Yamaha TW200ET User manual
INTRODUCTION
EAU10100
Welcome to the Yamaha world of motorcycling!
As the owner of the TW200E, you are benefiting from Yamaha’s vast experience and newest technology regarding the de-
sign and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TW200E. The owner’s manual
does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and
others from trouble and injury.
In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any
further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
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IMPORTANT MANUAL INFORMATION
EAU10150
Particularly important information is distinguished in this manual by the following notations:
NOTE:
●
This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle
is subsequently sold.
●
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
current product information available at the time of printing, there may be minor discrepancies between your motorcycle
and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
WARNING
EWA10030
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander, or a person inspecting or repairing the motorcy-
cle.
A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:
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TABLE OF CONTENTS
SAFETY INFORMATION
...................1-1
Location of important labels .............1-5
DESCRIPTION
...................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS
........................................3-1
Main switch/steering lock .................3-1
Indicator lights .................................3-2
Speedometer unit ............................3-2
Handlebar switches .........................3-3
Clutch lever ......................................3-4
Shift pedal ........................................3-4
Brake lever ......................................3-4
Brake pedal .....................................3-5
Fuel tank cap ...................................3-5
Fuel ..................................................3-6
Fuel cock .........................................3-6
Starter (choke) knob “
1
” .................3-7
Kickstarter ........................................3-8
Seat .................................................3-8
Helmet holder ..................................3-9
Shock absorber ...............................3-9
Carrier ..............................................3-9
Luggage strap holders ...................3-10
Sidestand .......................................3-10
Ignition circuit cut-off system .........3-11
PRE-OPERATION CHECKS
.............. 4-1
Pre-operation check list ................... 4-2
OPERATION AND IMPORTANT
RIDING POINTS
.................................. 5-1
Starting a cold engine ..................... 5-1
Starting a warm engine ................... 5-2
Shifting ............................................ 5-2
Tips for reducing fuel
consumption ................................ 5-3
Engine break-in ............................... 5-3
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR
.................................. 6-1
Owner’s tool kit ................................ 6-1
Periodic maintenance and
lubrication chart ........................... 6-2
Removing and installing the cowling
and panels ................................... 6-5
Checking the spark plug .................. 6-6
Engine oil and oil filter element ....... 6-8
Cleaning the air filter element and
check hose ................................. 6-10
Adjusting the carburetor ................ 6-12
Adjusting the engine idling
speed ......................................... 6-12
Adjusting the throttle cable free
play ............................................ 6-13
Adjusting the valve clearance ....... 6-13
Tires .............................................. 6-13
Spoke wheels ............................... 6-15
Adjusting the clutch lever free
play ............................................ 6-16
Adjusting the brake lever free
play ............................................ 6-17
Adjusting the brake pedal position
and free play .............................. 6-17
Adjusting the rear brake light
switch ......................................... 6-19
Checking the front brake pads and
rear brake shoes ........................ 6-19
Checking the front brake fluid
level ........................................... 6-20
Changing the brake fluid ............... 6-21
Drive chain slack ........................... 6-21
Lubricating the drive chain ............ 6-23
Checking and lubricating the
cables ........................................ 6-23
Checking and lubricating the
throttle grip and cable ................ 6-24
Checking and lubricating the
brake and shift pedals ............... 6-24
Checking and lubricating the
brake and clutch levers .............. 6-24
Checking and lubricating the
sidestand ................................... 6-25
Lubricating the rear suspension .... 6-25
Checking the front fork .................. 6-25
Checking the steering ................... 6-26
Checking the wheel bearings ........ 6-27
Battery ........................................... 6-27
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TABLE OF CONTENTS
Replacing the fuse .........................6-29
Replacing the headlight bulb .........6-30
Replacing the tail/brake light
bulb ............................................6-32
Replacing a turn signal light
bulb ............................................6-32
Supporting the motorcycle .............6-33
Front wheel ....................................6-34
Rear wheel ....................................6-35
Troubleshooting .............................6-36
Troubleshooting chart ....................6-37
MOTORCYCLE CARE AND
STORAGE
...........................................7-1
Care .................................................7-1
Storage ............................................7-3
SPECIFICATIONS ..............................8-1
CONSUMER INFORMATION
..............9-1
Identification numbers .....................9-1
Motorcycle noise regulation
(for Australia) ................................9-2
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1-1
1
SAFETY INFORMATION
EAU10310
MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE
USE AND OPERATION ARE DEPEN-
DENT UPON THE USE OF PROPER
RIDING TECHNIQUES AS WELL AS
THE EXPERTISE OF THE OPERA-
TOR. EVERY OPERATOR SHOULD
KNOW THE FOLLOWING REQUIRE-
MENTS BEFORE RIDING THIS MO-
TORCYCLE.
HE OR SHE SHOULD:
●
OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
●
OBSERVE THE WARNINGS
AND MAINTENANCE REQUIRE-
MENTS IN THE OWNER’S MAN-
UAL.
●
OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
●
OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECES-
SARY BY MECHANICAL CONDI-
TIONS.
Safe riding
●
Always make pre-operation
checks. Careful checks may help
prevent an accident.
●
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 ap-
proaching and passing through
intersections, since intersec-
tions are the most likely places
for motorcycle accidents to oc-
cur.
●
Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
●
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-
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 un-
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SAFETY INFORMATION
1-2
1
dercornering (insufficient lean an-
gle 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.
●
Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protec-
tive clothing that covers your legs,
ankles, and feet.
●
Passengers should also observe
the precautions mentioned above.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the re-
moval of original equipment, may ren-
der the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your mo-
torcycle illegal to use.
