Yamaha TW200M 1999 User manual

3XT-28199-29
OWNER’S MANUAL
TW200M
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EAU00000 INTRODUCTION
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Congratulations on your purchase of the Yamaha TW200. This model is the result of Yamaha’s
vast experience in the production of fine sporting, touring, and pacesetting racing machines. It
represents the high degree of craftsmanship and reliability that have made Yamaha a leader in
these fields.
This manual will give you an understanding of the operation, inspection, and basic mainte-
nance of this motorcycle. If you have any questions about the operation or maintenance of
your motorcycle, please consult a Yamaha dealer.
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IMPORTANT MANUAL INFORMATION
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EAU00005
Particularly important information is distinguished in this manual by the following notations:
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 motorcycle.
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.
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NOTE:
NOTE:
8This manual should be considered a permanent part of this motorcycle and should
remain with it even if the motorcycle is subsequently sold.
8Yamaha 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 manu-
al. If there is any question concerning this manual, please consult your Yamaha dealer.
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IMPORTANT MANUAL INFORMATION
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EW000002
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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
MOTORCYCLE.
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TW200M
OWNER’S MANUAL
©1999 by Yamaha Motor Co., Ltd.
1st Edition, July 1999
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
EAU00008
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EAU00009 TABLE OF CONTENTS
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SAFETY INFORMATION ....................................1-1
Safe riding ........................................................1-1
Protective apparel ............................................1-3
Modification......................................................1-3
Loading and accessories .................................1-3
Gasoline and exhaust gas ...............................1-5
Location of the important labels.....................1-7
DESCRIPTION .....................................................2-1
Left view............................................................2-1
Right view.........................................................2-2
Controls/Instruments .......................................2-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................................3-1
Main switch/Steering lock ...............................3-1
Indicator lights..................................................3-2
Speedometer....................................................3-2
Handlebar switches..........................................3-3
Clutch lever.......................................................3-4
Shift pedal.........................................................3-4
Front brake lever ..............................................3-5
Rear brake pedal ..............................................3-5
Fuel tank cap.....................................................3-5
Fuel....................................................................3-6
Fuel cock ...........................................................3-7
Starter (choke) “1”.........................................3-8
Kick starter........................................................3-8
Steering lock.....................................................3-9
Seat ...................................................................3-9
Helmet holder.................................................3-10
Rear shock absorber ......................................3-10
Rear carrier .....................................................3-11
Sidestand........................................................3-11
Sidestand/clutch switch operation check.....3-12
PRE-OPERATION CHECKS.................................4-1
Pre-operation check list ...................................4-1
OPERATION AND IMPORTANT RIDING
POINTS................................................................5-1
Starting and warming up a cold engine.........5-1
Starting a warm engine...................................5-4
Shifting..............................................................5-4
Tips for reducing fuel consumption ...............5-5
Engine break-in ................................................5-5
Parking ..............................................................5-6
PERIODIC MAINTENANCE AND MINOR
REPAIR ................................................................6-1
Tool kit ..............................................................6-1
Periodic maintenance and lubrication............6-3
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TABLE OF CONTENTS
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Cowling and panel removal and
installation ........................................................6-6
Cowling A .........................................................6-6
Panel A..............................................................6-7
Panel B ..............................................................6-7
Spark plug.........................................................6-7
Engine oil..........................................................6-9
Air filter ...........................................................6-12
Carburetor adjustment ..................................6-13
Idle speed adjustment ...................................6-13
Throttle cable free play inspection ...............6-14
Cam chain adjustment...................................6-14
Valve clearance adjustment ..........................6-14
Tires.................................................................6-15
Wheels ............................................................6-17
Clutch lever free play adjustment.................6-18
Front brake lever free play adjustment ........6-18
Rear brake pedal height and free play
adjustment......................................................6-19
