yamaha motor co., ltd. · pdf fileyamaha’s vast experience in the production of fine...

PRINTED IN JAPAN

2001·5–0.7×1(E) !

OWNER’S MANUAL

5FY-28199-14LIT-11626-15-17PRINTED ON RECYCLED PAPER

See your Authorized YAMAHA Dealer for a Genuine YAMAHAService Manual.

PROTECT YOUR INVESTMENT

Use Genuine YAMAHA Parts And Accessories.

YAMAHA MOTOR CO., LTD.TW200P(C)

EAU03438

EAU00002

INTRODUCTION

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Congratulations on your purchase of the Yamaha TW200/TW200C. This model is the result ofYamaha’s vast experience in the production of fine sporting, touring, and pacesetting racingmachines. It represents the high degree of craftsmanship and reliability that have made Yamaha aleader in these fields.

This manual will give you an understanding of the operation, inspection, and basic maintenance ofthis motorcycle. If you have any questions concerning the operation or maintenance of your motorcy-cle, please consult a Yamaha dealer.

The design and manufacture of this Yamaha motorcycle fully comply with the emissions standardsfor clean air applicable at the date of manufacture. Yamaha has met these standards without reduc-ing the performance or economy of operation of the motorcycle. To maintain these high standards, itis important that you and your Yamaha dealer pay close attention to the recommended maintenanceschedules and operating instructions contained within this manual.

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IMPORTANT MANUAL INFORMATION

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander or a person inspecting or repairing themotorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage tothe motorcycle.

A NOTE provides key information to make procedures easier or clearer.

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NOTE:

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, theremay be minor discrepancies between your motorcycle and this manual. If you have any ques-tions concerning this manual, please consult your Yamaha dealer.

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IMPORTANT MANUAL INFORMATION

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PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS”BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADE-QUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOUHAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPEC-TIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILLENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THISMOTORCYCLE.

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TW200P(C)OWNER’S MANUAL

©2001 by Yamaha Motor Corporation, U.S.A.1st edition, April 2001

All rights reserved.Any reprinting or unauthorized usewithout the written permission of

Yamaha Motor Corporation, U.S.A.is expressly prohibited.

Printed in Japan.P/N LIT-11626-15-17

EAU04247

AFFIX DEALER

LABEL HERE

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TABLE OF CONTENTS

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SAFETY INFORMATION....................................1-1Safe riding........................................................1-1Protective apparel ............................................1-3Modifications ....................................................1-3Loading and accessories .................................1-3Gasoline and exhaust gas ...............................1-5Location of important labels .............................1-7

DESCRIPTION....................................................2-1Left view...........................................................2-1Right view ........................................................2-2Controls and instruments .................................2-3

INSTRUMENT AND CONTROL FUNCTIONS .......................................................3-1

Main switch/steering lock .................................3-1Indicator lights..................................................3-2Speedometer unit.............................................3-2Handlebar switches..........................................3-2Clutch lever ......................................................3-4Shift pedal ........................................................3-4Brake lever.......................................................3-4Brake pedal ......................................................3-5Fuel tank cap ...................................................3-5Fuel ..................................................................3-6Fuel cock..........................................................3-7Starter (choke) knob ........................................3-8

Seat..................................................................3-8Helmet holder...................................................3-9Shock absorber................................................3-9Carrier ..............................................................3-9Luggage strap holders ...................................3-10Sidestand .......................................................3-10Ignition circuit cut-off system..........................3-11

PRE-OPERATION CHECKS ..............................4-1Pre-operation check list ...................................4-1

OPERATION AND IMPORTANTRIDING POINTS .................................................5-1

Starting and warming up a coldengine ............................................................5-1

Starting a warm engine ....................................5-3Shifting .............................................................5-3Recommended shift points ..............................5-4Engine break-in................................................5-5Parking.............................................................5-6

PERIODIC MAINTENANCE ANDMINOR REPAIR..................................................6-1

PERIODIC MAINTENANCE ............................6-1Owner’s tool kit ................................................6-1Periodic maintenance chart for theemission control system.................................6-3

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General maintenance andlubrication chart..............................................6-4

Removing and installing the cowling and panels ........................................6-7

Checking the spark plug ..................................6-9Canister (for California only) ..........................6-11Engine oil and oil filter element ......................6-11Cleaning the air filter element and check hose...................................................6-14

Cleaning the spark arrester............................6-16Adjusting the carburetor.................................6-17Adjusting the throttle cable free play .......................................................6-18

Adjusting the valve clearance ........................6-18Tires ...............................................................6-18Spoke wheels.................................................6-21Accessories and replacement parts...............6-21Adjusting the clutch lever free play ................6-22Adjusting the brake lever free play.................6-23Adjusting the brake pedal position and free play ................................................6-23

Adjusting the rear brake lightswitch ...........................................................6-25

Checking the front brake pads andrear brake shoes ..........................................6-25

Checking the brake fluid level ........................6-26Changing the brake fluid ................................6-27

Drive chain slack............................................6-28Lubricating the drive chain .............................6-29Checking and lubricating the cables...........................................................6-30

Checking and lubricating the throttle gripand cable .....................................................6-31

Checking and lubricating the brake and shift pedals..................................6-31

Checking and lubricating thebrake and clutch levers ................................6-31

Checking and lubricating thesidestand......................................................6-32

Lubricating the rear suspension.....................6-32Checking the front fork...................................6-32Checking the steering ....................................6-33Checking the wheel bearings.........................6-34Battery............................................................6-34Replacing the fuse .........................................6-37Replacing the headlight bulb..........................6-37Replacing a turn signal light bulb ...................6-39Replacing the tail/brake light bulb ..................6-39Supporting the motorcycle .............................6-40Front wheel ....................................................6-41Rear wheel .....................................................6-42Troubleshooting .............................................6-43Troubleshooting chart ....................................6-44

TABLE OF CONTENTS

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TABLE OF CONTENTS

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MOTORCYCLE CARE AND STORAGE...........................................................7-1

Care .................................................................7-1Storage ............................................................7-4

SPECIFICATIONS ..............................................8-1

CONSUMER INFORMATION.............................9-1Identification numbers......................................9-1Key identification number.................................9-1Vehicle identification number ...........................9-1Model label.......................................................9-2Reporting safety defects ..................................9-3Motorcycle noise regulation .............................9-4Maintenance record .........................................9-6Street and enduro motorcycle limited warranty..............................................9-8

Yamaha extended service .............................9-10

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Q SAFETY INFORMATION

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MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION AREDEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPER-TISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE-MENTS BEFORE RIDING THIS MOTORCYCLE.

HE OR SHE SHOULD:

1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTSOF MOTORCYCLE OPERATION.

2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MAN-UAL.

3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL

AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.

Safe riding

1. Always make pre-operation checks. Careful checks may help prevent an accident.2. This motorcycle is designed to carry the operator and a passenger.3. The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause

of automobile/motorcycle accidents. Many accidents have been caused by an automobile driverwho did not see the motorcycle. Making yourself conspicuous appears to be very effective inreducing the chance of this type of accident.

Therefore:a. Wear a brightly colored jacket.b. Use extra caution when approaching and passing through intersections, since intersections

are the most likely places for motorcycle accidents to occur.c. Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.

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4. Many accidents involve inexperienced operators. In fact, many operators who have beeninvolved in accidents do not even have a current motorcycle license.a. Make sure that you are qualified and that you only lend your motorcycle to other qualified oper-

ators.b. Know your skills and limits. Staying within your limits may help you to avoid an accident.c. We recommend that you practice riding your motorcycle where there is no traffic until you have

become thoroughly familiar with the motorcycle and all of its controls.5. Many accidents have been caused by error of the motorcycle operator. A typical error made by

the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficientlean angle for the speed).a. Always obey the speed limit and never travel faster than warranted by road and traffic condi-

tions.b. Always signal before turning or changing lanes. Make sure that other motorists can see you.

6. The posture of the operator and passenger is important for proper control.a. The operator should keep both hands on the handlebar and both feet on the operator footrests

during operation to maintain control of the motorcycle.b. The passenger should always hold onto the operator, the seat strap or grab bar, if equipped,

with both hands and keep both feet on the passenger footrests.c. Never carry a passenger unless he or she can firmly place both feet on the passenger

footrests.7. Never ride under the influence of alcohol or other drugs.

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Protective apparel

The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safetyhelmet is the single most critical factor in the prevention or reduction of head injuries.

1. Always wear an approved helmet.2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment

of vision that could delay seeing a hazard.3. The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing

abrasions or lacerations.4. Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or

wheels and cause injury or an accident.5. Never touch the engine or exhaust system during or after operation. They become very hot and

can cause burns. Always wear protective clothing that covers your legs, ankles, and feet.6. Passengers should also observe the precautions mentioned above.

Modifications

Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment,may render the motorcycle unsafe for use and may cause severe personal injury. Modifications mayalso make your motorcycle illegal to use.

Loading and accessories

Adding accessories or cargo to your motorcycle can adversely affect stability and handling if theweight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extremecaution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcy-cle that has added cargo or accessories. Here are some general guidelines to follow if loading cargoor adding accessories to your motorcycle:

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Loading

The total weight of the operator, passenger, accessories and cargo must not exceed the maximumload limit of 180 kg (397 lb) TW200/179kg (395 lb) TW200C. When loading within this weight limit,keep the following in mind:

1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible.Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to mini-mize imbalance or instability.

2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo aresecurely attached to the motorcycle before riding. Check accessory mounts and cargo restraintsfrequently.

3. Never attach any large or heavy items to the handlebar, front fork, or front fender. These items,including such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or aslow steering response.

Accessories

Genuine Yamaha accessories have been specifically designed for use on this motorcycle. SinceYamaha cannot test all other accessories that may be available, you must personally be responsiblefor the proper selection, installation and use of non-Yamaha accessories. Use extreme caution whenselecting and installing any accessories.

Keep the following guidelines in mind, as well as those provided under “Loading” when mountingaccessories.

1. Never install accessories or carry cargo that would impair the performance of your motorcycle.Carefully inspect the accessory before using it to make sure that it does not in any way reduceground clearance or cornering clearance, limit suspension travel, steering travel or control opera-tion, or obscure lights or reflectors.

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a. Accessories fitted to the handlebar or the front fork area can create instability due to improperweight distribution or aerodynamic changes. If accessories are added to the handlebar or frontfork area, they must be as lightweight as possible and should be kept to a minimum.

b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody-namic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstablein cross winds. These accessories may also cause instability when passing or being passed bylarge vehicles.

c. Certain accessories can displace the operator from his or her normal riding position. Thisimproper position limits the freedom of movement of the operator and may limit control ability,therefore, such accessories are not recommended.

2. Use caution when adding electrical accessories. If electrical accessories exceed the capacity ofthe motorcycle’s electrical system an electric failure could result, which could cause a dangerousloss of lights or engine power.

Gasoline and exhaust gas

1. GASOLINE IS HIGHLY FLAMMABLE:a. Always turn the engine off when refueling.b. Take care not to spill any gasoline on the engine or exhaust system when refueling.c. Never refuel while smoking or in the vicinity of an open flame.

2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes arepoisonous and may cause loss of consciousness and death within a short time. Always operateyour motorcycle in an area that has adequate ventilation.

3. Always turn the engine off before leaving the motorcycle unattended and remove the key fromthe main switch. When parking the motorcycle, note the following:

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a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place wherepedestrians or children are not likely to touch these hot areas.

b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over.c. Do not park the motorcycle near a flammable source (e.g., a kerosene heater, or near an open

flame), otherwise it could catch fire.4. When transporting the motorcycle in another vehicle, make sure that it is kept upright and that the

fuel cock(s) are turned to “ON” or “RES” (for vacuum type)/”OFF” (for manual type). If the motor-cycle should lean over, gasoline may leak out of the carburetor or fuel tank.

