2004 YAMAHA TW200 warning

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU22191
Adjusting the brake pedal
position and free play
WARNING

EWA10670
It is advisable to have a Yamaha
dealer make these adjustments.
Brake pedal position
The top of the brake pedal should be
positioned approximately 15.0 mm
(0.59 in) below the top of the footrest.
Periodically check the brake pedal po-
sition and, if necessary, adjust it as fol-
lows.
1. Loosen the locknut at the brake
pedal.2. To raise the brake pedal, turn the
adjusting bolt in direction (a). To
lower the brake pedal, turn the ad-
justing bolt in direction (b).
3. Tighten the locknut.
WARNING

EWA11230
After adjusting the brake pedal posi-
tion, the brake pedal free play must
be adjusted.Brake pedal free play
The brake pedal free play should mea-
sure 20.0–30.0 mm (0.79–1.18 in) as
shown. Periodically check the brake
pedal free play and, if necessary, adjust
it as follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod in
direction (a). To decrease the brake
pedal free play, turn the adjusting nut in
direction (b).
1. Brake pedal position
1

1. Locknut
2. Adjusting bolt
3. Brake pedal position
2 1
3
(a)
(b)

1. Brake pedal free play
1

PERIODIC MAINTENANCE AND MINOR REPAIR
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WARNING

EWA10680

After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
brake pedal free play.

If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this ad-
justment.

After adjusting the brake pedal
free play, check the operation of
the brake light.
EAU22270
Adjusting the rear brake light
switch
The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction (a). To
make the brake light come on later, turn
the adjusting nut in direction (b).
EAU22380
Checking the front brake pads
and rear brake shoes
The front brake pads and the rear brake
shoes must be checked for wear at the
intervals specified in the periodic main-
tenance and lubrication chart.
EAU22430
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disap-
1. Brake pedal free play adjusting nut
1
(a)
(b)

1. Rear brake light switch
2. Adjusting nut1
2
(a)
(b)

1. Brake pad wear indicator groove
1(×3)

PERIODIC MAINTENANCE AND MINOR REPAIR
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4. If the drive chain slack is incorrect,
adjust it as follows.

EAU22830
To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut.2. Loosen the axle nut.
3. To tighten the drive chain, turn the
adjusting plate on each side of the
swingarm in direction (a). To loos-
en the drive chain, turn the adjust-
ing plate on each side of the
swingarm in direction (b), and then
push the rear wheel forward.
NOTE:

Make sure that both adjusting plates
are in the same position for proper
wheel alignment.
CAUTION:

ECA10570
Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.
4. Tighten the axle nut to the speci-
fied torque.
5. Adjust the brake pedal free play.
(See page 6-18.)
WARNING

EWA10660
After adjusting the brake pedal free
play, check the operation of the
brake light.
1. Drive chain slack
1

1. Brake pedal free play adjusting nut
2. Axle nut
3. Adjusting plate32
1
(a)
(b)
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU23010
Lubricating the drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the General maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
CAUTION:

ECA10580
The drive chain must be lubricated
after washing the motorcycle or
riding in the rain.
1. Remove all dirt and mud from the
drive chain with a brush or cloth.
NOTE:

For a thorough cleaning, have a Yama-
ha dealer remove the drive chain and
soak it in solvent.
2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on both sides
and on the middle of the chain,
making sure that all side plates
and rollers have been sufficientlyoiled.
EAU23100
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING

EWA10720
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.
Recommended lubricant:
Engine oil

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU23200
Checking and lubricating the
sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
WARNING

EWA10730
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
EAU23250
Lubricating the rear
suspension
The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU23271
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

1. Grease nipple
Recommended lubricant:
Lithium-soap-based grease1(×2)

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CAUTION:

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

PERIODIC MAINTENANCE AND MINOR REPAIR
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6. If the electrolyte is at or below the
minimum level mark, add distilled
water to raise the electrolyte to the
maximum level mark.
WARNING

EWA10760

Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-lowing FIRST AID.

EXTERNAL: Flush with plenty
of water.

INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.

EYES: Flush with water for
15 minutes and seek prompt
medical attention.

Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.

KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
CAUTION:

ECA10610
Use only distilled water, as tap water
contains minerals that are harmful
to the battery.
7. Place the battery in the battery
compartment, and then hook thebattery band onto the holder.
8. Connect the breather hose to the
battery and make sure that it is
properly routed.
9. Connect and tighten the positive
1. Maximum level mark
2. Minimum level mark
1
2

1. Battery breather hose
1. Battery
2. Battery breather hose
1
1
2

PERIODIC MAINTENANCE AND MINOR REPAIR
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WARNING

EWA10790
Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.
5. Place a new bulb into position, and
then secure it with the bulb holder.
CAUTION:

ECA10660
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af-fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with al-
cohol or thinner.
6. Install the bulb cover, and then
connect the coupler.
7. Install the headlight unit by install-
ing the bolts.8. Install the cowling.
9. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Headlight bulb holder
1

1. Do not touch the glass part of the bulb.
1