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
~
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-----~
ENG ~
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CARB
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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
?
•
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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

STARTER DRIVE 4-35
BALANCER DRIVE
GEAR AND BALANCER GEAR 4-36
BEARING AND OIL SEAL 4-37
CRANKCASE 4-37
.-
2
GEN
INFO
INSP
ADJ
SPEC
ENGINE ASSEMBLY AND ADJUSTMENT 4-38
VALVE,
ROCKER ARM AND CAMSHAFT 4-38
BALANCER
AND CRANKSHAFT 4-44
TRANSMISSION
AND SHIFTER 4-44
CRANKCASE (LEFT) 4-45
CAM CHAIN AND CAM CHAIN GUIDE 4-48
COl MAGNETO 4-48
SHIFT SHAFT 4-49
KICK AXLE 4-52
PRIMARY DRIVE
GEAR AND BALANCER GEAR 4-53
OIL PUMP 4-54
STARTER MOTOR 4-54
CLUTCH 4-56
PISTON 4-60
CYLINDER HEAD 4-62
REMOUNTING ENGINE 4-66
CARB
•
CHAPTER 5
CARBURETION
CARBURETOR 5-1
REMOVAL 5-2
DISASSEMBLY 5-2
INSPECTION 5-5
ASSEMBLy 5-6
INSTALLATION 5-8
FUEL LEVEL ADJUSTMENT 5-9
ENG
o4
ELEC
CHAPTER 6
CHASSIS
FRONT WHEEL 6-1
REMOVAL 6-2
INSPECTION 6-2
INSTALLATION 6-5
REAR WHEEL 6-7
REMOVAL 6-8
INSPECTION 6-8
INSTALLATION 6-9
~
.....---
CHAS
~
7
?
•
TRBL
SHTG

FRONT FORK 6-11
REMOVAL 6-12
DiSASSEMBLy 6-13
INSPECTION 6-14
ASSEMBLy 6-15
INSTALLATION 6-18
STEERING AND HANDLEBAR 6-19
REMOVAL 6-20
INSPECTION 6-21
INSTALLATION 6-22
REAR SHOCK ABSORBER AND SWINGARM 6-25
HANDLING NOTES 6-26
NOTES
ON DISPOSAL ~ 6-26
REMOVAL '
6-27
DiSASSEMBLy 6-29
INSPECTION 6-29
ASSEMBLy 6-31
INSTALLATION 6-31
DRIVE CHAIN AND SPROCKETS 6-33
REMOVAL 6-33
INSPECTION 6-33
INSTALLATION
6-34
CHAPTER 7
ELECTRICAL
TW200T/TC CIRCUIT DIAGRAM 7-1
ELECTRICAL COMPONENTS ~ 7-3
IGNITION SYSTEM 7-5
CIRCUIT DIAGRAM 7-5
TROUBLESHOOTING 7-7
ELECTRICAL STARTING SYSTEME 7-15
CIRCUIT DIAGRAM 7-15
TROUBLESHOOTING 7-17
STARTING CIRCUIT OPERATION 7-20
STARTER MOTOR 7-21
CHARGING SYSTEM 7-27
CIRCUIT DIAGRAM 7-27
TROUBLESHOOTING 7-29
LIGHTING SYSTEM 7-31
CIRCUIT DIAGRAM 7-31
TROUBLESHOOTING 7-33

SIGNAL SYSTEME 7-35
CIRCUIT DIAGRAM 7-35
TROUBLESHOOTING 7-37
SWITCHES TEST 7-43
.-
CHAPTER 8
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING 8-1
FUEL SYSTEM 8-1
ELECTRICAL SYSTEM 8-2
COMPRESSION SYSTEM
8-3
POOR IDLE SPEED PERFORMANCE '.' 8-3
POOR IDLE SPEED PERFORMANCE 8-3
GEN
INFO
SPEC 2
CARB
INSP
ADJ
o4
•
ENG
CLUTCH SLIPPING/DRAGGING 8-6
CLUTCH SLIPPING 8-6
CLUTCH DRAGGING 8-6
IMPROPER KICKING
8-7
SLIPPING 8-7
HARD KICKING 8-7
KICK CRANK NOT RETURNING 8-7
FAULTY GEAR SHIFTING 8-5
HARD SHIFTING 8-5
CtiANGE PEDAL DOES NOT MOVE 8-5
JUMP-OUT GEAR 8-5
POOR MEDIUM AND HIGH SPEED PERFORMANCE 8-4
POOR MEDIUM AND HIGH SPEED PERFORMANCE 8-4
ELEC
FAULTY BRAKE 8-8
POOR BRAKING EFFECT 8-8
FRONT FORK OIL LEAKAGE
AND FRONT FORK
MALFUNCTION 8-8
OIL LEAKAGE 8-8
MALFUNCTION 8-8
INSTABLE HANDLING 8-9
INSTABLE HANDLING 8-9
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.......---
CHAS
~
7
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•
TRBL
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FAULTY SIGNAL AND LIGHTING SySTEM 8-10
HEADLIGHT DARK 8-10
BULB BURNT OUT 8-10
FLASHER DOES NOT LIGHT 8-10
FLASHER KEEPS ON 8-10
FLASHER WINKS SLOWER 8-11
FLASHER WINKS QUiCKER 8-11
HORN IS INOPERATiVE 8-11