5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get intoyour eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediate-ly wash the affected area with soap and water and change your clothes.

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EAU02977

Location of important labelsPlease read the following important labels carefully before operating this motorcycle.

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q WARNINGImproper loading can cause loss of control.Read owner’s manual for proper loading.

3JJ-28446-A0

WARNINGq

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This unit contains high pressure nitrogen gas.Mishandling can cause explosion.

Read owner's manual for instructions.Do not incinerate, puncture or open.

4AA-22259-80

TIRE INFORMATION

3XT-21668-A0

Cold tire normal pressure should be set asfollows.8 Up to 90kg (198 lbs) loadFRONT : 125 kPa, {1.25 kgf/cm2}, 18 psi

FRONT : 150 kPa, {1.50 kgf/cm2}, 22 psi

REAR : 125 kPa, {1.25 kgf/cm2}, 18 psi

REAR : 175 kPa, {1.75 kgf/cm2}, 25 psi

8 90kg (198 lbs) ~ maximum load

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q WARNINGBEFORE YOU OPERATE THIS VEHICLE, READTHE OWNER’S MANUAL AND ALL LABELS.ALWAYS WEAR AN APPROVED MOTORCYCLEHELMET, eye protection, and protective clothing.

3MX-2118K-A0

CAUTIONRead owner’s manual before servicing battery.Electrolyte will damage metal parts or paint.If electrolyte spills, wash area with freshwater immediately.Be sure to connect breather hose afterinstalling battery.

3JL-28177-A0

qWARNINGNEVER sit here.

3MX-24875-A0

3TB-24877-A0

LOAD LIMIT3 kg {7 lbs}

EMISSION HOSE ROUTINGCARB.

FROMFUEL TANK

CANISTERTO ATMOSPHERE

4YN-21686-00

3 CALIFORNIA ONLY

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DESCRIPTION

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91. Fuel tank cap (page 3-5)2. Fuel cock (page 3-7)3. Helmet holder (page 3-9)4. Luggage strap holders (page 3-10)5. Drive chain adjusting plate (page 6-28)

6. Air filter element (page 6-14)7. Starter (choke) knob (page 3-8)8. Shift pedal (page 3-4)

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Left view

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DESCRIPTION

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99. Carrier (page 3-9)

10. Battery (page 6-34)11. Engine oil level check window (page 6-11)12. Brake pedal (page 3-5, 6-23)13. Owner’s tool kit (page 6-1)

14. Fuse (page 6-37)15. Luggage strap holders (page 3-10)16. Spark arrester (page 6-16)

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Right view

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DESCRIPTION

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91. Clutch lever (page 3-4, 6-22)2. Left handlebar switches (page 3-2)3. Speedometer unit (page 3-2)4. Main switch/steering lock (page 3-1)5. Indicator lights (page 3-2)

6. Right handlebar switches (page 3-3)7. Brake lever (page 3-4, 6-23)8. Throttle grip (page 6-18)9. Fuel tank cap (page 3-5)

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Controls and instruments

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INSTRUMENT AND CONTROL FUNCTIONS

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Main switch/steering lockThe main switch/steering lock con-trols the ignition and lighting systems,and is used to lock the steering. Thevarious positions are describedbelow.

EAU00032

ONAll electrical systems are suppliedwith power, and the headlight, meterlighting, taillight and position lightscome on, and the engine can bestarted. The key cannot be removed.

EAU00038

OFFAll electrical systems are off. The keycan be removed.

EAU00043

LOCKThe steering is locked, and all electri-cal systems are off. The key can beremoved.

To lock the steering1. Turn the handlebars all the way

to the left or right.2. Push the key in from the “OFF”

position, release it, and then turnit to “LOCK”.

3. Remove the key.

a. Push.b. Release.c. Turn.

LOCK

OFFON

a b c

To unlock the steeringInsert the key and turn it to “OFF”.

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Never turn the key to “LOCK”while the motorcycle is moving.

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Speedometer unitThe speedometer unit is equippedwith a speedometer, an odometerand a tripmeter. The speedometershows riding speed. The odometershows the total distance traveled.The tripmeter shows the distancetraveled since it was last set to zerowith the reset knob. The tripmetercan be used to estimate the distancethat can be traveled with a full tank offuel. This information will enable youto plan future fuel stops.

1. Speedometer2. Odometer3. Tripmeter4. Reset knob EAU00118

Handlebar switchesEAU03888

Dimmer switch “&/%”Set this switch to “&” for the highbeam and to “%” for the low beam.

EAU03889

Turn signal switch “4/6”To signal a right-hand turn, push thisswitch to “6”. To signal a left-handturn, push this switch to “4”. Whenreleased, the switch returns to thecenter position. To cancel the turnsignal lights, push the switch in afterit has returned to the center position.

1. Dimmer switch 2. Turn signal switch 3. Horn switch “*”

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Indicator lightsEAU00057

Turn signal indicator light “5”This indicator light flashes when theturn signal switch is pushed to the leftor right.

EAU00063

High beam indicator light “&”This indicator light comes on whenthe high beam of the headlight isswitched on.

EAU00061

Neutral indicator light “N”This indicator light comes on whenthe transmission is in the neutralposition.

1. Turn signal indicator light “5”2. High beam indicator light “&”3. Neutral indicator light “N”

31 2

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EAU00129

Horn switch “*”Press this switch to sound the horn.

EAU00143

Start switch “,”Push this switch to crank the enginewith the starter.

EC000005

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See page 5-1 for starting instruc-tions prior to starting the engine.

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Engine stop switch “#/$”Set this switch to “#” before startingthe engine. Set this switch to “$” tostop the engine in case of an emer-gency, such as when the motorcycleoverturns or when the throttle cable isstuck.

1. Engine stop switch 2. Start switch “,”

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EAU00157

Shift pedalThe shift pedal is located on the leftside of the engine and is used incombination with the clutch leverwhen shifting the gears of the 5-speed constant-mesh transmissionequipped on this motorcycle.

1. Shift pedalN. Neutral

EAU00152

Clutch leverThe clutch lever is located at the lefthandlebar grip. To disengage theclutch, pull the lever toward the han-dlebar grip. To engage the clutch,release the lever. The lever shouldbe pulled rapidly and released slowlyfor smooth clutch operation.The clutch lever is equipped with aclutch switch, which is part of the igni-tion circuit cut-off system. (See page3-11 for an explanation of the ignitioncircuit cut-off system.)

1. Clutch lever

EAU00158

Brake leverThe brake lever is located at the righthandlebar grip. To apply the frontbrake, pull the lever toward the han-dlebar grip.

1. Brake lever

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N

5432

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EAU00162

Brake pedalThe brake pedal is on the right sideof the motorcycle. To apply the rearbrake, press down on the brakepedal.

1. Brake pedal

EAU00177

Fuel tank capTo remove the fuel tank cap

1. Insert the key into the lock andturn it 1/4 turn counterclockwise.

2. Turn the fuel tank cap 1/3 turncounterclockwise and pull it off.

1. Fuel tank capa. Unlock.b. Turn.

To install the fuel tank cap1. Insert the fuel tank cap into the

tank opening with the key insert-ed in the lock, and then turn thecap 1/3 turn clockwise.

2. Turn the key 1/4 turn clockwise,and then remove it.

NOTE:The fuel tank cap cannot be installedunless the key is in the lock. In addi-tion, the key cannot be removed if thecap is not properly installed andlocked.

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Make sure that the fuel tank cap isproperly closed and locked beforeriding.

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b

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FuelMake sure that there is sufficient fuelin the tank. Fill the fuel tank to thebottom of the filler tube as shown.

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8 Do not overfill the fuel tank,otherwise it may overflowwhen the fuel warms up andexpands.

8 Avoid spilling fuel on the hotengine.

1. Filler tube2. Fuel level

EAU00185

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Immediately wipe off spilled fuelwith a clean, dry, soft cloth, sincefuel may deteriorate painted sur-faces or plastic parts.

EAU04194

ECA00102

cC

Use only unleaded gasoline. Theuse of leaded gasoline will causesevere damage to the engine inter-nal parts such as valves, pistonrings, exhaust system, etc.

Your Yamaha engine has beendesigned to use regular unleadedgasoline with a pump octane number[(R+M)/2] of 86 or higher, or aresearch octane number of 91 orhigher. If knocking (or pinging)occurs, use a gasoline of a differentbrand or premium unleaded fuel. Useof unleaded fuel will extend sparkplug life and reduce maintenancecosts.

GasoholThere are two types of gasohol:gasohol containing ethanol and thatcontaining methanol. Gasohol con-taining ethanol can be used if theethanol content does not exceed10%. Gasohol containing methanol isnot recommended by Yamahabecause it can cause damage to thefuel system or vehicle performanceproblems.

Recommended fuel:UNLEADED GASOLINE ONLY

Fuel tank capacity:Total amount:

7.0 L (1.5 Imp gal, 1.8 US gal)

Reserve amount:1.0 L(0.2 Imp gal, 0.3 US gal)

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EAU03050

Fuel cockThe fuel cock supplies fuel from thetank to the carburetor while filtering italso.The fuel cock has three positions:

OFFWith the lever in this position, fuel willnot flow. Always return the lever tothis position when the engine is notrunning.

1. Arrow mark positioned over “OFF”

ONWith the lever in this position, fuelflows to the carburetor. Normal ridingis done with the lever in this position.

1. Arrow mark positioned over “ON”

RESThis indicates reserve. If you run outof fuel while riding, move the lever tothis position. Fill the tank at the firstopportunity. Be sure to set the leverback to “ON” after refueling!

1. Arrow mark positioned over “RES”

RES

ONFUEL

OFF

1

OFF: Closed position

OFF

ONFUEL

RES

1

RESRES: Reserve position

ONFUEL

RES

OFF

1ON

ON: Normal position

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EAU04038

Starter (choke) knob “1”Starting a cold engine requires a rich-er air-fuel mixture, which is suppliedby the starter (choke).Move the knob in direction a to turnon the starter (choke).Move the knob in direction b to turnoff the starter (choke).

1. Starter (choke) knob “1”

ab

1

EAU01092

Seat

To remove the seatRemove the bolts, and then pull theseat off.

1. Bolt (×2)

To install the seat1. Insert the projection on the front

of the seat into the seat holderas shown.

2. Place the seat in the originalposition, and then tighten thebolts.

NOTE:Make sure that the seat is properlysecured before riding.

1. Projection2. Seat holder

1

12

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EAU00260

Helmet holderTo open the helmet holder, insert thekey into the lock, and then turn thekey as shown.To lock the helmet holder, place it inthe original position, and then removethe key.

EW000030

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Never ride with a helmet attachedto the helmet holder, since the hel-met may hit objects, causing lossof control and possibly an acci-dent.

1. Helmet holder

1

EAU01343

Shock absorberEAU00315

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This shock absorber containshighly pressurized nitrogen gas.For proper handling, read andunderstand the following informa-tion before handling the shockabsorber. The manufacturer can-not be held responsible for proper-ty damage or personal injury thatmay result from improper han-dling.8 Do not tamper with or attempt

to open the gas cylinder.8 Do not subject the shock

absorber to an open flame orother high heat sources, other-wise it may explode due toexcessive gas pressure.

8 Do not deform or damage thegas cylinder in any way, asthis will result in poor damp-ing performance.

8 Always have a Yamaha dealerservice the shock absorber.

EAU00320

CarrierEW000032

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8 Do not exceed the load limit of3 kg (7 lb) for the carrier.

