2003 YAMAHA TW200 transmission

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EAU00056Indicator lights
EAU00059Turn indicator light “TURN”
This indicator flashes when the
turn switch is moved to the left or
right.
EAU00062Neutral indicator light “NEUTRAL”
This indicator comes on when the
transmission is in neutral.
1. Turn indicator light “TURN”
2. High beam indicator light
“HIGH BEAM”
3. Neutral indicator light “NEUTRAL”
EAU00064
High beam indicator light “HIGH
BEAM”
This indicator comes on when the
headlight high beam is used.
INSTRUMENT AND CONTROL FUNCTIONS
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EAU00098Speedometer
The speedometer shows riding
speed.
This speedometer is equipped with
an odometer.
1. Speedometer
2. Odometer
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EW000044
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This motorcycle must not be oper-
ated with the sidestand in the
down position. If the stand is not
properly retracted, it could contact
the ground and distract the opera-
tor, resulting in a possible loss of
control. Yamaha has designed into
this motorcycle a lockout system
to assist the operator in fulfilling
the responsibility of retracting the
sidestand. Please check carefully
the operating instructions listed
below and if there is any indication
of a malfunction, return the motor-
cycle to a Yamaha dealer immedi-
ately for repair.
INSTRUMENT AND CONTROL FUNCTIONS
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EAU00331
Sidestand/clutch switch
operation check
Check the operation of the side-
stand switch and clutch switch
against the information below.
TURN THE MAIN SWITCH TO “ON”
AND THE ENGINE STOP SWITCH TO
“RUN”.
TRANSMISSION IS IN GEAR AND
SIDESTAND IS UP.
PULL IN CLUTCH LEVER AND
PUSH THE START SWITCH.
ENGINE WILL START.
CLUTCH SWITCH IS OK.
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If improper operation is noted,
consult a Yamaha dealer immedi-
ately.
SIDESTAND IS DOWN.
ENGINE WILL STALL.
SIDESTAND SWITCH IS OK.
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1. Before riding this motorcycle,
become thoroughly familiar
with all operating controls and
their functions. Consult a
Yamaha dealer regarding any
control or function that you do
not thoroughly understand.
2. Never start your engine or let
it run for any length of time in
a closed area. The exhaust
fumes are poisonous and can
cause loss of consciousness
and death within a short time.
Always operate your motorcy-
cle in an area with adequate
ventilation.
3. Before starting out, always be
sure the sidestand is up.
Failure to retract the sidestand
completely can result in a seri-
ous accident when you try to
turn a corner.
EAU00411
Starting and warming up a
cold engine
NOTE:
This motorcycle is equipped with a
starting and an ignition circuit cut-
off switch.
1. The engine can be started only
under the following condi-
tions:
a. The transmission is in neutral.
b. The sidestand is up, the trans-
mission is in gear, and the
clutch is disengaged.
2. The motorcycle must not be
ridden when the sidestand is
down.
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Before going through the follow-
ing steps, check the function of the
sidestand switch and clutch
switch. (Refer to page 3-11.)
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EAU00372
OPERATION AND IMPORTANT RIDING POINTS
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2
3
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OPERATION AND IMPORTANT RIDING POINTS
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IF TRANSMISSION IS IN NEUTRAL
AND SIDESTAND IS DOWN,
PUSH START SWITCH OR
KICK THE KICK STARTER.
ENGINE WILL START.
RETRACT SIDESTAND AND PUT
TRANSMISSION IN GEAR.
MOTORCYCLE CAN BE RIDDEN.MOTORCYCLE CAN BE RIDDEN.
IF TRANSMISSION IS IN GEAR AND
SIDESTAND IS UP,
PULL IN CLUTCH LEVER AND PUSH START
SWITCH OR KICK THE KICK STARTER.
ENGINE WILL START.
TURN THE MAIN SWITCH TO “ON” AND
THE ENGINE STOP SWITCH TO “RUN”
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OPERATION AND IMPORTANT RIDING POINTS
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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.
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OPERATION AND IMPORTANT RIDING POINTS
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EAU00423
Shifting
The transmission lets you control
the amount of power you have
available at a given speed for start-
ing, accelerating, climbing hills,
etc. The use of the shift pedal is
shown in the illustration.
