Yamaha TW200C Owner's Manual

OWNER’S MANUALPRINTED IN JAPAN2002·5–0.6×1(E) !PRINTED ON RECYCLED PAPERYAMAHA MOTOR CO., LTD.PRINTED IN JAPAN2004.6–0.8×1 !(E)LIT-11626-18-275FY-2819

SAFETY INFORMATION 1-3 1 not exceed the maximum load limit of179 kg (395 lb) (CAL) 180 kg (397 lb)(U49). When loading within this weightlimit, keep t

SAFETY INFORMATION 1-4 1 motorcycle’s electrical system anelectric failure could result, whichcould cause a dangerous loss oflights or engine power.

SAFETY INFORMATION 1-5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.12

SAFETY INFORMATION 1-6 1WARNINGBEFORE YOU OPERATE THIS VEHICLE, READTHE OWNER’S MANUAL AND ALL LABELS.ALWAYS WEAR AN APPROVED MOTORCYCLEHELMET, eye

2-1 123456789 DESCRIPTION EAU10410 Left view12345687 1. Fuel tank cap (page 3-5)2. Fuel cock (page 3-7)3. Helmet holder (page 3-9)4. Luggage strap h

DESCRIPTION 2-2 23456789 EAU10420 Right view12654378 1. Carrier (page 3-9)2. Battery (page 6-31)3. Engine oil level check window (page 6-11)4. Brake

DESCRIPTION 2-3 123456789 EAU10430 Controls and instruments12 3 456789 1. Clutch lever (page 3-4)2. Left handlebar switches (page 3-3)3. Speedometer

3-1 23456789 INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock The main switch/steering lock controlsthe ignition and lighting sys

INSTRUMENT AND CONTROL FUNCTIONS 3-2 123456789 EAU10980 Indicator lights EAU11020 Turn signal indicator light “” This indicator light flashes when

INSTRUMENT AND CONTROL FUNCTIONS 3-3 23456789 EAU12343 Handlebar switches LeftRight EAU12400 Dimmer switch “ / ” Set this switch to “” for the high

5FY-9-17_hyoushi2&3 4/9/04 2:40 PM Page 1

INSTRUMENT AND CONTROL FUNCTIONS 3-4 123456789 EAU12820 Clutch lever The clutch lever is located at the lefthandlebar grip. To disengage theclutch,

INSTRUMENT AND CONTROL FUNCTIONS 3-5 23456789 EAU12941 Brake pedal The brake pedal is on the right side ofthe motorcycle. To apply the rearbrake, pr

INSTRUMENT AND CONTROL FUNCTIONS 3-6 123456789 EAU13210 Fuel Make sure that there is sufficient fuel inthe tank. Fill the fuel tank to the bottomof

INSTRUMENT AND CONTROL FUNCTIONS 3-7 23456789 EAU13560 Fuel cock The fuel cock supplies fuel from thetank to the carburetor while filtering it al-so

INSTRUMENT AND CONTROL FUNCTIONS 3-8 123456789 EAU13600 Starter (choke) knob “” Starting a cold engine requires a richerair-fuel mixture, which is s

INSTRUMENT AND CONTROL FUNCTIONS 3-9 23456789 EAU14281 Helmet holder To open the helmet holder, insert thekey into the lock, and then turn the keyas

INSTRUMENT AND CONTROL FUNCTIONS 3-10 123456789 EAU15170 Luggage strap holders There are four luggage strap holdersbelow the carrier. EAU15300 Sides

INSTRUMENT AND CONTROL FUNCTIONS 3-11 23456789 EAU15311 Ignition circuit cut-off system The ignition circuit cut-off system (com-prising the sidesta

INSTRUMENT AND CONTROL FUNCTIONS 3-12 123456789With the engine turned off:1. Move the sidestand down.2. Make sure that the engine stop switch is turn

4-1 23456789 PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickl

INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha TW200/TW200C. This model is the result of Yamaha’s vast experience inthe product

PRE-OPERATION CHECKS 4-2 123456789 EAU15602 Pre-operation check list ITEM CHECKS PAGEFuel ● Check fuel level in fuel tank. ● Refuel if necessary. ●