8 Do not exceed the maximumload of TW200: 180 kg (397lb)/TW200(C): 179 kg (395 lb)for the vehicle.

1. Carrier

1

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EAU01493

Luggage strap holdersThere are four luggage strap holdersbelow the carrier.

1. Luggage strap holder (×4)

1

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EAU00330

SidestandThe sidestand is located on the leftside of the frame. Raise the side-stand or lower it with your foot whileholding the motorcycle upright.

NOTE:The built-in sidestand switch is part ofthe ignition circuit cut-off system,which cuts the ignition in certain situ-ations. (See further down for anexplanation of the ignition circuit cut-off system.)

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The motorcycle must not be riddenwith the sidestand down, or if thesidestand cannot be properlymoved up (or does not stay up),otherwise the sidestand could con-tact the ground and distract theoperator, resulting in a possibleloss of control. Yamaha’s ignitioncircuit cut-off system has beendesigned to assist the operator infulfilling the responsibility of rais-ing the sidestand before startingoff. Therefore, check this systemregularly as described below andhave a Yamaha dealer repair it if itdoes not function properly.

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EAU03720

Ignition circuit cut-off systemThe ignition circuit cut-off system(comprising the sidestand switch,clutch switch and neutral switch) hasthe following functions.8 It prevents starting when the

transmission is in gear and thesidestand is up, but the clutchlever is not pulled.

8 It prevents starting when thetransmission is in gear and theclutch lever is pulled, but thesidestand is still down.

8 It cuts the running engine whenthe transmission is in gear andthe sidestand is moved down.

Periodically check the operation ofthe ignition circuit cut-off systemaccording to the following procedure.

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If a malfunction is noted, have aYamaha dealer check the systembefore riding.

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With the engine turned off:1. Move the sidestand down.2. Make sure that the engine stop switch is set to “#”.3. Turn the key to “ON”. 4. Shift the transmission into the neutral position.5. Push the start switch.Does the engine start?

The neutral switch may be defective.The motorcycle should not be ridden until checked by a Yamaha dealer.

With the engine still running:6. Move the sidestand up.7. Keep the clutch lever pulled.8. Shift the transmission into gear.9. Move the sidestand down.Does the engine stall?

After the engine has stalled:10. Move the sidestand up.11. Keep the clutch lever pulled.12. Push the start switch.Does the engine start?

The sidestand switch may be defective.The motorcycle should not be ridden until checked by a Yamaha dealer.

The clutch switch may be defective.The motorcycle should not be ridden until checked by a Yamaha dealer.

NO

NOTE:This check is most reliable if performed witha warmed-up engine.

YES

YES NO

The system is OK. The motorcycle can be ridden.

YES NO

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EAU01114

PRE-OPERATION CHECKS

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The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-ough visual inspection, to check the following points before each ride.

EAU03439

Pre-operation check list

ITEM CHECKS PAGE

Fuel• Check fuel level in fuel tank.• Refuel if necessary.• Check fuel line for leakage.

3-6

Engine oil• Check oil level in engine.• If necessary, add recommended oil to specified level.• Check vehicle for oil leakage.

6-11–6-14

Front brake

• Check operation.• If soft or spongy, have Yamaha dealer bleed hydraulic system.• Check lever free play.• Adjust if necessary.• Check fluid level in reservoir.• If necessary, add recommended brake fluid to specified level.• Check hydraulic system for leakage.

3-4, 6-23, 6-25–6-27

Rear brake• Check operation.• Check pedal free play.• Adjust if necessary.

3-5, 6-23–6-26

Clutch

• Check operation.• Lubricate cable if necessary.• Check lever free play.• Adjust if necessary.

3-4, 6-22

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Throttle grip• Make sure that operation is smooth.• Check free play.• If necessary, have Yamaha dealer make adjustment or lubricate.

6-18

Control cables • Make sure that operation is smooth.• Lubricate if necessary. 6-30

Drive chain

• Check chain slack.• Adjust if necessary.• Check chain condition.• Lubricate if necessary.

6-28–6-30

Wheels and tires

• Check for damage.• Check tire condition and tread depth.• Check air pressure.• Correct if necessary.

6-18–6-21

Brake and shift pedals • Make sure that operation is smooth.• Lubricate pedal pivoting points if necessary. 6-31

Brake and clutch levers • Make sure that operation is smooth.• Lubricate lever pivoting points if necessary. 6-31

Sidestand • Make sure that operation is smooth.• Lubricate pivot if necessary. 6-31

Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened.• Tighten if necessary. —

Instruments, lights, signals and switches

• Check operation. • Correct if necessary. 3-2–3-3, 6-37–6-39

Sidestand switch • Check operation of ignition circuit cut-off system.• If system is defective, have Yamaha dealer check vehicle. 3-10

ITEM CHECKS PAGE

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NOTE:Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in avery short time; and the added safety it assures is more than worth the time involved.

EWA00033

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If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat-ing the motorcycle.

Sidestand switch • Check operation of ignition circuit cut-off system.• If system is defective, have Yamaha dealer check vehicle. 3-10

Battery • Check fluid level.• Fill with distilled water if necessary. 6-34–6-36

ITEM CHECKS PAGE

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EAU00372

OPERATION AND IMPORTANT RIDING POINTS

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8 Become thoroughly familiarwith all operating controls andtheir functions before riding.Consult a Yamaha dealerregarding any control or func-tion that you do not thorough-ly understand.

8 Never start the engine or oper-ate it in a closed area for anylength of time. Exhaust fumesare poisonous, and inhalingthem can cause loss of con-sciousness and death within ashort time. Always make surethat there is adequate ventila-tion.

8 Before starting out, make surethat the sidestand is up. If thesidestand is not raised com-pletely, it could contact theground and distract the opera-tor, resulting in a possible lossof control.

EAU00376

cC

8 Make sure not to store person-al items near the air cleanerintake, otherwise air intake willbe blocked and performancewill suffer.

8 Make sure not to put anythingnear the battery and its termi-nals, otherwise electrical fail-ure and acid corrosion mayresult.

EAU01751

Starting and warming up acold engineIn order for the ignition circuit cut-offsystem to enable starting, one of thefollowing conditions must be met:8 The transmission is in the neutral

position.8 The transmission is in gear with

the clutch lever pulled and thesidestand up.

EW000054

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8 Before starting the engine,check the function of the igni-tion circuit cut-off systemaccording to the proceduredescribed on page 3-12.

8 Never ride with the sidestanddown.

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1. Turn the fuel cock lever to “ON”.2. Turn the key to “ON” and make

sure that the engine stop switchis set to “#”.

3. Shift the transmission into theneutral position.

NOTE:When the transmission is in the neu-tral position, the neutral indicator lightshould be on, otherwise have aYamaha dealer check the electricalcircuit.

1. Arrow mark positioned over “ON”

ONFUEL

RES

OFF

1ON

4. Turn the starter (choke) on andcompletely close the throttle.(See page 3-8 for starter (choke)operation.)

5. Start the engine by pushing thestart switch.

NOTE:If the engine fails to start, release thestart switch, wait a few seconds, andthen try again. Each starting attemptshould be as short as possible to pre-serve the battery. Do not crank theengine more than 10 seconds on anyone attempt.

6. After starting the engine, movethe starter (choke) knob backhalfway.

ECA00055

cC

For maximum engine life, alwayswarm the engine up before startingoff. Never accelerate hard whenthe engine is cold!

7. When the engine is warm, turnthe starter (choke) off.

NOTE:The engine is warm when it respondsnormally to the throttle with the starter(choke) turned off. To avoid the pos-sibility of excessive exhaust emis-sions, never leave the starter (choke)on longer than necessary. The timenecessary for starter (choke) usedepends upon the ambient tempera-ture. Temperatures above 10 °C (50 °F) require about 7 seconds ofstarter (choke) use and temperaturesbelow 10 °C (50 °F) require about 35seconds with the starter (choke)turned on, then about 2.5 minuteswith the starter (choke) in the halfwayposition.

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EAU01258

Starting a warm engineFollow the same procedure as forstarting a cold engine with the excep-tion that the starter (choke) is notrequired when the engine is warm.

EC000048

cC

8 Even with the transmission inthe neutral position, do notcoast for long periods of timewith the engine off, and do nottow the motorcycle for longdistances. The transmission isproperly lubricated only whenthe engine is running.Inadequate lubrication maydamage the transmission.

8 Always use the clutch whilechanging gears to avoid dam-aging the engine, transmis-sion, and drive train, which arenot designed to withstand theshock of forced shifting.

1

N

5432

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EAU00423

ShiftingShifting gears lets you control theamount of engine power available forstarting off, accelerating, climbinghills, etc.The gear positions are shown in theillustration.

NOTE:To shift the transmission into the neu-tral position, press the shift pedaldown repeatedly until it reaches theend of its travel, and then slightlyraise it.

1. Shift pedalN. Neutral position

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EAU02974

Recommended shift pointsThe recommended shift points duringacceleration and deceleration areshown in the table below.

EAU02988

To start out and accelerate1. Pull the clutch lever to disengage

the clutch.2. Shift the transmission into first

gear. The neutral indicator lightshould go out.

3. Open the throttle gradually, andat the same time, release theclutch lever slowly.

4. At the recommended shift pointsshown in the table on page 5-4,close the throttle, and at thesame time, quickly pull the clutchlever in.

5. Shift the transmission into sec-ond gear. (Make sure not to shiftthe transmission into the neutralposition.)

6. Open the throttle part way andgradually release the clutchlever.

7. Follow the same procedure whenshifting to the next higher gear.

NOTE:Always shift gears at the recommend-ed shift points.

EAU00427

To decelerate1. Apply both the front and the rear

brakes to slow the motorcycle.2. Shift the transmission into first

gear when the motorcycle reach-es 20 km/h (12.5 mi/h). If theengine is about to stall or runsvery roughly, pull the clutch leverin and use the brakes to stop themotorcycle.

3. Shift the transmission into theneutral position when the motor-cycle is almost completelystopped. The neutral indicatorlight should come on.

Acceleration shift point

km/h (mi/h)

Deceleration shift point

km/h (mi/h)

1st → 2nd2nd → 3rd3rd → 4th4th → 5th

15 (9.3)20 (12.5)30 (18.6)40 (24.9)

20 (12.5)20 (12.5)20 (12.5)20 (12.5)

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EAU01128

Engine break-inThere is never a more important peri-od in the life of your engine than theperiod between 0 and 1,600 km(1,000 mi). For this reason, youshould read the following materialcarefully.Since the engine is brand new, donot put an excessive load on it for thefirst 1,600 km (1,000 mi). The variousparts in the engine wear and polishthemselves to the correct operatingclearances. During this period, pro-longed full-throttle operation or anycondition that might result in engineoverheating must be avoided.

EAU01500

0-1,000 km (0-600 mi)Avoid prolonged operation above 1/3throttle.

1,000-1,600 km (600-1,000 mi)Avoid prolonged operation above 1/2throttle.

EC000057

cC

After 1,000 km (600 mi) of opera-tion, the engine oil must bechanged, the oil filter cartridge/ele-ment replaced, and the oil strainercleaned.

1,600 km (1,000 mi) and beyondThe vehicle can now be operatednormally.

EC000049

cC

If any engine trouble should occurduring the engine break-in period,immediately have a Yamaha dealercheck the vehicle.

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EAU00457

ParkingWhen parking, stop the engine,remove the key from the main switch,and then turn the fuel cock lever to“OFF”.

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8 Since the engine and exhaustsystem can become very hot,park in a place where pedestri-ans or children are not likelyto touch them.

