Yamaha TW200N User manual

TW200N
TW200NC
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-14-43 2YG-28197-11

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
TW200EN/TW200ENC. For complete service information procedures it is necessary to use this
Supplementary Service Manual together with the following manual.
TW200T/TC ’87 SERVICE MANUAL: LIT-11616-05-93 (2JX-28197-10)
TW200EU/EUC ’88 SUPPLEMENTARY SERVICE MANUAL: LIT-11616-06-26 (2YG-28197-10)
TW200N/TW200NC
SUPPLEMENTARY
SERVICE MANUAL
© 2000 by Yamaha Motor Corporation, U.S.A.
First edition, November 2000
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-14-43

EAS00003 NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
NOTE:
@
• This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
• Designs and specifications are subject to change without notice.
@@
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
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 checking 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.
WARNING
CAUTION:
NOTE:

EAS00007 HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
2Each chapter is divided into sections. The current section title is shown at the top of each page,
except in chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)
appears.
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.

EAS00008
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1to 8indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Carburetion
6Chassis
7Electrical system
8Troubleshooting
Symbols 9to Findicate the following.
9Serviceable with engine mounted
0Filling fluid
ALubricant
BSpecial tool
CTightening torque
DWear limit, clearance
EEngine speed
FElectrical data
Symbols Gto Lin the exploded diagrams
indicate the types of lubricants and lubrication
points.
GEngine oil
HGear oil
IMolybdenum disulfide oil
JWheel bearing grease
KLithium soap base grease
LMolybdenum disulfide grease
Symbols Mto Nin the exploded diagrams
indicate the following.
MApply locking agent (LOCTITE®)
NReplace the part
12
34
56
78
90
AB
CD
EF
GHI
JKL
MN
GEN
INFO
SPEC
CHK
ADJ ENG
CARB CHAS
–+
ELEC TRBL
SHTG
T
R
.
.
EGM
BLS M
LT New

CONTENTS
GENERAL INFORMATION...............................................................................1
MOTORCYCLE IDENTIFICATION ...........................................................1
VEHICLE IDENTIFICATION NUMBER ................................................1
MODEL CODE .....................................................................................1
SPECIFICATIONS ............................................................................................2
GENERAL SPECIFICATIONS .................................................................2
MAINTENANCE SPECIFICATIONS ........................................................ 4
ENGINE ................................................................................................4
TIGHTENING TORQUESS ..................................................................6
CHASSIS ..............................................................................................7
TIGHTENING TORQUESS ..................................................................8
ELECTRICAL .......................................................................................9
CABLE ROUTING ..................................................................................10
PERIODIC CHECKS AND ADJUSTMENTS..................................................18
INTRODUCTION ....................................................................................18
PERIODIC MAINTENANCE CHART FOR EMISSION
CONTROL SYSTEM ..............................................................................18
GENERAL MAINTENANCE AND LUBRICATION CHART .................... 19
ENGINE ..................................................................................................21
ADJUSTING THE THROTTLE CABLE FREE PLAY .........................21
CLEANING THE SPARK ARRESTER ...............................................22
CHASSIS ................................................................................................23
ADJUSTING THE FRONT BRAKE .................................................... 23
CHECKING THE BRAKE FLUID LEVEL ...........................................24
CHECKING THE BRAKE PADS ........................................................25
CHECKING THE BRAKE HOSE ........................................................25
BLEEDING THE HYDRAULIC BRAKE SYSTEM ..............................26
ENGINE...........................................................................................................28
CYLINDER HEAD ..................................................................................28
CHECKING THE TIMING CHAIN TENSIONER ................................29
INSTALLING THE TIMING CHAIN TENSIONER ..............................29
AC MAGNETO .......................................................................................30
STATOR COIL ASSEMBLY AND PICKUP COIL ...............................30
AC MAGNETO ...................................................................................31
CARBURETION..............................................................................................32
CARBURETOR ......................................................................................32
DISASSEMBLING THE CARBURETOR ............................................35
CHECKING THE CARBURETOR ......................................................35
ASSEMBLING THE CARBURETOR ..................................................37
INSTALLING THE CARBURETOR ....................................................38
MEASURING AND ADJUSTING THE FUEL LEVEL .........................39