PRE-OPERATION CHECKS 4-3 23456789 Drive chain ● Check chain slack. ● Adjust if necessary. ● Check chain condition. ● Lubricate if necessary.6-26, 6-2

5-1 123456789 OPERATION AND IMPORTANT RIDING POINTS EAU15950WARNING EWA10270 ● Become thoroughly familiarwith all operating controls andtheir functio

OPERATION AND IMPORTANT RIDING POINTS 5-2 23456789off. Never accelerate hard when the engine is cold! 7. When the engine is warm, turn thestarter (ch

OPERATION AND IMPORTANT RIDING POINTS 5-3 123456789CAUTION: ECA10260 ● Even with the transmission inthe neutral position, do notcoast for long perio

OPERATION AND IMPORTANT RIDING POINTS 5-4 23456789 EAU16841 Engine break-in There is never a more important periodin the life of your engine than th

6-1 123456789 PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 Safety is an obligation of the owner. Pe-riodic inspection, adjustment and lubri-cation

PERIODIC MAINTENANCE AND MINOR REPAIR 6-2 23456789 a Yamaha dealer perform it for you.WARNING EWA10340 Modifications not approved byYamaha may cause

PERIODIC MAINTENANCE AND MINOR REPAIR 6-3 123456789 EAU17580 Periodic maintenance chart for the emission control system * Since these items require

PERIODIC MAINTENANCE AND MINOR REPAIR 6-4 23456789 EAU32161 General maintenance and lubrication chart No. ITEM ROUTINEINITIAL ODOMETER READINGS600 m

IMPORTANT MANUAL INFORMATION EAU10130 Particularly important information is distinguished in this manual by the following notations:NOTE: ● This manu

PERIODIC MAINTENANCE AND MINOR REPAIR 6-5 123456789 9* Wheel bearings ● Check bearings for smooth operation. ● Replace if necessary. √√√√√ 10 * Swing

PERIODIC MAINTENANCE AND MINOR REPAIR 6-6 23456789 15 Brake and shift pedal pivot shafts ● Apply lithium-soap-based grease (all-purpose grease) light

PERIODIC MAINTENANCE AND MINOR REPAIR 6-7 123456789 * Since these items require special tools, data and technical skills, have a Yamaha dealer perfor

PERIODIC MAINTENANCE AND MINOR REPAIR 6-8 23456789 EAU18721 Removing and installing thecowling and panels The cowling and panels shown need tobe rem

PERIODIC MAINTENANCE AND MINOR REPAIR 6-9 123456789Panel B To remove the panelPull the panel off as shown.To install the panelPlace the panel in the

PERIODIC MAINTENANCE AND MINOR REPAIR 6-10 23456789To check the spark plug 1. Check that the porcelain insulatoraround the center electrode of thespa

PERIODIC MAINTENANCE AND MINOR REPAIR 6-11 123456789 EAU19671 Canister (for California only) This model is equipped with a canisterto prevent the di

PERIODIC MAINTENANCE AND MINOR REPAIR 6-12 23456789 3. Remove the engine oil filler capand drain bolt to drain the oil fromthe crankcase.CAUTION: EC

PERIODIC MAINTENANCE AND MINOR REPAIR 6-13 123456789 7. Check the O-ring for damage andreplace it if necessary.8. Clean the oil filter element with s

PERIODIC MAINTENANCE AND MINOR REPAIR 6-14 23456789 EAU20820 Cleaning the air filter elementand check hose The air filter element should be cleaneda

IMPORTANT MANUAL INFORMATION EAU10192 TW200T1/TW200T1(C)OWNER’S MANUAL©2004 by Yamaha Motor Corporation, U.S.A.1st edition, April 2004All rights rese

PERIODIC MAINTENANCE AND MINOR REPAIR 6-15 123456789To clean the air filter check hose 1. Check the hose at the bottom ofthe air filter case for accu

PERIODIC MAINTENANCE AND MINOR REPAIR 6-16 23456789 3. Insert the tailpipe into the muffler,and then install and tighten thescrew.NOTE: Make sure to