Loading and accessories
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 are some general guidelines to
follow if loading cargo or adding acces-
sories to your motorcycle:
Loading
The total weight of the operator, pas-
senger, accessories and cargo must
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SAFETY INFORMATION
1-3
1
not exceed the maximum load limit of
180 kg (397 lb). 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. Make
sure to distribute the weight as
evenly as possible on both sides of
the motorcycle to minimize imbal-
ance or instability.
●
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.
●
Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a slow
steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any ac-
cessories.
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
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SAFETY INFORMATION
1-4
1
motorcycle’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas
●
GASOLINE IS HIGHLY FLAMMA-
BLE:
●
Always turn the engine off when
refueling.
●
Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.
●
Never refuel while smoking or in
the vicinity of an open flame.
●
Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has ad-
equate ventilation.
●
Always turn the engine off before
leaving the motorcycle unattended
and remove the key from the main
switch. When parking the motorcy-
cle, note the following:
●
The engine and exhaust system
may be hot, therefore, park the
motorcycle in a place where pe-
destrians or children are not like-
ly to touch these hot areas.
●
Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.
●
Do not park the motorcycle near
a flammable source (e.g., a ker-
osene heater, or near an open
flame), otherwise it could catch
fire.
●
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 motorcycle
should lean over, gasoline may
leak out of the carburetor or fuel
tank.
●
If you should swallow any gaso-
line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediate-
ly. If any gasoline spills on your
skin or clothing, immediately wash
the affected area with soap and
water and change your clothes.
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SAFETY INFORMATION
1-6
1
1
2
4AA-22259-40
Before you operate this vehicle, read the owner’s manual.
5PA-21568-00
Prima di usare il veicolo, leggete il manuale di istruzioni.
Lire le manuel du propri
étaire avant d
’utiliser ce v
éhicule.
Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.
Antes de conducir este vehículo, lea el Manual del Propietario.
3
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DESCRIPTION
2-2
2
3
4
5
6
7
8
9
EAU10420
Right view
12
65
43
789
1. Carrier (page 3-9)
2. Battery (page 6-27)
3. Kickstarter (page 3-8)
4. Engine oil filter element (page 6-8)
5. Engine oil level check window (page 6-8)
6. Brake pedal (page 3-5)
7. Owner’s tool kit (page 6-1)
8. Fuse (page 6-29)
9. Luggage strap holder (page 3-10)
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DESCRIPTION
2-3
1
2
3
4
5
6
7
8
9
EAU10430
Controls and instruments
12 3 4
567
8
9
1. Clutch lever (page 3-4)
2. Left handlebar switches (page 3-3)
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)
8. Throttle grip (page 6-13)
9. Fuel tank cap (page 3-5)
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3-1
2
3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU10460
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.
EAU10510
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.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU10710
LOCK
The steering is locked, and all electrical
systems are off. The key can be re-
moved.
To lock the steering
Turn the handlebars all the way to the
left or right.
1. Push the key in from the “OFF”po-
sition, release it, and then turn it to
“LOCK”.
2. Remove the key.
To unlock the steering
Insert the key and turn it to “OFF”.
WARNING
EWA10070
Never turn the key to “LOCK”while
the motorcycle is moving.
LOCK
OFF
ON
1. Push.
2. Release.
3. Turn.
123
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INSTRUMENT AND CONTROL FUNCTIONS
3-2
1
2
3
4
5
6
7
8
9
EAU10980
Indicator lights
EAU11020
Turn signal indicator light “”
This indicator light flashes when the
turn signal switch is pushed to the left or
right.
EAU11060
Neutral indicator light “”
This indicator light comes on when the
transmission is in the neutral position.
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11630
Speedometer unit
The speedometer unit is equipped with
a speedometer, an odometer and a
tripmeter. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeter
shows the distance traveled since it
was last set to zero with the reset knob.
The tripmeter can be used to estimate
the distance that can be traveled with a
full tank of fuel. This information will en-
able you to plan future fuel stops.
1. Turn signal indicator light “”
2. High beam indicator light “”
3. Neutral indicator light “”
312
1. Speedometer
2. Odometer
3. Tripmeter
4. Reset knob
4
2
3
1
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INSTRUMENT AND CONTROL FUNCTIONS
3-3
2
3
4
5
6
7
8
9
EAU12343
Handlebar switches
Left
Right
EAU12400
Dimmer switch “/”
Set this switch to “”for the high
beam and to “”for the low beam.
EAU12460
Turn signal switch “/”
To signal a right-hand turn, push this
switch to “”. To signal a left-hand
turn, push this switch to “”. When re-
leased, the switch returns to the center
position. To cancel the turn signal
lights, push the switch in after it has re-
turned to the center position.
EAU12500
Horn switch “”
Press this switch to sound the horn.
EAU12660
Engine stop switch “/”
Set this switch to “”before starting
the engine. Set this switch to “”to
stop the engine in case of an emergen-
cy, such as when the vehicle overturns
or when the throttle cable is stuck.
EAU12710
Start switch “”
Push this switch to crank the engine
with the starter.
CAUTION:
ECA10050
See page 5-1 for starting instruc-
tions prior to starting the engine.
1. Dimmer switch “/”
2. Turn signal switch “/”
3. Horn switch “”
12
3
1. Engine stop switch “/”
2. Start switch “”
1
2
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INSTRUMENT AND CONTROL FUNCTIONS
3-4
1
2
3
4
5
6
7
8
9
EAU12820
Clutch lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See
page 3-11.)
EAU12870
Shift pedal
The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 5-speed con-
stant-mesh transmission equipped on
this motorcycle.
EAU12890
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
1. Clutch lever
1
1. Shift pedal
1
N
5
4
3
2
1
1. Brake lever
1
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