Owner'S Manual: 5FY-28199-EX

OWNERS MANUAL
TW200
5FY-28199-EX
INTRODUCTION
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Congratulations on your purchase of the Yamaha TW200. This model is the result of Yamahas 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 manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you have any questions about the operation or maintenance of 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: 1 2 3 4 5 NOTE: 6 7 8 9 NOTE: 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. If there is any question concerning this manual, please consult your Yamaha dealer. A NOTE provides key information to make procedures easier or clearer.
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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 or a person inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.
IMPORTANT MANUAL INFORMATION

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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
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TW200 OWNERS 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
GIVE SAFETY THE RIGHT OF WAY ..................1-1 DESCRIPTION .....................................................2-1 Left view............................................................2-1 Right view .........................................................2-2 Controls/Instruments .......................................2-3 INSTRUMENT AND CONTROL 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 Sidestand ........................................................3-10 Sidestand/clutch switch operation check.....3-11
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PRE-OPERATION CHECKS.................................4-1 Pre-operation check list ...................................4-1 OPERATION AND IMPORTANT RIDING 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 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
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CLEANING AND STORAGE ...............................7-1 Cleaning ............................................................7-1 Storage..............................................................7-2 SPECIFICATIONS................................................8-1 How to use the conversion table ....................8-4 CONSUMER INFORMATION .............................9-1 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 motorcycles 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-coverage 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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1-1
DESCRIPTION
Left view
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2 3 4 5
1. 2. 3. 4. 5.
Headlight (page 6-30) Fuel cock (page 3-7) Starter(choke) 1 (page 3-8) Air filter (page 6-12) Battery (page 6-27)
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6. Helmet holder (page 3-9) 7. Rear carrier (page 3-10) 8. Shift pedal (page 3-4)
DESCRIPTION
Right view
9 10
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12
11
8 9
9. 10. 11. 12.
Fuse (page 3-6) Kick starter (page 3-8) Rear brake pedal (page 3-5) Tool kit (page 6-1)
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DESCRIPTION
Controls/Instruments
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13
14
15
16
17
20
19
18
13. 14. 15. 16. 17.
Clutch lever (page 3-4, 6-18) Left handlebar switches (page 3-3) Speedometer (page 3-2) Right handlebar switches (page 3-3) Front brake lever (page 3-5, 6-18)
18. Throttle grip (page 6-14, 6-24) 19. Fuel tank cap (page 3-5) 20. Main switch (page 3-1)
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INSTRUMENT AND CONTROL FUNCTIONS

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OFF
ON
OFF: All electrical circuits are switched off. The key can be removed in this position.
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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.
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.
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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1. Turn indicator light TURN 2. High beam indicator light HIGH BEAM 3. Neutral indicator light NEUTRAL
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High beam indicator light HIGH BEAM This indicator comes on when the headlight high beam is used.
1. Speedometer 2. Odometer
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Speedometer
The speedometer shows riding speed. This speedometer is equipped with an odometer.
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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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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1. Dimmer switch LIGHTS 2. Turn signal switch TURN 3. Horn switch HORN
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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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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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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N. Neutral 1. Shift pedal

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Clutch lever
5 6 7 8 9 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.)
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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1. Unlock 2. Open
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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.
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.
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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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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Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts.
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Be sure the cap is properly installed and locked in place before riding the motorcycle.
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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OFF
RES OFF ON FUEL
ON
RES
Recommended fuel: Regular gasoline Fuel tank capacity: Total: 7.0 L Reserve: 1.0 L
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OFF ON FUEL
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1. Arrow mark
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ON 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: With the fuel cock in this position, fuel flows to the carburetor. Set the fuel cock to this position when starting the engine and while riding.
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RES
RES
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OFF
RES
1 1 b a
ON
FUEL
1. Arrow mark
1. Starter (choke) 1
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1. Kick starter
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RES: This indicates reserve. If you run out of fuel while riding, set the fuel cock to this position. Fill the tank at the first opportunity. Be sure to set the fuel cock back to ON after refueling!
Starter(choke) 1
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).
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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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.
1. Open 2. Helmet holder
Helmet holder
To open the helmet holder, insert the key in the lock and turn it as shown. To lock the helmet holder, replace the holder in its original position.
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Never ride with a helmet in the helmet holder. The helmet may hit objects, causing loss of control and possibly an accident.
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Rear shock absorber

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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.)
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.
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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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.
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
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Owners are personally responsible for their vehicles condition. Your motorcycles 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 Brakes 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 CHECKS Check operation, condition and free play. Adjust if necessary. Check operation and free play. Adjust if necessary. Check for smooth operation. Lubricate. Adjust throttle cable free play if necessary. Check oil level. Fill with oil if necessary. Check chain slack and condition. Adjust if necessary. Check tire pressure, wear, damage and spoke tightness. Tighten spokes if necessary. Check for smooth operation. Lubricate if necessary. Check for smooth operation. Lubricate if necessary. Check for smooth operation. Lubricate if necessary. Make sure that all nuts, bolts, and screws are properly tightened. Tighten if necessary. PAGE 3-5, 6-18 ~ 6-21 3-4, 6-18 6-14, 6-24 6-8 ~ 6-11 6-21 ~ 6-23 6-15 ~ 6-17 6-24 6-25 6-25
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Clutch Throttle grip and housing Engine oil Drive chain Wheels and tires Brake and shift pedal shafts Brake and clutch lever pivots Sidestand pivot Chassis fasteners
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PRE-OPERATION CHECKS
ITEM Fuel tank Lights, signals and switches Battery 9 Check fuel level. 9 Fill with fuel if necessary. 9 Check for proper operation. 9 Check fluid level. 9 Fill with distilled water if necessary. CHECKS PAGE 3-5 ~ 3-6 6-30 6-27 ~ 6-29
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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.
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If any item in the PRE-OPERATION CHECKS is not working properly, have it inspected and repaired before operating the motorcycle. 5 6 7 8 9
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OPERATION AND IMPORTANT RIDING POINTS

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1. Before riding this motorcycle, become thoroughly familiar with all operating controls and their functions. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. 2. Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time. Always operate your motorcycle in an area with adequate ventilation. 3. Before starting out, always be sure the sidestand is up. Failure to retract the sidestand completely can result in a serious accident when you try to turn a corner.
Starting and warming up a cold engine

