The key cannot be removed in this position.

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OFF:

All electrical circuits are switched off. The key can be removed in this position.

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LOCK:

The steering is locked in this position and all electrical circuits are switched off.

The key can be removed in this position.

To lock the steering, turn the handlebars all the way to the left. With the key at “OFF”, push it into the main switch and release it, turn it counterclockwise to “LOCK” and remove it.

To release the lock, turn the key to “OFF”.

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Never turn the key to “OFF” or “LOCK” when the motorcycle is moving. The electrical circuits will be switched off which may result in loss of control or an accident. Be sure the motorcycle is stopped before turning the key to “OFF” or “LOCK”.

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INSTRUMENT AND CONTROL FUNCTIONS

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1.Turn indicator light “TURN”

2.High beam indicator light “HIGH BEAM”

3.Neutral indicator light “NEUTRAL”

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Indicator lights

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Turn indicator light “TURN”

This indicator flashes when the turn switch is moved to the left or right.

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Neutral indicator light “NEUTRAL”

This indicator comes on when the transmission is in neutral.

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High beam indicator light “HIGH BEAM”

This indicator comes on when the headlight high beam is used.

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1.Speedometer

2.Odometer

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Speedometer

The speedometer shows riding speed.

This speedometer is equipped with an odometer.

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INSTRUMENT AND CONTROL FUNCTIONS

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1.Dimmer switch “LIGHTS”

2.Turn signal switch “TURN”

3.Horn switch “HORN”

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Handlebar switches

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Dimmer switch “LIGHTS”

Turn the switch to “HI” for the high beam and to “LO” for the low beam.

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Turn signal switch “TURN”

This is a three-position switch. The center position is off.

Turn to “L” to turn on the left flasher, and to “R” for the right flasher. Be sure to turn the switch off after completing a turn.

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Horn switch “HORN”

Press the switch to sound the horn.

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1.Engine stop switch “ENGINE STOP”

2.Start switch “START”

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Engine stop switch “ENGINE STOP”

The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system. Turn the switch to “RUN” to start the engine. In case of emergency, turn the switch to “OFF” to stop the engine.

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INSTRUMENT AND CONTROL FUNCTIONS

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Start switch “START”

The starter motor cranks the engine when pushing the start switch.

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See starting instructions prior to starting the engine.

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Clutch lever

The clutch lever is located on the left handlebar, and the ignition circuit cut-off system is incorporated in the clutch lever holder. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. (Refer to the engine starting procedures for a description of the ignition circuit cut-off system.)

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N. Neutral

1. Shift pedal

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Shift pedal

This motorcycle is equipped with a constant-mesh 5-speed transmission.

The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting.

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INSTRUMENT AND CONTROL FUNCTIONS

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Front brake lever

The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake.

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Rear brake pedal

The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to apply the rear brake.

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1.Unlock

2.Open

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Fuel tank cap

TO OPEN:

Insert the key and turn it 1/4 turn counterclockwise. Turn the cap 1/3 turn counterclockwise and remove it from the tank.

TO CLOSE:

Put the cap in the filler neck and turn it 1/3 turn clockwise. Lock the cap by turning the key 1/4 turn clockwise, and remove the key.

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INSTRUMENT AND CONTROL FUNCTIONS

NOTE:

The tank cap cannot be reinstalled unless it is unlocked. The key must remain in the cap until the cap is properly installed and locked onto the fuel tank.

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Be sure the cap is properly installed and locked in place before riding the motorcycle.

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Always wipe off spilled fuel imme- 2 diately with a dry and clean soft cloth. Fuel may deteriorate painted

surfaces or plastic parts.

1.Filler tube

2.Fuel level

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Fuel

Make sure there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown in the illustration.

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Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. Do not fill the fuel tank above the bottom of the filler tube or it may overflow when the fuel heats up later and expands.

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INSTRUMENT AND CONTROL FUNCTIONS

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Recommended fuel:
Regular gasoline			RES
Fuel tank capacity:		OFF
Total:
7.0 L			ON
Reserve:
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1.0 L
		1.	Arrow mark
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Fuel cock

The fuel cock supplies fuel from the tank to the carburetor while filtering it also.

The fuel cock has three positions, which should be set as shown in the illustrations.

OFF: With the fuel cock in this position, fuel will not flow. Always set the fuel cock to this position when the engine is not running.

