2003 YAMAHA TW200 brake light

EAU00009
TABLE OF CONTENTS
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9 GIVE SAFETY THE RIGHT OF WAY ..................1-1
DESCRIPTION .....................................................2-1
Left view............................................................2-1
Right view .........................................................2-2
Controls/Instruments .......................................2-3
INSTRUMENT AND CONTROL
FUNCTIONS ........................................................3-1
Main switch/Steering lock ...............................3-1
Indicator lights..................................................3-2
Speedometer ....................................................3-2
Handlebar switches..........................................3-3
Clutch lever .......................................................3-4
Shift pedal.........................................................3-4
Front brake lever ..............................................3-5
Rear brake pedal ..............................................3-5
Fuel tank cap.....................................................3-5
Fuel ....................................................................3-6
Fuel cock ...........................................................3-7
Starter (choke) “1” .........................................3-8
Kick starter ........................................................3-8
Seat ...................................................................3-9
Helmet holder ...................................................3-9
Rear shock absorber ......................................3-10
Rear carrier .....................................................3-10Sidestand ........................................................3-10
Sidestand/clutch switch operation check .....3-11
PRE-OPERATION CHECKS.................................4-1
Pre-operation check list ...................................4-1
OPERATION AND IMPORTANT RIDING
POINTS................................................................5-1
Starting and warming up a cold engine.........5-1
Starting a warm engine ...................................5-4
Shifting..............................................................5-4
Engine break-in ................................................5-5
Parking ..............................................................5-6
PERIODIC MAINTENANCE AND MINOR
REPAIR ................................................................6-1
Tool kit ..............................................................6-1
Periodic maintenance and lubrication............6-3
Cowling and panel removal and
installation ........................................................6-6
Cowling A .........................................................6-6
Panel A ..............................................................6-7
Panel B ..............................................................6-7
Spark plug inspection ......................................6-7
Engine oil ..........................................................6-8
Air filter ...........................................................6-12
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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
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6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
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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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6-23
PERIODIC MAINTENANCE AND MINOR REPAIR
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1
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.
EW000110
w
Always use a new cotter pin on
the axle nut.
1. Cotter pin
7. Adjust the free play in the
brake pedal.
EW000103
w
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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PERIODIC MAINTENANCE AND MINOR REPAIR
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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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8-3
SPECIFICATIONS
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Wheels:
Type:
Front Spoke wheel
Rear Spoke wheel
Size:
Front 18 ×2.50
Rear 14M/C ×MT4.50
Brakes:
Front:
Type Drum brake
Operation Right hand operation
Rear:
Type Drum brake
Operation Right foot operation
Suspension:
Front Telescopic fork
Rear Swingarm
(Monocross suspension)
Shock absorber:
Front Coil spring / oil damper
Rear Coil-gas spring / oil damper
Wheel travel:
Front 160 mm
Rear 150 mmElectrical:
Ignition system: C.D.I.
Charging system:
Type A.C. magneto
Standard output 12V 11A / 5,000 rpm
Battery:
Type GM7CZ-3D
Voltage, capacity 12V 7 AH
Headlight typeHalogen bulb
Bulb voltage, wattage ×quantity:
Headlight 12V 35W / 35W ×1
Stop / tail light 12V 27W / 8W ×1
Front flasher light 12V 27W / 8W ×2
Rear flasher light 12V 27W ×2
Meter light 12V 3.4W ×1
Neutral indicator light 12V 3.4W ×1
High beam indicator light 12V 3.4W ×1
Turn indicator light 12V 3.4W ×1
Fuse:
Main 15A
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