NOTE: This motorcycle is equipped with a starting and an ignition circuit cutoff switch. 1. The engine can be started only under the following conditions: a. The transmission is in neutral. b. The sidestand is up, the transmission is in gear, and the clutch is disengaged. 2. The motorcycle must not be ridden when the sidestand is down.
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Before going through the following steps, check the function of the sidestand switch and clutch switch. (Refer to page 3-11.)
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TURN THE MAIN SWITCH TO ON AND THE ENGINE STOP SWITCH TO RUN
1
IF TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN, PUSH START SWITCH OR KICK THE KICK STARTER. ENGINE WILL START. RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR. MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN. IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP, PULL IN CLUTCH LEVER AND PUSH START SWITCH OR KICK THE KICK STARTER. ENGINE WILL START.
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5-2

1. Turn the fuel cock to ON. 2. Turn the main switch to ON and the engine stop switch to RUN. 3. Shift transmission into neutral. NOTE: When the transmission is in neutral, the neutral indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect it. 4. Turn on the starter and completely close the throttle grip. 5. Start the engine by pushing the start switch or by kicking the kick starter. NOTE: If the engine fails to start, release the start switch, wait a few seconds, then try again. Each attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. If the engine does not start with the starter motor, kick the kick starter to start the engine. 6. After starting the engine, move the starter to the halfway position. NOTE: For maximum engine life, always warm up the engine before starting off. Never accelerate hard with a cold engine. 7. After warming up the engine, turn off the starter completely. NOTE: The engine is warm when it responds normally to the throttle with the starter turned off.
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Starting a warm engine

The starter (choke) is not required when the engine is warm.
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See the Engine break-in section prior to operating the motorcycle for the first time.
N. Neutral 1. Shift pedal

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Shifting
The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc. The use of the shift pedal is shown in the illustration. To shift into neutral, depress the shift pedal repeatedly until it reaches the end of its travel, then raise the pedal slightly.
1. Do not coast for long periods with the engine off, and do not tow the motorcycle a long distance. Even with gears in neutral, the transmission is only properly lubricated when the engine is running. Inadequate lubrication may damage the transmission. 2. Always use the clutch when changing gears. The engine, transmission, and driveline are not designed to withstand the shock of forced shifting and can be damaged by shifting without using the clutch.
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Engine break-in
1 2 3 4 5 6 7 8 9 There is never a more important period in the life of your motorcycle than the period between zero and 1,000 km. For this reason we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first 1,000 km. The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full throttle operation, or any condition which might result in excessive heating of the engine, must be avoided.
1. 0 ~ 150 km: Avoid operation above 1/3 throttle. Stop the engine and let it cool for 5 to 10 minutes after every hour of operation. Vary the speed of the motorcycle from time to time. Do not operate it at one set throttle position. 2. 150 ~ 500 km: Avoid prolonged operation above 1/2 throttle. Rev the motorcycle freely through the gears, but do not use full throttle at any time. 3. 500 ~ 1,000 km: Avoid cruising speeds in excess of 3/4 throttle.
4. 1,000 km and beyond: Avoid prolonged full-throttle operation. Vary speed occasionally.
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If any engine trouble should occur during the break-in period, consult a Yamaha dealer immediately.
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After 1,000 km of operation, be sure to replace the engine oil and clean the oil filter element and oil strainer.
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Parking
When parking the motorcycle, stop the engine and remove the ignition key. Turn the fuel cock to OFF whenever stopping the engine. 1 2 3 4 5 6 7 8 9
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The exhaust system is hot. Park the motorcycle in a place where pedestrians or children are not likely to touch the motorcycle. Do not park the motorcycle on a slope or soft ground; the motorcycle may overturn.
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PERIODIC MAINTENANCE AND MINOR REPAIR

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Periodic inspection, adjustment and lubrication will keep your motorcycle in the safest and most efficient condition possible. Safety is an obligation of the motorcycle owner. The maintenance and lubrication schedule chart should be considered strictly as a guide to general maintenance and lubrication intervals. YOU MUST TAKE INTO CONSIDERATION THAT WEATHER, TERRAIN, GEOGRAPHICAL LOCATIONS, AND A VARIETY OF INDIVIDUAL USES ALL TEND TO DEMAND THAT EACH OWNER ALTER THIS TIME SCHEDULE TO SHORTER INTERVALS TO MATCH THE ENVIRONMENT. The most important points of motorcycle inspection, adjustment, and lubrication are explained in the following pages.
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If you are not familiar with motorcycle service, this work should be done by a Yamaha dealer.
1. Tool kit
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Tool kit
The tool kit is located behind panel B. (See page 6-7 for panel removal and installation procedures.) The tools provided in the owners tool kit are to assist you in the performance of periodic maintenance. However, some other tools such as a torque wrench are also necessary to perform the maintenance correctly. The service information included in this manual is intended to provide you, the owner, with the necessary information for completing some of your own preventive maintenance and minor repairs.
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NOTE: If you do not have necessary tools required during a service operation, take your motorcycle to a Yamaha dealer for service.
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Modifications to this motorcycle not approved by Yamaha may cause loss of performance, and render it unsafe for use. Consult a Yamaha dealer before attempting any changes.
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PERIODIC MAINTENANCE AND LUBRICATION