Brake light switch adjustment.......................6-20
Checking the brake shoes..............................6-21
Drive chain slack check..................................6-21
Drive chain slack adjustment ........................6-22
Drive chain lubrication...................................6-23
Cable inspection and lubrication ..................6-24
Throttle cable and grip lubrication ...............6-24
Brake and shift pedal lubrication..................6-24
Brake and clutch lever lubrication ................6-25
Sidestand lubrication.....................................6-25
Rear suspension lubrication..........................6-25
Front fork inspection......................................6-26
Steering inspection........................................6-26
Wheel bearings ..............................................6-27
Battery.............................................................6-27
Fuse replacement...........................................6-29
Headlight bulb replacement..........................6-30
Turn signal light bulb replacement ..............6-31
Taillight bulb replacement ............................6-31
Supporting the motorcycle ...........................6-32
Front wheel removal......................................6-32
Front wheel installation.................................6-33
Rear wheel removal.......................................6-34
Rear wheel installation ..................................6-34
Troubleshooting.............................................6-35
Troubleshooting chart ...................................6-36
MOTORCYCLE CARE AND STORAGE ..............7-1
Care ...................................................................7-1
Storage..............................................................7-4
SPECIFICATIONS................................................8-1
How to use the conversion table ....................8-5
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9CONSUMER INFORMATION .............................9-1
Identification number records.........................9-1
Key identification number...............................9-1
Vehicle identification number.........................9-1
Model label.......................................................9-2
Noise regulation (For Australia)......................9-2
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QSAFETY INFORMATION
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TWO-WHEELED MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPER-
ATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE
EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING
REQUIREMENTS BEFORE RIDING.
HE OR SHE SHOULD:
1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS
OF 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 MANU-
AL 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 auto-
mobile 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:
a. Wear a brightly colored jacket.
b. Use extra caution when you approach and pass through intersections, since intersec-
tions are the most likely places for motorcycle accidents.
c. Ride where other motorists can see you. Avoid riding in another motorist’s “blind spot”.
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QSAFETY INFORMATION
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4. Many accidents involve inexperienced operators. In fact, many operators who have been
involved in accidents do not even have a current motorcycle license.
a. Make sure you are qualified. Also, only lend your motorcycle to experienced operators.
b. Know your skills and limits. Staying within your limits may help you to avoid an acci-
dent.
c. We recommend that you practice riding your motorcycle where there is no traffic until
you have become thoroughly familiar with your motorcycle and all of its controls.
5. Many motorcycle accidents have been caused by motorcycle operator errors. A typical
error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or under-
cornering (insufficient lean angle for the speed).
a. Always obey the speed limits and never travel faster than warranted by road and traffic
conditions.
b. Always signal before turning or changing lanes. Make sure other motorists see you.
6. The operator’s and passenger’s posture are important for proper control.
a. The operator should keep both hands on the handlebars and both feet on the operator
footrests during operation to maintain control of the motorcycle.
b. The passenger should always hold on to the operator, or the seat strap or grab bar if the
motorcycle is so 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 drugs.
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QSAFETY INFORMATION
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Protective apparel
The majority of fatalities from motorcycle accidents are the result of head injuries.
The use of a safety helmet 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 on your unprotected eyes could contribute to an
impairment of vision which could delay seeing a hazard.
3. The use of heavy boots, jacket, trousers, gloves, etc. is effective in preventing or reducing
abrasions or lacerations.
4. Never wear loose fitting clothing. It could catch on the control levers, footrests, or wheels
and cause injury or 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. A passenger should also observe the above precautions.
Modification
Modifications made to the motorcycle not approved by Yamaha, or the removal of original
equipment, may render your motorcycle unsafe for use and may cause severe personal injury.
Modifications may also make your motorcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your motorcycle can adversely affect stability and handling if
the weight distribution of the machine is changed. To avoid the possibility of an accident,
extreme caution should be used if adding cargo or accessories to your motorcycle. Use extra
care if riding a motorcycle which has added cargo or accessories. Here are some general
guidelines to follow if loading cargo or adding accessories to your motorcycle:
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QSAFETY INFORMATION
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Loading
The total weight of the operator, passenger, accessories and cargo must not exceed the maxi-
mum load limit of 180 kg.