CHASSIS ........................................................................................................40
FRONT WHEEL AND BRAKE DISC ......................................................40
REMOVING THE FRONT WHEEL ....................................................42
CHECKING THE BRAKE DISC .........................................................42
INSTALLING THE FRONT WHEEL ...................................................44
FRONT BRAKE ...................................................................................... 46
FRONT BRAKE PADS .......................................................................46
REPLACING THE FRONT BRAKE PADS .........................................47
FRONT BRAKE MASTER CYLINDER ...............................................50
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ........52
CHECKING THE FRONT BRAKE MASTER CYLINDER ..................52
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MATER CYLINDER ............................................................................53
FRONT BRAKE CALIPER .................................................................55
DISASSEMBLING THE FRONT BRAKE CALIPER ...........................57
CHECKING THE FRONT AND REAR BRAKE CALIPERS ...............58
ASSEMBLING AND INSTALLING
THE FRONT BRAKE CALIPERS .......................................................59
FRONT FORK ........................................................................................62
STEERING HEAD ..................................................................................63
INSTALLING THE BEARING (RETAINER TYPE) .............................65
ELECTRICAL..................................................................................................66
ELECTRICAL COMPONENTS ...............................................................66
SWITCHES .............................................................................................67
CHECKING SWITCH CONTINUITY ..................................................67
CHECKING THE SWITCHES ................................................................68
IGNITION SYSTEM ................................................................................ 70
CIRCUIT DIAGRAM ...........................................................................70
TROUBLESHOOTING .......................................................................71
ELECTRIC STARTING SYSTEM ...........................................................75
CIRCUIT DIAGRAM ...........................................................................75
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ................... 76
TROUBLESHOOTING .......................................................................77
SIGNALING SYSTEM ............................................................................81
CIRCUIT DIAGRAM ...........................................................................81
TROUBLESHOOTING .......................................................................82
CHECKING THE SIGNALING SYSTEM ............................................83
TW200EN/TW200ENC WIRING DIAGRAM

– 1 –
GEN
INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is
stamped into the right side of the steering head
pipe.
EAS00018
MODEL CODE
The model code label 1is affixed to the
frame. This information will be needed to order
spare parts.
MOTORCYCLE IDENTIFICATION

– 2 –
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model TW200EN/TW200ENC
Model code number: TW200EN: 5FY8
TW200ENC: 5FY9
Dimensions:
Overall length 2,090 mm (82.3 in)
Overall width 820 mm (32.3 in)
Overall height 1,120 mm (44.1 in)
Seat height 790 mm (31.1 in)
Wheelbase 1,325 mm (52.2 in)
Minimum ground clearance 265 mm (10.4 in)
Engine:
Engine type Air cooled 4-stroke, SOHC
Cylinder arrangement Forward inclined single cylinder
Displacement 196 cm3(11.96 cu.in)
Bore ×stroke 67.0 ×55.7 mm (2.638 ×2.193 in)
Compression ratio 9.5 : 1
Compression pressure (standard) 900 kPa (9 kg/cm2, 128 psi)
Starting system Electric starter
Carburetor:
Type/manufacturer MV28/TEIKEI
Spark plug:
Type/manufacturer DR8EA (NGK), X24ESR-U (N.D.)
Gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Chassis:
Frame type Diamond
Caster angle 25.8°
Trail 95 mm (3.74 in)
Tire:
Type With tube
Size (F) 130/80-18 66P TW31
Size (R) 180/80-14M/C 78P TW34
Wear Limit <1.0 mm (0.04 in)>
GENERAL SPECIFICATIONS

