Yamaha TW200 User manual

qRead this manual carefully before operating this vehicle.
OWNER’S MANUAL
B75-28199-15LIT-11626-33-20
TW200L1
TW200L1C
B75-9-15_Hyoshi.indd 1 2019/06/05 9:22:07

EAU10045
Operating, servicing and
maintaining a passenger vehicle or off-road vehicle can
expose you to chemicals including engine exhaust,
carbon monoxide, phthalates, and lead, which are
known to the State of California to cause cancer and
birth defects or other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not idle the
engine except as necessary, service your vehicle in a
well-ventilated area and wear gloves or wash your
hands frequently when servicing your vehicle. For more
information go to
www.P65Warnings.ca.gov/passenger-vehicle
Read this manual carefully before operating the vehicle. This manual should stay with the vehicle if it is sold.
B75-9-15_Hyoshi.indd 2 2019/06/05 9:22:09

Introduction
EAU10084
Congratulations on your purchase of the Yamaha TW200L1/TW200L1C. This model is the result of Yamaha’s vast experi-
ence in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsman-
ship and reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you
have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable
at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of
the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the
recommended maintenance schedules and operating instructions contained within this manual.
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most cur-
rent product information available at the time of printing, there may be minor discrepancies between your motorcycle and this
manual. If there is any question concerning this manual, please consult a Yamaha dealer.
WARNING
EWA10012
Please read this manual and the “YOU AND YOUR MOTORCYCLE: RIDING TIPS” booklet carefully before operating
this motorcycle. Do not attempt to operate this motorcycle until you have attained adequate knowledge of its con-
trols and operating features. Regular inspections and careful maintenance, along with good operating techniques,
will help ensure that you safely enjoy the capabilities and reliability of this motorcycle.
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Important manual information
EAU10134
Particularly important information is distinguished in this manual by the following notations:
*Product and specifications are subject to change without notice.
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury
or death.
A WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the
vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP
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Important manual information
EAU10194
TW200L1/TW200L1C
OWNER’S MANUAL
©2020 by Yamaha Motor Corporation, U.S.A.
1st edition, May 2019
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan.
P/N LIT-11626-33-20
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Table of contents
Location of important labels........... 1-1
Safety information ........................... 2-1
Description ....................................... 3-1
Left view ......................................... 3-1
Right view ....................................... 3-2
Controls and instruments................ 3-3
Instrument and control functions... 4-1
Main switch/steering lock................ 4-1
Indicator lights ................................ 4-2
Speedometer unit ........................... 4-2
Handlebar switches ........................ 4-3
Clutch lever..................................... 4-4
Shift pedal....................................... 4-4
Brake lever ..................................... 4-4
Brake pedal .................................... 4-5
Fuel tank cap .................................. 4-5
Fuel................................................. 4-6
Fuel cock ........................................ 4-7
Starter (choke) knob ....................... 4-8
Seat ................................................ 4-8
Helmet holder ................................. 4-9
Adjusting the shock absorber
assembly ..................................... 4-9
Carrier........................................... 4-10
Luggage strap holders.................. 4-10
Sidestand...................................... 4-11
Ignition circuit cut-off system ........ 4-11
For your safety – pre-operation
checks .............................................. 5-1
Operation and important riding
points................................................ 6-1
Starting and warming up a cold
engine ......................................... 6-1
Starting a warm engine .................. 6-2
Shifting ........................................... 6-2
Engine break-in .............................. 6-4
Parking ........................................... 6-4
Periodic maintenance and
adjustment ....................................... 7-1
Owner’s tool kit............................... 7-2
Periodic maintenance chart for
the emission control system ....... 7-3
General maintenance and
lubrication chart .......................... 7-5
Removing and installing the
cowling and panels ..................... 7-9
Checking the spark plug............... 7-10
Canister (for California) ................ 7-12
Engine oil and oil filter element .... 7-12
Cleaning the air filter element
and check hose......................... 7-15
Cleaning the spark arrester.......... 7-16
Carburetor .................................... 7-17
Checking the engine idling
speed ........................................ 7-17
Checking the throttle grip free
play........................................... 7-18
Valve clearance ........................... 7-18
Tires............................................. 7-18
Spoke wheels .............................. 7-20
Adjusting the clutch lever free
play........................................... 7-21
Adjusting the brake lever free
play........................................... 7-22
Adjusting the brake pedal height
and free play............................. 7-22
Checking the shift pedal .............. 7-24
Brake light switches ..................... 7-24
Checking the front brake pads
and rear brake shoes .............. 7-25
Checking the brake fluid level...... 7-25
Changing the brake fluid ............. 7-26
Drive chain slack.......................... 7-27
Cleaning and lubricating the
drive chain ................................ 7-28
Checking and lubricating the
cables ....................................... 7-28
Checking and lubricating the
throttle grip and cable............... 7-29
Checking and lubricating the
brake and clutch levers ............ 7-29
Checking and lubricating the
brake pedal............................... 7-30
Checking and lubricating the
sidestand .................................. 7-30
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Table of contents
Lubricating the swingarm
pivots......................................... 7-30
Checking the front fork ................. 7-31
Checking the steering................... 7-31
Checking the wheel bearings ....... 7-32
Battery .......................................... 7-32
Replacing the fuse........................ 7-34
Replacing the headlight bulb ........ 7-35
Replacing the brake/tail light
bulb ........................................... 7-36
Replacing a turn signal light
bulb ........................................... 7-37
Supporting the motorcycle............ 7-38
Front wheel................................... 7-38
Rear wheel ................................... 7-40
Troubleshooting............................ 7-41
Troubleshooting chart................... 7-42
Motorcycle care and storage .......... 8-1
Matte color caution ......................... 8-1
Care................................................ 8-1
Storage........................................... 8-3
Specifications .................................. 9-1
Consumer information .................. 10-1
Identification numbers .................. 10-1
Reporting safety defects............... 10-3
Motorcycle noise regulation.......... 10-4
Maintenance record...................... 10-5
YAMAHA MOTOR
CORPORATION, U.S.A.
