2004 YAMAHA TW200 brake pads

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

PRE-OPERATION CHECKS
4-2
1
2
3
4
5
6
7
8
9

EAU15601
Pre-operation check list
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.3-6
Engine oil

Check oil level in engine.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.6-7
Front brake

Check operation.

If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check lever free play.

Adjust if necessary.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.6-17, 6-19, 6-20
Rear brake

Check operation.

Check pedal free play.

Adjust if necessary.6-18, 6-19
Clutch

Check operation.

Lubricate cable if necessary.

Check lever free play.

Adjust if necessary.6-16
Throttle grip

Make sure that operation is smooth.

Check cable free play.

If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-13, 6-24
Control cables

Make sure that operation is smooth.

Lubricate if necessary.6-23

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
2
3
4
5
67
8
9

EAU17710
Periodic maintenance and lubrication chart
NOTE:


The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.

From 30,000 km, repeat the maintenance intervals starting from 6,000 km.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1,000 km)
ANNUAL
CHECK
1 6 12 18 24
1*
Fuel line


Check fuel hoses for cracks or damage.
√

√

√

√

√

2
Spark plug


Check condition.

Clean and regap.
√

√


Replace.
√

√

3*
Valves


Check valve clearance.

Adjust.
√

√

√

√

4
Air filter element


Clean.
√

√



Replace.
√

√

5*
Battery


Check electrolyte level and specific gravity.

Make sure that the breather hose is properly routed.
√

√

√

√

√

6
Clutch


Check operation.

Adjust.
√

√

√

√

√

7*
Front brake


Check operation, fluid level and vehicle for fluid leak-
age. (See NOTE following this chart.)
√

√

√

√

√

√



Replace brake pads. Whenever worn to the limit
8*
Rear brake

Check operation and adjust brake pedal free play.
√

√

√

√

√

√



Replace brake shoes. Whenever worn to the limit
9*
Brake hose

Check for cracks or damage.
√

√

√

√

√



Replace. (See NOTE following this chart.) Every 4 years

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
1
2
3
4
5
6
7
8
9
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
6-20
2
3
4
5
67
8
9
peared, have a Yamaha dealer replace
the brake pads as a set.

EAU22540
Rear brake shoes
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to dis-
assemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
set.
EAU32341
Checking the brake fluid level
Front brake
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:

When checking the fluid level,
make sure that the top of the mas-ter cylinder is level by turning the
handlebars.

Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.

Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.

Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.

Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.

As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
1. Wear indicator
2. Wear limit line
2
1

1. Minimum level mark
1

Recommended brake fluid:
DOT 4

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
2
3
4
5
67
8
9

EAU24360
Front wheel
EAU24580
To remove the front wheel
WARNING

EWA10820

It is advisable to have a Yamaha
dealer service the wheel.

Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Disconnect the speedometer ca-
ble from the front wheel.
2. Loosen the axle nut.
3. Lift the front wheel off the ground
according to the procedure onpage 6-33.
4. Remove the axle nut, pull the
wheel axle out, and then remove
the wheel.
CAUTION:

ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU24981
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.
2. Lift the wheel up between the fork
legs.
NOTE:

Make sure that there is enough space
between the brake pads before insert-
ing the brake disc and that the slot in
the speedometer gear unit fits over the
retainer on the fork leg.3. Insert the wheel axle, and then in-
stall the axle nut.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the axle nut to the speci-
fied torque.
6. Connect the speedometer cable.
1. Speedometer cable
2. Axle nut
1
2

1. Retainer
2. Speedometer cable
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
2 1