2004 YAMAHA TW200 air filter
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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 36 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
2
3
4
5
67
8
9
EAU18660
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
25
*
Front and rear brake
switches
Check operation.
√
√
√
√
√
√
26
Moving parts and cables
Lubricate.
√
√
√
√
√
27
*
Throttle grip housing
and cable
Check operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.
√
√
√
√
√
28
*
Lights, signals and
switches
Check operation.
Adjust headlight beam.
√
√
√
√
√
√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1,000 km)
ANNUAL
CHECK
1 6 12 18 24
Page 39 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
1
2
3
4
5
6
7
8
9
necessary.
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from thespark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
4. Install the spark plug cap.
EAU19792
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment cleaned at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-right side of the Specified spark plug:
NGK/DR8EA
DENSO/X24ESR-U
1. Spark plug gap
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
1
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf,
12.5 ft·lbf)
Page 40 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
2
3
4
5
67
8
9
crankcase.
NOTE:
The engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
To change the engine oil (with or
without oil filter element cleaning)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engineto collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
CAUTION:
ECA11000
When removing the engine oil drain
bolt, the O-ring, compression
spring, and oil strainer will fall out.
Take care not to lose these parts.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
2
3 1
1. Engine oil filler cap
1
1. Engine oil drain bolt
1
Page 41 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
1
2
3
4
5
6
7
8
9
NOTE:
Skip steps 4–9 if the oil filter element is
not being cleaned.
4. Remove the oil filter element drain
bolt to drain the oil from the oil filter
element.5. Remove the oil filter element cover
by removing the bolts.
6. Remove the oil filter element and
O-rings.7. Check the O-ring for damage and
replace it if necessary.
8. Clean the oil filter element with sol-
vent, and then install it.
NOTE:
Check the oil filter element for damage
and replace it if necessary.
9. Install the oil filter element cover by
installing the bolts and the drain
bolt, then tightening them to the
specified torques.
NOTE:
Make sure that the O-rings are properly
seated.
10. Clean the oil strainer with solvent,
and then check it for damage and
replace it if necessary.
11. Install the oil strainer, compression
spring, O-ring and engine oil drain
1. O-ring
2. Compression spring
3. Oil strainer
3
21
1. Oil filter element cover
2. Bolt
3. Oil filter element drain bolt
1. Oil filter element
2. O-ring
1
3
2(×2)
1 2
2
Tightening torques:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Page 42 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
2
3
4
5
67
8
9
bolt, and then tighten the drain bolt
to the specified torque.
12. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
CAUTION:
ECA11620
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
Make sure that no foreign mate-
rial enters the crankcase.
13. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
14. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU20830
Cleaning the air filter element
and check hose
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas. In addition, the air
filter check hose must be frequently
checked and cleaned if necessary.
To clean the air filter element
1. Remove panel A. (See page 6-5.)
2. Remove the air filter case cover by
removing the screws.
3. Pull the air filter element out.
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element removal:
1.00 L (1.06 US qt)
(0.88 Imp.qt)
With oil filter element removal:
1.10 L (1.16 US qt)
(0.97 Imp.qt)
1. Air filter case cover
2. Screw
1
2(×2)
2(×2)
Page 43 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
1
2
3
4
5
6
7
8
9
4. Remove the sponge material from
the air filter element frame, clean it
with solvent, and then squeeze the
remaining solvent out.
5. Apply oil of the recommended type
to the entire surface of the spongematerial, and then squeeze the ex-
cess oil out.
NOTE:
The sponge material should be wet but
not dripping.
6. Pull the sponge material over the
air filter element frame.
7. Insert the element into the air filter
case.
CAUTION:
ECA10480
Make sure that the air filter ele-
ment is properly seated in the
air filter case.
The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
8. Install the air filter case cover by in-
stalling the screws.
9. Install the panel.
To clean the air filter check hose
1. Check the hose at the bottom of
the air filter case for accumulated
dirt or water.
2. If dirt or water is visible, remove
the hose, clean it, and then install
it.
1. Sponge material
2. Air filter element frame
1
2
Recommended oil:
Engine oil
1. Hose
1
Page 74 of 80
SPECIFICATIONS
8-1
2
3
4
5
6
7
89
EAU26332
Dimensions:
Overall length:
2090 mm (82.3 in)
Overall width:
820 mm (32.3 in)
Overall height:
1120 mm (44.1 in)
Seat height:
790 mm (31.1 in)
Wheelbase:
1325 mm (52.2 in)
Ground clearance:
265 mm (10.43 in)
Minimum turning radius:
1900 mm (74.8 in)
Weight:
With oil and fuel:
126.0 kg (278 lb)
Engine:
Engine type:
Air cooled 4-stroke, SOHC
Cylinder arrangement:
Forward inclined single cylinder
Displacement:
196.0 cm
3
(11.96 cu.in)
Bore
×
stroke:
67.0
×
55.7 mm (2.64
×
2.19 in)
Compression ratio:
9.50 :1
Starting system:
Electric and kick starter
Lubrication system:
Wet sump
Engine oil:
Type:
YAMALUBE 4, SAE10W30 or SAE20W40
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Without oil filter element removal:
1.00 L (1.06 US qt) (0.88 Imp.qt)
With oil filter element removal:
1.10 L (1.16 US qt) (0.97 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
7.0 L (1.85 US gal) (1.54 Imp.gal)
Fuel reserve amount:
1.7 L (0.45 US gal) (0.37 Imp.gal)
Carburetor:
Manufacturer:
TEIKEI
Type x quantity:
MV28 x 1
Spark plug(s):
Manufacturer/model:
NGK/DR8EA
Manufacturer/model:
DENSO/X24ESR-U
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Wet, multiple-disc
Transmission:
Primary reduction system:
Spur gear
Primary reduction ratio:
73/22 (3.318)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
50/14 (3.571)
Transmission type:
Constant mesh 5-speed
Operation:
Left foot operation
Gear ratio:
1st:
34/12 (2.833)
2nd:
34/19 (1.789)
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40