8 Do not park on a slope or onsoft ground, otherwise themotorcycle may overturn.

1. Arrow mark positioned over “OFF”

RES

ONFUEL

OFF

1

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EAU00462

PERIODIC MAINTENANCE AND MINOR REPAIR

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EAU01790

Safety is an obligation of the owner.Periodic inspection, adjustment andlubrication will keep your vehicle inthe safest and most efficient condi-tion possible. The most importantpoints of motorcycle inspection,adjustment, and lubrication areexplained on the following pages.Maintenance, replacement, orrepair of the emission controldevices and systems may be per-formed by any repair establish-ment or individual that is certified(if applicable).

EW000060

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If you are not familiar with motor-cycle maintenance work, have aYamaha dealer do it for you.

EAU00467

PERIODIC MAINTENANCEPROPER PERIODIC MAINTE-NANCE OF YOUR MOTORCYCLEIS IMPORTANT IN ORDER TOENJOY LONG, PLEASURABLESERVICE. ESPECIALLY IMPOR-TANT ARE THE MAINTENANCESERVICES RELATED TO EMIS-SIONS CONTROL. THESE CON-TROLS NOT ONLY FUNCTION TOENSURE CLEANER AIR, BUT AREALSO VITAL TO PROPER ENGINEOPERATION AND MAXIMUM PER-FORMANCE. IN THE FOLLOWINGPERIODIC MAINTENANCECHARTS, THE SERVICES RELAT-ED TO EMISSIONS CONTROL AREGROUPED SEPARATELY. THESESERVICES REQUIRE SPECIALIZEDDATA, KNOWLEDGE, AND EQUIP-MENT. YAMAHA DEALERS ARETRAINED AND EQUIPPED TO PER-FORM THESE PARTICULAR SER-VICES.

1

EAU01175

Owner’s tool kitThe owner’s tool kit is located behindpanel B. (See page 6-8 for panelremoval and installation procedures.)The service information included inthis manual and the tools provided inthe owner’s tool kit are intended toassist you in the performance of pre-ventive maintenance and minorrepairs. However, additional toolssuch as a torque wrench may be nec-essary to perform certain mainte-nance work correctly.

1. Owner’s tool kit

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NOTE:If you do not have the tools or experi-ence required for a particular job,have a Yamaha dealer perform it foryou.

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Modifications not approved byYamaha may cause loss of perfor-mance and render the vehicleunsafe for use. Consult a Yamahadealer before attempting anychanges.

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EAU00471

Periodic maintenance chart for the emission control system

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.** California type only.

INITIAL ODOMETER READINGS

NO. ITEM ROUTINE600 mi 4,000 mi 7,000 mi 10,000 mi 13,000 mi

(1,000 km) or (6,000 km) or (11,000 km) or (16,000 km) or (21,000 km) or1 month 6 month 12 month 18 month 24 month

1 * Valve clearance 9Check and adjust valve clearance √ √ √ √ √when engine is cold.9Check condition.9Adjust gap and clean.

2 Spark plug 9Replace at 11,000 km (or 12 months) √ Replace √ Replaceand thereafter every 10,000 km (or 12 months).

3 * Fuel line9Check fuel hose for crack or damage. √ √9Replace if necessary.9Check for leakage.

4 * Exhaust system 9Retighten if necessary. √ √ √ √9Replace gaskets if necessary.

5 Spark arrester 9Clean. √ √ √ √

6 * Idle speed9Check and adjust engine idle speed. √ √ √ √9Adjust cable free play.

Evaporative 9Check control system7 * emission control for damage. √ √

system** 9Replace if necessary.

NOTE:From 16,000 mi (26,000 km) or 30 months, repeat the maintenance intervals starting from 4,000 mi (6,000 km) or 6 months.

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EAU00472

General maintenance and lubrication chartINITIAL ODOMETER READINGS

NO. ITEM ROUTINE TYPE 600 mi 4,000 mi 7,000 mi 10,000 mi 13,000 mi(1,000 km) or (6,000 km) or (11,000 km) or (16,000 km) or (21,000 km) or

1 month 6 month 12 month 18 month 24 month

1 Engine oil 9Warm-up engine See page 8-1. √ √ √ √ √before draining.9Clean filter element

2 * Oil filter/Strainer and oil strainer. — √ √ √9Replace oil filter and

strainer if damaged.9Wet type filter must Yamaha foam air filter

3 * Air filter be washed and oil or othe quality air filter √ √ √ √ √damped with oil. oil9Adjust free play.9Check fluid leakage.

(Front)(see NOTE page 6-6)

4 * Brake system 9Correct if necessary. — √ √ √ √ √9Replace pads if

necessary.(Front)9Replace shoes

if necessary.(Rear)5 * Clutch 9Adjust free play. — √ √ √ √ √

9Check chain condition. Special O-ring chain6 Drive chain 9Adjust and lubricate lubricant Every 300 mi (500 km)chain thoroughly.

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9

INITIAL ODOMETER READINGS

NO. ITEM ROUTINE TYPE 600 mi 4,000 mi 7,000 mi 10,000 mi 13,000 mi(1,000 km) or (6,000 km) or (11,000 km) or (16,000 km) or (21,000 km) or

1 month 6 month 12 month 18 month 24 month

Control and 9Apply chain lube Yamaha chain and 7 meter cable throughly. cable lube or engine √ √ √ √ √

oil.

Rear arm pivot 9Apply until new grease Lithium-soap-based 8 * shaft shows. grease. (all-purpose √ √ √ √

grease)

Brake/Clutch lever 9Apply chain lube Lithium-soap-based9 pivot shaft lightly. grease (all-purpose √ √ √ √

grease)

Brake pedal and 9 Lubricate. Lithium-soap-based10 shift pedal shaft 9Apply chain lube grease (all-purpose √ √ √ √

lightly. grease)9Check operation and Lithium-soap-based

11 * Sidestand pivots lubricate. grease (all-purpose √ √ √ √9Apply chain lube lightly. grease)

12 * Front fork 9Check operation and — √ √ √ √leakage.9Check bearings

13 * Steering bearings assembly for looseness. Medium weight wheel √ √ Repack √9Moderately repack every bearing grease.

10,000 mi (16,000 km)

14 * Wheel bearings 9Check bearings for — √ √ √ √smooth rotation.9Check specific gravity.9Check that the

15 Battery breather pipe is working — √ √ √ √properly.9Correct if necessary.

16 * Sidestand switch 9Check and clean or — √ √ √ √ √replace if necessary.

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

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EAU03906

NOTE:From 16,000 mi (26,000 km) or 30 months, repeat the maintenance intervals starting from 4,000 mi (6,000 km) or 6 months.

EAU03057

NOTE:8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.8 Hydraulic brake system9 When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid

level regularly and fill as required.9 Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.9 Replace the brake hoses every four years or if cracked or damaged.

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EAU03516

Removing and installing thecowling and panelsThe cowling and panels shown aboveneed to be removed to perform someof the maintenance jobs described inthis chapter. Refer to this sectioneach time the cowling or a panelneeds to be removed and installed.

1. Panel B1. Cowling A2. Panel A

1

2 1

1

EAU01145

Cowling ATo remove the cowlingRemove the screw, and then pull thecowling off as shown.

To install the cowlingPlace the cowling in the original posi-tion, and then install the screw.

1. Screw

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EAU01492

Panel ATo remove the panelRemove the screws, and then pullthe panel out at the area shown.

1. Panel A2. Screw (×2)

21

To install the panelPlace the panel in the original posi-tion, and then install the screws.

EAU00494

Panel BTo remove the panelPull the panel off as shown.

1. Panel B

1

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EAU01833

Checking the spark plugThe spark plug is an importantengine component, which is easy tocheck. Since heat and deposits willcause any spark plug to slowly erode,the spark plug should be removedand checked in accordance with theperiodic maintenance and lubricationchart. In addition, the condition of thespark plug can reveal the condition ofthe engine.

1. Spark plug wrench

To remove the spark plug1. Remove the spark plug cap.2. Remove the spark plug as

shown, with the spark plugwrench included in the owner’stool kit.

1

To install the panelPlace the panel in the original posi-tion.

5FY-9-14 (TW200, USA) 5/11/01 8:31 AM Page 48

To check the spark plug1. Check that the porcelain insula-

tor around the center electrodeof the spark plug is a medium-to-light tan (the ideal color when themotorcycle is ridden normally).

NOTE:If the spark plug shows a distinctlydifferent color, the engine could bedefective. Do not attempt to diagnosesuch problems yourself. Instead,have a Yamaha dealer check themotorcycle.

2. Check the spark plug for elec-trode erosion and excessive car-bon or other deposits, andreplace it if necessary.

NOTE:If a torque wrench is not availablewhen installing a spark plug, a goodestimate of the correct torque is1/4–1/2 turn past finger tight.However, the spark plug should betightened to the specified torque assoon as possible.

4. Install the spark plug cap.

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9Specified spark plug:DR8EA (NGK) orX24ESR-U (DENSO)

a

a. Spark plug gap

To install the spark plug1. Measure the spark plug gap with

a wire thickness gauge and, ifnecessary, adjust the gap tospecification.

2. Clean the surface of the sparkplug gasket and its mating sur-face, and then wipe off any grimefrom the spark plug threads.

3. Install the spark plug with thespark plug wrench, and thentighten it to the specified torque.

Spark plug gap:0.6–0.7 mm (0.02–0.03 in)

Tightening torque:Spark plug:

17.5 Nm(1.75 m·kgf, 12.5 ft·lb)

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3. Wait a few minutes until the oilsettles, and then check the oillevel through the check windowlocated at the bottom-right sideof the crankcase.

NOTE:The engine oil should be between theminimum and maximum level marks.

4. If the engine oil is below the min-imum level mark, add sufficientoil of the recommended type toraise it to the correct level.

1. Engine oil level check window2. Maximum level mark3. Minimum level mark

23

1EAU03936

Engine oil and oil filter elementThe engine oil level should bechecked before each ride. In addition,the oil must be changed and the oilfilter element cleaned at the intervalsspecified in the periodic maintenanceand lubrication chart.

To check the engine oil level1. Place the motorcycle on a level

surface and hold it in an uprightposition.

NOTE:Make sure that the motorcycle ispositioned straight up when checkingthe oil level. A slight tilt to the sidecan result in a false reading.

2. Start the engine, warm it up forseveral minutes, and then turn itoff.

1

2 3

4

1. Rollover valve2. Carburetor3. Canister4. Vent hose

EAU01796

Canister (for California only)This model is equipped with a canis-ter to prevent the discharging of fuelvapor into the atmosphere.8 Check each hose connection.8 Check each hose and canister

for cracks or damage. Replace ifdamaged.

8 Make sure the vent hose is notblocked. Clean it if necessary.

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To change the engine oil (with orwithout oil filter element cleaning)

1. Start the engine, warm it up forseveral minutes, and then turn itoff.

2. Place an oil pan under theengine to collect the used oil.

3. Remove the engine oil filler capand drain bolt to drain the oilfrom the crankcase.

1. Engine oil filler cap 1. Engine oil drain bolt

1

1

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When removing the engine oildrain bolt, the O-ring, spring, andoil strainer will fall out. Take carenot to lose these parts.

1. O-ring2. Spring3. Oil strainer

3

2

1

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9. Install the oil filter element coverby installing the bolts and thedrain bolt, then tightening themto the specified torques.

NOTE:Make sure that the O-rings are prop-erly seated.

10. Clean the oil strainer with sol-vent, and then check it for dam-age and replace it if necessary.

11. Install the oil strainer, spring, O-ring and engine oil drain bolt,and then tighten the drain bolt tothe specified torque.

5. Remove the oil filter elementcover by removing the bolts.

6. Remove the oil filter element andO-rings.

7. Check the O-ring for damageand replace it if necessary.

8. Clean the oil filter element withsolvent, and then install it.

NOTE:Check the oil filter element for dam-age and replace it if necessary.

