Yamaha TW200 User manual

274 Pgs +2 flo
THIS MANUAL
WAS PRINTED IN
1987!!! THINGS
HAVE
CHANGED!!!
REFER TO
SUPPLEMENT
BEFORE DOING
ANY WORK!!!!

TW200/200E (T-A) 87-90
SERVICE MANUAL
©1987 by Yamaha Motor Corporation, U.S.A.
1st Edition, January 1987
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
PIN: LIT-11616-06-26

NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It
is not possible to put an entire mechanic's education into one· manual,
so
it is assumed that persons using this book to perform maintenance and repairs on Yamaha motor-
cycles have abasic understanding
of the mechanical concepts and procedures inherent in motorcycle
repair technology.
Without such knowledge, attempted repairs or service to this model may render
it unfit to use and/ or unsafe.
Yamaha
Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha.
Modifications and significant changes in specifications or procedures will be forwarded
to all Authorized
Yamaha dealers and will, where applicable, appear in future editions
of this manual.
TECHNICAL PUBLICATIONS
SERVICE DIVISION
MOTORCYCLE OPERATIONS
YAMAHA MOTO.R CO., LTD.
HOW TO USE THIS MANUAL
PARTICULARLY IMPORTANT INFORMATION
This material is distinguished by the following notation.
NOTE: A
NOTE provides key information to make procedures easier or clearer.
:~i~i~j~I •• ilili:·:':: ACAUTION indicates special procedures that must be followed to avoid damage
::::::::;:::::::::;:;:::::::::::::::::::::::::::::;:;:::::::::;:::::::::;:::::;:;:;: ::::::::~::'
to the motorcycle.
WARNING:
AWARNING indicates special procedures that must be followed to avoid injury to
amotorcycle operator or person inspecting or repairing the motorcycle.
MANUAL FORMAT
All of the procedures in this manual are organized in asequential, step-by-step format. The informa-
tion has been compiled
to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations
of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition
of afaulty component will precede an arrow symbol and the course
of action required will follow the symbol, e.g.,
•Bearings
Pitting/Damage
-+ Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams b,efore each disassembly section for ease in identifying cor-
rect disassembly and assembly procedures.

eD ®
I,~~~ I ~llsPEcl fJ fI
@@
I ~g~ I fi I ....-E_N_G ~_'_.--'
@@
I COOLI ~ II-CA-RB"---I '-1
(j) @
ICHASI~ II ELECI 53 I
i~:t'~1 ?I® I·{l> I
ILLUSTRATED SYMBOLS
(Refer to the illustration)
IlIus~rated symbols CD to ® are designed as
thumb tabs to indicate the chapter's numberand
content.
eD General information
®Specifications
@Periodic inspection and adjustment
@Engine
@Cooling system
@Carburetion
(j) Chassis
@Electrical
®Troubleshooting
Illustrated symbols @ to ®are used to identify
the specifications appearing in the text.
®Filling fluid
@Lubricant
@Special tool
@Tightening
@Wear limit, clearance
®Engine speed
@O,V,A
@@@
111
mme
@@@
~E-
~L=Sn
~E.....-
@,
a
Illustrated symbols @ to @in the exploded dia-
gram indicate grade of lubricant and location of
lubrication point.
@ Apply engine oil
@ Apply gear oil
@) Apply molybdenum disulfide oil
@> Apply wheel bearing grease
@ Apply lightweight lithium-soap base grease
@ Apply molybdenum disulfide grease
@ Apply locking agent (LOCTITE®)

INDEX
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION
AND ADJUSTMENT
ENGINE OVERHAUL
CARBURETION
CHASSIS
ELECTRICAL
TROUBLESHOOTING
~
GEN
INFO
SPEC
P.I
INSP
ADJ
~
@W
-----~
ENG ~
•
CARB
c!cr"G
------ ~
CHAS J.:
eE5l
ELEC
?
•
""'-TR-B-L ~
SHTG ~e~

CONTENTS
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION 1-1
VEHICLE IDENTIFICATION NUMBER 1-1
ENGINE SERIAL NUMBER 1-1
IMPO'RTANT INFORMATION 1-2
PREPARATION FOR REMOVAL AND DiSASSEMBLy 1-2
ALL REPLACEMENT PARTS 1-3
GASKETS, OIL SEALS, AND O-RINGS 1-3
LOCK
WASHERS/PLATES AND COTTER PINS 1-3
BEARINGS
AND OIL SEALS 1-3
CIRCLIPS 1-4
SPECIAL TOOLS 1-4
FOR TUNE-UP 1-4
FOR ENGINE SERVICE '1-5
FOR CHASSIS SERVICE 1-7
FOR ELECTRICAL COMPONENTS 1-8
CHAPTER 2
SPECIFICATIONS
GENERAL SPECiFiCATIONS 2-1
MAINTENANCE SPECIFICATIONS 2-4
ENGINE 2-4
CHASSiS 2-11
ELECTRICAL 2-14
GENERAL TORQUE SPECIFICATIONS 2-16
DEFINITION OF UNITS
2-16
LUBRICATION POINTS AND TYPE OF LUBRICANTS 2-17
ENGINE 2-17
CHASSIS 2-18
LUBRICATION DIAGRAMS 2-19
CABLE ROUTING 2-21

