2002 YAMAHA TW200 check engine

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9i. Fill the engine with oil. Install
the oil filler cap and tighten.
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8Do not put in any chemical
additives. Engine oil also lubri-
cates the clutch and additives
could cause clutch slippage.
8Be sure no foreign material
enters the crankcase.
Recommended oil:
See page 8-1
Oil quantity:
Total amount:
1.3 L
Periodic oil change:
1.0 L
With oil filter replacement:
1.1 LTightening torque:
Drain plug:
10 Nm (1.0 m0kg)
Filter cover screw:
10 Nm (1.0 m0kg)
Drain bolt (filter cover):
10 Nm (1.0 m0kg)j. Start the engine and warm up
for a few minutes. While
warming up, check for oil leak-
age. If oil leakage is found,
stop the engine immediately
and check for the cause.
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9 To check the chain slack the motor-
cycle must be held straight up with
both wheels on the ground and
without rider. Check the slack at
the position shown in the illustra-
tion. Normal slack is approximately
30 ~ 40 mm. If the slack exceeds 40
mm, adjust.
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Drive chain slack adjustment
1. Loosen the rear brake adjust-
ing nut.
2. Remove the cotter pin from
the axle nut.
3. Loosen the axle nut.
4. Turn both left and right chain
adjusting plates the same
amount. Make sure that they
are in the same position for
proper wheel alignment.
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2
3 4
1. Adjusting nut
2. Axle nut
3. Cotter pin
4. Chain adjusting plate
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Too little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits.
5. After adjusting, be sure to
tighten the axle nut to the
specified torque.
Tightening torque:
Axle nut:
90 Nm (9.0 m0kg)
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Brake and clutch lever
lubrication
Lubricate the pivoting parts.
EAU00785
Sidestand lubrication
Lubricate the sidestand pivoting
point and metal-to-metal contact
surfaces. Check that the sidestand
moves up and down smoothly.
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If the sidestand does not move
smoothly, consult a Yamaha deal-
er.
Recommended lubricant:
Same as engine oil
Recommended lubricant:
Same as engine oil
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Rear suspension lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Lithium soap base grease
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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.
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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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Supporting the motorcycle
Since the Yamaha TW200E has no
centerstand, follow these precau-
tions when removing the front and
rear wheel or performing other
maintenance requiring the motor-
cycle to stand upright.
Front wheel service:
To stabilize the rear of the motor-
cycle, either use a motorcycle
stand or place a motorcycle jack
under the frame in front of the rear
wheel to prevent it from moving
from side to side. Then use a
motorcycle stand to elevate the
front wheel off of the ground.
Rear wheel service:
Use a motorcycle stand or motor-
cycle jack to elevate the motorcycle
so the rear wheel is off the ground.
Alternatively, two jacks can be
placed under the frame or
swingarm.Check that the motorcycle is in a
stable and level position before
starting any maintenance. A strong
wooden box can be placed under
the engine for added stability.
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2
41
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Front wheel removalEW000122
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8It is advisable to have a
Yamaha dealer service the
wheel.
8Securely support the motorcy-
cle so there is no danger of it
falling over.
1. Remove the clip holding the
speedometer cable in the
speedometer gear housing.
Then remove the speedometer
cable by pulling it outward.
1. Speedometer cable
2. Axle nut
3. Cotter pin
4. Clip
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Troubleshooting chartEW000125
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Never check the fuel system while smoking or in the vicinity of an open flame.
1. Fuel
2. Compression
3. Ignition
4. Battery
Use electric starter.
Remove spark
There is compression.
Go to ignition check.
No compression.
Ask a Yamaha dealer to inspect.
Wet
DryWipe clean with dry cloth and correct
Open the throttle half-way and start
Ask a Yamaha dealer to inspect.
Check if there is fuel
Enough fuel
No fuelGo to compression check.
Supply fuel.
in the fuel tank
electrode. plugs and check
Engine doesn’t start, go to battery
check. the engine. spark plug gap or replace spark plugs.
Engine turns over
Engine turns overBattery good.
Check fluid, recharge,
quickly.
slowly. check connections.Engine doesn’t start, ask aYamaha dealer to inspect.
Engine doesn’t start, go to compression check.
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