EVERY
1
No. ITEM CHECKS AND MAINTENANCE JOBS Initial (1,000 km)
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9 * Rear brake 1 * Fuel line 2 Spark plug 9 Check fuel hoses for cracks or damage. 9 Replace if necessary. 9 Check condition. 9 Clean, regap or replace if necessary. 9 Check valve clearance. 9 Adjust if necessary. 9 Check chain tension. 9 Adjust if necessary. 9 Clean or replace if necessary. 9 Check electrolyte level and specific gravity. 9 Correct or recharge if necessary. 9 Make sure that the breather hose is properly routed. 9 Check operation. 9 Adjust or replace cable. 9 Check operation. 9 Adjust cable and replace brake shoes if necessary. 9 Check operation. 9 Adjust cable and replace brake shoes if necessary. 9 Check balance, runout, spoke tightness and for damage. 9 Tighten spokes and rebalance, replace if necessary. 9 Check tread depth and for damage. 9 Replace if necessary. 9 Check air pressure. 9 Correct if necessary.
6,000 km or 6 months (Whichever comes first)
12,000 km or 12 months (Whichever comes first)
3 * Valves 4 * Cam chain 5 Air filter
6 * Battery 7 Clutch
8 * Front brake
10 * Wheels
11 * Tires
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EVERY No. ITEM CHECKS AND MAINTENANCE JOBS Initial (1,000 km) 6,000 km or 6 months (Whichever comes first) 12,000 km or 12 months (Whichever comes first)
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12 * Wheel bearings 13 * Swingarm
9 Check bearing for looseness or damage. 9 Replace if necessary. 9 Check swingarm pivoting point for play. 9 Correct if necessary. 9 Lubricate with lithium soap base grease. 9 Check chain slack. 9 Adjust if necessary. Make sure that the rear wheel is properly aligned. 9 Clean and lubricate. 9 Check bearing play and steering for roughness. 9 Correct accordingly. 9 Lubricate with lithium soap grease every 24,000 km or 24 months (whichever comes first). 9 Make sure that all nuts, bolts and screws are properly tightened. 9 Tighten if necessary. 9 Check operation. 9 Lubricate and repair if necessary. 9 Check operation. 9 Replace if necessary. 9 Check operation and for oil leakage. 9 Correct accordingly. 9 Check operation and shock absorber for oil leakage. 9 Replace shock absorber assembly if necessary. 9 Check operation. 9 Lubricate with lithium soap base grease every 24,000 km or 24 months (whichever comes first). 9 Check engine idling speed and starter operation. 9 Adjust if necessary.
14
Drive chain
Every 500 km and after washing the motorcycle or riding in the rain
15 * Steering bearings
16 * Chassis fasteners 17 18 Sidestand Sidestand switch
19 * Front fork 20 * Rear shock absorber assembly
Rear shock absorber 21 * assembly pivoting points 22 * Carburetor
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EVERY No. ITEM CHECKS AND MAINTENANCE JOBS Initial (1,000 km) 6,000 km or 6 months (Whichever comes first) 12,000 km or 12 months (Whichever comes first)
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23 24 Engine oil 9 Check oil level and vehicle for oil leakage. 9 Correct if necessary. 9 Change. (Warm engine before draining.) 9 Clean or replace if necessary.
Engine oil filter element 9 Clean or replace if necessary.
25 * Engine oil strainer
*: Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
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NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
6-5

2 1 1
1
2 3
1. Cowling A 2. Panel A
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1. Panel B
1. Screw
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Cowling and panel removal and installation

The cowlings and panels illustrated need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a cowling or panel has to be removed or reinstalled.
Cowling A
To remove: Remove the screw. To install: Place in the original position and install the screw.
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2
1 2 3 4 5 6 7 8 9 To install: Place the panel in its original position.
1. Panel A
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1 1 1
1. Panel B 2. Screw (2)

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1. Spark plug gap

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Panel A
To remove: Pull outward on the areas shown.
Panel B
To remove: Remove the screws and pull outward on the areas shown. To install: Place the panel in the original position and install the screws.
Spark plug inspection

The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. The ideal color on the white insulator around the center electrode is a medium-to-light tan color for a motorcycle that is being ridden normally. Do not attempt to diagnose any problems yourself. Instead, take the motorcycle to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly
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break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug. Specified spark plug: DR8EA (NGK) or X24ESR-U (DENSO) Before installing the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap to specification as necessary. Spark plug gap: 0.6 ~ 0.7 mm When installing the plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads and tighten the spark plug to the specified torque. Tightening torque: Spark plug: 17.5 Nm (1.75 m0kg)
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NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible.
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Engine oil
1. Oil level measurement a. Place the motorcycle on a level place and hold it in an upright position. Warm up the engine for several minutes. NOTE: Be sure the motorcycle is positioned straight up when checking the oil level. A slight tilt toward the side can result in false readings.
1 1 2 3
2 3 4 5 6 7 8 9
1. Level window 2. Maximum level mark 3. Minimum level mark
1
1. Oil filler cap 1. Drain plug
b. With the engine stopped, check the oil level through the level window located at the lower part of the right side crankcase cover. NOTE: Wait a few minutes until the oil level settles before checking. c. The oil level should be between the maximum and minimum marks. If the level is low, add sufficient oil to raise it to the proper level.
2. Engine oil replacement a. Warm up the engine for a few minutes. b. Stop the engine. Place an oil pan under the engine and remove the oil filler cap.
c. Remove the drain plug and drain bolt.
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1 4
1. 2. 3. 4.
2 3 4 5 6
1
1. Filter cover screw (2) 2. Drain bolt
2
1. Oil filter 2. O-ring (2)
Drain plug O-ring Compression spring Oil strainer

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When removing the oil drain plug, the O-ring, compression spring, and oil strainer will fall out. Take care not to lose these parts. NOTE: The oil filter cover is secured by two screws and a drain bolt. Remove the drain bolt to drain the filter cavity.
d. Remove the filter cover screws and the oil filter cover. e. Remove the oil filter element and O-ring. f. Clean the oil filter and strainer with solvent. Replace if necessary. g. Check the O-rings. If damaged, replace. h. Install the drain plug, filter cover, screws and drain bolt. Tighten the drain plug to the specified tightening torque.
NOTE: Make sure the O-ring is seated properly.
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7 8 9
Before reinstalling the oil drain plug, do not forget to install the Oring, compression spring, and oil strainer in position.
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Tightening torque: Drain plug: 10 Nm (1.0 m0kg) Filter cover screw: 10 Nm (1.0 m0kg) Drain bolt (filter cover): 10 Nm (1.0 m0kg) i. Fill the engine with oil. Install the oil filler cap and tighten. Recommended oil: See page 8-1 Oil quantity: Total amount: 1.3 L Periodic oil change: 1.0 L With oil filter replacement: 1.1 L j. Start the engine and warm up for a few minutes. While warming up, check for oil leakage. If oil leakage is found, stop the engine immediately and check for the cause.
1 2 3 4 5 6 7 8 9
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8 Do not put in any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slippage. 8 Be sure no foreign material enters the crankcase.
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1
5. Install the air filter in its case. 6. Install panel B.
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1
1. Screw (4)
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1 2 3 4 5 6 7 8 9
1. Air filter
Air filter
The air filter should be cleaned at the specified intervals. It should be cleaned more frequently if you are riding in unusually wet or dusty areas. 1. Remove panel B. (See page 6-7 for panel removal and installation procedures.) 2. Remove the air filter case fitting screws and the air filter case cover.
3. Remove the air filter from its case and clean it with solvent. After cleaning, remove the remaining solvent by squeezing the air filter. 4. Apply the recommended oil to the entire surface of the filter and squeeze out the excess oil. It should be wet but not dripping. Recommended oil: Same as engine oil
8 Make sure the air filter is properly seated in the filter case. 8 The engine should never be run without the air filter installed. Excessive piston and/or cylinder wear may result.
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Carburetor adjustment
1 2 3 4 5 6 7 8 9 The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjustments should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the following may be serviced by the owner as part of routine maintenance.
a 1 b
2. Set the idle to the specified engine speed by adjusting the throttle stop screw. Turn the screw in direction a to increase engine speed and in direction b to decrease engine speed. Standard idle speed: 1,350 ~ 1,450 r/min
1. Throttle stop screw

