2003 YAMAHA TW200 oil

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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4-1
EAU01114
PRE-OPERATION CHECKS
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9Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to
deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements).
Any damage, fluid leak or loss of tire pressure could have serious consequences. Therefore, it is very important
that, in addition to a thorough visual inspection, you check the following points before each ride.
EAU00340PRE-OPERATION CHECK LIST
ITEM CHECKS PAGE
Brakes9Check operation, condition and free play.
3-5, 6-18 ~ 6-21
9Adjust if necessary.
Clutch9Check operation and free play.
3-4, 6-18
9Adjust if necessary.
9Check for smooth operation.
Throttle grip and housing9Lubricate.6-14, 6-24
9Adjust throttle cable free play if necessary.
Engine oil9Check oil level.
6-8 ~ 6-11
9Fill with oil if necessary.
Drive chain9Check chain slack and condition.
6-21 ~ 6-23
9Adjust if necessary.
Wheels and tires9Check tire pressure, wear, damage and spoke tightness.
6-15 ~ 6-17
9Tighten spokes if necessary.
Brake and shift pedal shafts9Check for smooth operation.
6-24
9Lubricate if necessary.
Brake and clutch lever pivots9Check for smooth operation.
6-25
9Lubricate if necessary.
Sidestand pivot9Check for smooth operation.
6-25
9Lubricate if necessary.
Chassis fasteners9Make sure that all nuts, bolts, and screws are properly tightened.
—
9Tighten if necessary.
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OPERATION AND IMPORTANT RIDING POINTS
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94. 1,000 km and beyond:
Avoid prolonged full-throttle
operation. Vary speed occa-
sionally.
EC000049
cC
If any engine trouble should occur
during the break-in period, consult
a Yamaha dealer immediately.
EAU00436Engine break-in
There is never a more important
period in the life of your motorcy-
cle than the period between zero
and 1,000 km. For this reason we
ask that you carefully read the fol-
lowing material. Because the
engine is brand new, you must not
put an excessive load on it for the
first 1,000 km. The various parts in
the engine wear and polish them-
selves to the correct operating
clearances. During this period, pro-
longed full throttle operation, or
any condition which might result in
excessive heating of the engine,
must be avoided.
EAU00446
1. 0 ~ 150 km:
Avoid operation above 1/3
throttle. Stop the engine and
let it cool for 5 to 10 minutes
after every hour of operation.
Vary the speed of the motorcy-
cle from time to time. Do not
operate it at one set throttle
position.
2. 150 ~ 500 km:
Avoid prolonged operation
above 1/2 throttle. Rev the
motorcycle freely through the
gears, but do not use full throt-
tle at any time.
3. 500 ~ 1,000 km:
Avoid cruising speeds in
excess of 3/4 throttle.
EC000057
cC
After 1,000 km of operation, be
sure to replace the engine oil and
clean the oil filter element and oil
strainer.
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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
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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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PERIODIC MAINTENANCE AND MINOR REPAIR
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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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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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6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
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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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PERIODIC MAINTENANCE AND MINOR REPAIR
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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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