2001 YAMAHA TW200 steering

TABLE OF CONTENTS
SAFETY INFORMATION ............. 1-1
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 ................................ 3-10Ignition 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 ................................... 6-7
Cleaning the air filter element
and check hose ..................... 6-10
Adjusting the carburetor .......... 6-12Adjusting 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 .......................... 6-16
Adjusting the clutch lever free
play ....................................... 6-16
Adjusting the brake lever free
play ....................................... 6-17
Adjusting the brake pedal
position and free play ............ 6-18
Adjusting the rear brake light
switch .................................... 6-19
Checking the front brake pads
and rear brake shoes ............ 6-19
Checking the 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

TABLE OF CONTENTS
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
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 .......................................... 7-1Storage ..................................... 7-3
SPECIFICATIONS ....................... 8-1
CONSUMER INFORMATION ...... 9-1
Identification numbers ............... 9-1

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 havebeen 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

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)

INSTRUMENT AND CONTROL FUNCTIONS
3-1
2
34
5
6
7
8
9

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.
LOCKOFFON
1. Push.
2. Release.
3. Turn.
12
3

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
1
2
3
4
5
6
7
8
9

10

*
Wheels

Check runout, spoke tightness and for damage.

Tighten spokes if necessary.
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√

√

√


11

*
Tires

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Correct if necessary.
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√

√

√

√


12

*
Wheel bearings

Check bearing for looseness or damage.
√

√

√

√


13

*
Swingarm

Check operation and for excessive play.
√

√

√

√



Lubricate with lithium-soap-based grease. Every 24,000 km
14

Drive chain

Check chain slack.

Make sure that the rear wheel is properly aligned.

Clean and lubricate.Every 500 km and after washing the motorcycle or
riding in the rain
15

*
Steering bearings

Check bearing play and steering for roughness.
√

√

√

√

√



Lubricate with lithium-soap-based grease. Every 24,000 km
16

*
Chassis fasteners

Make sure that all nuts, bolts and screws are properly
tightened.
√

√

√

√

√


17

Sidestand

Check operation.

Lubricate.
√

√

√

√

√


18

*
Sidestand switch

Check operation.
√

√

√

√

√

√


19

*
Front fork

Check operation and for oil leakage.
√

√

√

√


20

*
Shock absorber assem-
bly

Check operation and shock absorber for oil leakage.
√

√

√

√


21

*
Carburetor

Check starter (choke) operation.

Adjust engine idling speed.
√

√

√

√

√

√


22

Engine oil

Change.

Check oil level and vehicle for oil leakage.
√

√

√

√

√

√


23

Engine oil filter element

Clean.
√

√

√


24

*
Engine oil strainer

Clean.
√

NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1,000 km)
ANNUAL
CHECK
1 6 12 18 24

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
2
3
4
5
67
8
9
CAUTION:

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

CONSUMER INFORMATION
9-1
1
2
3
4
5
6
7
8
9

EAU26351
Identification numbers
Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehi-
cle is stolen.
KEY IDENTIFICATION NUMBER:
VEHICLE IDENTIFICATION NUM-
BER:
MODEL LABEL INFORMATION:
EAU26390
Key identification number
The key identification number is
stamped into the key. Record this num-
ber in the space provided and use it for
reference when ordering a new key.
EAU26400
Vehicle identification number
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro-
vided.
NOTE:

The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcy-
cle with the licensing authority in your
area.
1. Key identification number
1

1. Vehicle identification number
1