EAU01168
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Idle speed adjustment

NOTE: A diagnostic tachometer must be used for this procedure. 1. Attach the tachometer. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle.
The carburetor was set at the Yamaha factory after many tests. If the settings are changed, poor engine performance and damage may result.
NOTE: If the specified idle speed cannot be obtained by performing the above adjustment, consult a Yamaha dealer.
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EAU00635 EAU00636 EAU00637
Throttle cable free play inspection

There should be a free play of 2 ~ 5 mm at the throttle grip. If the free play is incorrect, ask a Yamaha dealer to make this adjustment.
Cam chain adjustment

The cam chain becomes loose with use, resulting in improper valve timing and engine noise. To prevent this, the cam chain tensioner must be adjusted regularly. This adjustment, however, should be left to a professional Yamaha service technician.
Valve clearance adjustment

The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician. 1 2 3 4 5 6 7 8 9
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Tires
1 2 3 4 5 6 7 8 9 To ensure maximum performance, long service, and safe operation, note the following: 1. Tire air pressure Always check and adjust the tire pressure before operating the motorcycle.
Maximum load* Cold tire pressure: Up to 90 kg Front
157 kg Rear 125 kPa 150 kPa (1.25 kgf/cm2, (1.50 kgf/cm2, 1.25 bar) 1.50 bar) 150 kPa 175 kPa (1.50 kgf/cm2, (1.75 kgf/cm2, 1.50 bar) 1.75 bar) 125 kPa 125 kPa (1.25 kgf/cm2, (1.25 kgf/cm2, 1.25 bar) 1.25 bar) 150 kPa 175 kPa (1.50 kgf/cm2, (1.75 kgf/cm2, 1.50 bar) 1.75 bar)
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90 kg load ~ Maximum load*
Off-road riding
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High-speed riding
Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature. Tire inflation pressure must be adjusted according to total weight of cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if approved for this model), and vehicle speed.
* Load is the total weight of cargo, rider, passenger, and accessories.
Proper loading of your motorcycle is important for several characteristics 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 motorcycle, and distribute the weight evenly from side to side. Check the condition and pressure of your tires. NEVER OVERLOAD YOUR MOTORCYCLE. Make sure the total weight of the cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if approved for this model) does not exceed the maximum load of the motorcycle. Operation of an overloaded motorcycle could cause tire damage, an accident, or even injury.
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1
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FRONT: Manufacturer BRIDGESTONE REAR: Manufacturer Size Type TW32 Size 130/80-18 66P Type TW31
1. Tread depth 2. Side wall
2. Tire inspection Always check the tires before operating the motorcycle. If center tread depth reaches the limit as shown, if the tire has a nail or glass fragments in it, or if the side wall is cracked, contact a Yamaha dealer immediately and have the tire replaced.
After extensive tests, the tires mentioned below have been approved by Yamaha Motor Co., Ltd. for this model. No guarantee for handling characteristics can be given if tire combinations other than what is approved are used on this motorcycle. The front and rear tires should be of the same manufacture and design.
1 2 3 4
BRIDGESTONE 180/80-14M/C 78P Minimum tire tread depth : (front and rear)
1.0 mm
NOTE: These limits may be different by regulation from country to country. If so, conform to the limits specified by the regulations of your own country.
5 6 7 8 9
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1 2 3 4 5 6 7 8 9
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Wheels
To ensure maximum performance, long service, and safe operation, note the following: 1. Always inspect the wheels before a ride. Check for cracks, bends or warpage of the wheel. Be sure the spokes are tight and undamaged. If any abnormal condition exists in a wheel, consult a Yamaha dealer. Do not attempt even small repairs to the wheel. If a wheel is deformed or cracked, it must be replaced. 2. Tires and wheels should be balanced whenever either one is changed or replaced. Failure to have a wheel balanced can result in poor performance, adverse handling characteristics, and shortened tire life.
1. It is dangerous to ride with a worn-out tire. When a tire tread begins to show lines, have a Yamaha dealer replace the tire immediately. Brakes, tires, and related wheel parts replacement should also be left to a Yamaha dealer. 2. Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement.
3. Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal characteristics.
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3 a b 2 b 1
1. Locknut 2. Adjusting bolt 3. Free play
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1 3 b 2
1
a 2
1. Locknut 2. Adjusting bolt 3. Free play
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2 3 4 5 6 7 8 9
1. Adjusting nut 2. Locknut
Clutch lever free play adjustment

The clutch lever free play should be adjusted to 2 ~ 3 mm. 1. Loosen the locknut at the clutch lever. 2. Turn the adjusting bolt at the clutch lever in direction a to increase free play or in direction b to decrease free play. 3. Tighten the locknut at the clutch lever.
If the specified free play cannot be obtained, proceed with the following steps. 4. Loosen the locknut at the clutch lever. 5. Turn the adjusting bolt at the clutch lever in direction a to loosen the cable. 6. Loosen the locknut at the crankcase side. 7. Turn the adjusting nut at the crankcase in direction a to increase free play or in direction b to decrease free play. 8. Tighten the locknut at the crankcase and the clutch lever.
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Front brake lever free play adjustment

The front brake lever free play should be adjusted to 2 ~ 4 mm. 1. Loosen the locknut at the brake lever. 2. Turn the adjusting bolt at the brake lever in direction a to increase free play or in direction b to decrease free play. 3. Tighten the locknut at the brake lever .