1. Oil filter element2. O-ring (×2)

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2

2

NOTE:Skip steps 4-9 if the oil filter elementis not being cleaned.

4. Remove the oil filter elementdrain bolt to drain the oil from theoil filter element.

1. Oil filter element cover2. Bolt (×2)3. Oil filter element drain bolt

1

23

Tightening torques:Oil filter element cover bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lb)Oil filter element drain bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lb)

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EAU04211

Cleaning the air filter element and check hoseThe air filter element should becleaned at the intervals specified inthe periodic maintenance and lubrica-tion chart. Clean the air filter elementmore frequently if you are riding inunusually wet or dusty areas. In addi-tion, the air filter check hose must befrequently checked and cleaned ifnecessary.

To clean the air filter element1. Remove panel A. (See page 6-8

for panel removal and installationprocedures.)

12. Add the specified amount of therecommended engine oil, andthen install and tighten the oilfiller cap.

Tightening torque:Engine oil drain bolt:

43 Nm (4.3 m·kgf, 31 ft·lb)

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8 In order to prevent clutch slip-page (since the engine oil alsolubricates the clutch), do notmix any chemical additiveswith the oil or use oils of ahigher grade than “CD”. Inaddition, do not use oilslabeled “ENERGY CONSERV-ING II” or higher.

8 Make sure that no foreignmaterial enters the crankcase.

13. Start the engine, and then let itidle for several minutes whilechecking it for oil leakage. If oil isleaking, immediately turn theengine off and check for thecause.

14. Turn the engine off, and thencheck the oil level and correct it ifnecessary.

Recommended engine oil:See page 8-1.

Oil quantity:Without oil filter element removal:

1.0 L (0.9 Imp qt, 1.1 US qt)With oil filter element removal:

1.1 L (1.0 Imp qt, 1.2 US qt)Total amount (dry engine):

1.3 L (1.1 Imp qt, 1.4 US qt)

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5. Apply oil of the recommendedtype to the entire surface of thesponge material, and thensqueeze the excess oil out.

NOTE:The sponge material should be wetbut not dripping.

6. Pull the sponge material over theair filter element frame.

7. Insert the element into the air fil-ter case.

3. Pull the air filter element out.4. Remove the sponge material

from the air filter element frame,clean it with solvent, and thensqueeze the remaining solventout.

1. Sponge material2. Air filter element frame

Recommended oil:Yamaha foam air filter oil orother quality air filter oil

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2 2

1. Air filter case cover2. Screw (×4)

2. Remove the air filter case coverby removing the screws.

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To clean the air filter check hose1. Check the hose at the bottom of

the air filter case for accumulateddirt or water.

2. If dirt or water is visible, removethe hose, clean it, and theninstall it.

1. Air filter check hose

1

EC000082*

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8 Make sure that the air filter ele-ment is properly seated in theair filter case.

8 The engine should never beoperated without the air filterelement installed, otherwisethe piston and/or cylinder maybecome excessively worn.

8. Install the air filter case cover byinstalling the screws.

9. Install the panel.

EAU01549

Cleaning the spark arresterThe spark arrester should be cleanedat the intervals specified in thePeriodic maintenance and lubricationchart.

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8 Always let the exhaust systemcool prior to touching exhaustcomponents.

8 Do not start the engine whencleaning the exhaust system.

NOTE:Make sure to select a well-ventilatedarea free of combustible materials toclean the spark arrester.

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2. Tap the tailpipe lightly, and thenuse a wire brush to remove anycarbon deposits from the sparkarrester portion of the tailpipe.

3. Insert the tailpipe into the muf-fler, and then install and tightenthe screw.

NOTE:Make sure to align the screw holeswhen inserting the tailpipe.

1. Tailpipe2. Spark arrester

1

2

1. Remove the tailpipe by removingthe screw, and then pulling it outof the muffler.

1. Muffler2. Screw

1 2

EAU01752

Adjusting the carburetorThe carburetor is an important part ofthe engine and its emission controlsystem, which requires very sophisti-cated adjustment. Therefore, carbu-retor adjustments should be left toYamaha dealer, who has the neces-sary professional knowledge andexperience.

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EAU00635

Adjusting the throttle cablefree playThe throttle cable free play shouldmeasure 2–5 mm (0.08–0.20 in) atthe throttle grip. Periodically checkthe throttle cable free play and, ifnecessary, have a Yamaha dealeradjust it.

a. Free play

a

EAU00637

Adjusting the valve clearanceThe valve clearance changes withuse, resulting in improper air-fuel mix-ture and/or engine noise. To preventthis from occurring, the valve clear-ance must be adjusted by a Yamahadealer at the intervals specified in theperiodic maintenance and lubricationchart.

EAU03790

TiresTo maximize the performance, dura-bility, and safe operation of yourmotorcycle, note the following pointsregarding the specified tires.

Tire air pressureThe tire air pressure should bechecked and, if necessary, adjustedbefore each ride.

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8 The tire air pressure must bechecked and adjusted on coldtires (i.e., when the tempera-ture of the tires equals theambient temperature).

8 The tire air pressure must beadjusted in accordance withthe riding speed and with thetotal weight of rider, passen-ger, cargo, and accessoriesapproved for this model.

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Proper loading of your motorcycleis important for several character-istics of your motorcycle; such ashandling, braking, performanceand safety. Do not carry looselypacked items that can shift.Securely pack your heaviest itemsclose to the center of the motorcy-cle, and distribute the weight even-ly from side to side. Check thecondition and pressure of yourtires. NEVER OVERLOAD YOURMOTORCYCLE. Make sure the totalweight of the cargo, rider, passen-ger, and accessories (fairing, sad-dlebags, etc. if approved for thismodel) does not exceed the maxi-mum load of the motorcycle.Operation of an overloaded motor-cycle could cause tire damage, anaccident, or even injury.

12

a

1. Side wall2. Wear indicatora. Tread depth

Tire inspectionThe tires must be checked beforeeach ride. If the tire shows crosswiselines (minimum tread depth), if thetire has a nail or glass fragments in it,or if the sidewall is cracked, have aYamaha dealer replace the tire imme-diately.

NOTE:The tire tread depth limits may differfrom country to country. Always com-ply with the local regulations.

Tire air pressure(measured on cold tires)

Load* Front Rear

Up to 90 kg (198 lbs)125 kPa

(1.25 kgf/cm2,18 psi)

125 kPa(1.25 kgf/cm2,

18 psi)

90 kg (198 lbs)–maximum

150 kPa(1.50 kgf/cm2,

22 psi)

175 kPa(1.75 kgf/cm2,

25 psi)

Maximum load*180 kg (397 lb) TW200

179 kg (395 lb) TW200C

* Total weight of rider, passenger, cargo and accessories

Minimum tire tread depth (front and rear)

1.0 mm (0.04 in)

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8 Have a Yamaha dealer replaceexcessively worn tires.Besides being illegal, operat-ing the motorcycle with exces-sively worn tires decreasesriding stability and can lead toloss of control.

8 The replacement of all wheel-and brake-related parts,including the tires, should beleft to a Yamaha dealer, whohas the necessary profession-al knowledge and experience.

Tire informationThis motorcycle is equipped with tubetires.

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8 The front and rear tires shouldbe of the same make anddesign, otherwise the handlingcharacteristics of the motorcy-cle cannot be guaranteed.

8 After extensive tests, only thetires listed below have beenapproved for this model byYamaha Motor Co., Ltd.

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8 It is dangerous to ride with aworn-out tire. When a tiretread begins to show cross-wise lines, have a Yamahadealer replace the tire immedi-ately.

8 The replacement of all wheel-and brake-related parts,including the tires, should beleft to a Yamaha dealer, whohas the necessary profession-al knowledge and experience.

8 It is not recommended topatch a punctured tube. Ifunavoidable, however, patchthe tube very carefully andreplace it as soon as possiblewith a high-quality product.

FRONT

Manufacturer Size Model

BRIDGESTONE130/80-18 66P

TW31130/80-18 M/C 66P

REAR

Manufacturer Size Model

BRIDGESTONE 180/80-14M/C 78P TW34

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EAU00685

Spoke wheelsTo maximize the performance, dura-bility, and safe operation of yourmotorcycle, note the following pointsregarding the specified wheels.8 The wheel rims should be

checked for cracks, bends orwarpage, and the spokes forlooseness or damage beforeeach ride. If any damage isfound, have a Yamaha dealerreplace the wheel. Do notattempt even the smallest repairto the wheel. A deformed orcracked wheel must be replaced.

8 The wheel should be balancedwhenever either the tire or wheelhas been changed or replaced.An unbalanced wheel can resultin poor performance, adversehandling characteristics, and ashortened tire life.

8 Ride at moderate speeds afterchanging a tire since the tire sur-face must first be “broken in” forit to develop its optimal charac-teristics.

EAU00691

Accessories and replace-ment parts

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This motorcycle is not designed topull a trailer or to be attached to asidecar. The accessories orreplacement parts you choose foryour motorcycle should bedesigned specifically for thismodel, and they must be securelymounted to maintain the inherentstability of the original design.Genuine Yamaha Parts andAccessories are designed andtested to be compatible with yourmotorcycle. Please considerGenuine Yamaha Parts andAccessories before making a pur-chase. Use of non-Yamaha-approved accessories or replace-ment parts may cause loss ofhandling stability and riding safe-ty. Since Yamaha cannot controlthe quality of accessories or parts

manufactured by other companies,Yamaha cannot be held liable forany consequences caused by theuse of items which have not beenapproved by Yamaha.

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3. If the specified clutch lever freeplay could be obtained asdescribed above, tighten thelocknut and skip the rest of theprocedure, otherwise proceed asfollows.

4. Fully turn the adjusting bolt at theclutch lever in direction a toloosen the clutch cable.

EAU00694

Adjusting the clutch leverfree playThe clutch lever free play shouldmeasure 10–15 mm (0.40–0.60 in) asshown. Periodically check the clutchlever free play and, if necessary,adjust it as follows.

1. Loosen the locknut at the clutchlever.

2. To increase the clutch lever freeplay, turn the adjusting bolt indirection a. To decrease theclutch lever free play, turn theadjusting bolt in direction b.

1. Locknut (clutch lever)2. Adjusting boltc. Free play

c

1

2

a

b

5. Loosen the locknut at thecrankcase.

6. To increase the clutch lever freeplay, turn the adjusting nut indirection a. To decrease theclutch lever free play, turn theadjusting nut in direction b.

7. Tighten the locknut at the clutchlever and the crankcase.

1. Locknut (crankcase)2. Adjusting nut

2 1

b

a

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EAU00696

Adjusting the brake leverfree playThe brake lever free play shouldmeasure 2–5 mm (0.08–0.20 in) asshown. Periodically check the brakelever free play and, if necessary,adjust it as follows.

1. Loosen the locknut at the brakelever.

2. To increase the brake lever freeplay, turn the adjusting bolt indirection a. To decrease thebrake lever free play, turn theadjusting bolt in direction b.

3. Tighten the locknut.

1. Locknut2. Adjusting boltc. Free play

c1 2

a

b

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8 After adjusting the brake leverfree play, check the free playand make sure that the brakeis working properly.

8 A soft or spongy feeling in thebrake lever can indicate thepresence of air in thehydraulic system. If there is airin the hydraulic system, havea Yamaha dealer bleed thesystem before operating themotorcycle. Air in thehydraulic system will diminishthe braking performance,which may result in loss ofcontrol and an accident.

c

21b

a

EAU00707

Adjusting the brake pedalposition and free play

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It is advisable to have a Yamahadealer make these adjustments.