– 3 –
SPEC
GENERAL SPECIFICATIONS
* Load is the total weight of cargo, rider, passenger and accessories.
Basic weight:
With oil and full fuel tank 126 kg (278 lb)/(TW200EN), 127 kg (280 lb) (TW200ENC)
Maximum load* 157 kg (346 lb)/(TW200EN), 156 kg (344 lb) (TW200ENC)
Cold tire pressure: Front Rear
Up to 80 kg (176 lb) load* 125 kPa
(1.25 kg/cm2, 18 psi) 125 kPa
(1.25 kg/cm2, 18 psi)
80 kg (176 lb) ~ Maximum load* 150 kPa
(1.5 kg/cm2, 22 psi) 175 kPa
(1.75 kg/cm2, 25 psi)
Off-road riding 125 kPa
(1.25 kg/cm2, 18 psi) 125 kPa
(1.25 kg/cm2, 18 psi)
High speed riding 150 kPa
(1.5 kg/cm2, 22 psi) 175 kPa
(1.75 kg/cm2, 25 psi)
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Drum brake
Operation Right foot operation
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Gas and coil spring/oil damper
Bulb wattage/quantity:
Headlight 12 V, 60 W/55 W ×1
Tail/brake light 12 V, 8 W/27 W ×2
Front turn signal/position light 12 V, 27 W/8 W ×2
Rear turn signal light 12 V, 27 W ×2
Meter light 12 V, 3.4 W ×1
Model TW200EN/TW200ENC

– 4 –
SPEC
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Model TW200EN/TW200ENC
Camshaft:
Drive method Chain drive (left)
Cam cap inside diameter 25.000 ~ 25.021 mm (0.984 ~ 0.985 in)
Camshaft outside diameter 24.96 ~ 24.98 mm (0.983 ~ 0.984 in)
Shaft-to-cap clearance 0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in)
Cam dimensions:
Intake: “A” 36.538 ~ 36.638 mm (1.439 ~ 1.442 in)
“B” 30.152 ~ 30.252 mm (1.187 ~ 1.191 in)
“C” 6.588 mm (0.259 in)
Exhaust: “A” 36.58 ~ 36.68 mm (1.440 ~ 1.444 in)
“B” 30.266 ~ 30.366 mm (1.192 ~ 1.196 in)
“C” 6.63 mm (0.261 in)
Camshaft runout limit <0.03 mm (0.0012 in)>
Cam chain type/number of links DID 25SH/104 links
Cam chain adjustment method Automatic
Piston ring:
Sectional sketch:
Top ring Barrel
B = 1.2 mm (0.047 in)
T = 2.7 mm (0.106 in)
2nd ring Taper
B = 1.2 mm (0.047 in)
T = 2.7 mm (0.106 in)
Oil ring Expander
B = 2.5 mm (0.098 in)
T = 2.8 mm (0.110 in)
End gap (Installed): Top ring 0.15 ~ 0.30 mm (0.006 ~ 0.012 in)
2nd ring 0.15 ~ 0.35 mm (0.006 ~ 0.014 in)
Oil ring 0.3 ~ 0.9 mm (0.012 ~ 0.035 in)
Side clearance Top ring 0.03 ~ 0.07 mm (0.001 ~ 0.003 in)
2nd ring 0.02 ~ 0.06 mm (0.001 ~ 0.002 in)
C
A
B
TB
B
T
B
T

– 5 –
SPEC
MAINTENANCE SPECIFICATIONS
Carburetor:
ID mark TW200EN: 5FY10
TW200ENC: 5FY00
Main jet (M.J.) TW200EN: #126
TW200ENC: #128
Main air jet (M.A.J.) 1.2
Jet needle-clip/position (J.N) TW200EN: 5B21-1/1
TW200ENC: 5B21-1/3
Main nozzle (M.N.) 2.600
Pilot jet (P.J.) #31
Pilot air jet (P.A.J.) TW200EN: 0.95
TW200ENC: 1.0
Pilot outlet 0.8
Bypass 0.7
Valve seat (V.S.) 1.6
Starter jet (G.S1.) 0.6
(G.S2.) 0.8
Fuel level
(above the line on the float chamber
mating surface) (F.L.)
0.5 ~ 1.5 mm (0.02 ~ 0.06 in)
Float height 10 ~ 11 mm (0.39 ~ 0.43 in)
Engine idling speed 1,300 ~ 1,500 r/min
Vacuum pressure at idling speed 29.3 ~ 34.7 kPa
(220 ~ 260 mmHg, 8.66 ~ 10.24 inHg) or more
Model TW200EN/TW200ENC

