2004 YAMAHA TW200 ABS
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TABLE OF CONTENTS
SAFETY INFORMATION ............. 1-1
DESCRIPTION ............................. 2-1
Left view ..................................... 2-1
Right view................................... 2-2
Controls and instruments ........... 2-3
INSTRUMENT AND CONTROL
FUNCTIONS ................................ 3-1
Main switch/steering lock .......... 3-1
Indicator lights ........................... 3-2
Speedometer unit ...................... 3-2
Handlebar switches ................... 3-3
Clutch lever ............................... 3-4
Shift pedal ................................. 3-4
Brake lever ................................ 3-4
Brake pedal ............................... 3-5
Fuel tank cap ............................. 3-5
Fuel ........................................... 3-6
Fuel cock ................................... 3-6
Starter (choke) knob “
1
” .......... 3-7
Kickstarter ................................. 3-8
Seat ........................................... 3-8
Helmet holder ............................ 3-9
Shock absorber ......................... 3-9
Carrier ....................................... 3-9
Luggage strap holders ............ 3-10
Sidestand ................................ 3-10Ignition circuit cut-off system ... 3-11
PRE-OPERATION CHECKS ........ 4-1
Pre-operation check list ............ 4-2
OPERATION AND IMPORTANT
RIDING POINTS .......................... 5-1
Starting a cold engine ............... 5-1
Starting a warm engine ............. 5-2
Shifting ...................................... 5-2
Tips for reducing fuel
consumption ............................ 5-3
Engine break-in ......................... 5-3
Parking ...................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR ........................... 6-1
Owner’s tool kit ......................... 6-1
Periodic maintenance and
lubrication chart ....................... 6-2
Removing and installing the
cowling and panels ................. 6-5
Checking the spark plug ........... 6-6
Engine oil and oil filter
element ................................... 6-7
Cleaning the air filter element
and check hose ..................... 6-10
Adjusting the carburetor .......... 6-12Adjusting the engine idling
speed .................................... 6-12
Adjusting the throttle cable free
play ....................................... 6-13
Adjusting the valve
clearance .............................. 6-13
Tires ........................................ 6-13
Spoke wheels .......................... 6-16
Adjusting the clutch lever free
play ....................................... 6-16
Adjusting the brake lever free
play ....................................... 6-17
Adjusting the brake pedal
position and free play ............ 6-18
Adjusting the rear brake light
switch .................................... 6-19
Checking the front brake pads
and rear brake shoes ............ 6-19
Checking the brake fluid
level ....................................... 6-20
Changing the brake fluid ......... 6-21
Drive chain slack ..................... 6-21
Lubricating the drive chain ...... 6-23
Checking and lubricating the
cables .................................... 6-23
Checking and lubricating the
throttle grip and cable ........... 6-24
Page 22 of 80
INSTRUMENT AND CONTROL FUNCTIONS
3-9
2
34
5
6
7
8
9
EAU14280
Helmet holder
To open the helmet holder, insert the
key into the lock, and then turn the key
as shown.
To lock the helmet holder, place it in the
original position, and then remove the
key.
WARNING
EWA10160
Never ride with a helmet attached to
the helmet holder, since the helmet
may hit objects, causing loss of con-
trol and possibly an accident.
EAU15090
Shock absorber
WARNING
EWA10220
This shock absorber contains highly
pressurized nitrogen gas. For prop-
er handling, read and understand
the following information before
handling the shock absorber. The
manufacturer cannot be held re-
sponsible for property damage or
personal injury that may result from
improper handling.
Do not tamper with or attempt to
open the gas cylinder.
Do not subject the shock ab-
sorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.
Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping per-
formance.
Always have a Yamaha dealer
service the shock absorber.
EAU15110
Carrier
WARNING
EWA10170
Do not exceed the load limit of
3 kg (7 lb) for the carrier.
Do not exceed the maximum
load of 180 kg (397 lb) for the ve-
hicle.
1. Helmet holder
1
1. Carrier
1
Page 35 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
1
2
3
4
5
6
7
8
9
10
*
Wheels
Check runout, spoke tightness and for damage.
Tighten spokes if necessary.