PERIODIC MAINTENANCE AND MINOR REPAIR 6-17 123456789 EAU21400 Adjusting the valve clearance The valve clearance changes with use,resulting in improp

PERIODIC MAINTENANCE AND MINOR REPAIR 6-18 23456789to side. Check the condition andpressure of your tires. NEVEROVERLOAD YOUR MOTORCYCLE.Make sure th

PERIODIC MAINTENANCE AND MINOR REPAIR 6-19 123456789very carefully and replace it assoon as possible with a high-quality product. EAU21940 Spoke whee

PERIODIC MAINTENANCE AND MINOR REPAIR 6-20 23456789the use of items which have not been approved by Yamaha. EAU22041 Adjusting the clutch lever freep

PERIODIC MAINTENANCE AND MINOR REPAIR 6-21 123456789 ver free play, turn the adjusting nutin direction (b).6. Tighten the locknut at the clutch le-ve

PERIODIC MAINTENANCE AND MINOR REPAIR 6-22 23456789 EAU22192 Adjusting the brake pedalposition and free play WARNING EWA10670 It is advisable to have

PERIODIC MAINTENANCE AND MINOR REPAIR 6-23 123456789WARNING EWA10680 ● After adjusting the drive chainslack or removing and installingthe rear wheel,

PERIODIC MAINTENANCE AND MINOR REPAIR 6-24 23456789 indicator grooves have almost disap-peared, have a Yamaha dealer replacethe brake pads as a set.

TABLE OF CONTENTS SAFETY INFORMATION ...1-1Location of important labels ...1-5 DESCRIPTION ...

PERIODIC MAINTENANCE AND MINOR REPAIR 6-25 123456789 make sure that the top of the mas-ter cylinder is level by turning thehandlebars. ● Use only the

PERIODIC MAINTENANCE AND MINOR REPAIR 6-26 23456789 EAU22760 Drive chain slack The drive chain slack should bechecked before each ride and adjustedi

PERIODIC MAINTENANCE AND MINOR REPAIR 6-27 123456789CAUTION: ECA10570 Improper drive chain slack will over-load the engine as well as other vitalpar

PERIODIC MAINTENANCE AND MINOR REPAIR 6-28 23456789 EAU23090 Checking and lubricating thecables The operation of all control cables andthe condition

PERIODIC MAINTENANCE AND MINOR REPAIR 6-29 123456789 EAU23140 Checking and lubricating thebrake and clutch levers The operation of the brake and clu

PERIODIC MAINTENANCE AND MINOR REPAIR 6-30 23456789 EAU23271 Checking the front fork The condition and operation of the frontfork must be checked as

PERIODIC MAINTENANCE AND MINOR REPAIR 6-31 123456789 EAU23290 Checking the wheel bearings The front and rear wheel bearings mustbe checked at the in

PERIODIC MAINTENANCE AND MINOR REPAIR 6-32 23456789 5. Place the battery on a level sur-face, and then check the electro-lyte level in the battery.NO

PERIODIC MAINTENANCE AND MINOR REPAIR 6-33 123456789 battery band onto the holder.8. Connect the breather hose to thebattery and make sure that it is

PERIODIC MAINTENANCE AND MINOR REPAIR 6-34 23456789 EAU23501 Replacing the fuse The fuse holder is located behind panelB. (See page 6-8.)If the fuse

TABLE OF CONTENTS Checking the front fork ...6-30Checking the steering ...6-30Checking the wheel bearings ...6

PERIODIC MAINTENANCE AND MINOR REPAIR 6-35 123456789 4. Remove the headlight bulb holderby turning it counterclockwise, andthen remove the defective

PERIODIC MAINTENANCE AND MINOR REPAIR 6-36 23456789 8. Install the cowling.9. Have a Yamaha dealer adjust theheadlight beam if necessary. EAU24131 Re

PERIODIC MAINTENANCE AND MINOR REPAIR 6-37 123456789 EAU24201 Replacing a turn signal lightbulb 1. Remove the turn signal light lensby removing the