ON
RES		1
OFF
ON	FUEL	2
ON	1	3

1. Arrow mark

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	ON: With the fuel cock in this
	position, fuel flows to the car-	5
	buretor. Set the fuel cock to
	this position when starting	6
	the engine and while riding.
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INSTRUMENT AND CONTROL FUNCTIONS

	RES
	RES
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2	OFF
		1
	FUEL
3	ON

1. Arrow mark

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RES: This indicates reserve. If you

run out of fuel while riding,

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set the fuel cock to this position.

6Fill the tank at the first opportunity. Be sure to set the fuel

7cock back to “ON” after refu-

eling!

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1.	Starter (choke) “1”
Starter(choke) “1”		EAU00210

Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter(choke).

Move in direction b to turn off the starter(choke).

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1. Kick starter

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Kick starter

Rotate the kick starter away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary-coupled kick starter so the engine can be started in any gear if the clutch is disengaged. However, shifting to neutral before starting is recommended.

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INSTRUMENT AND CONTROL FUNCTIONS

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1. Bolt (×2)

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Seat

To remove the seat, remove the bolts.

To install the seat, insert the projection on the front of the seat into the holder and push down on the seat, then tighten the bolts.

NOTE:

Make sure that the seat is securely fitted.

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	1.	Open			4
	2.	Helmet holder
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	Helmet holder				5
	To open the helmet holder, insert
	the key in the lock and turn it as				6
	shown. To lock the helmet holder,
	replace the holder in its original				7
	position.
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	Never ride with a helmet in the		9
	helmet holder. The helmet may hit
	objects, causing loss of control
	and possibly an accident.

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INSTRUMENT AND CONTROL FUNCTIONS

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Rear shock absorber

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This shock absorber contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling.

1.Do not tamper with or attempt to open the cylinder assembly.

2.Do not subject the shock absorber to an open flame or other high heat source. This may cause the unit to explode due to excessive gas pressure.

3.Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance.

4.Take your shock absorber to a Yamaha dealer for any service.

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1. Rear carrier

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Rear carrier

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Do not exceed the load limit of 3 kg.

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Sidestand

This model is equipped with an ignition circuit cut-off system. The motorcycle must not be ridden when the sidestand is down. The sidestand is located on the left side of the frame. (Refer to page 5-1 for an explanation of this system.)

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INSTRUMENT AND CONTROL FUNCTIONS

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This motorcycle must not be operated with the sidestand in the down position. If the stand is not properly retracted, it could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha has designed into this motorcycle a lockout system to assist the operator in fulfilling the responsibility of retracting the sidestand. Please check carefully the operating instructions listed below and if there is any indication of a malfunction, return the motorcycle to a Yamaha dealer immediately for repair.

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Sidestand/clutch switch operation check

Check the operation of the sidestand switch and clutch switch against the information below.

TURN THE MAIN SWITCH TO “ON” AND THE ENGINE STOP SWITCH TO

“RUN”.

TRANSMISSION IS IN GEAR AND SIDESTAND IS UP.

PULL IN CLUTCH LEVER AND

PUSH THE START SWITCH.

ENGINE WILL START.

SIDESTAND IS DOWN.

ENGINE WILL STALL.

SIDESTAND SWITCH IS OK.

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If improper operation is noted, consult a Yamaha dealer immediately.

CLUTCH SWITCH IS OK.

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PRE-OPERATION CHECKS

Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual inspection, you check the following points before each ride.

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PRE-OPERATION CHECK LIST

	ITEM		CHECKS	PAGE
	Brakes	9	Check operation, condition and free play.	3-5, 6-18 ~ 6-21
		9	Adjust if necessary.
	Clutch	9	Check operation and free play.	3-4, 6-18
		9	Adjust if necessary.
	Throttle grip and housing	9	Check for smooth operation.
		9Lubricate.		6-14, 6-24
		9	Adjust throttle cable free play if necessary.
	Engine oil	9	Check oil level.	6-8 ~ 6-11
		9	Fill with oil if necessary.
	Drive chain	9	Check chain slack and condition.	6-21 ~ 6-23
		9	Adjust if necessary.
	Wheels and tires	9	Check tire pressure, wear, damage and spoke tightness.	6-15 ~ 6-17
		9	Tighten spokes if necessary.
	Brake and shift pedal shafts	9	Check for smooth operation.	6-24
		9Lubricate if necessary.
	Brake and clutch lever pivots	9	Check for smooth operation.	6-25
		9Lubricate if necessary.
	Sidestand pivot	9	Check for smooth operation.	6-25
		9	Lubricate if necessary.
	Chassis fasteners	9	Make sure that all nuts, bolts, and screws are properly tightened.	—
		9	Tighten if necessary.

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