2004 YAMAHA TW200 tires

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
4-3
2
3
45
6
7
8
9

Drive chain

Check chain slack.

Adjust if necessary.

Check chain condition.

Lubricate if necessary.6-21, 6-23
Wheels and tires

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Correct if necessary.6-13, 6-16
Brake and shift pedals

Make sure that operation is smooth.

Lubricate pedal pivoting points if necessary.6-24
Brake and clutch levers

Make sure that operation is smooth.

Lubricate lever pivoting points if necessary.6-24
Sidestand

Make sure that operation is smooth.

Lubricate pivot if necessary.6-25
Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened.

Tighten if necessary.—
Instruments, lights, signals
and switches

Check operation.

Correct if necessary.—
Sidestand switch

Check operation of ignition circuit cut-off system.

If system is defective, have Yamaha dealer check vehicle.3-11
Battery

Check fluid level.

Fill with distilled water if necessary.6-27
ITEM CHECKS PAGE

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.
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11

*
Tires

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Correct if necessary.
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12

*
Wheel bearings

Check bearing for looseness or damage.
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13

*
Swingarm

Check operation and for excessive play.
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√

√

√



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.
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√

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Lubricate with lithium-soap-based grease. Every 24,000 km
16

*
Chassis fasteners

Make sure that all nuts, bolts and screws are properly
tightened.
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√

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√


17

Sidestand

Check operation.

Lubricate.
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18

*
Sidestand switch

Check operation.
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19

*
Front fork

Check operation and for oil leakage.
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20

*
Shock absorber assem-
bly

Check operation and shock absorber for oil leakage.
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21

*
Carburetor

Check starter (choke) operation.

Adjust engine idling speed.
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22

Engine oil

Change.

Check oil level and vehicle for oil leakage.
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23

Engine oil filter element

Clean.
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24

*
Engine oil strainer

Clean.
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NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1,000 km)
ANNUAL
CHECK
1 6 12 18 24

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
1
2
3
4
5
6
7
8
9

EAU21380
Adjusting the throttle cable
free play
The throttle cable free play should mea-
sure at the throttle grip. Periodically
check the throttle cable free play and, if
necessary, have a Yamaha dealer ad-
just it.
EAU21400
Adjusting the valve clearance
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU21570
Tires
To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING

EWA10500

The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).

The tire air pressure must be ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
1. Throttle cable free play
1

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
2
3
4
5
67
8
9
WARNING

EWA10530
Proper loading of your motorcycle is
important for several characteristics
of your motorcycle; such as han-
dling, braking, performance andsafety. Do not carry loosely packed
items that can shift. Securely pack
your heaviest items close to the cen-
ter of the motorcycle, and distribute
the weight evenly from side to side.
Check the condition and pressure of
your tires. NEVER OVERLOAD
YOUR MOTORCYCLE. Make sure
the total weight of the cargo, rider,
passenger, and accessories (fairing,
saddlebags, etc. if approved for this
model) does not exceed the maxi-
mum load of the motorcycle. Opera-
tion of an overloaded motorcycle
could cause tire damage, an acci-
dent, or even injury.Tire inspection
The tires must be checked before each
ride. If the tire shows crosswise lines
(minimum tread depth), if the tire has a
nail or glass fragments in it, or if the
sidewall is cracked, have a Yamaha
dealer replace the tire immediately.
NOTE:

The tire tread depth limits may differ
from country to country. Always comply
Tire air pressure (measured on
cold tires):
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
)
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
)
Maximum load*:
180 kg (397 lb)
* Total weight of rider, passenger,
cargo and accessories
1. Tire sidewall
2. Tire wear indicator
3. Tire tread depth
Minimum tire tread depth (front
and rear):
1.0 mm (0.04 in)
123

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
1
2
3
4
5
6
7
8
9

with the local regulations.
Tire information
This motorcycle is equipped with tube
tires.
WARNING

EWA10460

The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the vehicle
cannot be guaranteed.

After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor Co., Ltd.
WARNING

EWA10560

It is dangerous to ride with a
worn-out tire. When a tire tread
begins to show crosswise lines,
have a Yamaha dealer replace
the tire immediately.

The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.

It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tubevery carefully and replace it as
soon as possible with a
high-quality product. Front tire:
Size:
130/80-18M/C 66P
Manufacturer/model:
BRIDGESTONE/TW31
Rear tire:
Size:
180/80-14M/C 78P
Manufacturer/model:
BRIDGESTONE/TW34

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-

MOTORCYCLE CARE AND STORAGE
7-4
1
2
3
4
5
6
7
8
9
from the spark plug, and then
install the spark plug and the
spark plug cap.
WARNING

EWA10950
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
6. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
9. Remove the battery and fully
charge it. Store it in a cool, dryplace and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place
(less than 0 °C [30 °F]) or more
than 30 °C [90 °F]). For more in-
formation on storing the battery,
see page 6-27.
NOTE:

Make any necessary repairs before
storing the motorcycle.