To shift into neutral, depress the
shift pedal repeatedly until it reach-
es the end of its travel, then raise
the pedal slightly.
EC000048
cC
1. Do not coast for long periods
with the engine off, and do
not tow the motorcycle a long
distance. Even with gears in
neutral, the transmission is
only properly lubricated when
the engine is running.
Inadequate lubrication may
damage the transmission.
2. Always use the clutch when
changing gears. The engine,
transmission, and driveline are
not designed to withstand the
shock of forced shifting and
can be damaged by shifting
without using the clutch.
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N5
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3
2
1
N. Neutral
1. Shift pedal
EAU01258Starting a warm engine
The starter (choke) is not required
when the engine is warm.
EC000046
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See the “Engine break-in” section
prior to operating the motorcycle
for the first time.
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EAU01010
CLEANING AND STORAGE
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EAU01301A. CLEANING
Frequent, thorough cleaning of
your motorcycle will not only
enhance its appearance but will
improve its
general performance and extend
the useful life of many compo-
nents.
ECA00002
cC
8Improper cleaning can damage
the cowlings, panels and other
plastic parts. Use only a soft,
clean cloth or sponge with
mild detergent and water to
clean plastic.
8Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abra-
sive cleaning products, solvent
or thinner, fuel (gasoline), rust
removers or inhibitors, brake
fluid, antifreeze or electrolyte.
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cC
Excessive hose pressure may
cause water seepage and deterio-
ration of wheel bearings, front
fork, brakes, transmission seals
and electrical parts.
Many expensive repair bills have
resulted from improper high pres-
sure detergent applications such
as those available in coin-operated
car washers.
4. After riding on salted roads,
wash the motorcycle with cold
water immediately. Do not use
warm water as it increases the
chemical reaction of the salt.
5. Once the majority of the dirt
has been hosed off, wash all
surfaces with warm water and
mild, detergent-type soap. An
old toothbrush or bottle brush
is handy for hard-to-get-at
places. 1. Before cleaning the motorcy-
cle:
a. Block off the end of the
exhaust pipe to prevent water
entry; a plastic bag and strong
rubber band may be used.
b. Make sure the spark plug and
all filler caps are properly
installed.
2. If the engine case is excessive-
ly greasy, apply degreaser
with a paint brush. Do not
apply degreaser to the chain,
sprockets or wheel axles.
3. Rinse the dirt and degreaser
off with a garden hose. Use
only enough pressure to do
the job.
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SPECIFICATIONS
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Spark plug:
Type / Manufacturer D8EA / NGK or
X24ES-U / DENSO
Spark plug gap 0.6 ~ 0.7 mm
Clutch type:Wet, multiple-disc
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 3.318
Secondary reduction system Chain drive
Secondary reduction ratio 3.571
Number of sprocket teeth
(Rear/Front) 50/14
Transmission type Constant mesh 5-speed
Operation Left foot operation
Gear ratio 1st 2.833
2nd 1.789
3rd 1.318
4th 1.040
5th 0.821
Chassis:
Frame type Diamond
Caster angle 26.5°
Trail 94 mmTire:
Type With tube
Size:
Front 130/80-18 66P
Rear 180/80-14M/C 78P
Manufacturer / model:
Front BRIDGESTONE / TW31
Rear BRIDGESTONE / TW32
Maximum load* 157 kg
Air pressure (cold tire):
up to 80 kg load*
Front 125 kPa; 1.25 kgf/cm
2; 1.25 bar
Rear 125 kPa; 1.25 kgf/cm
2; 1.25 bar
80 kg load ~ Maximum
load*
Front 150 kPa; 1.50 kgf/cm
2; 1.50 bar
Rear 175 kPa; 1.75 kgf/cm
2; 1.75 bar
Off-road riding
Front 125 kPa; 1.25 kgf/cm
2; 1.25 bar
Rear 125 kPa; 1.25 kgf/cm
2; 1.25 bar
High-speed riding
Front 150 kPa; 1.50 kgf/cm
2; 1.50 bar
Rear 175 kPa; 1.75 kgf/cm
2; 1.75 bar
*Load is total weight of cargo, rider, passenger and accessories.
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