1998 YAMAHA TW200 air condition

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PERIODIC MAINTENANCE AND MINOR REPAIR
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EW000060
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If you are not familiar with motor-
cycle service, this work should be
done by a Yamaha dealer.
EAU00464
Periodic inspection, adjustment
and lubrication will keep your
motorcycle in the safest and most
efficient condition possible. Safety
is an obligation of the motorcycle
owner. The maintenance and lubri-
cation schedule chart should be
considered strictly as a guide to
general maintenance and lubrica-
tion intervals. YOU MUST TAKE
INTO CONSIDERATION THAT
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATIONS, AND A VARIETY
OF INDIVIDUAL USES ALL TEND
TO DEMAND THAT EACH OWNER
ALTER THIS TIME SCHEDULE TO
SHORTER INTERVALS TO MATCH
THE ENVIRONMENT. The most
important points of motorcycle
inspection, adjustment, and lubri-
cation are explained in the follow-
ing pages.1
EAU01175Tool kit
The tool kit is located behind panel
B. (See page 6-7 for panel removal
and installation procedures.)
The tools provided in the owner’s
tool kit are to assist you in the per-
formance of periodic maintenance.
However, some other tools such as
a torque wrench are also necessary
to perform the maintenance cor-
rectly.
The service information included in
this manual is intended to provide
you, the owner, with the necessary
information for completing some
of your own preventive mainte-
nance and minor repairs.
1. Tool kit
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EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
EVERY
6,000 km 12,000 km
No. ITEM CHECKS AND MAINTENANCE JOBSInitial or or
(1,000 km) 6 months 12 months
(Whichever (Whichever
comes first) comes first)
1 * Fuel line 9Check fuel hoses for cracks or damage.
√√
9Replace if necessary.
2 Spark plug9Check condition.
√√√
9Clean, regap or replace if necessary.
3 * Valves9Check valve clearance.
√√√
9Adjust if necessary.
4 * Cam chain9Check chain tension.
√√√
9Adjust if necessary.
5 Air filter9Clean or replace if necessary.√√
9Check electrolyte level and specific gravity.
6 * Battery9Correct or recharge if necessary. √√
9Make sure that the breather hose is properly routed.
7 Clutch9Check operation.
√√√
9Adjust or replace cable.
8 * Front brake9Check operation.
√√√
9Adjust cable and replace brake shoes if necessary.
9 * Rear brake9Check operation.
√√√
9Adjust cable and replace brake shoes if necessary.
10 * Wheels9Check balance, runout, spoke tightness and for damage.
√√
9Tighten spokes and rebalance, replace if necessary.
9Check tread depth and for damage.
11 * Tires9Replace if necessary.
√√
9Check air pressure.
9Correct if necessary.
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1. Panel A
EAU00494Panel A
To remove:
Pull outward on the areas shown.
To install:
Place the panel in its original posi-
tion.
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EAU00495Spark plug inspection
The spark plug is an important
engine component and is easy to
inspect. The condition of the spark
plug can indicate the condition of
the engine. The ideal color on the
white insulator around the center
electrode is a medium-to-light tan
color for a motorcycle that is being
ridden normally. Do not attempt to
diagnose any problems yourself.
Instead, take the motorcycle to a
Yamaha dealer. You should period-
ically remove and inspect the spark
plug because heat and deposits
will cause the spark plug to slowly
1. Spark plug gap
12
1. Panel B
2. Screw (×2)
EAU01345Panel B
To remove:
Remove the screws and pull out-
ward on the areas shown.
To install:
Place the panel in the original posi-
tion and install the screws.
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Proper loading of your motorcycle
is important for several character-
istics of your motorcycle; such as
handling, braking, performance
and safety. Do not carry loosely
packed items that can shift.
Securely pack your heaviest items
close to the center of the motorcy-
cle, and distribute the weight
evenly from side to side. Check the
condition and pressure of your
tires. NEVER OVERLOAD YOUR
MOTORCYCLE. Make sure the
total weight of the cargo, rider,
passenger, and accessories (fair-
ing, saddlebags, etc. if approved
for this model) does not exceed
the maximum load of the motorcy-
cle. Operation of an overloaded
motorcycle could cause tire dam-
age, an accident, or even injury.
