2008 YAMAHA TW200 brake
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PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
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2
Spark plug
Check condition.
Clean and regap.
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Replace.
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3*
Valves
Check valve clearance.
Adjust.
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4
Air filter element
Clean.
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Replace.
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5*
Battery
Check electrolyte level and specific gravity.
Make sure that the breather hose is properly routed.
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6
Clutch
Check operation.
Adjust.
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7*
Front brake
Check operation, fluid level and vehicle for fluid leak-
age. (See NOTE following this chart.)
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Replace brake pads. Whenever worn to the limit
8*
Rear brake
Check operation and adjust brake pedal free play.
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Replace brake shoes. Whenever worn to the limit
9*
Brake hose
Check for cracks or damage.
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Replace. (See NOTE following this chart.) Every 4 years
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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.
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26
Moving parts and cables
Lubricate.
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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.
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28
*
Lights, signals and
switches
Check operation.
Adjust headlight beam.
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NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×
1,000 km)
ANNUAL
CHECK
1 6 12 18 24
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PERIODIC MAINTENANCE AND MINOR REPAIR
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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
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7. Tighten the locknut at the clutch le-
ver and the crankcase.
EAU22091
Adjusting the brake lever free
play
The brake lever free play should mea-
sure 5.0–8.0 mm (0.20–0.31 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the brake le-
ver.
2. To increase the brake lever free
play, turn the adjusting bolt in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
bolt in direction (b).3. Tighten the locknut.
WARNING
EWA10630
After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.
A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-
trol and an accident.
1. Locknut
2. Adjusting bolt
3. Brake lever free play
12
3
(b)
(a)
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Adjusting the brake pedal
position and free play
WARNING
EWA10670
It is advisable to have a Yamaha
dealer make these adjustments.
Brake pedal position
The top of the brake pedal should be
positioned approximately 15.0 mm
(0.59 in) below the top of the footrest.
Periodically check the brake pedal po-
sition and, if necessary, adjust it as fol-
lows.
1. Loosen the locknut at the brake
pedal.2. To raise the brake pedal, turn the
adjusting bolt in direction (a). To
lower the brake pedal, turn the ad-
justing bolt in direction (b).
3. Tighten the locknut.
WARNING
EWA11230
After adjusting the brake pedal posi-
tion, the brake pedal free play must
be adjusted.Brake pedal free play
The brake pedal free play should mea-
sure 20.0–30.0 mm (0.79–1.18 in) as
shown. Periodically check the brake
pedal free play and, if necessary, adjust
it as follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod in
direction (a). To decrease the brake
pedal free play, turn the adjusting nut in
direction (b).
1. Brake pedal position
1
1. Locknut
2. Adjusting bolt
3. Brake pedal position
2 1
3
(a)
(b)
1. Brake pedal free play
1
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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)
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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
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brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22720
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the brake master
cylinder and caliper as well as the
brake hose replaced at the intervals
listed below or whenever they are dam-
aged or leaking.
Oil seals: Replace every two
years.
Brake hose: Replace every four
years.
EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22770
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright po-
sition.
NOTE:
When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there should
be no weight on it.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.
Drive chain slack:
35.0–60.0 mm (1.38–2.36 in)