2007 YAMAHA TW200 Battery
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TABLE OF CONTENTS
Checking and lubricating the
brake and shift pedals ........... 6-24
Checking and lubricating the
brake and clutch levers ......... 6-24
Checking and lubricating the
sidestand ............................... 6-25
Lubricating the rear
suspension ............................ 6-25
Checking the front fork ............ 6-25
Checking the steering ............. 6-26
Checking the wheel
bearings ................................ 6-27
Battery ..................................... 6-27
Replacing the fuse .................. 6-29
Replacing the headlight bulb ... 6-30
Replacing the tail/brake light
bulb ....................................... 6-32
Replacing a turn signal light
bulb ....................................... 6-32
Supporting the motorcycle ...... 6-33
Front wheel ............................. 6-34
Rear wheel .............................. 6-35
Troubleshooting ...................... 6-36
Troubleshooting chart ............. 6-37
MOTORCYCLE CARE AND
STORAGE..................................... 7-1
Care .......................................... 7-1Storage ..................................... 7-3
SPECIFICATIONS ....................... 8-1
CONSUMER INFORMATION ...... 9-1
Identification numbers ............... 9-1
Page 12 of 80
DESCRIPTION
2-2
2
3
4
5
6
7
8
9
EAU10420
Right view
12
654 3
7
8
9
1. Carrier
2. Battery (page 6-27)
3. Kickstarter (page 3-8)
4. Engine oil filter element (page 6-7)
5. Engine oil level check window (page 6-7)
6. Brake pedal (page 3-5)
7. Owner’s tool kit (page 6-1)
8. Fuse (page 6-29)9. Luggage strap holder (page 3-10)
Page 28 of 80
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
Page 29 of 80
OPERATION AND IMPORTANT RIDING POINTS
5-1
1
2
3
4
5
6
7
8
9
EAU15950
WARNING
EWA10270
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU16530
Starting a cold engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the sid-
estand up.
WARNING
EWA10290
Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-11.
Never ride with the sidestand
down.
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
3. Shift the transmission into the neu-
tral position.
NOTE:
When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a Yama-
ha dealer check the electrical circuit.
4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-7.)
5. Start the engine by pushing the
start switch or by pushing the kick-
starter lever down.
NOTE:
If the engine fails to start by pushing the
start switch, release the switch, wait a
few seconds, and then try again. Each
starting attempt should be as short as
possible to preserve the battery. Do not
crank the engine more than 10 seconds
on any one attempt. If the engine does
not start with the starter motor, try using
the kickstarter.
6. After starting the engine, move the
starter (choke) back halfway.
Page 34 of 80
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
Page 59 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
1
2
3
4
5
6
7
8
9
EAU23290
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EAU23361
Battery
A poorly maintained battery will corrode
and discharge quickly. The electrolyte
level, battery lead connections and
breather hose routing should be
checked before each ride and at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.
To check the electrolyte level
1. Remove the seat. (See page 3-8.)
2. Disconnect the negative battery
lead from the battery.
3. Disconnect the positive battery
lead and the battery breather hose
from the battery.
4. Unhook the battery band, and then
pull the battery out of the battery
compartment.5. Place the battery on a level sur-
face, and then check the electro-
lyte level in the battery.
NOTE:
The electrolyte should be between the
minimum and maximum level marks.
1. Battery
2. Negative battery lead
3. Positive battery lead (red)
4. Battery breather hose
5. Battery band
4
1
23 5
Page 60 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
2
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5
67
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9
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
Page 61 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
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8
9
battery lead to the battery’s posi-
tive (+) terminal.
10. Connect and tighten the negative
battery lead to the battery’s nega-
tive (–) terminal.
11. Install the seat.
To store the battery
1. If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
2. If the battery will be stored for more
than two months, check the specif-
ic gravity of the electrolyte at least
once a month and fully charge the
battery whenever necessary.
3. Fully charge the battery before in-
stallation.
4. After installation, make sure that
the battery leads are properly con-
nected to the battery terminals and
that the breather hose is properly
routed, in good condition, and not
obstructed.
CAUTION:
ECA10600
If the breather hose is positioned insuch a way that the frame is ex-
posed to electrolyte or gas expelled
from the battery, the frame could
suffer structural and external dam-
ages.
EAU23500
Replacing the fuse
The fuse holder is located behind panel
B. (See page 6-5.)
If the fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn off
all electrical circuits.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
1. Fuse
2. Spare fuse
Specified fuse:
20.0 A
1 2