1 2
1 2
b a b a 1 2 4 5
b. Turn the adjusting bolt in direction a to raise pedal height or in direction b to lower pedal height. c. Tighten the locknut.
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1. Adjusting nut 2. Locknut 1. 2. 3. 4. 5. Locknut Adjusting bolt Footrest Pedal height: 10 mm Free play
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After adjusting the pedal height adjust brake pedal free play. If the specified free play cannot be obtained, proceed with the following steps. 4. Loosen the locknut at the brake lever. 5. Turn the adjusting bolt at the brake lever in direction a to loosen the cable. 6. Loosen the locknut at the brake hub. 7. Turn the adjusting nut at the brake hub in direction a to increase free play or in direction b to decrease free play. 8. Tighten the locknut at the brake hub and the brake lever.
Rear brake pedal height and free play adjustment
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It is advisable to have a Yamaha dealer make this adjustment. 1. Pedal height The brake pedal should be positioned so that its top end is approximately 10 mm below the top of the footrest. a. Loosen the locknut.
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a b 1
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1. Adjusting nut
2. Free play The rear brake pedal free play should be adjusted to 20 ~ 30 mm at the brake pedal end. Turn the adjusting nut on the brake rod in direction a to increase free play or in direction b to decrease free play.
8 Brake pedal free play should be checked whenever the chain is adjusted or the rear wheel is removed and then reinstalled. 8 Check the operation of the brake light after adjusting the rear brake. 8 If it is impossible to make proper adjustment, consult a Yamaha dealer.
1 2 a b
1 2 3
1. Brake light switch 2. Adjusting nut

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4 5 6 7 8 9
Brake light switch adjustment

The rear brake light switch is activated by the brake pedal and is properly adjusted when the brake light comes on just before braking takes effect. To adjust the rear brake light switch, hold the switch body so it does not rotate while turning the adjusting nut. Turn the adjusting nut in direction a to make the brake light come on earlier. Turn the adjusting nut in direction b to make the brake light come on later.
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FRONT REAR
1
2 3 4 5 6 7 8 9
1. Wear indicator 2. Wear limit
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2 a
2
1. Wear indicator 2. Wear limit a. 30 ~ 40 mm
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Checking the brake shoes

A wear indicator is provided on each brake. This indicator allows inspection of shoe wear without disassembling the brake. Apply the brake and inspect the position of the indicator. If the indicator reaches to the wear limit line, ask a Yamaha dealer to replace the shoes.
Drive chain slack check

NOTE: Spin the wheel several times and find the tightest position of the chain. Check and/or adjust the chain slack while its in this tightest position.
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To check the chain slack the motorcycle must be held straight up with both wheels on the ground and without rider. Check the slack at the position shown in the illustration. Normal slack is approximately 30 ~ 40 mm. If the slack exceeds 40 mm, adjust.
1. 2. 3. 4.
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Too little chain slack will overload the engine and other vital parts. Keep the slack within the specified limits. 5. After adjusting, be sure to tighten the axle nut to the specified torque. Tightening torque: Axle nut: 90 Nm (9.0 m0kg)
1 2 3 4 5 6 7 8 9
Adjusting nut Axle nut Cotter pin Chain adjusting plate

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Drive chain slack adjustment

1. Loosen the rear brake adjusting nut. 2. Remove the cotter pin from the axle nut. 3. Loosen the axle nut. 4. Turn both left and right chain adjusting plates the same amount. Make sure that they are in the same position for proper wheel alignment.
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7. Adjust the free play in the brake pedal. 1 2 3 4 5 6 7 8 9
1. Cotter pin
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Drive chain lubrication

The chain consists of many parts which work with each other. If the chain is not maintained properly, it will wear out quickly. Therefore, the chain must be serviced regularly. This service is especially necessary when riding in dusty areas. 1. The drive chain should be lubricated every 500 km. First, remove all dirt and mud from the chain with a brush or cloth. Then, spray any of the many brands of spray-type chain lubricant between both rows of side plates and on all center rollers. 2. To clean the chain thoroughly, remove it from the motorcycle, dip it in solvent, and clean out as much dirt as possible. Then, take the chain out of the solvent to dry it, and immediately lubricate it to prevent it from rusting.
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Check the operation of the brake light after adjusting the rear brake.
6. Insert a new cotter pin into the axle nut and bend the end of the cotter pin as shown in the illustration. If the notch in the nut and cotter pin hole do not match, tighten the nut slightly to align them.
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Always use a new cotter pin on the axle nut.
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Cable inspection and lubrication
Throttle cable and grip lubrication

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Brake and shift pedal lubrication

Lubricate the pivoting parts. Recommended lubricant: Same as engine oil 1 2 3 4 5 6 7
Damage to the outer housing of cables may lead to internal rusting and interfere with the cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions. Lubricate the cables and cable ends. If a cable does not operate smoothly, ask a Yamaha dealer to replace it. Recommended lubricant: Same as engine oil
The throttle twist grip assembly should be greased at the time that the cable is lubricated, since the grip must be removed to get at the end of the throttle cable. After removing the screws, hold the end of the cable up in the air and put in several drops of lubricant. With the throttle grip disassembled, coat the metal surface of the grip assembly with a suitable all-purpose grease.
8 9
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Brake and clutch lever lubrication

1 2 3 4 5 6 7 8 9 Lubricate the pivoting parts. Recommended lubricant: Same as engine oil
Sidestand lubrication
Lubricate the sidestand pivoting point and metal-to-metal contact surfaces. Check that the sidestand moves up and down smoothly. Recommended lubricant: Same as engine oil
Rear suspension lubrication