Brake pedal positionThe top of the brake pedal should bepositioned approximately 15 mm (0.6 in) below the top of the footrest.Periodically check the brake pedalposition and, if necessary, adjust it asfollows.

1. Locknut2. Adjusting boltc. Brake pedal position

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1. Loosen the locknut at the brakepedal.

2. To raise the brake pedal, turn theadjusting bolt in direction a. Tolower the brake pedal, turn theadjusting bolt in direction b.

3. Tighten the locknut.EWA00044

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After adjusting the brake pedalposition, the brake pedal free playmust be adjusted.

a

Brake pedal free playThe brake pedal free play shouldmeasure 20–30 mm (0.8–1.22 in) asshown. Periodically check the brakepedal free play and, if necessary,adjust it as follows.

a. Brake pedal free play

To increase the brake pedal freeplay, turn the adjusting nut at thebrake rod in direction a. Todecrease the brake pedal free play,turn the adjusting nut in direction b.

b

a 1

1. Brake pedal free play adjusting nut

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2a

b

EAU00713

Adjusting the rear brake lightswitchThe rear brake light switch, which isactivated by the brake pedal, is prop-erly adjusted when the brake lightcomes on just before braking takeseffect. If necessary, adjust the brakelight switch as follows.Turn the adjusting nut while holdingthe rear brake light switch in place.To make the brake light come on ear-lier, turn the adjusting nut in directiona. To make the brake light come onlater, turn the adjusting nut in direc-tion b.

1. Brake light switch2. Adjusting nut

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8 After adjusting the drive chainslack or removing andinstalling the rear wheel,always check the brake pedalfree play.

8 If proper adjustment cannot beobtained as described, have aYamaha dealer make thisadjustment.

8 After adjusting the brake pedalfree play, check the operationof the brake light.

EAU00720

Checking the front brakepads and rear brake shoesThe front brake pads and the rearbrake shoes must be checked forwear at the intervals specified in theperiodic maintenance and lubricationchart.

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EAU03938

Front brake padsEach front brake pad is provided withwear indicator grooves, which allowyou to check the brake pad wearwithout having to disassemble thebrake. To check the brake pad wear,check the wear indicator grooves. If abrake pad has worn to the point thatthe wear indicator grooves havealmost disappeared, have a Yamahadealer replace the brake pads as aset.

1. Wear indicator groove (×3)

EAU00727

Rear brake shoesThe rear brake is provided with awear indicator, which allows you tocheck the brake shoe wear withouthaving to disassemble the brake. Tocheck the brake shoe wear, checkthe position of the wear indicatorwhile applying the brake. If a brakeshoe has worn to the point that thewear indicator reaches the wear limitline, have a Yamaha dealer replacethe brake shoes as a set.

1. Wear indicator2. Wear limit line

1

FRONT

21

REAR

EAU03776

Checking the brake fluidlevelInsufficient brake fluid may allow airto enter the brake system, possiblycausing it to become ineffective.Before riding, check that the brakefluid is above the minimum level markand replenish if necessary. A lowbrake fluid level may indicate wornbrake pads and/or brake systemleakage. If the brake level is low, besure to check the brake pads forwear and the brake system for leak-age.

1. Minimum level mark

1

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Observe these precautions:8 When checking the fluid level,

make sure that the top of thebrake fluid reservoir is level.

8 Use only the recommended qual-ity brake fluid, otherwise the rub-ber seals may deteriorate, caus-ing leakage and poor brakingperformance.

8 Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction andlead to poor braking perfor-mance.

8 Be careful that water does notenter the brake fluid reservoirwhen refilling. Water will signifi-cantly lower the boiling point ofthe fluid and may result in vaporlock.

8 Brake fluid may deteriorate paint-ed surfaces or plastic parts.Always clean up spilled fluidimmediately.

8 As the brake pads wear, it is nor-mal for the brake fluid level togradually go down. However, ifthe brake fluid level goes downsuddenly, have a Yamaha dealercheck the cause.

Recommended brake fluid: DOT 4

EAU03985

Changing the brake fluidHave a Yamaha dealer change thebrake fluid at the intervals specified inthe NOTE after the periodic mainte-nance and lubrication chart. In addi-tion, have the oil seals of the brakemaster cylinder and caliper as well asthe brake hose replaced at the inter-vals listed below or whenever theyare damaged or leaking.8 Oil seals: Replace every two

years.8 Brake hose: Replace every four

years.

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EAU00744

Drive chain slackThe drive chain slack should bechecked before each ride and adjust-ed if necessary.

To check the drive chain slack1. Place the motorcycle on a level


NOTE:When checking and adjusting thedrive chain slack, the motorcycleshould be positioned straight up andthere should be no weight on it.

a. Drive chain slack

2. Shift the transmission into theneutral position.

3. Move the rear wheel by pushingthe motorcycle to locate the tight-est portion of the drive chain,and then measure the drivechain slack as shown.

4. If the drive chain slack is incor-rect, adjust it as follows.

a

Drive chain slack:35–60 mm (1.38–2.36 in)

EAU03765

To adjust the drive chain slack1. Loosen the brake pedal free play

adjusting nut.2. Loosen the axle nut.3. To tighten the drive chain, turn

the adjusting plate on each sideof the swingarm in direction a.To loosen the drive chain, turnthe adjusting plate on each sideof the swingarm in direction b,and then push the rear wheel for-ward.

1. Brake pedal free play adjusting nut2. Axle nut3. Adjusting plate

3

2

a

b

1

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NOTE:Make sure that both adjusting platesare in the same position for properwheel alignment.

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Improper drive chain slack willoverload the engine as well asother vital parts of the motorcycleand can lead to chain slippage orbreakage. To prevent this fromoccurring, keep the drive chainslack within the specified limits.

4. Tighten the axle nut to the speci-fied torque.

5. Adjust the brake pedal free play.(See page 6-24 for brake pedalfree play adjustment proce-dures.)

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After adjusting the brake pedalfree play, check the operation ofthe brake light.

Tightening torque:Axle nut:

90 Nm (9.0 m·kgf, 65 ft·lb)

EAU00767

Lubricating the drive chainThe drive chain must be cleaned andlubricated at the intervals specified inthe General maintenance and lubri-cation chart, otherwise it will quicklywear out, especially when riding industy or wet areas. Service the drivechain as follows.

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The drive chain must be lubricatedafter washing the motorcycle orriding in the rain.

1. Remove all dirt and mud fromthe drive chain with a brush orcloth.

NOTE:For a thorough cleaning, have aYamaha dealer remove the drivechain and soak it in solvent.

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2. Spray Yamaha Chain and CableLube or a high-quality spray-typedrive chain lubricant on bothsides and on the middle of thechain, making sure that all sideplates and rollers have been suf-ficiently oiled.

EAU03297*

Checking and lubricating thecablesThe operation of all control cablesand the condition of the cablesshould be checked before each ride,and the cables and cable endsshould be lubricated if necessary. If acable is damaged or does not movesmoothly, have a Yamaha dealercheck or replace it.

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Damage to the outer housing ofcables may result in internal rust-ing and cause interference withcable movement. Replace dam-aged cables as soon as possible toprevent unsafe conditions.

Recommended lubricant:Yamaha Chain and Cable Lubeor engine oil

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EAU03370

Checking and lubricating thebrake and shift pedalsThe operation of the brake and shiftpedals should be checked beforeeach ride, and the pedal pivotsshould be lubricated if necessary.

Recommended lubricant:Lithium-soap-based grease (all-purpose grease)

EAU03164

Checking and lubricating thebrake and clutch leversThe operation of the brake and clutchlevers should be checked beforeeach ride, and the lever pivots shouldbe lubricated if necessary.


EAU04034

Checking and lubricating thethrottle grip and cableThe operation of the throttle gripshould be checked before each ride.In addition, the cable should be lubri-cated or replaced at the intervalsspecified in the periodic maintenancechart.

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EAU03165

Checking and lubricating thesidestandThe operation of the sidestandshould be checked before each ride,and the sidestand pivot and metal-to-metal contact surfaces should belubricated if necessary.

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If the sidestand does not move upand down smoothly, have aYamaha dealer check or repair it.


EAU03166

Lubricating the rear suspensionThe pivoting points of the rear sus-pension must be lubricated at theintervals specified in the periodicmaintenance and lubrication chart.

1. Grease nipple (×2)

1


EAU02939

Checking the front forkThe condition and operation of thefront fork must be checked as followsat the intervals specified in the peri-odic maintenance and lubricationchart.

To check the conditionEW000115

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Securely support the motorcycleso that there is no danger of itfalling over.

Check the inner tubes for scratches,damage and excessive oil leakage.

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EAU00794

Checking the steeringWorn or loose steering bearings maycause danger. Therefore, the opera-tion of the steering must be checkedas follows at the intervals specified inthe periodic maintenance and lubrica-tion chart.

1. Place a stand under the engineto raise the front wheel off theground.

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Securely support the motorcycleso that there is no danger of itfalling over.

2. Hold the lower ends of the frontfork legs and try to move themforward and backward. If anyfree play can be felt, have aYamaha dealer check or repairthe steering.

To check the operation1. Place the motorcycle on a level


2. While applying the front brake,push down hard on the handle-bars several times to check if thefront fork compresses andrebounds smoothly.

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If any damage is found or the frontfork does not operate smoothly,have a Yamaha dealer check orrepair it.

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EAU01144

Checking the wheel bearingsThe front and rear wheel bearingsmust be checked at the intervalsspecified in the periodic maintenanceand lubrication chart. If there is playin the wheel hub or if the wheel doesnot turn smoothly, have a Yamahadealer check the wheel bearings.

EAU03806

BatteryA poorly maintained battery will cor-rode and discharge quickly. The elec-trolyte level, battery lead connectionsand breather hose routing should bechecked before each ride and at theintervals specified in the periodicmaintenance and lubrication chart.

4

1 2

35

1. Battery2. Negative lead (black)3. Positive lead (red)4. Battery breather hose5. Band

To check the electrolyte level1. Remove the seat. (See page 3-8

for seat removal and installationprocedures.)

2. Disconnect the negative batterylead from the battery.

3. Disconnect the positive batterylead and the battery breatherhose from the battery.

4. Unhook the battery band, andthen pull the battery out of thebattery compartment.

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EW000116

w8 Electrolyte is poisonous and

dangerous since it containssulfuric acid, which causessevere burns. Avoid any con-tact with skin, eyes or clothingand always shield your eyeswhen working near batteries.In case of contact, administerthe following FIRST AID.9 EXTERNAL: Flush with plen-

ty of water.9 INTERNAL: Drink large quan-

tities of water or milk andimmediately call a physician.

9 EYES: Flush with water for15 minutes and seek promptmedical attention.

8 Batteries produce explosivehydrogen gas. Therefore, keepsparks, flames, cigarettes,etc., away from the battery andprovide sufficient ventilationwhen charging it in anenclosed space.

8 KEEP THIS AND ALL BATTER-IES OUT OF THE REACH OFCHILDREN.

1. Battery breather hose

1

EC000100

cC

Use only distilled water, as tapwater contains minerals that areharmful to the battery.

7. Place the battery in the batterycompartment, and then hook thebattery band onto the holder.

8. Connect the breather hose to thebattery and make sure that it isproperly routed.

1

2

5. Place the battery on a level sur-face, and then check the elec-trolyte level in the battery.

NOTE:The electrolyte should be betweenthe minimum and maximum levelmarks.

6. If the electrolyte is at or belowthe minimum level mark, add dis-tilled water to raise the elec-trolyte to the maximum levelmark.

1. Maximum level mark2. Minimum level mark

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1. Battery2. Battery breather hose

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9. Connect and tighten the positivebattery lead to the battery’s posi-tive (+) terminal.

