2002 YAMAHA TW200 maintenance

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EAU00635
Throttle cable free play
inspection
There should be a free play of 2 ~ 5
mm at the throttle grip. If the free
play is incorrect, ask a Yamaha
dealer to make this adjustment.
EAU00636Cam chain adjustment
The cam chain becomes loose with
use, resulting in improper valve
timing and engine noise. To pre-
vent this, the cam chain tensioner
must be adjusted regularly. This
adjustment, however, should be
left to a professional Yamaha ser-
vice technician.
EAU00637
Valve clearance adjustment
The correct valve clearance
changes with use, resulting in
improper fuel/air supply or engine
noise. To prevent this, the valve
clearance must be adjusted regu-
larly. This adjustment however,
should be left to a professional
Yamaha service technician.
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EW000087
w
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.
EW000082
w
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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Manufacturer Size Type
BRIDGESTONE 130/80-18 66P TW31
Manufacturer Size Type
BRIDGESTONE
180/80-14M/C 78PTW32
REAR:
Minimum tire tread
depth : 1.0 mm
(front and rear)
FRONT:
1
2
2. Tire inspection
Always check the tires before
operating the motorcycle. If
center tread depth reaches the
limit as shown, if the tire has a
nail or glass fragments in it, or
if the side wall is cracked, con-
tact a Yamaha dealer immedi-
ately and have the tire
replaced.
1. Tread depth
2. Side wall
NOTE:
These limits may be different by
regulation from country to country.
If so, conform to the limits speci-
fied by the regulations of your own
country.
EW000078
w
After extensive tests, the tires
mentioned below have been
approved by Yamaha Motor Co.,
Ltd. for this model. No guarantee
for handling characteristics can be
given if tire combinations other
than what is approved are used on
this motorcycle. The front and rear
tires should be of the same manu-
facture and design.
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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.
EAU00680
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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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a
b 3
12
EAU00694
Clutch lever free play
adjustment
The clutch lever free play should
be adjusted to 2 ~ 3 mm.
1. Loosen the locknut at the
clutch lever.
2. Turn the adjusting bolt at the
clutch lever in direction ato
increase free play or in direc-
tion bto decrease free play.
3. Tighten the locknut at the
clutch lever.
1. Locknut
2. Adjusting bolt
3. Free play
If the specified free play cannot be
obtained, proceed with the follow-
ing steps.
4. Loosen the locknut at the
clutch lever.
5. Turn the adjusting bolt at the
clutch lever in direction ato
loosen the cable.
6. Loosen the locknut at the
crankcase side.
7. Turn the adjusting nut at the
crankcase in direction ato
increase free play or in direc-
tion bto decrease free play.
8. Tighten the locknut at the
crankcase and the clutch lever.
b
a213
EAU00699
Front brake lever free play
adjustment
The front brake lever free play
should be adjusted to 2 ~ 4 mm.
1. Loosen the locknut at the
brake lever.
2. Turn the adjusting bolt at the
brake lever in direction ato
increase free play or in direc-
tion bto decrease free play.
3. Tighten the locknut at the
brake lever .
1. Locknut
2. Adjusting bolt
3. Free play
a
b
1
2
1. Adjusting nut
2. Locknut
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9b. Turn the adjusting bolt in
direction ato raise pedal
height or in direction bto
lower pedal height.
c. Tighten the locknut.
EW000105
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After adjusting the pedal height
adjust brake pedal free play.
4
5 12
3
a b
EAU00707
Rear brake pedal height and
free play adjustment
EW000104
w
It is advisable to have a Yamaha
dealer make this adjustment.
1. Pedal height
The brake pedal should be
positioned so that its top end
is approximately 10 mm below
the top of the footrest.
a. Loosen the locknut.
1. Locknut
2. Adjusting bolt
3. Footrest
4. Pedal height: 10 mm
5. Free play
a b 1
2
If the specified free play cannot be
obtained, proceed with the follow-
ing steps.
4. Loosen the locknut at the
brake lever.
5. Turn the adjusting bolt at the
brake lever in direction ato
loosen the cable.
6. Loosen the locknut at the
brake hub.
7. Turn the adjusting nut at the
brake hub in direction ato
increase free play or in direc-
tion bto decrease free play.
8. Tighten the locknut at the
brake hub and the brake lever.
1. Adjusting nut
2. Locknut
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b1
2a
EAU00713
Brake light switch
adjustment
The rear brake light switch is acti-
vated by the brake pedal and is
properly adjusted when the brake
light comes on just before braking
takes effect. To adjust the rear
brake light switch, hold the switch
body so it does not rotate while
turning the adjusting nut.
Turn the adjusting nut in direction
ato make the brake light come on
earlier.
Turn the adjusting nut in direction
bto make the brake light come on
later.
1. Brake light switch
2. Adjusting nut
EW000106
w
8Brake pedal free play should
be checked whenever the
chain is adjusted or the rear
wheel is removed and then
reinstalled.
8Check the operation of the
brake light after adjusting the
rear brake.
8If it is impossible to make
proper adjustment, consult a
Yamaha dealer.
2. Free play
The rear brake pedal free play
should be adjusted to 20 ~ 30
mm at the brake pedal end.
Turn the adjusting nut on the
brake rod in direction ato
increase free play or in direc-
tion bto decrease free play.
a
b1
1. Adjusting nut
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EAU00744Drive chain slack check
NOTE:
Spin the wheel several times and
find the tightest position of the
chain. Check and/or adjust the
chain slack while it’s in this tightest
position.
EAU00719
Checking the brake shoes
A wear indicator is provided on
each brake. This indicator allows
inspection of shoe wear without
disassembling the brake. Apply the
brake and inspect the position of
the indicator. If the indicator reach-
es to the wear limit line, ask a
Yamaha dealer to replace the
shoes.
1
2
1. Wear indicator
2. Wear limit
FRONT
21
1. Wear indicator
2. Wear limit
REAR
a
a. 30 ~ 40 mm
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