2002 YAMAHA TW200 Owners Manual

6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
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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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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)
12 * Wheel bearings9Check bearing for looseness or damage.
√√
9Replace if necessary.
9Check swingarm pivoting point for play.
13 * Swingarm9Correct if necessary. √√
9Lubricate with lithium soap base grease.
9Check chain slack.
14 Drive chain9
Adjust if necessary. Make sure that the rear wheel is properly aligned.Every 500 km and after washing
9Clean and lubricate.the motorcycle or riding in the rain
9Check bearing play and steering for roughness.
15 * Steering bearings9Correct accordingly.
√√
9Lubricate with lithium soap grease every 24,000 km or
24 months (whichever comes first).
16 * Chassis fasteners9
Make sure that all nuts, bolts and screws are properly tightened.√√9Tighten if necessary.
17 Sidestand9Check operation.
√√
9Lubricate and repair if necessary.
18 Sidestand switch9Check operation.
√√√
9Replace if necessary.
19 * Front fork9Check operation and for oil leakage.
√√
9Correct accordingly.
20 *Rear shock absorber 9Check operation and shock absorber for oil leakage.
√√
assembly9Replace shock absorber assembly if necessary.
Rear shock absorber9Check operation.
21 * assembly pivoting9Lubricate with lithium soap base grease every 24,000 km or√√
points24 months (whichever comes first).
22 * Carburetor9Check engine idling speed and starter operation.
√√√
9Adjust if necessary.
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*: Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.EAU00479
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
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)
9Check oil level and vehicle for oil leakage.
23 Engine oil9Correct if necessary.√√√
9Change. (Warm engine before draining.)
24Engine oil filter element9Clean or replace if necessary.√√
25
*
Engine oil strainer9Clean or replace if necessary.√√
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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.
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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.
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.
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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.
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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
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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)
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