PERIODIC MAINTENANCE AND MINOR REPAIR 6-38 23456789 frame in front of the rear wheel or undereach side of the swingarm. EAU24360 Front wheel EAU2458

PERIODIC MAINTENANCE AND MINOR REPAIR 6-39 123456789 2. Lift the wheel up between the forklegs.NOTE: Make sure that there is enough spacebetween the

PERIODIC MAINTENANCE AND MINOR REPAIR 6-40 23456789 4. Lift the rear wheel off the groundaccording to the procedure onpage 6-37.5. Remove the axle nu

PERIODIC MAINTENANCE AND MINOR REPAIR 6-41 123456789 EAU25850 Troubleshooting Although Yamaha motorcycles receivea thorough inspection before shipme

PERIODIC MAINTENANCE AND MINOR REPAIR 6-42 23456789 EAU25962 Troubleshooting chart WARNING EWA10840 Keep away open flames and do not smoke while chec

7-1 123456789 MOTORCYCLE CARE AND STORAGE EAU26000 Care While the open design of a motorcyclereveals the attractiveness of the tech-nology, it also

MOTORCYCLE CARE AND STORAGE 7-2 23456789any marks. If the windshield isscratched, use a quality plasticpolishing compound after washing. After normal

1-1 1 SAFETY INFORMATION EAU10310 MOTORCYCLES ARE SINGLETRACK VEHICLES. THEIR SAFEUSE AND OPERATION ARE DEPEN-DENT UPON THE USE OF PROPERRIDING TECH

MOTORCYCLE CARE AND STORAGE 7-3 123456789ingly and make sure to wipe offany excess. ● Never apply oil or wax to anyrubber and plastic parts, buttreat

MOTORCYCLE CARE AND STORAGE 7-4 23456789 from the spark plug, and theninstall the spark plug and thespark plug cap.WARNING EWA10950 To prevent damage

8-1 123456789 SPECIFICATIONS EAU26337 Dimensions: Overall length: 2090 mm (82.3 in) Overall width: 820 mm (32.3 in) Overall height: 1120 mm (44.1 in

SPECIFICATIONS 8-2 23456789 3rd: 29/22 (1.318) 4th: 26/25 (1.040) 5th: 23/28 (0.821) Chassis: Frame type: Diamond Caster angle: 26.00 ° Trail: 95.0

SPECIFICATIONS 8-3 123456789Bulb voltage, wattage x quantity: Headlight: 12 V, 60 W/55.0 W × 1 Tail/brake light: 12 V, 8.0/27.0 W × 1 Front turn

9-1 23456789 CONSUMER INFORMATION EAU26351 Identification numbers Record the key identification number,vehicle identification number and mod-el labe

CONSUMER INFORMATION 9-2 123456789 EAU26460 Model label The model label is affixed to the loca-tion shown. Record the information onthis label in th

CONSUMER INFORMATION 9-3 23456789 EAU26550 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could

CONSUMER INFORMATION 9-4 123456789 EAU26560 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the fo

CONSUMER INFORMATION 9-5 23456789 EAU26611 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorc

SAFETY INFORMATION 1-2 1 dercornering (insufficient lean an-gle for the speed). ● Always obey the speed limit andnever travel faster than warrant-ed

CONSUMER INFORMATION 9-6 123456789 25000 mi(41000 km) or48 months28000 mi(46000 km) or54 months31000 mi(51000 km) or60 months MaintenanceintervalDate

CONSUMER INFORMATION 9-7 23456789 EAU26661 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITEDWARRANTY

CONSUMER INFORMATION 9-8 123456789

CONSUMER INFORMATION 9-9 23456789 EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine

CONSUMER INFORMATION 9-10 123456789We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowin

INDEX A Accessories and replacement parts ...6-19Air filter element and check hose, cleaning ...6-

INDEX Tires ..... 6-17Tool kit ..... 6-1Troublesh

OWNER’S MANUALPRINTED IN JAPAN2002·5–0.6×1(E) !PRINTED ON RECYCLED PAPERYAMAHA MOTOR CO., LTD.PRINTED IN JAPAN2004.6–0.8×1 !(E)LIT-11626-18-275FY-2819