2002 YAMAHA TW200 Owners Manual

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EAU01144Wheel bearings
If there is play in the front or rear
wheel hub or if the wheel does not
turn smoothly, have a Yamaha
dealer inspect the wheel bearings.
EW000115
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Securely support the motorcycle
so there is no danger of it falling
over.
EAU01071
Battery
Check the level of the battery elec-
trolyte and make sure that the ter-
minals are tight.
Fill with distilled water if the elec-
trolyte level is low.
EC000099
cC
When inspecting the battery, be
sure the breather hose is routed
correctly. If the breather hose is
positioned in such a way as to
cause battery electrolyte or gas to
exit onto the frame, structural and
cosmetic damage to the motorcy-
cle can occur.
1
2
1. Battery
2. Battery breather hose
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EW000116
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Battery electrolyte is poisonous
and dangerous, causing severe
burns, etc. It contains sulfuric acid.
Avoid contact with skin, eyes or
clothing.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities
of water or milk. Follow with milk
of magnesia, beaten egg, or veg-
etable oil. Call a physician immedi-
ately.
EYES: Flush with water for 15 min-
utes and get prompt medical
attention. Batteries produce explo-
sive gases. Keep sparks, flame, cig-
arettes etc., away. Ventilate when
charging or using in an enclosed
space. Always shield your eyes
when working near batteries.
KEEP OUT OF REACH OF CHIL-
DREN.
EW000117
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Take care not to spill battery fluid
on the chain.
Battery fluid may weaken the
chain causing shorter chain life
and possibly result in an accident
Battery storage
1. When the motorcycle will not
be used for a month or longer,
remove the battery, fully
charge it and store it in a cool,
dry place. Completely recharge
the battery before reinstalla-
tion.
2. If the battery will be stored for
longer than two months, check
the specific gravity of the fluid
at least once a month and fully
recharge the battery when it is
too low. Replenishing the battery fluid
A poorly maintained battery will
corrode and discharge quickly. The
battery fluid should be checked at
least once a month. The level
should be between the minimum
level and maximum level marks.
Use only distilled water if refilling
is necessary.
EC000100
cC
Normal tap water contains miner-
als which are harmful to a battery;
therefore, refill only with distilled
water.
1
2
1. Maximum level mark
2. Minimum level mark
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93. Always make sure the connec-
tions are correct when putting
the battery back in the motor-
cycle. Make sure the breather
hose is properly connected
and is not damaged or
obstructed.
EC000103
cC
Do not use fuses of higher amper-
age rating than those recommend-
ed. Substitution of a fuse of
improper rating can cause exten-
sive electrical system damage and
possibly a fire.
EAU01307Fuse replacement
The fuse is located behind panel A.
(See page 6-7 for panel removal
and installation procedures.)
If the fuse is blown, turn off the
main switch and the switch of the
circuit in question. Install a new
fuse of proper amperage. Turn on
the switches and see if the electri-
cal device operates. If the fuse
immediately blows again, consult a
Yamaha dealer.
1
1. Fuse
Specified fuse: 15A
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1
3. Remove the connector and the
bulb holder cover.
4. Turn the bulb holder counter-
clockwise to remove it and
remove the defective bulb.
EW000119
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Keep flammable products and your
hands away from a bulb while it is
on, as it is hot. Do not touch a bulb
until it cools down.
5. Put a new bulb into position
and secure it in place with the
bulb holder.
1. Bulb holder cover
EAU01191
Headlight bulb replacement
This motorcycle is equipped with a
quartz bulb headlight. If the head-
light bulb burns out, replace it as
follows:
1. Remove cowling A. (See page
6-6 for cowling removal and
installation procedures.)
2. Remove the headlight unit.
1
EC000105
cC
Avoid touching the glass part of a
bulb. Keep it free from oil; other-
wise, the transparency of the
glass, life of the bulb, and lumi-
nous flux will be adversely affect-
ed. If oil gets on a bulb, thoroughly
clean it with a cloth moistened
with alcohol or lacquer thinner.
6. Install the bulb holder cover,
connector and headlight unit.
7. Install the cowling.
8. If the headlight beam adjust-
ment is necessary, ask a
Yamaha dealer to make that
adjustment.
1. Bulb holder
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EAU00862
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.
3
2
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EAU00908
Front wheel removalEW000122
w
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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9 2. Loosen the brake cable free
play adjusting nuts. Remove
the brake cable from the han-
dlebar lever holder and then
from the front wheel hub.
3. Remove the cotter pin and
loosen the axle nut.
4. Elevate the front wheel by
placing a suitable stand under
the engine.
5. Remove the axle nut and
wheel axle.3. Make sure the axle nut is prop-
erly torqued, and a new cotter
pin is installed.
EW000124
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Always use a new cotter pin.
4. Adjust the free play in the
brake lever. Axle holder nut torque:
90 Nm (9.0 m0kg)EAU00927
Front wheel installation
When installing the front wheel,
reverse the removal procedure.
Pay attention to the following
points:
1. Make sure the wheel hub and
the brake shoe plate assembly
are installed with the projec-
tions meshed into the slots.
2. Make sure the slot in the brake
shoe plate fits over the stopper
on the front fork outer tube.
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EAU01304
Rear wheel removalEW000122
w
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 brake adjusting
nut and brake rod from the
brake cam lever.
1
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4 5
1. Adjusting nut
2. Brake rod
3. Axle nut
4. Cotter pin
5. Chain adjusting plate
2. Remove the axle nut cotter pin
and loosen the axle nut.
3. Elevate the rear wheel by plac-
ing a suitable stand under the
engine.
4. Remove the axle nut.
5. Push the wheel forward and
remove the drive chain.
6. Pull out the axle and remove
the rear wheel assembly by
pulling it backwards.EAU01308
Rear wheel installation
1. Install the wheel assembly and
insert the axle from the left-
hand side. Be sure that the
chain adjusting plates are
installed with the punched side
outward and the slot in the
brake shoe plate is fit over the
stopper on the swingarm.
2. Install and adjust the drive
chain. (See page 6-22 for
details about adjusting the
drive chain slack.)
3. Install the axle nut and let the
motorcycle down.
4. Tighten the axle nut to the
specified torque and install the
axle nut cotter pin.
Tightening torque:
Axle nut:
90 Nm (9.0 m0kg)
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EW000110
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Always use a new cotter pin on
the axle nut.
5. Insert the brake rod into the
brake cam lever and install the
brake pedal free play adjusting
nut.
6. Adjust the rear brake pedal
free play. (See page 6-19.)
EW000103
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Check the operation of the brake
light after adjusting the rear brake.
EAU01008Troubleshooting
Although Yamaha motorcycles
receive a rigid inspection before
shipment from the factory, trouble
may occur during operation.
Any problem in the fuel, compres-
sion, or ignition systems can cause
poor starting and loss of power.
The troubleshooting chart
describes a quick, easy procedure
for making checks.
If your motorcycle requires any
repair, bring it to a Yamaha dealer.
The skilled technicians at a
Yamaha dealership have the tools,
experience, and know-how to
properly service your motorcycle.
Use only genuine Yamaha parts on
your motorcycle. Imitation parts
may look like Yamaha parts, but
they are often inferior.
Consequently, they have a shorter
service life and can lead to expen-
sive repair bills.
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