2003 YAMAHA TW200 service

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PERIODIC MAINTENANCE AND MINOR REPAIR
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6. Insert a new cotter pin into the
axle nut and bend the end of
the cotter pin as shown in the
illustration. If the notch in the
nut and cotter pin hole do not
match, tighten the nut slightly
to align them.
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Always use a new cotter pin on
the axle nut.
1. Cotter pin
7. Adjust the free play in the
brake pedal.
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Check the operation of the brake
light after adjusting the rear brake.
EAU01106Drive chain lubrication
The chain consists of many parts
which work with each other. If the
chain is not maintained properly, it
will wear out quickly. Therefore,
the chain must be serviced regular-
ly. This service is especially neces-
sary when riding in dusty areas.
1. The drive chain should be
lubricated every 500 km. First,
remove all dirt and mud from
the chain with a brush or cloth.
Then, spray any of the many
brands of spray-type chain
lubricant between both rows
of side plates and on all center
rollers.
2. To clean the chain thoroughly,
remove it from the motorcycle,
dip it in solvent, and clean out
as much dirt as possible. Then,
take the chain out of the sol-
vent to dry it, and immediately
lubricate it to prevent it from
rusting.
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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.
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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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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.
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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
w
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
w
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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EAU01038
SPECIFICATIONS
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Specifications
Model TW200E
Dimensions:
Overall length 2,090 mm
Overall width 815 mm
Overall height 1,115 mm
Seat height 790 mm
Wheel base 1,325 mm
Ground clearance 250 mm
Minimum turning radius 1,900 mm
Basic weight (With oil and full
fuel tank):126 kg
Engine:
Engine type Air-cooled 4-stroke, SOHC,
gasoline
Cylinder arrangement Forward inclined
single cylinder
Displacement 196 cm
3
Bore ×Stroke 67.0 ×55.7 mm
Compression ratio 9.5:1
Starting system Electric and kick starter
Lubrication system Wet sumpEngine oil:
Type:
Classification API Service “SE”, “SF” type
or equivalent
(e.g. “SF-SE”, “SF-SE-CC”,
“SF-SE-SD” etc.)
Capacity:
Periodic oil change 1.0 L
With oil filter replacement 1.1 L
Total amount 1.3 L
Air filter:Wet type element
Fuel:
Type Regular gasoline
Fuel tank capacity 7.0 L
Reserve amount 1.7 L
Carburetor:
Type / quantity Y29P-5C / 1
Manufacturer TEIKEI
–10° 0° 10° 20° 30° 40°
SAE 10W/30
SAE 10W/40
SAE 20W/40
SAE 20W/50C
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