Lubricate the pivoting parts. Recommended lubricant: Lithium soap base grease
EW000113
If the sidestand does not move smoothly, consult a Yamaha dealer.
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2. Operation check Place the motorcycle on a level place. a. Hold the motorcycle in an upright position and apply the front brake. b. Push down hard on the handlebars several times and check if the fork rebounds smoothly.
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1 2 3 4 5 6 7 8 9
Front fork inspection
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Steering inspection
Periodically inspect the condition of the steering. Worn out or loose steering bearings may be dangerous. Place a stand under the engine to raise the front wheel off the ground. Hold the lower end of the front forks and try to move them forward and backward. If any free play can be felt, ask a Yamaha dealer to inspect and adjust the steering. Inspection is easier if the front wheel is removed.
Securely support the motorcycle so there is no danger of it falling over. 1. Visual check Check for scratches or damage on the inner tube and excessive oil leakage from the front fork.
If any damage or unsmooth movement is found with the front fork, consult a Yamaha dealer.
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1 2 3 4 5 6 7 8 9
1. Battery 2. Battery breather hose
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Wheel bearings
If there is play in the front or rear wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer inspect the wheel bearings.
Securely support the motorcycle so there is no danger of it falling over.
1 2
Battery
Check the level of the battery electrolyte and make sure that the terminals are tight. Fill with distilled water if the electrolyte level is low.
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When inspecting the battery, be sure the breather hose is routed correctly. If the breather hose is positioned in such a way as to cause battery electrolyte or gas to exit onto the frame, structural and cosmetic damage to the motorcycle can occur.
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Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call a physician immediately. EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes etc., away. Ventilate when charging or using in an enclosed space. Always shield your eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.
1 2
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Take care not to spill battery fluid on the chain. Battery fluid may weaken the chain causing shorter chain life and possibly result in an accident Battery storage 1. When the motorcycle will not be used for a month or longer, remove the battery, fully charge it and store it in a cool, dry place. Completely recharge the battery before reinstallation. 2. If the battery will be stored for longer than two months, check the specific gravity of the fluid at least once a month and fully recharge the battery when it is too low.
1 2 3
1. Maximum level mark 2. Minimum level mark
4 5 6 7 8 9
Replenishing the battery fluid A poorly maintained battery will corrode and discharge quickly. The battery fluid should be checked at least once a month. The level should be between the minimum level and maximum level marks. Use only distilled water if refilling is necessary.
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Normal tap water contains minerals which are harmful to a battery; therefore, refill only with distilled water.
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3. Always make sure the connections are correct when putting the battery back in the motorcycle. Make sure the breather hose is properly connected and is not damaged or obstructed.
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1 2 3 4 5 6 7 8 9
Do not use fuses of higher amperage rating than those recommended. Substitution of a fuse of improper rating can cause extensive electrical system damage and possibly a fire.
1. Fuse
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Fuse replacement
The fuse is located behind panel A. (See page 6-7 for panel removal and installation procedures.) If the fuse is blown, turn off the main switch and the switch of the circuit in question. Install a new fuse of proper amperage. Turn on the switches and see if the electrical device operates. If the fuse immediately blows again, consult a Yamaha dealer.
Specified fuse: 15A
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1
1 2
1
1. Bulb holder cover
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3
1. Bulb holder
Headlight bulb replacement

This motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows: 1. Remove cowling A. (See page 6-6 for cowling removal and installation procedures.) 2. Remove the headlight unit.
3. Remove the connector and the bulb holder cover. 4. Turn the bulb holder counterclockwise to remove it and remove the defective bulb.
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4 5 6 7 8 9
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Keep flammable products and your hands away from a bulb while it is on, as it is hot. Do not touch a bulb until it cools down. 5. Put a new bulb into position and secure it in place with the bulb holder.
Avoid touching the glass part of a bulb. Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on a bulb, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 6. Install the bulb holder cover, connector and headlight unit. 7. Install the cowling. 8. If the headlight beam adjustment is necessary, ask a Yamaha dealer to make that adjustment.
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Supporting the motorcycle

1 2 3 4 5 6 7 8 9 Rear wheel service: Use a motorcycle stand or motorcycle jack to elevate the motorcycle so the rear wheel is off the ground. Alternatively, two jacks can be placed under the frame or swingarm. Since the Yamaha TW200 has no centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand upright. Front wheel service: To stabilize the rear of the motorcycle, either use a motorcycle stand or place a motorcycle jack under the frame in front of the rear wheel to prevent it from moving from side to side. Then use a motorcycle stand to elevate the front wheel off of the ground.
Check that the motorcycle is in a stable and level position before starting any maintenance. A strong wooden box can be placed under the engine for added stability.
3 2 4 1
1. 2. 3. 4.
Speedometer cable Axle nut Cotter pin Clip

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Front wheel removal
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8 It is advisable to have a Yamaha dealer service the wheel. 8 Securely support the motorcycle so there is no danger of it falling over. 1. Remove the clip holding the speedometer cable in the speedometer gear housing. Then remove the speedometer cable by pulling it outward.
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2. Loosen the brake cable free play adjusting nuts. Remove the brake cable from the handlebar lever holder and then from the front wheel hub. 3. Remove the cotter pin and loosen the axle nut. 4. Elevate the front wheel by placing a suitable stand under the engine. 5. Remove the axle nut and wheel axle. 3. Make sure the axle nut is properly torqued, and a new cotter pin is installed.
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Always use a new cotter pin. Axle holder nut torque: 90 Nm (9.0 m0kg)
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1 2 3 4
Front wheel installation

When installing the front wheel, reverse the removal procedure. Pay attention to the following points: 1. Make sure the wheel hub and the brake shoe plate assembly are installed with the projections meshed into the slots. 2. Make sure the slot in the brake shoe plate fits over the stopper on the front fork outer tube.
4. Adjust the free play in the brake lever.
5 6 7 8 9
6-32

2. Remove the axle nut cotter pin and loosen the axle nut. 3. Elevate the rear wheel by placing a suitable stand under the engine. 4. Remove the axle nut. 5. Push the wheel forward and remove the drive chain. 6. Pull out the axle and remove the rear wheel assembly by pulling it backwards.
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Rear wheel installation