10. Connect and tighten the negativebattery lead to the battery’s neg-ative (–) terminal.

11. Install the seat.

To store the battery1. If the motorcycle will not be used

for more than one month,remove the battery, fully chargeit, and then place it in a cool, dryplace.

2. If the battery will be stored formore than two months, check thespecific gravity of the electrolyteat least once a month and fullycharge the battery whenevernecessary.

3. Fully charge the battery beforeinstallation.

4. After installation, make sure thatthe battery leads are properlyconnected to the battery termi-nals and that the breather hoseis properly routed, in good condi-tion, and not obstructed.

EC000099

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If the breather hose is positionedin such a way that the frame isexposed to electrolyte or gasexpelled from the battery, theframe could suffer structural andexternal damages.

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EC000103

cC

Do not use a fuse of a higheramperage rating than recommend-ed to avoid causing extensivedamage to the electrical systemand possibly a fire.

3. Turn the key to “ON” and turn onthe electrical circuits to check ifthe devices operate.

4. If the fuse immediately blowsagain, have a Yamaha dealercheck the electrical system.

EAU01528

Replacing the headlight bulbThis motorcycle is equipped with aquartz bulb headlight. If the headlightbulb burns out, replace it as follows.

1. Remove cowling A. (See page 6-7 for cowling removal andinstallation procedures.)

2. Remove the headlight unit byremoving the bolts.

1. Bolt (×2)

1

Specified fuse: 20A

EAU01307

Replacing the fuseThe fuse holder is located behindpanel B. (See page 6-8 for panelremoval and installation procedures.)If the fuse is blown, replace it as fol-lows.

1. Turn the key to “OFF” and turnoff all electrical circuits.

2. Remove the blown fuse, andthen install a new fuse of thespecified amperage.

1. Fuse2. Spare fuse

1

2

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3. Disconnect the headlight cou-pler, and then remove the head-light bulb cover.

1. Headlight coupler2. Headlight bulb cover

1

2

4. Remove the headlight bulb hold-er by turning it counterclockwise,and then remove the defectivebulb.

EW000119

w

Headlight bulbs get very hot.Therefore, keep flammable prod-ucts away from a lit headlight bulb,and do not touch the bulb until ithas cooled down.

5. Place a new bulb into position,and then secure it with the bulbholder.

1. Headlight bulb holder

1

EC000105

cC

Do not touch the glass part of theheadlight bulb to keep it free fromoil, otherwise the transparency ofthe glass, the luminosity of thebulb, and the bulb life will beadversely affected. Thoroughlyclean off any dirt and fingerprintson the headlight bulb using a clothmoistened with alcohol or thinner.

a. Do not touch this area.

a

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EAU01623

Replacing the tail/brake lightbulb

1. Remove the tail/brake light lensby removing the screws.

1. Screw (×2)

1

6. Install the bulb cover, and thenconnect the coupler.

7. Install the headlight unit byinstalling the bolts.

8. Install the cowling.9. Have a Yamaha dealer adjust

the headlight beam if necessary.

EAU03497

Replacing a turn signal lightbulb

1. Remove the turn signal light lensby removing the screw.

2. Remove the defective bulb bypushing it in and turning it coun-terclockwise.

3. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.

4. Install the lens by installing thescrew.

ECA00065

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Do not overtighten the screw, oth-erwise the lens may break.

1. Screw2. Bulb3. Lens

3

1

2

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2. Remove the defective bulb bypushing it in and turning it coun-terclockwise.

3. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.

4. Install the lens by installing thescrews.

EC000108

cC

Do not overtighten the screws,otherwise the lens may break.

1. Bulb

1

EAU01579

Supporting the motorcycleSince this model is not equipped witha centerstand, follow these precau-tions when removing the front andrear wheel or performing other main-tenance requiring the motorcycle tostand upright. Check that the motor-cycle is in a stable and level positionbefore starting any maintenance. Astrong wooden box can be placedunder the engine for added stability.

To service the front wheel1. Stabilize the rear of the motorcy-

cle by using a motorcycle standor, if an additional motorcyclestand is not available, by placinga jack under the frame in front ofthe rear wheel.

2. Raise the front wheel off theground by using a motorcyclestand.

To service the rear wheelRaise the rear wheel off the groundby using a motorcycle stand or, if amotorcycle stand is not available, byplacing a jack either under each sideof the frame in front of the rear wheelor under each side of the swingarm.

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3. Lift the front wheel off the groundaccording to the procedure onpage 6-40.

4. Remove the axle nut, pull thewheel axle out, and then removethe wheel.

ECA00048

cC

Do not apply the brake after thewheel has been removed togetherwith the brake disc, otherwise thebrake pads will be forced shut.

EAU03518

To install the front wheel1. Install the speedometer gear unit

into the wheel hub so that theprojections mesh with the slots.

2. Lift the wheel up between thefork legs.

NOTE:Make sure that there is enoughspace between the brake padsbefore inserting the brake disc andthat the slot in the speedometer gearunit fits over the retainer on the forkleg.

1. Retainer2. Speedometer cable

211

2

EAU03517

Front wheel

To remove the front wheelEW000122

w

8 It is advisable to have aYamaha dealer service thewheel.

8 Securely support the motorcy-cle so that there is no dangerof it falling over.

1. Disconnect the speedometercable from the front wheel.

2. Loosen the axle nut.

1. Speedometer cable2. Axle nut

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3. Insert the wheel axle, and theninstall the axle nut.

4. Lower the front wheel so that it ison the ground.


6. Connect the speedometer cable.


90 Nm (9.0 m·kgf, 65 ft·lb)

EAU03519

Rear wheel

To remove the rear wheelEW000122

w

8 It is advisable to have aYamaha dealer service thewheel.

8 Securely support the motorcy-cle so that there is no dangerof it falling over.

1. Loosen the axle nut.

1. Axle nut2. Brake pedal free play adjusting nut3. Brake rod4. Brake camshaft lever5. Drive chain adjusting plate

5a

2

1

3 42. Remove the brake pedal free

play adjusting nut, and then dis-connect the brake rod from thebrake camshaft lever.

3. Turn the drive chain adjustingplate on each side of theswingarm fully in direction a.

4. Lift the rear wheel off the groundaccording to the procedure onpage 6-40.

5. Remove the axle nut, and thenpull the wheel axle out.

6. Push the wheel forward, andthen remove the drive chain fromthe rear sprocket.

NOTE:The drive chain does not need to bedisassembled in order to remove andinstall the wheel.

7. Remove the wheel.

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3. Install the axle nut, and thenlower the rear wheel so that it ison the ground.


5. Install the brake rod onto thebrake camshaft lever, and theninstall the brake pedal free playadjusting nut onto the brake rod.

6. Adjust the brake pedal free play.(See page 6-23 for brake pedalfree play adjustment proce-dures.)

EW000103

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After adjusting the brake pedalfree play, check the operation ofthe brake light.


90 Nm (9.0 m·kgf, 65 ft·lb)

EAU01008

TroubleshootingAlthough Yamaha motorcyclesreceive a thorough inspection beforeshipment from the factory, troublemay occur during operation. Anyproblem in the fuel, compression, orignition systems, for example, cancause poor starting and loss ofpower.The following troubleshooting chartrepresents a quick and easy proce-dure for checking these vital systemsyourself. However, should yourmotorcycle require any repair, take itto a Yamaha dealer, whose skilledtechnicians have the necessary tools,experience, and know-how to servicethe motorcycle properly.Use only genuine Yamaha replace-ment parts. Imitation parts may looklike Yamaha parts, but they are ofteninferior, have a shorter service lifeand can lead to expensive repairbills.

1

EAU03520

To install the rear wheel1. Insert the wheel axle from the

left-hand side.

NOTE:Make sure that the drive chain adjust-ing plates are installed with thepunched sides facing to the outsideand that the slot in the brake shoeplate fits over the retainer on theswingarm.

2. Install the drive chain onto therear sprocket, and then adjustthe drive chain slack. (See page6-28 for drive chain slack adjust-ment procedures.)

1. Retainer

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EAU03473

Troubleshooting chartEW000125

w

Keep away open flames and do not smoke while checking or working on the fuel system.

Check the fuel level in the fuel tank.

1. FuelThere isenough fuel.

There isno fuel.

Check the compression.

Supply fuel. The engine does not start.Check the compression.

Operate theelectric starter.

2. CompressionThere is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealer check the vehicle.

Remove the spark plug and check electrodes.

3. IgnitionWet

Dry

Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug.

Have a Yamaha dealer check the vehicle.

The engine does not start. Have a Yamaha dealer check the vehicle.

The engine does not start.Check the battery.

Open the throttle halfway and operate the electric starter.

Operate theelectric starter.

4. BatteryThe engine turns overquickly.

The engine turns overslowly.

The battery is good.

Check fluid, recharge, check connections.

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EAU03521

MOTORCYCLE CARE AND STORAGE

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CareWhile the open design of a motorcy-cle reveals the attractiveness of thetechnology, it also makes it more vul-nerable. Rust and corrosion candevelop even if high-quality compo-nents are used. A rusty exhaust pipemay go unnoticed on a car, however,it detracts from the overall appear-ance of a motorcycle. Frequent andproper care does not only complywith the terms of the warranty, but itwill also keep your motorcycle lookinggood, extend its life and optimize itsperformance.

Before cleaning1. Cover the muffler outlet with a

plastic bag after the engine hascooled down.

2. Make sure that all caps and cov-ers as well as all electrical cou-plers and connectors, includingthe spark plug cap, are tightlyinstalled.

3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply suchproducts onto seals, gaskets,sprockets, the drive chain andwheel axles. Always rinse the dirtand degreaser off with water.

CleaningECA00010

cC

8 Avoid using strong acidicwheel cleaners, especially onspoked wheels. If such prod-ucts are used on hard-to-remove dirt, do not leave thecleaner on the affected areaany longer than instructed.Also, thoroughly rinse the areaoff with water, immediately dryit, and then apply a corrosionprotection spray.

8 Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Useonly a soft, clean cloth orsponge with mild detergentand water to clean plastic.

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8 Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abra-sive cleaning products, sol-vent or thinner, fuel (gasoline),rust removers or inhibitors,brake fluid, antifreeze or elec-trolyte.

8 Do not use high-pressurewashers or steam-jet cleanerssince they cause water seep-age and deterioration in thefollowing areas: seals (ofwheel and swingarm bearings,fork and brakes), electric com-ponents (couplers, connec-tors, instruments, switchesand lights), breather hosesand vents.

8 For motorcycles equippedwith a windshield: Do not usestrong cleaners or hardsponges as they will causedulling or scratching. Somecleaning compounds for plas-tic may leave scratches on thewindshield. Test the producton a small hidden part of thewindshield to make sure that itdoes not leave any marks. Ifthe windshield is scratched,use a quality plastic polishingcompound after washing.

After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge,and then rinse thoroughly with cleanwater. Use a toothbrush or bottle-brush for hard-to-reach areas.Stubborn dirt and insects will comeoff more easily if the area is coveredwith a wet cloth for a few minutesbefore cleaning.

After riding in the rain, near the seaor on salt-sprayed roadsSince sea salt or salt sprayed onroads during winter are extremelycorrosive in combination with water,carry out the following steps aftereach ride in the rain, near the sea oron salt-sprayed roads.

NOTE:Salt sprayed on roads in the wintermay remain well into spring.

1. Clean the motorcycle with coldwater and a mild detergent, afterthe engine has cooled down.

ECA00012

cC

Do not use warm water since itincreases the corrosive action ofthe salt.