– 6 –
SPEC
MAINTENANCE SPECIFICATIONS
TIGHTENING TORQUESS
Parts to be tightened Part name Thread
size Q’ty Tightening
torque Remarks
Nm m·kg ft·lb
Cam sprocket cover Bolt M6 2 10 1.0 7.2
Tappet cover Bolt M6 5 10 1.0 7.2
Timing chain tensioner Bolt M6 2 10 1.0 7.2
Oil filter cover Bolt M6 2 10 1.0 7.2
Muffler protector Screw M6 4 7 0.7 5.1
Crankcase Bolt M6 12 10 1.0 7.2
Crankcase cover (left) Bolt M6 9 10 1.0 7.2
Crankcase cover (right) Bolt M6 12 10 1.0 7.2
Pickup coil lead holder Bolt M6 1 10 1.0 7.2 Apply LOCTITE®
Pickup coil Bolt M6 2 10 1.0 7.2 Apply LOCTITE®
Stator coil assembly Bolt M6 3 10 1.0 7.2 Apply LOCTITE®

– 7 –
SPEC
MAINTENANCE SPECIFICATIONS
CHASSIS
Model TW200EN/TW200ENC
Steering system:
Steering bearing type Angular ball
Drive chain:
Type/manufacturer 428HG (I)/DAIDO
Number of links 121 links + joint
Chain free play 35 ~ 60 mm (1.38 ~ 2.36 in)
Front brake:
Brake type Single-disc brake
Disc outside diameter ×thickness 220 ×3.5 mm (8.66 ×0.14 in)
Max. deflection 0.15 mm (0.006 in)
Brake pad lining thickness 5.3 mm (0.21 in)
<Limit> <0.8 mm (0.03 in)>
Master cylinder inside diameter 11 mm (0.43 in)
Caliper cylinder inside diameter 26.9 mm (1.06 in) + 22.2 mm (0.87 in)
Recommended fluid DOT4
Rear brake:
Brake type Drum brake (leading and trailing)
Drum inside dia. 110 mm (4.33 in)
<Limit> <111 mm (4.37 in)>
Lining thickness Front 4 mm (0.16 in)
<Limit> <2 mm (0.08 in)>
Shoe spring free length 50.5 mm (1.99 in)
Brake lever and brake pedal:
Brake lever free play (at lever end) 2 ~ 5 mm (0.08 ~ 0.20 in)
Brake pedal free play (at pedal end) 20 ~ 30 mm (0.8 ~ 1.2 in)
Brake pedal position 15 mm (0.6 in)
(Vertical height below footrest top.)
Clutch lever free play (at lever end): 10 ~ 15 mm (0.39 ~ 0.59 in)

– 8 –
SPEC
MAINTENANCE SPECIFICATIONS
TIGHTENING TORQUESS
NOTE:
1. First, tighten the ring nut to approximately 38 Nm (3.8 m • kg, 27 ft • lb) with a torque wrench,
then loosen the ring nut completely.
2. Retighten the ring nut to specification.
Parts to be tightened Threadsize Tightening torque Remarks
Nm m·kg ft·lb
Throttle cable and carburetor M6 ×1.0 5 0.5 3.6
Pivot shaft and frame M12 ×1.25 83 8.3 60
Rear shock absorber and frame M10 ×1.25 56 5.6 41
Drive chain case and swingarm M5 ×0.8 5 0.5 3.6
Handlebar holder upper and upper bracket M8 ×1.25 20 2.0 14
Steering shaft and ring nut M25 ×1.0 18 1.8 13 See NOTE.
Front brake master cylinder and handlebar M6 ×1.0 7 0.7 5.1
Front wheel hub and brake disc M6 ×1.0 13 1.3 9.4
Front brake caliper bracket and outer tube M10 ×1.25 30 3.0 22
Front brake caliper and caliper bracket M10 ×1.25 27 2.7 19
Brake hose union bolt M10 ×1.25 30 3.0 22
Air bleeder screw M7 ×1.0 6 0.6 4.3
Passenger footrest and frame M8 ×1.25 15 1.5 11
Rear fender and cover M6 ×1.0 5 0.5 3.6