√
√
√
√
11
*
Tires
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
√
√
√
√
√
12
*
Wheel bearings
Check bearing for looseness or damage.
√
√
√
√
13
*
Swingarm
Check operation and for excessive play.
√
√
√
√
Lubricate with lithium-soap-based grease. Every 24,000 km
14
Drive chain
Check chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate.Every 500 km and after washing the motorcycle or
riding in the rain
15
*
Steering bearings
Check bearing play and steering for roughness.
√
√
√
√
√
Lubricate with lithium-soap-based grease. Every 24,000 km
16
*
Chassis fasteners
Make sure that all nuts, bolts and screws are properly
tightened.
√
√
√
√
√
17
Sidestand
Check operation.
Lubricate.
√
√
√
√
√
18
*
Sidestand switch
Check operation.
√
√
√
√
√
√
19
*
Front fork
Check operation and for oil leakage.
√
√
√
√
20
*
Shock absorber assem-
bly
Check operation and shock absorber for oil leakage.
√
√
√
√
21
*
Carburetor
Check starter (choke) operation.
Adjust engine idling speed.
√
√
√
√
√
√
22
Engine oil
Change.
Check oil level and vehicle for oil leakage.
√
√
√
√
√
√
23
Engine oil filter element
Clean.
√
√
√
24
*
Engine oil strainer
Clean.
√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1,000 km)
ANNUAL
CHECK
1 6 12 18 24
Page 71 of 80
MOTORCYCLE CARE AND STORAGE
7-2
1
2
3
4
5
6
7
8
9any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:
Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the motorcycle with cold wa-ter and a mild detergent, after the
engine has cooled down.
CAUTION:
ECA10790
Do not use warm water since it in-
creases the corrosive action of the
salt.
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stain-
less-steel parts, including the ex-
haust system. (Even the thermally
induced discoloring of stain-
less-steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
WARNING
EWA10930
Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent.
Before operating the motorcy-
cle test its braking performance
and cornering behavior.
CAUTION:
ECA10800
Apply spray oil and wax spar-
Page 75 of 80
SPECIFICATIONS
8-2
1
2
3
4
5
6
7
8
9
3rd:
29/22 (1.318)
4th:
26/25 (1.040)
5th:
23/28 (0.821)
Chassis:
Frame type:
Diamond
Caster angle:
26.0 °
Trail:
95.0 mm (3.74 in)
Front tire:
Type:
With tube
Size:
130/80-18M/C 66P
Manufacturer/model:
BRIDGESTONE/TW31
Rear tire:
Type:
With tube
Size:
180/80-14M/C 78P
Manufacturer/model:
BRIDGESTONE/TW34
Loading:
Maximum load:
180 kg (397 lb)
(Total weight of rider, passenger, cargo
and accessories)
Tire air pressure (measured on cold
tires):
Loading condition:
0–90 kg (0–198 lb)
Front:
125 kPa (18 psi) (1.25 kgf/cm
2
)
Rear:
125 kPa (18 psi) (1.25 kgf/cm
2
)
Loading condition:
90–180 kg (198–397 lb)
Front:
150 kPa (22 psi) (1.50 kgf/cm
2
)
Rear:
175 kPa (25 psi) (1.75 kgf/cm
2
)
Off-road riding:
Front:
125 kPa (18 psi) (1.25 kgf/cm
2
)
Rear:
125 kPa (18 psi) (1.25 kgf/cm
2
)
Front wheel:
Wheel type:
Spoke wheel
Rim size:
18x2.50
Rear wheel:
Wheel type:
Spoke wheel
Rim size:
14M/C x MT4.50
Front brake:
Type:
Single disc brake Operation:
Right hand operation
Recommended fluid:
Dot 4
Rear brake:
Type:
Drum brake
Operation:
Right foot operation
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
160.0 mm (6.30 in)
Rear suspension:
Type:
Swingarm (monocross)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
150.0 mm (5.91 in)
Electrical system:
Ignition system:
C.D.I.
Charging system:
A.C. magneto
Battery:
Model:
GM7CZ-3D
Voltage, capacity:
12 V, 7.0 Ah