2. Apply a corrosion protectionspray on all metal, includingchrome- and nickel-plated, sur-faces to prevent corrosion.

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After cleaning1. Dry the motorcycle with a

chamois or an absorbing cloth.2. Immediately dry the drive chain

and lubricate it to prevent it fromrusting.

3. Use a chrome polish to shinechrome, aluminum and stainless-steel parts, including the exhaustsystem. (Even the thermallyinduced discoloring of stainless-steel exhaust systems can beremoved through polishing.)

4. To prevent corrosion, it is recom-mended to apply a corrosion pro-tection spray on all metal, includ-ing chrome- and nickel-plated,surfaces.

5. Use spray oil as a universalcleaner to remove any remainingdirt.

6. Touch up minor paint damagecaused by stones, etc.

7. Wax all painted surfaces.

8. Let the motorcycle dry complete-ly before storing or covering it.

EWA00001

w

8 Make sure that there is no oilor wax on the brakes or tires.If necessary, clean the brakediscs and brake linings with aregular brake disc cleaner oracetone, and wash the tireswith warm water and a milddetergent.

8 Before operating the motorcy-cle test its braking perfor-mance and cornering behav-ior.

ECA00013

cC

8 Apply spray oil and wax spar-ingly and make sure to wipeoff any excess.

8 Never apply oil or wax to anyrubber and plastic parts, buttreat them with a suitable careproduct.

8 Avoid using abrasive polish-ing compounds as they willwear away the paint.

NOTE:Consult a Yamaha dealer for adviceon what products to use.

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7-4

StorageShort-termAlways store your motorcycle in acool, dry place and, if necessary, pro-tect it against dust with a porouscover.

ECA00014

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8 Storing the motorcycle in apoorly ventilated room or cov-ering it with a tarp, while it isstill wet, will allow water andhumidity to seep in and causerust.

8 To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)and areas where strong chemi-cals are stored.

Long-termBefore storing your motorcycle forseveral months:

1. Follow all the instructions in the“Care” section of this chapter.

2. For motorcycles equipped with afuel cock that has an “OFF” posi-tion: Turn the fuel cock lever to“OFF”.

3. Drain the carburetor float cham-ber by loosening the drain bolt;this will prevent fuel depositsfrom building up. Pour thedrained fuel into the fuel tank.

4. Fill up the fuel tank and add fuelstabilizer (if available) to preventthe fuel tank from rusting and thefuel from deteriorating.

5. Perform the following steps toprotect the cylinder, piston rings,etc. from corrosion.a. Remove the spark plug cap

and spark plug.b. Pour a teaspoonful of engine

oil into the spark plug bore.

c. Install the spark plug cap ontothe spark plug, and then placethe spark plug on the cylinderhead so that the electrodesare grounded. (This will limitsparking during the next step.)

d. Turn the engine over severaltimes with the starter. (Thiswill coat the cylinder wall withoil.)

e. Remove the spark plug capfrom the spark plug, and theninstall the spark plug and thespark plug cap.

EWA00003

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To prevent damage or injury fromsparking, make sure to ground thespark plug electrodes while turn-ing the engine over.

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6. Lubricate all control cables andthe pivoting points of all leversand pedals as well as of thesidestand/centerstand.

7. Check and, if necessary, correctthe tire air pressure, and then liftthe motorcycle so that both of itswheels are off the ground.Alternatively, turn the wheels alittle every month in order to pre-vent the tires from becomingdegraded in one spot.

8. Cover the muffler outlet with aplastic bag to prevent moisturefrom entering it.

9. Remove the battery and fullycharge it. Store it in a cool, dryplace and charge it once amonth. Do not store the batteryin an excessively cold or warmplace (less than 0 °C [30 °F]) ormore than 30 °C [90 °F]). Formore information on storing thebattery, see page 6-36.

NOTE:Make any necessary repairs beforestoring the motorcycle.

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EAU01038

SPECIFICATIONS

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Specifications

Model TW200(C)

Dimensions

Overall length 2,090 mm (82.3 in)

Overall width 820 mm (32.3 in)

Overall height 1,120 mm (44.1 in)

Seat height 790 mm (31.1 in)

Wheelbase 1,325 mm (52.2 in)

Ground clearance 265 mm (10.4 in)

Minimum turning radius 1,900 mm (74.8 in)

Basic weight (with oil and fullfuel tank) 126 kg (278 lb) (TW200)

127 kg (280 lb) (TW200C)

Engine

Engine type Air-cooled 4-stroke, SOHC

Cylinder arrangement Forward inclined single cylinder

Displacement 196 cm3

Bore × Stroke 67.0 × 55.7 mm

Compression ratio 9.5:1

Starting system Electric starter

Lubrication system Wet sump

Engine oil

Type

Recommended engine oilclassification API Service SE, SF, SG type

or higher

cCBe sure to use motor oils that do not contain anti-frictionmodifiers. Passenger car motor oils (often labeled “ENERGYCONSERVING”) contain anti-friction additives which willcause clutch and/or starter clutch slippage, resulting inreduced component life and poor engine performance.

Capacity

Without oil filter element removal 1.0 L (0.9 Imp qt, 1.1 US qt)

With oil filter element removal 1.1 L (1.0 Imp qt, 1.2 US qt)

Total amount (dry engine) 1.3 L (1.1 Imp qt, 1.4 US qt)

Air filter Wet type element

10° 30° 50° 70° 90° 110°0° 130°F

YAMALUBE 4 (10W30)or SAE 10W30

YAMALUBE 4 (20W40)or SAE 20W40

–10° 0° 10° 20° 30° 40°–20° 50°C

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8-2

SPECIFICATIONS

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Fuel

Type UNLEADED GASOLINE ONLY

Fuel tank capacity 7.0 L (1.5 Imp gal, 1.8 US gal)

Reserve amount 1.0 L (0.2 Imp gal, 0.3 US gal)

Carburetor

Manufacturer TEIKEI

Model × quantity MV28 × 1 (TW200)MV28 1B × 1 (TW200C)

Spark plug

Manufacturer/Type NGK/DR8EADENSO/X24ESR-U

Gap 0.6–0.7 mm (0.02–0.03 in)

Clutch type Wet, multiple-disc

Transmission

Primary reduction system Spur gear

Primary reduction ratio 73/22 (3.318)

Secondary reduction system Chain drive

Secondary reduction ratio 3.571

Number of drive chainsprocket teeth (rear/front) 50/14

Transmission type Constant mesh 5-speed

Operation Left foot

Gear ratio 1st 2.833

2nd 1.789

3rd 1.318

4th 1.040

5th 0.821

Chassis

Frame type Diamond

Caster angle 25.8°

Trail 95 mm (3.74 in)

Tires

Front

Type With tube

Size 130/80-18 66P or130/80-18 M/C 66P

Manufacturer/ BRIDGESTONE / TW31model

Rear

Type With tube

Size 180/80-14M/C 78P

Manufacturer/ BRIDGESTONE / TW34model

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8-3

SPECIFICATIONS

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Maximum load* 180 kg (397 lb) (TW200)179 kg (395 lb) (TW200C)

Air pressure (cold tire)up to 90 kg load*

Front 125 kPa (1.25 kgf/cm2, 18 psi)

Rear 125 kPa (1.25 kgf/cm2, 18 psi)

90 kg load–Maximumload*

Front 150 kPa (1.50 kgf/cm2, 22 psi)

Rear 175 kPa (1.75 kgf/cm2, 25 psi)

*Total weight of rider, passenger, cargo and accessories

Wheels

Front

Type Spoke wheel

Size 2.50 × 18

Rear

Type Spoke wheel

Size 14M/C × MT4.50Brakes

Front

Type Single disc brake

Operation Right hand

Fluid DOT 4

Rear

Type Drum brake

Operation Right foot

Suspension

Front

Type Telescopic fork

Rear

Type Swingarm (Monocross suspension)

Spring/shock absorber

Front Coil spring / oil damper

Rear Coil spring / gas-oil damper

Wheel travel

Front 160 mm (6.3 in)

Rear 150 mm (5.9 in)

Electrical

Ignition system C.D.I.

Charging system

Type A.C. magneto

Standard output 14 V, 170 W @ 5,000 r/min

Battery

Type GM7CZ-3D

Voltage, capacity 12 V, 7 AH

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8-4

SPECIFICATIONS

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Headlight bulb type Halogen bulb

Bulb voltage, wattage × quantity

Headlight 12 V, 60/55 W × 1

Tail/brake light 12 V, 8/27 W × 1

Front turn signal light 12 V, 27/8 W × 2

Rear turn signal light 12 V, 27 W × 2

Meter lighting 12 V, 3.4 W × 1

Neutral indicator light 12 V, 3.4 W × 1

High beam indicator light 12 V, 3.4 W × 1

Turn signal indicator light 12 V, 3.4 W × 1

Fuse 20 A

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EAU01039

CONSUMER INFORMATION

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EAU02944

Identification numbersRecord the key identification number,vehicle identification number andmodel label information in the spacesprovided below for assistance whenordering spare parts from a Yamahadealer or for reference in case thevehicle is stolen.

1. KEY IDENTIFICATION NUMBER:

2. VEHICLE IDENTIFICATIONNUMBER:

3. MODEL LABEL INFORMATION:

EAU01042

Key identification numberThe key identification number isstamped into the key.Record this number in the space pro-vided and use it for reference whenordering a new key.

1. Key identification number

EAU01043

Vehicle identification numberThe vehicle identification number isstamped into the steering head pipe.Record this number in the space pro-vided.

NOTE:The vehicle identification number isused to identify your motorcycle andmay be used to register your motor-cycle with the licensing authority inyour area.

1. Vehicle identification number

11

16

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EAU01039


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EAU03757

Model labelThe model label is affixed to the loca-tion shown. Record the informationon this label in the space provided.This information will be needed whenordering spare parts from a Yamahadealer.

1. Model label

1

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EAU01051

Reporting safety defectsIf you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should imme-diately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha MotorCorporation, U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defectexists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved inindividual problems between you, your dealer, or Yamaha Motor Corporation, U.S.A.To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington,D.C. area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain otherinformation about motor vehicle safety from the Hotline.

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EAU01053

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

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”.

These acts include tampering with the following systems; i.e., modification, removal, etc.

Exhaust systemMufflerExhaust pipeSilencer

Intake systemAir cleaner caseAir cleaner elementIntake duct

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EAU03052

Maintenance recordCopies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to documentthat maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as areminder that maintenance work is required. It is not acceptable proof of maintenance work.

Maintenanceinterval

Date of service

MileageServicing dealer

name and addressRemarks

600 mi(1,000 km) or

1 month

4,000 mi(6,000 km) or

6 months

7,000 mi(11,000 km) or

12 months

10,000 mi(16,000 km) or

18 months

13,000 mi(21,000 km) or

24 months

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16,000 mi(26,000 km) or

30 months

19,000 mi(31,000 km) or

36 months

22,000 mi(36,000 km) or

42 months

25,000 mi(41,000 km) or

48 months

28,000 mi(46,000 km) or

54 months

31,000 mi(51,000 km) or

60 months

Maintenanceinterval

Date of service

MileageServicing dealer

name and addressRemarks

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EAU02918

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EAU01063

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5FY-9-14 (TW200, USA) 5/11/01 8:32 AM Page 103

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

PRINTED IN JAPAN

2001·5–0.7×1(E) !

OWNER’S MANUAL

5FY-28199-14LIT-11626-15-17PRINTED ON RECYCLED PAPER

See your Authorized YAMAHA Dealer for a Genuine YAMAHAService Manual.

PROTECT YOUR INVESTMENT

Use Genuine YAMAHA Parts And Accessories.

YAMAHA MOTOR CO., LTD.TW200P(C)

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