MOTORCYCLE IDENTIFICATION I ~~~ I ~I
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number CD is on the
right side
of the steering head pipe.
Starting Serial Number:
TW200T JYA 2JYOO*HCOOO101
TW200TC
JYA 2JXOO*HCOOO101
NOTE: _
The vehicle identification number
is used to iden-
tify your motorcycle and may be used to register
your motorcycle
with the licensing authority in
your state.
D
ENGINE SERIAL NUMBER
The engine serial number (2) is stamped into the
elevated part
of the right rear section of the
engine.
Starting Serial Number:
TW200T 2JY-000101
TW200TC 2JX-000101
NOTE: ---..-----
-The first three digits of these numbers are for
model identifications; the remaining digits are
the
unit production number.
-Designs and specifications
are subject to change
without notice.
1-1

u
IMPORTANT INFORMATION II~~~ I~I
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBL Y
1. Remove all dirt, mud, dust, and foreign
material before
remo~ing and disassembling.
2. Use proper tools and cleaning equipment.
Refer
to IISPECIAL TOOL".
3. When disassembling the motorcycle, keep
mated parts together. This includes gears,
cylinders, pistons, and other mated parts
that
have been Ilmated" through normal wear.
Mated parts
must be reused as an assembly
or replaced.
4. During the motorcycle disassembly, clean all
parts and place them in trays in the order
of
disassembly. This will speed up assembly time
and help assure that
all parts are correctly rein-
stalled.
5. Keep away from fire.
1-2

IMPORTANT INFORMATION I ~~~ I ~I
ALL REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all replace-
ments. Use oil
and/ or grease recommended
by Yamaha for assembly and adjustment.
Other brands may
be similar in function and
appearance,
but inferior in quality. D
GASKETS, OIL SEALS, AND O-RINGS
1. All gaskets, seals, and a-rings should be
replaced when an engine is overhauled. All
gasket surfaces, oil
seal lips and a-rings must
be cleaned.
2. Properly oil
all mating parts and bearings dur-
ing reassembly.
Apply grease to the oil seal
lips.
300-000
300-003
300-002
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/Plates CD and cotter pins
must be replaced when they are removed.
Lock tab(s) should
be bent along the bolt or
nut flat(s) after the bolt or nut has been
properly tightened.
BEARINGS AND OIL SEALS
1. Install the bearing(s) and oil seal(s) with their
manufacturer's marks or numbers facing out-
ward. (In other words, the stamped letters
must be on the side exposed to view.)
When installing oil seal(s), apply alight coat-
ing
of light-weight lithium base grease to the
seal lip(s). Oil the bearings liberally when in-
stalling.
CD Oil seal
111'1·~811 _
Do not use compressed air to spin the bear-
ings dry. This causes damage to the bearing
surfaces.
CD Bearing
1-3

Il
300-001
1-4
SPECIAL TOOLS II~~~ I ~I
CIRCLIPS
1. All circlips should be inspected carefully be-
fore reassembly. Always replace piston pin
clips after one use. Replace distorted circlips.
When installing acirclip
CD, make sure that
the sharp edged corner @ is positioned op-
posite
to the thrust @ it receives. See the
sectional view.
@Shaft
SPECIAL TOOLS
The proper special tools are necessary for com-
plete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
caused bythe use
of impropertools or improvised
techniques.
FOR TUNE-UP
1. Inductive Timing Light
PIN. YU-33277
This tool is necessary
for adjusting the ignition
timing.
2. Fuel Level Gauge
PIN. YM-01312
This gauge is used
to measure the fuel level in
the float chamber.
3. Inductive Tachometer
PIN. YU-08036
This tool
is needed for detecting engine r.p.m.

SPECIAL TOOLS I ~~~ I ~I
4. Compression Gauge
PIN. YU-33223
This gauge is used to measure the engine com- U
pression.
1-5
FOR ENGINE SERVICE
1. Universal Clutch Holder
PIN. YM-91042
This tool is used to hold the clutch when loosen-
ing
or tightening the clutch boss locknut.
2. Valve Guide Remover (6.0 mm)
PIN. YM-04064-A
This too,l is used to remove the valve guide.
3. Valve Guide Installer (6.0 mm)
PIN. YM-04065-A
This tool is needed to install the valve guide
properly together
with the valve guide remover.
4. Valve Guide Reamer (6.0 mm)
PIN. YM-04066
This tool is used to rebore the new valve guide.

u
,....,
SPECIAL TOOLS II~~~ I ~I
5. Valve Seat Cutter
PIN. YM-91043
This tool is needed to reface the valve seat.
6. Valve Spring Compressor
PIN. YM-04019
This tool is needed to' remove and install the valve
assemblies.
7. Valve Adjusting Tool
PIN. YM-08035
This tool is used for adjusting the valve clearance.
8. Slide Hammer Set
PIN. YU-01083
These tools are used for removing the rocker arm
shaft.
1-6
9. Rotor Puller
PIN. YM-01080
This tool is used for removing the C.D.1. magneto.