– 9 –
SPEC
MAINTENANCE SPECIFICATIONS
ELECTRICAL
Model TW200EN/TW200ENC
C.D.I.:
Magneto model/manufacturer F5BT/YAMAHA
Pickup coil resistance (color) 656 ~ 984 Ωat 20 °C (68 °F) (R–W)
Source coil resistance (color) 624 ~ 936 Ωat 20 °C (68 °F) (Br–G)
C.D.I. unit-model/manufacturer 5LB/YAMAHA
Ignition coil:
Model/manufacturer 2JN/YAMAHA
Minimum spark gap 6 mm (0.24 IN) or more at 500 r/min
Primary winding resistance 0.18 ~ 0.28 Ωat 20 °C (68 °F)
Secondary winding resistance 6.3 ~ 9.5 kΩat 20 °C (68 °F)
Charging system:
Type A.C. magneto generator
Model/manufacturer 5FBT/YAMAHA
Charge coil resistance (color) 0.5 ~ 0.7 Ωat 20 °C (68 °F) (W–W)
Rectifier/regulator:
Type Semi conductor type
Model/manufacturer SH629A-12/SHINDENGEN
No load regulated voltage 14.1 ~ 14.9 V
Capacity 10 A
Withstand voltage 200 V
Starter motor:
Model/manufacture 5FY/YAMAHA
Output 0.4 kW
Armature coil resistance 0.017 ~ 0.021 Ω
Brush overall length 10 mm (0.39 in)
<Limit> <3.5 mm (0.14 in)>
Brush spring pressure 560 ~ 840 g (19.8 ~ 29.6 oz)
<Limit> <450 g (0.98 oz)>
Commutator dia. 22 mm (0.87 in)
<Limit> <21 mm (0.83 in)>
Mica undercut 1.5 mm (0.06 in)
Flasher relay:
Type Full transistor
Model/manufacturer FE246BH/DENSO
Self cancelling device No.
Flasher frequency 75 ~ 95 cycle/min
Wattage 27 W ×2 + 3.4 W
Circuit breaker:
Type Fuse
Amperage for individual circuit
Main 20 A

– 10 –
SPEC
CABLE ROUTING
1Throttle cable
2Front brake light switch lead
3Right handlebar switch lead
4Clutch cable
5Left handlebar switch lead
6Clutch switch lead
7Front turn signal/position
light lead (left)
8Main switch lead
9Indicator lights lead
0Speedometer cable
AMeter light lead
BHeadlight coupler
CWire harness
DFront turn signal/position
light lead (right)
EBrake hose
ÈFasten the brake hose with a
plastic locking tie to the
brake hose grommet.
ÉFasten the wire harness with
a plastic locking tie.
CABLE ROUTING

– 11 –
SPEC
1Clutch cable
2Left handlebar switch lead
3Clutch switch lead
4Resonator hose
5Main switch lead
6Rectifier/regulator lead
7Fuel hose
8Brake hose
9Speedometer cable
0Horn lead
ÈFasten the resonator hose with a plastic band between the resonator
hose protectors so that the fastener does not squeeze the hose.
ÉPass the canister hose through the guide of the frame. (for California)
ÊFasten the resonator hose with a plastic band in front of the resonator
hose protector.
ËFasten the rectifier/regulator lead and resonator hose with a plastic
band between the resonator hose protectors so that the fastener does
not squeeze the hose.
ÌFasten the brake hose with a plastic locking tie to the brake hose
grommet.
CABLE ROUTING

– 12 –
SPEC
1Sidestand switch lead
2Crankcase breather hose
3Battery negative terminal
4Carburetor air vent hose
5Carburetor overflow hose
6AC magneto lead
7Starter motor lead
8Neutral switch lead
ÈFasten the AC magneto leads with a plastic locking tie to the frame at
the section where the frame starts to curve.
ÉFasten the carburetor air vent hose, carburetor overflow hose, and
neutral switch lead with a plastic clip.
CABLE ROUTING

– 13 –
SPEC
1Ignition coil
2Throttle cable
3Horn lead
4Canister hose (for California)
5Canister (for California)
6Spark plug
7Starter motor lead
ÈFasten the wire harness, right handlebar switch lead, front brake light
switch lead, clutch switch lead, main switch lead, and throttle cable
with a plastic band.
ÉFasten the wire harness, right handlebar switch lead, front brake light
switch lead, clutch switch lead, main switch lead, and resonator hose
with a plastic band.
ÊFasten the throttle cable and canister hose with a plastic clip. Be sure
to face the ends of the clip downward from the frame. (for California)
ËFasten the throttle cable with a plastic locking tie through the hole in
the frame bracket.
CABLE ROUTING