2002 YAMAHA TW200 maintenance

6-6
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
1
EAU01139
Cowling and panel removal
and installation
The cowlings and panels illustrated
need to be removed to perform
some of the maintenance
described in this chapter.
Refer to this section each time a
cowling or panel has to be
removed or reinstalled.
1. Panel B
1
2
1. Cowling A
2. Panel A
1
1. Screw
EAU01344Cowling A
To remove:
Remove the screw.
To install:
Place in the original position and
install the screw.
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 35

6-7
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
1
1. Panel A
EAU00494Panel A
To remove:
Pull outward on the areas shown.
To install:
Place the panel in its original posi-
tion.
1
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.
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 36

6-8
PERIODIC MAINTENANCE AND MINOR REPAIR
6 break down and erode. If electrode
erosion becomes excessive, or if
carbon and other deposits are
excessive, you should replace the
spark plug with the specified plug.
Before installing the spark plug,
measure the electrode gap with a
wire thickness gauge; adjust the
gap to specification as necessary.
When installing the plug, always
clean the gasket surface and use a
new gasket. Wipe off any grime
from the threads and tighten the
spark plug to the specified torque.Specified spark plug:
DR8EA (NGK) or
X24ESR-U (DENSO)Spark plug gap:
0.6 ~ 0.7 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 m0kg)
NOTE:
If a torque wrench is not available
when you are installing a spark
plug, a good estimate of the cor-
rect torque is 1/4 to 1/2 turn past
finger tight. Have the spark plug
tightened to the specified torque as
soon as possible.EAU00517Engine oil
1. Oil level measurement
a. Place the motorcycle on a level
place and hold it in an upright
position. Warm up the engine
for several minutes.
NOTE:
Be sure the motorcycle is posi-
tioned straight up when checking
the oil level. A slight tilt toward the
side can result in false readings.
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 37

6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
1
2. Engine oil replacement
a. Warm up the engine for a few
minutes.
b. Stop the engine. Place an oil
pan under the engine and
remove the oil filler cap.
1. Oil filler cap
2
3 1
b. With the engine stopped,
check the oil level through the
level window located at the
lower part of the right side
crankcase cover.
NOTE:
Wait a few minutes until the oil
level settles before checking.
c. The oil level should be
between the maximum and
minimum marks. If the level is
low, add sufficient oil to raise
it to the proper level.
1. Level window
2. Maximum level mark
3. Minimum level mark
1
c. Remove the drain plug and
drain bolt.
1. Drain plug
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 38

6-10
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
1 2 3
4
EC000070
cC
When removing the oil drain plug,
the O-ring, compression spring,
and oil strainer will fall out. Take
care not to lose these parts.
NOTE:
The oil filter cover is secured by
two screws and a drain bolt.
Remove the drain bolt to drain the
filter cavity.
1. Drain plug
2. O-ring
3. Compression spring
4. Oil strainer
1
2
d. Remove the filter cover screws
and the oil filter cover.
e. Remove the oil filter element
and O-ring.
f. Clean the oil filter and strainer
with solvent. Replace if neces-
sary.
g. Check the O-rings. If damaged,
replace.
h. Install the drain plug, filter
cover, screws and drain bolt.
Tighten the drain plug to the
specified tightening torque.
1. Filter cover screw (×2)
2. Drain bolt
21
NOTE:
Make sure the O-ring is seated
properly.
EC000071
cC
Before reinstalling the oil drain
plug, do not forget to install the O-
ring, compression spring, and oil
strainer in position.
1. Oil filter
2. O-ring (×2)
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 39

6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9i. Fill the engine with oil. Install
the oil filler cap and tighten.
EC000066
cC
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.
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 40

6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EAU01094Air filter
The air filter should be cleaned at
the specified intervals. It should be
cleaned more frequently if you are
riding in unusually wet or dusty
areas.
1. Remove panel B. (See page 6-7
for panel removal and installa-
tion procedures.)
2. Remove the air filter case fit-
ting screws and the air filter
case cover.
1
1. Air filter
3. Remove the air filter from its
case and clean it with solvent.
After cleaning, remove the
remaining solvent by squeez-
ing the air filter.
4. Apply the recommended oil to
the entire surface of the filter
and squeeze out the excess oil.
It should be wet but not drip-
ping.
1
1. Screw (×4)
Recommended oil:
Same as engine oil
5. Install the air filter in its case.
6. Install panel B.
EC000085
cC
8Make sure the air filter is prop-
erly seated in the filter case.
8The engine should never be
run without the air filter
installed. Excessive piston
and/or cylinder wear may
result.
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 41

6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EAU00629Carburetor adjustment
The carburetor is a vital part of the
engine and requires very sophisti-
cated adjustment. Most adjust-
ments should be left to a Yamaha
dealer who has the professional
knowledge and experience to do
so. However, the following may be
serviced by the owner as part of
routine maintenance.
EC000094
cC
The carburetor was set at the
Yamaha factory after many tests. If
the settings are changed, poor
engine performance and damage
may result.
EAU01168Idle speed adjustment
NOTE:
A diagnostic tachometer must be
used for this procedure.
1. Attach the tachometer. Start
the engine and warm it up for
a few minutes at approximate-
ly 1,000 to 2,000 r/min.
Occasionally rev the engine to
4,000 to 5,000 r/min. The
engine is warm when it quickly
responds to the throttle.
b
a1
1. Throttle stop screw
2. Set the idle to the specified
engine speed by adjusting the
throttle stop screw. Turn the
screw in direction ato
increase engine speed and in
direction bto decrease engine
speed.
NOTE:
If the specified idle speed cannot
be obtained by performing the
above adjustment, consult a
Yamaha dealer.
Standard idle speed:
1,350 ~ 1,450 r/min
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 42