1. Install the wheel assembly and insert the axle from the lefthand side. Be sure that the chain adjusting plates are installed with the punched side outward and the slot in the brake shoe plate is fit over the stopper on the swingarm. 2. Install and adjust the drive chain. (See page 6-22 for details about adjusting the drive chain slack.) 3. Install the axle nut and let the motorcycle down. 4. Tighten the axle nut to the specified torque and install the axle nut cotter pin. Tightening torque: Axle nut: 90 Nm (9.0 m0kg)
1 2 3 4 5 6 7 8 9
1. 2. 3. 4. 5.
1 3 5 4
Adjusting nut Brake rod Axle nut Cotter pin Chain adjusting plate
Rear wheel removal
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8 It is advisable to have a Yamaha dealer service the wheel. 8 Securely support the motorcycle so there is no danger of it falling over. 1. Remove the brake adjusting nut and brake rod from the brake cam lever.
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Troubleshooting
Although Yamaha motorcycles receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your motorcycle requires any repair, bring it to a Yamaha dealer. The skilled technicians at a Yamaha dealership have the tools, experience, and know-how to properly service your motorcycle. Use only genuine Yamaha parts on your motorcycle. Imitation parts may look like Yamaha parts, but they are often inferior. Consequently, they have a shorter service life and can lead to expensive repair bills. 1 2 3 4 5 6 7 8 9
Always use a new cotter pin on the axle nut. 5. Insert the brake rod into the brake cam lever and install the brake pedal free play adjusting nut. 6. Adjust the rear brake pedal free play. (See page 6-19.)
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Check the operation of the brake light after adjusting the rear brake.
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Troubleshooting chart
1 2
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Never check the fuel system while smoking or in the vicinity of an open flame.
1. Fuel
3
Check if there is fuel in the fuel tank
Enough fuel
Go to compression check.
4 5 6
No fuel
Supply fuel.
Engine doesnt start, go to compression check.
2. Compression
Use electric starter.
There is compression.
Go to ignition check.
No compression.
Ask a Yamaha dealer to inspect. Open the throttle half-way and start the engine.
3. Ignition
7 8 9
Remove spark plugs and check electrode. Wet Wipe clean with dry cloth and correct spark plug gap or replace spark plugs.
Dry
Ask a Yamaha dealer to inspect.
Engine doesnt start, go to battery check.
4. Battery
Engine turns over quickly. Engine turns over slowly. Battery good. Engine doesnt start, ask a Yamaha dealer to inspect. Check fluid, recharge, check connections. 6-35
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CLEANING AND STORAGE

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A. CLEANING
Frequent, thorough cleaning of your motorcycle will not only enhance its appearance but will improve its general performance and extend the useful life of many components.
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8 Improper cleaning can damage the cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic. 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 abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
1. Before cleaning the motorcycle: a. Block off the end of the exhaust pipe to prevent water entry; a plastic bag and strong rubber band may be used. b. Make sure the spark plug and all filler caps are properly installed. 2. If the engine case is excessively greasy, apply degreaser with a paint brush. Do not apply degreaser to the chain, sprockets or wheel axles. 3. Rinse the dirt and degreaser off with a garden hose. Use only enough pressure to do the job.
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Excessive hose pressure may cause water seepage and deterioration of wheel bearings, front fork, brakes, transmission seals and electrical parts. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers. 4. After riding on salted roads, wash the motorcycle with cold water immediately. Do not use warm water as it increases the chemical reaction of the salt. 5. Once the majority of the dirt has been hosed off, wash all surfaces with warm water and mild, detergent-type soap. An old toothbrush or bottle brush is handy for hard-to-get-at places.
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7-1
CLEANING AND STORAGE

6. Rinse the motorcycle off immediately with clean water and dry all surfaces with a chamois, clean towel, or soft absorbent cloth. 7. Dry the chain and lubricate it to prevent rust. 8. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 9. Automotive-type wax may be applied to all painted and chrome-plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes.
EAU01107
B. STORAGE
Long term storage (60 days or more) of your motorcycle will require some preventive procedures to guard against deterioration. After thoroughly cleaning the motorcycle, prepare for storage as follows: 1. Fill the fuel tank with fuel and add fuel stabilizer (if available). 2. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug. Turn the engine over several times (ground spark plug lead) to coat the cylinder wall with oil.
1 2 3 4 5 6 7 8 9
EW000127
When using the starter motor to crank the engine, remove the spark plug wires, and ground them to prevent sparking.
3. Thoroughly clean and lubricate the drive chain. (For details, see Drive chain lubrication on page 6-23.) 4. Lubricate all control cables. 5. Block up the frame to raise both wheels off the ground. 6. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering. 7. If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat cover. 8. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0C or more than 30C. NOTE: Make any necessary repairs before storing the motorcycle.
7-2
EAU01038
SPECIFICATIONS
Specifications
Model Dimensions: Overall length Overall width Overall height Seat height Wheel base Ground clearance Minimum turning radius Basic weight (With oil and full fuel tank): Engine: Engine type Cylinder arrangement Displacement Bore Stroke Compression ratio Starting system Lubrication system Air-cooled 4-stroke, SOHC, gasoline Forward inclined single cylinder 196 cm
3
TW200
Engine oil: Type:

10 0 10 20 30 40C
1 2 3 4 5 6 7 8 9
2,090 mm 815 mm 1,115 mm 790 mm 1,325 mm 250 mm 1,900 mm 126 kg Capacity: Periodic oil change 1.0 L Classification
SAE 10W/30 SAE 10W/40 SAE 20W/40 SAE 20W/50
API Service SE, SF type or equivalent (e.g. SF-SE, SF-SE-CC, SF-SE-SD etc.)
With oil filter replacement 1.1 L Total amount Air filter: Fuel: Type Fuel tank capacity Reserve amount Carburetor: Type / quantity Manufacturer 8-1 Y29P-5C / 1 TEIKEI Regular gasoline 7.0 L 1.0 L 1.3 L Wet type element
67.0 55.7 mm 9.5:1 Electric and kick starter Wet sump
SPECIFICATIONS
EAU01038
1 2 3 4 5 6 7 8 9
Spark plug: Type / Manufacturer Spark plug gap Clutch type: Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Number of sprocket teeth (Rear/Front) Transmission type Operation Gear ratio 1st 2nd 3rd 4th 5th Chassis: Frame type Caster angle Trail Diamond 26.5 94 mm 8-2 Spur gear 3.318 Chain drive 3.571 50/14 Constant mesh 5-speed Left foot operation 2.833 1.789 1.318 1.040 0.821 D8EA / NGK or X24ES-U / DENSO 0.6 ~ 0.7 mm Wet, multiple-disc
Tire: Type Size: Front Rear Manufacturer / model: Front Rear Maximum load* Air pressure (cold tire): up to 80 kg load* Front Rear 80 kg load ~ Maximum load* Front Rear Off-road riding Front Rear High-speed riding Front Rear 150 kPa; 1.50 kgf/cm2; 1.50 bar 175 kPa; 1.75 kgf/cm2; 1.75 bar 125 kPa; 1.25 kgf/cm2; 1.25 bar 125 kPa; 1.25 kgf/cm2; 1.25 bar 150 kPa; 1.50 kgf/cm2; 1.50 bar 175 kPa; 1.75 kgf/cm2; 1.75 bar 125 kPa; 1.25 kgf/cm2; 1.25 bar 125 kPa; 1.25 kgf/cm2; 1.25 bar BRIDGESTONE / TW31 BRIDGESTONE / TW32 157 kg 130/80-18 66P 180/80-14M/C 78P With tube
*Load is total weight of cargo, rider, passenger and accessories.
SPECIFICATIONS
Wheels: Type: Front Rear Size: Front Rear Brakes: Front: Type Operation Rear: Type Operation Suspension: Front Rear Shock absorber: Front Rear Wheel travel: Front Rear 160 mm 150 mm 8-3 Coil spring / oil damper Coil-gas spring / oil damper Telescopic fork Swingarm (Monocross suspension) Drum brake Right foot operation Drum brake Right hand operation 18 2.50 14M/C MT4.50 Spoke wheel Spoke wheel
Electrical: Ignition system: Charging system: Type Standard output Battery: Type Voltage, capacity Headlight type Bulb voltage, wattage quantity: Headlight Stop / tail light Front flasher light Rear flasher light Meter light Neutral indicator light High beam indicator light Turn indicator light Fuse: Main 15A 12V 35W / 35W 1 12V 27W / 8W 1 12V 27W / 8W 2 12V 27W 2 12V 3.4W 1 12V 3.4W 1 12V 3.4W 1 12V 3.4W 1 GM7CZ-3D 12V 7 AH Halogen bulb A.C. magneto 12V 11A / 5,000 rpm C.D.I.
1 2 3 4 5 6 7 8 9
SPECIFICATIONS
EAU01064
HOW TO USE THE CONVERSION TABLE