2020 AND LATER MODEL
STREET & DUAL-PURPOSE
MOTORCYCLE LIMITED
WARRANTY ............................. 10-7
YAMAHA EXTENDED SERVICE
(Y.E.S.) ..................................... 10-9
Index ............................................... 11-1
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Location of important labels
EAU10385
Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of
your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label
is available from your Yamaha dealer.
123, 4, 5
6
7
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WARNING
NEVER sit here.
3MX-24875-A0
3TB-24877-A0
LOAD LIMIT
3kg {7 lbs}
1
4
5
7
WARNING
Improper loading can cause loss of control.
Read owner’s manual for proper loading.
3JJ
—
28446
—
A1
2 California only
3
WARNING
Thisunit containshigh pressure nitrogen gas.
Mishandling can cause explosion.
Read owner'smanual for instructions.
Do not incinerate, puncture or open.
4AA-22259-80
6
10D-21668-00
Cold tire normal pressure should be set
as follows.
Up to 90 kg (198Ibs) load
FRONT : 125 kPa, ( 1.25 kgf / cm2), 18psi
REAR :125 kPa, ( 1.25 kgf / cm2), 18psi
90 kg (198Ibs)
~ m aximum load
FRONT :150 kPa, ( 1.50 kgf / cm2), 22 psi
REAR : 175 kPa, ( 1.75 kgf / cm2), 25 psi
CARB.
FROM
FUEL TANK
CANISTER
TO ATMOSPHERE
4YN-21686-00
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1
Read owner’s manual before servicing battery.
Electrolyte will damage metal parts or paint.
If electrolyte spills, wash area with fresh
water immediately.
Be sure to connect breather hose after
installing battery.
10D-2815N-00
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Safety information
EAU1031C
Be a Responsible Owner
As the vehicle’s owner, you are respon-
sible for the safe and proper operation
of your motorcycle.
Motorcycles are single-track vehicles.
Their safe use and operation are de-
pendent upon the use of proper riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements before
riding this motorcycle.
He or she should:
Obtain thorough instructions from
a competent source on all aspects
of motorcycle operation.
Observe the warnings and mainte-
nance requirements in this Own-
er’s Manual.
Obtain qualified training in safe
and proper riding techniques.
Obtain professional technical ser-
vice as indicated in this Owner’s
Manual and/or when made neces-
sary by mechanical conditions.
Never operate a motorcycle with-
out proper training or instruction.
Take a training course. Beginners
should receive training from a cer-
tified instructor. Contact an autho-
rized motorcycle dealer to find out
about the training courses nearest
you.
Safe Riding
Perform the pre-operation checks each
time you use the vehicle to make sure it
is in safe operating condition. Failure to
inspect or maintain the vehicle properly
increases the possibility of an accident
or equipment damage. See page 5-1
for a list of pre-operation checks.
This motorcycle is designed to car-
ry the operator and a passenger.
The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.
Therefore:
• Wear a brightly colored jacket.
• Use extra caution when you are
approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.
• Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
• Never maintain a motorcycle
without proper knowledge. Con-
tact an authorized motorcycle
dealer to inform you on basic
motorcycle maintenance. Cer-
tain maintenance can only be
carried out by certified staff.
Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent motorcycle license.
• Make sure that you are qualified
and that you only lend your mo-
torcycle to other qualified opera-
tors.
• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
• We recommend that you prac-
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tice riding your motorcycle
where there is no traffic until you
have become thoroughly famil-
iar with the motorcycle and all of
its controls.
Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
erator is veering wide on a turn
due to excessive speed or under-
cornering (insufficient lean angle
for the speed).
• Always obey the speed limit and
never travel faster than warrant-
ed by road and traffic conditions.
• Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
The posture of the operator and
passenger is important for proper
control.
• The operator should keep both
hands on the handlebar and
both feet on the operator foot-
rests during operation to main-
tain control of the motorcycle.
• 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.
Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.
Never ride under the influence of
alcohol or other drugs.
Protective Apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the preven-
tion or reduction of head injuries.
Always wear an approved helmet.
Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or af-
ter operation and can cause burns.
A passenger should also observe
the above precautions.
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing car-
bon monoxide can cause headaches,
dizziness, drowsiness, nausea, confu-
sion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be pres-
ent even if you do not see or smell any
engine exhaust. Deadly levels of car-
bon monoxide can collect rapidly and
you can quickly be overcome and un-
able to save yourself. Also, deadly lev-
els of carbon monoxide can linger for
hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poison-
ing, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
Do not run engine indoors. Even if
you try to ventilate engine exhaust
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with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loading
Adding accessories or cargo to your
motorcycle can adversely affect stabili-
ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex-
treme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here, along with the information about
accessories below, are some general
guidelines to follow if loading cargo to
your motorcycle:
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
Operation of an overloaded vehicle
could cause an accident.
When loading within this weight limit,
keep the following in mind:
Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Se-
curely pack your heaviest items as
close to the center of the vehicle as
possible and make sure to distrib-
ute the weight as evenly as possi-
ble on both sides of the motorcycle
to minimize imbalance or instabili-
ty.
Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.
• Properly adjust the suspension
for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
• 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 han-
dling or a slow steering re-
sponse.
This vehicle is not designed to
pull a trailer or to be attached to
a sidecar.
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail-
able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection to
Yamaha manufacture parts and acces-
sories or offer other modifications for
Yamaha vehicles. Yamaha is not in a
position to test the products that these
aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
Maximum load:
179 kg (395 lb) (TW200L1C)
180 kg (397 lb) (TW200L1)
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mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories,
and Modifications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accessories
or modifications are not suitable be-
cause of potential safety hazards to you
or others. Installing aftermarket prod-
ucts or having other modifications per-
formed to your vehicle that change any
of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or death.
You are responsible for injuries related
to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.
• Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
• Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds. These ac-
cessories may also cause
instability when passing or being
passed by large vehicles.
• Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.
Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match the
performance capabilities and to provide
the best combination of handling, brak-
ing, and comfort. Other tires, rims, siz-
es, and combinations may not be
appropriate. Refer to page 7-18 for tire
specifications and more information on
replacing your tires.
Transporting the Motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.
Remove all loose items from the
motorcycle.
Check that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.
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Safety information
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Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.
Shift the transmission in gear (for
models with a manual transmis-
sion).
Secure the motorcycle with
tie-downs or suitable straps that
are attached to solid parts of the
motorcycle, such as the frame or
upper front fork triple clamp (and
not, for example, to rubber-mount-
ed handlebars or turn signals, or
parts that could break). Choose
the location for the straps carefully
so the straps will not rub against
painted surfaces during transport.
The suspension should be com-
pressed somewhat by the
tie-downs, if possible, so that the
motorcycle will not bounce exces-
sively during transport.
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Description
EAU10411
Left view
1234
568 7
1. Fuel tank cap (page 4-5)
2. Fuel cock (page 4-7)
3. Helmet holder (page 4-9)
4. Luggage strap holder (page 4-10)
5. Drive chain slack adjusting plate (page 7-27)
6. Air filter element (page 7-15)
7. Starter (choke) knob (page 4-8)
8. Shift pedal (page 4-4)
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Description
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EAU10421
Right view
12
6543
7
8
1. Carrier (page 4-10)
2. Battery (page 7-32)
3. Engine oil level check window (page 7-12)
4. Brake pedal (page 4-5)
5. Fuse (page 7-34)
6. Owner’s tool kit (page 7-2)
7. Luggage strap holder (page 4-10)
8. Spark arrester (page 7-16)
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Description
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EAU10431
Controls and instruments
12 3 4
567
8
1. Clutch lever (page 4-4)
2. Left handlebar switches (page 4-3)
3. Speedometer unit (page 4-2)
4. Main switch/steering lock (page 4-1)
5. Indicator lights (page 4-2)
6. Right handlebar switches (page 4-3)
7. Brake lever (page 4-4)
8. Throttle grip (page 7-18)
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Instrument and control functions
EAU10462
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
EAU10511
ON
All electrical systems are supplied with
power, and the headlight, meter light-
ing, taillight and position lights come
on, and the engine can be started. The
key cannot be removed.
EAU10662
OFF
All electrical systems are off. The key
can be removed.
WARNING
EWA10062
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving.
Otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident.
EAU10714
LOCK
The steering is locked, and all electrical
systems are off. The key can be re-
moved.
To lock the steering
1. Turn the handlebars all the way to
the left or right.
2. Push the key in from the “OFF” po-
sition, release it, and then turn it to
“LOCK”.
3. Remove the key.
TIP
If the steering will not lock, try turning
the handlebars back to the right or left
slightly.
To unlock the steering
Insert the key and turn it to “OFF”.
LOCK
OFF ON
1. Push.
2. Release.
3. Turn.
123
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