2003 YAMAHA TW200 battery

Carburetor adjustment ..................................6-13
Idle speed adjustment ...................................6-13
Throttle cable free play inspection ...............6-14
Cam chain adjustment ...................................6-14
Valve clearance adjustment ..........................6-14
Tires.................................................................6-15
Wheels ............................................................6-17
Clutch lever free play adjustment .................6-18
Front brake lever free play adjustment ........6-18
Rear brake pedal height and free play
adjustment ......................................................6-19
Brake light switch adjustment.......................6-20
Checking the brake shoes..............................6-21
Drive chain slack check ..................................6-21
Drive chain slack adjustment ........................6-22
Drive chain lubrication...................................6-23
Cable inspection and lubrication ..................6-24
Throttle cable and grip lubrication ...............6-24
Brake and shift pedal lubrication ..................6-24
Brake and clutch lever lubrication ................6-25
Sidestand lubrication .....................................6-25
Rear suspension lubrication..........................6-25
Front fork inspection ......................................6-26
Steering inspection ........................................6-26
Wheel bearings ..............................................6-27
Battery .............................................................6-27Fuse replacement ...........................................6-29
Headlight bulb replacement ..........................6-30
Supporting the motorcycle ...........................6-31
Front wheel removal ......................................6-31
Front wheel installation .................................6-32
Rear wheel removal .......................................6-33
Rear wheel installation ..................................6-33
Troubleshooting .............................................6-34
Troubleshooting chart ...................................6-35
CLEANING AND STORAGE ...............................7-1
Cleaning ............................................................7-1
Storage..............................................................7-2
SPECIFICATIONS................................................8-1
How to use the conversion table ....................8-4
CONSUMER INFORMATION .............................9-1
Identification numbers record.........................9-1
Key identification number ...............................9-1
Vehicle identification number .........................9-1
Model label .......................................................9-2
TABLE OF CONTENTS
1
2
3
4
5
6
7
8
9
7
8
9
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 6

EAU00026
DESCRIPTION
1
2
3
4
5
6
7
8
9
2-1
1. Headlight (page 6-30)
2. Fuel cock (page 3-7)
3. Starter(choke) “1“ (page 3-8)
4. Air filter (page 6-12)
5. Battery (page 6-27)6. Helmet holder (page 3-9)
7. Rear carrier (page 3-10)
8. Shift pedal (page 3-4)
123456 7
8
Left view
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 8

4-2
PRE-OPERATION CHECKS
1
2
3
4
5
6
7
8
9
NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accom-
plished in a very short time; and the added safety it assures is more than worth the time involved.
w
If any item in the PRE-OPERATION CHECKS is not working properly, have it inspected and repaired before oper-
ating the motorcycle.
ITEM CHECKS PAGE
Fuel tank9Check fuel level.
3-5 ~ 3-6
9Fill with fuel if necessary.
Lights, signals and
9Check for proper operation. 6-30
switches
Battery9Check fluid level.
6-27 ~ 6-29
9Fill with distilled water if necessary.
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 23

5-3
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
4
5
6
7
8
91. Turn the fuel cock to “ON”.
2. Turn the main switch to ON”
and the engine stop switch to
“RUN”.
3. Shift transmission into neutral.
NOTE:
When the transmission is in neu-
tral, the neutral indicator light
should be on. If the light does not
come on, ask a Yamaha dealer to
inspect it.
4. Turn on the starter and com-
pletely close the throttle grip.
5. Start the engine by pushing
the start switch or by kicking
the kick starter.
NOTE:
If the engine fails to start, release
the start switch, wait a few sec-
onds, then try again. Each attempt
should be as short as possible to
preserve the battery. Do not crank
the engine more than 10 seconds
on any one attempt. If the engine
does not start with the starter
motor, kick the kick starter to start
the engine.
6. After starting the engine, move
the starter to the halfway posi-
tion.
NOTE:
For maximum engine life, always
warm up the engine before starting
off. Never accelerate hard with a
cold engine.
7. After warming up the engine,
turn off the starter completely.
NOTE:
The engine is warm when it
responds normally to the throttle
with the starter turned off.
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 26

6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
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.
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 32

6-27
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
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
w
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
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 56

6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EW000116
w
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
w
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
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 57

6-29
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
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
5FY-9-E0 (TW200) 7/29/02 10:54 AM Page 58