1 2 3 4 5 6 7 8 9 All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC ** mm 2 mm MULTIPLIER 0.03937 0.03937 = = IMPERIAL ** in 0.08 in
Distance
CONVERSION TABLE
METRIC TO IMPERIAL Metric unit Torque m kg m kg cm kg cm kg kg g km/hr km m m cm mm cc (cm3) cc (cm3) lt (liter) lt (liter) kg/mm kg/cm2 Centigrade(C) Multiplier 86.794 0.0723 0.8679 2.205 0.03527 0.6214 0.6214 3.281 1.094 0.3937 0.03937 0.03527 0.06102 0.8799 0.2199 55.997 14.2234 9/5 + 32 Imperial unit 7.233 in lb ft lb in lb lb oz mph mi ft yd in in oz (IMP liq.) cu in qt (IMP liq.) gal (IMP liq.) lb/in psi (lb/in2) Fahrenheit(F) ft.lb
Weight Speed
Volume/ Capacity
Misc.
8-4
EAU01039
CONSUMER INFORMATION
EAU01040
Identification numbers record

Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER:
1 2 3
1. Key identification number

EAU01042
1. Vehicle identification number

EAU01043
4 5 6 7 8 9
Key identification number

The key identification number is stamped on the key. Record this number in the space provided and use it for reference when obtaining a new key.
Vehicle identification number

The vehicle identification number is stamped into the steering head pipe. Record this number in the space provided. NOTE: The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state.
2. VEHICLE IDENTIFICATION NUMBER:
3. MODEL LABEL INFORMATION:
1 6
9-1
CONSUMER INFORMATION
1
1 2 3 4 5 6 7 8 9
1. Model label
EAU01050
Model label
The model label is affixed to the frame under the seat. (See page 39 for seat removal procedures.) Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer.
9-2
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN 200250.11(E) !

Owner'S Manual: 5FY-28199-EX

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OWNERS MANUAL

IMPORTANT MANUAL INFORMATION

IMPORTANT MANUAL INFORMATION

Q GIVE SAFETY THE RIGHT OF WAY

9. 10. 11. 12.

13. 14. 15. 16. 17.

INSTRUMENT AND CONTROL FUNCTIONS

Main switch/Steering lock

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

Horn switch HORN Press the switch to sound the horn.

INSTRUMENT AND CONTROL FUNCTIONS

See starting instructions prior to starting the engine.

N. Neutral 1. Shift pedal

INSTRUMENT AND CONTROL FUNCTIONS

Front brake lever

Rear brake pedal

Fuel tank cap

INSTRUMENT AND CONTROL FUNCTIONS

1. Filler tube 2. Fuel level

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

1. Open 2. Helmet holder

INSTRUMENT AND CONTROL FUNCTIONS

Rear shock absorber

Do not exceed the load limit of 3 kg.

INSTRUMENT AND CONTROL FUNCTIONS

Sidestand/clutch switch operation check

SIDESTAND IS DOWN. ENGINE WILL STALL. SIDESTAND SWITCH IS OK.

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

CLUTCH SWITCH IS OK.

PRE-OPERATION CHECK LIST

OPERATION AND IMPORTANT RIDING POINTS

Starting and warming up a cold engine

OPERATION AND IMPORTANT RIDING POINTS

OPERATION AND IMPORTANT RIDING POINTS

OPERATION AND IMPORTANT RIDING POINTS

Starting a warm engine

N. Neutral 1. Shift pedal

OPERATION AND IMPORTANT RIDING POINTS

OPERATION AND IMPORTANT RIDING POINTS

PERIODIC MAINTENANCE AND MINOR REPAIR

PERIODIC MAINTENANCE AND MINOR REPAIR

PERIODIC MAINTENANCE AND MINOR REPAIR

PERIODIC MAINTENANCE AND LUBRICATION

6,000 km or 6 months (Whichever comes first)

12,000 km or 12 months (Whichever comes first)

3 * Valves 4 * Cam chain 5 Air filter

PERIODIC MAINTENANCE AND MINOR REPAIR

12 * Wheel bearings 13 * Swingarm

16 * Chassis fasteners 17 18 Sidestand Sidestand switch

19 * Front fork 20 * Rear shock absorber assembly

Rear shock absorber 21 * assembly pivoting points 22 * Carburetor

PERIODIC MAINTENANCE AND MINOR REPAIR

Engine oil filter element 9 Clean or replace if necessary.

25 * Engine oil strainer

PERIODIC MAINTENANCE AND MINOR REPAIR

Cowling and panel removal and installation

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Panel B 2. Screw (2)

1. Spark plug gap