* Load is the total weight of cargo, rider, passen-
ger, and accessories.
Maximum load* 157 kg
Cold tire pressure: Front Rear
125 kPa 150 kPa
Up to 90 kg (1.25 kgf/cm
2, (1.50 kgf/cm2,1.25 bar) 1.50 bar)
90 kg load ~150 kPa 175 kPa
Maximum load*(1.50 kgf/cm
2, (1.75 kgf/cm2,1.50 bar) 1.75 bar)
Off-road riding125 kPa 125 kPa
(1.25 kgf/cm
2, (1.25 kgf/cm2,1.25 bar) 1.25 bar)
High-speed riding150 kPa 175 kPa
(1.50 kgf/cm
2, (1.75 kgf/cm2,
1.50 bar) 1.75 bar)
EAU00668Tires
To ensure maximum performance,
long service, and safe operation,
note the following:
1. Tire air pressure
Always check and adjust the
tire pressure before operating
the motorcycle.
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Tire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire infla-
tion pressure must be adjusted
according to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if
approved for this model), and vehi-
cle speed.
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EAU00685Wheels
To ensure maximum performance,
long service, and safe operation,
note the following:
1. Always inspect the wheels
before a ride. Check for cracks,
bends or warpage of the
wheel. Be sure the spokes are
tight and undamaged. If any
abnormal condition exists in a
wheel, consult a Yamaha deal-
er. Do not attempt even small
repairs to the wheel. If a wheel
is deformed or cracked, it must
be replaced.
2. Tires and wheels should be
balanced whenever either one
is changed or replaced. Failure
to have a wheel balanced can
result in poor performance,
adverse handling characteris-
tics, and shortened tire life.3. Ride at moderate speeds after
changing a tire since the tire
surface must first be broken in
for it to develop its optimal
characteristics.
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1. It is dangerous to ride with a
worn-out tire. When a tire
tread begins to show lines,
have a Yamaha dealer replace
the tire immediately. Brakes,
tires, and related wheel parts
replacement should also be
left to a Yamaha dealer.
2. Patching a punctured tube is
not recommended. If it is
absolutely necessary to do so,
use great care and replace the
tube as soon as possible with
a good quality replacement.
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EAU00772
Cable inspection and
lubrication
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Damage to the outer housing of
cables may lead to internal rusting
and interfere with the cable move-
ment. Replace damaged cables as
soon as possible to prevent unsafe
conditions.
Lubricate the cables and cable
ends. If a cable does not operate
smoothly, ask a Yamaha dealer to
replace it.
Recommended lubricant:
Same as engine oil
EAU00773
Throttle cable and grip
lubrication
The throttle twist grip assembly
should be greased at the time that
the cable is lubricated, since the
grip must be removed to get at the
end of the throttle cable. After
removing the screws, hold the end
of the cable up in the air and put in
several drops of lubricant. With the
throttle grip disassembled, coat the
metal surface of the grip assembly
with a suitable all-purpose grease.
EAU00776
Brake and shift pedal
lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Same as engine oil
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EAU00793Front fork inspection
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Securely support the motorcycle
so there is no danger of it falling
over.
1. Visual check
Check for scratches or damage
on the inner tube and exces-
sive oil leakage from the front
fork.2. Operation check
Place the motorcycle on a level
place.
a. Hold the motorcycle in an
upright position and apply the
front brake.
b. Push down hard on the han-
dlebars several times and
check if the fork rebounds
smoothly.
EC000098
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If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer.
EAU00794Steering inspection
Periodically inspect the condition
of the steering. Worn out or loose
steering bearings may be danger-
ous. Place a stand under the
engine to raise the front wheel off
the ground. Hold the lower end of
the front forks and try to move
them forward and backward. If any
free play can be felt, ask a Yamaha
dealer to inspect and adjust the
steering. Inspection is easier if the
front wheel is removed.
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