CHAPTER 3
PERIODIC INSPECTION
AND ADJUSTMENT
INTRODUCTION 3-1
o4
~
7
•
ENG
GEN
INFO
INSP
ADJ
SPEC
ELEC
CARB
ELECTRICAL 3-29
BATTERY INSPECTION 3-29
FUSE INSPECTION
3-31
HEADLIGHT BEAM ADJUSTMENT 3-32
HEADLIGHT BULB REPLACEMENT 3-32
CHASSiS 3-19
FRONT BRAKE ADJUSTMENT 3-19
REAR BRAKE ADJUSTMENT '3-20
BRAKE SHOE INSPECTION
3-21
BRAKE LIGHT SWITCH ADJUSTMENT 3-21
DRIVE CHAIN SLACK ADJUSTMENT 3-21
DRIVE CHAIN LUBRiCATION 3-22
STEERING HEAD ADJUSTMENT 3-23
FRONT FORK OIL REPLACEMENT 3-24
TIRE INSPECTION 3-26
WHEEL INSPECTION 3-27
SPOKE INSPECTION AND TIGHTENING 3-27
CABLE INSPECTION AND LUBRiCATION 3-28
ENGINE 3-3
VALVE CLEARANCE
ADJUSTMENT 3-3
CAM CHAIN ADJUSTMENT 3-5
IDLE
SPEED ADJUSTMENT 3-6
THROTTLE CABLE
FREE PLAY ADJUSTMENT 3-7
SPARK PLUG INSPECTION '3-8
IGNITION TIMING CHECK 3-9
COMPRESSION PRESSURE MEASUREMENT 3-10
ENGINE OIL LEVEL INSPECTION
3-11
ENGINE OIL REPLACEMENT "3-12
CLUTCH
ADJUSTMENT 3-15
AIR FILTER CLEANING 3-17
CARBURETOR JOINT INSPECTION
~ 3-18
FUEL LINE INSPECTION 3-19
CRANKCASE VENTILATION HOSE INSPECTION 3-19
EXHAUST SYSTEM INSPECTION 3-19
PERIODIC MAINTENANCE/LUBRICATION INTERVALS 3-1
?
•
TRBL ~.l
SHTG ~e~

CHAPTER 4
ENGINE
OVERHAUL
ENGINE REMOVAL 4-1
FUEL TANK 4-1
EXHAUST PIPE AND ENGINE GUARD 4-1
CRANKCASE COVER (LEFT) 4-2
DRIVE SPROCKET 4-2
CARBURETOR 4-3
WIRING AND CABLES 4-3
ENGINE REMOVAL 4-4
DISASSEMBLY 4-5
.CYLINDER HEAD 4-5
CYLINDER 4-6
PiSTON 4-7
CLUTCH 4-8
STARTER MOTOR 4-9
OIL PUMP 4-10
PRIMARY DRIVE GEAR
AND BALANCER GE,A,R 4-10
KICK AXLE
4-11
SHIFT SHAFT 4-12
CDI MAGNETO 4-13
CAM CHAIN
AND CAM CHAIN GUIDE (INTAKE) 4-14
CRANKCASE (LEFT) 4-14
SHIFTER
AND TRANSMiSSiON :4-15
BALANCER
AND CRANKSHAFT 4-16
VALVE,
ROCKER ARM AND CAMSHAFT 4-16
INSPECTION AND REPAIR 4-19
CYLINDER HEAD 4-19
VALVE
AND VALVE GUIDE 4-20.
VALVE SEAT 4-22
VALVE SPRING 4-25
CAMSHAFT '4-26
ROCKER ARM
AND ROCKER ARM SHAFT 4-26
CAM CHAIN AND CAM SPROCKET 4-27
CAM CHAIN GUIDE 4-28
CYLINDER
AND PISTON 0 ••••••••••••••••••••••••••••••••• 4-28
PISTON
RING 0 ••••• 4-30
PISTON
PIN 4-31
CLUTCH 4-31
OIL PUMP 4-32
PRIMARY DRIVE 4-33
TRANSMISSION
AND SHIFTER 4-33
KICK STARTER 4-34
CRANKSHAFT 4-35