When loading within these weight limits, keep the following in mind:
1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible.
Be sure to distribute the weight as evenly as possible on both sides of the machine to mini-
mize imbalance or instability.
2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are
securely attached to the motorcycle before riding. Recheck accessory mounts and cargo
restraints frequently.
3. Never attach any large or heavy items to the handlebars, front forks, or front fender. These
items, including such cargo as sleeping bags, duffle bags, or tents, can create unstable
handling or slow steering response.
Accessories
Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since
Yamaha cannot test all other accessories which may be available, you must personally be
responsible for the proper selection, installation and use of non-Yamaha accessories. You
should use extreme caution when selecting and installing any accessories.
Keep in mind these guidelines for mounting accessories in addition to those provided under
“LOADING”.
1. Never install accessories or carry cargo that would impair the performance of your motor-
cycle. Carefully inspect the accessory before using it to make sure it does not in any way
reduce ground clearance or cornering clearance, limit suspension travel, steering travel or
control operation, or obscure lights or reflectors.
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QSAFETY INFORMATION
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a. Accessories fitted to the handlebar or the front fork area can create instability due to
improper weight distribution or aerodynamic 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.
b. Bulky or large accessories may seriously affect the stability of the motorcycle due to
aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may
become unstable in cross winds. These accessories may also cause instability when
being passed by or passing large vehicles.
c. Certain accessories can displace the operator from his or her normal riding position.
This improper position limits the freedom of movement of the operator and may limit
control ability. Therefore such accessories are not recommended.
2. Caution must be used if adding electrical accessories. If these accessories 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.
Gasoline and exhaust gas
1. GASOLINE IS HIGHLY FLAMMABLE:
a. Always turn off the engine 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 are poisonous and may cause loss of consciousness and death within a short time.
Always operate your motorcycle in an area that has adequate ventilation.
3. Always turn off the engine before leaving the motorcycle unattended and remove the igni-
tion key. When parking the motorcycle, note the following:
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QSAFETY INFORMATION
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a. The engine and exhaust system may be hot. Park the motorcycle in a place where
pedestrians or children are not likely to touch these hot areas.
b. Do not park the motorcycle on a slope or soft ground; the motorcycle may fall over.
c. Do not park the motorcycle near a flammable source, e.g. a kerosene heater, or near an
open flame. The motorcycle could catch fire.
4. When transporting the motorcycle in another vehicle, be sure it is kept upright and that the
fuel cock(s) is turned to “ON” or “RES” (for vacuum type)/”OFF” (for manual type). If it
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
in your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing,
immediately wash it off with soap and water and change your clothes.
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Location of the important labels
Please read the following labels carefully before operating this motorcycle.
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WARNING
Before you operate this vehicle,
read the owner’s manual.
English 3HP-21568-00
4AA-22259-40
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DESCRIPTION
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91. Headlight (page 6-30)
2. Fuel cock (page 3-7)
3. Starter (choke) “1“ (page 3-8)
4. Air filter (page 6-12)
5. Battery (page 6-27)
6. Helmet holder (page 3-10)
7. Rear carrier (page 3-11)
8. Shift pedal (page 3-4)
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Left view
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DESCRIPTION
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9. Fuse (page 6-29)
10. Kick starter (page 3-8)
11. Rear brake pedal (page 3-5, 6-19)
12. Tool kit (page 6-1)
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Right view
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DESCRIPTION
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13. Clutch lever (page 3-4, 6-18)
14. Left handlebar switches (page 3-3)
15. Speedometer (page 3-2)
16. Right handlebar switches (page 3-3)
17. Front brake lever (page 3-5, 6-18)
18. Throttle grip (page 6-14, 6-24)
19. Fuel tank cap (page 3-5)
20. Main switch (page 3-1)
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Controls/Instruments
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